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Rockwell Automation 700-1384-01 User Manual Download Page 292

Maintenance
Troubleshooting

292

MagneMotion

Rockwell Automation Publication MMI-UM007F-EN-P - September 2020

Node Controller Troubleshooting

This section covers the determination of problems within the node controllers.

Table 8-4: Node Controller 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 control-
ler to MagneMotion for repair.

Use the node controller web inter-
face 

Set Clock

 function to set the 

time (see the 

Node Controller 

Interface User Manual

, 

MMI-UM001

).

Summary of Contents for 700-1384-01

Page 1: ...3 00 700 1483 01 700 1483 03 700 1563 00 700 1616 00 700 1616 01 700 1616 02 700 1616 03 700 1616 04 700 1616 05 700 1616 06 700 1618 00 700 1618 01 700 1618 02 700 1618 03 700 1618 04 700 1618 05 700...

Page 2: ...opyright 2015 2020 MagneMotion Inc a Rockwell Automation Company All Rights Reserved The information that is included in this manual is proprietary or confidential to MagneMotion Inc Any disclosure re...

Page 3: ...23 Prerequisites 23 MagneMotion Documentation 24 Manual Conventions 24 Notes Safety Notices and Symbols 25 Notes 25 Safety Notices 25 Manual Structure 27 Related Documentation 27 Contact Information...

Page 4: ...Magnet Arrays 52 Shipping Magnet Arrays 53 Recycling and Disposal Information 54 QuickStick HT Transport System 54 Motor Stators 54 QSMC Motor Controllers 54 QSHT 5700 Inverters 55 Magnet Arrays 55 P...

Page 5: ...ation 98 MICS File Example 99 Magnet Arrays 102 High Flux Magnet Arrays 102 Magnet Array Length and Attractive Force 103 Number of Cycles 103 Magnet Array Forces 104 Magnet Array Use 104 Vehicles 106...

Page 6: ...0 Inverter Connectors 157 QuickStick HT 5700 Inverter Controls and Indicators 163 Communications 168 Ethernet Connection 168 TCP IP Communication Host Controller to HLC 168 TCP IP Communication Node C...

Page 7: ...98 Pxxx DC bus Power Supplies 186 Connecting Motors and Electronics 190 Wire Routing 190 RS 422 Motor Communications 192 Ethernet Motor Communications 196 Digital I O 201 Installing QSMC Motor Control...

Page 8: ...9 Power Management Within the Motor 239 Power Related Warnings and Faults when using QSMC Motor Controllers 240 Power Related Warnings and Faults when using QSHT 5700 Inverters 241 QSMC Power Related...

Page 9: ...Requirements 276 Safe Torque off Feature Bypass 277 Cascade the Safe Torque off Signal 278 Hardwired Safe Torque off Electrical Specifications 279 8 Maintenance Overview 281 Preventive Maintenance 28...

Page 10: ...2 Appendix Overview 313 Interconnect Diagrams 314 Interconnect Diagram Notes 314 Power Wiring Examples 316 Data for Transport System Design Calculations 317 Thrust Force Data 318 Attractive Force Data...

Page 11: ...3 13 Ethernet Wiring Power Supply In line with Inverters 80 3 14 Ethernet Wiring Power Supply Separate from Inverters 80 3 15 Ethernet Motor Wiring One Path One Ethernet Chain 81 3 16 Ethernet Motor W...

Page 12: ...igh Flux Magnet Array Mechanical Drawing 131 4 9 Motor Electrical Connections 133 4 10 1 m QSMC to Stator Drive Cable 135 4 11 1 2 m QSMC to Stator Drive Cable 136 4 12 QSMC to Stator Sense Cable 137...

Page 13: ...ltage 241 6 9 Power Dissipation Per Block vs Internal Propulsion Bus Voltage 241 6 10 Individual Block Current vs Internal Propulsion Bus Voltage 242 6 11 Power Dissipation Per Block vs Internal Propu...

Page 14: ...14 MagneMotion Rockwell Automation Publication MMI UM007F EN P September 2020 This page intentionally left blank...

Page 15: ...or Drive Cable Pinouts 139 4 10 1 2 m QSHT 5700 Inverter to Stator Drive Cable Pinouts 140 4 11 QSHT 5700 Inverter to Stator Sense Cable Pinouts 141 4 12 1 m Motor Power Requirements 142 4 13 QSMC Mot...

Page 16: ...4 46 Ethernet Link Speed Status Indicator 164 4 47 Ethernet Link Activity Status Indicator 164 4 48 Home Screen Functions 164 4 49 Soft Menu Functions 165 4 50 LCD Pages 165 4 51 RS 422 Cable Pinouts...

Page 17: ...Control Related Troubleshooting 294 8 7 Light Stack Related Troubleshooting 295 8 8 QuickStick HT MMI_path_qs_ht_faults_status Motor Faults 296 8 9 QuickStick HT Transport System Repair Procedures 30...

Page 18: ...18 MagneMotion Rockwell Automation Publication MMI UM007F EN P September 2020 This page intentionally left blank...

Page 19: ...upport Rev A Initial release Rev B Added the following In Chapter 4 Specifications and Site Requirements added information about repeated cycling of the HVDC power to the QSMC motor controllers that c...

Page 20: ...f the Gateway Node Cor rected motor thrust per magnet array cycle to 182 N at 10 9 A stator current Moved the Magnet Array Types information from Specifications and Site Requirements to Design Guideli...

Page 21: ...ifferences to identify functions that are not simulated In Chapter 8 Maintenance updated the Power Related Troubleshooting and Light Stack Troubleshooting In the Appendix updated the Transport System...

Page 22: ...mmunication Recommen dations and additional support for Ethernet motors including creating the Ethernet Motor MICS File In Chapter 4 Specifications and Site Requirements added information on the Ether...

Page 23: ...st and operate a QSHT transport system MagneMotion offers instructor led training classes that provide additional instruction in the installation configuration testing and operation of a QSHT transpor...

Page 24: ...eyboard keys and key combinations pressing multiple keys at a time are shown enclosed in angle brackets Examples F2 Enter Ctrl Ctrl x Dialog box titles or headers are shown in bold type capitalized ex...

Page 25: ...C2198 D032 2198 KITCON D032 L Text in blue is a hyperlink These links are active when viewing the manual as a PDF Select a hyperlink to change the manual view to the page of the item referenced In so...

Page 26: ...e or economic loss Attentions help to identify a haz ard avoid a hazard and recognize the consequence LIFTING HAZARD Identifies information about practices or circumstances where the specified object...

Page 27: ...operation directions for the QSHT components as part of a transport system QSHT 5700 Inverter Safe Torque off Function Provides an overview of the hardwired safe torque off function in the QuickStick...

Page 28: ...se width Modulated PWM AC Drives DRIVES IN001 System Design for Control of Electrical Noise Reference Manual GMC RM001 Kinetix Servo Drives Specifications Technical Data KNX TD003 Kinetix Motion Acces...

Page 29: ...the QSHT components in a transport system Use this manual to install test and debug the QSHT components in a transport system Some procedures can vary based on the transport system configuration comm...

Page 30: ...native to conventional belt and chain conveyors for OEM in machine applications and for demanding product conveyance require ments QuickStick HT motors provide repeatable positioning with no hard stop...

Page 31: ...ware tools simplify transport system design and optimization Versions available for use in cleanrooms and IP68 environments motors and magnet arrays only Less wear and tear no belts chains gears or ex...

Page 32: ...o end to provide a continuous path of motion Switch not shown Three motors that are configured to provide either a merge of two paths into one or one path that diverges into two Motor The QSHT linear...

Page 33: ...al signals to provide noise resistance Stator Sense Connector Provides the connection for the motor control sig nals Stator Drive Connector Provides the connection for the motor phase power Motor Moun...

Page 34: ...linear synchronous motor LSM Motor Drive Refers to the QSMC motor controller or the QSHT 5700 inverter Network Ethernet network providing communications TCP IP or EtherNet IP between the host controll...

Page 35: ...plied by MagneMotion to move vehicles for test or demonstration purposes This applica tion supports system testing without the host controller to verify that vehicles move correctly before integrating...

Page 36: ...Service MICS Files An XML file MICS_motor_data xml that contains the network topology parameters for the transport system when using Ethernet communication with the motors The file includes the MAC a...

Page 37: ...ftware applications are a general purpose computer PC running Microsoft Windows 7 with NET 4 0 An Ethernet port web interface and an optional RS 232 port console interface are required to connect to t...

Page 38: ...ce User Manual MMI UM001 and the NCHost TCP Interface Utility User Manual MMI UM010 8 Test and debug the transport system by using the NCHost TCP Interface Utility and Demo Scripts see Check out and P...

Page 39: ...ns are basic guidelines If the facility where the Quick Stick HT components are installed has additional safety guidelines they must be fol lowed as well along with the applicable local and national s...

Page 40: ...comply with the regulations from the organizations that are indicated in Table 2 1 EU RoHS and EU WEEE Compliance MagneMotion products are considered parts of a large scale fixed installation and as...

Page 41: ...ore 6 mm2 stranded copper with 90 C minimum rating Use MMI HT CBP05 xx and MMI HT CBS00 xx motor power and feedback cables for QuickStick HT motors The motor cable shield clamp on the drive with clamp...

Page 42: ...ng integration of the QuickStick HT components into their equipment is the responsibility of the user Responsibility for work that MagneMotion authorized technicians performs or for equipment that the...

Page 43: ...hysician to determine the susceptibility of their device to static magnetic fields and to determine a safe distance between themselves and the magnet array Handle only one vehicle magnet array at a ti...

Page 44: ...can exist with certain installation or service operations that are related to the QSHT transport system Equipment Safety Guidelines The following safety considerations are provided to aid in the plac...

Page 45: ...o help prevent contact with moving objects by personnel Do not install or operate the QSHT transport system if any of the components have been dropped damaged or are malfunctioning Keep cables and con...

Page 46: ...uld cause injury or equipment dam age Lifting Hazard Indicates that the specified object is heavy or awkward to handle Personnel must use lifting aids and proper techniques for lifting to avoid muscle...

Page 47: ...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 and so on...

Page 48: ...placed on those QuickStick HT components that require them These labels provide operators and service personnel with hazard identification and information about the QSHT components at the point of us...

Page 49: ...ceptible to vector motion forces Always account for the effects of acceleration deceleration and directional changes upon the payload Control forces to avoid projectile motion of the payload limit mov...

Page 50: ...any other specified action within the facility where the QSHT components are being used SHOCK HAZARD To avoid electric shock all electrical power to the QuickStick HT transport system must be dis con...

Page 51: ...onic implants must stay away from the magnet arrays CRUSH HAZARD Strong magnets in use To avoid severe injury from strong magnetic attractive forces Handle only one vehicle or magnet array at a time D...

Page 52: ...to come together against a body part usu ally fingers Do not 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 wi...

Page 53: ...handling is required Handle only one magnet array at a time If an array is attracted to another object DO NOT attempt to stop it Wearing gloves and safety glasses when handling the magnet arrays is re...

Page 54: ...e B QuickStick HT Transport System No hazardous materials other than the materials identified in this section are used in the QuickStick HT components The following items require special handling for...

Page 55: ...ymium Iron Boron NdFeB magnets and must be disposed of by following all facility local and national procedures for the disposal of hazardous materials Follow all safety procedures for the han dling of...

Page 56: ...Safety Guidelines 56 MagneMotion Rockwell Automation Publication MMI UM007F EN P September 2020 This page intentionally left blank...

Page 57: ...T transport system Included in this chapter are Design guidelines for laying out the QuickStick HT transport system and creating the interfaces to the system Design guidelines for using QuickStick HT...

Page 58: ...light stack The transport system layout is used to locate the motors and other transport system compo nents in the facility It is also used as a reference when connecting the components of the transpo...

Page 59: ...e paths and direct the vehicles from one path on the transport system to another path The switch mechanism is defined and supplied by the user Vehicles are user designed independent platforms with int...

Page 60: ...roller Configuration File Each motor is identified as belonging to a specific path and provided a unique identifier in the Node Controller Configuration File The node controller that is connected to t...

Page 61: ...e start or end of a path where vehicles move to or from the QuickStick HT transport system Gateway Node Connects a path in one Control Group in a transport system to a path in another Control Group wi...

Page 62: ...e nodes for example Merge Diverge and Relay NC E Node Controller Node controller with one active network port four digital inputs and four digital outputs This node controller can support multiple nod...

Page 63: ...2020 Figure 3 4 Sample QSHT Transport System Layout Showing Node Controllers Diverge Merge Path 2 Path 3 NOTE Arrows indicate direction of forward motion Path 1 Motor Drives NC HLC Node Controller NC...

Page 64: ...sing QSHT 5700 inverters use 2198 Pxxx DC bus power supplies pro viding 458 747V DC for propulsion power and DC power supplies providing 24V DC for logic power See Table 4 32 on page 154 for power sup...

Page 65: ...ng the motor drives One advantage of the QuickStick HT system is that it is possible to have vehicles move at dif ferent rates of speed in the same direction or in opposite directions without a collis...

Page 66: ...ehicle and guideway during use When choosing the materials for the vehicle and guideway consider those materials that provide low friction and low wear When choosing the materials for the vehicle and...

Page 67: ...rm the calculations as shown in Determining Thrust Force on page 321 to deter mine the optimal thrust force Vehicle Gap and magnet array size The QuickStick HT transport system allows only one vehicle...

Page 68: ...e shown best in Data for Transport System Design Calculations on page 317 Equations that use all of these variables are provided in Determining Thrust Force on page 321 At the nominal Vehicle Gap of 1...

Page 69: ...ailable Thrust Examples Required Thrust Several variables determine the thrust that is required to move a vehicle Required acceleration Mass to be moved Friction or drag between the vehicle and the gu...

Page 70: ...10 of the length of one of the arrays Larger gaps are possible but cause greater loss of thrust When using larger gaps and dual array vehicles the gap between motors must not be larger than the lengt...

Page 71: ...red of a node boundary such as a Terminus Node Motor Cogging Any cogging between the QSHT motor and the magnet array is typically not an issue unless there is a direct human interaction with the vehic...

Page 72: ...through the curve see Figure 3 32 To minimize some of this misalignment the magnet arrays that are used for curve geometry are wider than usual to provide more mag netic array coverage A dual array v...

Page 73: ...eneration events cause fluctuations in the voltage that is seen at the motor controller power terminals The power supplies and wiring for the system must be designed to minimize these fluctuations A b...

Page 74: ...power supply if these limits are exceeded To supplement any external power management schemes for the QSHT transport system a means of internally consuming regenerated power within a QSHT motor is inc...

Page 75: ...that can be used to reduce the drop of voltage in the system during acceleration The first method is to decrease the cable resistance between the power supply and the motor drives by either shortening...

Page 76: ...he GND stud on the motor control lers The QSHT 5700 inverter is grounded through the GND stud on the inverter The NC LITE is not grounded through its power connection The case of the NC LITE must be g...

Page 77: ...XX RS 422 110 0003 00 can be extended using 100 2090 XX DC POWER CABLE 100 2384 00 TYPICAL TO EACH MOTOR CONTROLLER RS 422 110 0090 XX RS 422 110 0090 XX RS 422 110 0090 XX 1 2 MSENSE 100 2386 XX 1 2...

Page 78: ...AT5 UTP CAT5 UTP CAT5 QSHT 5700 INVERTER MMI HT C2198 D032 ETHERNET PORT 1 ETHERNET PORT 2 DIGITAL INPUTS STATOR SENSE A STATOR SENSE B STATOR INVERTER OUT B STATOR INVERTER OUT A D C B U S P O W E R...

Page 79: ...tream of that device lose communication Closed loop ring Ethernet connections must be avoided industry standard Ethernet practice to help prevent network saturation Only pass transport system communic...

Page 80: ...or the inverters in the chain must be the first modules in the chain as shown in Figure 3 13 There is a maximum of 16 inverters per power supply power dependent The power supplies can also be connecte...

Page 81: ...m QSHT Motor x y 0 10 HLC Node Controller Straight Transport System Recommended One Ethernet Connection to Switch Power Supply Inline or Star One Chain One Path Downstream Host Controller Enet Switch...

Page 82: ...et Straight Transport System One Ethernet Connection per Motor Multiple Ethernet Switches Star Topology Power Supply Star to first Switch One Path HLC Node Controller x y 0 10 Ethernet Downstream Rela...

Page 83: ...Figure 3 20 Ethernet Motor Wiring One Path One Ethernet Chain Relay Host Controller Loop Transport System Recommended One Ethernet Connection to Switch Power Supply Inline or Star One Chain One Path...

Page 84: ...700 Inverter QSHT 5700 Inverter QSHT 5700 Inverter QSHT 5700 Inverter QSHT Motor QSHT 5700 Inverter QSHT 5700 Inverter Enet Switch Ethernet x y 0 10 HLC Node Controller Downstream Chains must not beco...

Page 85: ...5700 Inverter QSHT 5700 Inverter QSHT 5700 Inverter QSHT 5700 Inverter QSHT 5700 Inverter P1M11 x y 1 11 Loop Transport System with Switches Recommended One Ethernet Connection per Section Main Loop S...

Page 86: ...ath must be defined in the MICS file see Ethernet Motor MICS File on page 89 Straight Paths Figure 3 25 Ethernet Motor Wiring Two Paths Ethernet Chain and RS 422 Chain NOTICE When combining QSMC drive...

Page 87: ...onnects to Switch One RS 422 Chain connects to Node Controller Power Supply not shown Inline from Switch or Star Two Paths Host Controller Enet Switch x y 0 10 P1M1 P1M5 P2M2 x y 2 2 QSHT Motor QSHT M...

Page 88: ...r P1M10 x y 1 10 P1M9 x y 1 9 QSHT 5700 Inverter P1M8 x y 1 8 P2M1 x y 2 1 QSHT 5700 Inverter P1M7 x y 1 7 QSHT 5700 Inverter QSHT 5700 Inverter QSHT Motor P2M2 x y 2 2 QSHT 5700 Inverter P1M6 x y 1 6...

Page 89: ...al editing XML files can be viewed with browsers or code editors in tree fashion with the ability to expand or contract elements that contain other elements An overview of the XML format can be found...

Page 90: ...f the document In this case the declaration line is xml version 1 0 encoding US ASCII File Identification MICS files are identified in comment lines following the XML declaration The revision and last...

Page 91: ...Reference The XML tags that are shown in Table 3 4 are used to define and configure the MICS file Table 3 4 MICS File XML Elements Element Description Page XML Declaration Start of the document 92 MIC...

Page 92: ...e in the document It contains the XML version number and the character encoding for the file This element is a declaration there is no closing tag Syntax xml version 1 0 encoding US ASCII Attributes N...

Page 93: ...ICS XML files it contains all topology parameters for an Ethernet motor based transport system This tag contains no data it only contains other tags Syntax MICS_motor_data MICS_motor_data Attributes N...

Page 94: ...is tag contains no data it delineates information for one motor It contains only other tags Syntax Motor Motor Attributes None Parent Tag MICS_motor_data Contents All children tags Mac_addr IP_addr Tr...

Page 95: ...t is six groups of two hex digits a colon must be used to separate the digits ex hh hh hh hh hh hh The first three hexadecimal groups are the Organizationally Unique Identifier OUI The MAC address val...

Page 96: ...format ddd ddd ddd ddd where ddd is a decimal number of up to three digits in the range 0 to and 255 See Ethernet Motor Communication Recommendations on page 79 Validation Node controller requirement...

Page 97: ...cation The location is identified as PnMn Where Pn is the path number and Mn is the location of the motor in the path Validation Node controller requirements for startup and initialization Must not co...

Page 98: ...is located towards the upstream end of the path This tag is not used for MagneMover LITE switches since the connections to the switch define the ori entation For QuickStick motors this tag is not use...

Page 99: ...1 P3M3 10 14 3 3 P3M2 10 14 3 2 QSHT 5700 Inverter QSHT 5700 Inverter QSHT 5700 Inverter P1M2 10 14 1 2 P1M3 10 14 1 3 QSHT 5700 Inverter QSHT 5700 Inverter QSHT 5700 Inverter QSHT 5700 Inverter QSHT...

Page 100: ...1 7 IP_addr Motor IP address Track_location P1M7 Track_location Track NC Path Motor Motor Motor P1M8 Mac_addr C0 6C 6D E0 00 26 Mac_addr Motor MAC address IP_addr 10 14 1 8 IP_addr Motor IP address Tr...

Page 101: ...4 2 3 IP_addr Motor IP address Track_location P2M3 Track_location Track NC Path Motor Motor PATH 3 Motor P3M1 Mac_addr C0 6C 6D E0 00 50 Mac_addr Motor MAC address IP_addr 10 14 3 1 IP_addr Motor IP a...

Page 102: ...olar ity in the middle of the array and a North oriented half magnet at each end of the array Orien tation of the magnets is referenced to the surface that faces the motor as shown in Figure 3 30 Figu...

Page 103: ...ermining the force that is required to move a vehicle The magnetic attractive force is always present even if there is no power to the motor The amount of magnetic attractive force present is also dep...

Page 104: ...the motor This array width is typically used when QSHT motors are arranged in a curve to provide coverage when there is a misalignment between the motor and the magnet array This loss of coverage due...

Page 105: ...ember 2020 vent water ingress into the array through either its back surface or the seam where the cover meets the back iron of the array The top surface and sides of the cover are water resistant Ava...

Page 106: ...net array and the top of the QuickStick HT motor There are several design elements that must be met The vehicle supports the magnet array and its placement in the guideway must make sure that the Vehi...

Page 107: ...d the QSHT motors Vehicle Gap Wheel and roller materials affect the frictional resistance which affects the amount of thrust that is required to move a vehicle The selected material must be hard enoug...

Page 108: ...ouches the top of a motor Also with a larger gap the magnet array must be larger to provide the same thrust as would be achieved from a smaller Vehicle Gap NOTE The Vehicle Gap must be such that any d...

Page 109: ...e mounted on independent bogies On a curve there can be misalignment between the motor and the magnet array on the vehicle which could lead to a loss of force The dual array vehicle for use on curves...

Page 110: ...magnet array and the motor Up to two vehicles per meter 238 mm 9 4 in minimum length in motion or in queue The payload vehicle mass and required acceleration must be within the limits of the magnet ar...

Page 111: ...a small flat area if the vehicle remains station ary for a long time period due to the vehicle mass and the magnet attractive force In most cases these flat spots disappear after the vehicle is put i...

Page 112: ...in position to make sure that the spacing from motor to motor does not change see Figure 3 8 The guideway must hold the motors and support the vehicles to make sure that the Vehicle Gap see Figure 3 3...

Page 113: ...must be clear of aluminum as the aluminum can create eddy currents which create a breaking force Available in various weights thicknesses and prices Motor Mounts The QuickStick HT motors provide fixed...

Page 114: ...ectly to the track or mounting plate as shown in Figure 3 38 make sure that clearance holes for all motor connections are provided This mounting method does not provide for any adjustment of the motor...

Page 115: ...the motor mounting surface The motor mounts should allow the motors a small amount of movement relative to each other NOTE The upstream end of the motor has a hole for alignment with a locating pin a...

Page 116: ...of a guideway and vehicle where the guideway is con structed of stiff steel sides and a sheet metal base The vehicle has flanged wheels that ride on the top of the side plates which holds the vehicle...

Page 117: ...guideway is con structed of extruded aluminum with linear bearing guide rails The vehicle has linear bearing slides that ride on the rails and holds the vehicle and magnet array in the correct relatio...

Page 118: ...icle where the guideway is con structed of extruded aluminum with rollers that are mounted along the top of the guideway The vehicle sits on the rollers and between the side plates which hold the vehi...

Page 119: ...ation Figure 3 43 Straight Track Configuration Node types at the beginning of a path Simple Relay Terminus Gateway Node types at the end of a path Relay Terminus Gateway Keep the Motor Gaps consistent...

Page 120: ...rmined by motor length and magnet array vehicle length May require a vehicle with dual magnet arrays see Figure 3 32 Magnet Array to Motor Alignment on page 107 Motors may need to be configured as bei...

Page 121: ...magnet array vehicle length May require a vehicle with dual magnet arrays see Figure 3 32 Magnet Array to Motor Alignment on page 107 Motors in the curve section may need to be configured as being On...

Page 122: ...to provide movement of the moving path Moving path can consist of multiple motors Motor Gaps can vary from section to section of the guideway entry exit but keep the motor gaps consistent in each sec...

Page 123: ...pecifications for the QuickStick High Thrust transport system com ponents and the requirements for installation Included in this chapter are Mechanical specifications for all QuickStick HT components...

Page 124: ...tors on page 133 for the electrical specifications Contact ICT Customer Support for current detail drawings Exposed Materials 302 304 Stainless Steel 300 Series Corrosion Resistant Steel Aluminum allo...

Page 125: ...Support for current detail drawings Exposed Materials 302 304 Stainless Steel 300 Series Corrosion Resistant Steel Aluminum alloy with chromate over cadmium plating Nickel plated brass Nitrile Neopren...

Page 126: ...s Contact ICT Customer Support for current detail drawings Exposed Materials 302 304 Stainless Steel 300 Series Corrosion Resistant Steel Aluminum alloy with chromate over cadmium plating Nickel plate...

Page 127: ...w Mounting kit available for standard 19 in electronics rack Ingress Protection Rating IP20 See QSMC Motor Controller on page 142 for the electrical specifications Contact ICT Customer Support for cur...

Page 128: ...kit available for standard 19 in electronics rack Ingress Protection Rating IP20 See QSMC 2 Motor Controller on page 147 for the electrical specifications Contact ICT Customer Support for current deta...

Page 129: ...C Rack Mounting Bracket The rack mounting bracket can be used for mounting the QSMC motor controllers in a stan dard 19 in electronics rack Figure 4 6 Rack Mounting Bracket Mechanical Drawing Exposed...

Page 130: ...m motors or one 1 2 m double wide motor Figure 4 7 QuickStick HT 5700 Inverter Mechanical Drawing NOTE Each vent must be clear for unobstructed airflow Ingress Protection Rating IP20 See QuickStick HT...

Page 131: ...on the size of the array Contact ICT Customer Support for information on the availability of other widths Figure 4 8 High Flux Magnet Array Mechanical Drawing Table 4 1 High Flux Magnet Array Weights...

Page 132: ...il drawings Ingress Protection Rating IP50 IP68 optional Exposed Materials Low Carbon Steel Hardened Steel Nd Fe B magnets with Ni Cu Ni coating 304 Stainless Steel 18 8 Stainless Steel 7 838 mm 33 0...

Page 133: ...ied by the external QSMC motor controller or QSHT 5700 inverter see QSMC Motor Controller on page 142 or QuickStick HT 5700 Inverter on page 154 as appropriate for power requirements All power wiring...

Page 134: ...ported and can damage internal components Table 4 3 Stator Drive Connector Pinout 3 Pt Bayonet Size 16S 7 Pin Male 1 2 m motor uses only Stator 1 Stator Block 1 Phase A A Stator Block 1 Phase B B Sta...

Page 135: ...ctly to the QSMC motor controller and to the related motor Figure 4 10 1 m QSMC to Stator Drive Cable Table 4 5 1 m QSMC to Stator Drive Cable Pinouts Wire Gauge Motor Controller 3 Pt Reverse Bayonet...

Page 136: ...tator Drive Cable Pinouts Wire Gauge Motor Controller MINI CON X 4 Pin Male Motor 3 Pt Reverse Bayonet 16S 1 Female Stator Block Phase A 16 AWG 3 A Stator Block Phase B 16 AWG 2 B Stator Block Phase C...

Page 137: ...n for replacement cables The motor sense cable connects directly to the QSMC motor controller and to the related motor Figure 4 12 QSMC to Stator Sense Cable Table 4 7 QSMC to Stator Sense Cable Pinou...

Page 138: ...t male connector Turck RS 4 6T at the motor controller end Use stranded wire of the appropriate gauge for the length of the cable see Table 4 8 Manufacturing best practices must be followed Table 4 8...

Page 139: ...nnects directly to the QSHT 5700 inverter and to the related motor Figure 4 13 1 m QSHT 5700 Inverter to Stator Drive Cable Table 4 9 1 m QSHT 5700 Inverter to Stator Drive Cable Pinouts Wire Gauge In...

Page 140: ...4 10 1 2 m QSHT 5700 Inverter to Stator Drive Cable Pinouts Wire Gauge Inverter Motor Stator Block 1 Phase A 16 AWG U A Stator Block 1 Phase B 16 AWG V B Stator Block 1 Phase C 16 AWG W C Gnd 16 AWG P...

Page 141: ...eplacement cables The motor sense cable connects directly to the QSHT 5700 inverter and to the related motor Figure 4 15 QSHT 5700 Inverter to Stator Sense Cable Table 4 11 QSHT 5700 Inverter to Stato...

Page 142: ...rush current upon application of power The PTC is only used for inrush current limiting and is bypassed in normal operation Limit cycling of the pro pulsion power to 2 minutes between each turn on and...

Page 143: ...izer 4 Pin Male When using an NC LITE MagneMotion recommends connecting the upstream connections to the odd num ber connectors on the node controller and the downstream connections to the even number...

Page 144: ...Steady Control power is present not operating GREEN Flashing Control is OK RED Flashing Fault condition Red Green LED POWER ON Indicates that Drive Power is on HVDC 20V DC Red LED Table 4 15 QSMC Moto...

Page 145: ...MI UM007F EN P September 2020 Table 4 17 QSMC Motor Controller RS 422 Connector Pinouts UP STREAM DOWN STREAM M8 Nano Mizer 4 Pin Male M8 Nano Mizer 4 Pin Male RxD 1 RxD 1 RxD 2 RxD 2 TxD 3 TxD 3 TxD...

Page 146: ...19 QSMC Motor Controller Stator Drive Connector Pinout 16S 1S 7 Pin Female Stator Block 1 Phase A A Stator Block 1 Phase B B Stator Block 1 Phase C C Stator Block 2 Phase A D Stator Block 2 Phase B E...

Page 147: ...t upon application of power The PTC is only used for inrush current limiting and is bypassed in normal operation Limit cycling of the pro pulsion power to 2 minutes between each turn on and 20 seconds...

Page 148: ...n using an NC LITE MagneMotion recommends connecting the upstream connections to the odd num ber connectors on the node controller and the downstream connections to the even number connectors LVDC log...

Page 149: ...S GREEN Steady Control power is present not operating GREEN Flashing Control is OK RED Flashing Fault condition Red Green LED POWER ON Indicates that Drive Power is on HVDC 20V DC Red LED Table 4 24 Q...

Page 150: ...EN P September 2020 Table 4 26 QSMC 2 Motor Controller RS 422 Connector Pinouts UP STREAM DOWN STREAM M8 Nano Mizer 4 Pin Male M8 Nano Mizer 4 Pin Male RxD 1 RxD 1 RxD 2 RxD 2 TxD 3 TxD 3 TxD 4 TxD 4...

Page 151: ...MMI UM007F EN P September 2020 Table 4 28 QSMC 2 Motor Controller HVDC Power Connector Pinout Powerfast 3 Pin Male GND 1 PWR RTN 2 PWR HI 3 Table 4 29 QSMC 2 Motor Controller Stator Drive Connector P...

Page 152: ...s stator power to the motor controller Contact MagneMotion for replacement cables The HVDC Power cable connects directly to the HVDC power bus Each wire in the cable is color coded for identification...

Page 153: ...which provides logic power to the motor controller Contact MagneMotion for replacement cables The LVDC Power cable connects directly to the 24V DC power bus Each wire in the cable is color coded for i...

Page 154: ...and accelera tion of the vehicle the number of vehicles accelerating at once and the magnet array length All power wiring must be sized to carry the full load The QSHT 5700 Inverter uses the 2198 Pxxx...

Page 155: ...4V DC Control Power 24V DC 10 1 2 A typical Shared 24V Control Power Safety Hardwired Safe Torque off 16 Pin Terminal Block Link 1 Ethernet 10 100 1000 Base Tx RJ45 Link 2 Ethernet 10 100 1000 Base Tx...

Page 156: ...or Inverter Output B 8 9 kW 324 528V rms three phase 13 0 A rms continu ous 20 A max 4 Pin Terminal Block Table 4 34 QSHT 5700 Inverter Controls Label Description Control Type Display Navigation Navig...

Page 157: ...5700 Inverter Connectors Pinouts for all connectors on the QSHT 5700 inverter are provided The mating connectors are supplied as part of the inverter module connector set 2198 KITCON D032 L Table 4 3...

Page 158: ...used to enable motion when safety is not required by jumpering to the SS_COM pins 6 SS_IN_CH0 Safe stop input channel 1 Inverter B 7 SS_COM Safe stop input common 8 SS_IN_CH1 Safe stop input channel...

Page 159: ...nverter Ethernet Connector Pinout 1 TD 2 TD 3 RD 4 5 6 RD 7 8 Table 4 40 QSHT 5700 Inverter Stator Sense Connector Pinout 1 VCC output to HES board referenced to COM 2 VCC output to HES board referenc...

Page 160: ...2198 K57CK D15M universal feedback kit to support connecting discrete wires to this connector see Digital I O on page 201 1 Digital In Common 2 Digital In Common 3 No Connect 4 Digital In 1 5 Digital...

Page 161: ...Electrical Specifications QuickStick HT User Manual 161 Rockwell Automation Publication MMI UM007F EN P September 2020 Table 4 42 QSHT 5700 Inverter Connector Pinout 1 U closest to back of drive 2 V...

Page 162: ...ion Use MMI HT CB Pxx xx motor cables See Motor QSHT 5700 Inverter Drive Cable on page 139 and Motor QSHT 5700 Invert er Sense Cable on page 141 for cable specifications 10 0 0 39 0 5 0 6 4 4 5 3 Stat...

Page 163: ...ring commissioning or troubleshooting Do not attempt to use status indicators to determine operational status Table 4 44 Module Status Indicator Condition Status Steady Off No power is applied to the...

Page 164: ...enu provides the functions that are shown in Table 4 49 Table 4 46 Ethernet Link Speed Status Indicator Condition Status Steady Off 10 Mbit Steady On 100 Mbit Table 4 47 Ethernet Link Activity Status...

Page 165: ...he end of the list Press to select the highlighted menu item Press to return to the Home screen Press to display the fault help possible solutions in trou bleshooting tables Table 4 50 LCD Pages Menu...

Page 166: ...ODULE INFO Selects the MODULE INFO page MOTOR INFO Selects the MOTOR INFO page DIAGNOSTICS Selects the DIAGNOSTICS page MODULE INFO CATALOG NUMBER Catalog number 24 character string max FW Firmware re...

Page 167: ...dated in the menu screens MOTOR DIAGNOSTICS MOTOR TEMP Temperature of motor supplied by currently selected inverter 0 0 80 0 C OUT CURR Out current as commanded by currently selected inverter 0 0 20 0...

Page 168: ...NOTE While both TCP IP and EtherNet IP use the same hardware for communication the communication protocol itself is different This difference allows both protocols to run on the same network simultane...

Page 169: ...page 81 through Figure 3 26 on page 87 Addi tionally multiple paths can be connected to the node controller using the same Ethernet chain See Figure 4 20 for the location of these connections on the...

Page 170: ...oller with a 9 pin female D connector at any of the odd numbered RS 422 ports When using an NC S or NC 12 the RS 422 cables for upstream communications connect to the node controller with a 4 pin fema...

Page 171: ...straight through cable with a 4 pin female M8 connector on one end and a 4 pin female M8 connector on the other end One female M8 con nector plugs into the downstream communication port on the motor...

Page 172: ...nected to the same node controller Additionally multiple paths can be connected to one node controller using the same Ethernet chain The Ethernet cables for network connections to the NC 12 node contr...

Page 173: ...to 50 C 32 F to 122 F Storage 18 C to 50 C 0 F to 122 F Humidity 85 Maximum relative noncondensing QSHT 5700 Inverters Temperature Operating 0 C to 50 C 32 F to 122 F Storage 18 C to 50 C 0 F to 122 F...

Page 174: ...nd other compo nents See Facilities Connections on page 214 for the connection of all facilities to the QSHT transport system The facility is responsible for the main disconnect device between the Qui...

Page 175: ...rations of the QuickStick HT components that are used in a transport system Included in this chapter are Unpacking and inspection of the QuickStick HT transport system components QuickStick HT compone...

Page 176: ...d contents of the shipping packages depends on the items purchased See the shipping documents for the exact contents The checklist in Table 5 1 is pro vided for reference only Table 5 1 QuickStick HT...

Page 177: ...people with pacemakers and other medical electronic implants must stay away from the magnet arrays CRUSH HAZARD Strong magnets in use To avoid severe injury from strong magnetic attractive forces Han...

Page 178: ...ier and MagneMotion of any inspection discrepancy 2 Open each shipping package and verify the contents against the shipping documents 3 Carefully inspect the QuickStick HT components and all additiona...

Page 179: ...ounting points to help prevent any movement Installing Hardware To install the motors on user supplied supports make sure that the supports are properly pre pared to receive the motors see Mechanical...

Page 180: ...bend radius of all cables 5 Install the power supplies node controllers motor drives network switches and cables see Installing Electronics on page 183 6 Install magnet arrays on the vehicles and ins...

Page 181: ...r level to identify the datum throughout the installation area 3 Make sure that all sections of the track are level and correctly referenced to the datum and adjust the track as necessary Securing the...

Page 182: ...tor mounting hardware to 4 8 N m 42 in lb max NOTE Make sure that the tip of the mounting bolt does not extend beyond the depth of the mounting hole to prevent damage to the motor housing See the engi...

Page 183: ...plies If the node controllers are powered using a remote power supply instead of using PoE locate the power supply close to the node controller it is powering to minimize the length of all wir ing see...

Page 184: ...e service and exclusion zones that are identified in Figure 4 4 on page 127 and Figure 4 5 on page 128 are maintained Figure 5 1 QSMC and QSMC 2 Motor Controller Mounting Brackets Install the mounting...

Page 185: ...zones that are identified in Figure 4 7 on page 130 are maintained Figure 5 2 QSHT 5700 Inverter Mounting The QuickStick HT 5700 inverter is powered by the 2198 Pxxx DC bus power supply see Input Pow...

Page 186: ...ls the ground screw jumper set tings for the 2198 Pxxx DC bus power supply To access the ground screw on the 2198 Pxxx DC bus power supplies open the small plastic door on the right side of the module...

Page 187: ...settings for the QSHT 5700 inverter Table 5 3 Ground Screw Jumper Setting for the QSHT 5700 Inverter AC Power Source Type 2198 Pxxx DC bus Power Supply 2198 Pxxx DC bus power supply when 2198 DB20 F 2...

Page 188: ...d Screw ATTENTION To avoid personal injury the ground screw access door must be kept closed when power is applied If power is applied and then removed wait at least 5 minutes for the DC bus voltage to...

Page 189: ...t For hole patterns refer to the Kinetix 5700 Servo Drives User Manual publication 2198 UM002 Ground Screw Configuration Benefits of Configuration Grounded wye Installed UL and EMC compliance Reduced...

Page 190: ...that is required to make all motor connections as shown in Figure 4 9 Figure 4 16 Figure 4 17 and Figure 4 20 Connections to the node controllers are described in the Node Controller Hard ware User M...

Page 191: ...AC Drives DRIVES IN001 To maintain separate routes route these wires in separate conduit or use tray dividers See the following reference documents when design ing the wiring system for the QSHT tran...

Page 192: ...a detailed example When connecting the motor controllers to the node controllers both ends of a path do not need to connect to the same node controller However all connections to the motor controllers...

Page 193: ...ore information about nodes and paths Figure 5 7 QSHT Motor and QSMC RS 422 Communications Connections NOTICE Modifications to the MMI motor to motor controller cables or using custom cables violates...

Page 194: ...communication cable that is connected from the downstream connection on the motor controller for the last motor in the path to the node controller if the downstream end on that motor is connected in a...

Page 195: ...connector mounting screws to 0 34 N m 3 in lb do not overtighten NOTE When using an NC LITE a custom cross over gender changer can be used when connecting the downstream end of a path to one of the od...

Page 196: ...ocedure provides steps for connecting the motors as shown in the simplified wiring dia grams in Figure 5 8 and Figure 5 9 Simple QSHT Motor Host Controller QSHT Motor Enet Switch HLC Node Controller P...

Page 197: ...ple When connecting the inverters to the node controllers both ends of a path do not need to con nect to the same node controller However all connections to the inverters for motors at the ends of all...

Page 198: ...d position Route the cable so it is shielded from damage and can be easily accessed for service The factory supplied MMI HT Series motor cables are shielded and the braided cable shield must terminate...

Page 199: ...rter for that motor must be connected to the same network that the node controller responsible for that node is connected 1 Connect a Cat 5 communications cable from a spare port on the network switch...

Page 200: ...so it is shielded from damage and can be easily accessed for service For an NC E node controller connect from a dedicated standard network switch to the lower Network port auto MDIX and auto negotiati...

Page 201: ...four digital inputs that are available for user configured functions as described in Table 5 6 on page 218 See QuickStick HT 5700 Inverter on page 154 for the digital I O connection location and pino...

Page 202: ...nected to pin 16 If the cable does not include a drain wire create one from the overall shield during wire prepara tion and connect it to pin 16 16151413121110 12 0 0 5 Cable Shield DrainWire Cable Ja...

Page 203: ...aid and clamp 5 Attach a tie wrap customer supplied for stress relief 6 Tighten clamp screws to achieve 0 34 N m 3 0 lb in maximum torque 7 Replace the cover and install cover screw Tighten cover scre...

Page 204: ...Cable diameter 6 5 11 9 mm 0 26 0 47 in Screw terminal wire size 0 08 1 5 mm2 28 16 AWG Recommended wire strip length 5 mm 0 2 in single conductor Recommended torque Mounting screws Terminal screws Cl...

Page 205: ...in the QSHT transport system See Figure 5 5 and Figure 5 6 for simplified diagrams of the wiring Figure 5 15 shows the power connections being made to the motor controllers Figure 5 15 QSHT Power Conn...

Page 206: ...connector on the motor controller see Table 4 20 QSMC Motor Controller HVDC Power Connector Pinout on page 146 finger tighten only Route the cable so it is shielded from dam age and can be easily acc...

Page 207: ...to connect all motors on a path to the same power supply or to connect a power supply to only one path 11 Bundle and dress all power cables use nylon cable ties as required to keep all cable routing...

Page 208: ...tor locations on the 2198 Pxxx DC bus power supplies in the QuickStick HT transport system See Figure 5 8 and Figure 5 9 for simplified diagrams of the wiring Figure 5 16 shows the shared bus power co...

Page 209: ...connect between drive modules to extend the 24V control power from one drive module to another Wiring the Power Connections NOTE The AC power connections are made later see Facilities Connections on...

Page 210: ...to connect a power supply to only one path 6 Make sure that all NC LITE node controllers are mounted to grounded surfaces 7 Make sure that the ground stud on all NC 12 node controllers is connected to...

Page 211: ...ng the array The mounting must secure the array with a suitable form of gasketing to prevent water ingress into the array through either its back sur face or the seam where the cover meets the back ir...

Page 212: ...rays on one vehicle 1 Work on only one vehicle at a time 2 Make sure that the vehicle is secured to a work surface that is clear of any magnet arrays or ferrous material 3 Place the first magnet array...

Page 213: ...ong magnets in use To avoid severe injury people with pacemakers and other medical electronic implants must stay away from the magnet arrays CRUSH HAZARD Strong magnets in use To avoid severe injury f...

Page 214: ...sed for communi cation between node controllers When using QSHT 5700 inverters the same network is also used for communication between the inverters and the node controllers Use a dedicated sep arate...

Page 215: ...operation of the motors and other subsystems An AC electrical connection is provided on those components that require facility power See Electrical Specifications on page 133 for electrical require m...

Page 216: ...TE make sure that the Ethernet connection goes to a 18V DC PoE enabled network switch Plug the network switch power supply into the power distribution from the main power disconnect for the facility T...

Page 217: ...I O provided through a node controller for monitoring and control of local options such as a light stack The optional light stack cir cuit is the responsibility of the user and requires a user suppli...

Page 218: ...tick Configurator User Manual MMI UM009 for informa tion on configuring these nodes Table 5 6 QSHT 5700 Inverter Digital Input Configurable Functions Function Description Unassigned No action is taken...

Page 219: ...em See the Node Controller Interface User Manual MMI UM001 for details All QuickStick HT motors ship with just a basic software image installed This image is used for testing during manufacturing and...

Page 220: ...ller web interface to each node controller See the Node Controller Interface User Manual MMI UM001 for details NOTE Restart the node controller for the changes to take effect Motor Software Installati...

Page 221: ...e facility Make sure that all hardware is secure If the optional E stop circuit is being used make sure that the button is functional Manually move a vehicle through the entire QSHT transport system t...

Page 222: ...y check from the surfaces of the QuickStick HT transport system to a known good ground 5 Apply power to the QuickStick HT transport system CRUSH HAZARD Moving mechanisms vehicles have no obstruction s...

Page 223: ...sed see the Quick Stick Configurator User Manual MMI UM009 for additional configuration informa tion 9 Configure one node controller as the HLC See the Node Controller Interface User Manual MMI UM001...

Page 224: ...or MICS File on page 89 B Upload the MICS file to all node controllers see the Node Controller Interface User Manual MMI UM001 C Cycle logic power to the motors to force the motors to request their ne...

Page 225: ...e sure that the web interface for each node controller shows a status of run ning valid see the Node Controller Interface User Manual MMI UM001 4 Issue a Restart Services command for each node control...

Page 226: ...ation Publication MMI UM007F EN P September 2020 8 Move vehicles individually or create a Demo Script for repetitive testing see the NCHost TCP Interface Utility User Manual MMI UM010 9 Monitor transp...

Page 227: ...transport system The operation of the QSHT transport system is covered for both normal conditions and emergency conditions Included in this chapter are Theory of operation of the MagneMotion linear sy...

Page 228: ...ray of magnets that is attached to the object to move referred to as a vehicle The motor primary generates a mag netic field to move the motor secondary vehicle in a controlled manner The QSHT motors...

Page 229: ...or more other paths through a node or multiple nodes The design and operation of the QuickStick HT transport system uses a minimum of moving parts to minimize maintenance requirements Position sensors...

Page 230: ...tions are always defined from the beginning of a path 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...

Page 231: ...order is finished when the vehicle position is equal to the ordered destina tion Motor Cogging Brushless Permanent Magnet BPM motors that are iron core based inherently exhibit cog ging forces In tra...

Page 232: ...eration and maxi mum velocity as defined in the current motion order and determination of the interim destina tion for the vehicle and current acceleration and velocity setpoints The drive makes sure...

Page 233: ...for each motor releases ownership of blocks once the vehicle exits the block and is at least 3 mm away from that block Block ownership is also released if the vehicle is deleted Anti Collision The Qui...

Page 234: ...th a higher acceleration rate than the motor can provide the vehicle falls behind its ideal move profile while accelerating Figure 6 6 shows both the ideal move profile solid line and the degraded mov...

Page 235: ...ould be another vehicle a node not ready for a vehicle or a path that is suspended or has not completed startup Once the obstruction clears that is the obstructing vehicle moves the node becomes ready...

Page 236: ...s until it locates a new one or it tries to move an already located vehicle to make room to locate a new vehicle if there is additional room to move the already located vehicle that is in the way If t...

Page 237: ...ser Manual MMI UM004 A vehicle that has been manually moved bumped or dislodged and lost its signal is able to reacquire its signal when it is manually relocated to within approximately 25 mm of its o...

Page 238: ...or resists motion of the vehicle Once the vehicle is released it snaps back to its original position if it has not been moved vary far less than 25 mm unless the center of the magnet array on the vehi...

Page 239: ...The inverters that power the individual blocks within the motor are enabled when the internal propulsion bus for the motor rises above 350V DC which allows normal motor operation and are shut down if...

Page 240: ...be a mini mum of 2 minutes and a minimum of 20 seconds between turn off and turn on power cycle as shown in Figure 6 7 Figure 6 7 Power Cycle Timing To make sure that the soft start circuit resets fo...

Page 241: ...a nominal block coil resistance of 4 5 Ohms the dissipated power is 1 kW per block when the 15 A current level is reached and remains at this level up to 430V DC The dissi pated power vs the internal...

Page 242: ...n motor The current in these available blocks ramps linearly to 15 A over a 20 volt range from 805V DC to 825V DC The coil current remains constant at 15 A for voltages above 805V DC and drops to zero...

Page 243: ...ng operation the motor reports a soft start switch off fault through the HLC to the host controller When this fault is reported all inverters within the motor are disabled and any vehicles in motion o...

Page 244: ...o avoid issuing an overvoltage fault to the host controller due to spurious noise the internal propulsion bus that is used to trigger this event is filtered Based on the specific system wiring and veh...

Page 245: ...e on motors that are undergoing regeneration Reduce the cable resistance between the power supply and the motors if a voltage drop in these cables leads to under voltage on motors that are acceleratin...

Page 246: ...al MMI UM004 This fault self clears when the internal propulsion bus voltage rises above 350V DC If the internal propulsion bus voltage drops below 330V DC during operation the motor reports an underv...

Page 247: ...onal shunt capacity for applications where the DC bus power supply s internal shunt capacity is exceeded during power regeneration when braking See the Kinetix 5700 Servo Drives User Manual 2198 UM002...

Page 248: ...the regenerated power flowing back into the system Reduce the number of vehicles accelerating on motors that are connected to the same common 458 747V DC power supply Split the power bus into smaller...

Page 249: ...controller through either TCP IP or EtherNet IP The HLC distributes any commands or requests that are received to the appropriate node controller through the LAN using TCP IP and passes any messages...

Page 250: ...f the QuickStick HT compo nents are identified in the Electrical Specifications on page 133 Track Display The NCHost TCP Interface Utility can be used to display the Graphics Window which is shown in...

Page 251: ...Resume command to the paths associated with the E stop Interlocks When using a node controller with digital I O the node controller can be connected directly to an interlock circuit An interlock is a...

Page 252: ...ed paths Vehicles immediately decelerate with maximum thrust opposing their motion Previously commanded motion does not resume until a Resume Motion command is received The control loop is still enabl...

Page 253: ...ull amount of data is always returned if specific fault types do not apply zeros are returned Table 6 3 QSHT Faults Status Status Type Description OS Scheduler Errors Fault data for the task scheduler...

Page 254: ...hat are specified in the command with a maximum of the values specified in the Node Controller Configura tion File Simulating the transport system requires one node controller a fully defined Node Con...

Page 255: ...nual MMI UM009 B Select Show Simulated Vehicles from the Options menu C For each path where simulated vehicles start define the simulated vehicles and enter the starting location for each vehicle 1 In...

Page 256: ...ration and simulated operation are described in Table 6 4 Table 6 4 Simulated Operation Differences Feature Physical Operation Simulated Operation Motors All motors must be defined connected to the no...

Page 257: ...y path has been reset adds new simulated vehicles to that path Vehi Vehicles The vehicle properties must be defined in the Node Controller Configuration File All vehicles being used must be installed...

Page 258: ...ce all motion has stopped issue a Reset command for all paths All vehicle records are cleared Return the System to Normal Operation 1 Configure the node controller to run in Normal Mode NOTE It is not...

Page 259: ...paths All motors on the paths in the transport system 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...

Page 260: ...HT transport system The user must determine the exact usage of the QSHT transport system See the Host Control ler TCP IP Communication Protocol User Manual MMI UM003 for details of each com mand to us...

Page 261: ...n positions 3 Issue a Suspend Motion command for all paths All vehicles come to a controlled stop 4 Once all motion has stopped issue a Reset command for all paths The HLC clears all vehicle records 5...

Page 262: ...Operation 262 MagneMotion Rockwell Automation Publication MMI UM007F EN P September 2020 This page intentionally left blank...

Page 263: ...mber 2020 QSHT 5700 Inverter Safe Torque off Function 7 Overview This chapter provides an overview of the safe torque off STO functionality that is built into the QSHT 5700 Inverter Included in this c...

Page 264: ...ng power is considered to be the safe state For product certifications currently available from Rockwell Automation go to rok auto certi fications Important Safety Considerations The system user is re...

Page 265: ...fety related function is directly related to the probability of a dangerous failure per hour PFH PFH calculation is based on the equations from IEC 61508 and shows worst case values Table 7 1 provides...

Page 266: ...s described in Stop Category Definition on page 264 and protection against restart as specified in IEC 60204 1 ATTENTION The safe torque off STO feature is suitable only for performing mechanical work...

Page 267: ...s section is STANDARD data not SAFETY data and cannot be used as part of a safety function Table 7 2 Safety Related Axis Tags MMI_path_qs_ht_faults_status Name Bit Fault Definition Action Master Board...

Page 268: ...input discrep ancy is detected when safety inputs are in a different state for more than 1 0 second Verify safety wiring and connections Wire terminations at STO connector Cable header not seated cor...

Page 269: ...Hardwired Safe Torque off Electrical Specifications on page 279 for more information on the safety inputs Falling of suspended or inclined loads or a stopped position where one end of the vehicle mag...

Page 270: ...180 electrical degrees away from any given arbitrary initial position which corresponds to a distance of 60 mm ATTENTION Once there is a GuardStopInputFault recovery occurs once the STO inputs for bot...

Page 271: ...rst input is switched ON 4 Second input is switched ON within 1 second of event 3 5 Both inputs are in the ON state simultaneously within 1 second As a result Guard StopInputFault is not posted 6 The...

Page 272: ...put must also be turned OFF within 1 sec ond otherwise a fault is asserted see Figure 7 3 The fault is asserted even if the first safety input is turned ON again without the second input transitioning...

Page 273: ...The safe torque off fault is detected upon demand of the safe torque off function After troubleshooting the STO function or performing maintenance that might affect the STO function the STO function m...

Page 274: ...or Pinouts STO Pin Description Signal 1 Safety bypass plus signal Connect to both safety inputs to disable safe torque off function SB 2 10 Safe stop input channel 1 inverter A S1A 3 11 Safe stop inpu...

Page 275: ...vers clockwise into the locked position while inserting the STO connector plug Failure to do this can result in the connector plug pulling out of the QSHT 5700 inverter connector during normal operati...

Page 276: ...l Plug NOTICE The National Electrical Code and local electrical codes take precedence over the values and methods provided IMPORTANT Stranded wires must terminate with ferrules to prevent short circui...

Page 277: ...es must be installed to bypass the safe torque off circuitry QSHT 5700 inverters ship with a 16 pin wiring plug for wiring to safety devices To bypass the safety function wire these signals as shown i...

Page 278: ...vices Figure 7 9 Cascaded STO Wiring Dual Inverters with Two Safety Devices In this example the cascaded STO wiring is for an application with three QSHT inverters and a single safety device for all i...

Page 279: ...ts appropriate for the environmental conditions of the industrial location The protection class of the panel or cabi net must be IP54 or higher Table 7 6 Hardwired STO Electrical Specifications Attrib...

Page 280: ...QSHT 5700 Inverter Safe Torque off Function 280 MagneMotion Rockwell Automation Publication MMI UM007F EN P September 2020 This page intentionally left blank...

Page 281: ...HT compo nents Only trained qualified personnel should perform maintenance or troubleshooting on the QSHT transport system MagneMotion provides training in the troubleshooting and repair of the QSHT...

Page 282: ...ormation See Troubleshooting on page 286 if any problems are detected Table 8 1 QuickStick HT Transport System Preventive Maintenance Schedule Component Maintenance Action Frequency The specified freq...

Page 283: ...grain 3 Make sure that all components are dry 4 Resume motion on the sections of the QSHT transport system that were stopped Wear Surface Maintenance The vehicles that are used on the QSHT transport...

Page 284: ...rdware is secure 4 Make sure that all motor mounting hardware is secure 5 Make sure that all guideway mounting hardware is secure 6 Make sure that all vehicle grounding materials for example static br...

Page 285: ...vent water ingress into the array through either its back surface or the seam where the cover meets the back iron of the array The top surface and sides of the cover are water resistant MAGNETIC FIELD...

Page 286: ...prob lem area Table 8 2 Initial Troubleshooting Symptom Possible Problem Area Power lights do not turn on See Power Related Troubleshooting on page 287 Motors report power related faults Vehicles do n...

Page 287: ...full speed Motor drive is not providing full power Verify that the motor drive air fil ter is not dirty Clean or replace if necessary seeCleaning or Replacing the Motor Controller Fan Filter on page 3...

Page 288: ...age fault Turn off the HVDC power supply for a few minutes to allow the PTC to cool down sufficiently to allow proper resumption of opera tion upon reapplication of the HVDC power source Make sure tha...

Page 289: ...DC The motor reports an overvoltage fault Power being supplied to the QSMC controller is above 430V DC See Overvoltage Fault on page 244 The fault clears once the power bus drops below 420V DC Verify...

Page 290: ...Verify the voltage at the motor Reduce power cable resistance between motors that share a com mon HVDC power supply Reduce maximum speed and or maximum acceleration to reduce the amount of regenerated...

Page 291: ...the power wiring to the controller is not damaged There is a fault within the soft start circuit The red power LED is ON during this condition which indicates that there is input voltage to the motor...

Page 292: ...ted 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 c...

Page 293: ...of all connections Check communication to the host controller Make sure that logic power is enabled Host controller application issue Verify that the host controller is correctly configured Verify th...

Page 294: ...uideway Make sure that the guideways and motors are clean Misalignment of sections of the guideway Make sure that the joints between guideway sections are properly secured and co planar Power or commu...

Page 295: ...all connections to the light stack are properly wired see Light Stacks on page 252 Make sure that the bits specified in the Node Controller Configura tion File are the bits connected to the light sta...

Page 296: ...tion of the Path where the motor is located while the motor is suspended Table 8 8 QuickStick HT MMI_path_qs_ht_faults_status Motor Faults Master Board Faults 3 Safety Core Fault Definition Communicat...

Page 297: ...ondition Gate driver voltage drops below 13V Clear condition Gate driver voltage rises above 13V User action Power cycle the unit If problem persists return the unit Motor Suspend Fault Yes 9 Power Su...

Page 298: ...and run proof test If error persists return the unit Motor Suspend Fault Yes 1 Safe Torque off Fault Definition The safe torque off STO function detected a fault Set condition Internal error detected...

Page 299: ...satisfied issue a reset resume com mand User action Verify safety wiring and connections Wire terminations at safe torque off STO connector Cable header not seated correctly 24V power Check state of s...

Page 300: ...e changes Any corrective actions performed for example system reset replaced parts loaded software power cycle What were the results of those actions Any special system environmental conditions for ex...

Page 301: ...ge 175 NOTE The components of the QuickStick HT transport system are designed for easy replacement Motors drives and other modules do not contain any user serviceable parts NOTICE Only a qualified ser...

Page 302: ...tor is being replaced All vehicles come to a controlled stop 4 Once all motion has stopped issue a Reset command for the path where the motor is being replaced The HLC clears all vehicle records 5 Tur...

Page 303: ...2 Reconnect the power and sense connections to the motor refer to the labels previously placed on the cables 3 Restore power to the section of the QSHT transport system where the motor was replaced 4...

Page 304: ...Suspend Motion command for the path where the motor drive is being replaced All vehicles come to a controlled stop 4 Once all motion has stopped issue a Reset command for the path where the motor driv...

Page 305: ...ter A Update the MICS file see Ethernet Motor MICS File on page 89 with the new MAC address and static IPv4 address of the inverter B Upload the MICS file to all node controllers see the Node Controll...

Page 306: ...ive being replaced is a QSHT 5700 inverter A Update the MICS file see Ethernet Motor MICS File on page 89 with the new MAC address and static IPv4 address of the inverter B Upload the MICS file to all...

Page 307: ...n minimal contact with the edge and then lift the array away from the edge starting at one end of the array MAGNETIC FIELD HAZARD Strong magnets in use To avoid severe injury people with pacemakers an...

Page 308: ...uires cleaning remove the filter from the motor controller Use a small screwdriver with a flat blade and gently insert it between the front plate and the bezel of the filter housing near one of the re...

Page 309: ...MMI UM007F EN P September 2020 Ordering Parts If new or replacement parts are needed contact ICT Sales Main Office Sales MagneMotion Inc A Rockwell Automation Company 139 Barnum Road Devens MA 01434 U...

Page 310: ...pment Required Tools and Equipment Metric hex wrenches English hex wrenches Open end wrench adjustable Fork truck or appropriate lift as required SHOCK HAZARD Before beginning this procedure the Quick...

Page 311: ...for replacements MAGNETIC FIELD HAZARD Strong magnets in use To avoid severe injury people with pacemakers and other medical electronic implants must stay away from the magnet arrays CRUSH HAZARD Str...

Page 312: ...rd packing procedures 2 Using the container that the component was originally shipped in set the component into the container and secure using the supplied packing material 3 Close the shipping contai...

Page 313: ...luded to provide the user with one location for additional information that is related to the QuickStick HT transport system Included in this appendix are Interconnect diagrams for the QSHT 5700 inver...

Page 314: ...ers are preferred 4 Cable shield clamp with clamp spacers must be used to meet CE requirements with Bulletin 2090 power cables 2 AWG and smaller See Customer supplied Motor Power Cables in the Kinetix...

Page 315: ...ference international standards IEC 62061 and ISO 13849 1 estimation and safety performance categories ATTENTION An AC three phase mains contactor must be wired in series between the branch circuit pr...

Page 316: ...1 2 Bonded Cabinet Ground Bus Control Power CP Connectors Three phase Input IPD Connector 2198 DBRxx F Three phase AC Line Filter Note 3 Indicates User Supplied Component Chassis Customer Supplied 24V...

Page 317: ...are based on motors running at a 25 duty cycle thrust must be limited at 100 duty cycle to help prevent overheating of the motor Determine Thrust Force Choose a magnet array length number of cycles fr...

Page 318: ...hrust increases with an increase in the number of magnet array cycles The chart also shows that as the Vehicle Gap increases the available thrust decreases Table A 2 Thrust Force Data High Flux Magnet...

Page 319: ...net Array Figure A 3 Thrust Force vs Vehicle Gap High Flux Magnet Array 0 500 1000 1500 2000 2500 2 3 4 5 6 7 8 QuickStick HTHigh Flux Array Thrust Force N Magnet Array Cycles Vehicle Gap 4 mm 7 mm 10...

Page 320: ...mber of magnet array cycles Figure A 4 Attractive Force Data Curves High Flux Magnet Array Table A 3 Attractive Force Data High Flux Magnet Array Maximum Attraction N Length Vehicle Gap mm Cycles mm 4...

Page 321: ...y engaged by stators For example an 8 cycle long magnet array yields twice the thrust of a 4 cycle array assuming that both arrays are fully engaged by stators with the same drive current and gap valu...

Page 322: ...s has the same value whether or not the stator is powered Laboratory measurements of the hold down force that is obtained with a QuickStick HT motor at various operational parameter values were used t...

Page 323: ...ve been changed is recommended Keep copies of all original and backup files at a remote location for safety Creating Backup Files Backup files are not created automatically It is the responsibility of...

Page 324: ...identification of software versions identification of new features and enhancements and a list of known issues Reading this file is recommended before using the software Upgrade Procedure The Upgrade...

Page 325: ...h when all vehicles on the path are commanded forward downstream 45 vehicles maximum per path when all vehicles on the path are commanded backwards 384 5 120 6 000 vehicles maximum when using HLC Cont...

Page 326: ...Appendix 326 MagneMotion Rockwell Automation Publication MMI UM007F EN P September 2020 This page intentionally left blank...

Page 327: ...rs of the transport system that are stored in the Node Controller Configuration File Controller A device that monitors and controls the operating conditions of the equipment being monitored In a Magne...

Page 328: ...for use on MagneMover LITE transport systems that uses low friction skids to slide on the integral rails Global Directives The Demo Script commands that define the general operating characteristics f...

Page 329: ...Technology A programmable intelligent conveyor system that uses linear syn chronous motors for moving multiple independently controlled vehicles Interlock A user supplied circuit that is used to stop...

Page 330: ...onverts DC from the propulsion power bus to AC to ener gize the coils in a Motor Block and contains the Master and the Inverter for QuickStick HT motors See Drive Motor Gap The physical distance betwe...

Page 331: ...etween each other while in motion that is less than the Brick wall Headway PLC See Programmable Logic Controller Position A specific location on a Path which is measured from the beginning of that pat...

Page 332: ...ordinate controllers for the motor they communicate with the Master and operate the Inverters and position sense hardware They are internal to the motor assembly on MagneMover LITE and QuickStick 100...

Page 333: ...cle is removed or deleted Vehicle Directives The Demo Script commands that define the individual motion characteristics for a specific vehicle See also Global Directives Vehicle Gap The distance betwe...

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Page 335: ...on Configurator Connections communications 193 197 Ethernet 196 199 inverter to inverter 196 inverter to motor 198 Connections Continued motor controller to motor 194 motor controller to motor control...

Page 336: ...3 246 Force calculate attractive force 322 calculate thrust 321 G Gap downstream 70 motor 70 vehicle 108 317 Gender Changer 170 194 Getting Started 37 Ground Screw Jumper 186 Grounding transport syste...

Page 337: ...300 Sales 309 MagneMotion Configurator overview 35 MagneMotion Information and Configuration Service File see MICS File Magnet Array calculating size 317 cycle length 103 description 102 dimensions 13...

Page 338: ...imensions 127 exclusion zones 127 ground stud 143 IP rating 127 QSMC 2 connections 148 dimensions 128 exclusion zones 128 ground stud 148 Motor Controllers Continued QSMC 2 Continued IP rating 128 tem...

Page 339: ...onnel Safety 43 Power Cables connection 215 HVDC power 152 identification 34 installation 205 208 LVDC power 153 Power over Ethernet Wiring Diagram 214 Power Requirements QSHT motor 1 m 142 QSHT motor...

Page 340: ...ons location restrictions 70 Straight Track configuration 119 Switch configuration 121 transport system layout 59 System Configurator see MagneMotion Config urator T Tandem Vehicle see Dual Magnet Arr...

Page 341: ...ng startup 236 materials 110 obstructed 235 simulated 255 single magnet array 108 Virtual Scope Utility description 36 W Warnings overcurrent 244 247 Web Interface description 35 file upload 220 progr...

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Page 343: ...QuickStick HT User Manual 343 Rockwell Automation Publication MMI UM007F EN P September 2020 Notes...

Page 344: ...ter 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 K...

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