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MagneMover LITE User Manual

1

Rockwell Automation Publication MMI-UM002E-EN-P - March 2016

Installation

5

Overview

This chapter provides complete installation procedures for the various configurations of the 
MagneMover

®

 LITE components and transport systems.

Included in this chapter are:

•

Unpacking and inspection of the MagneMover LITE transport system components.

•

MagneMover LITE component installation including: hardware installation, facilities 
connections, and software installation and configuration.

•

Initial power-up and check-out.

•

Transport system testing using demonstration scripts.

Summary of Contents for MagneMover LITE

Page 1: ...MagneMover LITE User Manual ...

Page 2: ... respective owners This product is protected under one or more U S and International patents Additional U S and International patents pending 2011 2016 MagneMotion Inc All Rights Reserved The information included in this manual is MagneMotion Inc proprietary information and is provided for the use of MagneMotion Inc customers only and cannot be used for distribution reproduction or sale without th...

Page 3: ...otion Documentation xxiv Manual Conventions xxiv Notes Safety Notices and Symbols xxv Manual Structure xxvi Related Documentation xxvii Contact Information xxvii 1 Introduction Overview 1 1 MagneMover LITE Overview 1 2 MagneMover LITE Transport System Components 1 3 MagneMover Transport System Options 1 4 Precision Rails 1 4 Precision Locator 1 6 Transport System Overview 1 7 Transport System Soft...

Page 4: ...ion Rail Option Components 2 18 Precision Locator Option Components 2 20 Mechanical Hazards 2 22 Electrical Hazards 2 23 Pneumatic Hazards 2 24 Magnetic Hazards 2 25 Handling Magnet Arrays 2 26 Shipping Magnet Arrays 2 27 Recycling and Disposal Information 2 28 MagneMover LITE Transport System 2 28 Node Controllers 2 28 Magnet Arrays 2 28 3 Design Guidelines Overview 3 1 Transport System Layout 3 ...

Page 5: ...t Materials 3 24 Motor Mounts 3 24 Motor Mounting Methods 3 25 System Stands 3 28 Custom Motor Mounting 3 29 Puck Carrier 3 31 Cantilevered Loads 3 31 Transport System Options 3 33 Precision Rail 3 33 Precision Rails 3 34 Spine Plates 3 36 Support Post Assembly 3 37 Vehicles 3 38 Precision Rail Installation 3 39 Precision Locator 3 40 Precision Locators 3 40 Locator Stand 3 40 Pallet 3 41 Pallet D...

Page 6: ...ics Mounting Plate 4 24 MM LITE Power Supply 4 25 Precision Rail Option 4 26 Precision Rails 4 26 Precision Rail Single Array Vehicle 4 27 Precision Rail Dual Array Vehicle 4 28 Precision Rail Support Post Assembly 4 29 Spine Plates 4 30 Precision Locator Option 4 34 Actuator Assembly 4 34 Stand Assembly 4 35 Adjustable Motor Mount Bracket 4 36 Pallet 4 37 Electrical Specifications 4 38 Motors and...

Page 7: ...ucks Precision Rail Vehicles 4 67 Lighting Site 4 67 Floor Space and Loading 4 67 Facilities 4 67 Service Access 4 68 5 Installation Overview 5 1 Unpacking and Inspection 5 2 Unpacking and Moving 5 3 Required Tools and Materials 5 3 Unpacking and Moving Instructions 5 3 Transport System Installation 5 5 Installing Hardware 5 5 Required Tools and Materials 5 5 Installation Overview User Supplied Mo...

Page 8: ...ure Rails to Spine Plates 5 50 Secure Spine Plates to Support Posts 5 53 Install the Precision Rail Vehicles 5 53 Precision Locator Installation 5 54 Install Pallets and Pucks 5 55 Install the Precision Locators on the Stands 5 56 Install the Precision Locator Assemblies 5 56 Install the Motors 5 56 Install the Pneumatic Controls 5 58 Install the Covers 5 59 Teach the Precision Locator Position 5 ...

Page 9: ...ving Vehicles by Hand 6 8 Electrical System 6 10 Controls and Indicators 6 11 Track Display 6 11 Synchronization 6 12 E Stops 6 13 Interlocks 6 15 FastStop 6 16 Light Stacks 6 17 Digital I O 6 18 Transport System Simulation 6 19 Configuring a Simulation 6 19 Running a Simulation 6 21 Stopping a Simulation 6 22 Return the System to Normal Operation 6 22 Precision Rail Operation 6 24 Setup 6 24 Oper...

Page 10: ...Troubleshooting 7 21 Contact MagneMotion Technical Support 7 22 Repair 7 23 Adjust G3 Motors to Eliminate Rail Binding 7 25 Connect and Secure G3 Motors and G3 Switches 7 27 Connect G3 Motors and G4 Motors 7 29 Replacing Motors 7 31 Remove the Existing Motor 7 31 Install the New Motor 7 32 Programming Motors 7 33 Separating Magnet Arrays 7 34 Replace Pucks 7 35 Remove Pucks 7 36 Install Pucks 7 37...

Page 11: ...gs on Pallet 7 67 Replacing Pins on Precision Locator Arms 7 69 Replacing Z Datums on Precision Locator Stand 7 71 Ordering Parts 7 73 Shipping 7 74 Packing Procedure 7 75 Shipping Components 7 76 Shipping Systems or System Sections 7 76 Appendix Overview A 1 File Maintenance A 2 Backup Files A 2 Creating Backup Files A 2 Restoring from Backup Files A 2 Additional Documentation A 3 Release Notes A...

Page 12: ...Contents x MagneMotion Rockwell Automation Publication MMI UM002E EN P March 2016 This page intentionally left blank ...

Page 13: ...e Controller LITE 2 16 2 9 Locations of Labels on the MM LITE Power Supply 2 17 2 10 Locations of Labels on the Precision Rail Vehicles single array shown 2 18 2 11 Locations of Labels on the Precision Rail Spine Plates 2 19 2 12 Locations of Labels on the Precision Locator 2 20 2 13 Locations of Labels on the Precision Locator Puck 2 21 3 1 Sample MM LITE Transport System Layout Showing Motors 3 ...

Page 14: ...hanical Drawing G4 4 8 4 7 Left Switch Mechanical Drawing G4 4 9 4 8 Right Switch Mechanical Drawing G4 4 10 4 9 Standard Motor Mount Bracket Mechanical Drawing G4 4 11 4 10 Stand System Mechanical Drawing 4 12 4 11 Puck Mechanical Drawing G4 4 13 4 12 Puck Mechanical Drawing G4 2 4 14 4 13 Puck Mechanical Drawing G4 3 4 15 4 14 Tandem Puck Mechanical Drawing G4 4 16 4 15 Tandem Puck Mechanical Dr...

Page 15: ...uits 4 65 5 1 Connecting Beam Sections 5 11 5 2 Leg on a Single Path Beam Assembly 5 12 5 3 Legs on a Parallel Path Beam Assembly 5 13 5 4 Angle Bracket Assembly 5 14 5 5 System Leveling 5 15 5 6 Bracket Tie down 5 16 5 7 Foot Tie down 5 17 5 8 Installing Cable Chase Cover Mounting Brackets 5 18 5 9 Installing Motor Mounts on Motors and Switches 5 19 5 10 Installing Motors and Switches 5 20 5 11 P...

Page 16: ...r MagneMover LITE Motor Block 6 4 6 4 Vehicle Movement Profile 6 7 6 5 The Graphics Window 6 11 6 6 Transport System Wiring Diagram with Synchronization 6 12 6 7 E Stop Wiring Diagram Single Node Controller 6 14 6 8 E Stop Wiring Diagram Multiple Node Controllers 6 14 6 9 Interlock Wiring Diagram 6 15 6 10 Light Stack Wiring Diagram 6 17 7 1 Puck Cleaning 7 4 7 2 Precision Rail Vehicle Lubricating...

Page 17: ... Rail Vehicle Assembly 7 56 7 25 Precision Rail Vehicle Bearing Locations 7 59 7 26 Precision Rail Vehicle Concentric Bearings Disassembly Assembly 7 60 7 27 Precision Rail Vehicle Eccentric Bearings Disassembly Assembly 7 62 7 28 Remove Precision Locator Pallet from Magnet Assembly 7 65 7 29 Replace Bushings on Precision Locator Pallet 7 68 7 30 Replace Pins on Precision Locator Arms 7 69 7 31 Re...

Page 18: ...Figures xvi MagneMotion Rockwell Automation Publication MMI UM002E EN P March 2016 This page intentionally left blank ...

Page 19: ...cision Locator 2 20 2 14 Labels Used on the Precision Locator Pucks 2 21 3 1 Motor Assignments 3 4 3 2 MagneMover LITE Motor Blocks 3 10 3 3 MagneMover Light Thrust Force Guideline 3 10 3 4 Stand System Heights 3 28 3 5 Stand System Widths 3 28 3 6 Puck Carrier Overhang Limits 3 31 3 7 Precision Rail Types and Lengths 3 35 4 1 MagneMover LITE Motor and Switch Power Requirements 4 38 4 2 MagneMover...

Page 20: ... Sensor Pinout 4 60 4 30 Precision Locator Pneumatic Requirements 4 61 4 31 Precision Locator Connections 4 61 4 32 RS 422 Cable Pinouts 4 64 5 1 MagneMover LITE Component Packing Checklist Reference 5 2 5 2 Motor Mount Reference 5 21 5 3 Precision Rail to Spine Plate Attachment Screws 5 49 5 4 Startup Indicators 5 68 6 1 Simulated Operation Differences 6 21 7 1 MagneMover LITE Preventive Maintena...

Page 21: ...l drawings for the switches motor bracket tandem puck Node Controllers and power supply Added electrical connection and indicator information for the Node Controllers and power supply Added power and communication cable information Added procedures for securing the system to the floor using a bracket and for mounting the system electronics on the frame Added digital I O connection information and ...

Page 22: ...E G4 motors Updated the Transport System Overview to include the NC 12 Node Controller Updated the Transport System Software Overview to include new Type Files and updated the descriptions of existing Type Files Updated all mag net safety warnings and added to Personnel Safety Guidelines Updated all figures to show current labeling Updated the Recycling and Disposal Information to include all Node...

Page 23: ...e Standard Node Controller including software spare parts technical support and service continues to be available Removed all references to the MM LITE G3 series motors switches and pucks which have been replaced by the G4 series motors switches and pucks The G3 series motors switches and pucks are discontinued items and are not UL Recognized Support for the G3 series motors switches and pucks inc...

Page 24: ...nts for each component and corrected the temperature range for the magnet arrays Updated the Transport System Installation procedures Moved MagneMover LITE Transport System Advantages forward in the Theory of Operation Updated the descriptions of In Queue and Vehicle Length Through Curves and Switches Corrected the thrust specs in the Transport System Limits Updated all Troubleshooting charts Upda...

Page 25: ...he other manuals and documentation that accompanies the transport system along with the training classes offered by MagneMotion Inc to design install configure test and operate an MM LITE transport system Audience This manual is intended for all users of MagneMover LITE transport systems and provides information on how to install configure and operate the MM LITE transport system Prerequisites Thi...

Page 26: ...e in quick succession Control click Hold down Ctrl and press and release the left mouse button Click and hold Press down the left mouse button and hold it down while moving the mouse Select Highlight a menu item with the mouse or the tab or arrow keys Selectable menu choices option titles button check box and text box function titles and area or field titles in dialog boxes are shown in bold type ...

Page 27: ... Symbols used within this manual have very specific meanings and formats Examples of notes and the different types of safety notices and their general mean ings are provided below Adhere to all safety notices provided throughout this manual to ensure safe installation and use Notes Notes are set apart from other text and provide additional or explanatory information The text for Notes is in standa...

Page 28: ...ver LITE transport systems Specifications and Site Requirements Provides specifications and the requirements for installation of the MM LITE components as a transport system Installation Provides complete installation procedures for the MM LITE components Operation Provides complete operation directions for the MM LITE components as part of a transport system Maintenance Provides maintenance sched...

Page 29: ... Protocol User s Manual 990000436 Host Controller EtherNet IP Communication Protocol User s Manual 990000437 or Mitsubishi PLC TCP IP Library User s Manual 990000628 MagneMover LITE User s Manual 990000410 this manual LSM Synchronization Option User s Manual 990000447 Virtual Scope Utility User s Manual 990000759 NOTE Distribution of this manual and all addendums and attachments are not controlled...

Page 30: ...About This Manual xxviii MagneMotion Rockwell Automation Publication MMI UM002E EN P March 2016 This page intentionally left blank ...

Page 31: ... system Use this manual to install test and debug the MagneMover LITE components in a transport system Note that some procedures may vary based on the transport system configuration communications and other variables This manual supports MagneMover LITE transport systems Included in this chapter are overviews of The MagneMover LITE components and options in a transport system The transport system ...

Page 32: ...E provides repeatable positioning with no hard stops required bidi rectional travel smooth motion and continuous vehicle puck tracking and reporting Motor drive controller positioning and guidance built into the motor Servo repeatability at any position 0 5 mm 0 02 in straight motors only not applicable over the gaps between motors Servo repeatability at process stations 0 1 mm 0 004 in straight m...

Page 33: ...profiles PID control loop for fast and easy changeovers to new con figurations Standard motor and configuration elements provide plug and play capability and make it easy to implement layout changes MagneMover LITE Transport System Components Figure 1 1 Detailed View of MagneMover LITE Transport System Components Beam The structure mounted to the transport system legs that provides a rigid mountin...

Page 34: ...t motor and one curve motor enclosed in one module to provide either a merge of two Paths into one or a diverge from one Path into two System Leg Stand System Used to support the MagneMover LITE transport sys tem V Brace Used to align and secure adjacent sections of the guide rail to each other MagneMover Transport System Options Precision Rails The Precision Rail option provides customized stainl...

Page 35: ...ate located at the top of the assembly supports the rail components while the post mount located at the bottom of the assembly attaches to the underlying support structure to provide structural integrity throughout the system Spine Plate Attaches to the top of a support post assembly and provides a means for securing and interconnecting the rail segments within the Precision Rail system Precision ...

Page 36: ...cured in the Precision Locator 500 N 112 lbf higher loads possible based on pallet design Actuator position sensor option Figure 1 3 Detailed View of MagneMover LITE Precision Locator Components Pallet Carries the user s payload Replaces the standard puck s top plate May be provided by MagneMotion or custom designed by the user for their application Precision Locator Pneumatic mechanism used to fu...

Page 37: ...ed by the user it can be either PC based or a PLC Motor Refers to the MagneMover LITE linear synchronous motor LSM Network Ethernet network providing communications TCP IP or EtherNet IP between the Host Controller and the HLC TCP IP is used between Node Controllers Node Controller NC Coordinates motor operations and communicates with the High Level Controller Two types of Node Controllers are ava...

Page 38: ...agneMotion resident on the Node Controllers for administration of the Node Controller NCHost TCP Interface Utility A Windows software application supplied by MagneMotion to move vehicles pucks for test or demonstration purposes without the Host Controller to verify that vehicles move correctly before integrating a transport system into a production environment User s Host Controller EtherNet IP or...

Page 39: ...les XML files motor_type xml that contain basic information about the specific MagneMover LITE motor types being used The Motor Type Files are uploaded to all Node Controllers in the transport system Magnet Array Type Files XML files magnet_array_type xml that contain basic information about the specific MagneMotion magnet array type used on the vehicles pucks in the MagneMover LITE transport syst...

Page 40: ...cations are a PC running Microsoft Windows 7 with NET 4 0 and an Ethernet port 2 Install the components of the MM LITE transport system as described in the following sections of this manual A Prepare the facility for the installation Safety Considerations on page 2 4 Design Guidelines on page 3 1 Site Requirements on page 4 66 B Prepare the components for installation and install Unpacking and Ins...

Page 41: ... and the NCHost TCP Interface Utility User s Manual This provides an easy method to verify proper opera tion and make adjustments such as refining the control loop tuning NOTE The NCHost TCP Interface Utility is for test and verification trials only The user s Host Controller must be used to control the MagneMover LITE trans port system after verification of functionality 8 Configure the Host Cont...

Page 42: ...Introduction 12 MagneMotion Rockwell Automation Publication MMI UM002E EN P March 2016 This page intentionally left blank ...

Page 43: ...e facility where the Magne Mover LITE components are installed in a transport system has additional safety guidelines they should be followed as well along with the applicable local and national safety codes If any additional safety related upgrades or newly identified hazards associated with the Mag neMover LITE components are identified the Technical Support group will notify the owner of record...

Page 44: ...liance of the installed MagneMover LITE transport system with the appropriate facility local and national regulations EU RoHS and EU WEEE Compliance MagneMotion products are considered parts of a Large scale Fixed Installation and as a Large scale Stationary Industrial Tool for purposes of the European Union s RoHS and WEE Directives and are therefore exempt from mandatory compliance The CE Markin...

Page 45: ...ity for work performed by MagneMotion authorized tech nicians or for equipment transported or resold by the owner of record is determined on a case by case basis by MagneMotion Technical Support Any parts being returned to MagneMotion should be packaged according to the instructions provided in the Packing Procedure on page 7 75 MagneMotion provides training for the MagneMover LITE components as i...

Page 46: ...hese individuals must consult their physician to determine their device s susceptibility to static magnetic fields and to determine a safe distance between themselves and the magnet array Handle only one vehicle puck magnet array at a time Do not place any body parts such as fingers between the magnet array being handled and any ferrous material or another magnet array to avoid injury from strong ...

Page 47: ...Follow all facility local and national procedures for the disposal of any hazardous materials Ergonomic hazards may exist with certain installation or service operations pertaining to the MagneMover LITE transport system Equipment Safety Guidelines The following safety considerations are provided to aid in the placement and use of the Mag neMover LITE transport systems If hazardous materials are t...

Page 48: ...ts for any purpose other than as a linear transport system is not recommended and may cause damage to the MagneMover LITE components or the equipment they are connected to Always operate the MagneMover LITE transport system with appropriate barriers in place to prevent contact with moving objects by personnel Do not install or operate the MagneMover LITE transport system if any of the compo nents ...

Page 49: ... March 2016 MagneMover LITE Transport System Hazard Locations Figure 2 1 Locations of Hazardous Points on the MagneMover LITE Transport System Switch typical Mechanical Hazard Pinch Point Guideway typical Mechanical Hazard Pinch Point Vehicle Puck typical Mechanical Hazard Pinch Point Magnetic Field Hazard ...

Page 50: ...EN P March 2016 Precision Rail Option Hazard Locations Figure 2 2 Locations of Hazardous Points on the Precision Rail Option Rail Mounting typical Mechanical Hazard Pinch Point Rail typical Mechanical Hazard Pinch Point Vehicle typical Mechanical Hazard Pinch Point Magnetic Field Hazard ...

Page 51: ...tion Publication MMI UM002E EN P March 2016 Precision Locator Option Hazard Locations Figure 2 3 Locations of Hazardous Points on the Precision Locator Option Locator Arm Mechanical Hazard Cover Removed Locator Drive Mechanical Hazard Pinch Point normally covered Pinch Point ...

Page 52: ... or equip ment damage Lifting Hazard Indicates the specified object is heavy or awkward to han dle Personnel should use lifting aids and proper lifting techniques to avoid muscle strain or back injury Automatic Start Hazard Indicates the possibility of machinery automati cally starting or moving which could cause personal injury Hazardous Voltage Indicates a severe shock hazard is present that cou...

Page 53: ...isconnected using a method that prevents accidental reconnection Table 2 4 Prohibited Action Symbol Identification Symbol Description Magnetic or Electronic Media Prohibited Indicates that magnetic media memory disks chips credit cards tapes etc is not allowed in the specified area due to the possibility of damage to the media Metal Parts or Watches Prohibited Indicates that watches instruments el...

Page 54: ...ls to be visible only during maintenance operations The following tables list the labels that are affixed to the individual MagneMover LITE com ponents These labels are used to alert personnel to hazards on or within the MM LITE com ponents and to provide information about the components The figure after each table shows the location of each label identified in the table To replace a lost or damag...

Page 55: ...ty 1 Location On the bottom of the switch MAC ID Label Qty 1 Location On the bottom of the switch Pinch Hazard Label Qty 1 Location On the top of the switch Hazard Type Pinch Crush Possible injuries Pinch between vehicle puck and switch rail S N 1A 2B 3C 4D 5E 6F MAC A TE IN TE G B U R N TE S TE D Mad e in USA ww w ma gn em oti on co m XX VDC X X A Typ X X A Max S N P N 70 0 13 08 XX S N 13 09 01 ...

Page 56: ...Arrays and Pucks Table 2 7 Labels Used on the MagneMover LITE Magnet Arrays and Pucks Serial Number Label Qty 2 Location On the sides of the magnet array Magnet Hazard Label Qty 2 Location On the sides of the magnet array Hazard Type Magnetic field Possible injuries Pinch between magnet arrays danger to pacemakers and other electronics Magnet Hazard Label Serial Number Label ...

Page 57: ...s of Labels on the NC 12 Node Controller Table 2 8 Labels Used on the NC 12 Node Controller Product Information Label Qty 1 Location On the back of the NC 12 Node Controller MAC ID Label Qty 1 Location On the back of the NC 12 Node Controller S N 1A 2B 3C 4D 5E 6F MAC ATE BURN TESTED S N 130901234 MAC 1A 2B 3C 4D 5E 6F Information Label MAC ID Label ...

Page 58: ...Locations of Labels on the Node Controller LITE Table 2 9 Labels Used on the Node Controller LITE Product Information Label Qty 1 Location On the top of the Node Controller LITE MAC ID Label Qty 1 Location On the top of the Node Controller LITE S N 1A 2B 3C 4D 5E 6F MAC PW R LAN 18 VDC PoE ON LY Information Label MAC ID Label ...

Page 59: ...ower Supply Table 2 10 Labels Used on the MM LITE Power Supply Product Information Label Qty 1 Location On the bottom of the power supply P N 110 0001 00 S N X110400001 100 240 VAC 50 60 Hz 8 5A T 250V 10A Fuse www magnemotion com Made in USA P N 110 0001 00 S N X110400001 100 240 VAC 50 60 Hz 8 5 A T 250V 10A Fuse w w w m a g n e m o ti o n c o m Made in US A Information Label ...

Page 60: ... Precision Rail Vehicles Vehicle Serial Number Label Qty 1 Location On the body of the vehicle Magnet Array Serial Number Label Qty 2 per array Location On the sides of the magnet array Magnet Hazard Label Qty 2 per array Location On the sides of the magnet array Hazard Type Magnetic field Possible injuries Pinch between magnet arrays danger to pacemakers and other electronics Magnet Hazard Label ...

Page 61: ... March 2016 Figure 2 11 Locations of Labels on the Precision Rail Spine Plates Table 2 12 Labels Used on the Precision Rail Spine Plates Pinch Hazard Label Qty 1 Location On the top surface of the Spine Plate Hazard Type Pinch Crush Possible injuries Pinch between vehicle and spine plate post or rail Pinch Hazard Label ...

Page 62: ...gure 2 12 Locations of Labels on the Precision Locator Table 2 13 Labels Used on the Precision Locator Serial Number Label Qty 1 Location On the side of the housing Pinch Hazard Label Qty 1 Location On the front of the housing Hazard Type Pinch Crush Possible injuries Pinch between rocker arms and housing or pallet Pinch Hazard Label Serial Number Label ...

Page 63: ...e Precision Locator Puck Table 2 14 Labels Used on the Precision Locator Pucks Serial Number Label Qty 2 Location On the sides of the magnet array Magnet Hazard Label Qty 2 Location On the sides of the magnet array Hazard Type Magnetic field Possible injuries Pinch between magnet arrays danger to pacemakers and other electronics Magnet Hazard Label Serial Number Label ...

Page 64: ...utions specified within the facility where the MM LITE components are being used CAUTION Crush Hazard Moving mechanisms have no obstruction sensors Do not operate the MagneMover LITE components without barriers in place or personal injury could result in the squeez ing or compression of fingers hands or other body parts between moving mechanisms CAUTION Automatic Movement Hazard Whenever power is ...

Page 65: ...nents are being used WARNING Electrical Hazard All electrical power to the MagneMover LITE transport sys tem must be disconnected per the facility s lockout tagout procedure before servicing to prevent the risk of electrical shock CAUTION Electrical Hazard To avoid electric shock do not open any MagneMover LITE component Motors controllers and other components do not contain any user serviceable p...

Page 66: ...cility lockout tagout pro cedures and any other specified action within the facility where the Precision Locator is being used The MagneMover LITE Precision Locator option is a low energy device no additional pneu matic safety precautions are required CAUTION Pneumatic Hazard All pneumatic power to the MagneMover LITE transport system must be disconnected per the facility s lockout tagout procedur...

Page 67: ...lectronic implants must stay away from the magnet array on the vehicles pucks CAUTION Crush Hazard Strong magnets in use To avoid injury from strong magnetic attractive forces Handle only one vehicle puck or magnet array at a time Do not place any body parts such as fingers between a magnet array and any ferrous material or another magnet array Vehicles pucks and magnet arrays not being used shoul...

Page 68: ...t try to stop moving objects or magnet arrays that have been attracted to each other Impact Do not strike the magnet arrays as the magnets within them may shatter and break The magnets within the magnet arrays may spark on impact Handle carefully in explosive atmospheres Sharp Fragments The magnet arrays are very strong and unsecured magnet arrays can accelerate toward other magnets magnet arrays ...

Page 69: ...ttracted to another object DO NOT attempt to stop it MagneMotion recommends wearing gloves and safety glasses when handling the magnet arrays Inspect the area prior to handling the magnet arrays and ensure it is free of other mag net arrays or ferromagnetic materials Temperature If the temperature of the magnet arrays gets over approximately 80 C 176 F the magnets will begin to irreversibly loose ...

Page 70: ...clock when power is removed If this battery is being removed or disposed of it must be handled in the following manner Follow all facility local and national procedures for the disposal of hazardous materi als Magnet Arrays Neodymium Iron Boron NdFeB magnets are used in the magnet arrays attached to the vehi cles pucks as the motor secondary If these magnets are being removed or replaced they must...

Page 71: ... components Included in this chapter are Design guidelines for laying out the MagneMover LITE transport system and creating interfaces to the system Design guidelines for using MagneMover LITE motors and magnet arrays Guidelines for electrical wiring Design guidelines for the vehicles and guideways Guidelines for motor mounting Guidelines for option configuration Guidelines for transport system co...

Page 72: ...s used to physically locate the motors and other transport system components in the facility It is also used as a reference when connecting the components of the transport system and defining the elements of the Node Controller Configuration File refer to the MagneMover LITE Configurator User s Manual Refer to Table A 1 on page A 4 for a list of system limits To use the installed transport system ...

Page 73: ...ot available when using the railless motors for either the Precision Rail option or for custom designs Pucks are the pre configured independent vehicles with integral magnet arrays used on Mag neMover LITE transport systems Each vehicle puck is independently controlled and pro vides a platform for securing and carrying the payload in transit Forward vehicle motion is from upstream to downstream ho...

Page 74: ...ier in the Configuration File Paths are controlled by the Node Controller connected to the Path s upstream end Paths must have a connection to a Node Controller at their downstream end if a vehicle puck moves off the downstream end of the Path either onto another Path or onto another type of transport sys tem Refer to the MagneMover LITE Configurator User s Manual for a detailed description of Pat...

Page 75: ...e end of a Path to the beginning of a Path Terminus Node Defines the end or beginning of a Path where vehicles pucks move to or from the MagneMover LITE transport system Gateway Node Connects a Path in one Control Group in a transport system to a Path in another Control Group within the same transport system Merge Node Connects the ends of two Paths to the beginning of another Path Diverge Node Co...

Page 76: ...ported by the MM LITE transport system are Node Controller LITE NC LITE Compact Node Controller with four RS 422 ports This Node Controller typically supports one Node e g Merge However some configurations of Nodes will allow the Node Controller to support multiple Nodes e g Simple and Relay NC 12 Node Controller Full size Node Controller with 12 RS 422 ports two RS 232 ports 16 Digital Inputs and...

Page 77: ...power ing the MagneMover LITE motors Refer to Table 4 1 on page 4 38 for power supply sizing Network Switches Ethernet switches provide signal routing from the Host Controller to the Node Controllers and between Node Controllers All Node Controllers must be on the same Local Area Network subnet Host Controller User supplied controller running the user s application for monitoring and control of th...

Page 78: ...nclude Vehicles pucks are not held in place if power is removed There is no magnetic attractive force between the magnet array and the MagneMover LITE motors The Vehicle Gap distance between magnet array and motor see Figure 3 12 must be maintained throughout the system The Downstream Gap distance between motors see Figure 3 6 should be as small as possible to ensure there is enough thrust to move...

Page 79: ...e during startup restarts or if power is lost Before designing a MagneMover LITE transport system review the following information Desired throughput Maximum payload Total transport length Transport topography Move time Vehicle length Once these characteristics are known identify additional requirements Accommodations for track length and topology Refer to Figure 4 1 on page 4 3 through Figure 4 6...

Page 80: ...e Gap distance between the magnet array attached to the vehicle and the motor This is fixed in standard MM LITE configuration by the height of the rails on the motors and the location of the runners in the pucks Friction or drag between the vehicle and the guideway Motor Gap physical distance between motors and Downstream Gap actual distance between motor blocks in adjacent motors refer to Figure ...

Page 81: ...one motor to the first block of the stator in the next motor downstream which is referred to as the Downstream Gap shown in Figure 3 6 and is equivalent to the Motor Gap plus 2 mm NOTE MagneMotion recommends that the maximum Downstream Gap between motors is 10 of the magnet array length when a dual array vehicle is used it s 10 of the length of one of the arrays Larger gaps may be possible but wil...

Page 82: ...ring The MagneMover LITE motors are designed to operate at a nominal 36 VDC A block dia gram of a MM LITE transport system schematic is provided in Figure 3 7 Note that any part numbers shown are for reference only and are subject to change Power Wiring All power wiring must be constructed so there is minimal loss between the power supplies and the motors Additionally the power wiring must be able...

Page 83: ...p in the power supply circuit to dissipate power if the voltage on the bus goes above a certain level Signal Wiring Logic power of 36 VDC is provided separately Logic power is constant per motor refer to Table 4 1 on page 4 38 Separating the logic and propulsion power busses allows propulsion power to be removed e g during an EMO event without losing motor logic functions con figuration data vehic...

Page 84: ...ROLLER HUMAN MACHINE INTERFACE UTP CAT5 UTP CAT5 SYNC IT MOTOR SYNC CABLE 110 0085 00 UTP CAT5 UTP CAT5 J1 LAN CONSOLE PWR J2 J3 USB1 ETH1 ETH0 J1 J4 RS 422 RS 232 1 RS 232 2 ETHERNET POWER CONSOLE GND DIGITAL I O OUT 0 15 IN 0 15 4 3 2 1 8 7 6 5 12 11 10 9 CM2 CM1 CM2 CM1 CM2 CM3 LAN P1 CM4 CM1 S1 P1 P1 S1 TO NEXT MOTOR DOWNSTREAM IN STRAIGHT PATH TO NEXT MOTOR DOWNSTREAM IN CURVE PATH DC POWER B...

Page 85: ...ts the mag netic field on the side of the array facing the motor while cancelling the field to near zero on the other side with the magnets placed perpendicular to the direction of motion They come in one size with a full South oriented magnet is located in the middle of the array and a North oriented half magnet is located at each end of the array on the surface facing the motor as shown in Figur...

Page 86: ...er of poles Number of Cycles The amount of thrust force is reported as force per magnet array cycle The more cycles in the magnet array the greater the thrust force All MagneMover LITE magnet arrays are one cycle long and have a cycle length of 54 5 mm as shown in Figure 3 8 A magnet array cycle is The distance from the edge of a half North oriented magnet to the opposite edge of a half North orie...

Page 87: ...ehicle Gap and the Downstream Gap These other variables and their effect on available thrust are discussed later in this chapter Magnet Array Use The MagneMover LITE high flux magnet arrays are intended for use as the MM LITE motor secondary as part of the vehicle puck only and should not used for any other purpose NOTE If debris is accumulated it can get caught between the magnet array and the mo...

Page 88: ...hold the magnet array There are several design elements that must be met The vehicle supports the magnet array and its placement in the guideway must ensure the Vehicle Gap see Figure 3 12 is maintained throughout the system The vehicle design must provide guides to ensure the magnet array position is main tained over the center of the motor as shown in Figure 3 9 The vehicle platform must be at l...

Page 89: ...ded to move a vehicle The selected material should be hard enough to provide a low roll ing resistance but depending on the environment the system is used in soft enough to not cre ate excess noise when traversing joints between guideway sections Vehicles may have one or two magnet arrays attached to the surface closest to the motors based on the use of the vehicle as shown in Figure 3 10 and Figu...

Page 90: ...d vehicle The greater the tolerance on the flatness of the guideway the larger the Vehicle Gap must be to ensure the magnet array never touches the top of the motor A guideway using G3 pucks held to 0 5 mm should have a nominal Vehicle Gap of about 1 mm with a total gap range of 0 5 to 1 5 mm A guideway using G4 2 and later pucks held to 0 5 mm should have a nominal Vehi cle Gap of about 1 5 mm wi...

Page 91: ...ded and should not be removed Up to nine 9 62 mm vehicles pucks in motion per meter Up to ten 10 62 mm vehicles pucks in a queue per meter standard up to twelve 12 vehicles in queue per meter depending upon application The payload vehicle mass and required acceleration must be within the limits of the magnet array Vehicles that carry payloads sensitive to magnetic fields should provide shielding o...

Page 92: ...th moderate to low payload weights Plastic or urethane wheels may develop a small flat area if the vehicle remains station ary for a long time period due to the vehicle mass but in most cases the flat spots dis appear after the vehicle is put in motion again Higher rolling resistance than steel but usually operate more quietly than steel wheels when used on a metal guideway Typically requires the ...

Page 93: ...on next to the top of the motor The guideway must hold the motors in position to ensure the motor to motor spacing does not change see Figure 3 6 The Motor Gap should not be larger than 1 mm The guideway must hold the motors and support the vehicles to ensure the Vehicle Gap see Figure 3 12 is maintained throughout the system Guide rails on which the vehicles roll should be held flat to within 0 5...

Page 94: ...netic attractive force The area under the vehicle magnet array should be clear of aluminum as the aluminum may create eddy currents which will create a breaking force Available in a variety of weights thicknesses and prices Motor Mounts The MagneMover LITE motors provide mounting features on the bottom for a simple mount ing scheme refer to Mechanical Specifications on page 4 3 The following guide...

Page 95: ...esigning a guideway When attaching directly to the track or mounting plate as shown in Figure 3 14 ensure clearance holes for all motor connections are provided Note that this mounting method may not provide for any adjustment of the motor position once the motor is installed Figure 3 14 Motor Mounting to Flat Surface Clearance Holes for Motor Connections M6 Mounting Hardware MM LITE 1000 mm Motor...

Page 96: ...ring the brackets to the track as shown in Figure 3 15 ensure the brackets are located to allow access to all motor connections Note that this mounting method provides easy adjustment of the motor position once the motor is installed Figure 3 15 Motor Mounting Using Custom Brackets M6 Mounting Hardware Motor Mounting Bracket Track Mounting Bracket MM LITE 1000 mm Motor Hardware ...

Page 97: ...ounting Using Motor Mount Brackets When using any of the mounting methods shown 1 Loosely mount the motors to the motor mounting surface The motor mounts should allow the motors a small amount of movement relative to each other 2 Ensure consistent spacing between the motors 3 Ensure the top surface of all motors are coplanar to each other 4 Treating each motor to motor interface as a separate oper...

Page 98: ...available in dif ferent configurations which support different numbers of parallel motors as shown in Table 3 5 Figure 3 17 shows a 300 mm 2 motor wide stand Figure 3 17 System Stand Table 3 4 Stand System Heights Leg Height System Height 505 mm 745 mm 560 mm 800 mm 575 mm 815 mm 598 mm 838 mm 639 mm 879 mm 648 5 mm 889 mm 732 mm 972 mm Table 3 5 Stand System Widths Parallel Motors Minimum motor s...

Page 99: ... The motors should have a small amount of movement relative to each other 2 Ensure consistent spacing between the motors 3 Ensure the top surface of all motors are coplanar to each other 4 Install the V braces on all guide rails using M6 x 12 mm screws and tighten fin ger tight to pull the rails together NOTE For systems using railless motors the V braces are attached to the top of the motor body ...

Page 100: ...s secured the bolts on the motor mounts that attach to the custom motor mounting surface and to the motor for that V brace can be tightened Ensure that the motors and motor to motor connections are not distorted by over tightening the motor mounts 7 Once all the motor to motor joints have been secured with the V braces in the manner described above a final verification of all the joints should be ...

Page 101: ... Contact MagneMotion for design guidelines for applications using curves or switches Note that the maximum load indicated in Table 3 6 includes the weight of the carrier and the material being carried NOTE Off centered cantilevered loads and or large inertia loads can affect system perfor mance based on the system s configuration Figure 3 19 Puck Carrier Overhang Table 3 6 Puck Carrier Overhang Li...

Page 102: ...ck Carrier 32 MagneMotion Rockwell Automation Publication MMI UM002E EN P March 2016 90 293 100 270 110 250 120 233 130 218 140 205 150 193 Table 3 6 Puck Carrier Overhang Limits Continued Overhang Length mm Maximum Load g ...

Page 103: ... series of pre assembled support post assem blies each consisting of a spine plate support post and post mount These assemblies are designed to hold the precision rail in the correct relationship to the MM LITE motors Differ ent spine plates are available to support the varying rail to rail connection and interface requirements For installations using the standard beam support structure the post m...

Page 104: ...t and curve segments of varying lengths as shown in Table 3 7 The interface between curved sec tions of precision rail and straight sections uses an adjustment key to ensure alignment between the sections of rail Rail sections attach to the spine plates at the top of the support post assemblies as shown in Figure 3 21 Figure 3 21 Precision Rails Support Post Assembly Curve Rail Section Straight Ra...

Page 105: ...ell Automation Publication MMI UM002E EN P March 2016 Table 3 7 Precision Rail Types and Lengths Type Stainless Steel Straight Rail 250 mm 500 mm 750 mm 1000 mm 1250 mm 1500 mm 1750 mm 2000 mm 2250 mm 2500 mm 2750 mm 3000 mm 3250 mm 3500 mm Curved Rail 90 175 5 mm R 180 175 5 mm R ...

Page 106: ...1 The spine plates attach directly to the top of the support post assemblies The type of joint i e curve to curve curve to straight straight to straight determines the type of spine plate required Additional spine plates are provided to support the precision rails in areas where there is no joint Figure 3 22 Precision Rail Spine Plates Straight No Joint Straight to Curve Left Joint Curve to Curve ...

Page 107: ...bly The support post assembly shown in Figure 3 23 provides a mounting surface for the spine plates as shown in Figure 3 20 and Figure 3 21 and is used to ensure the precision rails are held the correct distance from the MagneMover LITE railless motors Figure 3 23 Precision Rail Support Post Support Post Support Post Mount Spine Plate Mounting Surface ...

Page 108: ...ay vehicle shown in Figure 3 25 Each vehicle provides a mounting surface for the user s payload The single array vehicle can carry payloads up to 2 5 kilogram the dual array vehicle can carry payloads up to 5 kilograms Figure 3 24 Precision Rail Single Array Vehicle Figure 3 25 Precision Rail Dual Array Vehicle Vehicle Body Magnet Array Mounting Plate Direction of Motion Bearings Direction of Moti...

Page 109: ...ons for the Precision Rail option These include the distance between the center of the precision rail to the center of the motor and the nominal gap between the bottom of the magnetic array and the top of the motor Figure 3 26 Precision Rail to Motor Reference Diagram 49 00 1 929 1 50 Motor Motor Mount Support Post Assembly Array Single Array Vehicle Rail All Dimensions in Millimeters Inches 0 059...

Page 110: ...gneMover LITE stand beam or to a user supplied custom mounting surface In each case the adjustable motor mounts should be used Figure 3 27 Precision Locator Option Precision Locators The Precision Locator is a small pneumatic powered fixture for precisely locating the pallet mounted on a puck at a process station The locator mechanism uses two rocker arms with precision pins that mate with precisi...

Page 111: ...sion Locator Basic Pallet Mechanical Drawing on page 4 37 Information is provided to allow the user to design and install their own custom pallet In each case the pallet replaces the standard puck s top plate to allow clamping by the locator s arms refer to Figure 1 3 on page 1 6 and has a pair of replaceable skis attached to its bottom sur face to allow it to ride on the MagneMover LITE motor rai...

Page 112: ...INCLUDED IN PALLET TO PALLET HEIGHT REPEATABILITY TOLERANCE STACKUP THIS AREA OF PALLET ALLOWED TO BE THICKER 0 1 SKI MOUNT FEATURES Ø9 10 Ø9 10 3 25 Ø4 5 Ø8 50 2 3 30 00 SECTION B B ROTATED 90 CW MAGNET ARRAY FEATURES SECTION A A ROTATED 90 CW BUSHING MOUNT FEATURES Ø9 50 Ø AND TOLERANCE HOLE FOR BUSHING MASKED COUNTERBORE DIAMETER LIGHT PRESS FIT RECOMMENDED Ø8 5 3 0 4 8 0 88 Ø14 75 MIN Ø7 5 50 ...

Page 113: ...aught to ensure the pallet is properly secured by the locator Then the location of the pallet while it is secured must be taught to the interfacing equipment NOTE Replacement of the locator stand may require reteaching of the pallet location Pneumatic Piping The Precision Locator is designed to operate at a nominal 2 03 cc3 sec 0 41 mPa 0 0043 scfm 60 psi per cycle 21 C 70 F sea level The compress...

Page 114: ...ystem Options 44 MagneMotion Rockwell Automation Publication MMI UM002E EN P March 2016 Figure 3 30 Precision Locator Pneumatic Block Diagram 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 Pallet Released Pallet Engaged Extended Retracted ...

Page 115: ...Transport System Configuration All examples provided are for horizontal track layouts unless otherwise specified Straight Track Configuration Figure 3 31 Straight Track Configuration Node Types at beginning of Path Simple Relay Terminus Gateway Node Types at end of Path Relay Terminus Gateway Rails MM LITE Straight Motor Top View Motor Gap ...

Page 116: ...n Publication MMI UM002E EN P March 2016 Curve Track Configuration Figure 3 32 Curve Track Configuration Node Types at beginning of Path Simple Relay Terminus Gateway Node Types at end of Path Relay Terminus Gateway Top View Rails MM LITE Straight Motor Motor Gap MM LITE Curve Motor ...

Page 117: ...e 3 33 Switch Configuration Node Types at switch Merge Diverge Provides a diverge from one Path into two single entry curve exit straight exit Provides a merge of two Paths into one straight entry curve entry merged exit Straight Entry Straight Exit Curve Entry Curve Exit Merged Exit Single Entry Top View Rails MM LITE MM LITE Motor Gap Straight Motor Right Switch ...

Page 118: ...Design Guidelines 48 MagneMotion Rockwell Automation Publication MMI UM002E EN P March 2016 This page intentionally left blank ...

Page 119: ...specifications for the MagneMover LITE transport system compo nents and the requirements for installation Included in this chapter are Mechanical specifications for all MagneMover LITE components including dimen sions Electrical specifications for power and communications including connector pinouts Site requirements including environmental and service access ...

Page 120: ... are available in either aluminum or stainless steel All motors allow up to nine 9 62 mm vehicles pucks in motion per meter 1 All motors allow up to twelve 12 62 mm vehicles pucks in a queue per meter 1 Shortest magnet array allowed is 1 cycle standard 62 mm puck Thrust at nominal Vehicle Gap is 6 N cycle at 25 duty cycle 2 Motor block length is 16 47 mm Internal motor controller Refer to Table A ...

Page 121: ...he MM LITE motor only Additional exclusion zones may be required based on the material being transported by the motor Refer to Motors and Switches on page 4 38 for the electrical specifications Exposed Materials 316 316L Stainless Steel 304L Stainless Steel with Electroless Nickel plating SS rails 6061 T6 Aluminum Al rails 6063 T5 Aluminum Al rails EPDM synthetic rubber Dow Corning Silicone 737 an...

Page 122: ... being transported by the motor Refer to Motors and Switches on page 4 38 for the electrical specifications Exposed Materials 316 316L Stainless Steel EPDM synthetic rubber Dow Corning Silicone 737 and 734 All Dimensions in Millimeters Inches Weight 6 9 kg 15 2 lb 0 19 68 5 500 0 0 223 0 0 8 780 28 46 5 723 0 0 7 953 202 0 0 27 63 8 702 0 0 POWER CONNECTOR CONNECTOR SYNC CABLE CONNECTOR CONNECTOR ...

Page 123: ... motor Refer to Motors and Switches on page 4 38 for the electrical specifications Exposed Materials 316 316L Stainless Steel 304L Stainless Steel with Electroless Nickel plating SS rails 6061 T6 Aluminum Al rails 6063 T5 Aluminum Al rails EPDM synthetic rubber Dow Corning Silicone 737 and 734 All Dimensions in Millimeters Inches Weight 2 kg 4 4 lb 0 3 03 77 00 3 86 98 00 3 03 77 00 3 86 98 00 COM...

Page 124: ...l being transported by the motor Refer to Motors and Switches on page 4 38 for the electrical specifications Exposed Materials 316 316L Stainless Steel EPDM synthetic rubber Dow Corning Silicone 737 and 734 All Dimensions in Millimeters Inches Weight 1 9 kg 4 2 lb 0 3 03 77 00 3 86 98 00 3 03 77 00 3 86 98 00 COMMUNICATION CABLE SYNC CABLE CONNECTOR CONNECTOR POWER CONNECTOR SYNC MOTOR ONLY COMMUN...

Page 125: ...otors and Switches on page 4 38 for the electrical specifications Exposed Materials 316 316L Stainless Steel 303 Stainless Steel with Electroless Nickel plating SS rails 6061 T6 Aluminum Al rails EPDM synthetic rubber Dow Corning Silicone 737 and 734 All Dimensions in Millimeters Inches Weight 1 8 kg 4 lb PUCK TRAVEL PATH 3 39 86 0 77 6 3 05 3 05 77 6 4 92 R125 0 3 39 86 0 167 5 6 59 6 59 167 5 0 ...

Page 126: ...ted by the motor Refer to Motors and Switches on page 4 38 for the electrical specifications Exposed Materials 316 316L Stainless Steel EPDM synthetic rubber Dow Corning Silicone 737 and 734 All Dimensions in Millimeters Inches Weight 1 7 kg 3 7 lb 3 40 86 3 3 40 86 3 3 06 77 7 4 92 R125 0 3 06 77 7 3 73 94 8 3 73 94 8 6 61 167 9 6 61 167 9 0 0 1 28 32 39 17 4 38 1 87 47 61 2 12 53 88 1 28 32 39 1...

Page 127: ...itches on page 4 38 for the electrical specifications Exposed Materials 316 316L Stainless Steel 303 Stainless Steel with Electroless Nickel plating SS rails 6061 T6 Aluminum Al rails EPDM synthetic rubber Viton Igus L280 Dow Corning Silicone 737 and 734 All Dimensions in Millimeters Inches Weight 4 1 kg 9 lb 0 0 2X 3 86 98 0 2 28 58 0 3 03 77 0 3 86 98 0 59 15 0 59 15 0 2 28 58 0 3 86 98 0 POWER ...

Page 128: ...s on page 4 38 for the electrical specifications Exposed Materials 316 316L Stainless Steel 303 Stainless Steel with Electroless Nickel plating SS rails 6061 T6 Aluminum Al rails EPDM synthetic rubber Viton Igus L280 Dow Corning Silicone 737 and 734 All Dimensions in Millimeters Inches Weight 4 1 kg 9 lb 0 0 COMMUNICATION CABLE CONNECTOR COMMUNICATION CABLE CONNECTOR COMMUNICATION CABLE CONNECTOR ...

Page 129: ... Figure 4 9 Standard Motor Mount Bracket Mechanical Drawing G4 Exposed Materials 6063 T5 Aluminum black anodized 304 Stainless Steel C L 46 98 1 850 9 00 0 354 THRU 625 15 88 3 200 81 3 005 3 150 0 13 80 00 13 95 549 0 05 002 80 0 3 150 2 03 080 2X 90 1 31 8 1 250 6 50 THRU 256 625 15 88 INSERT TANGED HLCL SLF LKG Ø5mm Ø0 2in X 5 00mm 0 200in L All Dimensions in Millimeters Inches ...

Page 130: ...ll Automation Publication MMI UM002E EN P March 2016 Stand System Figure 4 10 Stand System Mechanical Drawing Exposed Materials Galvanized Steel Zinc Electrophoretic coated 6060 T66 Anodized Aluminum PA6 Nylon Rubber 50 60 12 50 All Dimensions in Millimeters See Table 3 4 See Table 3 5 ...

Page 131: ...the G4 series pucks The G4 series pucks are fully back ward compatible with the G3 series Figure 4 11 Puck Mechanical Drawing G4 NOTE Replaced by the G4 3 Puck refer to Figure 4 13 Exposed Materials Stainless Steel 316 316L 316L 2 Stainless Steel PEEK PTFE UHMW Polyethylene 787 010 20 0 25 787 010 20 0 25 787 010 20 0 25 787 010 20 0 25 43 1 701 488 010 12 40 0 25 0 3MM TYPICAL WEAR NOT INCLUDED C...

Page 132: ... 2 Stainless Steel PEEK PTFE UHMW Polyethylene DIRECTION OF TRAVEL RUNNING SURFACES C L C L 62 0 R2 079 4X C L ABOUT SYMMETRIC 40 0 15 1 575 006 C L ABOUT SYMMETRIC 40 0 15 1 575 006 2 441 5X M4x0 7 6 3 MAX TORQUE SCREWS TO 8 IN LBS MAX IF REPLACING WEAR PARTS RE TORQUE SCREWS TO 13 IN LBS WET WITH THREAD LOCKER LOCTITE 243 OR EQUIV ALLOW TO CURE FOR 12 HR BEFORE USE 12 40 0 13 488 005 020 0 50 1 ...

Page 133: ...E UHMW Polyethylene RUNNING SURFACES THREAD LOCKER LOCTITE 243 OR EQUIV IF REPLACING WEAR COMPONENTS RE TORQUE SCREWS TO 13 IN LBS WET WITH ALLOW TO CURE FOR 12 HRS BEFORE USE 5X M4X0 7 6 3 MAX THD DEPTH TORQUE SCREWS TO 8 IN LBS MAX 2X 787 010 20 0 25 62 2 440 62 2 441 20 0 25 787 010 2X 20 0 25 787 010 2X 2X 787 010 20 0 25 43 02 1 694 488 010 12 40 0 25 0 3MM TYPICAL WEAR NOT INCLUDED DIRECTION...

Page 134: ...ard compatible with the G3 series Figure 4 14 Tandem Puck Mechanical Drawing G4 NOTE Replaced by the G4 3 Tandem Puck refer to Figure 4 16 Exposed Materials Stainless Steel 316 316L 316L 2 Stainless Steel PEEK PTFE UHMW Polyethylene Delrin FG150 Acetal All Dimensions in Millimeters Inches RUNNING SURFACES 882 007 022 22 40 0 18 0 55 394 10 00 2X 039 R1 ALL AROUND 2 105 53 46 C L C L C L C L 4X 1 5...

Page 135: ...ess Steel 316 316L 316L 2 Stainless Steel PEEK PTFE UHMW Polyethylene Delrin FG150 Acetal All Dimensions in Millimeters Inches RUNNING SURFACES 394 10 00 2X 039 R1 ALL AROUND 882 007 022 22 40 0 18 0 55 2 082 52 89 C L C L 8X M4 X 0 7 6 3 MAX TORQUE SCREWSTO 8 IN LBS MAX 5 906 150 0 2 441 62 0 4X 1 575 006 40 0 15 SYMMETRIC ABOUT C L 2X 1 575 006 40 0 15 SYMMETRIC ABOUT C L 2X 1 575 006 40 0 15 2X...

Page 136: ...Steel PEEK PTFE UHMW Polyethylene Delrin FG150 Acetal All Dimensions in Millimeters Inches 8X M4X0 7 6 3 MAX TORQUE SCREWS TO 8 IN LBS MAX 4X 1 575 006 40 0 15 SYMMETRIC ABOUT C L 2X C L C L 1 575 006 40 0 15 2X 1 575 006 40 0 15 SYMMETRIC ABOUT C L 2X 1 575 006 40 0 15 5 906 150 0 2 441 62 0 079 R2 TYP 3 425 87 00 2X 882 020 22 40 0 50 0 3MM TYPICAL WEAR NOT INCLUDED 394 10 0 2 087 53 02 RUNNING ...

Page 137: ...e been replaced by the G4 series arrays The G4 series arrays are fully backward compatible with the G3 series Figure 4 17 Magnet Array Mechanical Drawing G4 NOTE Replaced by the G4 2 Magnet Array refer to Figure 4 18 Exposed Materials Stainless Steel 316L 316L 2 Stainless Steel UHMW Polyethylene C L C L DIRECTION OF TRAVEL 7 12 2X 280 1 181 010 30 00 0 25 MAX 62 20 2 449 MAX 52 80 2 079 2X M 157 4...

Page 138: ...g G4 2 Exposed Materials Stainless Steel 316L 316L 2 Stainless Steel UHMW Polyethylene 2X M4 X 0 7 6H 4 5 MIN RECOMMENDED TORQUE 13 IN LB WITH LOCTITE 243 THREADLOCKER C L 2 417 016 61 4 0 4 C L SYMMETRIC ABOUT 30 0 0 13 1 181 005 52 6 0 4 2 070 016 2X 315 005 8 0 0 13 292 7 4 24 1 0 4 950 016 2X 16 7 0 3 657 012 315 8 0 All Dimensions in Millimeters Inches Weight 0 43 kg 0 9 lb ...

Page 139: ... available for standard 19 in electronics racks refer to Rack Mounting Bracket on page 4 22 Refer to NC 12 Node Controller on page 4 49 for the electrical specifications Exposed Materials The Node Controller provides openings for airflow and should not be located in an area where harsh conditions exist All Dimensions in Millimeters Inches Weight 3 6 kg 8 lb 4X 250 UNC 2B 310 8 18 207 7 7 00 177 8 ...

Page 140: ...k Mounting Bracket The rack mounting bracket can be used for mounting the NC 12 Node Controller in a standard 19 in electronics rack Figure 4 20 Rack Mounting Bracket Mechanical Drawing Exposed Materials Carbon Steel 1018 Steel Anodized Aluminum All Dimensions in Millimeters Inches 3 3 0 13 114 5 4 51 7 1 0 28 25 4 1 00 86 9 3 42 50 8 2 00 ...

Page 141: ...TE on page 4 54 for the electrical specifications Exposed Materials The Node Controller has unprotected openings and should not be located in an area where harsh conditions exist 8X ADJUSTABLE SLIDING MOUNTING BRACKETS MOUNTING PLATE REQUIRED ON CROSSHATCHED AREA 2X CABLE CONNECTOR EXCLUSION AREA CABLE CONNECTOR EXCLUSION AREA PWR LAN 18 VDC PoE ONLY CONSOLE 0 17 4 3 1 75 44 5 4 27 108 5 4 88 124 ...

Page 142: ...r and Ethernet Switches Figure 4 22 Electronics Mounting Plate Mechanical Drawing Exposed Materials 5052 H32 Aluminum 300 Series Stainless Steel A 286 Hardened Stainless Steel All Dimensions in Millimeters Inches 0 0 28 18 1 11 91 18 3 59 97 93 3 86 153 18 6 03 208 42 8 21 215 18 8 47 278 18 10 95 13 00 51 75 00 2 95 101 74 4 01 137 00 5 39 5 91 150 00 2X 10 00 0 39 4X M5 THRU 2X M4 THRU M5 X 12 M...

Page 143: ... LITE Power Supply on page 4 44 for the electrical specifications Exposed Materials The power supply provides openings for airflow and should not be located in an area where harsh conditions exist 70 17 78 4 5 114 3 6X BOTTOM SURFACE MOUNTING LOCATION 13 5 344 0 0 4 10 11 6 283 159 60 4 5 114 3 3 6 91 0 3 9 100 0 3 9 100 0 0 1 3 18 6 3 159 6 6 3 159 60 3 1 77 53 2 9 74 4 2 5 63 5 2 5 63 5 2 5 63 5...

Page 144: ...ation Publication MMI UM002E EN P March 2016 Precision Rail Option Precision Rails Figure 4 24 Precision Rail Mechanical Drawing Exposed Materials 420 Series Stainless Steel 25 74 0 025 10 0 0 025 THEORETICAL APEX C L A A THEORETICAL APEX 5 4 0 1 10 0 0 1 5 5 0 1 All Dimensions in Millimeters ...

Page 145: ... Single Array Vehicle Mechanical Drawing Exposed Materials Stainless Steel 316L 316L 2 Stainless Steel 440C Stainless Steel UHMW Polyethylene Nitrile Plastic Mobilgear 600 XP Oil All Dimensions in Millimeters Weight 0 8 kg 1 6 lb LOCKING HELICOIL INSERTS DIRECTION OF MOTION C L 3 46 88 0 1 54 39 0 0 683 17 35 0 906 23 00 0 906 23 00 1 024 26 00 1 54 39 0 3 807 96 70 4 553 115 64 1 937 49 21 1 134 ...

Page 146: ...Mechanical Drawing Exposed Materials Stainless Steel 316L 316L 2 Stainless Steel 440C Stainless Steel UHMW Polyethylene Nitrile Plastic Mobilgear 600 XP Oil All Dimensions in Millimeters Weight 1 2 kg 2 6 lb 1 937 49 21 1 201 30 51 1 134 28 81 LOCKING HELICOIL INSERTS DIRECTION OF MOTION C L 5 16 131 0 6 392 162 37 1 54 39 0 0 683 17 35 0 906 23 00 0 906 23 00 1 024 26 00 1 54 39 0 3 807 96 70 4 5...

Page 147: ... post and spine plate Figure 4 27 identifies the components used to construct the support post assembly NOTE Different spine plates are available to support the varying rail to rail interconnection and interface requirements Figure 4 27 Precision Rail Support Post Assembly Exposed Materials Galvanized Steel Zinc Electrophoretic coated 6060 T66 Anodized Aluminum PA6 Nylon 6061 T6 Aluminum Zinc plat...

Page 148: ...ates are pre assembled onto the support post assemblies used by the Precision Rail system Exposed Materials Aluminum MIC 6 Figure 4 28 Precision Rail Straight to Curve Spine Plates Mechanical Drawing 0 0 2X 54 98 64 98 94 99 114 98 138 90 150 0 5 62 26 63 50 63 68 0 4 30 0 35 6X R4 128 5 141 5 R169 88 125 0 0 25 6 35 Right Left All Dimensions in Millimeters ...

Page 149: ... Rockwell Automation Publication MMI UM002E EN P March 2016 Figure 4 29 Precision Rail Curve to Curve Spine Plates Mechanical Drawing 0 0 17 37 41 37 2X 63 70 2X 68 35 78 0 11 08 35 00 75 00 76 40 2X 95 00 98 92 110 30 0 25 6 35 141 5 128 5 R169 88 114 2 Right Left All Dimensions in Millimeters ...

Page 150: ...ght No Joint Spine Plate Mechanical Drawing Figure 4 31 Precision Rail Straight With Joint Spine Plate Mechanical Drawing 0 0 10 00 25 00 2X 55 00 85 00 100 00 110 0 4X 5 62 26 63 50 63 68 00 2X 125 0 2X 145 0 6X R4 0 25 6 35 All Dimensions in Millimeters 0 0 2X 5 62 26 63 50 63 68 00 2X 54 98 64 98 73 58 124 98 132 0 141 5 125 0 0 25 6 35 All Dimensions in Millimeters ...

Page 151: ...User Manual 33 Rockwell Automation Publication MMI UM002E EN P March 2016 Figure 4 32 Precision Rail Curve 180 No Joint Spine Plate Mechanical Drawing 0 0 17 37 41 37 2X 68 35 78 00 9 58 76 40 2X 95 00 100 42 110 30 128 5 141 5 R169 88 114 2 0 25 6 35 All Dimensions in Millimeters ...

Page 152: ... Precision Locator Actuator Mechanical Drawing NOTE Refer to Precision Locator on page 4 61 for the electrical and pneumatic specifica tions Exposed Materials 6061 T6 Aluminum Aluminum Hard Anodize Zinc Chromated Steel 18 8 A2 Stainless Steel 18 8 A2 Hardened Stainless Steel with Thin Dense Chrome plating SBR Rubber 106 5 90 0 128 6 All Dimensions in Millimeters inches Weight 0 9 kg 2 0 lb ...

Page 153: ...omation Publication MMI UM002E EN P March 2016 Stand Assembly Figure 4 34 Standard Precision Locator Stand Mechanical Drawing Exposed Materials 6061 T6 Aluminum anodized TIVAR HOT 18 8 A2 Stainless Steel 304 A4 Stainless Steel 159 8 112 0 182 1 96 0 All Dimensions in Millimeters inches Weight 1 1 kg 2 5 lb ...

Page 154: ... 35 Adjustable Motor Mount Bracket Mechanical Drawing Exposed Materials 6063 T5 Aluminum black anodized 304 Stainless Steel 18 8 Stainless Steel Nylon C L 1 850 46 98 9 00 0 354 THRU 0 625 15 88 3 150 80 0 3 03 77 0 0 080 2 03 2X 90 1 1 56 39 8 1 250 31 8 6 50 THRU 0 256 0 625 15 88 INSERT TANGED HLCL SLF LKG Ø5mm Ø0 2in X 5 00mm 0 200in L All Dimensions in Millimeters Inches ...

Page 155: ...recision Locator Basic Pallet Mechanical Drawing Exposed Materials Aluminum Hard Anodize 18 8 A2 Hardened Stainless Steel with Thin Dense Chrome plating Stainless Steel 316 316L 316L 2 Stainless Steel PEEK PTFE 62 0 MIN 2X 18 5 2X 6 0 2X FOR 2 0 PIN BUSHING ANTI ROTATION 25 0 25 0 0 3X 25 0 2X 37 5 3X 25 0 C L PAYLOAD 0 1 4X FOR SKI MOUNT 8 0 All Dimensions in Millimeters ...

Page 156: ...itches draw additional power when the vehicle puck is moving or accelerating refer to Table 4 1 The amount of additional power drawn depends on the vehicle s velocity and acceleration and the number of vehicles that may accelerate at once All power wiring must be capable of carrying the full load The propulsion power input P1 V Propulsion uses a PTC positive temperature coefficient resistor to lim...

Page 157: ...cle Single Array 15 35 W Vehicle Dual Array 30 W Control power Additional power drawn by the motor per magnet array when the vehicle puck is moving When the vehicle is moving at maximum acceleration the additional power drawn can be as much as 35 W per magnet array When multiple magnet arrays are on the motor at the same time the amount of power drawn per array will increase as the arrays get clos...

Page 158: ... MagneMover LITE Motor Connections Label Description Connector Type CM1 RS 422 communications M8 Nano Mizer 4 Pin Male CM2 RS 422 communications M8 Nano Mizer 4 Pin Male P1 Power 36 VDC 10 1000 mm motor 1 5 A typ 5 0 A max 250 mm motor 0 4 A typ 1 2 A max Curve motor 0 4 A typ 1 2 A max Mini Conn X 4 Pin Male S1 The Sync Option Connector is only present if the Synchronization option is installed E...

Page 159: ...ble 4 3 MagneMover LITE Motor RS 422 Pinouts M8 Nano Mizer 4 Pin Male RxD 1 RxD 2 TxD 3 TxD 4 Table 4 4 MagneMover LITE Motor Power Pinouts Mini Conn X 4 Pin Male V Propulsion 1 V Logic 2 V Return 3 RTN 4 Table 4 5 MagneMover LITE Sync Pinouts Micro Mizer 8 Pin Male RTN 1 V 2 SIMO 3 SCLK 4 SOMI 5 SS 6 not used 7 RESET 8 3 4 1 2 1 2 4 3 Keyway 8 1 2 Keyway ...

Page 160: ...trical Connections Table 4 6 MagneMover LITE Switch Connections Label Description Connector Type CM1 RS 422 communications M8 Nano Mizer 4 Pin Male CM2 RS 422 communications M8 Nano Mizer 4 Pin Male CM3 RS 422 communications M8 Nano Mizer 4 Pin Male CM4 RS 422 communications M8 Nano Mizer 4 Pin Male P1 36 VDC 10 1 5 A typ 5 0 A max Mini Conn X 4 Pin Male LAN Ethernet 10 100 1000 BaseTx RJ 45 Femal...

Page 161: ...P March 2016 Table 4 7 MagneMover LITE Switch RS 422 Pinouts M8 Nano Mizer 4 Pin Male RxD 1 RxD 2 TxD 3 TxD 4 Table 4 8 MagneMover LITE Switch Power Pinouts Mini Conn X 4 Pin Male V Propulsion 1 V Logic 2 V Return 3 RTN 4 Table 4 9 MagneMover LITE Switch Ethernet Pinout LAN RJ 45 Female TD 1 TD 2 RD 3 4 5 RD 6 7 8 3 4 1 2 1 2 4 3 Keyway 8 1 ...

Page 162: ...upply provides two 300W DC outputs for powering the MM LITE motors The number of power supplies required for a specific MM LITE configuration can be determined from Table 4 1 where the maximum power consumption for each component within the MagneMover LITE transport system is identified NOTE MagneMotion recommends that no more than 20 motors be powered from a single MM LITE Power supply 10 per 300...

Page 163: ... IEC 320 Male J4 DC Enable DE 9 Female Table 4 11 MM LITE Power Supply Indicators Label Description Indicator Type LOGIC ON Indicates motor logic power is on Green LED PROPULSION ON Indicates motor propulsion power is on Green LED GND J4 DC ENABLE SEE MANUAL FOR PINOUT 36 VDC 300W 8A MAX 36 VDC 300W 8A MAX J1 J2 GND V PROPULSION V LOGIC V RETURN V LOGIC V RETURN V PROPULSION AC Power DC Enable Mot...

Page 164: ...he power cables as all cabling is supplied with the transport system Table 4 12 MM LITE Power Supply DC Power Pinouts Individual Terminals V Propulsion Black V Logic White V Return MMI recommends tying V Return to RTN Red RTN Green Table 4 13 MM LITE Power Supply DC Enable DE 9 Female Pin Signal 1 DC OK DC OK signal is 0 1V when the PS is off and be tween 3 3 5 6V when the PS is on The sinking cur...

Page 165: ...er cable connects directly to the power supply Each wire in the cable is labeled for identification Connect each wire to the appropriate terminal on the power supply Figure 4 40 MM LITE DC Power Cables Table 4 14 DC Power Cable Pinouts Individual Terminals Mini Mizer 4 Pin Female Mini Mizer 4 Pin Male Mini Conn X 4 Pin Female V Propulsion Black 1 1 1 V Logic White 2 2 2 V Return Red 3 3 3 RTN Gree...

Page 166: ...system will still track vehicle IDs as logic power is maintained when propulsion power is removed NOTE The DC Enable circuit is not the same as an EMO Emergency Off which removes power to the MagneMover LITE transport system The DC Enable cable requires a 9 pin male D connector that plugs into the MM LITE power supply at J4 The pinout for this connection is provided in Table 4 13 The cable should ...

Page 167: ... must be capable of carrying the full load DC Power Option DC power from a user supplied power supply requires 22 30 VDC 20 W The actual power being drawn will depend upon operations being performed however all power wiring must be capable of carrying the full load and has a limited power source or is fused to the maximum rating of the power wiring CAUTION High Voltage Hazard 90 264 VAC 25 W AC po...

Page 168: ...O Con nection on page 4 65 Spring cage clamp RS 232 RS 232 external communications DE 9 Male RS 422 RS 422 motor communications M8 Nano Mizer 4 Pin Male MagneMotion recommends that the odd number connectors be used for upstream connections and the even number connectors be used for downstream connections POWER 22 30 VDC 20 W DC Power Jack 2 0 mm Coax Male M12 Thread Ground M6 threaded stud MagneMo...

Page 169: ...Mover LITE User Manual 51 Rockwell Automation Publication MMI UM002E EN P March 2016 Table 4 17 NC 12 Node Controller Console Pinout DE 9 Male 1 Rx 2 Tx 3 4 RTN 5 6 7 8 9 Table 4 18 NC 12 Node Controller Ethernet Pinout RJ 45 Female TD 1 TD 2 RD 3 4 5 RD 6 7 8 2 5 3 8 1 ...

Page 170: ...I UM002E EN P March 2016 Table 4 19 NC 12 Node Controller RS 232 Pinouts DE 9 Male 1 Rx 2 Tx 3 4 RTN 5 6 7 8 9 Table 4 20 NC 12 Node Controller RS 422 Pinouts M8 Nano Mizer 4 Pin Male RxD 1 RxD 2 TxD 3 TxD 4 Table 4 21 NC 12 Node Controller Power Pinout 2 0 mm Coax Male PWR Pin RTN Sleeve 2 5 3 3 4 1 2 Pin Sleeve ...

Page 171: ...ITE User Manual 53 Rockwell Automation Publication MMI UM002E EN P March 2016 AC Power Cable The NC 12 Node Controller optional remote power supply is supplied with a power cable Contact MagneMotion for replacement cables The AC power cable plugs directly into the power supply ...

Page 172: ...d on configuration and operating mode Inrush current 45 A 240 VAC max Refer to the manufacturer s data sheet for mechanical information The actual power being drawn will depend upon operations being performed however all power wiring must be capable of carrying the full load DC Power Option DC power from a user supplied power supply requires 7 18 VDC 5 W The Node Controller LITE can be powered by ...

Page 173: ... Passive PoE 18 VDC RJ 45 Female PWR 7 18 VDC 5 W DC Power Jack 2 0 mm Coax Male CONSOLE External terminal DE 9 Male RS 422 RS 422 motor communications DE 9 Male Female MagneMotion recommends that the odd number male connectors be used for upstream connections and the even number female connectors be used for downstream connections Table 4 23 Node Controller LITE Power Pinout 2 0 mm Coax Male PWR ...

Page 174: ...gneMotion Rockwell Automation Publication MMI UM002E EN P March 2016 Table 4 24 Node Controller LITE LAN Pinout RJ 45 Female TD 1 TD 2 RD 3 18 VDC 4 18 VDC 5 RD 6 RTN 7 RTN 8 Table 4 25 Node Controller LITE Console Pinout DE 9 Male 1 Rx 2 Tx 3 4 RTN 5 6 7 8 9 8 1 2 5 3 ...

Page 175: ...pplied with a power cable Con tact MagneMotion for replacement cables The AC power cable plugs directly into the power supply The remote power supply and AC cable for the Node Controller LITE is not required if Power over Ethernet is being used Table 4 26 Node Controller LITE RS 422 Pinouts Upstream Downstream J1 J3 DE 9 Male J2 J4 DE 9 Female 1 1 RxD 2 TxD 2 TxD 3 RxD 3 4 4 5 5 6 6 RxD 7 TxD 7 Tx...

Page 176: ...awn will depend upon operations being performed however all Ethernet cables used for PoE must be capable of carrying the full load The Power over Ethernet PoE switch provides 18 VDC 2 A max port for the Node Con troller LITE AC Power Cable The Ethernet Switch with PoE power supply is supplied with a power cable Contact Magne Motion for replacement cables The AC power cable plugs directly into the ...

Page 177: ...on page 4 34 for the mechanical drawing The electrical connections shown below are only avail able if the sensor option is installed Figure 4 45 Precision Locator Electrical Connections Table 4 27 Precision Locator Connections Label Description Connector Type Cylinder Up Sensor Connection M8 Locking 3 Pin Male Cylinder Down Sensor Connection M8 Locking 3 Pin Male Table 4 28 Precision Locator Senso...

Page 178: ...equirements Electrical Specifications 60 MagneMotion Rockwell Automation Publication MMI UM002E EN P March 2016 Table 4 29 Precision Locator Sensor Pinout M8 3 Pin Male DC 24 VDC max 40 mA max 1 DC 3 Output 4 Pin 4 Pin 3 Pin 1 ...

Page 179: ...cal drawing Figure 4 46 Precision Locator Pneumatic Connections Table 4 30 Precision Locator Pneumatic Requirements 37 5 mm Arms To ensure maximum service life and trouble free oper ation these devices should be actuated from arm up to arm down in no less than 100 ms accomplished by ad justing the flow controls on the user supplied pneumat ic valve for the locator Vertical Clamping Stroke 8 mm 0 3...

Page 180: ...IP and EtherNet IP use the same hardware for communication the communication protocol itself is different This allows both protocols to run on the same network at the same time without interfering with each other The Ethernet cables used are standard network cable UTP Cat5 with an 8 pin RJ 45 connec tor that plugs into the NC 12 Node Controller at the ETHERNET port and the Node Control ler LITE at...

Page 181: ... the NC 12 Node Controller is not used with the Magne Mover LITE transport systems RS 422 Serial Interface Connection RS 422 serial communications provides the ability to connect the Node Controllers to the motors and switches in a daisy chain using a simple 4 wire cable Refer to Figure 4 47 for cable identification and Table 4 32 for cable pinouts Refer to Figure 4 37 and Figure 4 38 for the loca...

Page 182: ...he last motor in the chain at the downstream communication port NOTE MagneMotion recommends that the upstream connection to the NC LITE Node Controller always be made to an odd numbered male DE 9 RS 422 port and the downstream connection always be made to an even numbered female DE 9 RS 422 port However a custom crossover gender changer may be used to connect an RS 422 DE 9 connector to the NC LIT...

Page 183: ...acks Digital I O signals can be connected to the NC 12 Node Controllers only Refer to Figure 4 43 for the location of these connections on the Node Controller Figure 4 48 Digital I O Equivalent Circuits The digital inputs can be wired as a sink where a 3 24 VDC signal is wired to the appropri ate digital input and COM is connected to the return minus side of the signal as shown in Figure 4 48 The ...

Page 184: ...nsing NC LITE Temperature Operating 0 C to 50 C 32 F to 122 F Shipping 18 C to 50 C 0 F to 122 F Storage 18 C to 50 C 0 F to 122 F Humidity 85 Maximum relative non condensing NC 12 Temperature Operating 0 C to 45 C 32 F to 113 F Shipping 18 C to 50 C 0 F to 122 F Storage 18 C to 50 C 0 F to 122 F Humidity 85 Maximum relative non condensing MM LITE Power Supply Temperature Operating 0 C to 50 C 32 ...

Page 185: ...he site for the MagneMover LITE transport system must meet the minimum space require ments defined after developing the layout as defined in Transport System Layout on page 3 2 and referencing the Mechanical Specifications on page 4 3 to ensure proper clearance for installation operation and servicing of the MM LITE motors and other components Note that the dimensions given are for the MM LITE mot...

Page 186: ...Typical service space required for the MM LITE motors and switches is shown in Figure 4 1 through Figure 4 8 Typical service space required for the Node Control lers and power supplies is shown in Figure 4 19 Figure 4 21 and Figure 4 23 Refer to the LSM Synchronization Option User s Manual for the service space required for the SYNC IT Controller Ensure that the MagneMover LITE transport system is...

Page 187: ...urations of the MagneMover LITE components and transport systems Included in this chapter are Unpacking and inspection of the MagneMover LITE transport system components MagneMover LITE component installation including hardware installation facilities connections and software installation and configuration Initial power up and check out Transport system testing using demonstration scripts ...

Page 188: ...r the exact contents Table 5 1 below is provided for ref erence only Table 5 1 MagneMover LITE Component Packing Checklist Reference Package Contents MagneMover LITE Motors MagneMover LITE linear synchronous motors MagneMover LITE Stands Modular aluminum stand system configured for the motors Includes beam sections motor mounts and cable chase covers MagneMover LITE Pucks or magnet arrays MagneMov...

Page 189: ...stem Installation on page 5 5 CAUTION Strong Magnets To avoid severe injury people with pacemakers and other medical electronic implants must stay away from the magnet array on the vehicles pucks To avoid injury from strong magnetic attractive forces Handle only one vehicle puck or magnet array at a time Do not place any body parts such as fingers between a vehicle puck or magnet array and any fer...

Page 190: ... any inspection discrepancy 2 Open each shipping package and verify the contents against the shipping documents 3 Carefully inspect the MagneMover LITE components and all additional items for signs of damage that may have occurred during shipping 4 Move all items to their destination refer to Transport System Installation on page 5 5 CAUTION Heavy Lift Hazard Some of the MagneMover LITE components...

Page 191: ...all the motors and switches on user supplied supports ensure the supports are properly prepared to receive the motors and switches refer to Mechanical Specifications on page 4 3 Install the motors and switches refer to Mounting Motors and Switches on page 5 20 making any adjustment necessary to account for the custom supports NOTE Any bolts with plastic caps have been pre tightened at the factory ...

Page 192: ... a Clean In Place CIP or wash down environment it must not exceed IP65 5 Install the power supplies Node Controllers network switches and cables refer to Installing Electronics on page 5 27 6 Install magnet arrays on the vehicles and install the vehicles on the system refer to Installing Pucks Magnet Arrays on page 5 40 NOTE Vehicles pucks should be installed on closed loop systems before installi...

Page 193: ...ops of all motors are coplanar to each other and tighten the V braces refer to Mounting Motors and Switches on page 5 20 Align and Secure Motors and Switches on page 5 23 and Verify Motor and Switch Installation on page 5 26 NOTE If railless motors are being used ensure the motor bodies are colinear to each other If motors are installed in a CIP or wash down environment it must not exceed IP65 7 I...

Page 194: ...ction to ensure it is flat and level refer to Leveling the MagneMover LITE on page 5 15 3 Secure the stand section to the floor or other equipment as required refer to Securing the Transport System on page 5 16 4 Attach cable chase cover brackets to curve motor mounts refer to Installing Cable Chase Cover Brackets on page 5 18 5 Attach the motor mounts to all motors refer to Installing Motor Mount...

Page 195: ...efer to Installing Cable Chase Covers on page 5 41 14 Install the user supplied electrical power and communications connections refer to Facilities Connections on page 5 60 15 Create the Node Controller Configuration File and install software refer to Software on page 5 64 16 Power up the system and check all operating safety features and connections refer to System Check out on page 5 66 and Syst...

Page 196: ...le motor mounts to all motors that will be used with the Precision Locators and install the motors refer to Install the Motors on page 5 56 5 Install the pneumatic controls for the Precision Locators refer to Install the Pneumatic Controls on page 5 58 6 Install the covers on the Precision Locators refer to Install the Covers on page 5 59 ...

Page 197: ...curing the individual sections Ensure it is installed in the correct orientation 3 Apply Loctite 243 to two M8 x 25 mm screws and install and tighten the screws to 26 N m 230 in lb using a 6 mm Hex bit NOTE The Loctite must cure for 2 hours at 22 C 72 F before using the transport system Figure 5 1 Connecting Beam Sections 4 Place the next beam section and align its end to the end of the previously...

Page 198: ... shown in Figure 5 2 NOTE Orient the feet as required to allow proper final installation of the beam Figure 5 2 Leg on a Single Path Beam Assembly A Insert two M8 T nuts and rotate into position in the channel on the bottom of the beam where the leg will be attached T nuts must be inserted so that the spring steel tabs are facing toward the beam then rotated clockwise into place B Position the leg...

Page 199: ...m then rotated clockwise into place B Insert one M8 T nut and rotate into position in the channel on the top of the leg where the beam will be attached C Position the leg over the T nuts using a machinist s square to ensure it is prop erly positioned D Locate an angle bracket at each beam leg crossing apply Loctite 243 to two M8 x 25 mm screws per bracket and install Tighten enough to secure the b...

Page 200: ...Ensure the leg is properly positioned and tighten the M8 screws to 26 N m 230 in lb using a 6 mm Hex bit NOTE The Loctite must cure for 2 hours at 22 C 72 F before using the transport system 4 Verify that all legs are perpendicular to the beams using a machinist square 5 Once the stand assembly is complete ensure the transport system is properly located ...

Page 201: ...vel to identify the datum throughout the installation area as shown in Fig ure 5 5 Figure 5 5 System Leveling 3 Ensure all sections of the beam are level and correctly referenced to the datum A Place a machinist square vertically on the beam at each location where a foot is located below the beam and reference the laser beam B Adjust the feet on the legs as required to reach the required height us...

Page 202: ... downs for facilities requiring earthquake protection are the responsibility of the user Tie down Using Brackets The legs of the MagneMover LITE frame should be secured to the facility floor to prevent system movement by installing tie down brackets and installing an appropriate fastener Figure 5 6 Bracket Tie down 1 Insert two M8 T nuts and rotate into position in the appropriate channel of the l...

Page 203: ...0 in lb using a 6 mm Hex bit NOTE The Loctite must cure for 2 hours at 22 C 72 F before using the transport system 4 Secure the bracket to the floor Tie down Using Feet The feet on the MagneMover LITE should be secured to the facility floor to prevent system movement by drilling a hole through each of the indicated locations on the feet that will be secured and installing an appropriate fastener F...

Page 204: ...switches Figure 5 8 Installing Cable Chase Cover Mounting Brackets 1 Install a curve bracket on one side of the curve motor mount using two M5 x 8 mm screws and tighten to 1 6 N m 14 in lb using a Phillips bit 2 Install a curve bracket on one side of the switch motor mount using two M5 screws and tighten to 1 6 N m 14 in lb using a Phillips bit 3 Install a switch bracket to the other side of the s...

Page 205: ...djustable motor mounts this is the end with the two nylon tipped set screws Ensure the orientation of the cable chase mounting brackets for curve motors and switches is correct refer to Figure 5 9 NOTE The 1 m motor requires two motor mounts When using adjustable motor mounts ensure the lock nut on the set screws is loose 3 Secure the motor mount to the motor using an M6 x 20 mm bolt and M6 split ...

Page 206: ...MagneMover LITE stand system ensure the motors are flat and level once assembled When using motors with integral rails before installing all the motors in a closed system add the pucks by sliding them onto the end of a motor that has been installed Ensure all motors on parallel paths are parallel Mounting the motors is the same for motors with rails and for railless motors Figure 5 10 Installing M...

Page 207: ...s shown in Figure 5 11 ensure the fixture is fully seated in the slot in the beam For switches also adjust the position of the switch on the motor mount to ensure the third face is properly positioned Tighten the M8 bolt securing the motor mount to the beam to 26 N m 230 in lb using a 13 mm Hex socket Figure 5 11 Positioning Motors and Switches Table 5 2 Motor Mount Reference Motor Type Motor Moun...

Page 208: ...ue to install motors and switches as described in Step 2 at every third motor verify the position of the motor as described in Step 3 5 Once all motors are mounted on the system adjust any motors as necessary to ensure consistent spacing between the motors and to ensure the top surface of all motors are coplanar to each other ...

Page 209: ...Rails G4 Motors 1 Loosen the M6 bolt securing the motor to the motor mount for all motors or switches being adjusted if necessary 2 For aluminum rails install the V braces at all guide rail joints using M6 x 12 mm screws and tighten finger tight to pull the rails together NOTE The guide rail joints on the aluminum rails contain locking inserts which will limit the depth of insertion when finger ti...

Page 210: ... 4 Tighten the M6 bolt securing the motor or switch to the motor mount to 5 5 N m 49 in lb using a 10 mm Hex socket NOTE For stainless steel rails the Loctite must cure for 2 hours at 22 C 72 F before using the transport system 5 Repeat Step 3 at all motor and switch joints 6 Repeat Step 4 at all motors and switches ...

Page 211: ...d Secure Motors and Switches on page 5 23 Figure 5 13 Align and Secure Railless Motors 1 Loosen the M6 bolt securing the motor to the motor mount for all motors being adjusted 2 Install the V braces at all motor to motor joints using M6 x 10 mm screws with Loctite 243 and tighten finger tight to pull the motors together 3 Align straight motors at the motor joints as shown in Figure 5 13 ensuring t...

Page 212: ... mount to 5 5 N m 49 in lb using a 10 mm Hex socket NOTE The Loctite must cure for 2 hours at 22 C 72 F before using the transport system 7 Repeat Step 3 at all straight motor to straight motor joints 8 Repeat Step 4 at all curve motor to straight motor joints 9 Repeat Step 5 at all curve motor to curve motor joints 10 Repeat Step 6 at all motors Verify Motor and Switch Installation Once all motor...

Page 213: ... Controller LITEs The Node Controller LITE should be located on the transport system stand close to the Nodes it is responsible for to minimize the length of all wiring The controller may be oriented in any direction required ensuring the service and exclusion zones identified in Figure 4 21 on page 4 23 are maintained Typical mounting methods are vertically on one of the transport system legs or ...

Page 214: ...ed using the remote power supply instead of using PoE the power supply should be located on the transport system stand close to the Node Controller it is powering to minimize the length of all wiring The power supply may be oriented in any direction required Mounting Network Switches The network switches should be located on the transport system stand close to the Node Con trollers they are connec...

Page 215: ...uts and rotate into position in the appropriate channel s of the frame 2 Install the mounting flanges onto the Node Controller if not already installed Apply Loctite 243 to four 1 4 20 flat head screws and tighten to 10 1 N m 90 in lb maxi mum thread length into threaded hole 7 87 mm 0 310 in 3 Orient the Node Controller as required and secure it to the T nuts apply Loctite 243 to two M8 screws an...

Page 216: ...rackets onto the Node Controller if not already installed 1 Remove the two M5 x 10 mm screws from the front of each side four screws total 2 Install two M5 X 12 mm flat head screws to secure each bracket and tighten to 2 0 N m 18 in lb four screws total 3 Locate the Node Controller in the rack and secure it using four screws two per mount ing bracket as specified by the rack manufacturer 4 Install...

Page 217: ...quired ensuring the service and exclusion zones identified in Figure 4 23 on page 4 25 are maintained Typical mounting methods are vertically on one of the transport system legs or horizontally between two parallel track sections as shown in Figure 5 17 Figure 5 17 Power Supply Mounting 1 Insert two M8 T nuts and rotate into position in the appropriate channel s of the frame 2 Remove the six screw...

Page 218: ...ors in the transport system All motors in a specific Path are chained together with the upstream end of the chain always connected to a Node Controller and the downstream end connected to a Node Controller if it terminates in a Node Power and communications cables can be run in the cable chase under the motors to protect them from damage and provide easy access for service The following procedure ...

Page 219: ...ext motor in Path NC PS Downstream Upstream Simple Node Power Connection Communication Connection Motor Section Straight or Curve Motor Section Straight or Curve Downstream Upstream PS Upstream Upstream Motor Section Straight or Curve Motor Section Straight or Curve Switch Section Merge Motor Section Straight or Curve From previous From previous motor in Path motor in Path To next motor in Path Mo...

Page 220: ...ect to the same Node Controller However all connections to the motors at the ends of all Paths meeting in a Node must be made to the same Node Controller Refer to the MagneMover LITE Configurator User s Manual for more information about Nodes and Paths Figure 5 20 Communication Cable Connections 1 Connect an external communications cable from an RS 422 connector on the Node Controller to the upstr...

Page 221: ...tions cable from the downstream end of the last motor in the Path to an RS 422 connector on the Node Controller if that Path ends at a Node e g Relay Node Switch Terminus Node and route the cable in the cable chase For an NC 12 Node Controller connect to any RS 422 port finger tighten only For a Node Controller LITE typically connect to either J2 or J4 using a small screwdriver do not overtighten ...

Page 222: ...supported and route the cable in the cable chase 2 When supplying power to the Node Controller LITE through PoE connect a Cat 5 net work cable for network communications from a dedicated Ethernet switch with 18 VDC PoE to LAN on each Node Controller LITE auto MDIX and auto negotia tion are supported and route the cable in the cable chase When supplying power directly to the Node Controller LITE co...

Page 223: ...I O connections use 12 26 AWG insulated wires and connect them to the appropriate input or output bits and to the respective COM GND or VDD connections Insert a small e g 2 flat blade screwdriver into the connector release slot above the appro priate connector refer to Figure 5 21 and rotate it in place to open the connector while insert ing the wire into the connector Once the wire is fully seate...

Page 224: ... be made at a later time refer to Facilities Connec tions on page 5 60 Refer to Electrical Wiring on page 3 12 to ensure all power wiring is properly sized Refer to Table 4 1 on page 4 38 when connecting the power cables to the motors to ensure each chain of motors does not exceed the rated output of the power supply 600 W MagneMotion recommends a maximum of 10 motors be connected to J1 or J2 on t...

Page 225: ...the T splitter finger tighten do not use tools to tighten and route the cable in the cable chase 6 Connect a T splitter power cable to the next motor finger tighten do not use tools to tighten 7 Connect the power bus cable from the last motor to the T splitter finger tighten do not use tools to tighten 8 Repeat Step 5 through Step 7 for each motor in the power chain NOTE It is not necessary to con...

Page 226: ...ng them out of the way If the transport system has been fully assembled and there is no section of the system config ured for loading unloading pucks refer to Replace Pucks on page 7 35 for the preferred method to add or remove pucks and Replace Precision Rail Vehicles on page 7 45 for the pre ferred method to add vehicles on transport systems with precision rails CAUTION Strong Magnets To avoid s...

Page 227: ...ganized Straight Motors Figure 5 23 Installing Straight Motor Cable Chase Covers 1 Locate a flat cover the same length as the motor against one side of the motor mount s 2 Install two M5 x 8 mm screws per mount to secure the cover 3 Locate another cover against the other side of the motor mount s 4 Install two M5 x 8 mm screws per mount to secure the cover 5 Tighten the M5 screws to 1 6 N m 14 in ...

Page 228: ... Chase Covers 1 Locate an inner cover against the bracket on the inside of the curve 2 Install two M5 x 8 mm screws to secure the cover 3 Locate an outer curve cover against the motor mount on the outside of the curve 4 Install two M5 x 8 mm screws to secure the cover 5 Tighten the four M5 screws to 1 6 N m 14 in lb using a Phillips bit Outer Cover Inner Cover M5 Screw 4X ...

Page 229: ...Covers 1 Locate an outer switch cover against the bracket on the outside of the switch 2 Install two M5 x 8 mm screws to secure the cover 3 Locate two inner covers against the bracket on the inside of the switch 4 Install two M5 x 8 mm screws each to secure each cover 5 Tighten the six M5 screws to 1 6 N m 14 in lb using a Phillips bit Outer Cover Inner Cover M5 Screw Inner Cover 6X ...

Page 230: ...ess motors is shown in Fig ure 5 26 NOTE Precision Rails cannot be used with the Precision Locator option Figure 5 26 MagneMover LITE Railless Motor System NOTE When installing the Precision Rail structural components they should be loosely fas tened finger tighten then back off one half turn to provide the parts a small amount of movement relative to each other to allow for final adjustments once...

Page 231: ...de the parts a small amount of movement relative to each other to allow adjustment 3 Loosely attach the appropriate spine plate to the post mount using two M6 x 16 mm Low Head SHC screws finger tighten then back off one half turn to provide the parts a small amount of movement relative to each other to allow adjustment NOTE Ensure the rail mounting edge of the spine plate is oriented towards the c...

Page 232: ...hey should be installed onto the beam as shown in Figure 5 29 Figure 5 29 Attach Precision Rail Support Post Assemblies to Beam 1 Locate each support post assembly at the appropriate position on the transport system 2 Remove the M8 T nuts from the connecting plate and install them into the channel on the outside of the beam at the support post s location and rotate into position 38 0 1 5 M8 T Nut ...

Page 233: ...gle rail as shown in Figure 5 32 NOTE Rail segments not used or rail ends not matched letter to letter will result in a mis match between rail ends and may require installation personnel to hone the rail ends to achieve acceptable alignment and performance Prior to attaching and securing the final rail within the system all vehicles should be installed onto the rails by sliding them onto an open s...

Page 234: ...ved rail and tighten the jacking screws enough to hold it in place C Insert the thin end of the adjustment key into the end of the straight rail D Loosen the jacking screw on one side of the rail and tighten the jacking screw on the other side of the rail to align the two rail section 3 Position the rails over the edge of the spine plates aligning the mounting holes in the rail over the spine plat...

Page 235: ...e plates using M5 SHC screws fin ger tighten then back off one half turn to provide the parts a small amount of move ment relative to each other to allow adjustment The number of screws required for each spine plate attachment is identified in Table 5 3 Table 5 3 Precision Rail to Spine Plate Attachment Screws Spine Plate Type Screws Joint Straight to Straight 2 Joint Straight to Curve 3 Joint Cur...

Page 236: ...straight rail to curve rail joints Figure 5 33 Tightening Sequence Straight to Curve Precision Rail Spine Plate 1 Use fingers to align the end of the straight rail with the end of the curved rail NOTE The jacking screws on the inside and outside end of the curved rail refer to Figure 5 31 are used for side to side alignment Loosen the jacking screw on one side of the rail and tighten the jacking s...

Page 237: ...own in Figure 5 34 3 Repeat Step 1 through Step 2 for all curved rail to curved rail joints in the system Straight Rail to Straight Rail Joints Refer to Figure 5 35 when aligning and securing all straight rail to straight rail joints Figure 5 35 Tightening Sequence Straight to Straight Precision Rail Spine Plate 1 Use fingers to align the ends of the straight rails 2 Once the rails are aligned tig...

Page 238: ... at the mid point Straight No Joint Locations Refer to Figure 5 37 when aligning and securing all straight rails at mid point locations NOTE For greater stability it is recommended that one spine plate be installed every 500 mm along straight rail segments that are greater than 500 mm in length Figure 5 37 Tightening Sequence Straight Rail No Joint Precision Rail Spine Plate 1 Once the rail is ali...

Page 239: ...the rail to make sure it is still properly aligned 3 Tighten the second M6 screw on the spine plate to 3 2 N m 28 in lb using a 5 mm Hex wrench 4 Select to the next closest spine plate and repeat Step 1 through Step 3 Continue secur ing each spine plate to its support post until all spine plates are secure Install the Precision Rail Vehicles Vehicles should be installed on closed loop systems befo...

Page 240: ...ed has been completed A typical assembly is shown in Figure 5 39 NOTE The Precision Locator cannot be used with the Precision Rails option Figure 5 39 MagneMover LITE Precision Locator Option Standard Back Plate Pallet Precision Locator Puck Adjustable Motor Mount M6 x 20 mm Bolt M6 Lock Washer M8 x 20 mm Bolt M8 Lock Washer M8 x 30 mm Bolt M8 Lock Washer 1X per Rib 1X per Rib M6 x 25 mm Screw 4X ...

Page 241: ...to Replacing Wear Surfaces on Pallet on page 7 64 2 Install the puck with the pallet on the system refer to Replace Pucks on page 7 35 for the preferred method to add or remove pucks NOTE Ensure the orientation of the puck locates the pallet correctly at the Precision Locator station Back Plate Pallet Precision Locator Puck Adjustable Motor Mount M6 x 20 mm Bolt M6 Lock Washer M8 x 20 mm Bolt M8 L...

Page 242: ...he Precision Locator stand Mounting the Standard Precision Locator Stand refer to Figure 5 39 A Install one M8 T nut in the top channel of the beam at the approximate location for each Precision Locator stand rib T nuts must be inserted so that the spring steel tabs are facing toward the beam then rotated clockwise into place B Position the locator stand on the beam and aligned to the T nuts insta...

Page 243: ...5 in between the puck lobes and the side surface of the rail With the puck out of the station verify that when the arm is in the down pinned the position the pin is below the pallet surface With the puck out of the station verify that when the arm is in the up position the pallet clears the pins 4 Tighten the lock nuts on the motor mount to 10 2 N m 90 in lb 5 Apply Loctite 243 to the M6 x 12 mm s...

Page 244: ...o the Host Controller s Digital I O B Connect the valve s pneumatic input to the facility s compressed air line C Connect the pneumatic valve s 2 output to Open on the Precision Locator s pneumatic cylinder D Connect the pneumatic valve s 4 output to Closed on the Precision Locator s pneumatic cylinder E Connect the pneumatic valve s exhaust 3 to a flow control valve The flow control valve should ...

Page 245: ...Locator s and tighten the screws to 0 68 N m 6 in lb using a 2 mm Hex wrench NOTE The Loctite must cure for 2 hours at 22 C 72 F before using the transport system Teach the Precision Locator Position Once the Precision Locator is installed the location for the pallet at the Precision Locator sta tion must be taught to ensure the pallet is properly secured by the locator Then the location of the pa...

Page 246: ...red to make all network communica tions and PoE connections to the Node Controllers as shown in Figure 5 42 NOTE The transport system s network should be a dedicated separate subnet to eliminate any unrelated network traffic Figure 5 42 Network Cable Connections 1 Connect a Cat 5 network cable for transport system network communications from the Host Controller to the Uplink connector on the netwo...

Page 247: ...ace User s Manual for more details If EtherNet IP is being used refer to the Magne Mover LITE Configurator User s Manual for additional configuration information 4 Configure one Node Controller as a High Level Controller Refer to the Node Control ler Web Interface User s Manual for more details Electrical Connections Electrical power is connected to the MagneMover LITE transport system for operati...

Page 248: ...ransport system can use Digital I O provided through an NC 12 Node Controller for monitoring and control of local options such as an E Stop The optional E Stop circuit is the responsibility of the user and requires a user supplied E Stop button and 3 24 VDC power supply for the Digital Input Refer to Figure 4 48 on page 4 65 for the Digital I O Equivalent Circuits Refer to E Stops on page 6 13 for...

Page 249: ...Refer to Figure 4 48 on page 4 65 for the Digital I O Equivalent Cir cuits Refer to Light Stacks on page 6 17 for the Light Stack circuit Refer to the Magne Mover LITE Configurator User s Manual for information on configuring a Light Stack General Purpose Digital I O The MagneMover LITE transport system can use Digital I O provided through an NC 12 Node Controller to allow the Host Controller to m...

Page 250: ...motors through the Node Controller Upgrades to the software can be uploaded through the network communications link Refer to the Upgrade Procedure in the Release Notes supplied with the software upgrade NOTE Specific builds of MagneMotion s software may not implement all of the features described in this manual Refer to the Release Notes provided with the software for additional information All so...

Page 251: ...d the configuration files through the Node Controller Web Interface to each Node Controller Refer to the Node Controller Web Interface User s Manual for details NOTE Restart the Node Controller for the changes to take effect Motor Software Installation 1 Upload the motor ERF image files motor_image erf to each Node Controller using the Node Controller Web Interface and program the motor masters an...

Page 252: ...securely installed in the facility Ensure that all hardware is secure If the optional E Stop circuit is being used ensure that the button is functional Manually move a vehicle puck through the entire MM LITE transport system to ensure free motion no binding Facility Checks Ensure that all facilities are capable of meeting or exceeding the requirements as described in the Electrical Specifications ...

Page 253: ...ted 2 Ensure the system is properly grounded 3 Connect the MagneMover LITE transport system to the plant s electrical services Ensure power remains off CAUTION Crush Hazard Moving mechanisms vehicles and switches have no obstruction sensors Do not operate the MagneMover LITE transport system without barriers in place or personal injury could result in the squeezing or compression of fingers hands ...

Page 254: ...addresses specify the Node Controller to be used as the High Level Controller and upload the configuration image and type files to each Node Controller refer to the Node Controller Web Interface User s Manual 9 Program the motors using the Motor Image Files refer to the Node Controller Web Interface User s Manual 10 Review the log files for each Node Controller to ensure that the system has been p...

Page 255: ...b Interface for each Node Controller shows a status of run ning valid refer to the Node Controller Web Interface User s Manual 4 Issue a Restart Services command for each Node Controller refer to the Node Con troller Web Interface User s Manual 5 Issue a Reset command for all Paths All of the motors on the Paths in the transport system are reset 6 Issue a Startup command to all Paths Motion on all...

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Page 257: ...rt system The operation of the MM LITE transport system is covered for both normal conditions and emergency conditions Included in this chapter are Theory of operation of the MagneMotion linear synchronous motors and the Magne Mover LITE transport system Controls and indicators provided on the system Simulation of MM LITE transport system operation Operational start up and safe shut down ...

Page 258: ...condary is an array of magnets that is attached to the object to move referred to as a vehicle puck The motor primary gen erates a magnetic field to move the motor secondary vehicle in a controlled manner The MM LITE motors also use the magnets on the vehicle puck to track the vehicle s position Figure 6 1 Linear Synchronous Motor Derived From Rotary Motor MagneMover LITE Transport System Advantag...

Page 259: ... the Path Vehicles can also be moved from one Path to another as long as there is a connection between the Paths either direct or through one or more Paths through a Node or multiple Nodes The design and operation of the MagneMover LITE transport system uses a minimum of moving parts to ensure minimal maintenance requirements Position monitoring circuits in all motors ensure accurate tracking and ...

Page 260: ... and sends it to the High Level Controller HLC For example the Order is to move Vehicle 1 to a Position 1 5 m on Path 1 Pdest at a maximum speed of 0 5 m s Vmax and acceleration deceleration of 1 m s2 Amax 2 The HLC routes the order to the appropriate Node Controller 3 The Node Controller generates a movement order and sends it to the appropriate vehi cle master motor controller for the motor wher...

Page 261: ...tion The new master is now responsible to continue the closed loop control of the vehicle 7 The movement order is finished when the vehicle position is equal to the ordered des tination Motor Cogging Brushless Permanent Magnet BPM motors that are iron core based inherently exhibit cog ging forces In traditional BPM motors these are felt when turning the shaft of the motor and are periodic in natur...

Page 262: ...e the vehicle must start slowing down for its current target to minimize the number of committed blocks and to ensure brick wall headway is maintained Permission to enter a motor block is only granted after previous vehicles have com pletely exited the block Each vehicle is controlled in such a manner that it is always able to stop in the last motor block it was granted permission to enter Anti Co...

Page 263: ... heavy line and provide a safe stop ping distance dashed heavy line based on the vehicle s current velocity and commanded acceleration This can be found by dividing the square of a vehicle s current velocity by twice its acceleration V2 2a Figure 6 4 Vehicle Movement Profile In Queue Typically the vehicles pucks will queue up while in route to a particular destination when another vehicle obstruct...

Page 264: ...th of the vehicle puck with a custom fixture is the same or smaller as the puck top 62 mm x 62 mm then the defined length of the vehicle puck in the configuration file must be 77 mm to ensure proper spacing in a curve Locating Vehicles During Startup The Node Controller scans for the magnet array on the vehicles starting from the upstream end of a Path and scanning towards the downstream end of th...

Page 265: ...d to within approximately 25 mm of its original position as measured from the center of the vehicle On return of the propulsion power the vehicle will not be able to move unless it had been returned to the same section of the motor where it was located when the power was shut off In this case the vehicle will be shown as having signal Vehicle Signal 1 but it will also show as Suspect Vehicles that...

Page 266: ...ors consume power while mov ing vehicles and voltage increases during regeneration events will lead to fluctuations in the voltages seen at the motor power terminals Under normal operating condition these fluctua tions are minimal and can be ignored The power supplies and wiring for the system must be designed to minimize these fluctuations refer to Electrical Wiring on page 3 12 ...

Page 267: ...MagneMover LITE components are identified in the Electrical Specifications on page 4 38 Track Display The NCHost TCP Interface Utility can be used to display the Graphics Window shown in Fig ure 6 5 which shows the transport system layout and all vehicles in the transport system for real time monitoring of transport system operation This can only be used if a Track File for the specific configurat...

Page 268: ...ors In synchronous operation the profile position velocity and acceleration generation for indi vidual vehicles is the responsibility of the Host Controller which generates profiles for all vehicles in the synchronization region This requires that the Host Controller be in charge of collision avoidance Once the vehicle leaves the sync region the MMI control system picks up profile generation and c...

Page 269: ...then be configured to be associated with a specific E Stop bit Any or all Paths may be associ ated with the same E Stop bit Refer to the MagneMover LITE Configurator User s Manual to configure the MagneMover LITE transport system to use an E Stop NOTE An external power supply for the E Stop circuit must be provided by the user A single E Stop circuit may have multiple buttons wired together in ser...

Page 270: ...r Figure 6 8 E Stop Wiring Diagram Multiple Node Controllers1 1 In this configuration other Digital I O functions may not be available Digital In Digital In E Stop NC 12 Node Controller COM V V E Stop 3 24 VDC Power Supply Digital In Digital In E Stop NC 12 Node Controller COM E Stop Digital In Digital In NC 12 Node Controller 8 max COM V V 3 24 VDC Power Supply ...

Page 271: ... the vehicle s current movement command Multiple Interlock circuits may be connected to a single NC 12 Node Controller Each Path can then be configured to be associated with a specific Interlock bit Any or all Paths may be associated with the same Interlock bit Refer to the MagneMover LITE Configurator User s Manual to configure the MagneMover LITE transport system to use an Interlock NOTE An exte...

Page 272: ... Path s Vehicles immediately decelerate with maximum thrust opposing motion Previously commanded movement does not resume until a Resume Movement command is received Note that the control loop is still enabled while movement is suspended holding all vehicles in place Refer to the Host Con troller TCP IP Communication Protocol User s Manual or the Host Controller EtherNet IP Communication Protocol ...

Page 273: ...ht stacks typically green yellow and red are sup ported by the MagneMover LITE transport system The Light Stack may be used to monitor the status of any or all Paths on the Node Controller where it is connected Refer to the Mag neMover LITE Configurator User s Manual to configure the MM LITE transport system to use a Light Stack NOTE An external power supply for the Light Stack circuit must be pro...

Page 274: ...l I O terminals on the Node Controller The Host Controller can then issue commands to set the value of the Digital Outputs or read the value of the Digital Inputs Refer to the Host Controller TCP IP Commu nication Protocol User s Manual or the Host Controller EtherNet IP Communication Protocol User s Manual for details on the use of the Digital I O commands NOTE An external power supply for the Di...

Page 275: ... the vehicle is not overloaded for the PID set being specified meaning that it will accelerate and decelerate at the rates specified in the command with a maximum of the values specified in the Node Controller Configuration File Simulating the transport system requires one Node Controller a fully defined Node Controller Configuration File and a Host Controller either the transport system s control...

Page 276: ...l B Select Show Simulated Vehicles from the Options menu C For each Path where simulated vehicles will start define the simulated vehicles and enter the starting location for each vehicle 1 In the Configuration Tree open the Paths list 2 Select the Path where the simulated vehicle will start 3 Right click on Simulated Vehicles and select Add to End to add a simulated vehicle 4 Select the simulated...

Page 277: ...i cle from the Path Issuing a Startup command to a Path where simulated vehicles have starting locations after any Path has been reset will add new simulated vehicles to that Path either at the location specified in the Configuration File or in the next available space downstream Table 6 1 Simulated Operation Differences Feature Physical Operation Simulated Operation Motors All motors must be defi...

Page 278: ...o run in Normal Mode NOTE It is not necessary to remove the simulated vehicles from the Node Controller Configuration File as they will be ignored during normal operation A Run the Node Controller Web Interface B Select IP Settings on the Main Menu The IP Settings page is displayed C In the Configured Functions section ensure This box is a High Level Con troller Simulator is cleared D In the Confi...

Page 279: ...are reset 3 Issue a Startup command to all Paths Motion on all Paths is enabled all vehicles on the Paths are identified and located and the Paths become operational 4 Move vehicles as required Use the NCHost TCP Interface Utility to move vehicles individually or create a Demo Script for repetitive testing refer to the NCHost TCP Interface Utility User s Manual Use the application developed for th...

Page 280: ...ed rails on the standard MagneMover LITE motors When using the Precision Rail option MM LITE railless motors are used with the precision rail aligned above the motors and supporting vehicles using precision sealed bearings Setup Install the Precision Rails as described in Precision Rail Installation on page 5 44 Operation Operation of the vehicles on the Precision Rail is the same as operation of ...

Page 281: ...re is no link between the Precision Locator and the Node Controllers in the transport system The typical sequence for operation is 1 Command the puck with the pallet mounted on it to the locator position 2 Command the Precision Locator to close locating and securing the pallet NOTE Actuation from arm up to arm down must be no less than 100 ms This is accomplished by adjusting the flow controls on ...

Page 282: ...he MM LITE transport system must be determined by the user Refer to the Host Controller TCP IP Communication Protocol User s Manual or the Mitsubi shi PLC TCP IP Library User s Manual for details of each command to use Host Controller TCP IP Communications Refer to the Host Controller EtherNet IP Communication Protocol User s Manual for details of each user defined tag and the PLC interface to use...

Page 283: ...ent command for all Paths All vehicles come to a controlled stop 4 Once all motion has stopped issue a Reset command for all Paths Clears all vehicle records 5 Turn off all electrical power to the motors 6 Turn off all pneumatic power to the Precision Locator option if installed 7 Turn off power to the Node Controllers 8 Turn off power to the Host Controller 9 Turn off the main power disconnect fo...

Page 284: ...Operation 28 MagneMotion Rockwell Automation Publication MMI UM002E EN P March 2016 This page intentionally left blank ...

Page 285: ...y trained qualified personnel should attempt to perform maintenance or troubleshooting on the MM LITE transport system MagneMotion provides training in the troubleshooting and repair of the MM LITE transport system Included in this chapter are Preventive maintenance procedures Troubleshooting procedures Contacting MagneMotion Technical Support Basic repair procedures Component and system shipping ...

Page 286: ...ied frequency is based on a certified clean inert environment The user should adjust their Preven tative Maintenance Schedule to account for any deviations from this environment Page MagneMover LITE Transport System General Cleaning 3 months or as required 7 3 Spray Cleaning 3 months or as required 7 3 Puck Cleaning 3 months or as required 7 4 Puck Wear Surface Maintenance 3 months or as required ...

Page 287: ...er LITE motors or the material being moved on the motors consists of providing a constant water spray as defined by IP65 as described below 1 Ensure all components that are not IP65 washdown compatible power supplies Node Controllers etc are appropriately covered 2 If the only the motors are being cleaned stop all motion on the sections of the MM LITE to be cleaned If material in transit is being ...

Page 288: ...ly dampened with isopropyl alcohol squeezing the swab should not cause any alcohol to drip by running the swab between the top and center plates using a back and forth motion in the direction of travel refer to Figure 7 1 Figure 7 1 Puck Cleaning 3 While wearing gloves clean external puck wear surfaces with a clean microfiber cloth slightly dampened with isopropyl alcohol squeezing the cloth shoul...

Page 289: ...restricting bend radii excessive tension or physical damage 4 Return the MM LITE transport system to normal operation Hardware Inspection 1 Stop all motion on the sections of the MM LITE transport system to be inspected 2 Turn off all MM LITE transport system components with accessible power controls 3 Ensure all motor stand hardware is secure 4 Ensure all motor mounting hardware is secure 5 Ensur...

Page 290: ...otion Support refer to the Node Controller Web Interface User s Manual Clean Power Supply Air Filter 1 Turn off power to the MM LITE Power Supply NOTE The power supply should not be used when the filter is not installed 2 Visually inspect the air filter If the filter needs to be cleaned remove the filter from the power supply 3 Inspect the air filter for damage If the filter is damaged contact Mag...

Page 291: ... If lubricators are not installed on the underside of the vehicles lubrication can be applied manually to the rails using a clean towel or wipe NOTE The frequency of lubrication depends on the rail use and environmental factors Required Tools and Equipment Disposable gloves Microfiber cleaning cloth 68 viscosity EP mineral oil Procedure 1 Stop all motion on the sections of the MagneMover LITE tran...

Page 292: ...le is located 2 Locate the lubricating applicator under the Precision Rail vehicle The applicators are located on the underside of the vehicle and can be mounted between the concentric bearings or the eccentric bearings as shown in Figure 7 2 CAUTION Strong Magnets To avoid severe injury people with pacemakers and other medical electronic implants must stay away from the magnet array on the vehicl...

Page 293: ...lustration of applicator housing Figure 7 2 Precision Rail Vehicle Lubricating Applicator Location Figure 7 3 Precision Rail Vehicle Lubricating Applicator Front and Rear 3 Insert the tip of the oil filled syringe into the refill hole on the applicator NOTE On single array vehicles if the applicator is located between the concentric bearings on the magnet array side of the vehicle use the lubricat...

Page 294: ...l Automation Publication MMI UM002E EN P March 2016 Figure 7 4 Precision Rail Single Array Vehicle Lubrication Portal 4 Replenish the oil in the applicator Do not overfill the reservoir 5 Return the MM LITE transport system to normal operation Oil Fill Portal ...

Page 295: ... To avoid severe injury people with pacemakers and other medical electronic implants must stay away from the magnet array on the vehicle To avoid injury from strong magnetic attractive forces Handle only one vehicle at a time Do not place any body parts such as fingers between a vehicle or magnet array and any ferrous material or another magnet array Vehicles or magnet arrays not being used should...

Page 296: ...efer to the cut away view shown in Figure 7 5 to make adjustments to the eccentric bearings on a vehicle 1 Stop all motion on the section of the MagneMover LITE transport system where the vehicle will be adjusted 2 Using a socket wrench loosen the nut on the eccentric bearing to be adjusted on the top of the vehicle refer to Figure 7 5 3 Using a thin open ended wrench turn the bearing nut to rotat...

Page 297: ...itial Troubleshooting Symptom Possible Problem Area Power lights do not turn on See Power Related Troubleshooting on page 7 14 Reset of switch and Paths associated with the switch fails Motors report power related faults Vehicles do not seem to move as fast as when the MagneMover LITE transport system was initially installed See Power Related Troubleshooting on page 7 14 See Motion Control Trouble...

Page 298: ...ot blown Replace if neces sary and determine cause to pre vent reoccurrence Motors not moving vehicles at full speed Power supply is not providing full power Verify power supply air filter is not dirty Clean or replace if nec essary Verify power supply vents are not obstructed refer to Figure 4 23 on page 4 25 Transport system motion control issues Review Motion Control Trouble shooting on page 7 ...

Page 299: ...efore sending any commands to the motor Reset of switch and Paths associ ated with the switch fails when propulsion power is turned off Propulsion power is required for homing of the switch s flipper Allow the reset to fail on the 1st try with the propulsion power dis abled Enable the propulsion power as no vehicles will move because there are no vehicle records Issue a reset to the Paths that fai...

Page 300: ...reports an over voltage fault Power being supplied to the motor is above 42 VDC Verify the voltage output from the power supply Verify the voltage at the motor The fault will clear once the power bus drops below 38 VDC Table 7 4 Power Related Troubleshooting Continued Symptom Problem Description Corrective Action ...

Page 301: ...r Related Troubleshooting Symptom Problem Description Corrective Action Node Controller logs do not indi cate the correct time The battery for the clock in the Node Controller has lost its charge Manually correct the time each time the Node Controller is pow ered up or return the Node Con troller to MagneMotion for repair Use the Node Controller Web Interface Set Clock function to set the time ref...

Page 302: ...oper connection and continuity of all connections Check communication to the Host Controller Ensure logic power is enabled Host Controller application issue Verify the Host Controller is cor rectly set up Verify the Host Application soft ware is correctly written Intermittent Communication with the Host Controller Communication is lost or inter mittent Ensure all network cables are properly seated...

Page 303: ...nt is noisy Debris on the guideway Ensure the guide rails and motors are clean Misalignment of sections of the guideway Ensure the guide rail alignment V braces are properly installed Power or communication to the affected motors is lost or intermit tent Ensure the power and communi cations cables to all motors are properly seated Motion configuration issue Ensure the PID values are correct Excess...

Page 304: ...scription Corrective Action Precision Rail vehicle s are mov ing abnormally slow or jerky Vehicles binding on the rails Ensure the rails are properly lubricated refer to Lubricating the Precision Rails on page 7 7 and Refilling a Precision Rail Vehicle s Lubricating Applicator on page 7 8 Vehicle bearings are not set cor rectly log messages indicate the motors are overheating Ensure the bearing ad...

Page 305: ...ut from the power supply Light stack is not wired properly Ensure all connections to the light stack are properly wired refer to Light Stacks on page 6 17 Ensure the bits specified in the Configuration File are the bits connected to the light stack Light stack is not configured properly Ensure the light stack is config ured to monitor the appropriate Paths and or Nodes Yellow light does not turn o...

Page 306: ...Provide the name of the person to contact e mail address and telephone number 5 List any error codes received during the failure 6 Prepare a detailed description of the events leading up to the error How long has the equipment been in operation Was any work done on the equipment prior to the error What command was the equipment performing when the error occurred List all actions taken after the er...

Page 307: ...s NOTICE Only a qualified service representative can service the components of the MagneMover LITE transport system Any attempt to open the transport sys tem modules by anyone other than a qualified MagneMotion service repre sentative will void the warranty Table 7 10 MagneMover LITE Repair Procedures Component Maintenance Action Page MagneMover LITE Trans port System Adjust G3 Motors to Eliminate...

Page 308: ...rch 2016 Precision Locator Replacing Wear Surfaces on Pallet 7 64 Replacing Bushings on Pallet 7 67 Replacing Pins on Precision Locator Arms 7 69 Replacing Z Datums on Precision Locator Stand 7 71 Table 7 10 MagneMover LITE Repair Procedures Continued Component Maintenance Action Page ...

Page 309: ...closest to where the binding is detected refer to Figure 7 6 for adjustment point locations NOTE Do not spread the rails on curve motors switches or any G4 motors or switches Figure 7 6 Rail Adjustment Points G3 Motors 3 Turn the handle on the fixture until it is fully seated ensure the fixture is pressed against the underside of the rails Turn the handle additionally as specified in Table 7 11 to...

Page 310: ...nce Repair 26 MagneMotion Rockwell Automation Publication MMI UM002E EN P March 2016 Figure 7 7 Adjust Rails G3 Motors 4 Return the MM LITE transport system to normal operation Rail Post Rail Spreader Rail Post ...

Page 311: ...Required Tools and Equipment 000 0600 00 Rail Alignment Fixture ML G3 motors and G3 switches only Torque wrench with the following bits T30 Torx 13 mm Hex socket Loctite 243 Thread locker Anaerobic Adhesive Blue Procedure Figure 7 8 Align and Secure Rails G3 Motors 1 Stop all motion on the sections of the MagneMover LITE transport system to be ser viced 2 Loosen the M8 bolt securing the motor to t...

Page 312: ... in Fig ure 7 8 Apply Loctite 243 to the two M6 x 12 mm screws on each V brace at that motor joint and tighten the screws to 3 4 N m 30 in lb using a T30 Torx bit NOTE The Loctite must cure for 2 hours at 22 C 72 F before using the transport system 5 Tighten the M8 bolt securing the motor to the motor mount to 12 N m 106 in lb using a 13 mm Hex socket 6 Repeat Step 2 through Step 5 at all motor an...

Page 313: ...ort system the Node Con troller software for the system must be upgraded to Version 4 X or greater This upgrade requires that all Type Files Image Files and the Node Controller Configu ration File be updated Required Tools and Equipment Torque wrench with the following bits T30 Torx 10 mm Hex socket 13 mm Hex socket 200 2060 01 V Brace G3 G4 Adapter Motor SS ML Loctite 243 Thread locker Anaerobic ...

Page 314: ...joints on the aluminum rails contain locking inserts which will limit the depth of insertion when finger tightening For stainless steel rails install the V braces at all guide rail joints using M6 x 12 mm screws and Loctite 243 and tighten finger tight to pull the rails together 5 Tighten the two M6 x 12 mm screws on each V brace at that motor joint to 3 4 N m 30 in lb using a T30 Torx bit NOTE Th...

Page 315: ...ll vehicles come to a controlled stop 4 Once all motion has stopped issue a Reset command for the Path where the motor will be replaced Clears all vehicle records 5 Turn off all electrical and pneumatic power to the section of the MagneMover LITE transport system where the motor will be replaced 6 Label the power and sense connections to the motor 7 Disconnect all connections 8 Remove the bolts se...

Page 316: ...nnect the power and sense connections to the motor referencing the labels previ ously placed on the cables 3 Restore power to the section of the MM LITE transport system where the motor was replaced 4 Program the new motor s masters and slaves with the current Motor image files refer to Programming Motors on page 7 33 5 Resume motion on the section of the MM LITE transport system where the motor w...

Page 317: ...ic motor soft ware image installed They must be programmed with the software supplied with the motors before use Required Tools and Equipment Computer with an Ethernet port and a web browser Motor ERF Image Files Procedure 1 Upload the motor ERF image files motor_image erf to each Node Controller using the Node Controller Web Interface and program the motor masters and slaves Refer to the Node Con...

Page 318: ... to Then moving the array so it is only in minimal contact with the edge and then lifting the array away from the edge starting at one end of the array CAUTION Strong Magnets To avoid severe injury people with pacemakers and other medical electronic implants must stay away from the magnet array on the vehicles pucks To avoid injury from strong magnetic attractive forces Handle only one vehicle puc...

Page 319: ...d locker Anaerobic Adhesive Blue CAUTION Strong Magnets To avoid severe injury people with pacemakers and other medical electronic implants must stay away from the magnet array on the vehicles pucks To avoid injury from strong magnetic attractive forces Handle only one vehicle puck or magnet array at a time Do not place any body parts such as fingers between a vehicle puck or magnet array and any ...

Page 320: ... motor C Lift the guide rail off of the motor 3 Remove pucks by sliding them from the adjacent motors into the open curve NOTE Once pucks are removed from the transport system they must be stored in their original packaging to protect the pucks and to minimize any safety risks 4 Replace the guide rail by reversing Step 2 A Apply Loctite 243 to the screws B Tighten the guide rail mounting screw and...

Page 321: ... securing the V braces to the guide rail B Remove the two screws securing the guide rail to the motor C Lift the guide rail off of the motor 3 Install pucks and slide them onto the adjacent motors 4 Replace the guide rail by reversing Step 2 A Apply Loctite 243 to the screws B Tighten the guide rail mounting screw and the V brace hardware to 3 4 N m 30 in lb NOTE The Loctite must cure for 2 hours ...

Page 322: ... Dri Loc 204 5 mm DL 2X 200 2202 00 Preload Spacer Compliant Puck Center Plate ML 200 2155 01 Strip Protective Puck Bottom Wide UHMW 200 2205 00 Center Plate Puck Ribs G5 ML CAUTION Strong Magnets To avoid severe injury people with pacemakers and other medical electronic implants must stay away from the magnet array on the vehicles pucks To avoid injury from strong magnetic attractive forces Handl...

Page 323: ...ace Pucks on page 7 35 2 Place the puck on a non metallic work surface with the magnet array down Keep the magnet array at least three feet away from metal objects and tools 3 Remove the two screws securing the puck top and center plates to the magnet assem bly using a 2 5 mm Hex wrench and lift the top and center plates off the magnet assembly as shown in Figure 7 11 and dispose of properly 4 If ...

Page 324: ... Then fold the holes at each end of the strip over the threaded standoffs as shown in Figure 7 11 NOTE Do not stretch the protective strip Stretching will reduce the life of the adhesive causing the strip to peel away from the array E Press the strip into place using a burnisher ensuring there are no bubbles 5 Remove the backing from the glue dot and apply the glue dot to the center surface of the...

Page 325: ...the standoffs on the magnet assembly and secure using the two M4 x 22 mm flat head screws and tighten to 1 5 N m 13 in lb using a 2 5 mm Hex wrench NOTE Once the screws have been installed the Loctite must cure for 2 hours at 22 C 72 F before using the puck 9 Replace the puck on the MM LITE transport system refer to Replace Pucks on page 7 35 ...

Page 326: ...ons CAUTION High Voltage Hazard 100 240 VAC 8 5 A AC power must be disconnected before servicing CAUTION Double Pole Neutral Fused AC power must be disconnected before servicing F3 LOGIC T 250V 10A F1 PROPULSION 1 T 250V 10A LOGIC PROPULSION F2 PROPULSION 2 T 250V 10A SEE MANUAL FOR FILTER MAINTENANCE GND J4 DC ENABLE SEE MANUAL FOR PINOUT 36 VDC 300W 8A MAX 36 VDC 300W 8A MAX J1 J2 GND V PROPULSI...

Page 327: ... Figure 7 14 Open the Power Entry Module 3 Remove the fuse module from the PEM by inserting a small flat blade screwdriver into the slot at the top and pressing outward as shown Figure 7 15 Remove the PEM Fuse Module 4 Remove the old fuse 5 Install a new fuse 6 Insert the fuse module into the PEM ensuring that it is oriented correctly Fuse Type Fuse Location T 250V 2A Single fuse on the right hand...

Page 328: ...peration DC Fuses 1 Turn off power to the MM LITE Power Supply and unplug the power cable 2 Remove the fuse by turning the fuse holder shown in Figure 7 13 counter clockwise 3 Remove the old fuse and install a new fuse 4 Insert the fuse holder and turn the fuse holder clockwise until fully seated 5 Return the power supply to normal operation Fuse Type Fuse Location T 250V 10A Single fuse per fuse ...

Page 329: ...arings on the outside or stand side of the rails This locates the magnet array over the motors and positions the bearings to allow motion through the curves Figure 7 25 shows the orientation of the bearings on a Precision Rail vehicle in relationship to the track system CAUTION Strong Magnets To avoid severe injury people with pacemakers and other medical electronic implants must stay away from th...

Page 330: ...will be created and the vehicle will not move freely along the rail 2 Slide the vehicle onto the rail with the eccentric bearings on the outside stand side of the rails 3 Once the vehicle is properly positioned on the rail slide it along both the straight and curve rails to determine if the factory pre load is satisfactory The vehicle should move smoothly along both straight and curve rails with l...

Page 331: ...on of the MagneMover LITE transport system where the vehicle will be installed 2 If a lubricant applicator is attached to the underside of the vehicle remove the applica tor and set it aside for reinstallation after the vehicle is installed See Replacing Lubri cating Applicators on Vehicles on page 7 50 3 Using a socket wrench loosen the nuts on the eccentric bearings on the top of the vehi cle re...

Page 332: ...em where the vehicle will be removed 2 Remove a small section of the precision rail by removing the M5 screws securing it to the spine plates 3 Move the vehicle to be removed to the open section and lift it out NOTE Once vehicles are removed from the transport system they must be stored in their original packaging to protect the vehicle and to minimize any safety risks 4 Replace the removed rail s...

Page 333: ...emove the lubricating applicator from the bottom of the vehicle Replacing Lubricat ing Applicators on Vehicles on page 7 50 3 Using a socket wrench loosen the nuts on the eccentric bearings on the top of the vehi cle refer to Figure 7 17 4 Using a thin open ended wrench turn the bearing nut to rotate both eccentric bearings to their outermost position 5 Slowly roll the magnet array side of the veh...

Page 334: ...refer to Refilling a Precision Rail Vehicle s Lubricating Applicator on page 7 8 Figure 7 20 Precision Rail Vehicle Lubricating Applicator CAUTION Strong Magnets To avoid severe injury people with pacemakers and other medical electronic implants must stay away from the magnet array on the vehicles To avoid injury from strong magnetic attractive forces Handle only one vehicle or magnet array at a t...

Page 335: ... NOTE When installing the vehicles on the rails alternate the vehicles so that two consecu tive vehicles do not have the applicator on the same side Figure 7 21 Precision Rail Vehicle Lubricating Applicator Location NOTE The felt tip contains a v groove that must be oriented correctly to the rail If the v groove does not align with the rail excess drag will be created and the vehicle will not move...

Page 336: ...sure the felt end of the applicator is facing toward the rail location Insert the two M3 x 8 mm screws through the top of the vehicle and into the holes on the applicator and tighten finger tight Note do not over tighten the screws or they will strip the holes on the applicators 3 Apply lubricant to the applicator refer to Refilling a Precision Rail Vehicle s Lubricat ing Applicator on page 7 8 ...

Page 337: ...her medical electronic implants must stay away from the magnet array on the vehicles To avoid injury from strong magnetic attractive forces Handle only one vehicle or magnet array at a time Do not place any body parts such as fingers between a vehicle or magnet array and any ferrous material or another magnet array Vehicles or magnet arrays not being used should be secured individually in isolated...

Page 338: ...k surface with the magnet array down Keep the magnet array at least three feet away from metal objects and tools For safety rea sons only remove and replace one magnet array at a time 4 Remove the two M4 x 12 mm screws securing the magnet array to the vehicle and store them in a safe location for reuse 5 Grasping the array firmly with one hand while holding the vehicle firmly with the other hand l...

Page 339: ... If the shims are removed or additional shims added the length of the screws must be adjusted appropriately 9 Place the mounting holes on the vehicle over the array posts Realign the shims if nec essary to ensure they line up with the vehicle 10 Secure the array to the vehicle using the two M4 x 12 mm screws removed in Step 4 and Loctite 243 Tighten each screw to 1 5 N m 13 in lb NOTE The Loctite ...

Page 340: ...agneMotion Rockwell Automation Publication MMI UM002E EN P March 2016 Dual Array Vehicles Figure 7 24 Dual Array Precision Rail Vehicle Assembly Dual Array Carriage Shim 1mm 2X Magnet Array M4 x 12mm Screw 4X Assembly Fixture ...

Page 341: ... mm screws securing the magnet arrays to the vehicle and store them in a safe location for reuse 6 Holding both arrays in the assembly fixture lift the vehicle off of the arrays and place on the work surface away from the arrays 7 Remove the shims from the top of the magnet arrays and store them in a safe location for reuse 8 Remove the arrays from the assembly fixture one at a time and place them...

Page 342: ...using the four M4 x 12 mm screws removed in Step 4 and Loctite 243 Tighten each screw to 1 5 N m 13 in lb NOTE The Loctite must cure for 2 hours at 22 C 72 F before using the puck 14 Replace the vehicle refer to Replace Precision Rail Vehicles on page 7 45 15 Restart the Path 16 Dispose of the removed magnet array appropriately ...

Page 343: ...ple with pacemakers and other medical electronic implants must stay away from the magnet array on the vehicles To avoid injury from strong magnetic attractive forces Handle only one vehicle or magnet array at a time Do not place any body parts such as fingers between a vehicle or magnet array and any ferrous material or another magnet array Vehicles or magnet arrays not being used should be secure...

Page 344: ...king Grade Green Replacing Concentric Bearings Figure 7 26 shows a dual array vehicle however the same process is used for single array vehicles Figure 7 26 Precision Rail Vehicle Concentric Bearings Disassembly Assembly 1 Stop all motion on the section of the MagneMover LITE transport system where the vehicle is located 2 Remove the vehicle from the Precision Rail refer to Replace Precision Rail ...

Page 345: ...Place the washer over the bearing post on top of the carriage NOTE Make sure all washers are placed on top of the carriage below the top nut Do not reassemble with washers on the underside of the carriage 8 Thread the nut onto the bearing over the washer on top of the carriage 9 Hold the bearing nut underneath the carriage in place with a 13 mm thin open ended wrench while using a 13 mm torque wre...

Page 346: ...ort system where the vehicle is located 2 Remove the vehicle from the Precision Rail refer to Replace Precision Rail Vehicles on page 7 45 3 Place the vehicle on a non metallic work surface with the magnet array down Keep the magnet array at least three feet away from metal objects and tools 4 Hold the bearing nut underneath the carriage in place with a 13 mm thin open ended wrench Unscrew and rem...

Page 347: ...hread the nut onto the bearing over the washer on top of the carriage 9 Hold the bearing nut underneath the carriage in place with a 13 mm thin open ended wrench while using a 13 mm torque wrench to tighten the nut on the top of the carriage and finger tighten NOTE Do not apply Loctite or tighten the eccentric bearing until after the vehicle is mounted on the Precision Rail system and all adjustme...

Page 348: ...t Head M4 X 20 mm L A4 SS per DIN 7991 2X 100 2378 00 Glue Dot Adhesive Hi Tack Semi Perm Lo Profile 0 250 200 2202 00 Preload Spacer Compliant Puck Center Plate ML 200 2205 00 Center Plate Puck Ribs G5 ML 200 2288 00 Replaceable Ski ML Puck 2X 200 2324 00 Spacer Magnet Array ML PL 2X 200 2155 01 Strip Protective Puck Bottom Wide UHMW Optional Isopropyl Alcohol Torque wrench with the following bit...

Page 349: ...tem refer to Replace Pucks on page 7 35 2 Remove the two M4 screws securing the pallet and center plate to the magnet assem bly using a 2 5 mm Hex wrench and lift the pallet and center plate off the magnet assembly as shown in Figure 7 28 OPTIONAL A Remove the protective strip from the magnet assembly M4 x 20 mm Screw 2X Magnet Assembly Pallet Center Plate Protective Strip Threaded Standoff Ski Gl...

Page 350: ...hown in Figure 7 28 5 If necessary replace the skis on the pallet as shown in Figure 7 28 A Remove the M4 screw securing each ski using a 2 5 mm Hex wrench B Clean the bottom surface of the pallet using isopropyl alcohol to remove any debris C Install the new skis by locating them into the features on the bottom of the pal let D Place two to three drops of Loctite 243 on the threads of each M4 x 8...

Page 351: ...ML PL 200 2342 01 Tapered Bushing SLOT Pallet ML PL 100 2457 01 Pin Dowel Ø2 mm X 5 mm L 18 8 SS per DIN 7 M6 2X 100 2202 05 Nut Jam Hex M6x1 18 8 A2 SS per DIN 439B 2X Isopropyl Alcohol Torque wrench with the following bits 6 mm CAUTION Crush Hazard Strong magnets in use To avoid severe injury Handle only one puck at a time Do not place any body parts such as fingers between a magnet array and an...

Page 352: ...pyl alcohol to remove any debris 6 If necessary install new dowel pins in the pallet using an arbor press 7 Install the new bushings in the pallet using an arbor press NOTE Ensure the bushings are located in the correct positions as shown in Fig ure 7 29 before pressing into place Ensure the top of the dowel pins are below the top of the bushings 8 Place two to three drops of Loctite 243 on the th...

Page 353: ...ate the pallet can be removed and replaced if they become damaged or worn due to extended use Required Tools and Equipment 200 2298 00 Pin Spherical Contact Precision Locator 2X Isopropyl Alcohol Torque wrench with the following bits 000 0772 04 Pinning Locator Installation Tool ML PL Procedure Figure 7 30 Replace Pins on Precision Locator Arms Spherical Contact Pin 2X ...

Page 354: ... Pin B Engage the 2 mm pin with the Installation Tool socket and remove the Spheri cal Contact Pin 3 Clean the surfaces of the Precision Locator arm using isopropyl alcohol to remove any debris 4 Install the new pin in the arm as shown in Figure 7 30 A Thread the new Spherical Contact Pin into the arm B Slide the 2 mm pin from the Installation Tool into the hole on the new Spheri cal Contact Pin C...

Page 355: ...he Precision Locator can be removed and replaced if they become damaged or worn due to extended use Required Tools and Equipment 100 0097 30 Loctite 243 Thread locker Anaerobic Adhesive Blue 200 2354 xx Z Datum Extended 2X 100 0117 01 Screw SHC Full Thd M4 X 6 mm L A2 SS 6X 12X Isopropyl Alcohol Torque wrench with the following bits 3 mm Procedure Figure 7 31 Replace Z Datum on Precision Locator S...

Page 356: ...datums will be replaced 2 Remove the M4 screws securing the z datums to the inner and outer supports as shown in Figure 7 31 and remove the z datums 3 Clean the z datum mounting surfaces of the stand using isopropyl alcohol to remove any debris 4 Install the new z datum using M4 screws and Loctite 243 tighten to 5 in lbs as shown in Figure 7 31 5 Return the MM LITE transport system to normal opera...

Page 357: ...anual 73 Rockwell Automation Publication MMI UM002E EN P March 2016 Ordering Parts If new or replacement parts are needed contact MagneMotion Sales Main Office MagneMotion Inc 139 Barnum Road Devens MA 01434 USA Phone 1 978 757 9100 Fax 1 978 757 9200 ...

Page 358: ...renches English Hex wrenches Open end wrench adjustable Fork truck or appropriate lift as required CAUTION Electrical Hazard Before beginning this procedure the MagneMover LITE transport system must be shut down following the procedure provided in Safe Shut down on page 6 27 CAUTION Heavy Lift Hazard Some of the MagneMover LITE components can weigh as much as 14 5 kg 32 lb Failure to take the prop...

Page 359: ...away from the magnet array on the vehicles pucks To avoid injury from strong magnetic attractive forces Handle only one vehicle puck or magnet array at a time Do not place any body parts such as fingers between a vehicle puck or magnet array and any ferrous material or another magnet array Vehicles pucks or magnet arrays not being used should be secured individually in isolated packaging To avoid ...

Page 360: ...ing Systems or System Sections on page 7 76 Shipping Components 1 Each component should be wrapped bagged and packed following standard packing procedures 2 Using the containers the component was originally shipped in set the component into the container and secure using the supplied packing material 3 Close the shipping container and secure 4 Ensure the container is properly labeled This End Up C...

Page 361: ...e sides of the crate are padded and will secure the system in place once they are attached to the crate 7 Secure the sides and top of the crate to the crate 8 Ensure the crate is properly labeled This End Up Caution Heavy etc and all ship ping documents are attached to the outside of the crate 9 Add tip indicators shock indicators moisture indicators etc to the outside of the ship ping container a...

Page 362: ...Maintenance 78 MagneMotion Rockwell Automation Publication MMI UM002E EN P March 2016 This page intentionally left blank ...

Page 363: ...016 Appendix Overview The following appendices are included to provide the user with a single location for additional information related to the MagneMover LITE transport system Included in this appendix are File maintenance Additional documentation Transport system configuration limits ...

Page 364: ...original and backup files should be kept at a remote location for safety Creating Backup Files Backup files are not created automatically It is the user s responsibility to create backups of all files by copying them to a safe location and naming them appropriately Restoring from Backup Files Damaged files can be restored by copying the backup files into the appropriate locations and renaming them...

Page 365: ...dentification of new features and enhancements and a list of known issues The Release Notes are supplied with the software MagneMotion recommends that this file be read before using the software Upgrade Procedure The Upgrade Procedure provides the instructions for upgrading from one version of Magne Motion software to another It also includes the procedures for upgrading files and drivers associat...

Page 366: ... 2 MagneMotion Transport System Motion Limits Acceleration Velocity Thrust Payload MagneMover LITE 2 0 m s2 0 2g 2 0 m s 4 5 mph 6 0 N cycle MM LITE thrust at 25 duty cycle nominal Vehicle Gap is 1 mm for G3 and 1 5 mm for G4 2 2 kg 4 4 lb MM LITE single puck maximum payload is 1 kg tandem puck maximum payload is 2 kg QuickStick 100 9 8 m s2 1 0g 2 5 m s 5 6 mph 15 9 N cycle QS 100 thrust at 4 0 A...

Page 367: ...hat monitors and controls the operating conditions of the equipment being monitored In a MagneMotion transport system these include the High Level Controller Motor Controller Node Controller and Host Controller Cycle Length Cycle Length is the distance between the centerlines of two like poles on the magnet array Demonstration Script A text file used with the NCHost TCP Interface Utility for test ...

Page 368: ...er it runs both the Node Controller and High Level Controller applications HLC See High Level Controller HLC Control Group The portion of a multi HLC LSM transport system under control of a specific HLC Host Application The user s software running on the Host Controller that provides monitoring and control of the transport system Host Controller The user supplied controller for the operation of th...

Page 369: ...l distance between two motors mounted end to end This does not include the distance from the end of the stator to the end of the motor housing NC See Node Controller Node A junction defined as the beginning end or intersection of Paths The differ ent Node types are defined by their use Simple Relay Terminus Merge Diverge etc Node Controller Configuration File The XML file unique to the transport s...

Page 370: ...trol sequencing and safety interlock logic for the operation of the transport system Propulsion Power The power used for vehicle movement See also Logic Power Puck A pre configured vehicle for use on MagneMover LITE transport systems See also Vehicle QS See QuickStick QuickStick A MagneMotion linear synchronous motor that enables quick efficient con veyance of large loads using user designed guide...

Page 371: ...ollers The vehicle typically exits the motor or Path on the Downstream end V Brace The mechanical fixture used to align and secure MagneMover LITE guide rail sections Vehicle The independently controlled moving element in a MagneMotion transport system The vehicle consists of a platform that carries the payload and a pas sive magnet array to provide the necessary propulsion and position sensing Al...

Page 372: ...le Signal A motor software flag for each vehicle used to indicate if the vehicle is cur rently detected on the transport system Vehicle Spacing The distance between two vehicles on the same Path Zero Point The position on the Upstream end of a Path that denotes the first part on which a Vehicle travels ...

Page 373: ... 4 22 network switch 5 28 Node Controller LITE 5 27 Node Controller NC 12 5 29 power supply 5 31 Brick wall Headway 6 7 C Cable Chase cover installation 5 41 cover mounting bracket 5 18 overview 1 3 Cables AC power 4 46 4 53 4 57 4 58 DC Enable 4 48 DC power 4 47 design 3 12 3 43 Ethernet 4 62 RS 422 4 63 Carrier Design 3 31 Cleaning 7 3 Communication Cables digital I O 4 65 Ethernet 4 62 identifi...

Page 374: ...hicle 3 38 vehicle 3 19 E Equipment Safety 2 5 E Stop connection 5 62 operation 6 13 Ethernet Cable 4 62 Ethernet TCP IP connections 5 60 description 4 62 EtherNet IP configuration 5 61 connections 5 60 description 4 63 F FastStop 6 16 G Gap downstream 3 11 motor 3 11 vehicle 3 20 Gender Changer 4 64 5 35 Getting Started 1 10 Guide Rail alignment G3 motors 7 25 alignment G4 5 23 precision overview...

Page 375: ...cle 6 8 L Labels magnet arrays 2 14 motors 2 12 Labels Continued Node Controller LITE 2 16 Node Controller NC 12 2 15 power supply 2 17 Precision Locator Puck 2 20 precision rail vehicle 2 18 pucks 2 14 2 21 spine plates 2 19 switches 2 13 Leg see Stand System Light Stack connection 5 63 operation 6 17 troubleshooting 7 21 Lighting site 4 67 Linear Synchronous Motor 6 2 LSM see Linear Synchronous ...

Page 376: ...ion 5 20 labels 2 12 limits A 4 mounting 5 20 mounting methods 3 25 overview 1 4 1 7 positioning 5 21 primary 6 2 programming 7 33 secondary 6 2 Motor Continued temperature 4 66 theory of operation 6 2 transport system layout 3 3 Motor Mount Design 3 24 Motor Mount Adjustable dimensions 4 36 installation 5 19 overview 1 6 Motor Mount Standard dimensions 4 11 installation 5 19 overview 1 4 Mounting...

Page 377: ...les 7 33 Node Controller Web Interface see Web Interface node_configuration xml see Node Controller Configuration File Nodes connections 5 34 limits A 4 transport system layout 3 5 Notes xxv O Obstruction vehicle 6 8 Operation monitoring 6 11 shut down 6 27 start up 6 26 7 2 P Pallet bushing replacement 7 67 design 3 41 extended use 7 64 maintenance 7 64 7 67 Paths connections 5 34 limits A 4 tran...

Page 378: ...nstallation 7 45 vehicle orientation 7 45 vehicle repair 7 23 vehicles 3 38 Precision Rail Vehicle bearing replacement 7 59 dimensions dual array 4 28 dimensions single array 4 27 dual array 3 38 4 28 humidity 4 67 installation 7 45 lubricating applicator installation 7 50 lubricating applicator refilling 7 8 replacing magnet arrays 7 53 single array 3 38 4 27 temperature 4 67 Puck see also Vehicl...

Page 379: ... 9 dimensions right 4 10 installation 5 20 labels 2 13 mounting 5 20 overview 1 4 positioning 5 21 transport system layout 3 3 SYNC IT Controller 6 12 Synchronization Option connection 4 65 connection location 4 40 operation 6 12 System Configurator see MagneMotion Config urator System Leg see Stand System T T cable 5 39 Tandem Vehicle see Dual Magnet Array Vehicle Temperature magnet array 4 67 mo...

Page 380: ...al magnet array 3 19 gap 3 20 jammed 6 8 labels 2 18 limits A 4 locating during startup 6 8 materials 3 21 obstructed 6 8 overview 1 4 1 5 simulated 6 20 single magnet array 3 19 Vehicle Precision Rail Option adjusting bearings 7 11 dual array 4 28 orientation on rail 7 45 replacing bearings 7 53 single array 4 27 Virtual Scope Utility description 1 9 W Web Interface description 1 8 Wheel Material...

Page 381: ...MagneMover LITE User Manual 501 Rockwell Automation Publication MMI UM002E EN P March 2016 Notes ...

Page 382: ...ion com global literature library overview page Product Compatibility and Download Center PCDC Get help determining how products interact check features and capabilities and find associated firmware http www rockwellautomation com global support pcdc page Rockwell Otomasyon Ticaret A Ş Kar Plaza İş Merkezi E Blok Kat 6 34752 İçerenköy İstanbul Tel 90 216 5698400 Rockwell Automation maintains curre...

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