THOMSON HD 100 User manual

Thomson Electrak®HD
Electric Linear Actuator
Installation Manual
Edition 2016-01
P-264-HD
www.thomsonlinear.com

Thomson
Thomson Electrak®HD Actuator - Installation Manual - 2016-012
Version history
Edition Reason for revision
2016-01 First edition
Warranty
The Thomson Electrak®HD 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 http://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,
microlm or any other method) or processed, copied or distributed by electronic means without the
written permission of Thomson.

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Thomson Electrak®HD Actuator - Installation Manual - 2016-01 3
Contents
1. General ...................................................................................................... 4
1.1 About this manual .................................................................................................. 4
1.2 Target group........................................................................................................... 4
1.3 Symbols used ........................................................................................................ 4
1.4 Transport and storage............................................................................................ 4
1.5 Packaging .............................................................................................................. 4
1.6 Disposal ................................................................................................................. 4
1.7 Support .................................................................................................................. 4
2. Safety......................................................................................................... 5
2.1 Safety notes........................................................................................................... 5
3. Standards.................................................................................................. 5
3.1 EC Declaration of conformity ................................................................................. 5
4. Installation ................................................................................................ 6
4.1 Product label.......................................................................................................... 6
4.2 Terminology ........................................................................................................... 6
4.3 Operation environment ......................................................................................... 6
4.4 Mechanical installation........................................................................................... 7
4.5 Electrical installation ............................................................................................ 10
4.6 Control options installation and operation............................................................ 12
5. CANBUS information ............................................................................. 20
5.1 Introduction to CANBUS SAE J1939 ................................................................... 20
5.2 CANBUS SAE J1939 communications protocol .................................................. 20
6. Technical specications ........................................................................ 24
6.1 Technical data...................................................................................................... 24
6.2 Ordering key ........................................................................................................ 25
Contents

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Thomson Electrak®HD Actuator - Installation Manual - 2016-014
General
1. General
1.1 About this manual
This manual contains mechanical and electrical installation instructions for the Thomson Electrak®HD
electric linear actuator. It also contains, among other things:
• technical data
• installation data
• type designation key.
It is important to carefully read this manual before installing the actuator and to have the correct
qualications needed to perform the installation.
1.2 Target group
This manual addresses qualied 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 Packaging
The packaging consists of a cardboard box. The box contains the actuator and this manual. For large
quantity orders bulk packaging may be used in which case the packaging and the content will vary
depending on the order agreement.
1.6 Disposal
Where required by law, used packaging and actuators are taken back by Thomson for professional
disposal if the transportation cost is paid by the sender. Please contact Thomson for shipping information.
1.7 Support
If technical support or information is needed for 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 contact us.

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Safety and Standards
2. Safety
2.1 Safety notes
• Only properly qualied personnel are permitted to perform mechanical and electrical
installation of this product. Properly qualied personnel are familiar with mechanical or electrical
installation work and have the appropriate qualications for their job.
• Read this manual and any other available documentation before working on the equipment
that the actuator is or shall be a part of.
• Conform strictly to the information contained in this manual and on the actuator product label
on the actuator. 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 damaged in any way and notify an
appropriate person so that corrective actions can be taken.
• Never 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 incorporation of partly completed machinery
We, Thomson Linear
declare that this product corresponds with the International Standard ISO 13766:2006-05 2nd Edition
(Earth Moving Machinery, Electromagnetic Compatibility). The directive (MD) 2006/42/EC annex 2.1.B,
RoHSII directive 2011/65/EU, and that the standard EN ISO 12100:2010, Safety of machinery, have been
applied.
Thomson Electrak®HD Linear Actuator HDxxBxxx-xxxxxxxxxxx
Product Description
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 2016-02-16
Date
Håkan Persson Business Unit Manager
Name Title Signature

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Thomson Electrak®HD Actuator - Installation Manual - 2016-016
4. Installation
4.1 Product label
The product label can be found on the side of the cover tube. It will tell you which model of actuator
you have, its basic performance data and where it is manufactured. Please study the product label
to determine actuator type before starting any installation or service on the actuator. If you need any
assistance from Thomson, please provide the serial number, manufacturing date and the designation of
the actuator(s) in question. You can also use the QR code on the label to directly access Electrak HD
information on www.thomsonlinear.com.
4.2 Terminology
4.3 Operation environment
1. Operation temperature range is -40 to +85° Celsius (-40 to +185° Fahrenheit).
2. Protection degree against the ingress of water and particles is IP67 / IP69K.
3. Relative humidity range is 10 - 90 % non-condensing.
Installation
Min. -40° C (-40° F) Max. +85° C (+185° F) IP67 / IP69K
a. power cable b. signal cable c. housing
d. manual override input e. cable connector cover plate f. cover tube
g. extension tube h. rear adapter i. product label
j. limit switch slots k. front adapter

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4.4 Mechanical installation
4.4.1 General installation safety notes
• Never work on the actuator with the power switched on!
• Do not hold the extension tube while the unit is energized.
• Failure modes of the actuator should be considered to ensure it does not create harm.
4.4.2 Basic installation considerations
1. Only mount the actuator using the holes in the rear (a) and front (b) adapters. Check the model
number on the actuator product label (section 4.1) and then look at the ordering key (section 6.2)
to nd out your adapter type conguration. See the below drawings and table to nd out the exact
adapter dimensions.
2. Make sure that the actuator mounting position allows access to the cable connector cover plate (c), so
that it can be removed to allow access to the cable connector(s) (section 4.4.4).
3. The cable or cables (d) exit the cable slot at the rear of the actuator housing at delivery but can be
made to leave the housing at any point after the cable connector cover plate.
4. The manual override input (e) must have enough free space around it to allow it to be operated
(section 4.4.5).
5. If external limit switches will be used, the mounting of the actuator must allow access to the limit
switch slots (f) running along the underside of the cover tube (section 4.4.6).
Installation
Adapter Dimensions [mm (in)]
Adapter type
M E N F P G
a1 12.2 E9 (0.48) 12.8 (0.506) 12.2 E9 (0.48) 12.8 (0.506) - -
a2 - - 8.2 (0.323) 8.2 (0.323) - -
b1 10.9 (0.429) 10.9 (0.429) 12.9 (0.508) 12.9 (0.508) 30 (1.18) 30 (1.18)
b2 12.2 E9 (0.48) 12.8 (0.506) 12.2 E9 (0.48) 12.8 (0.506) M12 × 1.75 1/2-20 NF-2B
b3 - - 8.2 (0.323) 8.2 (0.323) 19 (0.748) 19 (0.748)

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4.4.3 Mounting orientation and forces
1. The actuator can be mounted in any orientation and handle both pushing and pulling loads.
2. Always install actuator so that the force of the load acts in the center of the extension tube and the
rear adapter.
3. Only mount the actuator to the rear and front adapter mounting holes.
4. Only use solid mounting pins and support them at both ends.
5. The mounting pins must be parallel to each other both radially and axially.
4.4.4 Cable connector cover plate
1. The cover plate is held in place by a screw (M3 with Torx T10 head) that can be accessed through
the hole in the top of the cover plate (a). Keep in mind to mount the actuator so that there is enough
clearance to access the screw with a tool!
2. Once the cover plate is released it needs to be pushed about 20 mm (0.8 inch) in the direction of
the arrow symbol on the cover plate before it can be removed from the actuator (b). The connectors
are a part of the backside of the cover plate and can be accessed once the cover plate is removed.
3. Make sure to put the cover plate back correctly and torque the screw to 1.2Nm (10.6 in-lb) to ensure
that the actuator cover plate and connectors are properly sealed.
YES NO

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4.4.5 Manual override mounting and operation
1. Make sure when mounting the actuator that there is space enough between the rear adapter and any
object behind it to allow the manual override to be operated!
2. To operate the manual override, remove the cover plug (a) using a at head screw driver. Then
turn on the manual override input hexagon key (b) using a 6 mm hexagon deepwall socket (c).
3. The maximum torque required to move the extension tube at the fully rated actuator load using the
manual override is typically 1.7 Nm (15 in-lb).
4. The distance the extension tube travels per manual override input revolution depends on the
actuator type. See the table below.
Always make sure to switch off the power to the actuator before using the manual override.
Do not apply higher torque than 1.7 Nm (15 in-lb) to the manual override input.
Never run the extension tube in to the end of stroke as that may damage the actuator.
Never use any type of drill or power tool to operate the manual override.
4.4.6 Mounting of optional external limit switches
1. The external limit switches are mounted in the two slots (a) at the bottom of the cover tube.
2. Put the sensor (b) into one of the slots and and lock it at the desired position by turning the clamp
screw 45 degrees (c).
If the sensor is mounted in the immediate vicinity of magnetic components, the
switching characteristics of the sensor may change.
Extension Tube Movement / Manual Override Input Revolution [mm (in)]
Actuator type Movement
HDxx-B026 0.224 (0.0088)
HDxx-B045 0.134 (0.0053)
HDxx-B068 0.099 (0.0039)
HDxx-B100 0.059 (0.0023)

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Installation
4.5 Electrical installation
4.5.1 General notes
• Make sure the leads/cables leading to the motor can handle the maximum motor current.
• An emergency stop is recommended to reduce the chance of a crushing hazard.
• Never work on the actuator or the wiring with the power switched on!
4.5.2 Fuse size
Protect the actuator and the wiring by using a slow blow fuse between the actuator and the power source.
4.5.3 Electrical connections
The actuator is always supplied with a power cable (a). Depending on which control option was selected, it
can also have a signal cable (b). The cable(s) have ying leads in one end for customer connections. In the
other end the cable(s) are integrated in to the cable connector cover plate (c) (section 4.4.4). The plug in
connector allows replacing the actuator without disconnecting the ying leads.
4.5.4 Lead cross sections
To avoid malfunction due to voltage drop the cross section of the leads between the actuator power
cable leads and the power source must be of sufcient size. For longer cables than stated in the table,
calculations based on the supply voltage, the current draw, the length of the cables and the ambient
temperature must be done.
Power Lead Cross Sections
Length of cable (L) Min. allowed cross section (X)
0 - 4 m 2.5 mm2[AWG 14]
4 - 10 m 4 mm2[AWG 12]
Recommended Fuse Size
Actuator supply voltage Fuse size
12 VDC 40 A
24 VDC 20 A
2.5 mm2[AWG 14]
Power cable
Signal cable
X
0.5 mm2[AWG 20]