STABILUS ACE TUBUS TR-HD 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
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
TR-HD
TUBUS TR-HD
Profile Dampers
Compact powerhouse in solid material
Radial damping, heavy duty version
Energy capacity 405 Nm/cycle to 11,840 Nm/cycle
Maximum stroke 12 mm to 44 mm
The identification numbers listed are the
respective standard units of the corresponding
damper series. Special types can have deviating
identification numbers.
General instructions and technical details
Operating and mounting instructions
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 TR-HD range are designed for force
absorption in an radial direction.
Description and function
The TR-HD profile dampers of the ACE TUBUS series are
maintenance-free, ready-to-install damping elements made from
a co-polyester elastomer. Like the TR standard model, they are
radially loaded, yet, thanks to their solid design, offer higher force
and energy capacity with a smaller damping path. Various material
hardness ratings mean that different damping characteristic
curves can be attained. The energy absorption is between 43 %
and 72 %.
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.
Characteristic curves
550
500
450
400
350
300
250
200
150
100
50
0
5 10 15 20 25 30 35 40
Stroke (mm)
Force (kN)
TR52-14HD
TR47-17HD
TR105-28HD
TR97-35HD
TR-HD product family
Force stroke characteristic curves (static)
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
Profile Dampers TR-HD (radial damping, heavy duty version)
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:
M10: 7 Nm
M12: 12 Nm
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.
E
B
C
Max.
Stroke
M
D
A +/- 3.1 mm
LM
TR-HD
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
F max.
static
N
Stroke max.
mm
A
mm
B
mm
C
mm
D
mm
E
mm
LM
mm
M Weight
kg
TR42-14HD 405 567 63,900 14 34 148 42 59 102 20 M10 0.170
TR47-12HD 857 1,200 149,600 12 31 150 47 58 102 19 M10 0.170
TR47-17HD 850 1,190 122,100 17 32 150 47 70 102 24 M10 0.180
TR52-14HD 1,634 2,288 304,500 14 29 153 52 69 102 22 M10 0.180
TR57-21HD 1,194 1,672 104,800 21 48 149 57 79 102 18 M10 0.340
TR62-15HD 1,790 2,506 245,000 15 40 153 62 77 102 16 M10 0.330
TR62-19HD 2,940 4,116 389,900 19 41 152 62 94 102 16 M10 0.360
TR63-24HD 2,061 2,885 194,400 24 46 153 63 92 102 20 M10 0.330
TR72-26HD 1,700 2,380 124,800 26 59 149 72 98 102 23 M12 0.560
TR79-20HD 2,794 3,912 289,300 20 54 153 79 98 102 24 M12 0.570
TR79-31HD 2,975 4,165 226,600 31 58 155 79 112 102 23 M12 0.560
TR85-33HD 2,526 3,536 146,100 33 71 150 85 111 102 23 M12 0.710
TR89-21HD 4,438 6,213 477,400 21 48 162 89 112 102 22 M12 0.560
TR90-37HD 3,780 5,292 240,700 37 69 155 90 128 102 23 M12 0.750
TR93-24HD 3,421 4,789 302,500 24 64 155 93 115 102 23 M12 0.790
TR97-31HD 7,738 10,833 575,200 31 63 159 97 129 102 21 M12 0.800
TR97-35HD 2,821 3,949 152,800 35 82 151 97 131 102 20 M12 1.060
TR102-44HD 4,697 6,576 254,500 44 81 156 102 147 102 22 M12 1.050
TR105-28HD 5,641 7,897 427,600 28 72 156 105 126 102 21 M12 1.000
TR117-30HD 8,457 11,840 639,100 30 66 166 117 143 102 25 M12 1.010
1Energy capacity per stroke during continuous duty.
All data are nominal dimensions. Tolerances are available on request.
Mounting instructions and mounting accessories
Profile Dampers TR-HD (radial damping, heavy duty version)

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: 405 Nm/cycle to 11,840 Nm/cycle
Energy absorption: 43 % to 72 %
Dynamic force range: 78,800 N to 812,900 N
Operating temperature range: -40 °C to +90 °C
Construction size: 42 mm to 117 mm
Mounting: in any position
Material hardness rating: Shore 40D, Shore 55D
Material: Profile body: Co-polyester elastomer
Mounting screws: Socket head screws with internal hex socket, zinc-plated steel according to DIN 7984 - 8.8:
M10x30, M12x35
For seawater applications please use stainless steel bolts – these are not included.
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.:
M10: 7 Nm
M12: 12 Nm
Application field: Offshore industry, Agricultural machinery, Impact panels, Conveyor systems, Stacking units, Shipbuilding, Shovels or
articulated joints for construction machinery, Transport roads, Loading and lifting equipment
Note: Suitable for emergency stop applications and for continuous use. For applications with preloading and increased temperatures
please consult ACE.
Safety instructions: Mounting screw should additionally be secured with Loctite.
On request: Special strokes, -characteristics, -spring rates, -sizes and -materials.
Profile Dampers TR-HD (radial damping, heavy duty version)
Manual