Pacific Scientific 6445-001-K-N

Description

Rated Voltage: 48 VDC (nominal)
Rated Current (Continuous): 3.8 A RMS per phase
Peak Current (30 seconds): 11.4 A RMS per phase
Rated Speed: 3000 RPM (base speed)
Maximum Speed: 4500 RPM (field-weakened region)
Rated Torque (Continuous): 0.64 Nm (5.7 in-lbs)
Peak Torque (30 seconds): 1.92 Nm (17.0 in-lbs)
Rated Power (Continuous): 200 W
Peak Power (30 seconds): 600 W

Encoder Type: Incremental optical encoder, integrated
Encoder Resolution: 2500 lines per revolution (10,000 counts per revolution, quadrature)
Encoder Output: RS-422 (Differential Line Driver), TTL compatible
Encoder Channel Configuration: A, B, Z (index) — quadrature with index pulse
Encoder Supply Voltage: 5 VDC ± 5% (supplied by drive)
Encoder Maximum Frequency: 2.5 MHz (at 3000 RPM)

Accuracy (Positioning): ±0.05° electrical (with encoder)
Repeatability: ±0.02° electrical
Torque Ripple: Less than 3% peak-to-peak at rated load
Speed Regulation: ±0.1% of set speed (closed-loop)
Thermal Time Constant: 12 minutes (motor body to ambient)
Electrical Time Constant: 0.8 ms
Mechanical Time Constant: 4.5 ms
Rotor Inertia: 1.2 × 10⁻⁴ kg·m² (120 g·cm²)

Operating Temperature Range: 0°C to +50°C (32°F to +122°F) (with derating above 40°C)
Storage Temperature Range: -20°C to +70°C (-4°F to +158°F)
Ambient Humidity: 5% to 95% RH, non-condensing
Altitude: Up to 1000 m (3280 ft) above sea level (derate 1% per 100 m above 1000 m)
Vibration: 5 g, 10–500 Hz (operating); 10 g, 10–500 Hz (survival)
Shock: 30 g, 11 ms half-sine
Ingress Protection: IP54 (shaft seal only; use external filter for IP65+)

Housing Material: Anodized aluminum alloy 6061-T6 (body and end bells)
Shaft Material: Stainless steel 17-4 PH (hardened and ground)
Shaft Diameter: 12.7 mm (0.500″)
Shaft Length: 25.4 mm (1.00″) from face mount
Shaft Keyway: 4 mm × 2.5 mm (DIN 6885) — standard on all units
Bearings: Sealed ball bearings, Class ABEC-5 (front and rear)
Bearing Life (L10): 10,000 hours at rated speed and load
Winding Insulation: Class H (180°C), vacuum-impregnated epoxy
Winding Material: Copper, Class H magnet wire
Magnet Material: Neodymium Iron Boron (NdFeB), N42SH grade
Encoder Disk Material: Glass, chrome-on-glass pattern
Connector: MIL-DTL-5015 circular connector, 10-pin (motor side)
Cable: Shielded, 24 AWG, 1.5 m (5 ft) standard length

Structure:

• NEMA 23 square face-mount flange with 4 × M6 mounting holes on 57 mm bolt circle
• Integral shaft-mounted centrifugal cooling fan on the non-drive end
• 10-pin MIL-DTL-5015 connector on the rear end bell
• Integrated 2500-line optical encoder mounted on the drive end
• Keyed shaft with set screw locking (2 × M3 set screws, 90° apart)
• Overall dimensions (approximate): 114 mm × 57 mm × 57 mm (L × W × H, excluding shaft)
• Weight: 1.8 kg (4.0 lbs) without cable

Working Principle:
The motor uses a three-phase brushless DC design with permanent magnet rotor and stationary copper windings (stator). An external servo drive generates a six-step (trapezoidal) or sinusoidal commutation waveform that energizes the stator windings in sequence, creating a rotating magnetic field. The NdFeB permanent magnet rotor locks to and follows this rotating field, producing smooth, continuous torque without mechanical commutation. The integrated optical encoder provides real-time position feedback to the servo drive, enabling closed-loop position, velocity, and torque control. The encoder generates quadrature A/B pulses for direction and speed, plus an index (Z) pulse once per revolution for absolute reference.

Key Features:

• Brushless design — zero commutator wear, zero arcing, zero brush maintenance
• Integrated 2500-line encoder — eliminates separate encoder mounting and alignment
• NdFeB permanent magnets — high torque density in compact NEMA 23 frame
• Class H insulation (180°C) — superior thermal margin for continuous duty
• Sealed ABEC-5 ball bearings — long life, no lubrication required
• MIL-DTL-5015 connector — robust, keyed, vibration-resistant connection
• Keyed shaft with set screw — positive drive, no slippage
• Shaft-mounted fan cooling — self-ventilated, no external blower required

Advantages:

• Zero brush maintenance — brushless design eliminates the #1 failure mode of DC servo motors
• High torque-to-inertia ratio — fast acceleration and deceleration for dynamic applications
• Low torque ripple (under 3%) — smooth motion at low speeds, no cogging
• Long bearing life (10,000 hours L10) — reduces unplanned downtime
• Compact NEMA 23 form factor — fits in space-constrained machine designs
• Integrated encoder eliminates alignment errors — one component instead of two
• Class H insulation — operates reliably in high-ambient-temperature environments

Applicable Industries:

• CNC Machining Centers — axis drive (X, Y, Z) on milling machines and lathes
• Robotics — joint actuators on articulated and SCARA robots
• Packaging Machinery — high-speed pick-and-place, sealing, and labeling
• Printing & Converting — web tension control, register control
• Semiconductor Equipment — wafer handling, die bonders
• Medical Devices — CT scanner gantries, lab automation
• Textile Machinery — yarn feed, loom control
• Automated Assembly — press fitting, screw driving, inspection systems

Model Series:

Brake Option (Model 6445-002-K-N / 6445-004-K-N):

• Type: Electromagnetic spring-applied, power-released hold brake
• Holding Torque: 2.5 Nm (22 in-lbs) minimum
• Release Voltage: 24 VDC nominal
• Release Time: Less than 15 ms
• Engagement Time: Less than 10 ms

Installation Requirements:

• Mount the motor on a rigid, flat surface using the 4 × M6 mounting holes on the 57 mm bolt circle
• Use torque-controlled fasteners — tighten to 8 Nm (71 in-lbs) maximum
• Align the motor shaft with the driven load shaft using a dial indicator — allowable misalignment: 0.05 mm (0.002″) angular, 0.1 mm (0.004″) parallel
• Use a flexible coupling (bellows or jaw type) — do not use rigid couplings
• Connect the MIL-DTL-5015 connector to the matching drive connector — do not force the keying
• Ground the motor housing to the machine frame using the dedicated grounding lug on the end bell
• Verify the encoder cable shield is grounded at the drive end only (single-point ground)
• Set the shaft set screws to 3 Nm (27 in-lbs) after alignment is confirmed

Usage Precautions:

• Do not exceed the rated voltage of 48 VDC — overvoltage will demagnetize the NdFeB rotor magnets permanently
• Do not exceed the peak current of 11.4 A RMS per phase for more than 30 seconds — winding insulation will degrade
• Do not operate the motor without a servo drive — applying raw DC to the phases will destroy the windings
• Do not run the motor without the cooling fan — the fan is integral to thermal management; do not remove it
• Do not expose the motor to temperatures above 50°C — derate torque by 2% per °C above 40°C
• Do not apply axial loads greater than 25 N (5.6 lbs) to the shaft — this will damage the bearings
• Do not apply radial loads greater than 100 N (22.5 lbs) at the shaft end — use an external bearing support
• Do not disassemble the motor — the encoder and winding are not user-serviceable; contact Pacific Scientific for repair
• Do not use the motor in environments with conductive dust or metal shavings without an IP65 external enclosure — the motor is only IP54 rated
• Verify encoder polarity and phasing with the drive before first energization — reversed A/B channels cause incorrect motion direction

Certifications:

• CE Marked (Machinery Directive 2006/42/EC, EMC Directive 2014/30/EU, Low Voltage Directive 2014/35/EU)
• UL Recognized (File E211762) — motor only (drive must be separately listed)
• RoHS Compliant (Directive 2011/65/EU)
• REACH Compliant (Regulation EC 1907/2006)

Documentation Reference:

• Pacific Scientific 6445 Series Servo Motor Installation Manual (Document 6445-IM-001)
• Pacific Scientific 6445 Series Technical Data Sheet (Document 6445-TDS-001)
• Pacific Scientific Servo Motor Selection Guide (Document 6445-SG-001)
• Pacific Scientific Encoder Wiring Diagram (Document 6445-ENC-001)

Replacement Parts: