Rockwell Automation HPK-Series User Manual

Installation Instructions

HPK-Series Asynchronous Servo
Motors

Catalog Numbers HPK-B1307, HPK-E1307, HPK-B1308, HPK-E1308,
HPK-B1310, HPK-E1310, HPK-B1609, HPK-E1609, HPK-B1611, HPK-E1611,
HPK-B1613, HPK-E1613, HPK-B1815, HPK-E1815, HPK-B2010, HPK-E2010,
HPK-B2212C, HPK-E2212C, HPK-B2510C

Topic Page

Important User Information 2

Motor Catalog Number Identification 3

Before You Begin 4

Installation and Maintenance Guidelines 4

Installing an HPK Motor 11

Product Dimensions 15

Motor Connectors 26

Load Force Capacities 27

Troubleshooting and Maintenance 29

Shaft Key Removal and Installation 32

Motor Cables and Accessory Kits 33

Specifications 33

Additional Resources 34

About This Publication

This publication provides installation instructions for the HPK-Series asynchronous motors
with a frame size of 1307 mm (51.5 in.), 1600 mm (63.0 in.), 1815 mm (71.5 in.), 2010 mm
(79.1 in.), 2212 mm (86.7 in.), or 2510 mm (98.8 in.).

Use this document if you are responsible for installing these Allen-Bradley motors. Please read all
instructions before installing this motor.

2 HPK-Series Asynchronous Servo Motors

IMPORTANT

Important User Information

Solid state equipment has operational characteristics differing from those of electromechanical equipment.
Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls, publication
SGI-1.1, is available from your local Rockwell Automation sales office or online at
http://www.rockwellautomation.com/literature. It describes some important differences between solid state
equipment and hard-wired electromechanical devices. Because of this difference, and also because of the
wide variety of uses for solid state equipment, all persons responsible for applying this equipment must
satisfy themselves that each intended application of this equipment is acceptable.

In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages
resulting from the use or application of this equipment.

The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many
variables and requirements associated with any particular installation, Rockwell Automation, Inc. cannot
assume responsibility or liability for actual use based on the examples and diagrams.

No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits,
equipment, or software described in this manual.

Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell
Automation, Inc., is prohibited.

Throughout this manual, when necessary, we use notes to make you aware of safety considerations.

WARNING: Identifies information about practices or circumstances that
can cause an explosion in a hazardous environment, which may lead to
personal injury or death, property damage, or economic loss.

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ATTENTION: Identifies information about practices or circumstances
that can lead to personal injury or death, property damage, or economic
loss. Attentions help you to identify a hazard, avoid a hazard, and
recognize the consequences.

SHOCK HAZARD: Labels may be located on or inside the equipment, for
example, a drive or motor, to alert people that dangerous voltage may be
present.

BURN HAZARD: Labels may be located on or inside the equipment, for
example, a drive or motor, to alert people that surfaces may be dangerous
temperatures.

Identifies information that is critical for successful application and
understanding of the product.

Motor Catalog Number Identification

HPK - B 1307 C- S A 4 2 A A

HPK-Series Asynchronous Servo Motors 3

FACTORY DESIGNATED OPTIONS
A = Standard
MOUNTING TYPE/SHAFT KEY
A = IEC Metric, Free Mounting Holes

B = IEC Metric, Free Mounting Holes

BRAKE
2 = No Brake
4 = 380…460V ac Brake
CONNECTORS
4 = Right-angle Rotatable
BLOWER/JUNCTION BOX
A = Inline Blower, F3 Jx Box
B = Top-mount Blower, F1 Jx Box
C = Top-mount Blower, F2 Jx Box
FEEDBACK
M = Multi-turn High Resolution Encoder
S = Single-turn High Resolution Encoder
RATED SPEED (rpm)
C = 1500
E = 3000
FRAME SIZE (mm)
1307
1308
1310
1609
1611
1613
1815
2010
2212
2510
VOLTAGE RATING
B = 460V ac
E = 400V ac
BULLETIN
HPK = Asynchronous Servo

(Type FF), Foot and Flange Mount,
Keyed Shaft

(Type FF), Foot Mount Only, Keyed
Shaft

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4 HPK-Series Asynchronous Servo Motors

Before You Begin

Before unpacking the product, inspect the shipping carton for damage. If damage is visible,
immediately contact the shipper and request assistance. Otherwise, proceed with unpacking.

Remove the motor carefully from its shipping container, and visually inspect the motor for any
damage. Carefully examine the motor frame, front output shaft, and mounting pilot for any
defects.

Motors are shipped with wooden blocking to prevent axial movement of the shaft during
shipment. Remove the blocking and bolts securing it and verify that the motor shaft turns freely.
If motor is to be shipped or placed in long-term storage, blocking of the bearing is recommended.

Keep the original packing material in case you need to return the product for repair or to
transport it to another location. Use both the inner and outer packing cartons to provide

adequate protection for a unit returned for service.

ATTENTION: Do not attempt to open and modify the motor. Modifications that
can be performed in the field are described in this manual; other changes
should not be attempted.

Only a qualified Allen-Bradley employee can service this type of motor.

Failure to observe these safety procedures could result in personal injury or
damage to equipment.

Installation and Maintenance Guidelines

The guidelines in this section provide you with information about installing servo motor so it
provides safe and reliable service.

Handling

Exercise care when lifting the motor. Always lift in the direction intended in the design of the
lifting mechanism, and lift using all of the eyebolts or lifting lugs provided.

ATTENTION: Eyebolts or lifting lugs are intended for lifting only the motor and
factory mounted accessories.

Do not mount additional equipment before lifting and securing the motor.

Failure to observe this precaution could result in bodily injury.

The angle of lift formed by a lifting rope or chain must be greater than 45 degrees from
horizontal. Diagrams are provided that show proper rigging and lift practices.

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HPK-Series Asynchronous Servo Motors 5

1

/

>2A

45

°

A

Take precautions during a lift to prevent hazardous overload due to deceleration, acceleration, or
shock forces caused by abrupt raising or lowering, or swinging and twisting of a suspended

motor.

ATTENTION: Eyebolts may unscrew during lifting. Prior to lifting, check the
eyebolts to verify that they are tight and attach lifting equipment to restrict
turning during the lift. Alternatively, lift the unit on a platform or with a sling.

Failure to observe this precaution could result in bodily injury.

Lifting Guidelines

For unusual conditions, such as side-wall and ceiling mounting of horizontal motors and
installation of vertical motors shipped in a horizontal position, special precautions must be
taken. We recommend that an experienced rigger be employed.

To Prolong Motor Life

Thoughtful design and proper maintenance can increase the life of a servo motor. The following
are guidelines to maximize the life of a servo motor.

• Always provide a drip loop in a cable to reduce the potential for moisture related

problems. A drip loop is a downward bend in the cable that lets water gather and drip off
the cable rather than continue to flow along the cable.

• Avoid installing the motor with the shaft pointing upward. This orientation increases

the risk of contaminant ingress.

• Environmentally-sealed connectors and cables are required to achieve an International

Protection (IP) rating of IP54 for the motor.

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6 HPK-Series Asynchronous Servo Motors

IMPORTANT

Cables enter from above.
Drip loops are not formed.

Cables enter from below.
A drip loop is formed in each cable.

Cable Orientation for Drip Loop

• Brakes on these servo motors are holding brakes. The brakes are spring-set, and release

when voltage is applied to the brake coil. A separate power source is required to
disengage the brake. This power source may be applied by a servo motor controller, in
addition to manual operator control.

If system main power fails, holding brakes can withstand occasional use as stopping
brakes. However, this creates rotational mechanical backlash that is potentially damaging
to the machine, increases brake wear, and reduces brake life.

Holding brakes are not designed to stop rotation of the motor shaft, nor are
they intended to be used as a safety device. They are designed to hold a motor
shaft at 0 rpm for up to the rated brake holding torque.

The recommended method of preventing motor shaft rotation is a four step
process: first - command the servo drive to 0 rpm; second - verify the motor is at
0 rpm; third - engage the brake; and fourth - disable the drive.

Disabling the drive removes the potential for brake wear caused by a badly
tuned servo system oscillating the shaft.

Mechanical Connections

Mechanical connections to the motor shaft, such as couplings and pulleys, require a torsionally
rigid coupling or a reinforced timing belt. The high dynamic performance of servo motors can
cause couplings, pulleys, or belts to loosen or slip over time. A loose or slipping connection will
cause system instability and may damage the motor shaft. All connections between the machine
and the motor shaft must be rigid to achieve acceptable system response. Periodically inspect
connections to verify their rigidity.

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HPK-Series Asynchronous Servo Motors 7

When mounting couplings or pulleys to the shaft, verify that the connections are properly
aligned and that axial and radial loads are within the motor specifications.

ATTENTION: Do not strike the shaft, key, couplings, or pulleys with tools
during installation or removal.

Damage may occur to the motor bearings and the feedback device if sharp
impact to the shaft is applied during installation of couplings and pulleys, or a
shaft key. Damage to the feedback device also may result by applying leverage
from the faceplate to remove devices mounted on the motor shaft.

To remove a friction-fit or stuck device, apply a constant pressure to the user
end of the shaft with a wheel puller.

Failure to observe these procedures could result in damage to the motor and its
components.

A shaft key provides a rigid mechanical connection with the potential for self-alignment, but the
key must be properly installed in the keyway. The Product Dimensions
information on the key and shaft keyway. Refer to the Shaft Key Removal and Installation
section for recommendations on how to remove and install a shaft key.

section provides sizing

Requirements for Mounting

HPK-Series asynchronous motors have a mounting pilot for aligning the motor on a machine.
The installation must comply with all local regulations and use of equipment and installation
practices that promote electromagnetic compatibility and safety.

ATTENTION: Unmounted motors, disconnected mechanical couplings, loose
shaft keys, and disconnected cables are dangerous if power is applied.

Disassembled equipment should be appropriately identified (tagged-out) and
access to electrical power restricted (locked-out).

Before applying power to the motor, remove the shaft key and other mechanical
couplings that could be thrown from the shaft.

Failure to observe these safety procedures could result in personal injury.

• The motor shaft and the load shaft must be parallel and pulleys aligned.

• Pulleys, gears, and similar devices should be mounted as close as practical to the front

motor bearing to minimize bearing load.

• Flexible couplings may be used between the motor shaft and a load shaft. The motor

shaft and load shaft must be aligned to values recommended for the specific coupling
before coupling is connected.

• Stainless steel fasteners are preferred for mounting the motor.

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8 HPK-Series Asynchronous Servo Motors

IMPORTANT

Allow sufficient clearances in the area of the motor for it to stay within its specified operating
temperature range. Refer to Specifications for the operating range. Do not install the motor in an
area with restricted airflow. Keep other heat producing devices away from the motor.

Sufficient clearance must be provided on all inlet and outlet openings to
provide for unrestricted flow of air. Allow at least 152 mm (6.0 in.) of clearance
between the blower exhaust opening and adjacent walls or floor.

Recommended mounting bolts and the torque values are listed below.

Motor Hole

Diameter

HPK-B and HPK-E mm (in.) N•m (lbs.) N•m (lbs.)

1307 12 (0.47) M10-1.5 8.8 (78) 12.9 (114)

1308 M10-1.5 50 (442) 72 (637)

1310 15 (0.60) M12-1.75 126 (1115) 158 (1398)

1609 M10-1.75

1611 19 (0.75) M16-2.5 238 (2106) 337 (2983)

1613 M16-2.5 420 (3717) 596 (5275)

1815 24 (0.95) M22-2.5 658 (5823) 934 (8266)

2010 M22-2.5

2212 19 (0.75) M16-2.5 420 (3717) 596 (5275)

2510 21 (0.81) M20-2.5 495 (4381) 920 (8142)

Bolt Size
and
Thread

Recommended Torque

Bolt Grade 8.8 Bolt Grade 12.9

Refer to Load Force Capacities to determine the radial and axial shaft load limitations of your
motor.

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HPK-Series Asynchronous Servo Motors 9

IMPORTANT

Interconnect Cables

Knowledgeable cable routing improves system electromagnetic compatibility (EMC). Refer to
Grounding of Signal Wire Shields Within a Cable for suggested cable trim lengths, and for cable
shield grounding at the motor frame.

The recommended wire size is based on motor current requirements and
terminal block sizing. Consult your local electrical code before selecting wire
gauge for your application

To install the cables:

• Keep wire lengths as short as physically possible.

• Route signal cables away from motor and power wiring. Typical signal cables transmit

encoder, serial, or analog data at low voltages.

• Separate cables by 0.3 m (1 ft) minimum for every 9 m (30 ft) of parallel run.

• Ground both ends of the cable shield and twist the signal wire pairs to prevent

electromagnetic interference from other equipment.

ATTENTION: High voltage can be present on power cable shielding, if the
shielding is not grounded.

Verify there is a connection to ground for all power cable shielding.

Failure to observe these safety procedures could result in personal injury or
damage to equipment.

Electrical Noise

Electromagnetic interference (EMI), commonly called noise, may adversely impact motor
performance by inducing stray signals. Effective techniques to counter EMI include filtering the
ac power, shielding and separating signal carrying lines, and practicing good grounding
techniques. Effective ac power filtering can be achieved by using isolated ac power transformers
or properly installed ac line filters. The effect of EMI on motor signals can be minimized by two
installation practices.

• Physically separate signal lines from motor cabling and power wiring. Do not route

signal wires with motor and power wires, and do not route signal wires over the vent
openings of servo drives or other electrical power sources.

• Ground all equipment using a single-point parallel ground system that employs ground

bus bars or large straps. If necessary, use additional electrical noise reduction techniques
to reduce EMI in a noisy environment.

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10 HPK-Series Asynchronous Servo Motors

Two Shielded Signal Wires within Cable

Overall Cable Shield

Signal Shield (one of two)
Customer loops to contact Overall Cable Shield.

}

Cable as Supplied

Cable Field Modified

Attach to Cable Ground Clamp on Drive
Clamp must contact all cable shields.

Power Cable Shielding

HPK-Series motors with brakes integrate the brake signals (BR+ and BR-) with the 380…460V
power at the termina l block. The separate shield surrounding the brake sig nals must be grounded
to the overall system ground. To properly ground the brake ground shield, or any separately
shielded signal, follow these wiring guidelines.

Verify each cable shield connects to the overall chassis ground by routing as shown in diagram.
Clamp all shields together at the power cable (chassis) ground connection on the drive.

ATTENTION: High voltage can be present on the shields of a power cable, if
the shields are not grounded.

Verify that there is a connection to ground for each shield in the power cable.

Failure to observe these safety procedures could result in personal injury or
damage to equipment.

Power Cable Shielding

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HPK-Series Asynchronous Servo Motors 11

Installing an HPK Motor

Observe the following when installing an HPK-Series motor.

ATTENTION: Do not strike the shaft, couplings, or pulleys with tools during
installation or removal.

Damage may occur to the motor bearings and the feedback device if sharp
impact to the shaft is applied during installation of couplings and pulleys.

Failure to observe these procedures could result in damage to the motor and its
components.

1. Rotate the wiring junction box and position the motor so the junction box may be
accessed for initial wiring and occasional verification of and maintenance to the wiring
connections.

Refer to Cable Orientation for Drip Loop
motor and cable positioning.

2. Properly mount the motor.

Refer to the motor outline drawings for dimensions. If necessary, shim the motor to
achieve proper alignment of the shaft.

3. Align the motor shaft on the index pulse.

The index pulse occurs on a single-turn encoder when the shaft key is aligned with the
top of the motor. Refer to the motor outline drawings for a visual reference of this
alignment.

4. Form a drip loop in the cables directly before each cable enters the motor.

A drip loop lets liquids gather and drip off the cable rather than flow along the cable to
an electrical connection or the motor. Refer to Cable Orientation for Drip Loop

page 6 for a visual example.

ATTENTION: Be sure that feedback cable is installed and restrained to
prevent uneven tension or flexing at the cable connector.

Excessive and uneven lateral force at the feedback connector may result in the
connector’s environmental seal opening and closing as the cable flexes.

Failure to observe these safety procedures could result in damage to the motor
and its components.

on page 6 for a visual reference of correct

on

5. Remove the access cover on the junction box, and rotate the box in 90° increments to
improve cable access.

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