Rockwell Automation Allen-Bradley MP-Series User manual

Installation Instructions
MP-Series Heavy Duty Electric Cylinders
Catalog Numbers MPAI-A2xxxC, MPAI-B2xxxC, MPAI-A3xxxC, MPAI-B3xxxC,
MPAI-A3xxxE, MPAI-B3xxxE, MPAI-A3xxxR, MPAI-B3xxxR, MPAI-A3xxxS, MPAI-B3xxxS,
MPAI-A4xxxC, MPAI-B4xxxC, MPAI-A4xxxE, MPAI-B4xxxE, MPAI-A4xxxR, MPAI-B4xxxR,
MPAI-A4xxxS, MPAI-B4xxxS MPAI-A5xxxC, MPAI-B5xxxC, MPAI-A5xxxE, MPAI-B5xxxE
Topic Page
Important User Information 2
Catalog Number Explanation 3
About the MP-Series Heavy Duty Electric Cylinders 5
Before You Begin 6
Install the Electric Cylinder 9
Mount the Electric Cylinder 13
Change Connector Orientation 16
Dimensions 17
Connector Data 29
Commissioning 30
Lubrication 46
Troubleshooting 51
Accessories 53
Specifications 64
Additional Resources 66

2 MP-Series Heavy Duty Electric Cylinders
Rockwell Automation Publication MPAI-IN001E-EN-P - March 2012
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, available from your local Rockwell
Automation® sales office or online at http://www.rockwellautomation.com/literature 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.
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.
IMPORTANT
Identifies information that is critical for successful application and understanding of the product.

MP-Series Heavy Duty Electric Cylinders 3
Rockwell Automation Publication MPAI-IN001E-EN-P - March 2012
Catalog Number Explanation
This is the catalog explanation for the MPAI electric cylinders.
Special Feature (1)
Blank = IP67 is standard
W = Food grade (white paint) stainless steel rod
Actuator Mounting
A = Front face, side front, bottom front and rear tapped mounting holes
B = Front trunnion, no tapped mounting holes
C = Rear clevis mount, no tapped mounting holes
(food-grade paint only)
E = Front face mount, front face tapped mounting holes
(food-grade paint only)
Holding Brake
2 = No brake
4 = 24V DC brake
Motor Type
1 = 76 mm (3 in.) stroke length
3 = 150…450 mm (6…18 in.) stroke length
Motor Feedback Type
M = Multi-turn, 1024 sin/cos, absolute encoder, Hiperface protocol(2)
V = Multi-turn, 128 sin/cos, absolute encoder, Hiperface protocol
Mechanical Drive/Screw Lead, Motor Type
C = 5.0 mm/rev ball screw (0.197 in./rev)
E = 10.0 mm/rev ball screw (0.394 in./rev) (2)
R = 5.0 mm/rev roller screw (0.197 in./rev) (2)
S = 10.0 mm/rev roller screw (0.394 in./rev)(2)
Rod Stroke Length
076 = 76.2 mm (3.0 in.) (3)
150 = 152.4 mm (6.0 in.)
300 = 304.8 mm (12.0 in.)
450 = 457.2 mm (18.0 in.) (2)
Actuator Frame Size
2 = 64 mm (2.52 in.)
3 = 83 mm (3.27 in.)
4 = 110 mm (4.33 in.)
5 = 144 mm (5.67 in.)
Voltage Class
A = 200V
B = 400V
Actuator Type
AI = Actuator rod
Actuator Series
MP-Series
(1) The Special Feature field is for customer specific coding.
(2) Not available in the 64 mm (2.25 in.) frame.
(3) 76 mm (3.0 in.) stroke length, is only available in the 64 mm (2.5 in.) and 83 mm (3.27 in.) frames.
MP AI - x x xxx x x x x x -x

4 MP-Series Heavy Duty Electric Cylinders
Rockwell Automation Publication MPAI-IN001E-EN-P - March 2012
This is the catalog explanation for the MPAI electric cylinder accessories.
Stroke Length (1)
76 = 76.2 mm (3.0 in.)
15 = 152.4 mm (6.0 in.)
30 = 304.8 mm (12.0 in.)
45 = 457.2 mm (18.0 in.)
Version Number
01 = If NAx01 = Front flange mount
If NRx01 = Roller screw grease cartridge
If NEx01 = Alignment coupling attachment
21 = NAx21, Front flange mount (stainless steel)
02 = If NAx02 = Front flange mount
If NEx02 = Anti-rotation option
If NRx02 = Ball screw grease cartridge
03 = If NAx03 = Rear clevis mount
If NEx03 = Spherical rod-eye
If NRx03 = Replacement zerk fitting
23 = NEx23, Spherical rod-eye (corrosion resistant)
04 = If NEx04, Rod clevis
If NRx04, Grease plug
24 = NEx24, Rod clevis (stainless steel)
05 = Replacement zerk fitting cap
06 = If NAx06 = Mounting plates kit
If NRx06 = Front wiper seal kit
07 = Front bearing block and wiper kit
Actuator Frame Size
2 = 64 mm (2.52 in.)
3 = 83 mm (3.27 in.)
4 = 110mm (4.33in.)
5 = 144 mm (5.67 in.)
Accessory Type
NA = Accessory mounting
NE = Rod-end accessory
NR = Replacement kit accessory
Actuator Type
AI = Actuator rod
Actuator Series
MP-Series
(1) The Stroke Length field is used only for the anti-rotation guide, catalog number MPAI-NEx02xx.
MP AI -xx xxx xx

MP-Series Heavy Duty Electric Cylinders 5
Rockwell Automation Publication MPAI-IN001E-EN-P - March 2012
About the MP-Series Heavy Duty Electric Cylinders
MP-Series™ electric cylinders feature multi-turn high resolution encoders and are available with
24V DC brakes. The MP-Series motor drives a ball screw or roller screw that converts rotary
motion into linear movement. The linear motion extends or retracts the thrust rod within the
electric cylinder housing.
The MP-Series electric cylinders have been designed for exact positioning at high speeds.
IMPORTANT
The MP-A/Bxxxxxx2x electric cylinders are non-braking. When there is no input torque, the
thrust rod can be moved freely. To achieve self-locking of your motion system, use an electric
cylinder with an integrated brake (catalog number MPAI-A/Bxxxxxx4x).
Item Description
1 Feedback connector
2 Power connector
3 Motor with feedback device
4 Actuator cylinder
5 Threaded mounting holes on front, sides, rear, and bottom surfaces (1)
(1) Trunnion mount electric cylinders, not shown, have threaded mounting holes only on the rear surface.
6 Wrench flats for counteracting torque on thrust rod when installing rod-end accessories
7 Grease fitting (not included on catalog number MPAI-x2xxxC)
8 Thrust rod
8
5
6
3
2
1MP-Series Heavy Duty Electric Cylinder
(MPAI-A3150CM32A is shown)
4
7

6 MP-Series Heavy Duty Electric Cylinders
Rockwell Automation Publication MPAI-IN001E-EN-P - March 2012
Before You Begin
Remove all packing materials from within and around the item. After unpacking, verify the
nameplate catalog number against the purchase order.
1. Remove the polyethylene foam cushioning.
2. Remove the electric cylinder carefully from its shipping container.
Consider the weight of the electric cylinder. Depending on the design, the electric
cylinder can weigh up to 49 kg (108 lb).
Do not rotate the thrust rod. Rotating the thrust rod will cause the home position to be
lost.
3. Visually inspect the electric cylinder for damage.
Closely examine the mounting surface, frame, and thrust rod for defects.
4. Notify the carrier of shipping damage immediately.
Planning Your Installation
Refer to the Kinetix® Motion Control Selection Guide, publication GMC-SG001, for the
specifications and additional products referenced in this section:
•This product can be operated in compliance with the relevant safety regulations, only if
the maximum loading limits are observed.
ATTENTION: Electric cylinders that exceed 23 kg (51 lb) require a two man lift. Do not lift
the electric cylinder by the thrust rod.
ATTENTION: Do not rotate the thrust rod. Rotating the thrust rod will cause the factory
set home position to be lost and require the electric cylinder be homed before its initial
use.
ATTENTION: Do not attempt to open and modify the electric cylinder beyond changing
motor connector orientation as described on page 16, or installing a rear clevis mount as
described on page 12. Only a qualified Allen-Bradley employee can service the internal
working of the electric cylinder.
Failure to observe these safety precautions could result in personal injury or damage to
equipment.
ATTENTION: The electric cylinder is not intended to be used in applications where
side-loading occurs. Loads must be guided and supported. Aligned load with the
line-of-motion of the thrust rod.
Side loading will reduce the lifetime of the electric cylinder.

MP-Series Heavy Duty Electric Cylinders 7
Rockwell Automation Publication MPAI-IN001E-EN-P - March 2012
•If you are mounting your electric cylinder in a vertical or sloping position, include safety
measures that will control the work load, should the spindle nut fail.
•Keep the rod from rotating when in use to achieve consistent linear motion. In most
applications the connection to the load inherently provides anti-rotation. If your work
load is free to rotate when the actuator is attached use the anti-rotate option, catalog
MPAI-NEx02xx, to prevent rotation.
•Corrosive environments reduce the service life of electric cylinders.
•Where possible, install the electric cylinder with the grease fitting facing up. This will
reduce the residual grease from falling or dripping on your application.
•Factory-manufactured feedback and power cables are available in standard cable lengths.
They provide environmental sealing and shield termination. Contact your
Allen-Bradley® sales office or refer to the Kinetix Motion Control Selection Guide,
publication GMC-SG001, for additional information.
Prolonging Electric Cylinder Life
Thoughtful design and proper maintenance can increase the life of an electric cylinder. Follow
these guidelines to maximize the life of a electric cylinder especially within a food processing
environment:
•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, thrust
rod, seals, and their junctions from contamination by foreign matter or fluids.
•Replace the thrust rod seals at or before its expected lifetime of 12-months.
Refer to page 59 for catalog information on thrust rod seals.
•Inspect the seals for damage or wear on a regular basis. If damage or excessive wear is
observed, replace the item.
ATTENTION: Uncontrolled moving masses can cause injury or damage to property.
If there is a spindle nut fracture inside the actuator cylinder due to wear, the working
mass will drop down.
Check whether additional external safety measures are required to prevent damage in
the event of a spindle nut fracture.

8 MP-Series Heavy Duty Electric Cylinders
Rockwell Automation Publication MPAI-IN001E-EN-P - March 2012
Electric Cylinders with Brake Option
The brake option on this servo motor is a spring-set holding brake that releases when voltage is
applied to the brake coil. A separate power source is required to disengage the brake. This power
source can be applied by a servo motor controller or 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 system,
increases brake wear, and reduces brake life.
An unpowered electric cylinder will require a brake to maintain its position if the force on the
actuator exceeds the Back Drive Force listed in Kinetix Linear Motion Specifications Technical
Data, publication GMC-TD002.
A brake can be use with the actuator to keep it from backdriving, typically in vertical
applications. A brake may be used for safety reasons or for energy savings allowing the actuator to
hold position when unpowered.
Preventing Electrical Noise
Electromagnetic interference (EMI), commonly called electrical noise, can reduce motor
performance. Effective techniques to counter EMI include filtering the AC power, by 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 System Design for Control of Electrical Noise Reference Manual, publication
GMC-RM001, for additional information on reducing the effects of EMI.
IMPORTANT
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.

MP-Series Heavy Duty Electric Cylinders 9
Rockwell Automation Publication MPAI-IN001E-EN-P - March 2012
Build and Route Cables
Knowledgeable cable routing and careful cable construction improves system electromagnetic
compatibility (EMC).
To build and install cables, perform these steps.
1. Keep wire lengths as short as physically possible.
2. Route signal cables (encoder or serial) away from motor and power wiring.
3. Separate cables by 0.3 m (1 ft) minimum for every 9 m (30 ft) of parallel run.
4. Ground both ends of the encoder cable shield and twist the signal wire pairs to prevent
electromagnetic interference (EMI) from other equipment.
Install the Electric Cylinder
The installation must comply with all local regulations and use of equipment and installation
practices that promote electromagnetic compatibility and safety.
Follow these steps to prepare the electric cylinder for installation on the machine.
1. Provide sufficient clearances in the area of the electric cylinder for it to stay within its
specified operating temperature range.
Refer to Specifications on page 64 for the operating temperature range. Do not enclose
the electric cylinder unless forced air is blown across the electric cylinder for cooling.
Keep other heat producing devices away from the electric cylinder.
2. Make sure the mounting surface supports the electric cylinder evenly so that it is free of
mechanical stress and distortion.
•Evenness of the mounting surface must be within 0.127 mm (0.005 in.).
•The thrust rod must be parallel to the guide within 0.0254 mm (0.010 in.).
ATTENTION: High voltage can be present on the shield of a power cable, if the shield is not
grounded.
Make sure there is a connection to ground for any power cable shield.
Failure to observe these safety precautions could result in personal injury or damage to equipment.
ATTENTION: Unmounted electric cylinders, disconnected mechanical couplings, and disconnected
cables are dangerous if power is applied.
Appropriately identify (tag-out) disassembled equipment, and restrict (lock-out) access to
electrical power.
Failure to observe these safety precautions could result in personal injury.

10 MP-Series Heavy Duty Electric Cylinders
Rockwell Automation Publication MPAI-IN001E-EN-P - March 2012
3. Attach mounting accessories, shown on page 53, to the electric cylinder.
Use these torque values to attach mounting accessories to the cylinder.
If desired, you may seal the actuator front flange to the drive equipment by applying a
bead of food grade RTV around the periphery of the join between the actuator and the
machine surface. Use of a gasket or RTV on the mating surface is not recommended, as
this can cause the misalignment of the shaft and result in damage to the actuator and the
driven equipment.
4. Attach rod-end accessories, see on page 54, to the work load as outlined below.
Be sure the work load center of gravity is centric to the thrust rod.
5. Use these torque values to attach a rod eye or rod clevis to the thrust rod.
ATTENTION: Proper attachment of the rear clevis mount is important to achieving an
IP67 rating. Refer to Installing the Rear Clevis Mounting Kit on page 12.
Failure to observe precautionary steps could result in damage to the electric cylinder
and its components.
Frame
Size Mounting Plates Front FlangeRear Clevis (1)
(1) Rear clevis requires removal of the end cap from the electric cylinder. If the cylinder is opened, take precautions to avoid
contamination and then reseal the cylinder so an IP67 rating is achieved.
Torque, max (2) (3)
(2) Unless otherwise noted, torque specifications have a ±20% tolerance.
(3) The anti-rotation guide is not included in this step. Refer to page 11 for anti-rotation guide torque values.
64 MPAI-NA206 MPAI-NA202 MPAI-NA203 13.2 N•m (117 lb•in)
83 MPAI-NA306 MPAI-NA302 MPAI-NA303
39.5 N•m (29.1 lb•ft)
110 MPAI-NA406 MPAI-NA402 MPAI-NA403
144 MPAI-NA506 MPAI-NA502 MPAI-NA503 56.5 N•m (41.7 lb•ft)
ATTENTION: Damage may occur to the electric cylinder bearings and the feedback
device if sharp impact to the thrust rod is applied during installation. Do not strike the
thrust rod with tools during installation or removal.
Failure to observe these safety precautions could result in damage to the electric cylinder
and its components.
Frame
Size
Thrust Rod
Thread Wrench Flats Width Torque, max (1)
(1) Unless otherwise noted, torque specifications have a ±20% tolerance.
64 M10 x 1.25 22.99 mm (.905 in.) 24.4 N•m (18.0 lb•ft)
83 M16 x 1.5 26.97 mm (1.062 in.) 61.0 N•m (45.0 lb•ft)
110 M20 x 1.5 38.08 mm (1.489 in.) 76.3 N•m (56.3 lb•ft)
114 M27 x 2.0 53.98 mm (2.125 in.) 135.6 N•m (100.0 lb•ft)
Wrench
Flats