THOMSON WhisperTrak Series User manual

Thomson WhisperTrak™
Electric Linear Actuator
Installation Manual
Edition 2018-01
DW110685-GB-1803
www.thomsonlinear.com

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Thomson WhisperTrak™ Electric Linear Actuator - Installation Manual - 2018-01
2
Version History
Edition Reason for revision
2011-06 First edition.
2012-05 4000 N model added and updated safety information.
2012-08 High speed version added.
2013-04 General technical update, changed page count, updated address list.
2013-07 Rewritten Electrical Installation section. Drawings and diagrams removed.
2016-05 New control options added. Updated some technical data and address list.
2017-01 Operation temp. for 4000 N changed. Performance and temp. derate diagrams added.
Slow blow added to fuse table. Safety nut info. and cleaning recommendations added.
2017-03 Certications line changed and ETL note added to table on page 12.
2017-05 Slow blow removed from fuse text and table on page 8.
2017-05:2 Molex connector wiring table changed.
2018-01 Sentence changed to “** Channel A leads channel B when extending“ on page 11.
Warranty
The Thomson WhisperTrak™ 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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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 Name plate ............................................................................................................ 6
4.2 Terminology ........................................................................................................... 6
4.3 Operation environment ......................................................................................... 6
4.4 Mechanical installation........................................................................................... 7
4.5 Electrical installation .............................................................................................. 8
5. Technical specications ........................................................................ 12
5.1 Technical data...................................................................................................... 12
5.2 Performance diagrams ........................................................................................ 13
5.3 Safety nut information.......................................................................................... 14
5.4 Cleaning............................................................................................................... 14
5.3 Type designation key........................................................................................... 15
Contents

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General
1. General
1.1 About this manual
This manual decribes how to install the Thomson WhisperTrak™ electric linear actuator both 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
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 -25 to +40 °C (-13 to +104 °F). Avoid
shocks to the package. If the package is damaged, check the actuator for visible damage and notify the
carrier, and if appropiate also Thomson.
1.5 Packaging
The packaging consists of a cardboard box. The box contains the actuator and this manual.
1.6 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.
1.7 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.

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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 on this product. Properly qualied personnel are familiar with mechanical or electrical
installation work and that have the appropiate qualications 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
exceeed 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
appropiate 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, RoHS directive 2002/95/EC, WEEE
directive 2002/96/EC, low voltage directive 2006/95/EC (EN60204-1:2006), directive of electromagnetic
compatibility 2004/108/EC (EN55014-1:2006, EN61000-6-3:2007, EN50011, EN55015:2006 &
EN55022:2006) and the standard for medical electrical equipment - part 1-2 (EN 60601-1-2 third edition).
Thomson WhisperTrak™ W12(24)xx-xxxxx-xxxx
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 2011-01-24
Date
Håkan Persson Product Line Manager
Name Title Signature

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4. Installation
4.1 Name plate
The name plate can be found on the actuator housing. 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 deisgnation of the actuator(s) in question.
4.2 Terminology
a. rear adapter c. housing e. extension tube
b. cable outlet d. cover tube f. front adapter
4.3 Operation environment
Operation temperature range is between -25 to +40° Celcius (-13 to +104° Fahrenheit). Two actuator
versions with option E will have a reduced load capacity at lower temperatures. See diagram “Load
Capacity vs. Operating Temperature” on page 13.
Protection degree against the ingress of water and particles is IP67.
Relative humidity range is 10 - 90 % non-condensing.
Installation
Wxx02-: Min. -25° C (-13° F) Max. +40° C (+104° F) IP67

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4.4 Mechanical installation
Always install actuator so that the force of the load acts in the center of the extension tube and the rear
adapter and support the mounting pins at both ends (a). Only mount the actuator to the rear and front
mounting adaptors using solid pins (b). The mounting pins must be parallel to each other both radially and
axially and be supported in both ends.
The actuator is equipped with an anti-rotation mechanism where the moving extension tube is internally
restrained from rotating. The maximum radial play allowed by the anti-rotation mechanism in the
extension tube is 10 degrees (c).
Failure modes of the actuator should be considered to ensure it does not create harm.
Warning! Do not hold the extension tube while the tube is moving or the unit is energized.
Installation
ø 10 mm
Radial play max. 10 °
ø 10 mm

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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.
• We recommend to include an emergency stop to avoid any 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 fuse between the actuator and the power source. See table
below for recommended fuse size.
4.5.3 Wire cross sections
To avoid malfunction due to voltage drop the cross section of the wires between the actuator motor 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.
Wire cross sections
Length of cable (L) Min. allowed cross section (X)
00 - 10 m 1.0 mm2(AWG 18)
10 - 20 m 1.5 mm2(AWG 14)
L
X0.34 mm (AWG 22)**
2
1 mm (AWG 18) *
2
U
12 VDC
24 VDC
+
-
* Leads for motor connections.
** Leads for signal/logic connections.
Recommended fuse size
Actuator supply voltage Max. load Fuse size
12 VDC 2000 N 5 A
12 VDC 4000 N 8 A
24 VDC 2000 N 2 A
24 VDC 4000 N 3 A

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Installation
M
STOP
+
–
M
STOP
+
–
M
+
–
STOP
S2
S1
S1
COM
EXT
RET
E
M
STOP
+
–
S1
P
D
F
FF
F
M
STOP
+
–
M
STOP
+
–
M
+
–
STOP
S2
S1
S1
COM
EXT
RET
E
M
STOP
+
–
S1
P
D
F
FF
F
black
black
red
brown
green
white
red
4.5.4 Connector wiring congurations
4.5.5 Installation of standard actuator with no electrical options (option N) or Electronic Limit
Switches (option X)
4.5.6 Installation of actuator with Electronic Limit Switches / Low Level Switching (option E)
M Actuator motor
S2 Single pole double throw (SPDT) switch
F Fuse
E Electronic limit switches device
Molex type connector (cable and connector option 3)
Pac Con type connector (cable and connector option 4)
By switching the polarity of the voltage to the
motor the extension tube will change direction.
Make sure the switch used can handle the
maximum motor current.
Option N: the actuator voltage must be switched
off when reaching the ends of stroke or due to a
mid-stroke overload to avoid causing damage to
the actuator.
Option X: the actuator will automatically switch off
when reaching the ends of stroke or a mid-stroke
overload.
The direction of the extension tube is controlled
by switching the COM (common) output to the
EXT (extend) or RET (retract) inputs.
The actuator will automatically switch off when
reaching the ends of stroke or a mid-stroke
overload.
Two actuator versions with option E will have a
reduced load capacity at lower temperatures.
They are Wxx02-54AxxxE (2000 N high speed
version) and Wxx04-58AxxxE (4000 N version).
Also see diagram “Load Capacity vs. Operating
Temperature” on page 13.
M
STOP
+
–
M
STOP
+
–
M
+
–
STOP
S2
S1
S1
COM
EXT
RET
E
M
STOP
+
–
S1
P
D
F
FF
F
M
STOP
+
–
M
STOP
+
–
M
+
–
STOP
S2
S1
S1
COM
EXT
RET
E
M
STOP
+
–
S1
P
D
F
FF
F
M Actuator motor
S1 Double pole double throw (DPDT) switch
F Fuse
Molex type connector wiring
Pin Option N Option D
1 black black
2 - -
3 - brown
4 - orange
5 - white
6 - -
7 - green
8 red red
red
black
1
2
3
4
5
6
7
8
A
B
Wiring diagram for option N and X
Wiring diagram for option E

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Technical specifications
4.5.7 Installation of standard actuator with Analog Feedback (option P) or Analog Feedback +
Electronic Limit Switches (option Z)
M
STOP
+
–
M
STOP
+
–
M
+
–
STOP
S2
S1
S1
COM
EXT
RET
E
M
STOP
+
–
S1
P
D
F
FF
F
black
red
brown
+5 V
0 V
* From 0.5 V at fully retracted (
3
5
7
5 VDC
DCG
) to 4.5 V at fully extended (
3
5
7
5 VDC
DCG
).
output 0.5 - 4.5 V* white
green
M
STOP
+
–
M
STOP
+
–
M
+
–
STOP
S2
S1
S1
COM
EXT
RET
E
M
STOP
+
–
S1
P
D
F
FF
F
M Actuator motor
S1 Double pole double throw (DPDT) switch
F Fuse
P Analog feedback device
S Actuator stroke length
CP Calibration point for analog feedback signal
By switching the polarity of the voltage to the
motor the extension tube will change direction.
Make sure the switch used can handle the
maximum motor current.
Option P: the actuator voltage must be switched
off when reaching the ends of stroke or due to a
mid-stroke overload to avoid causing damage to
the actuator.
Option Z: the actuator will automatically switch off
when reaching the ends of stroke or a mid-stroke
overload.
Feedback output is most accurate under uni-
directional loading when approaching the position
from the same direction.
Absolute positioning is affected by load direction
and value, clearance in the mounting points,
actuator end play, gear backlash, feedback
sensor linearity and the control systems capability
to control the motor.
To minimize the effects of stroke tolerances,
feedback output is calibrated at the factory to
provide 2.5 VDC output at the nominal mid stroke
position of the actuator (for example at 50 mm
for a 100 mm stroke). Applications should be
designed for travel between the maximum retract
position and the minimum extended length.
The smallest amount of positional movement the
analog feedback sensor can detect and reect is
0.12 mm.
Analog feedback data
Actuator stroke length [mm] Voltage resolution [V/mm]
100 0.040
200 0.020
300 0.0133
400 0.010
500 0.008
S
==
0.5 4.5
V
CP
2.5
Wiring diagram for option P and Z