Profile Rail Linear Guides

Profile Rail Linear Guides 

500 Series Ball Profile Rail 

500 Series Roller Profile Rail 

AccuMini 

MicroGuide 

T-Series 

A DANAHER MOTION COMPANY 

Linear Motion. Optimized.

Thomson - 

Linear Motion. Optimized. 


Often the ideal design solution is not about finding the fastest, sturdiest, most accurate or even the least expensive option. 

Rather, the ideal solution is the optimal balance of performance, life and cost. 

Thomson is best positioned to help you most quickly configure the optimal linear motion solution for your application. 

• Thomson invented anti-friction linear bearing technology. We own the broadest standard product offering of mechanical 

motion technologies in the industry. 

• Modified versions of standard product are routine. White sheet design solutions available across our entire portfolio. 

• Choose Thomson and gain access to over 70 years of global application experience in diverse industries including 

packaging, factory automation, material handling, medical, clean energy, printing, automotive, machine tool, aerospace 

and defense. 

• As part of Danaher Motion, we are financially strong and unique in our ability to bring together control, drive, motor, 

power transmission and precision linear motion technologies. 

Thomson is the name you can trust for quality, innovation, on-time delivery, controlled costs, and 

reduced risk. 

In addition to the information contained in this document, a wealth of product and application information is available online 

at www.thomsonlinear.com. Also online are downloadable 3D models, software tools, our distributor locator and global 

contact information for Thomson. For immediate assistance in North America contact us at 1-540-633-3549 or email us at 

Thomson@danahermotion.com. 

Talk to us early in the design process to see how Thomson can help identify the optimal balance of performance, life and 

cost for your next application. And, call us or any of our 2000+ distribution partners around the world for fast delivery of 

replacement parts. 

The Danaher Business System - 

Building sustainable competitive advantage into your business 

The Danaher Business System (DBS) was established to increase the value we bring to customers. It is a mature and successful 

set of tools we use daily to continually improve manufacturing operations and product development processes. DBS is based 

on the principles of Kaizen which continuously and aggressively eliminate waste in every aspect of our business. DBS 

focuses the entire organization on achieving breakthrough results that create competitive advantages in quality, delivery and 

performance – advantages that are passed on to you. Through these advantages Thomson is able to provide you faster times 

to market as well as unsurpassed product selection, service, reliability and productivity. 

Local Support Around the Globe 

Application Centers Global Manufacturing Operations Global Design & Engineering Centers 

Application Centers 

Global Manufacturing Operations 

Global Design & Engineering Centers

An Overview of Danaher Motion – Thomson Profile Rail 


500 Series Ball 

Profile Rail 

Overview ...................................................................................................................... 4 

500 Series Ball Profile Rail Linear Guide .............................................................. 8 

Thomson Next Generation Profile Rail. Superior Design. Superior Quality. 

Product overview ................................................................................................. 9 

Part numbering ................................................................................................... 19 

Datasheets .......................................................................................................... 21 

Options and accessories .................................................................................. 31 

Accuracy information ....................................................................................... 42 

Preload information ........................................................................................... 42 

500 Series Roller Profile Rail Linear Guide ........................................................ 44 

Thomson Next Generation Profile Rail. Superior Design. Superior Quality. 

Product overview ............................................................................................... 45 


Datasheets .......................................................................................................... 55 

Options and accessories .................................................................................. 59 

Lubrication Fittings ............................................................................................ 70 



AccuMini.................................................................................................................... 73 

Ultra Compact, High Roll & Superior, Patented Ball Control Design. 

Product overview ............................................................................................... 73 


Datasheets .......................................................................................................... 74 



MicroGuide ................................................................................................................ 77 

T-Series ....................................................................................................................... 84 

Installation Guide ..................................................................................................... 92 

Engineering Guide .................................................................................................... 96 

Sizing, selection and life load calculations ................................................... 97 

Deflection .......................................................................................................... 104 

Lubrication ........................................................................................................ 126 

Bellow cover calculations ............................................................................. 128 

Butt joint specification sheets ....................................................................... 129 

Conversion factors .......................................................................................... 132 

Interchange Guide .................................................................................................. 134 

For more information, or to place an order, please contact your local authorized 

Thomson distributor or Danaher Motion at 1-540-633-3400, Fax: 1-540-633-4162, 

or E-mail at profilerail@danahermotion.com. 

500 Series Roller 

Profile Rail AccuMini 

MicroGuide T-Series 

Lubrication 

Fittings 

Installation 

Guide 

Engineering 

Guide 

DANAHER MOTION is a registered trademark of Danaher Corporation. Danaher Motion makes every attempt to ensure accuracy and reliability of the specifications in this publication. Specifications are subject to change without notice. 

Danaher Motion provides this information „AS IS“ and disclaims all warranties, express or implied, including, but not limited to, implied warranties of merchantability and fitness for a particular purpose.It is the responsibility of the product user 

to determine the suitability of this product for a specific application. ©2004 Danaher Motion. 

www.thomsonlinear.com 3 

Interchange 

Guide


Overview of Danaher Motion – Thomson Profile Rail Linear Guides 

Since the invention of the linear anti-friction Ball Bushing 

bearing by Thomson over 50 years ago, the Thomson 

precision linear products have meant high quality, 

innovative products. Today, Danaher Motion continues 

producing and developing these high quality, innovative 

products. The Danaher Motion Thomson Profile Rail 

assortment consists of the Next Generation Profile 

Rail “500 Series” Ball and Roller Linear Guides, compact 

miniature “MicroGuide,“ lightweight “T-Series,” 

and AccuMini. 

The Danaher Motion Profile Rail – Linear Guide Assortment 

is a complete assortment of rails and carriages in a 

broad range of styles, sizes and unique features 

produced to industry standard dimensions for 

easy retrofitting into existing applications or designing 

into new applications. 

500 Series Ball Profile Rail Linear Guide 

Features & Benefits 

Superior Design. Superior Quality. 

• Straight rails through advanced 

grinding technologies 

• Simple installation and greater accuracy 

with joint-free rails up to 6 meters 

• Smooth, quiet movement through patented insert 

molded recirculation paths and optimized geometries 

• Extended lubrication life as a result of grease 

pockets built into the recirculation path 

• Multiple carriage styles and sizes available 

• On site field modifiable modular seals 

• Rail and carriage options from stock or short delivery 

• Customization with expanded accessory offering 

• Replaces AccuGlide 

Typical Applications 

• Industrial Automation 

• Machine Tool Equipment 

• Material Handling 

• Precision Measuring Equipment 

• Industrial Robots 

• Food Processing Equipment 

4 

www.thomsonlinear.com




500 Series Roller Profile Rail Linear Guide 


Superior Design. Superior Quality. 

• Industry leading load capacities 

• High rigidity from back to back four roller track arrangement 

• Straight rails through advanced grinding technologies 

• Simple installation and greater accuracy with jointfree 

rails up to 6 meters 

• Smooth, quiet movement through patented insert 

molded recirculation paths and optimized geometries 

• Multiple carriage styles and sizes available 

• On site field modifiable modular seals 

• Rail and carriage options from stock or short delivery 

• Customization with expanded accessory offering 

• Replaces Accumax 


• Industrial Automation 

• Material Handling 

• Industrial Robots 

• Machine Tool Equipment 

• Precision Measuring Equipment 

• Food Processing Equipment 

AccuMini 


• Ball control design for smooth, quiet, low friction 

at high speeds 

• Full length integral wiper which protects important 

bearing from contaminants… effective system life 

is maximized 

• Gothic design, which provides high roll moment 

capacity...a requirement for stand-alone applications 

• Wear-resistant, engineered polymer retainer which 

reduces system inertia and noise 


• Wafer Handling Equipment 

• Assembly Equipment 

• Inspection and Measurement Equipment 

www.thomsonlinear.com 5


MicroGuide 


• Industry standard drop-in replacement 

• 440 stainless steel construction (corrosion resistance, 

little or no lubrication) 

• High precision accuracy (up to ±0.010mm) 

• Extremely smooth, quiet operation 

• Unlimited stroke 

• Low Profile 

• High Moment Load Capacity for single rail / carriage 

applications 

• Whisper quiet movement 

• Gothic arch ball groove geometry provides enables 

single rail application 

• Sizes: 5mm, 7mm, 9mm, 12mm, 15mm (MicroGuide 

standard) 

• Sizes: 7mm, 9mm, 12mm, 15mm (MicroGuide wide) 

• Technical engineering support from Danaher Motion 

• One-piece length up to 1 meter (in sizes 7mm - 15mm) 

• Contact Danaher Motion for custom lengths and 

configurations 


• Front end semiconductor processing equipment 

• Backend semiconductor packaging and handling 

equipment 

• Medical diagnostic and imaging equipment 

• Laboratory automation equipment 

• Testing and inspection equipment 

T-Series 


• Lightweight, flexible and forgiving alternative to all-steel 

profile rail. 

• High quality product made from aircraft aluminum alloy 

with hardened steel load bearing plates and ball paths. 

• Ideal choice for applications requiring reduced weight 

inertia. 

• High flexibility translates into N class radial run out only. 

• Proprietary "U" channel construction allows the rail to 

"flex" to accommodate poor machine bases or 

misalignment errors. 

• Lower cost installation and reduced installation time by 

eliminating the need for a costly machined base and 

special tools. 

• Drop-in replacement for conventional all-steel profile 

linear guides. 


• Airplanes 

• Automobiles 

• Machine Tool 

• Ships 

• Packaging 

6 


Assortment 




SIZE MM 

500 Series Ball 500 Series Roller AccuMini MicroGuide T-Series 

Standard Narrow Standard Narrow Standard Standard Wide Standard 

––– Long Long Long Short Long Long 

––– ––– ––– ––– High High ––– ––– ––– ––– ––– ––– ––– ––– ––– ––– 

5 • 

7 • • 

9 • • 

10 • 

12 • • 

15 • • • • • • • 

20 • • • • • • • • • • 

25 • • • • • • • • • • • • • • 

30 • • • • • • 

35 • • • • • • • • • • • • • • 

45 • • • • • • • • 

55 • • • • 

65 • • • • 

Style A B C D E F G A B C D A N/A N/A A G E F 

Page 21 21 23 23 25 25 27 55 55 57 57 75 78 80 87 87 89 89 

Application Criteria 

Feature 500 Series Ball 500 Series Roller AccuMini MicroGuide T-Series 

Load Capacity ••• •••• •• • •• 

Equivalent Loads all directions ••• •••• •• •• • 

Ultra Compactness • • ••• •••• • 

High Travel Accuracy •••• •••• •••• •••• ••• 

Rigidity ••• •••• •• •• • 

Smoothness ••• •• •••• •••• ••• 

Friction Characteristic •••• •• •••• •••• •• 

Admissable Speed •••• ••• •••• •••• ••• 

Ease of Installation ••• •• •• ••• •••• 

Lightweight • • •• ••• •••• 

Industry Standard Dimensions •••• •••• •••• •••• 

Page 8 44 73 77 84 

• = satisfactory •••• = excellent 





High load capacities 

in all directions 

Industry standard dimensions 

Patented insert molded 

recirculation path with grease 

pockets resulting in quiet, 

low noise operation 

Multiple carriage designs, 

accuracies and preloads available 

Multiple rail accuracies 

Optimized ball path geometries and 

transitions for quiet, smooth operation 

One piece rail length up to 6 meters 

(size 25 and up) 

Multiple rail mounting hole plug options, 

or rails that mount up from underneath 

are available 

Both sides of rail are reference edges 

Six-runner block attachment bolts 

per carriage for superior system 

rigidity 

Universal mounting holes–runner blocks can be 

attached from top or bottom 

Multiple lubrication inlet points, easy 

field modification 

Superior rail straightness as a result 

of advanced grinding and straightening 

technology 

Modular accessories for on site 

upgrade without having to 

remove the carriage from the rail 

Corrosion resistance with Duralloy ® 

Thin Dense Chrome plating optional 

Low drag longitudinal seals standard for 

added protection along rail surface 

Removable double lip seal 

or low drag seal 

Extended standard dowel hole 

options for rails and carriages 

Complete interchangeability 

between rails and carriages 

Two point ball contact resulting 

in low friction 

High rigidity from optimized 

trapezoidal profile, allows for 

single carriage application 

Speeds up to 5 m/s 

Accelerations up to 100 m/s 2 

8 






Features 

The Thomson 500 Series Ball Linear Guide provides long life, 

exceptional rigidity, high dynamic and static load capa cities, 

accommodation for high moment loads, high running 

accuracy, multiple sealing options and multiple lubrication 

inlet options. This allows for on-site field modifications, and 

interchangeability with competitor offering. 

These properties result in improved machine accuracies and 

rigidity resulting in reduced vibration extending machine and 

tool life. This has a direct effect on operational efficiency 

resulting in cost savings for the user. 

Available in 7 carriage designs, and sizes 15 to 45mm. 

Materials Linear Guides 

The 500 Series Ball Linear Guides are produced from high 

quality bearing steel. All carriages and rolling elements are 

through hardened and all rails are case hardened (except 

size 15 rail which is through hardened). The end cap is 

constructed of a high strength, glass filled nylon with nitrile 

rubber seal. Stringent quality controls are in place to ensure 

consistency of materials from the source, allowing us to 

ensure that we delivery the highest quality product. 

Interchangeability 

The 500 Series Ball Linear Guides are completely 

interchangeable. Any carriage can be run on any rail of the 

same accuracy without compromising system accuracy. 

This is the result of our stringent manufacturing process 

controls. 

Accuracy and Preload 

The 500 Series Ball Linear Guides are available in three 

different accuracy classes, three different preload ranges 

and with clearance to allow for customization to your 

appli cation needs. 

Straightness 

The 500 Series Ball rail is subjected to multiple straightening 

processes during and after grinding of the roller paths. 

These added processes and inspections result in some of 

the straightest rails in the market today, improving machine 

accuracies wherever the 500 Series Ball is used. 

Rigidity 

The 500 Series Ball Linear Guide rail utilizes a special 

trapezoidal profile that maximizes the carriage cross 

section, resulting in the highest possible rigidity. 





Running Smoothness / Low Noise 

The running smoothness and low noise are the result of 

a patented, custom insert molded recirculation path that has 

an optimized geometric shape and minimal transitions, to 

ensure smooth and quiet operation in both low and high-speed 

operation. 

In addition, the balls make contact at only two points 

between rail and carriage. As a result, friction is reduced to 

a minimum, resulting in quiet, smooth operation. 

Back-to-Back 

The 500 Series Linear Guide utilizes a back-to-back bearing 

arrangement, resulting in added rigidity. As a result, the 500 

Series Ball can be used in single rail applications. 

Internal Grease Pockets 

The patented insert molded recirculation path has built in 

grease pockets. These provide an extra level of security by 

ensuring adequate lubrication is available to the ball bearings 

to help extend life. 

The pocket and area between the balls provide greater grease 

quantities in the ball path than a conventional 

designed linear guide bearing. 

Multiple Lubrication Options 

The standard end cap is designed for flexibility. The end cap 

comes standard with four lubrication inlet options. These 

inlet options are easily changed on-site in the field or can be 

supplied from the factory. 

Unsure of the best lubrication inlet location? These carriages 

allow the user to make these changes easily in the field to 

optimize the system performance. In addition, they allow for 

ease in maintenance – all without removing the carriage from 

the rail. 

10 






Modular Accessory Options 

The standard carriage is supplied with low friction 

double lip seals and longitudinal seals that completely 

encase the bearing carriage to protect the balls and track 

surfaces and minimize lubrication loss. 

Optional metal scrapers or wipers, lube blocks and oil 

reservoir components can be easily added on-site in the 

field or can be supplied assembled from the factory. 

The trapezoidal rail profile allows for easy servicing and 

replacing or adding of the end cap, additional wiper and 

oil reservoir without removing the carriage from the 

rail. 

These innovative design features allow users to easily, 

efficiently, and economically upgrade carriage sealing. 

Longitudinal Seals 

The carriage has built-in under carriage low drag longitudinal 

seals that protect the balls and ball path from 

contamination. These longitudinal seals are an added 

protection to increase the life and overall performance. 

Extended Standards 

Extended Standards are an assortment of Danaher Motion 

dowel hole options for both carriage and rail products. 

Take the guesswork out of design by using our standard 

assortment of dowel hole options for ease of design and 

availability, another solution from Danaher Motion. Refer 

to page 29, 30 and 33 for more information and detailed 

datasheets. 

Rail Accessories 

The rails have multiple options to protect the mounting 

holes to eliminate possible contamination entry into the 

bearing. Custom designed plastic plugs, mylar tape and 

stainless steel rail cover strip are available. 

Retained Balls 

The rolling elements of the carriages are retained within 

the bearing so the carriage can be removed from the rail 

without worrying about the balls falling out. It is recommended 

to place any removed carriage onto an assembly 

rail or shipping arbor to provide added protection to the 

rolling elements. 



500 Series Profile Rail Enhanced Carriage 

New, 66% Smoother Running Design, with 50% 

Lower Drag Force * 

New Ball Spacer and Stainless Steel Options 

Features and Benefits 

Now available in all sizes: the new Thomson 500 Series 

Profile Rail enhanced carriage design can improve the 

smoothness and precision of your linear motion application. 

New optional 440B stainless carriages and rails provide 

corrosion resistance well-suited for medical, food, electronic 

assembly and semiconductor applications. 

• New ball spacer carriage option provides smooth, quiet 

motion. 

• New, smoother running design optimizes the surface 

interfaces between steel and plastic transition areas along 

the ball bearing circulation path. 

• New standard end seals provide twice the contaminant 

protection compared to competitive products. Optional low 

drag end seals are ideal for low push force requirements. 

• Four longitudinal seals per carriage provide much better 

contaminant protection than competitive designs with 

only two longitudinal seals. 

• Additional lubrication reservoir enables longer running 

time and easy change end caps & seals are quick to 

replace. 

• 100% interchangeable with previous Thomson 500 Series 

carriage and rail. 

* 66% smoothness increase measured as variability of drag force while the 

carriage is in motion. 50% lower drag force measured with new low drag 

seals option; 41% lower drag force measured with standard wiper option. 

12 






Modular Accessory Exploded View 

Standard end cap 

(531 EC) 

Integral double lip seal 

Standard end cap* 

(531 EC) 

Recirculation path 

Oil reservoir* 

(531 OW) 

Balls 

Additional wiper* 

(531 WR or VR) 

Metal scraper 

(531 ZZ) 

Plastic plugs 

(531 HP) 

Rail 

(521) 

Grease fitting 

Attaching bolts 

Also available (not shown): 

• Lube Block (531 LL) 

• Mylar Rail Tape (531 RT) 

• Bolt up from bottom rail (521 Type U) 

• Stainless Steel Rail, Cover Strip and Rail (521 Type C 

and 531RCS) 

* Can be installed without removing carriage from the 

rail 

The modular building block design of the 500 Series Ball 

Profile Rail Linear Guide assembly allows for easy on-site 

field upgrades for quick seal or lubrication changes, all 

without the need to remove the carriage from the rail. 


www.thomsonlinear.com 

14 


500 Series Ball Standard Carriages 

15 

20 

25 

30 

35 

45 

20 

25 

30 

35 

45 

15 

20 

25 

30 

35 

20 

25 

30 

35 

1500 

3000 

6000 

6000 

6000 

6000 

3000 

6000 

6000 

6000 

6000 

1500 

3000 

6000 

6000 

6000 

3000 

6000 

6000 

6000 

511H15A0 

- 

- 

511H20A0 

- 

- 

511H25A0 

- 

- 

511H30A0 

- 

- 

511H35A0 

- 

- 

511H45A0 

- 

- 

511H20B0 

- 

- 

511H25B0 

- 

- 

511H30B0 

- 

- 

511H35B0 

- 

- 

511H45B0 

- 

- 

511H15C0 

- 

- 

511H20C0 

- 

- 

511H25C0 

- 

- 

511H30C0 

- 

- 

511H35C0 

- 

- 

511H20D0 

- 

- 

511H25D0 

- 

- 

511H30D0 

- 

- 

511H35D0 

- 

- 

H 

P 

U 

H 

P 

U 

H 

P 

U 

H 

P 

U 

H 

P 

U 

H 

P 

U 

H 

P 

U 

H 

P 

U 

H 

P 

U 

H 

P 

U 

H 

P 

U 

H 

P 

U 

H 

P 

U 

H 

P 

U 

H 

P 

U 

H 

P 

U 

H 

P 

U 

H 

P 

U 

H 

P 

U 

H 

P 

U 

511H15A1 

511P15A1 

511U15A1 

511H20A1 

511P20A1 

511U20A1 

511H25A1 

511P25A1 

511U25A1 

511H30A1 

511P30A1 

511U30A1 

511H35A1 

511P35A1 

511U35A1 

511H45A1 

511P45A1 

511U45A1 

511H20B1 

511P20B1 

511U20B1 

511H25B1 

511P25B1 

511U25B1 

511H30B1 

511P30B1 

511U30B1 

511H35B1 

511P35B1 

511U35B1 

511H45B1 

511P45B1 

511U45B1 

511H15C1 

511P15C1 

511U15C1 

511H20C1 

511P20C1 

511U20C1 

511H25C1 

511P25C1 

511U25C1 

511H30C1 

511P30C1 

511U30C1 

511H35C1 

511P35C1 

511U35C1 

511H20D1 

511P20D1 

511U20D1 

511H25D1 

511P25D1 

511U25D1 

511H30D1 

511P30D1 

511U30D1 

511H35D1 

511P35D1 

511U35D1 

511H15A2 

511P15A2 

511U15A2 

511H20A2 

511P20A2 

511U20A2 

511H25A2 

511P25A2 

511U25A2 

511H30A2 

511P30A2 

511U30A2 

511H35A2 

511P35A2 

511U35A2 

511H45A2 

511P45A2 

511U45A2 

511H20B2 

511P20B2 

511U20B2 

511H25B2 

511P25B2 

511U25B2 

511H30B2 

511P30B2 

511U30B2 

511H35B2 

511P35B2 

511U35B2 

511H45B2 

511P45B2 

511U45B2 

511H15C2 

511P15C2 

511U15C2 

511H20C2 

511P20C2 

511U20C2 

511H25C2 

511P25C2 

511U25C2 

511H30C2 

511P30C2 

511U30C2 

511H35C2 

511P35C2 

511U35C2 

511H20C2 

511P20D2 

511U20D2 

511H25D2 

511P25D2 

511U25D2 

511H30D2 

511P30D2 

511U30D2 

511H35D2 

511P35D2 

511U35D2 

- 

511P15A3 

511U15A3 

- 

511P20A3 

511U20A3 

- 

511P25A3 

511U25A3 

- 

511P30A3 

511U30A3 

- 

511P35A3 

511U35A3 

- 

511P45A3 

511U45A3 

- 

511P20B3 

511U20B3 

- 

511P25B3 

511U25B3 

- 

511P30B3 

511U30B3 

- 

511P35B3 

511U35B3 

- 

511P45B3 

511U45B3 

- 

511P15C3 

511U15C3 

- 

511P20C3 

511U20C3 

- 

511P25C3 

511U25C3 

- 

511P30C3 

511U30C3 

- 

511P35C3 

511U35C3 

- 

511P20D3 

511U20D3 

- 

511P25D3 

511U25D3 

- 

511P30D3 

511U30D3 

- 

511P35D3 

511U35D3 

521H15A 

521P15A 

521U15A 

521H20A 

521P20A 

521U20A 

521H25A 

521P25A 

521U25A 

521H30A 

521P30A 

521U30A 

521H35A 

521P35A 

521U35A 

521H45A 

521P45A 

521U45A 

521H20A 

521P20A 

521U20A 

521H25A 

521P25A 

521U25A 

521H30A 

521P30A 

521U30A 

521H35A 

521P35A 

521U35A 

521H45A 

521P45A 

521U45A 

521H15A 

521P15A 

521U15A 

521H20A 

521P20A 

521U20A 

521H25A 

521P25A 

521U25A 

521H30A 

521P30A 

521U30A 

521H35A 

521P35A 

521U35A 

521H20A 

521P20A 

521U20A 

521H25A 

521P25A 

521U25A 

521H30A 

521P30A 

521U30A 

521H35A 

521P35A 

521U35A 

Size 

Style 

Standard 

Carriage 

A 

B 

C 

Narrow 

Long 

Carriage 

Narrow 

Carriage 

Standard 

Long 

Carriage 

D 

Accuracy Clearance 0.03C 0.08C 

Preload 

Basic Part Number 

0.13C 

Appropriate Rail 

Standard Style 

Max. Single Piece 

Rail Length (mm) 

Danaher Motion offers six carriage styles with six mounting 

holes allowing for additional mounting configurations in 

the field or for retrofitting. All provide superior rigidity and 

design flexibility.




Narrow 

High 

Carriage 

Narrow 

High 

Long 

Carriage 

Narrow 

Short 

Carriage 

Style 

E 

F 

G 

Size 

15 

25 

30 

35 

45 

25 

30 

35 

45 

15 

20 


Accuracy Preload 

Clearance 0.03C 0.08C 

H 

P 

U 

H 

P 

U 

H 

P 

U 

H 

P 

U 

H 

P 

U 

H 

P 

U 

H 

P 

U 

H 

P 

U 

H 

P 

U 

H 

P 

U 

H 

P 

U 

511H15E0 

- 

- 

511H25E0 

- 

- 

511H30E0 

- 

- 

511H35E0 

- 

- 

511H45E0 

- 

- 

511H25F0 

- 

- 

511H30F0 

- 

- 

511H35F0 

- 

- 

511H45F0 

- 

- 

511H15G0 

- 

- 

511H20G0 

- 

- 

511H15E1 

511P15E1 

511U15E1 

511H25E1 

511P25E1 

511U25E1 

511H30E1 

511P30E1 

511U30E1 

511H35E1 

511P35E1 

511U35E1 

511H45E1 

511P45E1 

511U45E1 

511H25F1 

511P25F1 

511U25F1 

511H23F1 

511P30F1 

511U30F1 

511H35F1 

511P35F1 

511U35F1 

511H45F1 

511P45F1 

511U45F1 

511H15G1 

511P15G1 

511U15G1 

511H20G1 

511P20G1 

511U20G1 

511H15E2 

511P15E2 

511U15E2 

511H25E2 

511P25E2 

511U25E2 

511H30E2 

511P30E2 

511U30E2 

511H35E2 

511P35E2 

511U35E2 

511H45E2 

511P45E2 

511U45E2 

511H25F2 

511P25F2 

511U25F2 

511H30F2 

511P30F2 

511U30F2 

511H35F2 

511P35F2 

511U35F2 

511H45F2 

511P45F2 

511U45F2 

511H15G2 

511P15G2 

511U15G2 

511H20G2 

511P20G2 

511U20G2 

0.13C 

- 

511P15E3 

511U15E3 

- 

511P25E3 

511U25E3 

- 

511P30E3 

511U30E3 

- 

511P35E3 

511U35E3 

- 

511P45E3 

511U45E3 

- 

511P20F3 

511U20F3 

- 

511P30F3 

511U30F3 

- 

511P35F3 

511U35F3 

- 

511P45F3 

511U45F3 

- 

511P15G3 

511U15G3 

- 

511P20G3 

511U20G3 

Appropriate Rail 

Standard Style 

521H15A 

521P15A 

521U15A 

521H25A 

521P25A 

521U25A 

521H30A 

521P30A 

521U30A 

521H35A 

521P35A 

521U35A 

521H45A 

521P45A 

521U45A 

521H25A 

521P25A 

521U25A 

521H30A 

521P30A 

521U30A 

521H35A 

521P35A 

521U35A 

521H45A 

521P45A 

521U45A 

521H15A 

521P15A 

521U15A 

521H20A 

521P20A 

521U20A 



1500 

6000 

6000 

6000 

6000 

6000 

6000 

6000 

6000 

1500 

3000 

Type A 

Type U 

Extended Standard Carriage Options 

The carriages are also available with the Thomson standard dowel holes or lubrication 

inlets as shown on pages 29 to 33 or special lubricants either from stock or with a short 

lead-time. 

Rail Types and Accessories 

The rails are available in two configurations: 

• Bolt down from the top – 521 Type A 

• Bolt up from the bottom – 521 Type U 

The standard 521 rail mounting holes can be plugged or sealed after installation with the 

options below. 

Plastic Plugs 

531HP plastic plugs are an inexpensive and simple method to seal the rail attachment 

bolt area. The plastic plugs are easily driven in place to any rail with a soft non-metallic 

drift. They can easily be removed. 

Mylar Tape 

A simple and low cost alternative is specialty Mylar tape that can be placed quickly on 

the top surface of the rail. Part number 531RT is available in 3 meter lengths. 

Stainless Steel Cover Strip 

Option 531RCS utilizes a special rail (521 Type C) and stainless steel cover strip that is 

easily installed with the proper mounting tool. 



Additional Seal Types and Lubrication Accessories 

The carriage is designed with modular sealing and 

lubrication options for simple on-site field modification 

or can be supplied factory direct. 

The standard carriage end cap has an integral low friction 

double lip seal and longitudinal seal that completely 

encase the bearing carriage. The double lip design 

keeps contaminants out and lubrication in. It also allows 

for grease to purge out of the carriage to prevent 

excessive lubrication, which can result in higher operating 

temperatures. This double lip design can be used with oil 

lubrication. 

The standard carriage end cap is equipped with a lubrication 

inlet centered with a specially designed lubricant 

channel to direct the lubrication to individual ball tracks. 

The lubrication inlet can be easily changed in the field 

or supplied from the factory with a side inlet or top inlet. 

Additional Seal 

The 531 WR and 531 VR seals provide an additional 

level of protection from contaminants to the assembly. 

These additional components can easily be added on-site 

without removing the carriage from the rail. They are 

supplied with the required screws to make the installation 

simple. 

• 531 WR is constructed from durable nitrile rubber (Buna N) 

• 531 VR is constructed from durable Viton ® 

These seals can be used in conjunction with other 

optional modular accessories providing an easy upgrade 

to the standard seal. These can be easily installed on-site 

in the field or can be supplied from the factory. 

Metal Scraper 

The Type 531 ZZ Metal Scraper made of stainless steel, 

serves as an added protection to the seal lips against 

large dirt particles, metal shavings or chips. Large 

contaminants are easily pushed away providing an extra 

level of protection to the seal lips. The Metal Scraper 

is easily installed in conjunction with the other optional 

modular accessories providing you with an easy upgrade 



16 





Oil Reservoir 

The Type 531 OW oil reservoir is a cost effective, automatic 

lubrication system. It is constructed with an integrated oil 

reservoir that provides a uniform, consistent lubricating 

oil to the ball paths for extended periods of time. The Type 

531 OW oil reservoir lubrication plate eliminates the need 

for a routine maintenance schedule, assures lubrication 

gets to the required points, can be refilled if required, and 

can operate up to 5000 km of travel. The Type 531 OW oil 

reservoir can be easily installed in conjunction with other 


to the standard seals. These can be easily installed 

on-site in the field or can be supplied from the factory. 

Lube Block 

The 531 LL Lube Block is a solid lubricant that is a mixture 

of polymers, oils and selected additives that reduce the 

penetration of dirt, grit, and liquids into the ball path, preventing 

premature failures. The oil diffuses, lubricating the 

ball path surfaces by capillary action. Additional oil is supplied 

to the ball path surfaces from the polymer. For additional 

protection the assembly is packed with EP2 grease. There 

is no need for maintenance or additional lubrication during 

the life of the Lube Block filled bearing. The 531 LL Lube 

Block can be easily installed in conjunction with the other 




Relative Drag Comparison for Design Consideration 

Type 

Standard carriage 

Rubber Wiper (531 WR) 

Viton ® Wiper (531 VR) 

Metal Scraper (531 ZZ) 

Oil Reservoir (531 OW) 

Lube Block (531 LL) 

• Low 

Relative Drag 

• 

• • • 

• • • 

• 

• • 

• • • • 

For ordering information 

or for additional 

Seal Types and 

Lubrication Accessories, 

see pages 37 to 38. 

Bellows 

Standard bellows are available for all assemblies. The 

bellows cover the entire length of the rail. The bellows 

are used to provide additional protection against dirt, dust 

and splashed liquids. Installation is simple and requires 

little time. Retrofitting is possible when the rail ends are 

drilled for the attachment of the end plate 531. Bellows 

are available in three styles: 

• Type B “Low Profile” with outside dimensions that do 

not exceed the carriage 

• Type C “High Compression” 

• Type W “Walk On” capable of handling the harshest 

environments with a 90kg load bearing capacity 

The bellow can be easily installed in conjunction with 

other optional modular seals providing you with a simple 

upgrade to the standard seal. These can be installed 


Note: Additional modular accessories add additional drag 

to the carriage assembly resulting in increased start up 

friction and power consumption. 



500 Series Ball Spacer 

500 Series Ball Profile Rail carriages are now available with 

ball spacer elements that significantly reduce the running 

noise of the carriage. The ball spacer carriage is available 

in sizes 20, 25, 30, 35 and 45. It is a drop-in replacement for 

the current ball carriage; all external carriage dimensions 

are exactly the same. 

The noise reduction is achieved by inserting plastic discs 

between each ball bearing. This reduces noise by preventing 

the balls from contacting each other as well as bumping 

into the ball track. The addition of the plastic discs requires 

a reduced number of load carrying balls, which leads to a 

slight reduction of the static and dynamic load capacity of 

the ball spacer carriage. 

Features and Benefits: 

• Significant noise reduction (-6 dB) 

• Minimum reduction of dynamic and static load capacity- 

Contact Danaher Motion Application Engineering for 

load rating details 

• Drop-in replacement for 511 ball carriage 

• Same accessory options as 511 ball carriage 

• Better or identical performance in comparison to 

competitor push force and noise 

• Carriage type designation: 513 

Noise Measurement, 35mm Carriage 

Old design 

Ball Spacer Technology Comparison 

Thomson Ball Spacer 

Enhanced design 

Enhanced design 

(with ball spacer) 

Competitor 1 

(without caged ball) 

Competitor 2 

(without caged ball) 

Competitor 2 

(with caged ball) 

62 64 66 68 70 72 74 76 

Noise, dB(A) at 1m/s 

Competitor Ball Chain 

Spacer 

Ball 

Ball Spacer Spacer Link 

Thomson 513 Ball Spacer 

Competitor Ball Chain 

Internal Forces No tensile load Tensile load on spacer links 

Quality Automatic inspection of each spacer element Optical inspection not possible without bending link 

Balltrack 

clearances 

Any clearance between balls and spacers is 

minimized during assembly 

Spacer link tolerances leads to undefined 

clearances 

Push Force Slight increase in push force Significant increase in push force 

Reliability Fewer elements = fewer failure modes Broken link elements can block re-circulation path 

18 






Part Numbering Description 

Ball Carriage 

STANDARD Standard 

OPTIONS 

5 1 1 H 15 A 1 D L W Z ES1 SM 

500 Series 

Profile Carriage 

Specials 

SM Special per customer print 

Product Type 

1 Carriage 

Type 

1 Ball 

3 Ball Spacer 

Accuracy Class 2 

H High Grade 

P Precision Grade 

U Ultra Precision Grade 

Carriage Style 

A Standard 

B Standard Long 

C Narrow 

D Narrow Long 

E Narrow High 

F Narrow Long High 

G Narrow Short 

4 

Size 

15 30 

20 35 

25 45 

Preload 

0 Clearance 

1 Approximately 0.03 C 



Extended Standards - Options 

ES1 6mm Dowel Hole - Slip Fit 

ES2 10mm Dowel Hole - Slip Fit 

ES3 1/4” Dowel Hole - Slip Fit 

ES4 3/8” Dowel Hole - Slip Fit 

ES10 Side lubrication in end caps 

ES11 Top lubrication in end caps 

ES12 (2) 6mm Dowel Holes - Press Fit 

ES13 (2) 10mm Dowel Holes - Press Fit 

ES14 (2) 1/4” Dowel Holes - Press Fit 

ES15 (2) 3/8” Dowel Holes - Press Fit 

G1 Greased with Mobilux ® EP2 

G2 

GS 

Corrosion-resistant Option 

® 

D Duralloy Thin Dense Chrome 

S Stainless Steel Material 

(available in sizes 15 and 

20 and carriage styles A and 

C only) 

Greased with Krytox ® GPL227 

Greased per customer 

specification 

Accessories 1 

L Long Life Lube Block 

N Additional Oil Reservoir 

W Additional Rubber Wiper 

V Additional Viton Wiper 

Z Metal Scraper 

C Bellow Clips 

K Low Drag Seal 

1. Accessory combination part numbers are listed from carriage end cap 

outward. Not all combinations are available. For specific combination 

availability see pages 35-36. 

3. New enhanced carriage does not retain ball bearings when end cap 

is removed. Removal of end caps can result in loss of ball bearings. 

4. Ball Spacer carriage not available in size 15. 

2. The 500 Series Ball lowest accuracy grade is High as a result of tight 

manufacturing controls and grinding capabilities. We do not offer 

Normal grade accuracy, our High grade is our Normal grade. 




Part Numbering Description 

Ball Rail 

Type 

1 Ball 

500 Series 


Product Type 

2 Rail 

STANDARD 

OPTIONS 

STANDARD 

5 2 1 H 15 A D DH1 SM +xxxx Y= (see note 1) 

Length (mm) 

xxxx Customer Specified Length 

RL1500 Stock Length 2 

Accuracy Class 

H High Grade 



Rail Style 

A Standard 

U Bolt up from Bottom 

C Cover Strip 

4 

15 

20 

25 

Size 

30 

35 

45 

Corrosion-resistant option 

D Duralloy ® (H and P accuracy only) 

5 

S Stainless Steel Material 

Machined Options 

DH1 6mm Dowel Hole + Slot 

DH2 10mm Dowel Hole + Slot 

DH3 1⁄4” Dowel Hole + Slot 

DH4 3⁄8” Dowel Hole + Slot 

JT 3 Butt Joint 

E Bellow Clips Attached 

Specials 

SM Special Per Customer Print 

1. Y = Distance from end of rail to center of first mounting hole, 

Y1 = Y2 unless specified 

2. Stock length rails are considered random length, total length may 

exceed specified length, and Y1/Y2 are not equal. To be used by 

customer who will cut to length. 

3. Customer drawing required at time of quote and order. 

See page 130 for more information and templates. 

4. Cover strip rail available in size 25 and up only. 

5. Available in sizes 15 and 20 only. Max. rail length at 1,000mm. 

Ball Accessories 

5 3 1 WR 

15 

Type 

1 Ball 

500 Series 


Product Type 

3 Accessory 

15 

20 

25 

Size 

30 

35 

45 

Bellows 

BB Low Profile Bellows 1 

BC High Compression Bellows 1 

BW Walk On Bellows 1 

CC Bellow clips for Carriage 

CR Bellow clips for Rail 

Rail Hole Covers or Plugs 

HP Plastic Rail Plugs 

RT Mylar Rail Tape 

RCS Rail Cover Strip 1 2 

RCT Rail Cover Strip Installation Tool 

RCP Rail Cover End Cap 

Modular Seal Accessories 2 

WR Rubber Wiper 

VR Viton ® Wiper 

ZZ Metal Scraper 

OW Oil Reservoir 

LL Lube Block 

LS 

K 

Replacement Spring for LL Option 

Low Drag Seal 

Mounting Assembly Tools 

MT Mounting Rail 

1. Bellows and rail cover strip must include length at time of order. 

Example: 531BB15 + 1000mm. See page 128 on how to calculate 

bellows length. 

2. Cover strip rail available in size 25 and up only. 

3. Two standard screws included with each item. Screws for attaching 

this accessory to carriage and not combinations of accessories. 

20 


J 


B 




511 / 513 Style A and B 

Reference Edge 

P 

O 

45 

M 1 

F 3 

F 3 

S 2 (From top) 

E 

F F 

G 1 

G 2 

J G 1 

A 

J 1 

G 2 

Y 

X 

F 2 

S3 Screw 

Size 

S 1 (From bottom) 

F 1 

B 2 

B 1 

511 / 513 

Style A 

Part Number 

Location 

Length 

L 2 

N 

L 1 

Y 2 

L 3 X Y 1 

L 

L 1 

511 / 513 

Style B 

L 2 

L 3 

L 

511 / 513 † Style A – Standard Ball 

Size Dimensions (mm) Ball 

A B B 1 * B 2 J J 1 L L 1 L 2 L 3 X N S 1 S 2 S 3 F F 1 F 2 F 3 Ø G G 1 G 2 M 1 O P 

+0.4 ±0.05 

–0.0 

15 24 47 15 16 20.2 15.7 56.6 30 26 39.6 60 38 M 4 M 5 M 4 4.4 4.5 8 7.5 3.2 7 4.5 9.5 4 7 7 

20 30 63 20 21.5 25.5 19 71.5 40 35 49.5 60 53 M 5 M 6 M 5 5.4 5.8 10 9.5 40 8 6.5 11.5 5.2 8 8 

25 36 70 23 23.5 30.5 22.7 84.5 45 40 59.5 60 57 M 6 M 8 M 6 6.8 7 11 11 4.8 9 8 14 5.5 7 11 

30 42 90 28 31 35.9 26 97.4 52 44 69.4 80 72 M 8 M 10 M 8 8.5 9 15 15 5.6 12 10 14.5 7 8 12 

35 48 100 34 33 41 29.5 111.6 62 52 79.6 80 82 M 8 M 10 M 8 8.5 9 15 15 6.4 12 12 18 7 8 14 

45 60 120 45 37.5 50.8 37 137.1 80 60 99.1 105 100 M 10 M 12 M 12 10.5 14 20 18 7.9 15 15 22 8 10 17.5 

511 / 513 † Style B – Standard Long Ball 


A B B 1 * B 2 J J 1 L L 1 L 2 L 3 X N S 1 S 2 S 3 F F 1 F 2 F 3 Ø G G 1 G 2 M 1 O P 

+0.4 ±0.05 

–0.0 

20 30 63 20 21.5 25.5 19 87.5 40 35 65.5 60 53 M 6 M 6 M 5 5.4 5.8 10 9.5 4.0 8 6.5 11.5 5.2 8 8 

25 36 70 23 23.5 30.5 22.7 103.5 45 40 78.5 60 57 M 8 M 8 M 6 6.8 7 11 11 4.8 9 8 14 5.5 7 11 

30 42 90 28 31 35.9 26 119.4 52 44 91.4 80 72 M 10 M 10 M 8 8.5 9 15 15 5.6 12 10 14.5 7 8 12 

35 48 100 34 33 41 29.5 137.1 62 52 105.1 80 82 M 10 M 10 M 8 8.5 9 15 15 6.4 12 12 18 7 8 14 

45 60 120 45 37.5 50.8 37 168.6 80 60 130.6 105 100 M 12 M 12 M 12 10.5 14 20 18 7.9 15 15 22 8 10 17.5 

* Standard tolerance shown, special lower tolerances are available upon request. Please consult application engineering for additional information. 

† 513 Spacer ball not available in size 15. 




511 Style A and B 

Dynamic Load and Moment Ratings 

C = Dynamic load rating 

M P = Dynamic pitch and yaw moment rating 

M R = Dynamic roll moment rating 

Static Load and Moment Ratings 

C O = Static load rating 

M OP = Static pitch and yaw moment rating 

M OR = Static roll moment rating 

M P /M OP 

C 

C O 

M P /M OP 

M R /M OR 

Roll 

Pitch 

C/C O C/C O 

Yaw 

511 

Style 

A 

B 

Size 

15 

C O 

(N) 

Static 

M OR 

(Nm) 

M OP, OY 

(Nm) 

C 

(N) 

Load Rating 

M R 

(Nm) 

M P,Y 

(Nm) 

19 600 181 146 9 000 83 67 

Dynamic 

100 Km 50 Km 

C 

(N) 

M R 

(Nm) 

M P, Y 

(Nm) 

Carriage 

(kg) 

Weights 

(kg/m) 

11 339 105 84 0.2 1.4 

15-S 19 600 181 146 7 600 70 57 9 576 88 106 0.2 1.4 

20 31 400 373 292 14 400 171 134 18 143 215 169 0.5 2.2 

20-S 31 400 373 292 12 000 143 112 15 120 180 141 0.5 2.2 

25 46 100 631 513 21 100 289 235 26 584 364 296 0.7 3.0 

30 63 700 1 084 829 29 200 497 380 36 790 626 479 1.2 4.3 

35 84 400 1 566 1 252 38 700 718 574 48 759 905 723 1.8 5.4 

45 134 800 3 193 2 498 61 900 1 466 1 147 77 989 1 847 1 445 3.3 8.8 

20 41 100 490 495 17 400 206 208 21 923 260 262 0.6 2.2 

25 

60 300 825 863 25 500 349 365 


32 128 440 460 0.9 3.0 

30 83 300 1 414 1 390 35 300 599 589 44 475 755 742 1.5 4.3 

35 110 300 2 048 2 104 46 700 867 891 58 838 1 092 1 123 2.3 5.4 

45 176 300 4 175 4 199 74 700 1 769 1 779 94 116 2 229 2 241 4.2 8.8 

1. The dynamic load and moment ratings are based on the travel life 

specified on the table (100 km or 50 km). When comparing these 

load ratings with other bearings you must take into consideration 

the proper travel life basis. 

2. The static load and moment ratings are the maximum radial load 

and moment load that should be applied to the bearing when there 

is no relative motion between the carriage and the rail. 

3. For 513 Ball Spacer load ratings, contact Danaher Motion 

Application Engineering. 

Bearing Travel Life Comparison 

L = (C/F) 3 x 100km 

where: 

L = travel life, km 

C = 100 km dynamic load rating 

F = applied dynamic load, N 

1⁄ 3 

100 

C min = F L 

( ) 

where: 

Cmin = minimum required 

dynamic load rating, N 


L = required travel life, km 

Operating Parameters: 

Maximum Velocity: 5 m/s 

Maximum Acceleration: 100 m/s 2 

Temperature: Min: – 40° C 

Max: 80° C 

Max peak: 120° C short time* 

*without bellows 

Conversion Factors: See Page 130 

22 


J 





511 / 513 Style C and D 


M1 

O 

B 

Y 

X 

F 2 

S3 Screw 

Size 

S 2 

J 1 

F 1 

G 2 

J 1 

G 

A 

G 2 

B 2 

B 1 

511 / 513 

Style C 

N 

Y1 

X 

511 / 513 

Style D 

Part Number 

Location 

Y2 

L 1 

L 3 

Length 

L 

L 1 

L 3 

L 

N 

511 / 513 † Style C Narrow 

Size Dimensions (mm) 

A B B 1 * B 2 J J 1 L L 1 L 3 X N S 2 /S 3 F 1 F 2 

Ball 

Ø G G 2 M 1 O 

+0.4 +0.05 

– 0.0 

15 24 34 15 9.5 20.2 15.7 56.6 26 39.6 60 26 M 4 4.5 8 3.2 5 9.5 4 5.5 

20 30 44 20 12 25.5 19 71.5 36 49.5 60 32 M 5 5.8 10 4.0 7 11.5 5.2 6 

25 36 48 23 12.5 30.5 22.7 84.5 35 59.5 60 35 M 6 7 11 4.8 9 14 5.5 7.5 

30 42 60 28 16 35.9 26 97.4 40 69.4 80 40 M 8 9 15 5.6 11 14.5 7 8 

35 48 70 34 18 41 29.5 111.6 50 79.6 80 50 M 8 9 15 6.4 12 18 7 8 

511 / 513 † Style D Narrow Long 

Size Dimensions (mm) 

A B B 1 * B 2 J J 1 L L 1 L 3 X N S 2 /S 3 F 1 F 2 

Ball 

Ø G G 2 M 1 O 

+0.4 +0.05 

– 0.0 

20 30 44 20 12 25.5 19 87.5 50 65.5 69.5 32 M 5 5.8 10 4.0 7 11.5 5.2 6 

25 36 48 23 12.5 30.5 22.7 103.5 50 78.5 60 35 M 6 7 11 4.8 9 14 5.5 7.5 

30 42 60 28 16 35.9 26 119.4 60 91.4 80 40 M 8 9 15 5.6 11 14.5 7 8 

35 48 70 34 18 41 29.5 137.1 72 105.1 80 50 M 8 9 15 6.4 12 18 7 8 







511 Style C and D 









C 

C O 

M R /M OR 

Roll 

C/C O C/C O 

M P /M OP 

Pitch 

M P /M OP 

Yaw 

511 

Style 

C 

Size 

15 

C O 

(N) 

Static 

M OR 

(Nm) 

M OP, OY 

(Nm) 

C 

(N) 

19 600 181 146 9 000 83 67 

Load Rating 

Dynamic 

100 Km 50 Km 

M R 

(Nm) 

M P,Y 

(Nm) 

C 

(N) 

M R 

(Nm) 

M P, Y 

(Nm) 

Carriage 

(kg) 

Weights 

(kg/m) 

11 339 105 84 0.2 1.4 

15-S 19 600 181 146 7 600 70 57 9 576 88 106 0.2 1.4 

20 31 400 373 292 14 400 171 134 18 143 215 169 0.5 2.2 

20-S 31 400 373 292 12 000 143 112 15 120 180 141 0.5 2.2 

25 46 100 631 513 21 100 289 235 26 584 364 296 0.7 3.0 

30 63 700 1 084 829 29 200 497 380 36 790 626 479 1.2 4.3 


35 84 400 1 566 1 252 38 700 718 574 48 759 905 723 1.8 5.4 

20 41 100 490 495 17 400 206 208 21 923 260 262 0.6 2.2 

D 

25 

60 300 825 863 25 500 349 365 

32 128 440 460 0.9 3.0 

30 83 300 1 414 1 390 35 300 599 589 44 475 755 742 1.5 4.3 

35 110 300 2 048 2 104 46 700 867 891 58 838 1 092 1 123 2.3 5.4 











L = (C/F) 3 x 100 km 

where: 




1⁄ 3 

100 

C min = F L 

( ) 

where: 

C min = minimum required 








Max: 80° C 




24 


J 





511 / 513 Style E and F 


M 1 

O 

B 

S 2 

G 

J 1 

A 

J 1 

G 2 

Y 

X 

F 2 

S3 Screw 

Size 

G 2 

F 1 

B 2 

B1 

511 / 513 

Style E 

N 

X Y 1 

511 / 513 

Style F 

Part Number 

Location 

L 1 

L 3 

Y 2 

L 

Length 

L 1 

L 3 

L 

N 

511 / 513 † Style E Narrow High 


A B B 1 * B 2 J J 1 L L 1 L 3 X N S 2 /S 3 F 1 F 2 Ø 

+0.4 +0.05 

G G 2 M 1 O 

-0.0 

15 28 34 15 9.5 24.2 15.7 56.6 26 39.6 60 26 M 4 4.5 8 3.2 6 9.5 8 6 

25 40 48 23 12.5 34.5 22.7 84.5 35 59.5 60 35 M 6 7 11 4.8 9 14 9.5 11 

30 45 60 28 16 38.9 26 97.4 40 69.4 80 40 M 8 9 15 5.6 11 14.5 10 11 

35 55 70 34 18 48 29.5 111.6 50 79.6 80 50 M 8 9 15 6.4 12 18 14 15 

45 70 86 45 20.5 60.8 37 137.1 60 99.1 105 60 M 10 14 20 7.9 18 22 18 19 

511 / 513 † Style F Narrow Long High 


A B B 1 * B 2 J J 1 L L 1 L 3 X N S 2 /S 3 F 1 F 2 Ø 

+0.4 +0.05 

G G 2 M 1 O 

-0.0 

25 40 48 23 12.5 34.5 22.7 103.5 50 78.5 60 35 M 6 7 11 4.8 9 14 9.5 11 

30 45 60 28 16 38.9 26 119.4 60 91.4 80 40 M 8 9 15 5.6 11 14.5 10 11 

35 55 70 34 18 48 29.5 137.1 72 105.1 80 50 M 8 9 15 6.4 12 18 14 15 

45 70 86 45 20.5 60.8 37 168.6 80 130.6 105 60 M 10 14 20 7.9 18 22 18 19 







511 Style E and F 









C 

C O 

M R /M OR 

Roll 

C/C O C/C O 

M P /M OP 

Pitch 

M p /M OP 

Yaw 

511 

Style 

E 

F 

Size 

15 

C O 

(N) 

Static 

M OR 

(Nm) 

M OP, OY 

(Nm) 

C 

(N) 

M R 

(Nm) 

M P,Y 

(Nm) 

19 600 181 146 9 000 83 67 

Load Rating 

Dynamic 

100 Km 50 Km 

C 

(N) 

M R 

(Nm) 

M P, Y 

(Nm) 

Carriage 

(kg) 

Weights 


(kg/m) 

11 339 105 84 0.2 1.4 

25 46 100 631 513 21 100 289 235 26 584 364 296 

30 63 700 1 084 829 29 200 497 380 36 790 626 479 

35 84 400 1 566 1 252 38 700 718 574 48 759 905 723 

0.5 2.2 

0.7 3.0 

1.2 4.3 

45 134 800 3 193 2 498 61 900 1 466 1 147 77 989 1 847 1 445 1.8 5.4 

25 60 300 825 863 25 500 349 365 32 128 440 460 0.6 2.2 

30 83 300 1 414 1 390 35 300 599 589 44 475 755 742 0.9 3.0 

35 110 300 2 048 2 104 46 700 867 891 58 838 1 092 1 123 1.5 4.3 

45 176 300 4 175 4 199 74 700 1 769 1 779 94 116 2 229 2 241 2.3 5.4 






and moment load that should be applied to the bearing when 

there is no relative motion between the carriage and the rail. 



Bearing Travel Life Calculation 

L = (C/F) 3 x 100 km 

where: 




( ) 

L 1⁄ 3 

C min = 

100 

F 

where: 









Max: 80° C 




26 






511 Style G 


M1 

O 

B 

Y 

X 

F 2 

S3 Screw 

Size 

J 

G 2 

J 1 

G 

A 

G 2 

S 2 

J 1 

F 1 

B 2 

B 1 

Y2 

Length 

L 3 

L 

L 1 

L 3 

L 

X 

Y1 

Part Number 

Location 

N 

511 Style G Narrow Short 

Size 

A 

Dimensions (mm) 

B B 1 * B 2 J J 1 L L 3 X N s 2 /s 3 F 1 F 2 

Ball 

Ø G G 2 M 1 O 

+0.4 +0.05 

-0.0 

15 24 34 15 9.5 20.2 15.7 37.6 20.6 60 26 M4 4.5 8 3.2 6 9.5 4 6 

20 28 44 20 12 23.5 19 47.7 25.7 60 32 M5 5.8 10 4.0 6 11.5 4.2 4 


** When using additional modular seals or lubrication plates, the total length L will increase. Consult page 35-36 for additional information. 

Length of rail to be specified at time of order, Y1 will equal Y2 unless specified otherwise at time of order. 





511 Style G 









C 

C O 

M R /M OR 

Roll 

C/C O C/C O 

M P /M OP 

Pitch 

M P /M OP 

Yaw 

Style 

G 

Size 

15 

C O 

(N) 

Static 

M OR 

(Nm) 

M OP, OY 

(Nm) 

C 

(N) 

M R 

(Nm) 

M P,Y 

(Nm) 

8 500 78 30 5 200 48 18 

Load Rating 

Dynamic 

100 Km 50 Km 

C 

(N) 

M R 

(Nm) 

M P, Y 

(Nm) 

Carriage 

(kg) 

Weights 


(kg/m) 

6 552 60 23 0.2 1.4 

20 13 100 150 58 8 400 99 37 10 583 125 47 0.5 2.2 









L = (C/F) 3 x 100 km 

where: 




C min = F 

where: 

L 

( ) 

1⁄ 3 

100 









Max: 80° C 




28 





Carriage Dowel Holes 

Dowel holes are commonly used to ensure proper alignment 

during installation and replacement of carriages and rails. 

The standard slip fit dowel hole options for the 500 series 

Standard Ball Carriages are: 

Style A and B 

Style C, D, E and F 



Single Dowel 

Slip Fit 

D 

L 12 

D 

L 12 

P 

H 

P 

H 

511 

Style Size 

All dimensions in mm, unless otherwise specified. 

Hole Tolerance D +0/-0.013 

ES1 ES2 ES3 ES4 

L 12 ØD H P ØD H P ØD H P ØD H P 

15 15 6 4.5 7 – – – 1/4“ 4.5 7 – – – 

20 20 6 5 9 – – – 1/4“ 5 9 – – – 

Type A 25 22.5 6 6.5 9 – – – 1/4“ 6.5 9 – – – 

30 26 6 9 12 10 9 12 1/4“ 9 12 3/8“ 9 12 

35 31 – – – 10 9 14 – – – 3/8“ 9 14 

45 40 – – – 10 10 18 – – – 3/8“ 10 18 

20 20 6 5 9 – – – 1/4“ 5 9 – – – 

25 22.5 6 6.5 9 – – – 1/4“ 6.5 9 – – – 

Type B 30 26 6 9 12 10 9 12 1/4“ 9 12 3/8“ 9 12 

35 31 – – – 10 9 14 – – – 3/8“ 9 14 

45 40 – – – 10 10 18 – – – 3/8“ 10 18 

15 13 6 4 6 – – – 1/4“ 4 6 – – – 

20 18 6 6 9 – – – 1/4“ 6 9 – – – 

Type C 25 17.5 6 6.5 9 – – – 1/4“ 6.5 9 – – – 

30 20 6 10 12 10 10 12 1/4“ 10 12 3/8“ 10 12 

35 25 – – – 10 10 12 – – – 3/8“ 10 12 

20 25 6 6 9 – – – 1/4“ 6 9 – – – 

25 25 6 6.5 9 – – – 1/4“ 6.5 9 – – – 

Type D 30 30 6 10 12 10 10 12 1/4“ 10 12 3/8“ 10 12 

35 36 – – – 10 10 12 – – – 3/8“ 10 12 

15 13 6 4 6 – – – 1/4“ 4 6 – – – 

Type E 25 17.5 6 6.5 9 – – – 1/4“ 6.5 9 – – – 

30 20 6 10 12 10 10 12 1/4“ 10 12 3/8“ 10 12 

35 25 – – – 10 10 12 – – – 3/8“ 10 12 

45 30 – – – 10 13 12 – – – 3/8“ 13 12 

25 25 6 6.5 9 – – – 1/4“ 6.5 9 – – – 

Type F 30 30 6 10 12 10 10 12 1/4“ 10 12 3/8“ 10 12 

35 36 – – – 10 10 12 – – – 3/8“ 10 12 

45 40 – – – 10 13 12 – – – 3/8“ 13 12 




Carriage Dowel Holes (continued) 

Style A and B 




Double Dowel 

Press Fit 

D 

D 

L 12 

L 12 

P 

H 

P 

H 

511 

ES12 ES13 ES14 ES15 

Style Size L 12 ØD H P ØD H P ØD H P ØD H P 

15 15 6 4.5 7 – – – 1/4“ 4.5 7 – – – 

20 20 6 5 9 – – – 1/4“ 5 9 – – – 

Type A 25 22.5 6 6.5 9 – – – 1/4“ 6.5 9 – – – 

30 26 6 9 12 10 9 12 1/4“ 9 12 3/8“ 9 12 

35 31 – – – 10 9 14 – – – 3/8“ 9 14 

45 40 – – – 10 10 18 – – – 3/8“ 10 18 

20 20 6 5 9 – – – 1/4“ 5 9 – – – 

25 22.5 6 6.5 9 – – – 1/4“ 6.5 9 – – – 

Type B 30 26 6 9 12 10 9 12 1/4“ 9 12 3/8“ 9 12 

35 31 – – – 10 9 14 – – – 3/8“ 9 14 

45 40 – – – 10 10 18 – – – 3/8“ 10 18 

15 13 6 4 6 – – – 1/4“ 4 6 – – – 

20 18 6 6 9 – – – 1/4“ 6 9 – – – 

Type C 25 17.5 6 6.5 9 – – – 1/4“ 6.5 9 – – – 

30 20 6 10 12 10 10 12 1/4“ 10 12 3/8“ 10 12 

35 25 – – – 10 10 12 – – – 3/8“ 10 12 

20 25 6 6 9 – – – 1/4“ 6 9 – – – 

25 25 6 6.5 9 – – – 1/4“ 6.5 9 – – – 

Type D 30 30 6 10 12 10 10 12 1/4“ 10 12 3/8“ 10 12 

35 36 – – – 10 10 12 – – – 3/8“ 10 12 

15 13 6 4 6 – – – 1/4“ 4 6 – – – 

Type E 25 17.5 6 6.5 9 – – – 1/4“ 6.5 9 – – – 

30 20 6 10 12 10 10 12 1/4“ 10 12 3/8“ 10 12 

35 25 6 10 12 10 10 12 1/4“ 10 12 3/8“ 10 12 

45 30 6 13 12 10 13 12 1/4“ 13 12 3/8“ 13 12 

25 25 6 6.5 9 – – – 1/4“ 6.5 9 – – – 

Type F 30 30 6 10 12 10 10 12 1/4“ 10 12 3/8“ 10 12 

35 36 – – – 10 10 12 – – – 3/8“ 10 12 

45 40 – – – 10 13 12 – – – 3/8“ 13 12 


Hole Tolerance D +0/-0.013 

30 


Lubrication Inlet Options 




The standard carriage is supplied with a lubrication 

inlet centered over the rail. The carriage has multiple 

lubrication inlet point options. The options can be 

easily modified on-site in the field or can be supplied 

factory direct (Standard inlet hole is M3 for 15mm, M6 

for 20mm, 25mm, 30mm 35mm, 45mm). See page 73 for 

available lubrication fittings. 

Option 

ES10 

ES11 

Inlets on side – both ends– all sides 

Inlet on top* – both ends 

Notes: 

1. * An O-Ring is required to properly seat the mating surfaces to 

prevent grease or oil from escaping. 

One is supplied with this option. 

Size 15 O-ring ID M3 x 1.78mm thick. 

Sizes 20–45 O-ring ID M6 x 1.78mm thick. 

2. Set screws are installed to plug all holes. 

Lubrication inlet locates standard and ES10 option. 

Size 

Style M1 M3 M4 D1 D2 

15 

A 

C 

4 4 

E 8 8 

4 

G 4 4 

A 

20 

B 

C 

5.2 5.2 5.2 

D 

G 4.2 4.2 5 

A 

B 

5.5 5.5 

C 

25 

6 

D 

E 

F 9.5 9.5 

A 

B 

30 

C 7 7 

D 

6 

E 

F 

10 10 

A 

B 

7 7 

C 

35 

D 

6 

E 

F 

14 14 

A 

45 

B 8 8 

E 

F 

18 18 

7.5 

All dimensions in mm unless specified. 

M3 

M6 

M3 

M6 

M6 

M6 

M6 

M3 

M3 

M3 

M6 

M6 

M6 

M6 

M 3 

M 4 

D 2 

D 1 

M 1 

ES10 

ES10 

ES10 

1. D1 and D2 are threaded holes in the end cap to ensure proper 

integrity and durability of connection. 

2. Carriages are shipped with a grease fitting in the box. 

Size 15 include fitting 530LF3, Size 20 and up include fitting 530LN. 

See page 68 for more information. 




Lubrication inlet location ES11 option 

Size 

Style C7 D1 D2 D3 D4 

A 8.000 

15 C 10.000 

E 10.000 

A 10.500 

B 18.500 

20 

C 12.500 

D 13.500 

A 13.200 

B 22.700 

C 18.200 

25 

D 20.200 

E 18.200 

F 20.200 

A 13.200 

B 22.700 

C 18.200 

30 

D 20.200 

E 18.200 

F 20.200 

A 14.500 

B 27.250 

C 20.500 

35 

D 22.250 

E 20.500 

F 22.250 

A 17.000 

B 32.750 

45 

E 27.000 

F 32.750 

All dimensions in mm. 

4.47 8 

6.75 10 

8.75 

8.75 

8.75 

8.75 

12 

12 

12 

12 

1.78 4 

1.78 6 

1.78 8 

1.78 8 

1.78 8 

1.78 8 

1/16” NPT hole drilled in carriage ES7 option. 

511 ES7 

Style Size D L 14 J 2 

20 1/16”-27 NPT 12.0 5.2 

25 1/16”-27 NPT 12.0 5.5 

A 30 1/16”-27 NPT 13.0 7 

35 1/16”-27 NPT 12.5 7 

45 1/16”-27 NPT 15.0 8 

20 1/16”-27 NPT 12.0 5.2 

25 1/16”-27 NPT 12.0 5.5 

B 30 1/16”-27 NPT 13.0 7 

35 1/16”-27 NPT 12.5 7 

45 1/16”-27 NPT 15.0 8 

25 1/16”-27 NPT 9.2 5.5 

C 30 1/16”-27 NPT 15.4 6 

35 1/16”-27 NPT 14.3 7 

25 1/16”-27 NPT 9.2 5.5 

D 30 1/16”-27 NPT 15.4 6 

35 1/16”-27 NPT 14.3 7 

20 1/16”-27 NPT 10.0 5.2 

25 1/16”-27 NPT 9.2 8.5 

E 30 1/16”-27 NPT 15.4 9 

35 1/16”-27 NPT 14.3 13 

45 1/16”-27 NPT 13.9 18 

20 1/16”-27 NPT 10.0 5.2 

25 1/16”-27 NPT 9.2 8.5 

F 30 1/16”-27 NPT 15.4 9 

35 1/16”-27 NPT 14.3 13 

45 1/16”-27 NPT 13.9 18 

All dimensions in mm unless specified. 

D 2 

Style A and B 




C 7 

D1 = O-Ring internal diameter 

D2 = Counterbore diameter 

D3 = O-Ring thickness 

D4 = Max. recommended diameter of 

lubrication inlet from above plate 

L 14 

J 2 

L 14 

J 2 

This is typically not a stocked item, please consult Danaher Motion 

for availability. For short lead time we recommend ES10 option. 

32 


Grease Lubricants 




Standard carriages are sold with oil preservative to protect 

the balls from corrosion during storage and transit. The 

carriages are available with the following assortment of 

lubricants. Additional greases are available upon request, 

please consult Danaher Motion Application Engineering. 

Option Type Notes Viscosity Temperature Range 

G1 Mobilux ® EP2 All purpose NLGI2 grease 160cSt @40°C –20°C to 130°C 

G2 Krytox ® GPL227 High Temperature NLGI2 440cSt @40°C –30°C to 288°C 

GS 

Customer specified at time of order 

Rail Length 

Maximum Length of One Piece Rail 

Size (mm) 15 20 25 30 35 45 

One Piece 

Rail Length 1500 mm 3000 mm 6000 mm 

Extended Standard Rail Options 

Y1 

F 

LENGTH AS PER CUSTOMER SPECIFICATION 

X (REF) TYP 

L3 + 1.5mm (0.60”) 

- 0 

G 

Y2 

C MIN 

L1 ± .12mm (.005”) 

F 

Ø D Dowel Hole 

G 

± 0.05mm 

(.002”) 

D 

L2 ± .4mm (.016”) 

Option D L1 L2 L3 C 

DH1 6mm 30mm 30mm 10.2 mm 9.5 mm 

DH2 10mm 30mm 30mm 13.8 mm 9.5 mm 

DH3 1/4“ 1.181“ 1.181“ .542“ 3/8“ 

DH4 3/8“ 1.181“ 1.181“ .542“ 3/8“ 

Y1 = Y2 unless specified at time of ordering 

*Size 25 and up step will be present around bottom of slot to control width 

tolerance during milling of slot. 

The rail can be supplied with dowel holes, radial holes 

and coaxial holes to meet your application needs. Please 

provide a drawing of your requirement and our Application 

Engineering Team can provide a quote or select one of 

our extended standard options. 




521 Type U Rail – Bolt Up From Bottom 

Size X E G Weight 

(mm) (kg/m) 

Y 

G 

X 

E 

15 60 M5 8 1.4 

20 60 M6 10 2.2 

25 60 M6 12 3 

30 80 M8 15 4.3 

35 80 M8 15 5.4 

45 105 M12 19 8.8 

Customer to specify Y dimensions upon ordering Y 1 = Y 2 if not specified 

Thin Dense Chrome Plating 

Rails and carriages are available with Duralloy ® DSV 

Thin Dense Chrome Plating with a thickness of 2 – 4 µm. 

As a result of the plating thickness range compared to 

the tolerance ranges in the different accuracy classes, 

it is only available in the High and Precision accuracy 

classes up to 3 meters long as a single rail; longer 

lengths require butt joints. 

Carriage assortment with Thin Dense Chrome 

Preload 

Preload 

Type Style Size Accuracy Clearance 0.03C 0.08C 

15 

20 

H 

H 

511H15A0D 

511H20A0D 

511H15A1D 

511H20A1D 

511H15A2D 

511H20A2D 

P 

P 

- 

- 

511P15A1D 

511P20A1D 

511P15A2D 

511P20A2D 

A 

25 

H 511H25A0D 511H25A1D 511H25A2D 

P 

- 511P25A1D 511P25A2D 

30 

H 511H30A0D 511H30A1D 511H30A2D 

P 

- 511P30A1D 511P30A2D 

35 

45 

H 

H 

511H35A0D 

511H45A0D 

511H35A1D 

511H45A1D 

511H35A2D 

511H45A2D 

P 

P 

- 

- 

511P35A1D 

511P45A1D 

511P35A2D 

511P45A2D 

20 

H 511H20B0D 511H20B1D 511H20B2D 

P 

- 511P20B1D 511P20B2D 

511 

H 511H25B0D 511H25B1D 511H25B2D 

25 

P 

- 511P25B1D 511P25B2D 

B 

H 511H30B0D 511H30B1D 511H30B2D 

30 

P 

- 511P30B1D 511P30B2D 

35 

45 

H 

H 

511H35B0D 

511H45B0D 

511H35B1D 

511H45B1D 

511H35B2D 

511H45B2D 

P 

P 

- 

- 

511P35B1D 

511P45B1D 

511P35B2D 

511P45B2D 

H 511H15C0D 511H15C1D 511H15C2D 

15 P 

- 511P15C1D 511P15C2D 

H 511H20C0D 511H20C1D 511H20C2D 

C 

20 

P 

- 511P20C1D 511P20C2D 

H 511H25C0D 511H25C1D 511H25C2D 

25 

P 

- 511P25C1D 511P25C2D 

H 511H30C0D 511H30C1D 511H30C2D 

30 

P 

- 511P30C1D 511P30C2D 

H 511H35C0D 511H35C1D 511H35C2D 

35 

P 

- 511P35C1D 511P35C2D 

0.13C 

- 

511P15A3D 

- 

511P20A3D 

- 

511P25A3D 

- 

511P30A3D 

- 

511P35A3D 

- 

511P45A3D 

- 

511P20B3D 

- 

511P25B3D 

- 

511P30B3D 

- 

511P35B3D 

- 

511P45A3D 

- 

511P15C3D 

- 

511P20C3D 

- 

511P25C3D 

- 

511P30C3D 

- 

511P35C3D 

Type Style Size Accuracy Clearance 0.03C 0.08C 

20 

H 511H20D0D 511H20D1D 511H20D2D 

P 

- 511P20D1D 511P20D2D 

H 511H25D0D 511H25D1D 511H25D2D 

25 

D 

P 

- 511P25D1D 511P25D2D 

30 

35 

15 

25 

H 

H 

H 

H 

511H30D0D 

511H35D0D 

511H15E0D 

511H25E0D 

511H30D1D 

511H35D1D 

511H15E1D 

511H25E1D 

511H30D2D 

511H35D2D 

511H15E2D 

511H25E2D 

P 

P 

P 

P 

- 

- 

- 

- 

511P30D1D 

511P35D1D 

511P15E1D 

511P25E1D 

511P30D2D 

511P35D2D 

511P15E2D 

511P25E2D 

E 

H 511H30E0D 511H30E1D 511H30E2D 

30 

P 

- 511P30E1D 511P30E2D 

511 

H 511H35E0D 511H35E1D 511H35E2D 

35 

P 

- 511P35E1D 511P35E2D 

45 

25 

H 

H 

511H45E0D 

511H25F0D 

511H45E1D 

511H25F1D 

511H45E2D 

511H25F2D 

P 

P 

- 

- 

511P45E1D 

511P25F1D 

511P45E2D 

511P25F2D 

H 511H30F0D 511H30F1D 511H30F2D 

30 

P 

- 511P30F1D 511P30F2D 

F 

H 511H35F0D 511H35F1D 511H35F2D 

35 

P 

- 511P35F1D 511P35F2D 

H 511H45F0D 511H45F1D 511H45F2D 

45 

P 

- 511P45F1D 511P45F2D 

H 511H15G0D 511H15G1D 511H15G2D 

15 

P 

- 511P15G1D 511P15G2D 

G 

H 511H20G0D 511H20G1D 511H20G2D 

20 

P 

- 511P20G1D 511P20G2D 

Duralloy carriages and rails are designed and manufactured to be used together. If a non-Duralloy carriage is used on a Duralloy rail the 

clearance or preload of the carriage will be increased approximately one class. If a Duralloy carriage is used on a non-Duralloy rail the 

clearance or preload will be decreased approximately one class. This is the result of the coating thickness. 

0.13C 

- 

511P20D3D 

- 

511P25D3D 

- 

511P30D3D 

- 

511P35D3D 

- 

511P15E3D 

- 

511P25E3D 

- 

511P30E3D 

- 

511P35E3D 

- 

511P45E3D 

- 

511P25F3D 

- 

511P30F3D 

- 

511P35F3D 

- 

511P45F3D 

- 

511P15G3D 

- 

511P20G3D 

34 


Modular Accessory Combination Options and Screw Size 




Option 

Description 

15 

Size 

20 25 

L 3 

"Lube for Life" Lube Block 

Low/socket head screw 

M2.5-0.45x20 


M2.5-0.45x25 


M4-0.7x35 

N 3 

Oil Reservoir 


M2.5-0.45x20 


M2.5-0.45x25 


M4-0.7x30 

W 3 

Rubber Wiper 


M2.5-0.45x20 


M2.5-0.45x20 


M4-0.7x25 

V 3 

Viton Wiper 


M2.5-0.45x20 


M2.5-0.45x20 


M4-0.7x25 

Z 3 

Metal Scraper 


M2.5-0.45x15 


M2.5-0.45x15 


M4-0.7x20 

C 3 

Bellows Clips 

Flat/socket head screw 

M2.5-0.45x15 


M2.5-0.45x15 


M4-0.7x20 

LW 

Lube Block + Wiper 


M2.5-0.45x25 


M2.5-0.45x30 


M4-0.7x35 

LWC 

Lube Block, Wiper + Bellows Clip 


M2.5-0.45x25 


M2.5-0.45x30 


M4-0.7x35 

LWZ 

Lube Block, Wiper + Scraper 


M2.5-0.45x25 


M2.5-0.45x30 


M4-0.7x35 

LWZC 

Lube Block, Wiper, Scraper + Bellows Clip 


M2.5-0.45x25 


M2.5-0.45x30 


M4-0.7x35 

LZ 

Lube Block + Scraper 


M2.5-0.45x20 


M2.5-0.45x25 


M4-0.7x35 

LZC 

Lube Block, Scraper + Bellows Clip 


M2.5-0.45x20 


M2.5-0.45x25 


M4-0.7x35 

LC 

Lube Block + Bellows Clip 


M2.5-0.45x20 


M2.5-0.45x25 


M4-0.7x35 

NW 

Oil Reservoir + Wiper 


M2.5-0.45x30 


M2.5-0.45x30 


M4-0.7x40 

NWZ 

Oil Reservoir, Wiper + Scraper 


M2.5-0.45x30 


M2.5-0.45x35 


M4-0.7x40 

NWC 

Oil Reservoir, Wiper + Bellows Clip 


M2.5-0.45x30 


M2.5-0.45x30 


M4-0.7x40 

NWZC 

Oil Reservoir, Wiper, Scraper + Bellows Clip 


M2.5-0.45x30 


M2.5-0.45x35 


M4-0.7x40 

NZ 

Oil Reservoir + Scraper 


M2.5-0.45x25 


M2.5-0.45x30 


M4-0.7x35 

NZC 

Oil Reservoir, Scraper + Bellows Clips 


M2.5-0.45x25 


M2.5-0.45x30 


M4-0.7x35 

NC 

Oil Reservoir + Bellows Clips 


M2.5-0.45x20 


M2.5-0.45x25 


M4-0.7x35 

WC 

Wiper + Bellows Clip 


M2.5-0.45x20 


M2.5-0.45x20 


M4-0.7x25 

WZ 

Wiper + Scraper 


M2.5-0.45x20 


M2.5-0.45x25 


M4-0.7x25 

WZC 

Wiper, Scraper + Bellows Clip 


M2.5-0.45x20 


M2.5-0.45x25 


M4-0.7x30 

VZ 

Viton Wiper + Scraper 


M2.5-0.45x20 


M2.5-0.45x25 


M4-0.7x25 

ZC 

Scraper + Bellows Clip 


M2.5-0.45x15 


M2.5-0.45x15 


M4-0.7x20 

1. All fasteners are standard threads. 

2. Consult Danaher Motion for options not listed, engineering review is required. 

3. When ordering component only, two screws include. 




Option 

Description 

Size 

30 35 

45 

L 

"Lube for Life" Lube Block 


M4-0.7x40 


M4-0.7x45 


M5-0.8x50 

N 

Oil Reservoir 


M4-0.7x30 


M4-0.7x35 


M5-0.8x45 

W 

Rubber Wiper 


M4-0.7x25 


M4-0.7x30 


M5-0.8x35 

V 

Viton Wiper 


M4-0.7x25 


M4-0.7x30 


M5-0.8x35 

Z 

Metal Scraper 


M4-0.7x20 


M4-0.7x25 


M5-0.8x30 

C 

Bellows Clips 


M4-0.7x20 


M4-0.7x25 


M5-0.8x30 

LW 

Lube Block + Wiper 


M4-0.7x40 


M4-0.7x45 


M5-0.8x50 

LWC 

Lube Block, Wiper + Bellows Clip 


M4-0.7x40 


M4-0.7x45 


M5-0.8x50 

LWZ 

Lube Block, Wiper + Scraper 


M4-0.7x40 


M4-0.7x45 


M5-0.8x50 

LWZC 

Lube Block, Wiper, Scraper + Bellows Clip 


M4-0.7x40 


M4-0.7x45 


M5-0.8x50 

LZ 

Lube Block + Scraper 


M4-0.7x40 


M4-0.7x45 


M5-0.8x50 

LZC 

Lube Block, Scraper + Bellows Clip 


M4-0.7x40 


M4-0.7x45 


M5-0.8x50 

LC 

Lube Block + Bellows Clip 


M4-0.7x40 


M4-0.7x45 


M5-0.8x50 

NW 



M4-0.7x40 


M4-0.7x45 


M5-0.8x50 

NWZ 

Oil Reservoir, Wiper + Scraper 


M4-0.7x40 


M4-0.7x45 


M5-0.8x55 

NWC 

Oil Reservoir, Wiper + Bellows Clip 


M4-0.7x40 


M4-0.7x45 


M5-0.8x55 

NWZC 

Oil Reservoir, Wiper, Scraper + Bellows Clip 


M4-0.7x45 


M4-0.7x50 


M5-0.8x55 

NZ 



M4-0.7x35 


M4-0.7x40 


M5-0.8x45 

NZC 

Oil Reservoir, Scraper + Bellows Clips 


M4-0.7x35 


M4-0.7x40 


M5-0.8x50 

NC 



M4-0.7x35 


M4-0.7x40 


M5-0.8x50 

WC 



M4-0.7x25 


M4-0.7x30 


M5-0.8x35 

WZ 



M4-0.7x25 


M4-0.7x30 


M5-0.8x35 

WZC 

Wiper, Scraper + Bellows Clip 


M4-0.7x30 


M4-0.7x30 


M5-0.8x35 

VZ 



M4-0.7x25 


M4-0.7x30 


M5-0.8x35 

ZC 



M4-0.7x20 


M4-0.7x25 


M5-0.8x30 

Consult Danaher Motion for options not listed, engineering review required. 

36 


Modular Accessories 




Additional Wiper 

Size Rubber Viton ® L1 L2 Weight 

Part No. Part No. (mm) (mm) (kg) 

15 531WR15 531VR15 7 4 0.005 

20 531WR20 531VR20 7 4 0.008 

25 531WR25 531VR25 7 4 0.010 

30 531WR30 531VR30 7 4 0.016 

35 531WR35 531VR35 7 4 0.022 

45 531WR45 531VR45 7 4 0.036 

L1 – wiper thickness, L2 – max. screw head stickout 

Can be installed without removing carriage from rail 

L2 

L2 

L1 

L1 

Metal Scraper 

Size Scraper L1 L2 Weight 

Part No. (mm) (mm) (kg) 

15 531ZZ15 1.5 4 0.005 

20 531ZZ20 1.5 4 0.009 

25 531ZZ25 1.5 4 0.011 

30 531ZZ30 1.5 4 0.018 

35 531ZZ35 1.5 4 0.024 

45 531ZZ45 1.5 4 0.057 

L1 – scraper thickness, L2 – max. screw head stickout 

L2 

L2 

L1 

L1 

Oil Reservoir 

Size Lubrication L1 Weight 

Plate (mm) (kg) 

15 531OW15 8.5 0.004 

20 531OW20 11 0.010 

25 531OW25 12.7 0.017 

30 531OW30 14 0.023 

35 531OW35 16.2 0.039 

45 531OW45 19.2 0.065 

L1 = Oil reservoir thickness, screw heads are recessed in plate 

L1 

L1 




MicroPoly® 

Lube Block 

Screws 

Stand Offs 

Spring 

Size Lubrication L1 L2 Weight 

Plate (mm) (mm) (kg) 

15 531 LL 15 9.9 4 0.009 

20 531 LL 20 11.9 4 0.024 

25 531 LL 25 19.5 4 0.083 

30 531 LL 30 21.2 4 0.213 

35 531 LL 35 24.7 4 0.069 

45 531 LL 45 26.9 4 0.123 

L2 

L2 

L1 

L1 

Size 15 and 20 Scraper (531ZZ) 

Size 25 and up Rubber Wiper (531WR) 

L1 = Lube Block thickness, L2 = max. screw head stickout 

When supplied from the factory as a complete unit the carriage is 

packed with EP2 grease and spring is loose for customer to install 

after assembling carriage on the rail. 

Example 

511 Size 45 carriage with 531OW and 531WR 

modular seals on both sides: 

Carriage Length (L) = 89.3 

531 OW 45 L 1 x 2 = 12.7 x 2 

531 WR 45 L 1 x 2 = 7 x 2 

531 WR 45 L 2 x 2 = 4 x 2 

Total Length 

= 136.7 mm 

Each modular seal is supplied with the proper screws to install 

the seal over the standard end cap. When combinations of 

modular seals are used longer screws may be required, 

consult table on page 35 & 36 for proper screw size. 

38 


Bellows Dimensional Information 




Bellows are available in three styles: 

531 BB “Low Profile” with outside dimensions that 

do not exceed the carriage, constructed of 

polyurethane coated polyester, maximum 

ambient temperature of 80°C (175°F). 

531 BC “High Compression” constructed of a spark 

resistant Teflon ® coated fiberglass and 

designed to allow for higher compression, 

maximum ambient temperature exceeds 

maximum bearing peak temperatures. 

531 WC “Walk On” capable of handling the harshest 

environments, including welding and grinding 

applications, with a 90 kg load bearing 

capacity. 

The bellows can be easily installed in conjunction with 

the other optional modular seals providing you with an 

easy upgrade to the standard seal. Installation is simple 

and requires little time. Retrofitting is possible. The rail 

ends have to be drilled for the attachment of the bellow 

clip adapter plate, 531 CR. These can be easily installed 


B 

531 BB “Low Profile” Bellows 

Size Part No. B J A CR 

J 

A 

15 531 BB15 45 23 26 0.17 

20 531 BB20 41.6 24 29 0.17 

25 531 BB25 43.7 29 35.5 0.17 

30 531 BB30 51.2 33.3 40.3 0.17 

35 531 BB35 64 39.5 47.5 0.15 

45 531 BB45 76 48 58 0.15 

Customer to specify extended length at time of order, see page 128 for how to calculate. 

531 BC “High Compression” Bellows 

B 


J 

A 

15 531 BC15 59 33 36 0.10 

20 531 BC20 61.6 34 39 0.10 

25 531 BC25 63.7 39 45.5 0.10 

30 531 BC30 71.5 43.3 50.3 0.10 

35 531 BC35 84 49.5 57.5 0.07 

45 531 BC45 76 58 68 0.07 


B 

531 BW “Walk On” Bellows 


15 531 BW15 55 30 31 0.19 

J 

A 

20 531 BW20 61 33 34 0.19 

25 531 BW25 65 36 40.5 0.19 

30 531 BW30 70 39 44.2 0.19 

35 531 BW35 77 42 48 0.19 

45 531 BW45 101 53 61 0.015 





Bellow Clip Adapter Plates 

531 CC Carriage Bellows Clips – Attachment Plate 

The 531 CC Carriage Bellows Clip – Attachment Plate is 

used to attach the bellows to the carriage. The bellows 

clip – adapter plate is made of steel. 

Size Part No. 

15 531 CC15 

20 531 CC20 

25 531 CC25 

30 531 CC30 

35 531 CC35 

45 531 CC45 

531 CR Rail Bellows Clips – Attachment Plate 

The 531 CR Rail Bellow Clip – Attachment Plate is used 

to attach the bellows to the rail. The attaching holes can 

be drilled in the end of the rail if retrofitting or can be 

supplied from the factory. (Note: Size 15 rail is through 

hardened, annealing the end of the rail is required to 

properly drill end plate clip this results in an area on 

the end of the rail that will be soft and possibly out of 

tolerance). The bellows clip – adapter plate is made 

of steel. 

Rail End Machine Detail 

Rail Machining Detail Screw 1 

Size Part No. 

Depth Depth 

A B C Min Max 

Size Pitch Length Type 

MinY 2 

15 3 531 CR15 3.50 8.00 7.50 14 

20 531 CR20 5.00 8.00 10.00 5.70 7.70 M3 0.5 8 Button 15 

25 531 CR25 7.24 10.00 11.50 Head 17 

30 531 CR30 9.12 10.00 14.00 7.70 9.70 M4 0.7 10 Cap 20 

35 531 CR35 11.00 10.00 17.00 Screw 20 

45 531 CR45 15.01 10.00 22.50 22 


1. Two screws are supplied with each Rail Bellow Clip. 

2. Min Y dimension to ensure drill depth does not break through rail mounting hole. 

3. Rail end may require annealing, see note above. 

40 


Maintenance and Installation Tools and Accessories 




The assembly rail is required when the carriage must 

be removed from the rail and then reinstalled to ensure 

proper installation. It is recommended to leave the carriage 

on the assembly rail when it is removed to protect 

the balls against contamination. If necessary, the two 

internal mounting screws for fastening runner blocks 

to the carriage can be tightened to ensure the carriage 

remains on the assembly rail. The assembly rail is made 

of plastic. 

Assembly Rail – 531 MT 

Part Number Size Length (mm) Weight (kg) 

531 MT 15 15 80 0.010 

531 MT 20 20 115 0.021 

531 MT 25 25 130 0.031 

531 MT 30 30 160 0.061 

531 MT 35 35 165 0.076 

531 MT 45 45 200 0.135 

Standard Rail Plugs and Tape for use with to 500 Series Ball Carriage Type A 

Type HP plastic plugs Size 

531 HP 15 15 

531 HP 20 20 

531 HP 25 25 

531 HP 30 30 

531 HP 35 35 

531 HP 45 45 

Material: Nylon 

Mylar Tape Size Length 

531 RT 15 15 3m 

531 RT 20 20 3m 

531 RT 25 25 3m 

531 RT 30 30 3m 

531 RT 35 35 3m 

531 RT 45 45 3m 

500 Series Rail with Stainless Steel Cover Strip 

Rail Coverstrip Replacement Standard Coverstrip Max Single 

End Caps Mounting Tool End Caps Coverstrip Rail Width (mm) PC Length (mm) 

Size Part Number 1 Part Number Part Number 2 Part Number 3 

25 531RCS25 531RCT25 531RCP25 521H25C 15 6000 

30 531RCS30 531RCT30 531RCP30 521H30C 19 6000 

35 531RCS35 531RCT35 531RCP35 521H35C 25 6000 

45 531RCS45 531RCT45 531RCP45 521H45C 25 6000 

1. Customer to specify length of rail to be used on at time of order. 

Delivered piece will be 2 to 3.5 mm longer in order to properly install and fit end caps. 

2. Two end caps are supplied with each piece of 531RCS ordered. 

3. H grade accuracy shown for example purposes, P and U grade accuracy are available. 





Three tolerances describe the accuracy of a Profile Rail 

bearing: Running Parallelism, Pair Variation, and Assembly 

Accuracy. These are measured from the rail base to the 

center of the carriage top (H), and from the rail reference 

edge to the center of the carriage reference edge (A3). 

H 

P1 

Running Parallelism describes the tolerance on H and A3 

as a function of axial travel, measured from one carriage 

down the length of the rail. This is analogous to 

straightness of travel. As such, parallelism describes 

attributes of the rail only. 

P1 

A3 

P1 

Assembly Accuracy describes the tolerance on H and A3 

as a function of a carriage – rail assembly, measured from 

the nominal dimensions. 

40 

30 

Pair Variation describes tolerance on H and A3 as a function 

of carriages at the same position on a common rail. Pair 

variation describes carriage precision only. 

P1 

(µm) 

20 

10 

H 

P 

The accuracy class selected will partially determine the 

accuracy of the system. Other factors such as mounting 

surface flatness and straightness also significantly affect 

system accuracy. 

U 

1000 

2000 3000 


Tolerances 

All values in µm 


H - High P - Precision U - Ultra Precision 

Assembly Accuracy Tolerance on dimension H and A3 (measured at middle of carriage at any point along rail) ±50 ±20 ±5 

Pair Variation Max variation in dimensions H and A3 measured on multiple carriages mounted on the same rail 15 7 3 

(measured at the middle of carriage at same position on rail) 

Running Parallelism 100 40 10 

Preload 

Three Preload classes and one clearance class are 

available with the 500 Series Ball Profile Rail carriages. 

Preload will minimize elastic deformation caused by 

external forces resulting in increased rigidity. Preload 

will eliminate internal clearances between the rail and 

carriage resulting in zero backlash. 

Preload Accuracy Combinations 

Accuracy 

Preload 

Clearance 

Class 0.03C 1 0.08C 1 0.13C 1 

H 0 1 2 

P, U 1 2 3 

42 

1. C = Dynamic load capacity of the bearing 

2. A preloaded bearing loaded beyond the preload value 

has the same characteristics as a clearance bearing. 

Example: Size 25 A style carriage has dynamic load 

capacity of 21.1kN, 

Medium Preload = 0.08C = 0.08 x 21.1kN = 1.7kN; 

if applied load is greater than 1.7kN preload has no benefit. 


NOTES : 








High load capacities 

in all directions 

Multiple rail accuracies 

Multiple rail mounting hole plug 

options, or rails that mount up 

from underneath are available 

Both sides of rail are reference edges 


Patented insert molded 

recirculation path resulting in 

quiet,low noise operation 

Multiple carriage designs, 

accuracies and preloads available 

Optimized roller path geometries and 

transitions for quiet, smooth operation 

Six-runner block attachment bolts per 

carriage for superior system rigidity 

Universal mounting holes – runner blocks 

can be attached from top or bottom 

Multiple lubrication inlet points, 

easy field modification 

Superior rail straightness 

as a result of advanced 

grinding and straightening 

technology 

One piece rail lengths up to 6 meters 

Corrosion resistance with 

Duralloy ® Thin Dense Chrome 

plating optional 

Low drag longitudinal seals standard 

for added protection along rail surface 

Modular accessories for on site 

upgrade without having 

to remove the carriage 

from the rail 

Low friction double 

lip seal on all 

standard carriages 

Extended standard dowel 

hole options for rails 

Retained rollers when carriage is off 

the rail and when end cap is removed 

High rigidity from 

back-to-back geometry 

four roller path arrangement 

High load capacities resulting 

from large contact surface area 

between roller and rail 

Speeds up to 3m/s 

Accelerations up to 50 m/s 2 

44 




Features 

The Thomson 500 Series Linear Guide provides long life, 

exceptional rigidity, high dynamic and static load capacities, 

accommodation for high moment loads, high 

running accuracy, multiple sealing options and multiple 

lubrication inlet options. This allows for on-site field 

modification, and interchangeability with competitor 

offering. 



These properties result in improved machine accuracies 

and rigidity resulting in reduced vibration extending 

machine and tool life. This has a direct effect on your 

operational efficiency resulting in cost savings for the 

user. 

Available in 4 carriage designs. 

Materials 

The 500 Series Roller Linear Guide is produced from 

high quality bearing steel. The end cap is made of a 

high strength, glass-filled nylon with a nitrile rubber 

seal. All carriages and rolling elements are through 

hardened and all rails are case hardened. Stringent 

quality controls are in place to ensure consistency of 

materials from the source, allowing us to ensure that we 

deliver the highest quality product. 

Interchangeability 

The 500 Series Roller Linear Guide is completely interchangeable. 

Any carriage can be run on any rail of the 

same accuracy without compromising system accuracy. 

This is the result of our stringent manufacturing process 

controls. 

Accuracy and Preload 

The 500 Series Roller Linear Guide is available in three 

different accuracy classes, and three different preloads 

ranges to allow for customization to your application 

needs. 

Straightness 

The 500 Series Roller rail is subjected to multiple 

straightening processes during and after grinding of the 

roller paths, on one piece rails up to 6 meters long. 

These added processes and inspections result in some 

of the straightest rails in the market today, improving 

machine accuracies wherever the 500 Series Roller is 

used. 




Load 

Rigidity 

Profile Rail Linear Guide bearings have a significant effect 

on the overall system rigidity. The 500 Series Roller rigidity 

is achieved by using the equivalent of a back-to-back 

bearing arrangement, complemented by special rollers 

that are crowned to prevent roller edge loading when 

misalignment is present. This results in lower elastic 

deformation as the load increases compared to a ball 

carriage or face-to-face bearing arrangement. 

Deflection 

Load Capacity 

The roller has an increased load capacity over the ball as 

a result of the increased contacting surface across the 

length of the roller. A ball provides a single point contact 

area, while a roller provides a much greater line contact 

area. This results in a substantially higher load carrying 

capacity and lower wear with minimum rolling friction. 

Running Smoothness / Low Noise 

The running smoothness and low noise are the result 

of a propriety insert molded recirculation path that has 

an optimized geometric shape and minimal transitions. 

This ensures smooth, quiet operation. 

Multiple Lubrication Options 

The carriage standard end cap is designed for flexibility. 

The end cap is equipped with six lubrication inlet points 

and additional internal options for directing grease or oil 

to the proper location. These options are easily changed 


Not all options available on size 25. 

Unsure of the best lubrication inlet location? These carriages 

will allow the user to make these changes easily in 

the field to optimize the system performance. In addition, 

they allow for ease in maintenance. 

46 



Modular Accessory Options 

The carriage is supplied standard with low friction double 

lip seals and longitudinal seals that completely enclose 

the bearing carriage to protect the rollers and track 

surfaces and minimize lubrication loss. 

Optional metal scrapers or wiper and oil reservoir 

components can be easily added on-site in the field 

or can be supplied assembled from the factory. 



These innovative design features allow users to easily, 

efficiently, and economically upgrade carriage sealing 

and lubrication without needing to replace the entire 

carriage assembly. 

Longitudinal Seals 

The carriage has built-in under carriage low drag 

longitudinal seals that protect the rollers and roller track 

surfaces from contamination. These longitudinal seals 

are an added protection to increase the life and overall 

performance. 

Rail Accessories 

The rails have multiple options to fill the mounting holes 

to eliminate possible contamination entry into the bearing. 

Custom designed plugs are available in plastic, brass, 

or stainless steel. A special rail is available that utilizes 

a custom cover strip. In addition, Danaher Motion stocks 

an assortment of bellows to protect the entire assembly. 

All options are available from stock and represent another 

innovative design feature of the 500 Series. Mounting tools 

for easy and correct installation are available as well. 

Retained Rollers 

The rolling elements of the carriages are retained within 

the bearing so the carriage can be removed from the rail, 

or the end cap from the carriage, without worrying about 

the rollers falling out. It is recommended to place any 

removed carriage onto a mounting rail or shipping arbor 

to provide added protection to the rolling elements. 





Modular Design Exploded View 

Standard end cap assembly for 

easy field modification with 

lubrication channels 

Plastic plug (532HP) 

Standard end cap (532EC) 

Standard rail 

Oil reservoir (532OW) 

Additional wiper 

(532WR or VR) 

Metal scraper (532ZZ) 

Cover strip (532 RCS) 

and special rail (522 Type C) 

Grease fitting 

Attaching bolts 

Also available (not shown): 

• Stainless Steel Rail Plugs (532 HS) 

• Brass Rail Plugs (532 HB) 

• Mylar Tape (532 RT) 

• Bolt up from bottom rail (522 Type U) 

The modular, building block design of the 500 Series Roller 

Profile Rail Linear Guide assembly for easy on-site field 

upgrades, for quick seal or lubrication upgrades all without 

the need for new carriage or rails. 

48 



500 Series Roller Standard Carriages 

Danaher Motion offers four carriage styles with six mounting 

holes allowing for additional mounting configurations in the 

field or retrofitting. All provide superior rigidity and design 

flexibility. 

Narrow 

High 

Carriage 

Narrow 

High 

Long 

Carriage 

Narrow 

Short 

Carriage 

Narrow 

Long 

Carriage 

A 

B 

C 

D 

Style 

Size 

25 

35 

45 

55 

25 

35 

45 

55 

65 

25 

35 

45 

55 

25 

35 

45 

55 

65 

Accuracy 

P 

S 

U 

P 

S 

U 

P 

S 

U 

P 

S 

U 

P 

S 

U 

P 

S 

U 

P 

S 

U 

P 

S 

U 

P 

S 

U 

P 

S 

U 

P 

S 

U 

P 

S 

U 

P 

S 

U 

P 

S 

U 

P 

S 

U 

P 

S 

U 

P 

S 

U 

P 

S 

U 


Preload 

0.03C 0.08C 0.13C 

512P25A1 

512S25A1 

512U25A1 

512P35A1 

512S35A1 

512U35A1 

512P45A1 

512S45A1 

512U45A1 

512P55A1 

512S55A1 

512U55A1 

512P25B1 

512S25B1 

512U25B1 

512P35B1 

512S35B1 

512U35B1 

512P45B1 

512S45B1 

512U45B1 

512P55B1 

512S55B1 

512U55B1 

512P65B1 

512S65B1 

512U65B1 

512P25C1 

512S25C1 

512U25C1 

512P35C1 

512S35C1 

512U35C1 

512P45C1 

512S45C1 

512U45C1 

512P55C1 

512S55C1 

512U55C1 

512P25D1 

512S25D1 

512U25D1 

512P35D1 

512S35D1 

512U35D1 

512P45D1 

512S45D1 

512U45D1 

512P55D1 

512S55D1 

512U55D1 

512P65D1 

512S65D1 

512U65D1 

512P25A2 

512S25A2 

512U25A2 

512P35A2 

512S35A2 

512U35A2 

512P45A2 

512S45A2 

512U45A2 

512P55A2 

512S55A2 

512U55A2 

512P25B2 

512S25B2 

512U25B2 

512P35B2 

512S35B2 

512U35B2 

512P45B2 

512S45B2 

512U45B2 

512P55B2 

512S55B2 

512U55B2 

512P65B2 

512S65B2 

512U65B2 

512P25C2 

512S25C2 

512U25C2 

512P35C2 

512S35C2 

512U35C2 

512P45C2 

512S45C2 

512U45C2 

512P55C2 

512S55C2 

512U55C2 

512P25D2 

512S25D2 

512U25D2 

512P35D2 

512S35D2 

512U35D2 

512P45D2 

512S45D2 

512U45D2 

512P55D2 

512S55D2 

512U55D2 

512P65D2 

512S65D2 

512U65D2 

512P25A3 

512S25A3 

512U25A3 

512P35A3 

512S35A3 

512U35A3 

512P45A3 

512S45A3 

512U45A3 

512P55A3 

512S55A3 

512U55A3 

512P25B3 

512S25B3 

512U25B3 

512P35B3 

512S35B3 

512U35B3 

512P45B3 

512S45B3 

512U45B3 

512P55B3 

512S55B3 

512U55B3 

512P65B3 

512S65B3 

512U65B3 

512P25C3 

512S25C3 

512U25C3 

512P35C3 

512S35C3 

512U35C3 

512P45C3 

512S45C3 

512U45C3 

512P55C3 

512S55C3 

512U55C3 

512P25D3 

512S25D3 

512U25D3 

512S35D3 

512S35D3 

512U35D3 

512P45D3 

512S45D3 

512U45D3 

512P55D3 

512S55D3 

512U55D3 

512P65D3 

512S65D3 

512U65D3 

Standard Rail 

Part Number 

522P25A 

522S25A 

522U25A 

522P35A 

522S35A 

522U35A 

522P45A 

522S45A 

522U45A 

522P55A 

522S55A 

522U55A 

522P25A 

522S25A 

522U25A 

522P35A 

522S35A 

522U35A 

522P45A 

522S45A 

522U45A 

522P55A 

522S55A 

522U55A 

522P65A 

522S65A 

522U65A 

522P25A 

522S25A 

522U25A 

522P35A 

522S35A 

522U35A 

522P45A 

522S45A 

522U45A 

522P550A 

522S55A 

522U55A 

522P25A 

522S25A 

522U25A 

522P35A 

522S35A 

522U35A 

522P45A 

522S45A 

522U45A 

522P55A 

522S55A 

522U55A 

522P65A 

522S65A 

522U65A 



6000 

6000 

6000 

6000 

6000 

6000 

6000 

6000 

6000 

6000 

6000 

6000 

6000 

6000 

6000 

6000 

6000 

6000 






500 Series Roller Rail Options 

Bolt down from the top – 522 Type A 

Bolt down from the bottom – 522 Type U 

Rail Types and Accessories 

The 500 Series Roller Profile Rail is available in two 

configurations : 

• Bolt Down from the top – 522 Type A 

• Bolt Up from the bottom – 522 Type U 

The bolt down from the top design has various types of 

options to plug the holes. 

The standard 522 Type A rail mounting holes can be plugged 

or sealed after installation using the options below. 

Plastic Plugs 

532 HP plastic plugs are an inexpensive and simple method 

to seal the rail attachment bolt area. The plastic plugs are 

easy driven in place to any rails with a soft non-metallic 

drift. They can easily be removed. 

Brass Plugs 

532 HB brass plugs are more rugged than the plastic plug, 

slightly more expensive, and require more precision during 

installation. They fit in all stand 500 Series Roller Rails and 

require some hand buffing or polishing of the rail surface 

after installation. 

Two-piece Stainless Steel Plugs 

532 HS two-piece stainless plugs are the most rugged plugs 

available for the roller rails. The two piece construction and 

design allows the plugs to lock into place and rest on the top 

of the socket head bolt. They require no post installation 

polishing. The recommended hex head socket must be used to 

properly install the 532 HS plugs. For correct installation, 

we recommend use of the 532 HST mounting tools found 

on page 69. 

Mylar Tape 

A simple and low cost alternative is specialty Mylar tape 

that can be placed quickly on the top surface of the rail. 

Part number 532 RT is available in 3 meter lengths. 

Optional 500 Series Rail 

Option 532 RC utilizes a special rail 522 Type C that is easily 

installed with the 532 RCT mounting tool found on page 69. 

Carriage Option 

The 500 Series Roller Profile carriages are also available 

with special lubrications. They can be ordered directly from 

stock or with a short lead-time. 

50 




Additional Seal Types and Lubrication Accessories 

The carriages are designed with modular sealing and lubrication 

options for simple on-site field modification or factory 

direct. 

The standard carriage end cap has an integral low friction 

double lip seal and longitudinal seals that completely 

enclose the bearing carriage. The double lip design keeps 

contaminants out and lubrication in. It also allows for grease 

to purge out of the carriage to prevent excessive lubrication, 

which can result in higher operating temperatures. This 

double lip design allows for use with oil lubrication. 



This standard carriage end cap comes standard with a lubrication 

inlet centered in the end cap with specially designed 

and modified lubrication channels to direct the lubrication 

to the different roller tracks. The lubrication inlet can be 

easily changed in the field or supplied from the factory for 

side inlet, offset inlet or top inlet. Additionally, the internal 

configuration can be modified to allow for separating the 

lubrication paths for vertical mounting or oil lubrication. 

The standard carriage end cap is equipped with lubrication 

channels directing lubrication to proper roller paths. The 

standard carriage end plate can be easily modified on-site 

in the field to channel lubrication separately or can be factory 

ordered. 

Optional – on site field installable modular seals 

and accessories 

Additional Seal 

The 532 WR and 532 VR seals provide an additional level 

of protection from contaminants to the assembly. These 

additional components can be easily added on-site. They are 

supplied with the required screws to make installation simple. 

• 532 WR is made of durable nitrile rubber (Buna N) 

• 532 VR is made of durable Viton ® 

These seals can be used in conjunction with other optional 

modular accessories providing an easy upgrade to the 

standard seal. These can be easily installed on-site in the 

field or can be supplied from the factory. 

Metal Scraper 

The 532 ZZ Metal Scraper made of stainless steel, serves 

as an added protection to the seal lips against large dirt 

particles, metal shavings or chips. Large contaminants are 

easily pushed away for an extra level of protection to the seal 

lips. The Metal Scraper is easily installed in conjunction with 

other optional modular accessories providing you with an 

easy upgrade to the standard seal. These are easily installed 





Oil Reservoir 

The 532 OW Oil Reservoir is a cost effective, automatic 

lubrication system. It is constructed with an integrated oil 

reservoir that provides a uniform, consistent lubricating 

oil to the roller paths for extended periods of time. The 

Type 532 OW oil reservoir eliminates the need for a routine 

maintenance schedule, assures lubrication gets to the 

required points, can be refilled if required, and can operate 

up to 5000 km of travel. 

The Type 532 OW oil reservoir can be easily installed 

in conjunction with other optional modular seals for an 

easy upgrade to the standard seal. These can be easily 

installed on-site in the field or can be supplied from the 

factory. 

Bellows 

Standard bellows are available for all assemblies. The bellows 

cover the entire length of the rail. The bellows are used to 

provide additional protection against dirt, dust and splashed 

liquid. Installation is simple and requires little time. Retrofitting 

is possible when the rail ends are drilled for the attachment 

of the rail clip 532 CR. 

Bellows are available in three styles : 

• Type B “Low Profile” with outside dimensions that do 

not exceed the carriage 

• Type C “High Compression” 

• Type W “Walk-On” capable of handling the harshest 

environments with a 90 kg load bearing capacity 

The bellow can be easily installed in conjunction with 

the other optional modular accessories and are an 

easy up grade to the standard seal. These can be easily 

installed on-site in the field. 

Note: Additional Modular accessories add additional drag 

to the carriage assembly resulting in increased start-up 

friction and power consumption. 

Relative Drag Comparison for Design Consideration 

For ordering information or for 

additional 

Seal Types and 

Lubrication Accessories, 

see page 64. 

Type 

Standard carriage 

Rubber Wiper (531 WR) 

Viton ® Wiper (531 VR) 

Metal Scraper (531 ZZ) 

Oil Reservoir (531 OW) 

• Low 

Relative Drag 

• 

• • • 

• • • 

• 

• • 

52 



Roller Carriage 

500 Series 

Profile Carriage 


OPTIONS 

5 1 2 P 25 A 1 D N W Z ES1 SM 

Specials 

SM Special per customer 

print 



Product Type 

1 Carriage 

Type 

2 Roller 



S Super Precision Grade 


Size 

25, 35, 45, 55, 65 

Extended Standards 3 

ES1 Offset lubrication in end caps 1 

ES2 Side lubrication in end caps 1 

ES3 Top lubrication in end caps 

ES4 ES1 + individual lubrication channels 1 

ES5 ES2 + individual lubrication channels 1 

G1 Greased with Mobilux ® EP2 

G2 Greased with Krytox ® GPL227 

GS Greased per customer specification 


A Standard 

B Standard Long 

C Narrow 

D Narrow Long 

Preload 




Coating Option 

D Duralloy ® Thin Dense Chrome 

(P accuracy only) 

Accessories 2 

N Additional Oil Reservoir 

W Additional Rubber Wiper 

V Additional Viton ® Wiper 

Z Metal Scraper 

C Bellow Clips 

1. ES1, ES2, ES4 and ES5 options are available size 35, 45, 55 and 65 

only. 

2. Accessory combination part numbers are listed from carriage 

end cap outward. Not all combinations are available. For specific 

combination availability see page 63 or consult Danaher Motion. 

3. Optional inlet and grease options may not be functional with all 

accessory combinations. (Example: G1 and Oil Reservoir “N”). Prior 

to selecting an inlet option review any interference or conflicts with 

the accessories selected. 




Roller Rail 


OPTIONS 

5 2 2 P 25 A D DH1 SM 

STANDARD 

+xxxx Y= (see note 1) 

Type 

2 Roller 

500 Series 


Product Type 

2 Rail 



S Super Precision Grade 


Size 

25, 35, 45, 55, 65 

Rail Style 

A Standard 

U Bolt up from Bottom 

C Cover Strip 

1. Y = Distance from end of rail to center of first mounting hole, Y1 = Y2 

unless specified. 

2. Stock length rails are considered random length, total length may 

exceed specified length, and Y1/Y2 are not equal. To be used by 

customer who will cut to length. 

Coating Option 

D Duralloy ® (P Class only) 

Length (mm) 

+xxxx Customer Specified 



Specials 

SM Special per customer print 

Machined Options 

DH1 8mm dowel hole + slot 



DH4 3/8” dowel hole + slot 

DH5 1/2” dowel hole + slot 

JT 3 Butt Joint 

E Bellow Clips Attached 

3. Customer drawing required at time of quote and order. See page 

130 for more information and templates. 

Roller Accessories 

Type 

2 Roller 

500 Series 


Product Type 

3 Accessories 

5 3 2 EC 25 

Size 

25, 35, 

45, 55, 65 

Bellows 

BB Low Profile Bellows 1 

BC High Compression Bellows 1 

BW Walk On Bellows 1 

CC Bellow clips for Carriage 

CR Bellow clips for Rail 

Rail Hole Covers and Plugs 

HP Plastic Rail Plugs 

HS Stainless Steel 2pc plugs 

HB Brass Rail Plugs 

RT Mylar Rail Tape 

HST HS and HB Installation Tool 

HSTC Hydraulic Cylinder for HST 

RCS Rail Cover Strip 1 

RCT Rail Cover Installation Tape 

RCP Rail Cover End Cap 

Modular Seal/Accessory 

EC Replacement End Cap 

WR Rubber Wiper 

VR Viton ® Wiper 

ZZ Metal Scraper 

OW Oil Reservoir 

Mounting Assembly Tools 

MT Mounting Rail 

1. Bellows and rail cover strip must include length at time of order. 

(Example : 532BB35 + 1000 mm). See page 128 for how to 

calculate bellows length. 

54 


J 





P 

O 

M 1 

B 

N 

F 3 

E 

F 

45 ° B 2 B 1 

G 1 

F 

F 3 

S 2 

G 2 

J 1 

A 

G 

J1 

G2 

Y 

X 

F2 

F1 

S3 Screw 

Size 



512 

Y 1 

Style A 512 

X Style B 

Part Number 

Location 

L 2 

L 1 

Y L 2 3 

L 

Length 

L 1 

L 2 

L 3 

L 

N 

512 Style A – Standard Roller 

Size Dimensions (mm) Roller 

A B B 1 * B 2 J J 1 L L 1 L 2 L 3 X N S 2 S 3 F F 1 F 2 F 3 Ø G G 1 G 2 M 1 O P 

±0.05 

25 36 70 23 23.5 29.5 24.5 81 45 40 60 30 57 M8 M6 6.8 7 11 11 3.2 9 6.5 13 5.5 7.5 17.5 

35 48 100 34 33 40 32 109 62 52 80 40 82 M10 M8 8.5 9 15 15 4.5 12 10 15 7 8 23 

45 60 120 45 37.5 50 40 137.5 80 60 104 52.5 100 M12 M12 10.5 14 20 18 5 15 11 21 8 10 30.5 

55 70 140 53 43.5 57 48 163.5 95 70 120 60 116 M14 M14 12.5 16 24 20 6 18 13.5 26 9 12 34.5 

512 Style B – Standard Long Roller 


A B B 1 * B 2 J J 1 L L 1 L 2 L 3 X N S 2 S 3 F F 1 F 2 F 3 Ø G G 1 G 2 M 1 O P 

±0.05 

25 36 70 23 23.5 29.5 24.5 103.4 45 40 79.4 30 57 M8 M6 6.8 7 11 11 3.2 9 6.5 13 5.5 7.5 17.5 

35 48 100 34 33 40 32 136 62 52 103 40 82 M10 M8 8.5 9 15 15 4.5 12 10 15 7 8 23 

45 60 120 45 37.5 50 40 172.5 80 60 135 52.5 100 M12 M12 10.5 14 20 18 5 15 11 21 8 10 30.5 

55 70 140 53 43.5 57 48 205.5 95 70 162 60 116 M14 M14 12.5 16 24 20 6 18 13.5 26 9 12 34.5 

65 90 170 63 53.5 76 58 251 110 82 201 75 142 M16 M16 14.5 18 26 23 7 23 19 32 13 15 51 

* Standard tolerance shown, special lower tolerances are available 

upon request. Please consult application engineering for additional 

information. 

** When using additional modular seals or lubrication plates, the 

total length L will increase. Consult page 63-64 for additional 

information. 

Length of rail to be specified at time of order, Y 1 = Y 2 unless specified 

otherwise at time of order. 








M L = Dynamic pitch and yaw moment rating 

M Q = Dynamic roll moment rating 

Static Load and Moment Capacities 

C O = Static load capacity 

M OL = Static pitch and yaw moment capacity 

M O = Static roll moment capacity 

M Q /M OQ 

M L /M OL 

C 

C o 

Roll 

Pitch 

C/C o 

C/C o 

M L /M OL 

Yaw 

Loading Capabilities Moments Weights 

Size & Co C M OQ M Q M OL M L Carriage Rail 

Style (N) (N) (Nm) (Nm) (Nm) (Nm) (kg) (kg/m) 

25A 49800 27700 733 408 476 265 0.7 

25B 70300 39100 1035 576 936 521 0.9 3.4 

35A 93400 52000 2008 1118 1189 662 1.6 

35B 128500 71500 2762 1537 2214 1232 2.2 6.5 

45A 167500 93400 4621 2577 2790 1556 3.2 

45B 229500 127800 6333 3527 5161 2874 4.3 10.7 

55A 237000 131900 7771 4325 6650 2637 5.0 

55B 324000 180500 10624 5919 8745 4872 6.8 15.2 

65B 530000 295000 20912 11640 17930 9980 13.5 22.5 

1. The dynamic load and moment ratings are based upon 100 km travel 

life. When comparing these load ratings with other bearings take 

into consideration that some manufacturers dynamic and moment 

ratings are based on 50 km travel life. In order to compare with 

bearing dynamic and moment ratings based on 50 km travel life, 

divide the dynamic capacity of the bearing rated for 50 km by 1.23 

to get an accurate comparison. 

2. The static load and moment rating are the maximum radial load and 

moment load that should be applied to the bearing while there is no 

relative motion between the carriage and rail. 


L = (C/F) 3 x 100km 

where: 


C = dynamic load rating, N 


1⁄ 3 

100 

C min = F L 

( ) 

where: 









Max: 80° C 



56 


J 





M 1 

O 


B 

N 

S 2 

G 2 G 

J 1 

A 

J1 

G2 

Y 

X 

F2 

F1 

S3 Screw 

Size 



B 2 

B 1 

Part Number Location 

512 

Style C 

Part Number 

Location 

Y 1 

X 

512 

Style D 

Length 

L 3 

Y 2 

L 1 

L 

L 3 

L 1 

L 

N 

512 Style C Narrow Roller 


A B B 1 * B 2 J J 1 L L 1 L 3 X N S 2 S 3 F 1 F 2 Ø G G 2 M 1 O 

+0.05 

25 40 48 23 12.5 33.5 24.5 81 35 57 30 35 M6 M6 7 11 3.2 9 13 9.5 7.5 

35 55 70 34 18 47 32 109 50 76 40 50 M8 M8 9 15 4.5 12 15 14 8 

45 70 86 45 20.5 60 40 137.5 60 100 52.5 60 M10 M12 14 20 5 18 21 18 10 

55 80 100 53 23.5 67 48 163.5 75 120 60 75 M12 M14 16 24 6 19 26 19 12 

512 Style D Narrow Long Roller 


A B B 1 * B 2 J J 1 L L 1 L 3 X N S 2 S 3 F 1 F 2 Ø G G 2 M 1 O 

+0.05 

25 40 48 23 12.5 33.5 24.5 103.4 50 79.4 30 35 M6 M6 7 11 3.2 9 13 9.5 7.5 

35 55 70 34 18 47 32 136 72 103 40 50 M8 M8 9 15 4.5 12 15 14 8 

45 70 86 45 20.5 60 40 172.5 80 135 52.5 60 M10 M12 14 20 5 18 21 18 10 

55 80 100 53 23.5 67 48 205.5 95 162 60 75 M12 M14 16 24 6 19 26 19 12 

65 90 126 63 31.5 76 58 251 120 201 75 76 M16 M16 18 26 7 20 32 13 15 

* Standard tolerance shown, special lower tolerances are available 

upon request. Please consult application engineering for additional 

information. 

** When using additional modular seals or lubrication plates, the 

total length L will increase. Consult page 63-64 for additional 

information. 

Length of rail to be specified at time of order, Y1 = Y2 unless specified 

otherwise at time of order. 








M L = Dynamic pitch and aw moment rating 

M Q = Dynamic roll moment rating 


M Q /M OQ 

C O = Static load capacity 

M OL = Static pitch and yaw moment capacity 

M OQ = Static roll moment capacity 

M L /M OL 

C 

C O 

Roll 

Pitch 

C/C O 

C/C O 

M L /M OL 

Yaw 

Loading Capabilities Moments Weights 

Size & Co C M OQ M Q M OL M L Carriage Rail 

Style (N) (N) (Nm) (Nm) (Nm) (Nm) (kg) (kg/m) 

25C 49800 27700 733 408 476 265 0.6 

25D 70300 39100 1035 576 936 521 0.7 3.4 

35C 93400 52000 2008 1118 1189 662 1.5 

35D 128500 71500 2762 1537 2214 1232 2.0 6.5 

45C 167500 93400 4621 2577 2790 1556 3.0 

45D 229500 127800 6333 3527 5161 2874 4.0 10.7 

55C 237000 131900 7771 4325 4738 2637 4.5 

55D 324000 180500 10624 5919 8745 4872 6.1 15.2 

65D 530000 295000 20912 11640 17930 9980 10.4 22.5 

1. The dynamic load and moment ratings are based upon 100 km 

travel life. When comparing these load ratings with other bearings 

take into consideration some manufacturers dynamic and moment 

ratings are based on 50 km travel life. In order to compare with 

bearing dynamic and moment ratings based on 50 km travel life, 

divide the dynamic capacity of the bearing rated for 50 km by 1.23 

to get an accurate comparison. 

2. The static load and moment rating are the maximum radial load and 

moment load that should be applied to the bearing while there is no 

relative motion between the carriage and rail. 


L = (C/F) 3 x 100km 

where : 




1⁄ 3 

100 

where : 

C min = F L 

( ) 





Operating Parameters : 

Maximum Velocity : 3 m/s 

Maximum Acceleration : 50 m/s 2 

Temperature : Min: – 40° C 

Max: 80° C 



58 



Rail Modifications 

The rails can be supplied with dowel holes, radial 

holes and coaxial holes. Please provide a drawing 

of your requirement and our Application Engineering 

Team can provide a quote. 

Maximum Length of Single Piece Rail 

Size (mm) 25 35 45 55 65 

Maximum 

6000 mm 

Length 



Extended Standard Rail Options 

LENGTH AS PER CUSTOMER SPECIFICATION 

Y1 X (REF) TYP Y2 

F 

G 

9.5 MIN 

STEP ALLOWED 

ALL AROUND 

SLOT 

PERIMETER 

C 

SECTION F-F 

L 3 

F 

L 1 O D - SLIP FIT DOWEL HOLE 

G 

L 2 

SECTION G-G 

522 Type U Rail Bolt Up From Bottom 

Option 

DH1 

DH2 

DH3 

DH4 

DH5 

Size 

D L 1 L 2 L 3 C 

+.013 

+1.5 

-0 

+0.12 +0.40 

-0 

+0.05 

25 

15 15 

11.5 

35 20 20 17 

45 8 

12 22.5 

55 30 30 

26.5 

65 31.5 

25 N/A N/A N/A N/A N/A 

35 

20 20 

17 

45 

22.5 

10 

15 

55 30 30 

26.5 

65 31.5 

25 

35 

N/A N/A N/A N/A N/A 

45 

22.5 

55 12 30 30 18 26.5 

65 31.5 

25 N/A N/A N/A N/A N/A 

35 

.787” .787” 

.669” 

45 

.886” 

3/8” 

.550” 

55 1.181” 1.181” 

1.043” 

65 1.240” 

25 

35 

N/A N/A N/A N/A N/A 

45 

.886” 

1/2” 1.181” 1.181” .750” 

55 1.043” 

65 1.240” 

All dimensions in mm unless otherwise specified. 

Y1 = Y2 unless otherwise specified. 

Size X E G Weight 

(mm) 

(kg/in) 

25 30 M6 12 3.4 

Y 

G 

X 

E 

35 40 M8 15 6.5 

45 52.5 M12 19 10.7 

55 60 M14 22 15.2 

65 75 M16 25 22.5 

Y1 = Y2 unless specified at time of ordering. 




Lubrication Inlet Options 

The standard carriage is supplied with a straight lubrication 

fitting centered. The carriage end cap has 

multiple lubrication inlet points and lubrication channels 

options and is supplied standard with the end cap 

center inlet plugged. These options can be easily 

modified on-site in the field or can be supplied factory 

direct. (Not available for size 25.) 

Option Inlet Lubrication Channel 

ES 1 2 Inlets offset - both sides - all four Standard channel 

ES 2 Inlets on side - both sides - all four Standard channel 

ES 3 1 Inlet on top Standard channel 

ES 4 2 Inlets offset - both sides - all four Individually channeled path 

ES 5 Inlets offset - both sides - all four Individually channeled path 

1. An O-Ring or adapter is required to properly seal the mating 

surfaces to prevent grease or oil from escaping. One is supplied with 

this option. The adapter is for C and D style carriages. 

Lubrication options available in size 35, 45, 55 and 65 only. 

2. Option can not be used in combination with additional modular 

accessories. 

3. Set screws are installed to plug all holes. 

Lubrication inlet locations. Front of end cap above rail and slide. 

Size Style M 1 M 2 M 4 M 3 D 1 D 2 

25 

A 

B 

5.5 

C 

D 

9.5 

N/A N/A N/A M6 N/A 

35 

A 

7 

7 

B 

32 6.5 

C 

14 14 

D 

M6 M6 

45 

A 

8 

8 

B 

40 7.5 

C 

18 18 

D 

M6 M6 

55 

A 

9 

9 

B 

50 8.5 

C 

19 19 

D 

M6 M6 

65 

B 

D 

13 64 12.5 13 M6 M6 

M 3 

M 

M 

4 

2 

D 2 

ES1 D 1 

M 1 

ES2/ 

ES5 

ES2/ 

ES5 

ES1/ES4 

ES2/ES5 

1. D1 and D2 are threaded holes in the end cap to ensure proper 

integrity and durability of connection. 

2. Carriages are shipped with a grease fitting in the box (fitting 530LN). 

See page 70 for more information. 


60 



Lubricant Inlet Options, cont’d 

Lubrication inlet locations. Inlet on top. “ES3” 

Size Style C7 D1 D2 D3 D4 Adapter 1 

A 12.0 

N/A 

B 23.2 

25 

6.75 10 1.78 6 

C 17.0 

532ES3ADP25 

D 20.7 

A 14.0 

N/A 

B 27.5 

35 C 6.75 10 1.78 6 

20.0 

532ES3ADP35 

D 22.5 

A 17.0 

N/A 

B 34.5 

45 

6.75 10 1.78 6 

C 27.0 

532ES3ADP45/55 

D 34.5 

A 21.5 

N/A 

B 42.5 

55 

6.75 10 1.78 6 

C 31.5 

532ES3ADP45/55 

D 42.5 

B 54.0 

65 

6.5 10 2 6 N/A 

D 49.0 

D 2 

C 7 

D1 = O-Ring internal diameter 

D2 = Counterbore diameter 

D3 = O-Ring thickness 

D4 = Max. diameter of lubrication inlet diameter from above 




1. Adapter supplied when ordering ES3 option. 

Grease Lubricants 

Standard carriages are sold with oil preservative to protect 

the rollers from corrosion during storage and transit. The 

carriages are available with the following assortment of 

lubricants as standard. 

Option Type Notes Viscosity Temperature Range 

G1 Mobilux ® EP2 All purpose NLGI2 grease 160cSt @40°C –20°C to 130°C 

G2 Krytox ® GPL227 High Temperature NLGI2 440cSt @40°C –30°C to 288°C 

GS 

Customer specified grease 

Additional greases may be available upon request. Please consult 

Danaher Motion Application Engineering. 




Thin Dense Chrome Plating 

Rails and carriages are available with Duralloy ® DSV 

Thin Dense Chrome Plating with a thickness of 2–4 µm. 

As a result of the plating thickness range compared to 

the tolerance ranges in the different accuracy classes, 

it is only available with Precision accuracy classes up 

to 3 meters long as a single rail ; long lengths can be butt 

jointed. 

Carriage Assortment with Thin Dense Chrome 

Preload 

Type Style Size Accuracy 0.03C 0.08C 

0.13C 

Appropriate 


Max One Piece 


512 

A 

B 

C 

D 

25 P 512P25A1D 512P25A2D 512P25A3D 522P25AD 3000 




25 P 512P25B1D 512P25B2D 512P25B3D 522P25AD 3000 





25 P 512P25C1D 512P25C2D 512P25C3D 522P25AD 3000 




25 P 512P25D1D 512P25D2D 512P25D3D 522P25AD 3000 





Note : Duralloy carriages and rails are designed and manufactured to be 

used together. If a non-Duralloy carriage is used on a Duralloy rail the 

preload of the carriage will be increased approximately one class. 

If a Duralloy carriage is used on a non-Duralloy rail the preload will be 

decreased approximately one class. This is the result of the coating 

thickness. 

62 



Modular Accessory Combination Options and Screw Size 

Option 

N 3 

W 3 

V 3 

Z 3 

C 3 

NW 

NWZ 

NWC 

NWZC 

NZ 

NZC 

NC 

WC 

WZ 

WZC 

VZ 

ZC 

Oil Reservoir 

Rubber Wiper 

Viton Wiper 

Metal Scraper 

Bellows Clips 

Description 


Oil Reservoir, Wiper + 

Scraper 

Oil Reservoir, Wiper + 

Bellows Clip 

Oil Reservoir, Wiper, Scraper 

+ Bellows Clip 


Oil Reservoir, Scraper + 

Bellows Clips 




Wiper, Scraper + 

Bellows Clip 



25 

Low/socket 

head screw 

Low/socket 

head screw 

Low/socket 

head screw 

Low/socket 

head screw 

Flat/socket 

head screw 

Low/socket 

head screw 

Low/socket 

head screw 

Flat/socket 

head screw 

Flat/socket 

head screw 

Low/socket 

head screw 

Flat/socket 

head screw 

Flat/socket 

head screw 

Flat/socket 

head screw 

Low/socket 

head screw 

Flat/socket 

head screw 

Low/socket 

head screw 

Flat/socket 

head screw 

M4x30 

M4x25 

M4x25 

M4x20 

M4x20 

M4x40 

M4x40 

M4x40 

M4x40 

M4x35 

M4x35 

M4x35 

M4x25 

M4x25 

M4x25 

M4x25 

M4x20 

Low/socket 

head screw 

Low/socket 

head screw 

Low/socket 

head screw 

Low/socket 

head screw 

Flat/socket 

head screw 

Low/socket 

head screw 

Low/socket 

head screw 

Flat/socket 

head screw 

Flat/socket 

head screw 

Low/socket 

head screw 

Flat/socket 

head screw 

Flat/socket 

head screw 

Flat/socket 

head screw 

Low/socket 

head screw 

Flat/socket 

head screw 

Low/socket 

head screw 

Flat/socket 

head screw 

1. All fasteners standard thread. 

2. Consult Danaher Motion for options not listed, engineering review 

is required. 

M4x35 

M4x30 

M4x30 

M4x25 

M4x25 

M4x45 

M4x45 

M4x45 

M4x50 

M4x40 

M4x40 

M4x40 

M4x30 

M4x30 

M4x30 

M4x30 

M4x25 

Size 

35 45 

55 65 

Low/socket 

head screw 

Low/socket 

head screw 

Low/socket 

head screw 

Low/socket 

head screw 

Flat/socket 

head screw 

Low/socket 

head screw 

Low/socket 

head screw 

Flat/socket 

head screw 

Flat/socket 

head screw 

Low/socket 

head screw 

Flat/socket 

head screw 

Flat/socket 

head screw 

Flat/socket 

head screw 

Low/socket 

head screw 

Flat/socket 

head screw 

Low/socket 

head screw 

Flat/socket 

head screw 

M5x45 

M5x35 

M5x35 

M5x30 

M5x25 

M5x50 

M5x55 

M5x50 

M5x55 

M5x50 

M5x50 

M5x50 

M5x30 

M5x35 

M5x35 

M5x35 

M5x25 

Low/socket 

head screw 

Low/socket 

head screw 

Low/socket 

head screw 

Low/socket 

head screw 

Flat/socket 

head screw 

Low/socket 

head screw 

Low/socket 

head screw 

Flat/socket 

head screw 

Flat/socket 

head screw 

Low/socket 

head screw 

Flat/socket 

head screw 

Flat/socket 

head screw 

Flat/socket 

head screw 

Low/socket 

head screw 

Flat/socket 

head screw 

Low/socket 

head screw 

Flat/socket 

head screw 

M6x45 

M6x35 

M6x35 

M6x35 

M6x30 

M6x55 

M6x60 

M6x55 

M6x60 

M6x55 

M6x55 

M6x55 

M6x35 

M6x35 

M6x35 

M6x35 

M6x30 

Low/socket 

head screw 

Low/socket 

head screw 

Low/socket 

head screw 

Low/socket 

head screw 

Flat/socket 

head screw 

Low/socket 

head screw 

Low/socket 

head screw 

Flat/socket 

head screw 

Flat/socket 

head screw 

Low/socket 

head screw 

Flat/socket 

head screw 

Flat/socket 

head screw 

Flat/socket 

head screw 

Low/socket 

head screw 

Flat/socket 

head screw 

Low/socket 

head screw 

Flat/socket 

head screw 

M6x55 

M6x40 

M6x40 

M6x35 

M6x35 

M6x65 

M6x65 

M6x65 

M6x65 

M6x60 

M6x60 

M6x60 

M6x40 

M6x40 

M6x40 

M6x40 

M6x35 

3. Each modular accessory is supplied with proper screws to install 

over end cap only and not combinations of modular accessories. 






Modular Seals and Lubrication Accessories 

Additional Wipers 

532WR – Rubber Wiper 

532VR – Viton ® Wiper 

Size Rubber Viton ® L1 L2 Weight 

Part Number Part Number (mm) (mm) (kg) 

25 532WR25 532VR25 7 4 0.005 

35 532WR35 532VR35 7 4 0.012 

45 532WR45 532VR45 7 4 0.024 

55 532WR55 532VR55 7 4 0.029 

65 532WR65 532VR65 7 4 0.040 

L2 

L2 

L1 

L1 

L1 – wiper thickness, L2 – max. screw head stickout 

Metal Scraper 

532 ZZ 

Size Part Number L1 (mm) L2 (mm) Weight (kg) 

25 532ZZ25 1.5 4 0.011 

35 532ZZ35 1.5 4 0.022 

45 532ZZ45 1.5 4 0.034 

55 532ZZ55 1.5 4 0.044 

65 532ZZ65 1.5 4 0.078 

L2 

L2 

L1 

L1 

L1 = scraper thickness, L2 = max. screw head stickout 

Oil Reservoir 

532 OW 

Size Lubrication Plate L1 (mm) Weight (kg) 

25 532OW25 12.7 0.013 

35 532OW35 16.7 0.032 

45 532OW45 19 0.056 

55 532OW55 22 0.103 

65 532OW65 25.2 0.179 

L1 = lubrication plate thickness, screw heads are recessed in plate 

L1 

L1 

64 



When using a combination of different plates, add the 

cumulative thickness of the plates to get an accurate 

overall carriage length. 

Example : 

512 Size 45 carriage with 532 OW and 532 WR modular 

seals on both sides : 

511 Size 35 carriage with 531OW modular seal on both 

sides and 531VR modular seals on one side: 



Carriage Length (L) = 137.5 

532 OW L1 x 2 = 19 x 2 

532 WR L1 x 2 = 7 x 2 

532 WR L2 x 2 = 4 x 2 

Total Length = 193.5 mm 

Carriage Length (L) = 109 

532 OW L1 x 2 = 16.7 x 2 

532 VR L1 x 1 = 7 x 1 

532 VR L2 x 1 = 4 x 1 

Total Length = 153.4 mm 

Each modular accessory is supplied with the proper 

screws to install them over the end cap. When 

combinations of modular seals are used longer screws 

may be required. The following sizes are available from 

our stock. 




Bellows Dimensional Information 

Bellows are available in three styles: 

532 BB “Low Profile” with outside dimensions that 

do not exceed the carriage, constructed 

of polyurethane coated polyester, maximum 

ambient temperature of 80°C (175°F). 

532 BC “High Compression” constructed of a spark 

resistant Teflon ® coated fiberglass and 

designed to allow for higher compression, 

maximum ambient temperature exceeds 

maximum bearing peak temperatures. 

532 BW “Walk On” capable of handling the harshest 

environments, including welding and grinding 

applications, with a 90 kg load bearing 

capacity. 

The bellows can be easily installed in conjunction with 

the other optional modular seals providing you with an 

easy upgrade to the standard seal. Installation is simple 

and requires little time. Retrofitting is possible. The rail 

ends have to be drilled for the attachment of the bellow 

clip adapter plate, 532 CR. These can be easily installed 


B 

J 

A 

532 BB “ Profile” Bellows 


25 532 BB25 47 30.5 36 0.17 

35 532 BB35 70 41.3 47.5 0.15 

45 532 BB45 81 51 59 0.15 

55 532 BB55 99 58 69 0.10 

65 532 BB65 109 65 79 0.10 


B 

J 

A 

532 BC “High Compression” Bellows 


25 532 BC25 67 40.5 46 0.10 

35 532 BC35 90 51.3 57.5 0.07 

45 532 BC45 101 61 69 0.07 

55 532 BC55 119 68 79 0.06 

65 532 BC65 129 75 89 0.06 


B 

J 

A 

532 BW “Walk On” Bellows 


25 532 BW25 57 35,5 41 0.19 

35 532 BW35 77 42 48.2 0.19 

45 532 BW45 101 53 61 0.15 

55 532 BW55 111 58 69 0.15 

65 532 BW65 119 70 84 0.15 


66 



Bellow Clip Adapter Plates 

532 CC Carriage Bellow Clips – Attachment Plate 

The 532 CC Carriage Bellow Clip – Attachment Plate is 

used to attach the bellows to the carriage. The bellows 

clip – adapter plate is made of steel. 

Size Part No. 

25 532 CC25 

35 532 CC35 

45 532 CC45 

55 532 CC55 

65 532 CC65 



532 CR Rail Bellow Clips – Attachment Plate 

The 532 CR Rail Bellow Clip – Attachment Plate is used 

to attach the bellows to the rail. The attaching holes 

can be drilled in the end of the rail if retrofitting or can 

be supplied from the factory. The bellows clip – adapter 

plate is made of steel. 

Rail Machining Detail Screw 1 

Size Part No. 

Depth Depth 

MinY 

A B C 

Size Pitch Length Type 

Min Max 

25 532 CR25 7.24 11.50 12 

35 532 CR35 11.00 17.00 

Button 

20 

45 532 CR45 15.01 10 22.50 7.7 9.70 M4 0.70 10.00 Head Cap 22 

55 532 CR55 18.01 26.50 

Screw 

24 

65 532 CR65 24.00 31.50 28 


1. Two screws are supplied with each Rail Bellow Clip. 

2. Min Y dimension to ensure drill depth does not break through rail mounting hole. 

B 

A 

C 

D 




500 Series Roller Rail Information 

Maintenance and Installation Tools & Accessories : 

Assembly Rail – 532 MT 

An assembly rail is required when the carriage must be 

removed from the rail and then reinstalled during the 

installation. It is recommended to leave the carriage on 

the assembly rail to protect the rollers against con the 

carriage can be tightened. The assembly rail is made 

of plastic. 


Size Part Number Length (mm) Weight (kg) 

25 532 MT25 145 0.062 

35 532 MT35 185 0.152 

45 532 MT45 230 0.317 

55 532 MT55 265 0.525 

65 532 MT65 320 0.914 

Standard Rail Plugs and Tape 

HP plastic plugs 

Size Part Number Qty per pack Weight (kg) 

25 532 HP25 25 .007 

35 532 HP35 25 .014 

45 532 HP45 25 .025 

55 532 HP55 25 .047 

65 532 HP65 25 .053 

HB brass plugs 


25 532 HB 25 1 .002 

35 532 HB 35 1 .005 

45 532 HB 45 1 .008 

55 532 HB 55 1 .011 

65 532 HB 65 1 .013 

HS two-piece stainless steel plugs 


25 532 HS 25 1 set .003 

35 532 HS 35 1 set .008 

45 532 HS 45 1 set .012 

55 532 HS 55 1 set .019 

65 532 HS 65 1 set .026 

68 



Mylar tape 

Size Part Number Length 

25 532 RT 25 3 m 

35 532 RT 35 3 m 

45 532 RT 45 3 m 

55 532 RT 55 3 m 

65 532 RT 65 3 m 



HST Stainless Steel and Brass installation tool 

532HSTC 

Insertion plug 

included with 532HSTxx 

532HSTxx 

Sliding Block with insertion plug Weight (kg) 

532 HST 25 For size 25 rail 2.0 





Hydraulic cylinder (for all sizes) Weight (kg) 

532 HSTC 1 0.53 

1. Hydraulic fitting size 1/4”-18 NPT, max pressure 120 x 103 hPa (120 bar). 

Optional 500 Series Rail with Stainless Steel Cover Strip 

Rail Coverstrip Replacement Standard Coverstrip Max Single 

End Caps Mounting Tool End Caps Coverstrip Rail Width (mm) PC Length (mm) 

Size Part Number 1 Part Number Part Number 2 Part Number 3 

25 532RCS25 532RCT25 532RCP25 522P25C 15 6000 

35 532RCS35 532RCT35 532RCP35 522P35C 19 6000 

45 532RCS45 532RCT45 532RCP45 522P45C 25 6000 

55 532RCS55 532RCT55 532RCP55 522P55C 28.5 6000 

65 532RCS65 532RCT65 532RCP65 522P65C 32 6000 

1. Customer to specify length of rail to be used on at time of order. 

Delivered piece will be 2 to 3.5 mm longer in order to properly install 

and fit end caps. 

2. Two end caps are supplied with each piece of 532RCS ordered. 

3. P grade accuracy shown for example purposes, S and U grade 

accuracy are available. 

532RCS (includes 2 pc. 532RCP) 

532RCT 

532RCP 




Lubrication Fittings 

L 2 L 1 

SW 

D 

530LN 

Hydraulic-type lubricating nipple, 

straight. 

530BF6 = 2.5 mm / 530BF8 = 4mm 

D L 1 L 2 SW 

M6 16 10.5 7 

* Note: 1 pc included with each carriage 

L 2 

G 

D R 

D 

L1 

530LA3 

Straight screw-in connection M3 

For tubing with ext. diameter D R = 3 mm 

D ØG L 1 L 2 

M3 6 12 9.5 

L 2 

SW 

B 

D 

L 1 

530LN45 


45° angle 

D L 1 L 2 B SW 

M6 21 15.5 15 9 

D 1 

L 2 L 1 

D 2 

SW 

530LA... Adapter 

Adapter with hexagon insert bit 

For tubing with ext. diameter = 4 mm 

PIN D 1 D 2 L 1 L 2 

530LA4 G1/8 M6 20 14 

530LA5 M8x1” M6 20 14 

B 

L 2 L 1 

D 

530LN90 


90° angle 

SW D L 1 L 2 B SW 

M6 18 12.5 19 9 

D 1 

L 2 

L 1 

D 2 

D 

530LA6 

Adapter, external round 

For tubing with ext. diameter = 4 mm 

D 1 D 2 L 1 L 2 Ø 

M8X1” M6 20 14 10 

L 1 

SW 

L 2 

D 

530LF3 

Funnel type lubricating nipple M3 

D L 1 L 2 SW 

M3 6.6 1.6 5 

D 1 

L 

D 

SW 

D 2 H 

2 

L 1 

530BF... Banjo Fittings 

For tubing with ext. diameter 

530BF6=2.5 mm/530BF8 =4mm 

P/N D 1 D 2 L 1 L 2 H 

530BF6 M6x0.75 M6 22 16 18 

530BF8 M8x1 M6 22 15.5 22 

L 2 

L 1 

SW 

D 

530LF6 

Funnel type lubricating nipple M6 

D L 1 L 2 SW 

M6 9.5 3 7 

530LGA... Grease Gun Extension 

Grease gun extension, for lubricating 

530LF3 and 530LF6 funnel type 

lubricating nipples 

P/N L D Manu Manu P/N 

ØD 1 

530LG 

Grease gun for funnel type 

lubricating nipple M3 

530LGA1 3” Lincoln Industrial 5803 

530LGA2 6” Lincoln Industrial 5806 

D 2 

L 2 

L 1 

L 1 L 1 ØD 1 ØD 2 

210 55 34 5.5 

70 




Three tolerances describe the accuracy of a Profile 

Rail bearing : Running Parallelism, Pair Variation, and 

Assembly accuracy. These are measured from the rail 

base to the center of the carriage top (H), and from 

the rail reference edge to the center of the carriage 

reference edge (A3) (Figure 1). 

H 

P1 

P1 

A3 



Running Parallelism describes the tolerance on H and 

A3 as a function of axial travel, measured from one 

carriage down the length of the rail (Figure 2). This is 

analogous to straightness of travel. As such, parallelism 

describes attributes of the rail only. 

P1 

Assembly Accuracy [Table 1] describes the tolerance 

on H and A3 as a function of a carriage – rail assembly, 

measured from the nominal dimensions. 

40 

30 

Pair Variation [Table 1] describes tolerance on H and 

A3 as a function of carriages at the same position on a 

common rail. Pair variation describes carriage precision 

only. 

P1 

(m) 

20 

10 

P 

S 

U 

The accuracy class selected will partially determine the 

accuracy of the system. Other factors such as mounting 

surface flatness and straightness also significantly 

affect system accuracy. 

1000 

2000 3000 


Tolerances 

P - Precision 


S - Super Precision U - Ultra Precision 

Assembly Accuracy Tolerance 

on dimension H and A3 ±20 ±10 ±5 

(measured at middle of carriage 

at any point along rail) 

Pair Variation Max 

variation in dimensions H and 

A3 measured on multiple 

carriages mounted on the 10 5 3 

same rail (measured at the 

middle of carriage at same 

position on rail) 

Running Parallelism 40 20 10 

All values in µm 

Preload 

Three Preload classes are available with the 500 Series 

Roller Profile rail carriages. Preload will minimize elastic 

deformation caused by external forces resulting in 

increased rigidity. 

Preload Accuracy Combinations 

Accuracy 

Preload 

Class 0.03C 1 0.08C 1 0.13C 1 

P, S, U 1 2 3 

1. C = Dynamic load capacity of the bearing 



NOTES : 

72 



AccuMini Linear Ball Guides 

Ultra compact, high roll moment capacity 

Thomson AccuMini Linear Ball Guides offer : 

• A ball control design for smooth, quiet, low friction 

at high speeds 

• A full length integral wiper which protects important 

bearing from contaminants…effective system life is 

maximized 

• A Gothic design, which provides high roll 

moment capacity…a requirement for stand-alone 

applications 

• A resistant, engineered polymer retainer which 

reduces system inertia noise 

AccuMini 

Part Number Description and Specification 

AccuMini Assembly 

# of Carriages Per Rail 

AccuMini Assembly 

Size: 10, 15, 20 

Style 

AA 

Description 

Standard 

1 AD 10 AA A H LXXXX Y= (See Note 1 Below) -XXX 

Preload Designation 

A 

B 

Length 

Description 

Clearance 

Approx. 0.03 C 

Options 

-A Armoloy Plating 

-LDS Low Drag Seal 

-Mxx Special Option 


H = High P = Precision 

AccuMini Carriage Only 

AccuMini Carriage 

Size: 10, 15, 20 

Style Description 

AA Standard 

CD 10 AA A H -XXX 

Preload Designation Description 

A 

Clearance 

B 

Approx. 0.03 C 

Options 

-A Armoloy Plating 

-LDS Low Drag Seal 

-Mxx Special Option 


H = High P = Precision 

AccuMini Rail Only 

RD 10 H LXXXX Y= (See Note 1 Below) 

AccuMini Rail 

Size: 10, 15, 20 

Length 

H = High 


P = Precision 

1. Y= Distance from end of rail to center of 1st mounting hole 



AccuMini 

(Miniature Series) 

Low Profile, Compact Design 

1. “Y” dimension will be equal on both ends unless specified 

by customer. 

NOTE : 

The AccuMini linear guide series carriages do not have 

retained balls. Removing the carriage from the rail without 

an arbor will result in the balls falling out. 

AccuMini Linear Guide Series 

(mm) 

Size A A1 A2 A3 H H1 H2 B E1 E2 S2 S3 S5 S6 

10 26 13 10 8 15 13 9 40 17 20 M2,5 M2,5 3 5,5 

15 38 19 15 11,5 21 19 13 58 28 30 M4 M4 4,5 8 

20 50 25 20 15 28 25,6 18 76 37 40 M5 M5 5,5 9,5 

74 



M r , M ro 

C, Co 



M p = Dynamic pitch moment rating 

M r = Dynamic roll moment rating 

M y = Dynamic yaw moment rating 

The dynamic load and moment ratings are based upon 

a 100 km travel life. In order to compare with bearings 

rated for 50 km, divide the dynamic capacity of the bearing 

rated for 50 km by 1.26. 


Co = Static load capacity 

M po = Static pitch moment capacity 

M ro = Static roll moment capacity 

M yo = Static yaw moment capacity 

The static load and moment capacities are the maximum 

radial load and moment load that should be applied to 

the bearing while there is no relative motion between 

the carriage and rail. 

AccuMini 

M y , M yo 

M p , M po 


L = (C/F) 3 x 100 km 

C min = F L 1⁄ 

( ) 

3 

100 

where : 

where : 





F = applied dynamic load, N F = applied dynamic load, N 


Operating Parameters 

Maximum Velocity = 3 m/s 

Maximum Acceleration = 50 m/s 2 

Maximum Temperature = 80° C 

AccuMini Series 

(mm) 

Load N 

Moment Nm MASS 

Rating (lbf) 

Rating (lbf-ft) Carriage Rail 

Size N3 N6 X L max ‡ C(@100 km) C o M p , M y M po , M yo M r M ro kg kg/m 

10 4,5 5,5 25 1500 

2820 5300 10 20 15 28 

(635) 1,190 (7) (15) (11) (21) 

0,045 0,65 

15 6 7,5 40 1500 

6375 15200 35 66 51 96 

(1,430) (3,420) (26) (49) (38) (71) 

0,141 1,42 

20 8 9,5 60 3000 

11870 

(2,670) 

23000 

(5,170) 

75 

(55) 

140 

(105) 

125 

(92) 

235 

(175)z 

0,345 2,55 

‡ Maximum rail length in one section. Multiple sections can be butt 

jointed together for longer lengths. 



Figure 1 - Dimensions H and A3 

Figure 2 - Running Parallelism 

End View 

Table 1 - Tolerances (µm) 

Accuracy Classes 

H 

P 

High 

Precision 

1. Dim. H and A3 (measured 

at middle of carriage at any ±40 ±20 

point along rail) 

2. Max variation in dimensions 

H and A3 measured on 

multiple carriages mounted 15 7 

on the same rail (measured 

at middle of carriage at 

same position on rail) 

3. Parallelism 

(applies to the system) See Figures 1 and 2 

Table 2 - Preload / Accuracy Combinations 

† 

Where C=Dynamic Load Rating 

Preload 

Clearance 

Light 

Accuracy up to approximately 

Class 10 µm 0,03 C † 

P ___ B 

H A B 

Table 3 - Calculations 

To determine proper carriage size : 

Table 4 - Conversions 

1 lb f = 4,448 N 

C min = F • ( 

L 

) 1/3 

100 

C min = minimum required dynamic 

load capacity of carriage (N) 

F = equivalent load on carriage (N) 

L = required travel life (km) 

To determine travel life : 

L = ( C 3 

) • 100 

F 

L = normal travel life (km) 

C = rated dynamic load capacity 

of carriage (N) 


1 kg f = 9,8 N 

1 km = 39,370 inches 

1 Nm = 0.7376 lb f - ft 



Maximum Acceleration = 50 m/s 2 

Maximum Temperature = 80° C 

76 


MicroGuide Profile Rail 


Two track gothic arch 

ball groove geometry enables 

single rail application 

High Moment Load Capacity for 

single rail/carriage applications 

Low Profile 

440 stainless steel construction 

(little or no lubrication required) 

Whisper quiet 

movement 

Industry standard, 

drop-in replacement 

Extremely smooth 

operation 

High precision accuracy 

(up to ±0.010mm) 

Ball are not retained 

in carriage 

One piece rail lengths 

over 1 meter 

MicroGuide 

Two styles available 

(Standard and wide) 

Sizes: 5mm*, 7mm, 9mm, 12mm, 15mm 

MicroGuide Part Numbering 

Number of 

Carriages 

2 TSR 12 WZ M UU C1 +350 P 

Custom lengths 

and configurations 

Rail and 

Carriage Size 

Types TSR 

Style 

Z Standard 

WZ Wide 

Material 

M Stainless Steel 

(standard) 

Seal Configuration 

UU Lip Seal Standard 

Preload 

Clearance Fit 

C1 Light Preload 

Accuracy 

Normal 

H High 

P Precision 

Length 

*For 5mm size, there are only 2 mounting holes per carriage. 

For more information, or to place an order, please contact your local authorized Thomson distributor 

or Danaher Motion at 1-540-633-3400, Fax: 1-540-633-4162, or E-mail at profilerail@DanaherMotion.com. 





TSR-Z Standard 

W3 

W1 

W2 

4 — S x 

d2 

L1 

L2 

L3 

h 

H4 

H 

d3 

H1 

N 

W4 

W 

Y 

X 

X 

Standard Lengths of Rail 

Sizes 5 7 9 12 15 

TSR 7, 9, 12, 15Z 

TSR 5 Z 

Standard 

Lengths 

40 

55 

70 

100 

130 

160 

40 

55 

70 

85 

100 

130 

1000 

55 

75 

95 

115 

135 

155 

175 

195 

275 

1015 

70 

95 

120 

145 

170 

195 

220 

245 

270 

320 

370 

470 

1020 

X 15 15 20 25 40 

Y 5 5 7.5 10 15 

Longer lengths may be supplied with butt-joints on sizes 7 through 15. 

150 

230 

310 

430 

550 

670 

1030 

MicroGuide TSR-Z (Standard) 

Size Assembly Dimensions Carriage Dimensions Rail Dimensions 

H H1 N W1 W2 W3 L1 L2 L3 Sx W W4 H4 d2 d3 h Y X 

5 6 1.5 3.5 12 8 2 17 12.8 - M2X1.5 1 5 2.5 4 3.5 2.4 1 5 15 

7 8 1.5 5 17 12 2.5 23.5 13.5 8 M2X2.5 7 3.5 4.7 4.2 2.4 2.3 5 15 

9 10 2.2 5.5 20 15 2.5 31 20.0 10 M3X3 9 4.5 5.5 6 3.5 3.3 7.5 20 

12 13 3 7.5 27 20 3.5 35 20.8 15 M3X3.5 12 6 7.5 6 3.5 4.5 10 25 

15 16 4 8.5 32 25 3.5 43 25.7 20 M4X6 15 7.5 9.5 6 3.5 4.5 15 40 

(1) For 5mm size, there are only 2 mounting holes per carriage. Note All: Dimensions in mm except where noted otherwise. Longer lengths are available with butt joints on sizes 7-15. 

Sizes in between standards are available, Y dimensions will be the same unless specified at time of ordering. 



78 




TSR-Z Standard 

Dynamic Loand and Moment Ratings 



Co = Static load rating 

M PO = Static pitch moment capacity 

M YO = Static yaw moment capacity 

M RO = Static roll moment capacity 

MYO 

MRO 

C C O 

MPO 

Load Capacity (N) Moments (Nm) Mass 

Size Dynamic C 1 Limit Co 2 M PO M YO M RO Carriage [kg] Rail [kg/m] 

5 336 620 0.8 0.8 1.47 0.01 0.14 

7 924 1440 2.55 2.55 5.10 0.02 0.23 

9 1544 2360 5.10 5.10 10.4 0.02 0.32 

12 2780 4220 8.04 8.72 14.7 0.04 0.58 

15 4410 6570 16.5 17.9 30.2 0.07 0.93 

MicroGuide 

Notes: 

1. The dynamic load and moment ratings are based upon 50km travel life. 

2. The static load and moment capacities are the maximum radial load and moment load that should be applied to the bearing while there is no relative motion 

between the carriage and rail. 

3. The load limit is the maximum load that may be applied to a system. It is important to analyze the application so that peak and/or shock loads do not exceed 

the load limit. 

Load/Life Calculations 

To determine proper carriage size: 

50 

C min = F • ( ) 1/3 

L 





To determine travel life: 

C 

L = ( ) 3 F • 50 







Maximum Acceleration: 50 m/s 






TSR-WZ Wide 

TSR7WZ 

L3 

W1 

d2 

L1 

L2 

S x 

H 

H1 

W 

H4 

d3 

H1 

X 

Y 

TSR9&12WZ 

L3 


Y 

X 

W2 

Sizes 7 9 12 15 

Standard 

Lengths 

50 50 70 110 

85 110 150 190 

170 260 310 270 

100 350 390 430 

130 440 470 590 

260 530 630 750 

350 620 790 910 

440 800 950 1030 

530 1010 1030 

620 

800 

1010 

X 30 30 40 40 

Y 10 10 15 15 

W1 

H 

H1 

TSR15WZ 

W1 

H4 

d2 

d3 

Y 

d2 

X 

H1 

L1 

L2 

L3 

L1 

L2 

S x 

S x 

W5 W2 

H 

H1 

H4 

H1 

MicroGuide TSR-WZ Wide 

Size Assembly Dimensions Carriage Dimensions Rail Dimensions 

H H1 N W1 W2 L1 L2 L3 Sx W W5 H4 d2 d3 h Y X 

7 9 2 5.5 25 - 31 21.5 12 M4X3.5 14 - 5.2 6 3.5 3.2 10 30 

9 12 4.2 6 30 21 39 28 12 M2.6X3 18 - 7.5 6 3.5 4.5 10 30 

12 14 4 8 40 28 44.5 30.5 15 M3X3.5 24 - 8.5 8 4.5 4.5 15 40 

15 16 4 9 60 45 55.5 38.5 20 M4X4.5 42 23 9.5 8 4.5 4.5 15 40 

Note: All dimensions in mm except where noted otherwise. Longer lengths are available with butt joints. 

Sizes in between standards are available, Y dimensions will be the same unless specified at time of ordering. 

*For 7mm size, there are only 2 mounting holes per carriage. 



80 




TSR-WZ Wide 




C = Static load rating 

M PO = Static pitch moment capacity 

M YO = Static yaw moment capacity 

M RO = Static roll moment capacity 

C C O 

Load Capacity (N) Moments (Nm) Mass 

MPO 

MYO 

MRO 

Size Dynamic C 1 Limit Co 2 M PO M YO M RO Carriage [kg] Rail [kg/m] 

7 1370 2160 5.39 5.39 15.2 0.03 0.51 

9 2450 3920 16.3 16.3 36.0 0.04 1.08 

12 4020 6080 17.2 18.6 47.6 0.08 1.5 

15 6660 9800 35.2 38.2 137 0.17 3.0 

MicroGuide 

Notes: 

1. The dynamic load and moment ratings are based upon 50 km travel life. 

2. The static load and moment capacities are the maximum radial load and moment load that should be applied to the bearing while there is no relative motion 


3. The load limit is the maximum load that may be applied to a system. It is important to analyze the application so that peak and/or shock loads do not exceed 

the load limit. 



50 

C min = F • ( ) 1/3 

L 






C 

L = ( ) 3 F • 50 













TSR-Z (Standard) Accuracy Tolerance 

Datum 

Plane 

C 

H 

A D 

B 

N 

Height 

H 

Width 

N 

Accuracy of 

each part 

Dimensional 

Tolerance 

Pair Tolerance 

Dimensional 

Tolerance 


Normal 

(blank) 

±0.030 

0.015 

±0.030 

0.015 

TSR5 Z 

Precision 

P 

±0.015 

0.005 

±0.015 

0.005 

TSR7 Z, TSR9 Z, TSR12 Z & TSR15 Z 

Normal 

(blank) 

±0.040 

0.030 

±0.040 

0.030 

High 

H 

±0.020 

0.015 

±0.025 

0.020 

Precision 

P 

±0.010 

0.007 

±0.015 

0.010 

TSR-Z (Standard) Running Parallelism 

Running Parallelism 

Δ C and Δ D (μm) 

25 

20 

15 

10 

5 

Normal 

High 

Precision 

TSR-Z (Standard) Fit Up 

Series Type, 

Size, and Style 

TSR5 Z 

TSR7 Z 

TSR9 Z 

TSR12 Z 

Radial Clearances (µm) 

clearance fit (blank) light preload C1 

0~+1.5 

±2 

±2 

±3 

-1.5~0 

-3~0 

-4~0 

-6~0 

200 400 600 

Length of Rail L(mm) 

TSR15 Z 

±5 

-10~0 

Accuracy ToleranceRunning Parallelism 

Datum 

Plane 

C 

A 

H 

D 

B 

N 

Height 

H 

Width 

N 

Accuracy of 

each part 

Dimensional 

Tolerance 


Dimensional 

Tolerance 


Normal 

(blank) 

±0.040 

0.030 

±0.040 

0.030 

TSR WZ 

High 

H 

±0.020 

0.015 

±0.025 

0.020 

Precision 

P 

±0.010 

0.007 

±0.015 

0.010 

TSR-WZ (Wide) Running Parallelism 

Running Parallelism 

Δ C and Δ D (μm) 

25 

20 

15 

10 

Normal 

High 

TSR-WZ (Wide) Fit Up 

Series Type, 

Size, and Style 

TSR7 WZ 

TSR9 WZ 

Radial Clearances (µm) 

clearance fit (blank) light preload C1 

±2 

±2 

-3~0 

-4~0 

5 

Precision 

TSR12 WZ 

±3 

-6~0 

200 400 600 

Length of Rail L(mm) 

TSR15 WZ 

±5 

-10~0 



82 






Sizes 7 WZ 9 WZ 12 WZ 15 WZ 

Standard 

Lengths 

50 

110 

170 

260 

350 

440 

530 

620 

800 

1010 

50 

110 

170 

260 

350 

440 

530 

620 

800 

1010 

70 

150 

230 

310 

390 

470 

630 

790 

950 

1030 

110 

190 

270 

430 

590 

750 

910 

1030 

X 30 30 40 40 

Y 10 10 15 15 


50 

C min = F • ( ) 1/3 L 





Conversions 


C 

L = ( ) 3 F • 50 





1 lb f = 4.448 N 1 km = 39,370 inches 

1 kg f = 9.8 N 

1 Nm = 0.7376 lbf - ft 

Maximum Travel Speed: V max = 3 m/s 

Maximum Acceleration: a max = 50 m/s 2 

MicroGuide 

How To Order 

M for stainless steel 

(standard) 

(blank) for clearance fit 

C1 for light preload 

(blank) for normal grade 

H for high grade 

P for precision grade 

Z for standard style 

WZ for wide style 

UU for end seals only 

(standard) 





T-Series Profile Rail 


Low cost installation – no need for high 

precision base mounts 

Approximately 5 times more forgiving 

than all steel profile rail guides 

Forgiving and flexible proprietary U Channel design accomodates 

misalignment from machine basesor installation errors 

Lightweight design and construction 

Balls are not retained in carriage 

Lubrication inlets on both ends of carriage 

N class radial run out accuracy 

Sold as assemblies only 

Low drag seal option available 

One piece rail length 

up to 3 meters 

Aluminum rail with hardened 

steel ball path insert 

Contamination protection with lip seal 

Speeds up to 3m/s 

Acceleration up to 50 m/s 2 

Multiple carriage design 

Four-runner block attachment bolts 

Corrosion resistance with Armoloy® 

Thin Dense Chrome plating optional 

T-Series 

AT 25 A LXXXX LDS 

Y= 

Product Type 

AT T-Series 

Size 

Length 

Y Dimension 

The distance (from the rail 

end to the first hole) will be 

equal unless specified 


A Dimensionally Interchangeable with THK HSR A, B, CA & CB 

E Dimensionally Interchangeable with THK HSR R & TR 

F Dimensionally Interchangeable with THK SR W 

G Dimensionally Interchangeable with THK SR TB 

Extended Standards 

A Armoloy 

LDS Low Drag Seal 

S... Special Option – 

sequential numbers 

Note: 1. Sold as assemblies only 

2. Carriages are dimensionally matched to rails during assembly 

84 



T-Series Ball Profile Rail 

Features 

The Thomson T-Series Ball Profile Rail is lightweight, 

highly flexible and forgiving — an ideal choice for poor 

misalignment. It has a low cost of installation and industry 

standard dimensions for easy replacement. It is a lightweight 

and forgiving alternative to all-steel profile rail. 

Materials 

The Thomson T-Series Ball Profile Rail carriage and rail 

is produced from high quality aircraft aluminum alloy. The 

carriage has hardened steel load bearing plates. The rail has 

a custom ball path insert made of hardened steel. Stringent 

quality controls are in place to ensure consistency of steel 

from the source, allowing us to ensure that we deliver the 

highest quality product. 

Lightweight 

The aluminum carriage and rail dramatically reduces the 

total weight of the assembly making Thomson T-Series 

an ideal choice for applications requiring reduced weight 

inertia such as airplanes, ships, automobiles, etc. 

Accuracy 

As a result of it’s high flexibility to misalignment errors, the 

T-Series Ball Profile Rail is available in an N class radial run 

out only. 

T-Series 

Forgiving to Misalignment 

The Thomson T-Series propriety “U” channel construction 

allows the rail to “flex” to accommodate poor machine 

bases or misalignment errors. 

Low Cost 

The Thomson T-Series can be mounted direct to nonmachined 

bases without sacrificing total operational 

efficiency or the need for special tools or gauges to ensure 

proper rail and base straightness. By eliminating the costly 

machined base and special tools the installation time or 

machine build time can be cut in half, saving valuable time 

and money. 

Drop-in Replacement 

The Thomson T-Series is designed to industry standard 

dimensions and rail hole patterns. This means it can be 

used as a drop-in replacement for any conventional all steel 

profile linear guide in the market today. 





T-Series Carriage Styles 

Standard Carriage Style A 

Sizes 20, 25, 35 

Dimensionally interchangeable to THK 

HSR A, B, CA, CB and Thomson 511 A 

Standard Short Hole Spacing Style G 

Sizes 20, 25, 35 

Dimensionally interchangeable to THK SR TB 

Narrow Carriage Style E 

Sizes 20, 25, 35 

Dimensionally interchangeable to THK 

HSR R and TR and Thomson 511 E 

Narrow High Style F 

Sizes 20, 25, 35 

Dimensionally interchangeable 

to THK SR W 



86 




Style A and G 

H 

H 1 

N 1 

N 5 

S 2 Thread 

Lubrication Access 

Both Ends 

S 1 

Screw Size 

Y † 

S 6 

H 2 

N 6 

X 

S 3 Screw Size 

A 3 

A 2 

S 5 

A 1 

A 

†- Will be equal on both ends, 

unless otherwise specified. 

Supplied 


L 

E 1 

E 1 B 

45 

15 

9 

M6 

Tapered Thread 

M6 


T-Series 

T-Series Profile Rail Standard High “A” Style 

Size A A1 A2 A3 H H1 H2 B E1 E2 S1 S2 S3 S5 S6 N1 N5 N6 X L max 

20 63 31.5 20 21.5 30 25 18 76 53 40 M5 M6 M5 5.8 9.5 10 6.25 7,5 60 3000 

25 70 35 23 23.5 36 29.5 22 88 57 45 M6 M8 M6 7 10.7 12 8 10 60 3000 

35 100 50 34 33 48 40 29 117 82 62 M8 M10 M8 9 14 15.26 6.6 11 80 3000 

All dimensions in mm unless shown otherwise 

T-Series Profile Rail Standard “G” Style 

Size A A1 A2 A3 H H1 H2 B E1 E2 S1 S2 S3 S5 S6 N1 N5 N6 X L max 

20 59 29.5 20 19.5 28 23 18 76 49 32 M5 M6 M5 5.8 9.5 8 4.25 7.5 60 3000 

25 73 36.5 23 25 33 26.5 22 88 60 35 M6 M8 M6 7 10.7 9 5 10 60 3000 

35 100 50 34 33 48 40 29 117 82 50 M8 M10 M8 9 14 15.26 6.6 11 80 3000 






Style A and G 

Dynamic Load Rating 


The dynamic load rating is based upon a 100 km travel life. 

In order to compare with bearings rated for 50 km, divide the 

dynamic rating of the bearing rated for 50 km by 1.26. 

Static Load Capacity 

C o = Static load capacity 

The static load capacity is the maximum radial load that should 

be applied to the bearing while there is no relative motion 


F c F Load Ratings N (Ibf) Mass 

t 

Carriage 

F s 


Size Style C (@100km) C o kg kg/m 

20 A 9000 (2025) 11000 (2475) 0.22 0.79 

G 

25 A 13000 (2925) 15000 (3375) 0.30 1.06 

G 

35 A 25000 (5620) 28000 (6295) 0.74 2.27 

G 

Dynamic Load 

Load Rating Limit 

F c C C 

F t C 0.6C 

F s C 0.6C 


L = (C/F) 3 x 100 km 

where: 






Maximum Acceleration = 50 m/s2 

Maximum Temperature = 80°C 



88 




Style E and F 

N 5 

A 

S 2 Thread x N3 Deep 

H 

H 1 

Lubrication Access 

Both Ends 

Y † 

X 

S 3 Screw Size 

S 6 

A 3 

A 2 

A 1 

H 2 

A 4 

N 6 

S 5 

†- Will be equal on both ends, 

unless otherwise specified. 

L 

E 1 

E 1 B 

45° 

15 

9 

Supplied 


M6 


M6 


T-Series 

T-Series Profile Rail Narrow “E” Style 

Size A A1 A2 A3 A4 H H1 H2 B E1 E2 S2 S3 S5 S6 N3 N5 N6 X L max 

20 44 22 20 12 41.5 30 25 18 76 32 36 M5 M5 5.8 9.5 6 6.25 7.5 60 3000 

25 48 24 23 12.5 50.9 40 33.5 22 88 35 35 M6 M6 7 10.7 8 12 10 60 3000 

35 70 35 34 18 68.0 55 47 29 117 50 50 M8 M8 9 14 12 13.6 11 80 3000 


T-Series Profile Rail Narrow High “F” Style 

Size A A1 A2 A3 A4 H H1 H2 B E1 E2 S2 S3 S5 S6 N3 N5 N6 X L max 

20 42 21 20 11 41.5 28 23 18 76 32 32 M5 M5 5.8 9.5 6 4.25 7.5 60 3000 

25 48 24 23 12.5 51.0 33 26.5 22 88 35 35 M6 M6 7 10.7 8 5 10 60 3000 

35 70 35 34 18 68.0 48 40 29 117 50 50 M8 M8 9 14 12 6.6 11 80 3000 







Style E and F 

Dynamic Load Rating 


The dynamic load rating is based upon a 100 km travel life. 

In order to compare with bearings rated for 50 km, divide the 

dynamic rating of the bearing rated for 50 km by 1.26. 

Static Load Capacity 

C o = Static load capacity 

The static load capacity is the maximum radial load that should 



F c 

F t 

Load Ratings N (Ibf) 

Mass 

Carriage Rail 

Size Style C (@100km) C o kg kg/m 

20 E 9000 (2025) 11000 (2475) 0.22 0.79 

F 

25 E 13000 (2925) 15000 (3375) 0.30 1.06 

F 

35 E 25000 (5620) 28000 (6295) 0.74 2.27 

F 

F s 

Dynamic Load 

Load Rating Limit 

F c C C 

F t C 0.6C 

F s C 0.6C 


L = (C/F) 3 x 100 km 

where: 






Maximum Acceleration = 50 m/s2 

Maximum Temperature = 80°C 



90 



NOTES : 

Lubrication 

Fittings 



Installation Guidelines for 500 Series Ball, Roller, AccuMini and T-Series 

Figure 1 

P1 

Table 1. Parallelism Between Multiple Rails, mm 

Preload 

Bearing Type Clearance 0,03 C † 0,08 C † 0,03 C † 

500 Series Ball Linear Guide 

15 .015 .010 .007 .003 

20 .017 .012 .008 .004 

25 .024 .016 .010 .005 

30 .024 .016 .010 .005 

35 .032 .021 .014 .008 

45 .036 .024 .016 .009 

500 Series Roller Linear Guide 

25 – .016 .010 .005 

35 – .012 .014 .008 

45 – .024 .016 .009 

55 – .026 .017 .010 

65 – .028 .018 .011 

AccuMini Linear Guide 

10 .009 .004 – – 

15 .011 .006 – – 

20 .013 .008 – – 

T-Series * Linear Guide 

15 .045 – – – 

20 .045 – – – 

25 .050 – – – 

30 .055 – – – 

35 .060 – – – 

† Where C = Dynamic Load Capacity 

Surface Preparation 

ProfileRail* bearings are generally mounted to 

structures that are inherently stiffer than the rail. For 

this reason, the bearings tend to assume the orientation 

of the surfaces to which they are fastened, through 

bearing deflection. When a deflection is imposed upon 

a bearing, especially a preloaded one, resultant forces 

occur. These forces are transferred to the rolling 

elements and races, potentially resulting in an increase 

in system friction and a decrease in system resolution, 

precision and life. 

Various sources can contribute to the overall error of the 

mounting surfaces. These include the surface flatness 

of the base surfaces, the location and parallelism of 

the reference surfaces, and the attendant errors of the 

bearing as described within the accuracy classes. 

The surfaces that contact the base and reference 

edges may be milled, scraped, ground, or prepared 

by any other method that will produce a flat mounting 

surface free of inconsistencies, which would tend to 

distort or skew the bearing. A simple stone may be used 

to remove high spots. Dirt and debris should be cleaned 

off, as they could contribute to the inaccuracies. 

Associated with preload is a slight potential concavity 

of the carriage top surface. The preload is established 

when all the carriage screws are affixed to a planar 

surface, flattening the carriage base. Deviations 

affecting the planarity of the carriage mounting surface 

could result in a preload change. 

Mounting Tolerances 

The tolerances found in Tables 1 – 3 are intended to 

provide an installation for which the associated derating 

is negligible. These specifications are based upon the 

assumption that the structures of the application are 

infinitely rigid and are of consideration for the bearing 

reactions only. 

Rail Parallelism (See Figure 1) 

A variation in the distance between the rails will induce 

a shear or side load on the bearings. 

In order to minimize the effect of this shear load, 

tolerances for rail reference edge parallelism may be 

found in Table 1. 

92 



Installation Guidelines for 500 Series Ball, Roller, AccuMini, and T-Series 

Figure 2 

Rail Vertical Offset (See Figure 2) 

A vertical offset of the rails across the axis will induce a 

roll moment onto the carriages. 

a 

S 1 

To minimize the effect of this roll moment, tolerances 

for the vertical offset may be found in Table 2. This 

tolerance describes the attributes of the mounting 

surface, perpen dicular to the rail axis. 

Table 2. Allowable Vertical Offsets Between Rails (S1/a) 

Preload 

Bearing Type Clearance 0,03 C † 0,08 C † 0,03 C † 

500 Series Ball 0,0006 0,0004 0,0003 0,0002 

500 Series Roller – 0,0007 0,0005 0,0004 

AccuMini Linear Guide 0,0006 0,0004 – – 

T-Series Linear Guide 0.0020 – – – 

† 

Where C = Dynamic Load Capacity 

Figure 3 

S 2 

Vertical Carriage Offset (See Figure 3) 

A vertical offset between fore and aft carriages will 

induce a pitch moment on the bearings. 

Lateral Carriage Offset (See Figure 4) 

A lateral offset of the carriage reference edges will 

induce a yaw moment. 

In order to minimize the effects of these pitch and yaw 

moments, tolerances may be found in Table 3. This 

tolerance describes the attributes of the mounting 

surface parallel to the rail axis, and the reference edge 

straightness. 

NOTE : All mounting tolerances should be inclusive of 

the H and A3 tolerances. Thus, a lower accuracy class 

bearing may require a more accurate installation. 

Figure 4 

b 

Figure 5. Shoulder Heights 

and Corner Radii 

Mounting Hole Tolerances 

The positional tolerance between the through holes in 

the rails is 0.5 mm. 

r 2 

The positional tolerance of the first rail mounting 

hole dimensioned from the datum end (called the 

“Y-dimension”) is ±1.0 mm. 

b 

h 2 

The overall rail length tolerance is ±2.0 mm. 

S 2 

h1 

r 1 

Table 3. Allowable Carriage Offsets (S2/b) 

Preload 

Clearance 0,03 C † 0,08 C † 0,03 C † 

0,00006 0,00005 0,00004 0,00003 

† Where C=Dynamic Load Capacity 

The positional tolerance between the mounting holes in 

the carriages is 0.2 mm. 

Reference Edge Specifications 

The maximum shoulder heights and corner radii are 

listed in Table 4. 

Installation 

Guide 

T-Series* Linear Guide 0,00012 




Table 4. Shoulder heights and corner radii, mm 

Guide Type Rail Carriage 

h1 max r1 max h2 r2 max 

500 Series Ball Linear Guide 

15 3.5 .8 3.5 .6 

20 4 .9 4 .9 

25 5 1.1 5 1.1 

30 5.5 1.3 5.5 1.3 

35 6 1.3 6 1.3 

45 8 1.3 8 1.3 

500 Series Roller Linear Guide 

25 5 .8 5 .8 

35 6 .8 6 .8 

45 8 .8 8 .8 

55 10 1.2 10 1.2 

65 10 1.5 10 1.5 


10 1.75 0.4 3.5 0.4 

15 1.75 0.4 5 0.4 

20 2 0.5 7 0.5 

T-Series * Linear Guide 

15 3 .3 8 .2 

20 3.9 0.4 10 0.3 

25 5.5 0.5 12 0.4 

30 5.9 0.7 14 0.5 

35 5.9 0.8 15 0.6 

Table 5. Recommended Bolt Tightening Torque, Nm 

Bolt Size Class 8.8 Class 12.9 

M2.5 0,7 1,2 

M4 2,8 4,6 

M5 5,7 9,5 

M6 9,5 16 

M8 23 39 

M10 46 77 

M12 80 135 

M14 129 215 

M16 198 330 

Installation Procedure 

Clean and inspect all mating surfaces for burrs, nicks, 

dirt, etc. A simple stone can be used to remove minor 

imperfections in the mounting surfaces. 

Note : T-Series is not as sensitive to imperfections of the 

mounting surface. 

Rail Mounting 

1. Carefully place the rail on the mounting surface. 

2. Insert screws into the mounting holes and tighten 

lightly. 

3. Clamp the reference edge of the rail against a locating 

edge on the mounting surface. 

The locating edge can be a machined reference edge, 

a straight edge, a row of dowels or keys, or some other 

edge which the rail can be clamped against. It should 

be straight, either within the mounting tolerances 

shown in Table 3 or according to the application 

requirements, whichever is tighter. 

4. Starting from the center of the rail moving outwards, 

tighten each screw to the recommended tightening 

torque in Table 5. 

5. If parallel rails are to be used, one of the following 

methods may be employed to obtain the parallelism 

recommended in Table 1 : 

a. two parallel locating edges 

b. a gage block or parallel between the rails 

c. the use of the top plate with the carriages mounted, 

to locate or “float” the second rail into place. 

6. Repeat steps 1 – 4 to install the second rail. 

7. Insert a rail plug into each counterbore in the rail. 

Carefully tap rail plugs into place using a soft material 

such as brass or wood. When properly installed, the rail 

plugs should be flush with the top surface of the rail. 

Do not countersink the rail plugs. 

Note : Rail plugs are available and are shipped with all 

rails except for the AccuMini Linear Guide size 10. 

8. If desired, rail tape can then be applied to the top of 

the rail. For sizes 35 and below, the rail tape may be 

used without the rail plugs. 

94 



Figure 6. Butt jointed rails 

Joint Indicator 


Joint 

A A 

Z 

X 

(TYP) 

Butt Joints 

For rails longer than the longest length available in one 

piece, a butt joint is required. A butt joint is formed by 

butting the end of two matched rails together. The ends of 

rails to be butt jointed are specially machined and marked 

with same letter (A, B, C, etc.). 

We strongly recommend the use of a locating edge when 

using butt jointed rails. This will ensure proper alignment 

of the raceways across the joint. 

500 Series Ball and Roller linear guide rails, the mounting 

hole spacing across the joint, Z, will be equal to the standard 

mounting hole spacing, X. 

Once mounted, a gap between the ends of the butt jointed 

rails of 0.5 mm or less is acceptable. 

Figure 7. Recommended Tightening Sequence 

3 4 

1 2 

5 6 

Carriage Mounting 

1. Carefully place the table top on the carriages. 

2. Insert the screws into the mounting holes and tighten 

lightly. 

3. Clamp the reference edge of the carriages to locating 

edges under the top plate. 

Note : This is only required if the location of the center 

of the top plate is critical to the application, or if the top 

plate is being used to position a second rail parallel. 

4. Tighten each screw to the recommended tightening 

torque in Table 5. For carriages with six mounting 

screws, the tightening sequence shown in Figure 7 is 

recommended. 

5. Lubricate bearings. 

Note : Extreme care should be taken when mounting the 

carriages to the rails. Forcing a carriage onto a rail can 

knock out rolling elements and/or damage the carriage 

and rail. 

Installation 

Guide 

For large side forces, hard mounting is recommended to 

resist any translation. Some methods for hard mounting 

are the use of tapered gibs, retaining plates, or set 

screws in combination with machined reference edges. 

Other methods include the use of an epoxy/replicating 

material, dowels, and keys. Upon request, carriages 

and rails can be special machined to accommodate 

dowels or keys. Consult the factory for details. 




Profile Rail Engineering Guide 

Fere illius hiemis 

Eos auctore Nervium quam maxi mas manus cognut et de 

improviso as Ciceronis hiberna advolant. Huic accidit ut 

nonnulli mili tesm qui lignationes causa incaute in silvas 

di scesserant, improviso equitum ave intercludere intur. 

His captis Eburo nes Nerv ique legionem opp ugnare incipiunt. 

• Profile Anostris Rail cumplures Selectiondies ta onti resistur, ut de vallo • Actuation Force 

decederent • Technology nemo. Overview Top se Cicero, quamvis infirma valetudine • Lubrication 

esset, • Sizing nei. & Defining Guide Characteristics 

• Bellow Cover Length Calculations 

• Applied Loading Calculations 

• Butt Joint Fax-back Worksheet 

Fere • illius Load hiemis Ratings temus : Rolling intercessit, Element quin Guides Cesar Sliding aliquem de • Conversion Table 

tumultu Contact Gallorum Guides nun tium accipere m Diebus paucis post, 

quam • Preloading Cicero legatus & Linear cuma. Guide Eegione Deflection in haberna sa Ner vios 

venit, tumultus ab Ambrio rige, Ebus principe, oritur. Null 

um fere illius hiemis temus intecessit, quin Cesar aliab 

Ambri orige, numus principe, oritur. Qui cu num equitatu 

in Nervios proficiscitur hor taturque eos. 

His captis Eburo nes Nerv ique legionem opp ugnare incipiunt. 

Anostris cumplures dies ta onti resistur. 

96 



Profile Rail Selection 

The selection of a linear guide can greatly affect 

machine performance and overall cost. In order to 

meet the wide variety of demands created by today’s 

applications, proper selection from a broad range of 

linear guides is required. 

For example, selecting a guide with too much rigidity 

will decrease the allowable installation tolerances, 

therefore, greatly increasing surface preparation 

costs. If the mounting surface is not prepared properly, 

the guide will run rough, and need to be replaced more 

frequently due to an unexpected reduction in travel 

life. 

Consider all criteria appropriate for the application. 

Selection criteria include : 

Technology Overview 

The performance of a linear guide is based upon contact 

type, rolling element type, inner race geometry (Round 

Rail and Profile Rail), and other characteristics such as 

self-aligning capabilities. It is important to recognize 

that the options available for each characteristic have 

performance attributes. The selection process should 

be focused on matching these attributes with the most 

critical requirements of the application. The following 

technology guidelines can be used to assist in selecting 

the most appropriate type of profile rail. For a detailed 

application analysis, contact the Danaher Motion 

Assistance Center at (540) 633- 3400 or your local 

Danaher Motion distributor. 

• Rigidity 

• Travel accuracy 

• Travel life 

• Smoothness of travel 

• Speed & Acceleration 

• Envelope 

• Environment 

• Cost of Product 

• Cost of Installation 

• Cost of Replacement 

Selection of the most appropriate type of guide, should 

be based on quantitative / qualitative requirements and 

ranking by importance of the above selection criteria, 

as well as the following guidelines for the technology 

available. 

Engineering 

Guide 




Sizing & Defining Guide Characteristics 

The following 9 step procedure can be used to select the 

characteristics necessary to generate the appropriate 

part number : 

1. Determine the load on the most heavily loaded carriage 

or bearing (see Applied Loading Calculations). Multiply 

by a safety factor if desired in your application. 

2. Determine the minimum required travel life for the 

application based on the intended duty cycle. 

3. Calculate the Minimum Required Dynamic Load 

Rating, C min (see Page 88). 

4. Select the size which offers the load rating, C, equal 

to or greater than the minimum required dynamic load 

rating, C min . Also, consider Dynamic Load Limit and 

Static Capacities. 

5. If the guide selected offers various preload † levels, 

select a preload based upon the allowable bearing 

deflection. Contact the factory for detailed deflection 

information. Some carriage or bearing Deflection 

Charts are provided in this catalog. 

6. If the guide selected offers various accuracy classes, 

select an accuracy class based upon the required 

travel accuracy. 

7. Determine the need for accessories or options. 

8. Calculate the guide length based upon the stroke 

and platten length. Remember to include additional 

length of accessories (i.e. self-lubricating option) and 

the stroke reduction caused by the use of bellows, if 

applicable. 

9. Once the above characteristics have been determined, 

assign the appropriate part number based on the part 

numbering instructions located in the catalog section 

corresponding to the linear guide selected. 

† Choosing a higher preload level will reduce the allowable installation 

tolerances. For this reason, the minimum preload which meets 

the applications requirements should be selected. If the highest 

preload level does not meet the deflection requirements, a larger 

size may be required. 

98 



Applied Loading Calculations 

The majority of applications utilize a four carriage or 

bearing and two rail design for stability. Shown are four 

typical configurations and calculations for the resultant 

loads applied to each bearing. Resultant loads are 

divided into a horizontal and a vertical components, 

which represent the static or constant velocity condition 

and account for gravity but not acceleration. 

Use the appropriate configuration to determine the 

hori zontal and vertical components of the resultant 

applied load on the most heavily loaded carriage or 

bearing. These values will be referred to henceforth as 

FH & FV, respectively. 

Terms : 

d 0 = distance between centerlines of carriages or 

bearings (in) or (mm) 

d = 1 distance between centerlines of rails (in) 

or (mm) 

d 2 = distance from centerline of carriage or bearing 

to load action point (in) or (mm) 

d 3 = distance from centerline of carriage or bearing 

to load action point (in) or (mm) 

W = Applied Load (lbf) or (N) 

FNH = Horizontal component of resultant applied 

load with respect to each carriage or bearing 

(lbf) or (N) 

FNV = Vertical component of resultant applied 

load with respect to each carriage or bearing 

(lbf) or (N) 

Reminder: 

• Be sure to use consistent units (English or metric). 

• Be sure to use the appropriate sign (positive or 

negative). 

• A negative number is used when the actual force is 

in the opposite direction represented by the arrow. 

( 

F 1v = W + 

W d 2 

• - 

W d 3 

• 

4 2 d 0 2 d 1 

( 

F 2v = W - 

W d 2 

• - 

W d 3 

• 

4 2 d 0 2 d 1 

( 

F 3v = W - 

W d 2 

• + W • d3 

4 2 d 0 2 d 1 

( 

F 4v = W + 

W d 2 

• + 

W d 3 

• 

4 2 d 0 2 d 1 

( 

( 

( 

( 

( 

( 

( 

( 

( 

( 

( 

( 

d3 

4 3 

L 

1 2 

d0 

2 

d2 

d0 

F1v F4v W 

F2v F3v 

Horizontal Application I 

At the time of movement with uniform velocity or at the time of stop. 

( 

F 1v = W + 

W d 2 

• - 

W d 3 

• 

4 2 d 0 2 d 1 

( 

F 2v = W - 

W d 2 

• - 

W d 3 

• 

4 2 d 0 2 d 1 

( 

F 3v = W - 

W d 2 

• + W • d3 

4 2 d 0 2 d 1 

( 

F 4v = W + 

W d 2 

• + 

W d 3 

• 

4 2 d 0 2 d 1 

( 

( 

( 

( 

( 

( 

( 

( 

( 

( 

( 

( 

d3 

W 

d2 

1 2 

4 3 

d0 

W 

2 

d0 

F1v F4v 

F2v F3v 

Horizontal Application II 


F 1v = F 2v = - 

F 3v = F 4v = + 

W • 

d 3 

2 d 1 

W • 

d 3 

2 d 1 

F 1H = F 4H = W + 

W d 2 

• 

4 2 d 0 

F 1H = F 4H = W - 

W d 2 

4 2 • 

d 0 

( 

( 

( 

( 

( 

( 

( 

( 

W 

d2 

F1H 

1 2 

F4H 

4 3 

d0 

2 

d0 

F3H 

F2H 

d1 

d1 

2 

d1 

d1 

2 

W 

d3 

F1v, F2v 

F3v, F4v 

Side Mounted Application 


d1 

F 1v = F 4v = - 

F 3v = F 4v = + 

( 

( 

W • 

d 2 

2 d 0 

W • 

d 2 

2 d 0 

F 1H = -F 2H = -F 3H = F 4H = W • d3 

2 d 0 

( 

( 

F1H 

d0 

F2H 

F1v 

F4v 

d1 F2v 

d2 

W 

d3 

Engineering 

Guide 

Vertical Application 


At the time of start & stop, the load varies because of inertia. 




Equivalent Applied Load † 

An equivalent load is used to consolidate applied load 

components into one value which can later be used 

to calculate the minimum required load rating and the 

expected life of the carriage / bearing selected. 

F V 

For ProfileRail* Carriages & Closed RoundRail* Bearings : 

F EQ = F H + F V 

F H 

F EQ = Equivalent Load 

F H = Horizontal Component of Resultant Applied Load 

F V = Vertical Component of Resultant Applied Load 

For Single Carriage or Single Rail Configurations : 

F EQ = F H + F V + (M / M C ) x C 

M = Applied Moment Load 

M C = Dynamic Moment Capacity of Bearing 

C = Dynamic Load Capacity of Bearing 

For Preloaded Carriages [ Only when F EQ < (3 x Fp) ] : 

Even with no external load applied, a preloaded bearing 

has a load on the races. A load greater than the externally 

applied load is present within a bearing with an externally 

applied load less than the preload end point. In order to 

calculate the loads on the load sets, the following formulae 

may be employed : 

F EQ = F p + 2 ⁄ 3 (F H + F V ) 

F p = Initial Preload Force 

(i.e., for ‘B’ Preload Designation F p = .03 x C) 

† Before calculating F EQ , make sure that neither F H or F V exceeds the 

Dynamic Load Limit of the guide intended for use. (See Dynamic Load 

Limit on Page 102). 

‡ The 0.6 value used accounts for a derating factor of the capacity during 

tensile loading. Therefore, when calculating expected life based on F EQ , 

the Full Dynamic Load Rating (C) may be used. 

100 



Mean Dynamic Load 

In applications with loads of varying magnitude, a mean 

dynamic load should be calculated. 

Where : 

F EQ1 …F EQn = equivalent dynamic load for distances d1 

through dn 

D = total distance of stroke = d1+d2…+dm 

P = 3 (linear guides w/Ball Type Rolling Elements) 

10/3 (linear guides w/Roller Type Rolling Elements) 

Load Ratings for Rolling Element Guides 

Dynamic Load Rating, C, and Travel Life 

The dynamic load rating, C, is the load at which when 

applied will yield the rated travel life. The rated travel life, 

Lr, for most linear guides is 100 km for metric products and 

4 million inches for inch products (the rated travel life is 

listed on the page with the dynamic load rating). For a given 

applied load, P, the dynamic load rating and rated travel 

life are used to calculate the travel life using the following 

load / life equation : 

L = (C/F EQ ) n x L r 

Where : 

L = calculated travel life 

C = dynamic load rating 

F EQ = equivalent applied load 

n = 3 for ball guides, 10/3 for roller guides 

= rated travel life 

L r 

Some manufacturers dynamic load ratings are based upon 

a 50 km life. To compare dynamic load ratings for guides 

with a 50 km rated life with a 100 km life, divide the 50 km 

dynamic load rating by 1.26. 

C 100 km = C 50 km / 1.26 

Some types of linear guides do not have the same dynamic 

load rating in all directions. The dynamic load rating for 

orthogonal load directions is shown as a percentage 

of C. It is not necessary to use this percentage of C 

in the load / life equation provided that the Equivalent 

Applied Load Section has been adhered to, because the 

calculations for equivalent applied load already account 

for it. 

Engineering 

Guide 




Calculating the Minimum Required Dynamic Load Rating, C min 

The load / life equation above can be rewritten to calculate 

the minimum required dynamic load rating which should 

be selected for a given applied load and minimum required 

travel life : 

C min = P(L m / L r) 1 / n 

Where : 

C min = minimum required dynamic load rating 

P = applied load 

L m = minimum required travel life 

L r = rated travel life 

n = 3 for ball guides, 10/3 for roller guides 

Note : Check that the applied load, P does not exceed the 

dynamic load limit. 

Dynamic Load Limit 

The dynamic load limit, is the maximum load which should 

be applied to the carriage / pillowblock. In some cases, 

the dynamic load capacity equals the dynamic load rating. 

In others, a limit shown as a percentage of the dynamic 

load rating is the maximum load which should be applied. 

A dynamic load limit less than the dynamic load rating 

does not derate the life of the guide. 

Static Capacities 

The static capacities are the maximum loads that should 


between the rolling elements and the raceways. The 

value C 0 is the static load capacity for a radial load acting 

orthogonal to the axis of travel. The values M OL and M OQ 

are the static roll, pitch, and yaw moment capacities. 

It is important to analyze the application so that shock 

loads do not exceed these capacities. Exceeding these 

capacities may permanently deform the rolling elements 

and raceways. This type of damage will be realized by an 

increase in friction, noise, and vibration, as well as by an 

increase in clearance between the carriage and the rail. 

For systems experiencing repetitive shock loading less than the static 

load capacities, the bearing life should be determined by means of 

fatigue calculations. 

102 



Preloading & Linear Guide Deflection 

Deflection Curves 

Preload 

A preloaded bearing has a condition of interference 

between the races of the rails, the rolling elements, and 

the races of the carriage. 

Preloading decreases the deflection due to external 

loads. This occurs because the contact reaction has 

already developed, eliminating much of the initial nonlinear 

deflection associated with rolling elements. 

The rolling element reactions within a preloaded bearing 

may be considered as having two components. One 

com ponent acts in the direction of external load, and 

one component acts in the opposing direction in order 

to maintain static equilibrium. These components are 

referred to as load sets. As external load is applied, 

one load set increases in load, as the opposite load 

set decreases in load. At some point, the load on the 

decreasing load set becomes zero. This point, at which 

the preload is relieved, is called the preload end point. 

Preload end typically occurs when the external load is 

approximately three times the preload. 

The following pages contain deflection charts for the 

500 Series Profile Rail Linear Guides. The charts shown 

are calculated. The calculation is based on theoretical 

conditions regarding shape, position and dimension of 

the balls and raceways of the carriage and rails under 

the specified loading. The real behavior of the carriage 

can vary slightly in the application as a result of base 

flatness, angle of loading, temperature, etc. 

Note that the deflection decreases as the preload or the 

bearing size increases. 

For deflection characteristics of linear guide types 

not shown, contact Danaher Motion Application 

Engineering at (540) 633-3490. 

Preload end point : 

F ext = 3F p 

where: 

F ext = externally applied load 

F p = preload 

By definition, a preloaded bearing, loaded beyond the preload 

endpoint, has the same deflection characteristics 

of an unpreloaded bearing externally loaded to that percentage 

of its dynamic load capacity. A preload level is 

assigned as a percentage of the dynamic load capacity 

of the bearing. 

Engineering 

Guide 




Deflection vs. Applied Load 

511 Style A, C, E 

Size 15 

Compressive Load 

Deformation (µm) 

70 

65 

60 

55 

50 

45 

40 

35 

30 

25 

20 

15 

10 

5 

0 

0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6 6.5 7 7.5 8 8.5 9 

Load F (kN) 

1 

2 

3 

Tensile Load 


65 

60 

55 

50 

45 

40 

35 

30 

25 

20 

15 

10 

5 

0 

0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6 6.5 7 7.5 8 8.5 9 

Load F (kN) 

1 

2 

3 

Lateral Load 


70 

65 

60 

55 

50 

45 

40 

35 

30 

25 

20 

15 

10 

5 

0 

0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6 6.5 7 7.5 8 8.5 9 

Load F (kN) 

1 

2 

3 

1. Preload 3% of C 



C = Dynamic load carrying capacity 

104 




511 Style A, C, E 

Size 20 



75 

70 

65 

60 

55 

50 

45 

40 

1 

35 

2 

3 

30 

25 

20 

15 

10 

5 

0 

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 

Load F (kN) 

Tensile Load 


75 

70 

65 

60 

55 

50 

45 

40 

35 

30 

25 

20 

15 

10 

5 

0 

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 

Load F (kN) 

1 

2 

3 

Lateral Load 


75 

70 

65 

60 

55 

50 

45 

40 

35 

30 

25 

20 

15 

10 

5 

0 

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 

Load F (kN) 





1 

2 

3 

Engineering 

Guide 





511 Style B, D, F 

Size 20 



70 

65 

60 

55 

50 

45 

40 

35 

30 

25 

20 

15 

10 

5 

0 

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 

Load F (kN) 

1 

2 

3 

Tensile Load 


70 

65 

60 

55 

50 

45 

40 

35 

30 

25 

20 

15 

10 

5 

0 

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 

Load F (kN) 

1 

2 

3 

Lateral Load 


75 

70 

65 

60 

55 

50 

45 

40 

35 

30 

25 

20 

15 

10 

5 

0 

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 

Load F (kN) 

1 

2 

3 





106 




511 Style A,C,E 

Size 25 



75 

70 

65 

60 

55 

50 

45 

40 

35 

30 

25 

20 

15 

10 

5 

0 

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 

Load F (kN) 

1 

2 

3 

Tensile Load 


75 

70 

65 

60 

55 

50 

45 

40 

35 

30 

25 

20 

15 

10 

5 

0 

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 

Load F (N) 

1 

2 

3 

Lateral Load 


75 

70 

65 

60 

1 

55 

2 

3 

50 

45 

40 

35 

30 

25 

20 

15 

10 

5 

0 

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 

Load F (kN) 





Engineering 

Guide 






Size 25 



70 

65 

60 

55 

50 

45 

40 

35 

30 

25 

20 

15 

10 

5 

0 

0 1 2 3 4 5 6 7 8 9 1011121314151617181920212223242526 

Load F (kN) 

1 

2 

3 

Tensile Load 


70 

65 

1 

2 

60 

3 

55 

50 

45 

40 

35 

30 

25 

20 

15 

10 

5 

0 

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 

Load F(kN) 

Lateral Load 


70 

65 

60 

1 

55 

2 

50 

3 

45 

40 

35 

30 

25 

20 

15 

10 

5 

0 

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 

Load F (kN) 





108 





Size 30 



85 

80 

75 

70 

65 

60 

55 

50 

45 

40 

35 

30 

25 

20 

15 

10 

5 

0 

0 2.5 5 7.5 10 12.5 15 17.5 20 22.5 25 27.5 30 

Load F (kN) 

1 

2 

3 

Tensile Load 


85 

1 

80 

2 

75 

3 

70 

65 

60 

55 

50 

45 

40 

35 

30 

25 

20 

15 

10 

5 

0 

0 2.5 5 7.5 10 12.5 15 17.5 20 22.5 25 27.5 30 

Load F (kN) 

Lateral Load 


85 

80 

75 

1 

70 

2 

65 

3 

60 

55 

50 

45 

40 

35 

30 

25 

20 

15 

10 

5 

0 

0 2.5 5 7.5 10 12.5 15 17.5 20 22.5 25 27.5 30 

Load F (kN) 





Engineering 

Guide 






Size 30 



80 

75 

70 

65 

60 

55 

50 

1 

45 

2 

3 

40 

35 

30 

25 

20 

15 

10 

5 

0 

0 2.5 5 7.5 10 12.5 15 17.5 20 22.5 25 27.5 30 32.5 35 

Load F (kN) 

Tensile Load 


80 

75 

70 

65 

60 

55 

50 

45 

40 

35 

30 

25 

20 

15 

10 

5 

0 

0 2.5 5 7.5 10 12.5 15 17.5 20 22.5 25 27.5 30 32.5 35 

Load F (kN) 

1 

2 

3 

Lateral Load 


80 

75 

70 

1 

65 

2 

60 

3 

55 

50 

45 

40 

35 

30 

25 

20 

15 

10 

5 

0 

0 2.5 5 7.5 10 12.5 15 17.5 20 22.5 25 27.5 30 32.5 35 

Load F (kN) 





110 





Size 35 



100 

95 

90 

85 

80 

75 

70 

65 

60 

1 

55 

2 

50 

3 

45 

40 

35 

30 

25 

20 

15 

10 

5 

0 

0 2.5 5 7.5 10 12.5 15 17.5 20 22.5 25 27.5 30 32.5 35 37.5 40 

Load F (kN) 

Tensile Load 


100 

1 

95 

2 

90 

85 

3 

80 

75 

70 

65 

60 

55 

50 

45 

40 

35 

30 

25 

20 

15 

10 

5 

0 

0 2.5 5 7.5 10 12.5 15 17.5 20 22.5 25 27.5 30 32.5 35 37.5 40 

Load F (kN) 

Lateral Load 


100 

95 

90 

85 

80 

75 

70 

65 

60 

55 

50 

45 

40 

35 

30 

25 

20 

15 

10 

5 

0 

0 2.5 5 7.5 10 12.5 15 17.5 20 22.5 25 27.5 30 32.5 35 37.5 40 

Load F (kN) 





1 

2 

3 

Engineering 

Guide 






Size 35 



100 

95 

90 

85 

80 

75 

70 

65 

60 

55 

50 

45 

40 

35 

30 

25 

20 

15 

10 

5 

0 

0 2.5 5 7.5 10 12.5 15 17.5 20 22.5 25 27.5 30 32.5 35 37.5 40 42.5 45 47.5 

Load F (kN) 

1 

2 

3 

Tensile Load 


100 

95 

90 

85 

80 

75 

70 

65 

60 

55 

50 

45 

40 

35 

30 

25 

20 

15 

10 

5 

0 

0 2.5 5 7.5 10 12.5 15 17.5 20 22.5 25 27.5 30 32.5 35 37.5 40 42.5 45 47.5 

1 

2 

3 

Load F (kN) 

Lateral Load 


100 

95 

90 

85 

80 

75 

70 

65 

60 

55 

50 

45 

40 

35 

30 

25 

20 

15 

10 

5 

0 

0 2.5 5 7.5 10 12.5 15 17.5 20 22.5 25 27.5 30 32.5 35 37.5 40 42.5 45 47.5 

Load F (kN) 





1 

2 

3 

Engineering 

Guide 

112 





Size 45 


120 

115 

110 

105 

100 

95 

90 

85 

Deformation (μm) 

80 

75 

70 

65 

60 

55 

50 

45 

40 

35 

30 

25 

20 

15 

10 

5 

0 

0 2.5 5 7.5 10 12.5 15 17.5 20 22.5 25 27.5 30 32.5 35 37.5 40 42.5 45 47.5 50 52.5 55 57.5 60 

Load F (kN) 

1 

2 

3 

Tensile Load 


120 

115 

110 

105 

100 

95 

90 

85 

80 

75 

70 

65 

60 

55 

50 

45 

40 

35 

30 

25 

20 

15 

10 

5 

0 

0 2.5 5 7.5 10 12.5 15 17.5 20 22.5 25 27.5 30 32.5 35 37.5 40 42.5 45 47.5 50 52.5 55 57.5 60 

Load F (kN) 

1 

2 

3 

Lateral Load 

120 

115 

110 

105 

100 

95 

90 

85 


80 

75 

70 

65 

60 

55 

50 

45 

40 

35 

30 

25 

20 

15 

10 

5 

0 

0 2.5 5 7.5 10 12.5 15 17.5 20 22.5 25 27.5 30 32.5 35 37.5 40 42.5 45 47.5 50 52.5 55 57.5 60 

Load F (kN) 





1 

2 

3 

Engineering 

Guide 






Size 45 


120 

115 

110 

105 

100 

95 

90 

85 


80 

75 

70 

65 

60 

55 

50 

45 

40 

35 

30 

25 

20 

15 

10 

5 

0 

0 2.5 5 7.5 10 12.5 15 17.5 20 22.5 25 27.5 30 32.5 35 37.5 40 42.5 45 47.5 50 52.5 55 57.5 60 62.5 65 67.5 70 72.5 75 

Load F (kN) 

1 

2 

3 

Tensile Load 


120 

115 

110 

105 

100 

95 

90 

85 

80 

75 

70 

65 

60 

55 

50 

45 

40 

35 

30 

25 

20 

15 

10 

5 

0 

0 2.5 5 7.5 10 12.5 15 17.5 20 22.5 25 27.5 30 32.5 35 37.5 40 42.5 45 47.5 50 52.5 55 57.5 60 62.5 65 67.5 70 72.5 75 

Load F (kN) 

1 

2 

3 

Lateral Load 


105 

100 

95 

90 

85 

80 

75 

70 

65 

60 

55 

50 

45 

40 

35 

30 

25 

20 

15 

10 

5 

0 

0 2.5 5 7.5 10 12.5 15 17.5 20 22.5 25 27.5 30 32.5 35 37.5 40 42.5 45 47.5 50 52.5 55 57.5 60 62.5 65 67.5 70 72.5 75 

Load F (kN) 

1 

2 

3 





114 




512 Style A and C 

Size 25 


30 

25 Compressive Load 

Preload 1, 2, 3 

25 

Deformation Ο, μm 

20 

15 

10 

1 

2 

3 

5 

Tensile Load 

0 

0 2 4 6 8 10 12 

Load F, kN 

30 

25 Tensile Load 


1 

25 

2 


20 

15 

10 

3 

5 

0 

0 2 4 6 8 10 12 

Load F, kN 

Lateral Load 

30 

25 Lateral Load 


25 

1 


20 

15 

10 

2 

3 

5 

0 

0 2 4 6 8 10 12 

Load F, kN 

Engineering 

Guide 









512 Style B and D 

Size 25 


30 



25 


20 

15 

10 

1 

2 

3 

5 

Tensile Load 

0 

30 

0 2 4 6 8 10 12 

Load F, kN 



14 16 

1 


25 

20 

15 

10 

2 

3 

5 

Lateral Load 

0 

30 

0 2 4 6 8 10 12 

Load F, kN 



14 16 

25 

1 


20 

15 

10 

2 

3 

5 

0 

0 2 4 6 8 10 12 

Load F, kN 

14 16 





116 





Size 35 


45 

40 

35 




30 

25 

20 

15 

10 

5 

1 

2 

3 

Tensile Load 

0 

45 

40 

0 2 4 6 8 10 12 

Load F, kN 



14 16 18 20 22 

1 


35 

30 

25 

20 

15 

10 

5 

2 

3 

Lateral Load 

0 

0 2 4 6 8 10 12 14 16 18 20 22 

Load F, kN 

45 



40 


35 

30 

25 

20 

15 

10 

5 

0 

0 2 4 6 8 10 12 

Load F, kN 

1 

2 

3 

14 16 18 20 22 

Engineering 

Guide 










Size 35 


45 

40 

35 




30 

25 

20 

15 

10 

5 

1 

2 

3 

Tensile Load 

0 

0 

45 

40 

35 

2 4 6 8 10 12 

14 16 18 20 22 24 26 28 30 

Load F, kN 



1 

2 


30 

25 

20 

15 

10 

5 

3 

Lateral Load 

0 

0 2 4 6 8 10 12 

45 

14 16 

Load F, kN 



18 20 22 24 26 28 30 

40 


35 

30 

25 

20 

15 

10 

5 

1 

2 

3 

0 

0 2 4 6 8 10 12 

14 16 18 20 22 24 26 28 30 

Load F, kN 





118 





Size 45 



55 

50 

45 

40 

35 

30 

25 

20 

15 

10 

5 

0 



0 5 10 15 20 25 30 35 40 

Load F, kN 

1 

2 

3 

Tensile Load 

55 

50 



1 


45 

40 

35 

30 

25 

20 

15 

2 

3 

10 

5 

0 

0 5 10 15 20 

Load F, kN 

25 30 35 40 

Lateral Load 




55 

50 

45 

1 

40 

35 

2 

30 

3 

25 

20 

15 

10 

5 

0 

0 5 10 15 20 25 30 35 40 

Load F, kN 

Engineering 

Guide 










Size 45 


Tensile Load 

Lateral Load 






55 

50 

45 

40 

35 

30 

1 

25 

2 

20 

3 

15 

10 

5 

0 

0 5 10 15 20 25 30 35 40 45 50 55 

Load F, kN 

55 

50 

45 

40 

35 

30 

25 

20 

15 

10 

5 

0 

0 

55 

50 

45 

40 

35 

30 

25 

20 

15 

10 

5 

0 

5 10 15 20 



25 30 35 40 45 50 55 

Load F, kN 



0 5 10 15 20 25 30 35 40 45 50 55 

Load F, kN 

1 

2 

3 

1 

2 

3 





120 





Size 55 


70 



60 


50 

40 

30 

20 

1 

2 

3 

10 

Tensile Load 

0 

0 10 20 30 40 50 60 

Load F, kN 

70 




60 

50 

40 

30 

20 

1 

2 

3 

10 

0 

0 10 20 30 40 50 60 

Load F, kN 

Lateral Load 

70 



60 


50 

40 

30 

20 

1 

2 

3 

10 

0 

0 10 20 30 40 50 60 

Load F, kN 

Engineering 

Guide 










Size 55 


70 



60 


50 

40 

30 

20 

1 

2 

3 

10 

0 

0 10 20 30 40 50 60 70 80 

Load F, kN 

Tensile Load 

70 




60 

50 

40 

30 

20 

1 

2 

3 

10 

0 

0 10 20 30 40 50 60 70 80 

Load F, kN 

Lateral Load 

70 



60 


50 

40 

30 

20 

1 

2 

3 

10 

0 

0 10 20 30 40 50 60 70 80 

Load F, kN 





122 





Size 65 


70 



60 


50 

40 

30 

20 

1 

2 

3 

10 

0 

0 10 20 30 40 50 60 70 80 90 100 110 120 

Load F, kN 

Tensile Load 

70 



1 

60 

2 


50 

40 

30 

20 

3 

10 

Lateral Load 

0 

70 

0 10 20 30 40 50 60 70 80 90 100 110 120 

Load F, kN 




60 

50 

40 

30 

20 

1 

2 

3 

10 

0 

0 10 20 30 40 50 60 70 80 90 100 110 120 

Load F, kN 

Engineering 

Guide 








Actuation Force 

The force required to actuate a linear guide (FA) has 

four basic components : 

1. Frictional resistance (F f ) 

2. Intrinsic resistance (D int ) 

3. Inertia of the moving components (F inertia ) 

4. Viscose drag of the lubrication (D l ) 

F A = F f + D int + F inertia + D l 

Frictional Resistance 

Rolling Element Guides 

Friction occurs in rolling element guides as a result of 

slipping of the rolling elements on the raceways. The 

frictional resistance can be calculated by means of 

the following equation : 

F f = µ x F i 

Where : 

µ = coefficient of friction (dependent upon type of guide 

type, rolling element type and load) 

F i = force internal to the linear guide 

The following table lists the coefficient of friction for 

different types of guides : 


Ball Type 

Roller Type 

0.002 - 0.003 0.001 - 0.002 

The value for the coefficient of friction is a function of 

the applied load. The coefficient of friction increases 

as load is applied. This is due to the increased contact 

area between the rolling elements and races. 

The force internal to the linear guide is equal to the 

external force (F ext ) applied to the linear guide in nonpreloaded 

guides, and preloaded guides loaded beyond 

3 times the preload value (F p ). 

F i = F ext 

For preloaded guides loaded below a level of 3 times 

the preload value (F p ), the internal force can be 

approximated with the following equation : 

F i = 2F p + 1/3 F ext 

124 



Intrinsic Resistance 

The intrinsic resistance is the measured actuation 

force required to move the guide at a constant velocity, 

without lubrication, regardless of load. It consists of 

the seal drag (larger component) and force required 

to circulate the rolling elements (smaller component). 

The intrinsic resis tance can be assumed to be a 

constant for linear guides carrying more than 5% of 

their dynamic load rating (C). For guides loaded below 

that value, the force required to circulate the rolling 

elements will increase. 

The following chart shows the intrinsic resistance, D int , 

for different types and sizes of linear guides. 

Inertia of Moving Components 

Inertia is directly related to the mass and acceleration 

by the following equation : 

F inertia = Ma 

Viscose Drag of the Lubrication 

The viscose drag of the lubricant is dependent upon the 

viscosity of the lubricant selected. 

Preload 

Preload of the assembly has an effect on intrinsic 

resistance, the greater the preload the greater the 

intrinsic resistance to move the guide. 

500 Series Ball Profile Rail 

Size Carriage Style Carriage Style 

A, C B, D 

D int (N) D int (N) D int (N) 

Preload 0.03C 0.13C 0.03C 0.13C 

15 7 15 8 14 

20 10 16 11 18 

25 13 22 14 22 

30 16 26 19 30 

35 23 37 25 41 

45 27 44 30 49 

Values for lubricant oil VG 68, speed 0.1 m/s 



A, C B, D 

D int (N) 

D int (N) 

25 17 18 

35 35 51 

45 53 60 

55 98 124 

65 — 170 

Value for 0.13 C Preload, lubricant oil VG68, speed 0.1 m/s 


Size 


AA 

D int (N) 

10 0.9 

15 2.8 

20 7.0 

Values for clearance preload, no lubricant 

Engineering 

Guide 




Lubrication 

Lubrication provides protection against wear, corrosion, 

heat, and friction. Application-specific variables, such 

as load, speed, and environmental conditions, determine 

the most suitable lubricant and lubrication schedule for 

that specific application. 

Danaher Motion’s general lubricant recommendation 

for linear guides is a grade 2 grease. A maximum of 

one year or 100 km, whichever comes first, between 

applications of lubricant is recommended. A grease with 

an extreme pressure additive should be used for guides 

loaded beyond 50 of their dynamic load rating (C). Oil 

can also be used and is recommended in applications 

where the bearings experience high speeds. Use the 

uppermost lubrication port on oil-lubricated bearings 

that are vertically oriented to ensure gravity-assisted 

lubricant dispersal. 

Linear guide products are supplied with a light coating 

of preservative oil. This preservative oil is for storage 

purposes only and is not recommended as lubrication 

for the bearing. 

Lubrication Procedure 

For best lubrication dispersal, the carriage should be 

moved on the rail while applying lubricant to ensure 

circulation to all internal bearing surfaces. It is not 

possible to over lubricate the bearings, as excess 

lubricant will merely exit the carriage under the seals. 

Recommended initial volumes of lubricant for 500 Series 

bearings are shown in the tables. The recommended 

volume for relubrication is 1/2 the initial volume. 

Short Stroke 

In the case of a stroke less than 2X´s the carriage 

length, two lubrication connections are recommended, 

one at each end to ensure adequate lubrication to the 

entire ball or roller track. 

Oil Reservoir 

The oil reservoir is supplied from the factory ready for 

installation (filled with oil). Relubrication is dependent 

upon many factors such as speeds, temperature, 

cleanliness, etc. The following is a guideline for 

relubrication. (It is recommended to relubricate every 

12 months.) 

Initial Grease Volume for 500 Series Ball Bearings 


A, C, E (cm 3 ) B, D, F (cm 3 ) 

15 0.9 — 

20 1.7 2.1 

25 2.8 3.5 

30 4.7 5.8 

35 6.6 8.1 

45 12.6 15.6 

Initial Grease Volume for 500 Series Roller Bearings 


A, C (cm 3 ) B, D (cm 3 ) 

25 1.9 2.2 

35 2.9 3.7 

45 5.3 6.6 

55 10.6 10.6 

65 — 18.9 

Oil Reservoir Refill Quantity 

Size 500 Series Ball 500 Series Roller 

531OW Oil 

532OW Oil Qty 

(cm 3 ) (cm 3 ) 

15 0.5 — 

20 1.4 — 

25 2.4 2.2 

30 2.9 — 

35 5. 6 

45 10.9 11 

55 — 19 

65 — 43 

Relubrication Interval 

Size 15 20 25 30 35 45 55 65 

Travel 

Distance 

2500 km 5000 km 

The oil reservoir is filled in the factory with Kluber 

Lamora D220 oil. If relubricating with different oil it is the 

responsibility of the user to determine oil compatibility. 

The recommended refill quantity is shown in the table. 

126 



Self-Lubricating Profile Rail Lube Block 

The self-lubricating Lube Block option offers 

maintenance free operation and enhanced protection 

for a broad range of applications. It offers : 

• Reduced system cost by eliminating the need for 

designing, purchasing, and installing expensive lubrication 

systems. 

• Environmentally friendly operation. 

• Increased bearing life by offering enhanced 

protection. 

Design 

The self-lubricating option utilizes self-lubricating 

attachments at both ends of the carriage and includes 

an initial EP2 grease pack of the carriage. The selflubricating 

attachments consist of a section of oil 

saturated polymer actively compressed by a contact 

spring, inside a double lip seal. 

A contact spring assures continuous contact with the 

rail, releasing oil as the carriage moves. This ensures 

a film of lubricant between the rolling elements and 

races. When the carriage is at rest, oil is re-absorbed 

by the polymer. 

Performance 

The design has incorporated a proven oil-saturated 

polymer used for over 10 years to lubricate radial 

bearings. This method of lubrication has a successful 

track record in applications ranging from food processing 

to automotive assembly. 

The graph below shows the theoretical L10 life 

expectancy and actual test results for the following two 

methods of lubrication : 

1. Bearing with self-lubricating attachments only. 

2. Bearing initially packed with EP2 grease only. 

Life Expectancy with Self-Lubricating Option and 

Initial Grease Pack vs. L10 Theoretical Life 

Load 

(Percent of Dynamic Load Rating) 

100% 

90% 

80% 

70% 

60% 

50% 

40% 

30% 

20% 

10% 

0 500 1000 

L10 Life Expectancy 

Lubricated with Self-Lubrication Attachments 

Initially Lubricated with EP-2 Grease 

1500 2000 2500 3000 3500 4000 

Life (km) 

Testing Parameters 

Stroke : 500 mm 

Speed : 0,6 m/s 

This chart illustrates how using the self-lubricating 

option, which combines the self-lubricating attachments 

and initial grease pack, will enable the bearing to 

achieve the L10 life expectancy under all loading 

condition. Note that for travel lives exceeding 30,000 km, 

recharging or replacing of the self-lubricating polymer 

is recommended. 

Engineering 

Guide 




Calculations for Bellow Cover Extended Length & Rail Length 

Given the Stroke and Distance Between Carriage 

Extremes : 

Way Cover Extended Length (mm) = Stroke (mm) / (1-CR). 

After dividing, round number up to the next increment of 

5 mm. This value is used as the length in the way cover 

part number when ordering. 

Bellows Extended Length 

Bellows 

Compressed 

Length 

Distance between 

carriage extremes 

Stroke 

Bellows 

Compressed 

Length 

Y X 

(ref.) 

typ. 

Rail Length 

Y 

The Way Cover Extended Length will be cut to next vee at the 

factory. 

Way Cover Compressed Length (mm) = 

Way Cover Extended Length (mm) - Stroke (mm). 

Rail Length = Compressed Length + Extended Length + Distance 

Between Carriage Extremes. 

Example : 

Product : 500 Series Ball Linear Guide Size 35 

Stroke Length = 200 mm 

Distance Between Carriage Extremes = 520 mm 

Bellows Type = Walk-On 

CR = 0.19 for size 35 500 Series Ball Walk-on type 

bellows 

Way Cover Extended Length = Stroke / 

(1-CR) =200 mm / (1-0.19) = 200 mm / .81 = 246.91 mm 

Round up to next increment of 5 mm, therefore, Way 

Cover Extended Length = 250 mm 

Way Cover Compressed Length = Way Cover Extended 

Length - Stroke = 250 mm - 200 mm = 50 mm 

Rail Length = Compressed Length + Extended Length 

+ Distance Between Carriage Extremes = 50 mm + 

250 mm + 520 mm = 820 mm 

128 



Specification Sheet for the Butting of Rails 

A butt joint will be require for rail lengths longer than 

the maximum shown in the chart below. If a butt 

joint is required, the 1st and 2nd rail lengths must 

each be less than the maximum shown. The “Y1” and 

“Y2” dimensions must be between the minimum and 

maximum shown below to avoid cutting into a mounting 

hole. The standard “Z” dimension should be used for 

best performance. 

Linear Guide Size “X” dim Standard Minimum Maximum Fastener size Maximum length 

Product “Z” dim “Y” dim “Y” dim without a joint 

500 Series Ball 15 60 30 8 52 M4 1 500 

500 Series Ball 20 60 30 8 52 M5 3 000 

500 Series Ball 25 60 30 8 52 M5 6 000 

500 Series Ball 30 80 40 10 70 M8 6 000 

500 Series Ball 35 80 40 10 70 M8 6 000 

500 Series Ball 45 105 52.5 13 92 M12 6 000 

500 Series Roller 25 30 30 8 52 M6 6 000 


500 Series Roller 45 52.5 52.5 13 39.5 M12 6 000 




Engineering 

Guide 




Request for Quotation Form 

1 

2 

3 

4 

A B C D E F 

Specification sheet for the butting of 2 rails 

“Y1” dim mm 

“Y2” dim mm 

“X” dim (typ) 

“Z” dim mm 

1st rail length 

mm 

2nd rail length 

mm 

Overall length 

mm (ref) 

1. “Z” composed of the two rail ends that form joint, which must be of equal value from center of closest hole to end of rails. 

Radford, VA 

Customer: ___________________________________________ 

TITLE 

APPROVAL DATE 

Quotation Number: ____________________________________ 

A 

DO NOT SCALE DRAWING 

DRAWN BY DATE 

Drwg Number: ___________ 

B C D E F 

FAX A COPY OF THIS FORM TO SALES ENGINEERING DEPARTMENT, FAX# 1-540-633-3490 

1 

2 

3 

4 

130 



Request for Quotation Form 

1 

2 

3 

4 

Engineering 

Guide 

A B C D E F 

Specification sheet for the butting of 3 or more rails 

1 

2 

“Z” dim mm 

“Z” dim 

mm 

“ Y1” dim mm “X” dim 

“Y2” dim 

(typ) 

mm 

1st rail length 

mm 

Middle rail length 

mm Last rail length 

mm 

Quantity of middle rails 

Overall length 

3 

mm 

1. “Z” composed of the two rail ends that form joint, which must be of equal value from center of closest hole to end of rails. 

Radford, VA 

4 

Customer: ___________________________________________ 

TITLE 

APPROVAL DATE 

Quotation Number: ____________________________________ 

A 

DO NOT SCALE DRAWING 

DRAWN BY DATE 

Drwg Number: ___________ 

B C D E F 

FAX A COPY OF THIS FORM TO SALES ENGINEERING DEPARTMENT, FAX# 1-540-633-3490 




Conventional 

Quantity Inch Unit Metric Unit (MKS) SI Unit Conversion Factors 

Length Inch Meter Metre 1 in = 25.4 mm 

in m m 1 mm = 0.03937 in 

1 m = 3.2808 ft 

1 ft = 0.3048 m 

Area Square Inch Square Meter Square Metre 1 in 2 = 6.4516 cm 2 

in 2 m 2 m 2 1 cm 2 = 0.155 in 2 

1 m 2 = 10.764 ft 2 

1 ft 2 = 0.092903 m 2 

Mass Pound Kilogram Kilogram 1 lb m = 0.45359237 kg 

lb m kg kg 1 kg = 2.2046 lb 

Force Pound Force Kilogram Force Newton 1 lb f = 0.45359237 kg f 

lb f kg f N 1 lb f = 4.44822 N 

1 kg f = 2.2046 lb f 

1 kg f = 9.80665 N 

1 N = 0.1019716 kg f 

1 N = 0.224809 lb f 

Stress or Pounds per Kilograms per Pascal 1 MPa = 10 6 N/m 2 = N/mm 2 

Pressure Square Inch Square Meter Pa 1 kPa = 10 3 N/m 2 

lb f / in 2 kg f / m 2 1 lb f /in 2 = 0.070307 kg f /cm 2 

1 lb f /in 2 = 7.0307 x 10 -4 kg f /mm 2 

1 lb f /in 2 = 6.8947 x 10 -3 N /mm 2 (MPa) 

1 kg f /cm 2 = 14.2233 lb f /in 2 

1 kg f /cm 2 = 9.80665 x 10 -2 N /mm 2 (MPa) 

Torque or Inch Kilogram Newton- 1 lb f - in = 1.1521 kg f - cm 

Work Pounds Meters Metres 1 kg f - cm = 0.8679 lb f - in 

lb f - in kg f - m Nm 1 lb f - in = 0.1129848 Nm 

1 kg f - m = 9.80665 Nm 

1 kg f - cm = 9.80665 x 10 -2 Nm 

1 Nm = 8.85 lb f - in 

1 Nm = 10.19716 kg f - cm 

Power Foot Pound Force per Newton Metre 1 kW = 1000 Nm / s 

per Minute Second per Second 1 kW = 60,000 Nm / s 

lb f -ft / min kg f - m / s Nm / s 1 kW = 44,220 lb f - ft / min 

1 kW = 1.341 hp 

1 hp = 75 kg f - m / s 

1 hp = 44,741 Nm/min 

1 hp = 33,000 lb f -ft/min 

1 hp = 0.7457 kW 

Velocity Feet per Meters per Metres per 1 ft / sec = 0.3048 m / s 

Second Second Second 1 in / sec = 2.54 cm / s 

ft / s m / s m / s 1 ft / sec = 0.00508 m/s 

1 mile / hr = 0.44704 m/s 

1 km / hr = 0.27777 m/s 

1 mile / hr = 1.609344 km / hr 

Acceleration Feet per Meters per Metres per 1 ft / s 2 = 0.3048 m / s 2 

Second Squared Second Squared Second Squared 

ft / s 2 m / s 2 m / s 2 

132 



NOTES : 

Engineering 

Guide 




Interchange Guide 

THK HSR LM GUIDE TO THOMSON 500 SERIES BALL PROFILE RAIL INTERCHANGE SHEET 

THK HSR 

THOMSON 500 SERIES BALL 

Assembly Part Number 

Carriage Part Number 

HSR 20 A 2 SS C1 + 1000 P (2) pcs 511 P 20 A 1 Z 

1 2 3 4 9 5 7 6 4 1 6 2 3 5 9 

and 

Rail Part Number 

(1) pc 521 P 20 A 1000 

4 1 6 2 8 7 



HSR 20 A UU 511 P 20 A 1 

1 2 3 9 1 6 2 3 4 



HSR 20 + 1000L 521 P 20 A 1000 

1 2 7 1 6 2 8 7 

1. TYPE 

THK 


Carriage - HSR Carriage - 511 

Rail - HSR Rail - 521 

2. SIZE 

THK 


15 15 

20 20 

25 25 

30 30 

35 35 

45 45 

55 N/A 

3. CARRIAGE STYLE 

THK 


A 

A 

B 

A 

CA 

A 

CB 

A 

LA 

B 

LB 

B 

HA 

B 

HB 

B 

R 

E 

TR 

E 

LR 

F 

HTR 

F 

4. CARRIAGES PER RAIL 

THK 

5. PRELOAD 


blank 0 

C1 1 

C2 2 

N/A 3 

6. ACCURACY 

THK 


blank 

H 

H 

H 

P 

P 

SP 

U 

UP 

U 

7. LENGHT 

THK 


xxxxL 

xxxx 

8. RAIL STYLE 

THK 


blank 

A 

K 

U 

N/A 

C 

9. SEALS 

THK 


SS 

blank 

UU 

blank 

ZZ 

Z 

DD 

W 

KK 

WZ 

QZ 

N 

N/A 

L 

134 



STAR BALL RAIL SYSTEMS TO THOMSON 500 SERIES BALL INTERCHANGE SHEET 

STAR 

THOMSON 



16 51 - 8 1 2 - 10 511 P 20 A 1 

1 2 3 4 5 7 1 5 3 2 4 



16 05 - 8 0 2 - 31, 1000 521 P 20 A + 1000 

1 2 3 5 6 1 5 3 2 6 

RAIL CARRIAGE 

STAR 

1. TYPE 

THOMSON 

16 Carriage - 511 

Rail - 521 

2. STYLE 

STAR 

THOMSON 

03 B 

04 A 

21 E 

22 C 

23 D 

24 F 

51 A 

53 B 

66 G 

1605-X0X-XX 

1605-X3X-XX 

1605-X6X-XX 

1607-XXX-XX 

1645-X03-XX 

1645-X33-XX 

1647-X03-XX 

A + 531HP 

C + 531RCS (size 25 & up) 

C + 531RCS (size 25 & up) 

U 

AD + 531HP 

CD + 531RCS (size 25 & up) 

UD 

3. SIZE 

STAR 

THOMSON 

1 15 

2 25 

3 35 

4 45 

5 N/A 

6 N/A 

7 30 

8 20 

4. PRELOAD 

STAR 

THOMSON 

1 1 

2 2 

3 3 

9 0 

5. ACCURACY 

STAR 

THOMSON 

1 U 

2 P 

3 H 

4 H 

9 0 

6. RAIL LENGTH 

STAR 

THOMSON 

XXXX 

+XXXXX 

7. REVISION 

STAR 

THOMSON 

10 blank 

20 blank 


Interchange 

Guide



STAR ROLLER RAIL SYSTEM TO THOMSON 500 SERIES ROLLER PROFILE RAIL INTERCHANGE SHEET 

STAR 

THOMSON 



18 51 - 2 1 2 - 10 512 P 20 A 1 

1 2 3 4 5 7 1 5 3 2 4 



18 05 - 2 0 2 - 31 , 1000 522 P 25 A + 1000 

1 2 3 8 5 9 6 1 5 3 2 6 

CARRIAGE 

STAR 

1. TYPE 

THOMSON 

18 Carriage - 512 

Rail - 522 

2. STYLE 

STAR 

THOMSON 

51 A 

53 B 

21 C 

24 D 

Rail - see RAIL STYLE - 1, 2, 8 and 9 Section 

3. SIZE 

STAR 

THOMSON 

2 25 

3 35 

4 45 

5 55 

6 65 

4. PRELOAD 

STAR 

THOMSON 

1* 1 

2 2 

3 3 

5. ACCURACY 

STAR 

THOMSON 

3 N/A 

2 P 

1 S 

9 U 

STAR 

XXXX 

STAR 

6. LENGTH 

7. VERSION 

THOMSON 

+XXXX 

THOMSON 

10 blank 

13 (ALUMINIUM END CAP) N/A 

18 ES4 

60 D-Thine Dense Chrome 

RAIL STYLE 1,2,8 AND 9 

STAR 

THOMSON 

1805-x2x-31 

1805-x3x-31 C + 532RCS (size 25) 

1805-x3x-61 

1805-x5x-31 

C 

C + 532RCS (size 35 & up) 

1805-x6x-31 C + 532RCS (size 25) 

1805-x6x-61 

1806-x5x-31 

1807-x0x-11 

1845-x1x-31 

A 

C + 532RCS (size 35 & up) 

A 

U 

A + Thin Dense Chrome 

1845-x5x-31 C + Thin Dense Chrome + 532RCS (size 25) 

1845-x5x-61 

1845-x8x-31 

1847-x1x-31 

C + Thin Dense Chrome + 532RCS (size 35 & up) 

C + Thin Dense Chrome + 532RCS 

U + Thin Dense Chrome 

18xx-xxx-41 Coated End for Thin Dense Chrome options in place of -31 

18xx-xxx-71 Coated End for Thin Dense Chrome options in place of -61 

136 



The Thomson 500 Series Ball Profile Rail replaces the 

Thomson AccuGlide Profile Rail. 

The 500 Series Ball Profile Rail provides the following 

advantages when compared to AccuGlide : 

• Increased rail straightness through advanced grinding 

technologies 

• Simpler installation and greater accuracy on jointfree 

rails up to 6 meters long 

• Smoother, quieter movement through insert molded 

recirculation paths, minimized transitions and 

optimized geometries 

• Increased load capacity from longer ball paths and 

total number of rolling elements 

• On-site field modifiable and upgradeable easy-to-use 

modular carriage and seal designs 

• Customization with expanded accessories offering 

THOMSON AccuGlide* TO THOMSON 500 SERIES BALL PROFILE RAIL INTERCHANGE SHEET 

THOMSON AccuGlide* 




CG 20 AA B P 511 P 20 A 1 

1 2 3 4 5 8 1 5 2 3 4 8 



RG 20 P L1000 521 P 20 A 1000 

1 2 5 6 8 1 5 2 7 8 6 

1. TYPE 

AccuGlide 


Carriage - CG Carriage - 511 

Rail - CG Rail - 521 

2. SIZE 

AccuGlide 


15 15 

20 20 

25 25 

30 30 

35 35 

45 45 

55 N/A 


AccuGlide 


A 

A 

BA 

B 

CE 

C 

DE 

D 

EE 

E 

HE 

F 

4. PRELOAD 

AccuGlide 


A 0 

B 1 

C 2 

D 3 

5. ACCURACY 

AccuGlide 


N 

H 

H 

H 

P 

P 

S 

U 

U 

U 

6. LENGHT 

AccuGlide 


Lxxxx 

xxxx 

7. RAIL STYLE 

AccuGlide 


– A 

N/A 

U 

N/A 

C 

8. OPTIONS 1 

AccuGlide 


A 

D 

C2C2 (plastic) 

C (steel) 

C3C3 

C 

D#### 

See pg. 122 or Consult Danaher Motion 

KK 

W 

LDS 

Standard Longitudinal Seal is low drag 

LL 

L 

M### 


R2R2 

E 

ZZ 

Z 

N/A 

V (Viton Wiper) 

N/A 

N (Oil Reservoir) 


Interchange 

Guide



The Thomson 500 Series Roller Profile Rail replaces the 

Thomson AccuMax Profile Rail. 

The 500 Series Roller Profile Rail provides the following 

advantages when compared to AccuMax : 

• Increased rail straightness through advanced grinding 

technologies 

• Simpler installation and greater accuracy on jointfree 

rails up to 6 meters long 

• Smoother, quieter movement through insert molded 

recirculation paths, minimized transitions and 

optimized geometries 

• Increased load capacity from longer roller paths and 

total number of rolling elements 

• Expanded offering of ultra-rigid roller carriage sizes 

and styles for all applications 

• On-site field modifiable and upgradeable easy-to-use 

modular carriage and seal designs 

• Customization with expanded accessories offering 

THOMSON AccuMax* TO THOMSON 500 SERIES ROLLER PROFILE RAIL INTERCHANGE SHEET 

THOMSON AccuMAX* 

THOMSON 500 SERIES ROLLER 



CM 35 AA B S 512 S 35 A 1 

1 2 3 4 5 8 1 5 2 3 4 8 



RM 35 S L1000 522 S 35 A 1000 

1 2 5 6 8 1 5 2 7 8 6 

1. TYPE 

AccuMax 


Carriage - CM Carriage - 512 

Rail - RM Rail - 522 

2. SIZE 

AccuMax 


N/A 25 

35 35 

45 45 

55 55 

N/A 65 


AccuMax 


A 

A 

N/A 

B 

N/A 

C 

N/A 

D 

4. PRELOAD 

AccuMax 


B 1 

C 2 

D 3 

5. ACCURACY 

AccuMax 


P 

P 

S 

S 

U 

U 

6. LENGHT 

AccuMax 


Lxxxx 

xxxx 

7. RAIL STYLE 

AccuMax 


– A 

N/A 

U 

N/A 

C 

8. OPTIONS 1 

AccuMax 


A 

D 

C2C2 (plastic) 

C (steel) 

C3C3 

C 

D#### 


KK 

W 

LDS 

Standard Longitudinal Seal is low drag 

LL 

L 

M### 


R2R2 

E 

ZZ 

Z 

N/A 

V (Viton Wiper) 

138 



Common AccuGlide Options 

Carriage 

Carriage 

Options 500 Series Option 

Options 500 Series Option 

C2C2 

C 

M097 

ZES15 

C3C3 

C 

M099 

CES15 

D035 

ES1 

M125 

ES11 

D047 

ES10* 

M134 

ES6 

D065 

ES2 

M147 

CES7 

D086 

ES1ES10* 

M153 

W 

D087 

ES8 or ES1ES10* 

M157 

WZ 

D088 

ES2ES10* 

M168 

Duralloy 

D089 

ES9 or ES2ES10* 

M171 

Z 

D134 

ZCES1 

M183 

ZES5 

D135 

CES1 

M186 

ES5 

D147 

CES10* 

M187 

CES5 

D150 

ZC 

M188 

CES10* 

D164 

ZCES2 

M189 

CES6 

D165 

CES2 

M192 

ZES6 

D186 

CES1ES10* 

M209 

LES6 

D187 

CES7 or CES10* 

M210 

WES7 

D188 

CES10* 

M234 

LES3 

D189 

CES9 or CES2ES10* 

M235 

LZES3 

D192 

LCES9 or LCES2ES10* 

M236 

LZCES3 

D234 

LES1 

M241 

LC 

D235 

LZES1 

M242 

Duralloy + L 

D236 

LZCES1 

M249 

LCES7 or LCES10* 

D237 

LCES1 

M251 

LZC 

D241 

LC 

M263 

LES4 

D251 

LZC 

M264 

ZES4 

D262 

LES2 

M265 

LZES4 

D263 

LCES2 

M266 

LZCES4 

D264 

ZES2 

M267 

LCES4 

D265 

LZES2 

M275 

LZES14G1 

D266 

LZCES2 

M287 

LES5 

D267 

LCES2 

M289 

LES6 

D274 

LES12 

M290 

LCES6 

D275 

LZES12 

M292 

LZES6 

D289 

LES9 or LES2ES10* 

M293 

WES5 

D292 

LZES9 or LZES2ES10* 

M294 

GS 

LDS 

now standard 

ZZ 

Z 

LL 

L 

LLZZ 

LZ 

* ES10 option is side lube in end cap, size 15 = M3, size 20 and up=M6. 

M035 

ES3 

M038 

CES3 

Rail Options 500 Series Designation 

M041 

1/4-28 in side options: ES7 or ES10 option* 

D080 

DH1 

M043 

C + 1/4-28 in side options: CES7 or CES10 option* D085 

DH2 

M047 

ES7 or ES10* 

D181 

EDH1 

M049 

CES7 or CES10* 

D185 

EDH2 

M063 

CES4 

D187 

EDH2 

M065 

ES4 

M080 

DH3 

M075 

ES14 

M082 

EDH3 

M077 

ES14 + ES7 

M083 

EDH3 

M087 

ES5 

M085 

DH4 

M088 

ES4ES10 

M088 

EDH4 

M089 

ES6 

M091 

EDH4 

M094 

ES7 + ES15 

R2R2 

E 

M095 

ES15 

R3R3 

E 


Interchange 

Guide



NOTES : 

140 



NOTES : 


Interchange 

Guide



NOTES : 

142 



NOTES : 


Interchange 

Guide



NOTES : 

144 



NOTES : 


Interchange 

Guide


NOTES : 

146 


USA, CANADA and MEXICO 

Danaher Motion 

203A West Rock Road 

Radford, VA 24141 USA 

Phone: 1 540 633 3549 

Fax: 1 540 633 0294 

E-mail: Thomson@danahermotion.com 

Literature: www.literature.danahermotion.com 

Germany 

Danaher Motion GmbH 

Nuertinger Strasse 70 

72649 Wolfschlugen 

Germany 

Phone: +49 (0) 7022 504 100 

Fax: +49 (0) 7022 504 405 

E-Mail: sales.wolfschlugen@danahermotion.com 

ASIA 

China 


Rm 2205, Scitech Tower 

22 Jianguomen Wai Street 

Beijing, China, 100004 

Phone: +86 10 6515 0260 

Fax: +86 10 6515 0263 

E-mail: sales.china@danahermotion.com 

Japan 

Danaher Motion Japan 

2F, Sigma Hatchobori Bldg, 

2-7-1 Hatchobori Chuo-ku, 

Tokyo 104-0032 Japan 

Phone: +81 3 6222 1051 

Fax: +81 3 6222 1055 

E-mail: info@danahermotion.co.jp 

Asia Pacific 

Danaher Motion (HK) Ltd 

Unit A, 16 Floor, 169 Electric Road 

Manulife Tower, North Point 

Hong Kong 

Phone: +852 2503 6581 

Fax: +852 2571 8585 

E-mail: victor.lim@danahermotion.com 

EUROPE 

United Kingdom 


Chartmoor Road, Leighton Buzzard 

LU7 4WG; United Kingdom 

Phone: +44 (0)1525 243 243 

Fax: +44 (0)1525 243 244 

E-mail: sales.uk@danahermotion.com 

Italy 

Danaher Motion srl 

Largo Brughetti 

I-20030 Bovisio Masciago 

Italy 

Phone: +39 0362 594260 

Fax: +39 0362 594263 

E-mail: info@danahermotion.it 

Sweden 


Box 9053 

SE-291 09 Kristianstad 

Sweden 

Phone: +46 (0) 44-24 67 00 

Fax: +46 (0) 44-24 40 85 

E-mail: helpdesk.kid@danahermotion.com 

Switzerland 

Danaher Motion SA 

La Pierreire 2 

1029 Villars-Ste-Croix 

Switzerland 

Phone: +41 (0) 21 631 33 33 

Fax: +41 (0) 21 636 05 09 

E-mail: info@danaher-motion.ch 

France 


C.P 80018 

12, Rue Antoine Becquerel – Z.I. Sud 

F-72026 Le Mans Cedex 2 

France 

Phone: +33 (0) 243 50 03 30 

Fax: +33 (0) 243 50 03 39 

E-mail: sales.france@tollo.com 

200802-11 TPS 10K MIDS 5/12/2008 USA 

Specifications are subject to change without notice. It is the responsibility of the product user to determine 

the suitability of this product for a specific application. All trademarks property of their respective owners. 

© Thomson 2009 

www.thomsonlinear.com 

Linear Motion. Optimized.

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