Allen-Bradley Rockwell Automation RDD Series User manual

Installation Instructions
RDD-Series Rotary Direct Drive Bearingless
Motors
Catalog Numbers RDB-B2901, RDB-B2902, RDB-B2903,
RDB-B4101, RDB-B4102, RDB-B4103
About the Direct Drive Bearingless Motors
RDD-Series direct drive motors feature single-turn or multi-turn high resolution
encoders. These bearingless housed motors provide a compact design for direct
drive applications.
Topic Page
Important User Information 2
Catalog Number Explanation 3
Before You Begin 4
Install the Motor 9
Remove the Motor 19
Connector Data 26
Product Dimensions 27
Specifications 30
Additional Resources 31

2RDD-Series Rotary Direct Drive Bearingless Motor Installation Instructions
Publication RDB-IN002A-EN-P — October 2009
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://literature.rockwellautomation.com 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.
IMPORTANT
Identifies information that is critical for successful application and understanding of
the product.
ATTENTION
Identifies information about practices or circumstances that can lead to personal injury
or death, property damage, or economic loss. Attentions help you identify a hazard,
avoid a hazard and recognize the consequences.
SHOCK HAZARD
Labels may be 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 on or inside the equipment, for example, a drive or motor, to alert
people that surfaces may reach dangerous temperatures.

RDD-Series Rotary Direct Drive Bearingless Motor Installation Instructions 3
Publication RDB-IN002A-EN-P — October 2009
Catalog Number Explanation
FACTORY DESIGNATED OPTIONS
AA = Standard
BRAKE
2 = No Brake
CONNECTORS
7 = Circular, Right Angle, Feedback 180° Rotatable
ENCLOSURE/SHAFT
B = IP65 Housing/Blind Bore
T = IP64 Housing/Thru Bore
FEEDBACK
3 = Single-turn High Resolution Heidenhain
7 = Multi-turn High Resolution Heidenhain
NOMINAL SPEED
4 = 200 rpm @ 440V
5 = 250 rpm @ 440V
6 = 375 rpm @ 440V
8 = 625 rpm @ 440V
9 = 750 rpm @ 440V
MAGNET STACKS
1 = One Stack
2 = Two Stacks
3 = Three Stacks
FRAME SIZE - Bolt Circle Diameter
290 = 290 mm
410 = 410 mm
VOLTAGE RATING
A = 200V Class
B = 400V Class
HOUSING TYPE
DB = Direct Drive, Bearingless Housing
BULLETIN NUMBER
R = Premium Permanent Magnet Rotary Servo Motor
RDB-B410 3F-7B72AA

4RDD-Series Rotary Direct Drive Bearingless Motor Installation Instructions
Publication RDB-IN002A-EN-P — October 2009
Before You Begin
Remove all packing material, wedges, and braces from within and around the item.
After unpacking, verify the nameplate catalog number against the purchase order.
1. Remove the motor carefully from its shipping container.
2. Visually inspect the motor, mounting pilot, and encoder for damage.
3. Notify the carrier of any shipping damage immediately.
4. Retain the cardboard cover and protective paper sleeving from the mounting
end of the motor.
ATTENTION
The mounting end of the motor exposes magnetized material within the motor.
Accidental entry of foreign material will harm motor performance.
Always cover the mounting end of motor immediately after removing the motor. This will
greatly reduce magnetic or non-magnetic particles from accidentally entering the motor.

RDD-Series Rotary Direct Drive Bearingless Motor Installation Instructions 5
Publication RDB-IN002A-EN-P — October 2009
Required Tools
These tools are needed to install this product.
These additional tools are needed when removing this product.
Tools Required for Installation Value
Hex bit, 150 mm (6 in.) minimum length 6 mm
Torque wrench Capable of applying at least 65 N•m (50 lb•ft)
Screwdriver Phillips #2
Micrometer N/A
Straight edge
Caliper
Runout indicator
Cleaning cloth
Shaft key (provided)
Additional Tools Required for Removal Value
M6 x 1 x 120 hex bolt or rod
(For RDB-B4103 motor only)
Qty 1
M10 and M12 hex bolts Qty 2 min
Flashlight N/A
Hammer

6RDD-Series Rotary Direct Drive Bearingless Motor Installation Instructions
Publication RDB-IN002A-EN-P — October 2009
Prolonging Motor Life
Thoughtful design and proper maintenance can increase the life of this motor.
Follow these guidelines to maximize the life of the motor:
• Always provide a drip loop in each cable to carry liquids away from the
connection to the motor.
• If design requirements permit, provide shields that protect the motor
housing, shaft, seals, and their junctions from contamination by foreign
matter or fluids.
• Inspect the motor for damage or wear on a regular basis. If damage or
excessive wear is observed, replace the item.
Preventing Electrical Noise
ElectroMagnetic Interference (EMI), commonly called electrical noise, can reduce
motor performance. Effective techniques to counter EMI include filtering the AC
power, using shielded cables, separating signal cables from power wiring, and
practicing good grounding techniques.
Follow these guidelines to avoid the effects of EMI:
• Isolate the power transformers or install line filters on all AC input power
lines.
• Physically separate signal cables from motor cabling and power wiring.
Do not route signal cables with motor and power wires, or over the vent
openings of servo drives.
• Ground all equipment by 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 noisy environments.
Refer to the System Design for Control of Electrical Noise Reference Manual,
publication GMC-RM001, for additional information on reducing the effects of EMI.

RDD-Series Rotary Direct Drive Bearingless Motor Installation Instructions 7
Publication RDB-IN002A-EN-P — October 2009
Build and Route Cables
Knowledgeable cable routing and careful cable construction improves system
performance.
Follow these guidelines to build and install cables:
• Keep wire lengths as short as physically possible.
• Route noise sensitive wiring (encoder, serial, I/O) away from input power
and motor power wiring.
• Separate cables by 0.3 m (1 ft) minimum for every 9 m (30 ft) of parallel
run.
• Ground both ends of the encoder cable shield and twist the signal wire
pairs to prevent electromagnetic interference (EMI) from other equipment.
WARNING
Do not tightly gather or coil the excess length of a power cable. Heat is generated within
a cable whenever power is applied. Always position a power cable so it may freely
dissipate any heat.
A power cable should not be coiled, except for temporary use when building or testing a
machine. If you temporarily coil a power cable, you must also derate the cable to meet
local code or follow an authoritative directive, such as Engineering Section 310.15(C) of
the NEC Handbook.
Failure to observe these safety procedures could result in personal injury or equipment
damage.

8RDD-Series Rotary Direct Drive Bearingless Motor Installation Instructions
Publication RDB-IN002A-EN-P — October 2009
Ground the Shielded Signal Wires within a Power Cable
Always ground the shield on any signal wires inside a power cable. Connecting this
shield to chassis ground reduces the potential for voltage inductance and EMI.
To ground the shield wire on a 2090-CPBM7DF-xxAFxx or 2090-XXNPMF-xxSxx
power cable:
1. Loop the signal wire pair to the overall cable shield as shown in the
diagram.
• Cable 2090-CPBM7DF-xxAFxx (shown) contains one signal wire pair.
• Cable 2090-XXNPMF-xxSxx contains two signal wire pairs.
2. Clamp all signal wire shields and the overall power-cable shield in the
power cable (chassis) ground clamp on the drive.
Grounding of Signal Wire Shields in a Power Cable
SHOCK HAZARD
If any shield on a power cable is not grounded, high voltage can be present on that
shield.
Make sure there is a connection to ground for all shield wires inside a power cable, and
for the overall power cable shield.
Failure to observe safety precautions could result in personal injury or damage to
equipment.
Shielded Signal Wires (one pair shown) within Power
Cable
Overall Power Cable Shield
Signal Wire Shield Contacts Overall Power
Cable Shield
Factory Supplied
Field Modified
All power and signal wire shields must connect to
machine ground.

RDD-Series Rotary Direct Drive Bearingless Motor Installation Instructions 9
Publication RDB-IN002A-EN-P — October 2009
Install the Motor
All motors include a mounting pilot for aligning the motor on the machine.
Preferred fasteners are hardened steel. The installation must comply with all local
regulations and use equipment and installation practices that promote safety and
electromagnetic compatibility.
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 precautions could result in personal injury.
ATTENTION
Servo drive power must be turned off before connecting or disconnecting the cables to the
motor, and if a cable is left disconnected at the motor end.
Arcing or unexpected motion could occur if the feedback, power, or brake cables are
connected or disconnected while power is applied to the servo drive.
Failure to observe these safety procedures could result in personal injury or damage to the
motor and equipment.
ATTENTION
Do not attempt to open or modify this motor.
Only an authorized Allen-Bradley repair center shall service this item. Refer to Rockwell
Automation Support for assistance to locate the nearest repair center.
Failure to observe safety precautions could result in personal injury or damage to
equipment.

10 RDD-Series Rotary Direct Drive Bearingless Motor Installation Instructions
Publication RDB-IN002A-EN-P — October 2009
Preparing the Motor for Installation
Follow these steps to prepare a motor for installation.
1. Verify sufficient clearance, heatsink mass, and air flow for the motor so it
stays within the operating temperature range of 0…40 °C (32…104 °F).
Do not enclose the motor unless cooling air is forced across the motor, and
keep other heat producing devices away from the motor. Heatsink
requirements are listed in a footnote to the Specifications table.
2. Wipe the shaft and the rotor hub to remove excess grease or other
contaminants.
A light oil coating is acceptable.
Outer surfaces of a motor can reach high temperatures, 125 °C (275 °F), during operation.
Take precautions to prevent accidental contact with hot surfaces. Consider motor surface
temperature when selecting connections and cables to install on a motor.
Failure to observe safety precautions could result in personal injury or damage to
equipment.
BURN HAZARD

RDD-Series Rotary Direct Drive Bearingless Motor Installation Instructions 11
Publication RDB-IN002A-EN-P — October 2009
Verify Machine Mounting Dimensions
Verify proper fit of the motor to the machine mount by measuring the following
machine mounting dimensions:
1. Verify these dimensions are within the measurement range in the tables:
• Pilot diameter
• Shaft diameter, large and small
• Shaft length, small and overall
2. Verify the Total Indicator Readout (TIR) of these dimensions is less than the
value in the tables when measured with a dial indicator:
• Shaft runout
• Pilot concentricity
• Mounting surface perpendicularity
Machine Mounting Dimensions
Machine
Mounting
Surface
Small Shaft
Diameter Large Shaft Diameter
Pilot
Diameter
Small Shaft Length
Overall Shaft Length
Pilot
Extension

12 RDD-Series Rotary Direct Drive Bearingless Motor Installation Instructions
Publication RDB-IN002A-EN-P — October 2009
RDB-B2901, RDB-B2902, RDB-B2903 Machine Mounting Dimensions
RDB-B4101, RDB-B4102, RDB-B4103 Machine Mounting Dimensions
Attribute Value
Pilot Diameter 232.92…232.96 mm (9.170…9.172 in.)
Shaft Diameter, Small 59.988…59.999 mm (2.3617…2.3622 in.)
Shaft Diameter, Large 69.988…69.999 mm (2.7554…2.7559 in.)
Shaft Length, Small
RDB-Bxxx1
RDB-Bxxx2
RDB-Bxxx3
43.81…44.07 mm (1.725…1.735 in.)
88.01…88.27 mm (3.465…3.475 in.)
124.58…124.84 mm (4.905…4.915 in.)
Shaft Length, Overall
RDB-Bxxx1
RDB-Bxxx2
RDB-Bxxx3
89.42…91.42 mm (3.480…3.600 in.)
132.61…135.61 mm (5.220…5.340 in.)
169.19…172.19 mm (6.660…6.780 in.)
Shaft Runout 0.038 mm (0.0015 in.) max
Pilot Concentricity 0.05 mm (0.002 in.) max
Mounting Surface Perpendicularity 0.05 mm (0.002 in.) max
Attribute Value
Pilot Diameter 333.94…333.98 mm (13.147…13.149 in.)
Shaft Diameter, Small 69.988…69.999 mm (2.7554…2.7559 in.)
Shaft Diameter, Large 79.988…79.999 mm (3.1491…3.1496 in.)
Shaft Length, Small
RDB-Bxxx1
RDB-Bxxx2
RDB-Bxxx3
40.26…40.52 mm (1.585…1.595 in.)
83.69…83.95 mm (3.295…3.305 in.)
118.49…118.75 mm (4.665…4.675 in.)
Shaft Length, Overall
RDB-Bxxx1
RDB-Bxxx2
RDB-Bxxx3
112.55…115.55 mm (4.430…4.550 in.)
166.39…169.39 mm (6.550…6.670 in.)
251.99…254.99 mm (9.920…10.040 in.)
Shaft Runout 0.038 mm (0.0015 in.) max
Pilot Concentricity 0.05 mm (0.002 in.) max
Mounting Surface Perpendicularity 0.05 mm (0.002 in.) max

RDD-Series Rotary Direct Drive Bearingless Motor Installation Instructions 13
Publication RDB-IN002A-EN-P — October 2009
Mount the Motor
Follow these steps to install a motor on the machine.
1. Insert the shaft key (provided) into the keyway of the machine shaft.
Position the point on the shaft key in the direction of the motor, and then
fully seat the key in the slot.
2. Verify the cardboard cover and protective paper sleeving are removed.
3. Slide the motor onto the shaft, and position the motor on the pilot extension
of the machine.
4. Rotate the motor on the machine shaft to align the mounting holes with
those on the machine.
5. Insert a fastener in each of the four (4) mounting holes in the motor
faceplate, and hand-tighten each fastener to secure the motor to the machine
frame.
6. Using an alternating pattern, tighten each fastener within the recommended
torque range.
IMPORTANT
When the shaft key is properly installed, it provides a rigid mechanical
connection with the potential to assist in the alignment of the motor.
Cat. No. Torque Range
RDB-x290x50…65 N•m (40…50 lb•ft)
RDB-x410x135…190 N•m (100…140 lb•ft)
4
1
3
5
5
Motor Mount Extension
on the Machine

14 RDD-Series Rotary Direct Drive Bearingless Motor Installation Instructions
Publication RDB-IN002A-EN-P — October 2009
Remove the End Cover
Loosen each pan head screw with a Phillips screwdriver.
• The RDB-x290xmotor has eight (8) screws to loosen.
• The RDB-x410xmotor has eleven (11) screws to loosen.
IMPORTANT
Do not attempt to remove the pan head screws from the cover. The screws are
attached to the end cover with a mechanical lock-ring.
Foam Holder for Shipping Hardware
End Cover

RDD-Series Rotary Direct Drive Bearingless Motor Installation Instructions 15
Publication RDB-IN002A-EN-P — October 2009
Tighten the Compression Coupling
Follow these steps to secure the motor on the machine shaft.
1. Access the compression coupling bolts through the holes labeled A.
• The RDB-x290xmotor has six (6) bolts to tighten.
• The RDB-x410xmotor has ten (10) bolts to tighten.
2. Moving in a circular pattern, use a 6 mm hex bit to tighten each compression
coupling bolt to the torque value shown in the table, and repeat as listed in
the table.
Torque Value Number of Repetitions
Hand-tighten - 0.1 N•m (1 lb•in.) 1x
13 N•m (10 lb•ft) 2x
20 N•m (15 lb•ft) 2x
30 N•m (22 lb•ft) 2x
30 N•m (22 lb•ft) Until no bolt moves.
IMPORTANT
The torque sequence requires at least eight steps to secure the compression
coupling on the machine shaft. Each step gradually increases the torque value,
until the final value is attained. Several steps are performed a more than once
to verify the torque force is applied evenly to all bolts as they seat.
Tightening the compression coupling in this manner balances the forces applied
by the compression coupling to the machine shaft. This result in a secure
connection with evenly distributed forces that can be more easily released at a
later time.
B
B
B
B
C
C
C
C
B
B
B
B
C
C
C
C
A
A
A
A
AA
A
A
A
A
D
D
RDB-x410x with Rear Cover Removed
(RDB-x4103 is shown)
RDB-x290x with
Rear Cover Removed

16 RDD-Series Rotary Direct Drive Bearingless Motor Installation Instructions
Publication RDB-IN002A-EN-P — October 2009
Remove and Secure the Shipping Hardware
Follow these steps to remove the shipping bolts and set screws that prevent rotor
movement during shipping.
1. Remove the shipping bolt from each hole B using a 6 mm hex bit, and store
each bolt in the foam holder.
There are four (4) shipping bolts total. Refer to the diagram on page 15 for
the location of each hole B.
2. Remove the set screw from each hole C using a 6 mm hex bit, and store
each screw in the foam holder.
There are four (4) set screws total. Refer to the diagram on page 15 for the
location of each hole C.
3. Rotate the shaft or load by hand to verify free rotation of the motor.
Replace the End Cover
Follow these steps to align and secure the end cover in its original position.
1. Verify the O-ring is undamaged, and in position around the inside edge of
the cover.
2. Carefully position the end cover over the motor opening.
3. Rotate the end cover so the alignment mark on the cover aligns with the
corresponding mark on the motor housing.
4. Secure the end cover by tightening the pan head screws with a Phillips
screwdriver.
• The RDB-x290xmotor has eight (8) screws to tighten.
• The RDB-x410xmotor has eleven (11) screws to tighten.

RDD-Series Rotary Direct Drive Bearingless Motor Installation Instructions 17
Publication RDB-IN002A-EN-P — October 2009
Attach Motor Cables
Follow these steps to attach the feedback and power/brake cables after the motor is
mounted.
1. Form a drip loop in the cable before attaching it.
A drip loop creates a low spot in the cable. Gravity causes any liquid to flow
to the low spot and away from the connectors, thereby reducing the
potential for any liquid to enter the connector.
2. If you use a cable with a SpeedTec plug, remove the O-ring from the motor
connector.
The O-ring on the motor connector dampens the effects of vibration at the
cable-to-motor connection. This creates a more secure connection for a
cable with a threaded plug. O-rings interior to the threaded and SpeedTec
plug provide complete environmental sealing for the cable.
ATTENTION
Make sure that cables are installed and restrained to prevent uneven tension or flexing at
the motor-to-cable connections.
Excessive and uneven lateral force at the motor connectors can result in the connector’s
environmental seal opening and closing as the cable flexes.
Failure to observe safety precautions could result in damage to the motor and its
components.
IMPORTANT
The 2090-XXNPMF-xxSxx power cable and the 2090-XXNFMF-Sxx feedback cable require
an O-ring on the motor connector.
Power Connector Feedback Connector
O-ring removed for
SpeedTec plug.
O-ring
Threaded Power Plug - Install O-ring SpeedTec Feedback Plug - Remove O-ring
Align the flat surfaces
before securing connection.

18 RDD-Series Rotary Direct Drive Bearingless Motor Installation Instructions
Publication RDB-IN002A-EN-P — October 2009
3. Carefully align the flat surface on the feedback or power/brake cable plug
with the flat surface on the motor connector.
4. Hand-tighten the collar on the plug to fully seat it on the connector.
• The threaded plug requires five to six revolutions.
• The SpeedTec plug requires approximately one-quarter of a revolution.
Do not apply excessive force when mating the cable plug with the motor
connector. If the plug and connector do not go together with light hand
force, realign the flat surfaces and try again.
IMPORTANT
The connector orientation shown is used to clearly show the alignment marker
on each cable socket.
The recommended orientation when installed positions the connectors at the
bottom of the motor.
TIP
A fully-seated threaded plug leaves a small opening, approximately
1…4 mm (0.04…0.16 in.), between the connector and the plug.
ATTENTION
Keyed connectors and cable plugs must properly align and be hand-tightened the
recommended number of turns.
Improper alignment is indicated by the need for excessive force, such as the use of tools,
to fully seat a plug.
Failure to observe safety precautions could result in damage to the motor and cable, and
their components.

RDD-Series Rotary Direct Drive Bearingless Motor Installation Instructions 19
Publication RDB-IN002A-EN-P — October 2009
Remove the Motor
Remove the motor from a machine as outlined below.
Remove the End Cover
Loosen each pan head screw with a Phillips screwdriver.
• The RDB-x290xmotor has eight (8) screws to loosen.
• The RDB-x410xmotor has eleven (11) screws to loosen.
Outer surfaces of a motor can reach high temperatures, 125 °C (275 °F), during operation.
Take precautions to prevent accidental contact with hot surfaces. Consider motor surface
temperature when selecting connections and cables to install on a motor.
Failure to observe safety precautions could result in personal injury or damage to
equipment.
ATTENTION
Servo drive power must be turned off before connecting or disconnecting the cables to the
motor, and if a cable is left disconnected at the motor end.
Arcing or unexpected motion could occur if the feedback, power, or brake cables are
connected or disconnected while power is applied to the servo drive.
Failure to observe these safety procedures could result in personal injury or damage to the
motor and equipment.
IMPORTANT
Do not attempt to remove the pan head screws from the cover. The screws are affixed to
the end cover with a mechanical lock-ring.
BURN HAZARD

20 RDD-Series Rotary Direct Drive Bearingless Motor Installation Instructions
Publication RDB-IN002A-EN-P — October 2009
Align the Rotor
Follow these steps to align the rotor prior to removing the motor.
1. Use a flashlight to illuminate all holes (A, B and C) in the housing.
To locate the holes, refer to the diagrams on page 15.
2. Turn the shaft by hand until a threaded hole directly aligns with each
hole B, and the hex bolts on the compression coupling are visible through
each hole A.
3. Verify each hole C shows the flat surface of the rotor.
The holes are not evenly spaced. If necessary, continue to slowly rotate the
shaft until the above conditions are met.
IMPORTANT
Correct alignment of holes A and B is critical for the successful release of the
compression coupling and the subsequent removal of the motor.