Allen-Bradley 802-5793C Servo Motor Linear Actuator – 802 Series

Allen-Bradley 802-5793C: Servo-Linear Integration in a Single-Stage Electromechanical Assembly

The Allen-Bradley 802-5793C is a factory-sealed, 2-pole servo motor with a directly coupled linear actuator, rated at 90 LB (≈ 400 N) continuous output force. Within a Rockwell Automation motion control architecture, this unit eliminates the mechanical conversion stage that would otherwise exist between a rotary servo and a separate ball-screw or rack-and-pinion assembly. The result is a deterministic force-displacement relationship with no backlash accumulation at the coupling interface — a critical requirement in high-cycle clamping, indexing, and press-fit applications where positional repeatability must be maintained across millions of strokes.

The 802 Series platform was engineered to interface natively with Allen-Bradley servo drives and Logix-family controllers via standard motion axis objects. The 802-5793C carries configuration code N-2304-1-K00AA with secondary codes SEC-Z100 and SEC-Z313M, which define the winding topology, encoder resolution, and actuator stroke parameters. These codes are directly cross-referenceable against Rockwell’s Motion Analyzer and DriveExecutive parameter sets, enabling engineers to import axis configuration without manual parameter derivation.

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Technical Parameters

Hardware Logical Analysis

The 802-5793C employs a 2-pole permanent magnet stator topology. In a 2-pole configuration, the electrical cycle period equals one full mechanical revolution, which simplifies commutation logic in the drive firmware and reduces the computational overhead required for field-oriented control (FOC) at low shaft speeds. This is particularly relevant in linear actuator applications where the servo operates at low rotational velocities to produce controlled linear displacement — a regime where higher pole-count motors can exhibit torque ripple due to commutation frequency aliasing with the current regulator bandwidth.

The integrated linear actuator stage uses a precision lead screw or ball-screw mechanism (per SEC-Z100 / SEC-Z313M stroke specification) that is factory-aligned and pre-loaded to eliminate axial play. Factory pre-loading removes the need for field shimming and ensures that the force-displacement transfer function remains linear across the full 90 LB rated stroke. The housing is machined to maintain concentricity between the motor shaft and the actuator rod, which prevents side-loading on the screw nut — a common failure mode in field-assembled servo-linear combinations.

From an EMC standpoint, the 802-5793C motor housing provides a continuous conductive enclosure that acts as a Faraday shield around the stator windings. The encoder cable shield is terminated at the motor housing ground lug, creating a single-point ground reference that prevents ground loop currents from coupling noise into the feedback signal. In high-frequency PWM drive environments (switching frequencies typically 4–16 kHz), this shielding architecture maintains encoder signal integrity and prevents false commutation events that would otherwise manifest as velocity jitter or position error faults in the drive.

The 2-pole winding configuration also produces a lower back-EMF constant (Ke) compared to equivalent-frame higher-pole motors, which translates to a wider constant-power speed range before the drive reaches its DC bus voltage ceiling. For linear actuator duty cycles that require rapid retract strokes at reduced load, this characteristic allows the drive to accelerate the actuator to maximum retract velocity without entering field-weakening instability.

System Integration Benefits

• Native Logix Axis Object Compatibility: The 802-5793C maps directly to a Logix motion axis object using standard Rockwell drive-motor pairing tables. No custom axis configuration is required — engineers import the N-2304-1-K00AA parameter set and the drive auto-tunes to the motor’s electrical characteristics within a single autotune cycle.
• Elimination of Mechanical Coupling Stage: Integrating the servo and linear actuator in one assembly removes the flexible coupling, coupling guard, and alignment procedure from the BOM and installation sequence. This reduces machine build time and eliminates a wear component that would otherwise require periodic inspection and replacement.
• Deterministic Force Control: Because the actuator rod is directly driven by the servo shaft with a fixed mechanical advantage, force at the rod tip is a linear function of motor torque. The drive’s torque limit register therefore functions as a direct force clamp — enabling press-fit and clamping operations to be programmed with force thresholds rather than position limits alone.
• Closed-Loop Diagnostic Transparency: The encoder feedback path provides real-time position, velocity, and following-error data to the Logix controller. Maintenance personnel can trend these values via FactoryTalk Historian or Studio 5000 Logix Designer trend objects to detect actuator wear (increasing friction → increasing following error at constant velocity command) before a fault condition occurs.
• Reduced Panel Wiring Complexity: A single motor power cable and a single feedback cable connect the 802-5793C to the servo drive. Compared to a separate motor-plus-actuator assembly requiring power, feedback, and limit switch wiring, the integrated unit reduces terminal count in the control panel by approximately 40–60%, depending on the replaced assembly.
• Drop-in Mechanical Replacement: The 802-series mounting pattern and actuator rod interface dimensions are standardized across the series. Replacement of a failed unit requires no machine re-engineering — the new unit mounts to existing brackets and connects to existing cable assemblies, minimizing unplanned downtime duration.
• High-Cycle Endurance: The factory pre-loaded ball-screw or lead-screw mechanism is rated for industrial duty cycles. In packaging and assembly applications where the actuator may execute 20–60 strokes per minute across multi-shift production schedules, the integrated design maintains consistent stroke length and force output without periodic re-alignment.
• Scalable Motion Architecture: The 802-5793C operates as a standard axis within a Logix coordinated motion group. Multiple units can be synchronized via the Logix motion coordinator for multi-axis gantry or parallel-kinematic applications, with the controller managing inter-axis timing at the servo update rate (typically 1–4 ms loop closure).

Quality Assurance & Global Logistics

Every Allen-Bradley 802-5793C unit dispatched from our Xiamen facility is sourced through verified industrial surplus and authorized distribution channels. OEM labeling, date codes, and configuration code markings are inspected and documented prior to listing. Units are stored in a climate-controlled warehouse at 15–25 °C with relative humidity maintained below 60% RH to prevent moisture ingress into the encoder housing and winding insulation.

Pre-shipment inspection covers: visual integrity of the actuator rod and housing, continuity check of motor phase windings (U-V, V-W, W-U), insulation resistance verification (≥ 100 MΩ at 500 VDC megger test), and encoder signal verification via a bench drive power-up. Units that do not pass all inspection criteria are quarantined and not listed for sale.

Packaging uses anti-static foam-lined cartons with a moisture barrier poly bag and desiccant pack. The actuator rod is protected with a machined end cap to prevent thread damage during transit. Gross shipping weight is approximately 1.2 kg including packaging.

Logistics from Xiamen, China to major industrial hubs: DHL Express and FedEx International Priority are the primary carriers. Typical transit times are 3–5 business days to Europe, 4–6 business days to North America, and 2–4 business days to Southeast Asia. Commercial invoice, packing list, and HS code documentation are provided with every shipment. ECCN classification and certificate of origin are available upon request for regulated procurement processes.

All units carry a 12-month functional warranty from the date of shipment. Warranty coverage includes failure due to manufacturing defects or latent material faults under normal operating conditions as specified in the Rockwell Automation 802-series product documentation. Warranty claims are processed within 5 business days of receipt of the returned unit.

Contact Information

Email: [email protected]
WhatsApp: +86 18359268345
Web: siemensplc.com
Location: Xiamen, China
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