STABILUS ACE TUBUS TC Service manual

ACE Stoßdämpfer GmbH · Postfach 1510 · D-40740 Langenfeld · T +49 (0)2173 - 9226-10 (Technik -20) · F +49 (0)2173 - 9226-19 · [email protected] · www.ace-ace.comStand 03.2021 ACE Stoßdämpfer GmbH · www.ace-ace.com21_22_0019 Issue 05.2022
TC
TC-S
TUBUS TC and TC-S
Safety Dampers
Compact powerhouse
Crane installations
Energy capacity 630 Nm/cycle to 17,810 Nm/cycle
Maximum stroke 30 mm to 198 mm
Table of contents Page
General instructions................................. 2
Safety information ................................... 2
Intended use........................................... 2
Description and function........................... 2
Calculation and design ............................. 2
Delivery and storage ................................ 2
Maintenance and care.............................. 2
Disassembly and disposal......................... 2
Mounting instructions................................ 3
Warranty ................................................. 4
Expected service life ................................. 4
Technical data.......................................... 4
The identification numbers listed are the
respective standard units of the corresponding
damper series. Special types can have deviating
identification numbers.
Operating and mounting instructions
General instructions and technical details
Profile Body
Mounting Screw

ACE Stoßdämpfer GmbH · Postfach 1510 · D-40740 Langenfeld · T +49 (0)2173 - 9226-10 (Technik -20) · F +49 (0)2173 - 9226-19 · [email protected] · www.ace-ace.comStand 03.2021 ACE Stoßdämpfer GmbH · www.ace-ace.com21_22_0019 Issue 05.2022
2
General instructions
This manual is for the disruption-free use of the product
types listed on page 1; its compliance is a prerequisite
for the fulfilment of any warranty claims.
Therefore, make sure to read this manual before use.
Please always maintain the specified limits from the per-
formance table (technical data). Take into account the
predominant environmental conditions and restrictions.
Note the regulations of the trade association, TÜV or
corresponding national, international and European reg-
ulations. Installation and commissioning only according
to mounting instructions.
Intended use
ACE profile dampers are an alternative product to the hydraulic
end position damper. They are used wherever moving masses do
not have to be accurately stopped and the energy does not have
to be completely absorbed. The reversible profile dampers are
intended for emergency stop and continuous uses. The TUBUS
profile dampers of the TC range are designed for force absorption
in an axial direction.
Description and function
The TC profile dampers of the ACE TUBUS series are mainte-
nance-free, ready-to-install damping elements made from a
co-polyester elastomer. The diminishing damping characteristic
curve causes a high energy capacity at the start of stroke. The
energy absorption is between 31 % and 64 %.
A structural change in the production process of these damping
elements creates a defined preloading, whereby the TUBUS
converts the occurring force into heat through friction.
One part of the occurring energy is therefore absorbed, whilst the
other part is released again by the return of the body to its original
position.
Calculation and design
In order to ensure an optimum, fault-free and durable function of
the TUBUS Profile Dampers they must be correctly dimensioned
and designed. The following parameters must be known and used
in the calculation:
- Moving mass [kg]
- Impact velocity of the mass into the profile damper(s) [m/s]
- Additionally acting propelling force, propelling power or propel-
ling torque [N, kW, Nm]
- Number of profile dampers acting in parallel [n]
- Number of strokes or cycles per hour [1/h]
The dampers must be dimensioned in such a way that the
maximum energy capacity per stroke is not exceeded during
continuous duty or for emergency stop applications. The specified
performance data and dimensions for the profile damper type
used can be found in the performance table. The correct size
of the profile dampers for emergency stop applications can be
determined with the ACE online calculation programme at www.
ace-ace.com. The calculations are based on dynamic loads.
Where necessary we will also happily send you the respective
dynamic and static characteristic curves. You can also send us
the completed online form by email for checking.
Or make use of our free calculation service by phoning: +49
(0)2173 9226 20
Delivery and storage
The profile damper can become damaged when opening the
packaging. Do not use cutting tools if possible.
- After delivery please check the profile dampers for any damage.
- Profile dampers can generally be stored in any position.
Maintenance and care
Profile dampers are made from one part and therefore do not need
any special maintenance. Profile dampers that are not regularly
operated (e.g. emergency stop devices) are checked at least
once per year as part of the normal safety check of the plant. The
surface is to be checked for cracks and deformations and the
mounting elements checked that they are properly secured. For
profile dampers that are regularly operated, these checks should
take place at intervals of no more than three months.
What should be noted after a damper impact?
Profile dampers that are not regularly operated are to be checked
after a damper impact.
Disassembly and disposal
The profile damper is 100 % recyclable and can be discarded in
household waste.
Example:
Type TC90-49 characteristic curve
Stroke (mm)
Energy (Nm)
1800
1500
1200
900
600
300
0
10 15 20 25 30 35 40
450
400
350
300
250
200
150
100
50
0
10 15 20 25 30 35 40
Stroke (mm)
Force (kN)
absorbed energy
rebound stroke energy
F
in
F
back
Energy stroke characteristic curve (dynamic)
(With impact velocity range over 0.5 m/s)
Force stroke characteristic curve (dynamic)
(With impact velocity range over 0.5 m/s)
WARNING
If TUBUS profile dampers are used where a failure of the
product could lead to personal injuries and/or material
damage, additional safety elements must be implemented.
Free-moving masses can lead to injuries by crushing
during installation of the profile damper. Secure moving
masses against inadvertent starting with suitable safety
precautions before installing the profile damper.
Safety information
The total energy and its absorbed portion can be determined from the selection charts.
Example: Energy to be absorbed 1,300 Nm = stroke used 38 mm see example energy stroke characteristic curve.
At the force stroke characteristic curve the determined stroke can be used to determine the share of absorbed or returned force.
As the return force is required for these types, note that at least 90 % of the stroke is used.
Dynamic (v > 0.5 m/s) and static (v ≤ 0.5 m/s) characteristic curves available for all types on request.
TC and TC-S Safety Dampers (crane installations)
Manual

ACE Stoßdämpfer GmbH · Postfach 1510 · D-40740 Langenfeld · T +49 (0)2173 - 9226-10 (Technik -20) · F +49 (0)2173 - 9226-19 · [email protected] · www.ace-ace.comStand 03.2021 ACE Stoßdämpfer GmbH · www.ace-ace.com21_22_0019 Issue 05.2022
3
Installation instructions
Before installation and use check whether the identification
number on the damper or on the packaging matches the
respective designation on the delivery note. Profile dampers are
maintenance-free and ready to install.
Operating temperature range: -40 °C to +90 °C
Temperature effect: The W3values given in the performance
table are valid for room temperature in the environment. At higher
temperatures the energy capacity per stroke is reduced.
Mounting: in any position, however, always in such a way that
the impact surface of the profile damper is evenly loaded. A side
load angle between profile damper and occurring mass is to be
avoided as transverse forces can lead to tearing off or permanent
deformation of the damper.
The outer diameter of the damper increases upon impact. Note
the max. compressed diameter (d1) listed in the table. The moving
mass should have at least the same diameter so that the entire
impact surface is loaded.
Mounting information: To mount the damper we recommend
the use of original ACE mounting screws. The listed maximum
torque is to be observed. Please also check the thread length (LM)
along with all further dimensions listed in the table.
Permissible torque of mounting screw:
M12: 50 Nm
M16: 40 Nm (DIN912)
M16: 120 Nm (collar bolt)
Note: For seawater applications please use stainless steel bolts
– these are not included.
Packaging disposal
Please dispose of the transportation packaging in an environ-
mentally-friendly manner. Recycling packaging materials saves
raw materials and reduces waste. The packaging materials do not
contain any prohibited materials.
d3
d2d1
LMA
Max.
Stroke
M
d3 d2d1
LMA
Max.
Stroke
M
Model Type TC Model Type TC-S
TC and TC-S
WARNING
A failure of the product can lead to personal injuries and/or
material damage. Use additional safety elements.
During installation/disassembly of the profile dampers,
moving masses can lead to injuries due to inadvertent
starting. Secure moving masses against inadvertent
moving.
The profile dampers may be unsuitable for use and
have an insufficient damping effect. Before installation
check the correct size of the dampers using the field
data, performance table (page 4) and calculations. The
energy capacity per stroke during continuous duty and for
emergency stop applications may not be exceeded (see
performance table).
The profile damper can tear off upon impact. Always lay out
the connection structure in such a way that the maximum
occurring forces can be absorbed with sufficient safety.
The maximum reacting forces Q listed in the calculations
may deviate from the actually occurring reacting forces, as
these are based on theoretical values.
The profile dampers may be unsuitable for use as a
rebound effect can occur. Note that the moving mass is
not accurately braked and the energy is not completely
absorbed. A limited application range is therefore to be
observed for the following drive types: toothed belt drive,
threaded spindle drive, drive with gears. The maximum
return forces listed in the calculations may deviate from
the actually occurring return forces, as these are based on
theoretical values.
Exceeding or falling below the maximum or minimum
temperature can lead to the destruction of the damper
material and the profile damper could lose its function.
Maintain the operating temperature range of -40 °C to
+90 °C.
Fluids or aggressive media in the surrounding area can
attack or destroy the material of the profile damper and
cause it to fail. Insulate the "external materials" in the area
around the profile damper. Note the chemical resistance
list.
Impact velocity that is too high can lead to damage to
the profile damper and failure. Note the maximum impact
velocity of 5 m/s.
The profile dampers for emergency stop may be unsuitable
for continued use after one impact. Profile dampers
that are not regularly operated (e.g. for emergency stop
devices) are to be checked after a damper impact.
Damage to the surface by other external influences
can lead to an insufficient damping and to a premature
failure of the profile damper. We recommend regularly
checking the surface for cracks and deformations as well
as checking the mounting elements are properly secured.
Check emergency stop devices at least once per year and,
in the case of continuous duty, at intervals of a maximum
of three months.
Please mount the dampers in such a way that there is
sufficient room for the max. compressed external diameter.
The moving mass should have at least the same diameter
so that it does not buckle or crack.
Performance data and dimensions
TYPES
1W3
Nm/cycle
Emergency
stop
W3
Nm/cycle
Stroke max.
mm
A
mm
d1
mm
d2
mm
d3
mm
LM
mm
M Weight
kg
TC64-62-S 450 630 62 79 64 52 89 12 M12 0.174
TC74-76-S 980 1,372 76 96 74 61 114 12 M12 0.260
TC83-73-S 1,940 2,715 73 94 83 69 127 12 M12 0.328
TC86-39 1,210 1,695 39 56 86 78 133 12 M12 0.284
TC90-49 1,640 2,295 49 68 90 67 124 12 M12 0.264
TC100-59 1,785 2,500 59 84 100 91 149 12 M12 0.452
TC102-63 1,970 2,760 63 98 102 82 140 22 M16 0.662
TC108-30 1,900 2,660 30 53 108 77 133 12 M12 0.392
TC117-97 3,710 5,195 97 129 117 100 188 16 M16 1.043
TC134-146-S 7,310 10,230 146 188 134 117 215 30 M16 1.573
TC136-65 4,250 5,950 65 106 136 106 178 16 M16 1.147
TC137-90 6,350 8,890 90 115 137 113 216 21 M16 1.201
TC146-67-S 8,330 11,660 67 118 146 99 191 16 M16 1.573
TC150-178-S 8,860 12,400 178 241 150 132 224 16 M16 2.674
TC153-178-S 7,260 10,165 178 226 153 131 241 16 M16 2.522
TC168-124 10,100 14,140 124 166 168 147 260 16 M16 2.533
TC176-198-S 12,725 17,810 198 252 176 150 279 16 M16 3.685
1Energy capacity per stroke during continuous duty.
All data are nominal dimensions. Tolerances are available on request.
Mounting instructions and mounting accessories
TC and TC-S Safety Dampers (crane installations)

ACE Stoßdämpfer GmbH · Postfach 1510 · D-40740 Langenfeld · T +49 (0)2173 - 9226-10 (Technik -20) · F +49 (0)2173 - 9226-19 · [email protected] · www.ace-ace.comStand 03.2021 ACE Stoßdämpfer GmbH · www.ace-ace.com21_22_0019 Issue 05.2022
4
Warranty
Fundamentally, all modifications to the product by third parties
lead to exclusion from the warranty.
Obvious defects must be reported to the vendor in writing immedi-
ately after delivery, no later than one week, but in any case before
processing or installation, otherwise the assertion of a warranty
claim is excluded. A timely dispatch is sufficient to keep the term.
The vendor is to be given an opportunity to check on site. If the
complaint is justified the vendor offers warranty by repair or re-
placement at its own discretion. If the rectification fails, the buyer
may choose to demand reduction of payment or cancellation of
the contract. If there is only a minor lack of conformity, particularly
with only minor defects, the buyer nevertheless has a right of
withdrawal.
If, after failed rectification, the buyer chooses to cancel the
contract due to a defect of title or material defect, they are not
entitled to additionally claim for damages.
If, after failed fulfilment, the buyer chooses compensation, the
goods remain with the buyer, if this is reasonable. The compen-
sation is limited to the difference between the purchase price and
the value of the defective item. This does not apply if the vendor
maliciously causes the breach of contract.
The quality of the goods is only considered as agreed upon with
the product description of the vendor. Public statements, claims
or advertising of the manufacturer do not represent an additional
contractual specification of quality of the goods.
If the buyer receives defective mounting instructions, the buyer
is only obligated to deliver defect-free mounting instructions and
only if the defect to the mounting instructions prevents proper
mounting.
The warranty period is two years and begins upon completion.
Exchange and return of custom products are fundamentally
excluded. The factory conditions of the manufacturing factory
apply to parts not manufactured and processed by the vendor,
which can be viewed by the orderer at the vendor at any time.
Construction and installation parts are delivered according to the
present standard of engineering.
Service life
In general TUBUS profile dampers are machine elements that
are subject to wear. The wear is largely dependent upon the
respective application and its operating parameters.
When used under optimum conditions and maintaining the
parameters specified in the performance table, a service life of up
to 1 million load changes is to be expected. Technical data
Energy capacity: 630 Nm/cycle to 17,810 Nm/cycle
Energy absorption: 31 % to 64 %
Dynamic force range: 80,000 N to 978,000 N
Operating temperature range: -40 °C to +90 °C
Construction size: 64 mm to 176 mm
Material hardness rating: Shore 55D
Material: Profile body: Co-polyester elastomer
Mounting screws: Special socket head screws with internal hex socket, zinc-plated 44Smn28 material (SAE 1144 machining
steel):
M12x18, M16x26
Socket head screws with internal hex socket, zinc-plated steel according to ISO 4762 - 8.8:
M16x35, M16x45, M16x60 (with washer according to DIN 7349, zinc-plated steel)
For seawater applications please use stainless steel bolts – these are not included.
Mounting: in any position
Environment: Resistant to microbes, seawater or chemical attack. Excellent UV and ozone resistance.
Material does not absorb water or swell.
Impact velocity range: Max. 5 m/s
Torque max.:
M12: 50 Nm
M16: 40 Nm (DIN912)
M16: 120 Nm (collar bolt)
Application field: Crane systems, Loading and lifting equipment, Hydraulic devices, Electro-mechanical drives
Note: Suitable for emergency stop applications and for continuous use. For applications with preloading and increased temperatures
please consult ACE.
On request: Special strokes, -characteristics, -spring rates, -sizes and -materials.
TC and TC-S Safety Dampers (crane installations)
Manual