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MagneMover LITE User Manual
ii MagneMotionRockwell Automation Publication MMI-UM002E-EN-P - March 2016
Although every effort is made to ensure the accuracy of this document, MagneMotion, Inc. assumes no responsibility forany errors, omissions, or inaccuracies. Information provided within this manual is subject to change without notice. Anysample code referenced in this document and that may be included with MagneMotion software is included for illustrationonly and is, therefore, unsupported.
MagneMotion®, MagneMover®, QuickStick®, MM LITE®, and SYNC IT™ are trademarks or registered trademarks ofMagneMotion, Inc. Microsoft® and Windows® are registered trademarks of Microsoft Corporation. All other trademarksare properties of their respective owners.
This product is protected under one or more U.S. and International patents. Additional U.S. and International patentspending.
©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 fordistribution, reproduction, or sale without the express written permission of MagneMotion, Inc. In no event willMagneMotion, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application ofthis equipment.
MagneMotion, Inc.139 Barnum RoadDevens, MA 01434USAPhone: +1 978-757-9100Fax: +1 978-757-9200www.magnemotion.com
This technology is subject to United States Export Administration Regulations and authorized to the destination only;diversion contrary to U.S. law is prohibited.
Printed in the U.S.A.
MagneMover LITE User Manual iRockwell Automation Publication MMI-UM002E-EN-P - March 2016
Contents
Figures ........................................................................................................... xi
Tables............................................................................................................. xvii
ChangesOverview...................................................................................................................... xix
Rev. A .................................................................................................................... xixRev. B .................................................................................................................... xixRev. C .................................................................................................................... xxRev. D .................................................................................................................... xxRev. E..................................................................................................................... xxi
About This ManualOverview...................................................................................................................... xxiii
Purpose................................................................................................................... xxiiiAudience ................................................................................................................ xxiiiPrerequisites........................................................................................................... xxiii
MagneMotion Documentation ..................................................................................... xxivManual Conventions .............................................................................................. xxivNotes, Safety Notices, and Symbols ...................................................................... xxvManual Structure.................................................................................................... xxviRelated Documentation.......................................................................................... xxvii
Contact Information..................................................................................................... xxvii
1 IntroductionOverview........................................................................................................................1-1MagneMover LITE Overview .......................................................................................1-2
MagneMover LITE Transport System Components ...............................................1-3MagneMover Transport System Options.................................................................1-4
Precision Rails ...................................................................................................1-4Precision Locator ...............................................................................................1-6
Transport System Overview ..........................................................................................1-7Transport System Software Overview...........................................................................1-8Getting Started with the MagneMover LITE Transport System ...................................1-10
Contents
ii MagneMotionRockwell Automation Publication MMI-UM002E-EN-P - March 2016
2 SafetyOverview........................................................................................................................2-1Regulatory Compliance .................................................................................................2-2
EU RoHS and EU WEEE Compliance....................................................................2-2Equipment Regulatory Guidelines...........................................................................2-2
Safety Considerations ....................................................................................................2-4Personnel Safety Guidelines ....................................................................................2-4Equipment Safety Guidelines ..................................................................................2-5MagneMover LITE Transport System Hazard Locations .......................................2-7Precision Rail Option Hazard Locations .................................................................2-8Precision Locator Option Hazard Locations............................................................2-9
Symbol Identification ....................................................................................................2-10Label Identification and Location..................................................................................2-12
Standard MagneMover LITE Components..............................................................2-12Precision Rail Option Components..........................................................................2-18Precision Locator Option Components....................................................................2-20
Mechanical Hazards.......................................................................................................2-22Electrical Hazards ..........................................................................................................2-23Pneumatic Hazards ........................................................................................................2-24Magnetic Hazards ..........................................................................................................2-25
Handling Magnet Arrays .........................................................................................2-26Shipping Magnet Arrays ..........................................................................................2-27
Recycling and Disposal Information .............................................................................2-28MagneMover LITE Transport System.....................................................................2-28Node Controllers......................................................................................................2-28Magnet Arrays .........................................................................................................2-28
3 Design GuidelinesOverview........................................................................................................................3-1Transport System Layout...............................................................................................3-2
Transport System Overview ....................................................................................3-2Motors, Switches, and Vehicles (Pucks) .................................................................3-3Paths.........................................................................................................................3-4Nodes .......................................................................................................................3-5Node Controllers......................................................................................................3-6Additional Connections ...........................................................................................3-7
Transport System Design...............................................................................................3-8Overview..................................................................................................................3-8Design Guidelines....................................................................................................3-8Motors ......................................................................................................................3-9
Motor Types.......................................................................................................3-10Available Thrust ................................................................................................3-10Required Thrust .................................................................................................3-11Motor Gap..........................................................................................................3-11Downstream Gap ...............................................................................................3-11Motor Cogging...................................................................................................3-12Motor Controllers ..............................................................................................3-12
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MagneMover LITE User Manual iiiRockwell Automation Publication MMI-UM002E-EN-P - March 2016
Electrical Wiring......................................................................................................3-12Power Wiring.....................................................................................................3-12Signal Wiring.....................................................................................................3-13Ground ...............................................................................................................3-13
Magnet Arrays .........................................................................................................3-15High Flux Magnet Arrays ..................................................................................3-15Magnet Array Length and Attractive Force.......................................................3-16Magnet Array Use..............................................................................................3-17Available Magnet Arrays...................................................................................3-17
Vehicles ...................................................................................................................3-18Single Array Puck..............................................................................................3-19Dual Array (Tandem) Puck................................................................................3-19Vehicle Gap .......................................................................................................3-20Vehicle Design...................................................................................................3-21Mounting Magnet Arrays to Vehicles ...............................................................3-22
Guideways ...............................................................................................................3-23Custom Guideway Design .................................................................................3-23Guideway and Support Materials ......................................................................3-24Motor Mounts ....................................................................................................3-24Motor Mounting Methods..................................................................................3-25
System Stands ..........................................................................................................3-28Custom Motor Mounting ...............................................................................................3-29Puck Carrier ...................................................................................................................3-31
Cantilevered Loads ..................................................................................................3-31Transport System Options .............................................................................................3-33
Precision Rail ...........................................................................................................3-33Precision Rails ...................................................................................................3-34Spine Plates........................................................................................................3-36Support Post Assembly......................................................................................3-37Vehicles .............................................................................................................3-38
Precision Rail Installation........................................................................................3-39Precision Locator .....................................................................................................3-40
Precision Locators..............................................................................................3-40Locator Stand.....................................................................................................3-40Pallet ..................................................................................................................3-41Pallet Design ......................................................................................................3-41
Precision Locator Installation ..................................................................................3-43Pneumatic Piping ...............................................................................................3-43
Transport System Configuration....................................................................................3-45Straight Track Configuration ...................................................................................3-45Curve Track Configuration ......................................................................................3-46Switch Configuration...............................................................................................3-47
4 Specifications and Site RequirementsOverview........................................................................................................................4-1Motor Types...................................................................................................................4-2
MagneMover LITE G3 Motors................................................................................4-2MagneMover LITE G4 Motors................................................................................4-2
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Mechanical Specifications .............................................................................................4-31000 Millimeter Motor ............................................................................................4-31000 Millimeter Railless Motor...............................................................................4-4250 Millimeter Motor ..............................................................................................4-5250 Millimeter Railless Motor.................................................................................4-6125 Millimeter Radius 90° Curve............................................................................4-7125 Millimeter Radius 90° Curve Railless Motor ...................................................4-890° Left Switch ........................................................................................................4-990° Right Switch......................................................................................................4-10Standard Motor Mount Bracket ...............................................................................4-11Stand System............................................................................................................4-12Pucks........................................................................................................................4-13Tandem Pucks..........................................................................................................4-16Magnet Arrays .........................................................................................................4-19NC-12 Node Controller ...........................................................................................4-21Rack Mounting Bracket ...........................................................................................4-22Node Controller LITE..............................................................................................4-23Electronics Mounting Plate......................................................................................4-24MM LITE Power Supply .........................................................................................4-25Precision Rail Option...............................................................................................4-26
Precision Rails ...................................................................................................4-26Precision Rail Single Array Vehicle ..................................................................4-27Precision Rail Dual Array Vehicle ....................................................................4-28Precision Rail Support Post Assembly ..............................................................4-29Spine Plates........................................................................................................4-30
Precision Locator Option .........................................................................................4-34Actuator Assembly ............................................................................................4-34Stand Assembly .................................................................................................4-35Adjustable Motor Mount Bracket ......................................................................4-36Pallet ..................................................................................................................4-37
Electrical Specifications ................................................................................................4-38Motors and Switches................................................................................................4-38
Straight and Curve Motors.................................................................................4-40Switches .............................................................................................................4-42
MM LITE Power Supply .........................................................................................4-44AC Power Cable ................................................................................................4-46Motor Power Cable ............................................................................................4-47DC Enable..........................................................................................................4-48DC Enable Jumper Plug.....................................................................................4-48
NC-12 Node Controller ...........................................................................................4-49AC Power Option...............................................................................................4-49DC Power Option...............................................................................................4-49AC Power Cable ................................................................................................4-53
Node Controller LITE..............................................................................................4-54AC Power Option...............................................................................................4-54DC Power Option...............................................................................................4-54AC Power Cable ................................................................................................4-57
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MagneMover LITE User Manual vRockwell Automation Publication MMI-UM002E-EN-P - March 2016
Ethernet Switch with Power over Ethernet Injector ................................................4-58AC Power Cable ................................................................................................4-58
Precision Locator .....................................................................................................4-59Pneumatic Specifications ...............................................................................................4-61
Precision Locator .....................................................................................................4-61Communications ............................................................................................................4-62
Ethernet Connection ................................................................................................4-62TCP/IP Communication...........................................................................................4-62EtherNet/IP Communication....................................................................................4-63RS-232 Serial Interface Connection ........................................................................4-63RS-422 Serial Interface Connection ........................................................................4-63Sync Connection ......................................................................................................4-65Digital I/O Connection.............................................................................................4-65
Site Requirements ..........................................................................................................4-66Environment.............................................................................................................4-66
Motors ................................................................................................................4-66NC LITE ............................................................................................................4-66NC-12.................................................................................................................4-66MM LITE Power Supply ...................................................................................4-66Precision Locator ...............................................................................................4-67Magnet Arrays, Pucks, Precision Rail Vehicles ................................................4-67Lighting, Site: ....................................................................................................4-67
Floor Space and Loading .........................................................................................4-67Facilities...................................................................................................................4-67Service Access .........................................................................................................4-68
5 InstallationOverview........................................................................................................................5-1Unpacking and Inspection .............................................................................................5-2
Unpacking and Moving ...........................................................................................5-3Required Tools and Materials............................................................................5-3Unpacking and Moving Instructions..................................................................5-3
Transport System Installation ........................................................................................5-5Installing Hardware..................................................................................................5-5
Required Tools and Materials............................................................................5-5Installation Overview – User-Supplied Mounting.............................................5-6Installation Overview – MMI Supplied Mounting ............................................5-7Installation Overview – MMI Precision Rails ...................................................5-8Installation Overview – MMI Precision Locator ...............................................5-9
Stand System Installation.........................................................................................5-11Assembling Beams ............................................................................................5-11Installing System Legs.......................................................................................5-12Leveling the MagneMover LITE.......................................................................5-15Securing the Transport System ..........................................................................5-16
Motor Installation ....................................................................................................5-18Installing Cable Chase Cover Brackets .............................................................5-18Installing Motor Mounts on Motors and Switches ............................................5-19
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Mounting Motors and Switches .........................................................................5-20Align and Secure Motors and Switches .............................................................5-23Align and Secure Railless Motors .....................................................................5-25Verify Motor and Switch Installation ................................................................5-26
Installing Electronics ...............................................................................................5-27Installing Electronics on the Transport System .................................................5-27
Connecting Motors and Electronics.........................................................................5-32Installing Pucks/Magnet Arrays...............................................................................5-40
Magnet Array Installation..................................................................................5-40Puck Installation ................................................................................................5-40
Installing Cable Chase Covers .................................................................................5-41Option Installation .........................................................................................................5-44
Precision Rail Installation........................................................................................5-44Assemble Precision Rail Support Posts .............................................................5-45Attach Precision Rail Support Posts to the Beam..............................................5-46Attach Rails to Spine Plates...............................................................................5-47Align and Secure Rails to Spine Plates..............................................................5-50Secure Spine Plates to Support Posts.................................................................5-53Install the Precision Rail Vehicles .....................................................................5-53
Precision Locator Installation ..................................................................................5-54Install Pallets and Pucks ....................................................................................5-55Install the Precision Locators on the Stands ......................................................5-56Install the Precision Locator Assemblies...........................................................5-56Install the Motors ...............................................................................................5-56Install the Pneumatic Controls ...........................................................................5-58Install the Covers ...............................................................................................5-59Teach the Precision Locator Position ................................................................5-59
Facilities Connections....................................................................................................5-60Network Connections ..............................................................................................5-60Electrical Connections .............................................................................................5-61
E-Stop Circuit ....................................................................................................5-62Interlock Circuit .................................................................................................5-62Light Stack Circuit.............................................................................................5-63General Purpose Digital I/O ..............................................................................5-63
Software .........................................................................................................................5-64Software Overview ..................................................................................................5-64Software Configuration............................................................................................5-64
Node Controller Software Installation...............................................................5-65Motor Software Installation ...............................................................................5-65
Check-out and Power-up ...............................................................................................5-66System Check-out ....................................................................................................5-66
Mechanical Checks ............................................................................................5-66Facility Checks ..................................................................................................5-66Pre-operation Checks .........................................................................................5-66
System Power-up .....................................................................................................5-67System Testing...............................................................................................................5-69
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MagneMover LITE User Manual viiRockwell Automation Publication MMI-UM002E-EN-P - March 2016
6 OperationOverview........................................................................................................................6-1Theory of Operation.......................................................................................................6-2
MagneMover LITE Transport System Advantages.................................................6-2Motion Control ........................................................................................................6-3Motor Topology.......................................................................................................6-3Motor Operation ......................................................................................................6-4
Motor Cogging...................................................................................................6-5Motor Blocks ...........................................................................................................6-5
Block Acquisition ..............................................................................................6-6Anti-Collision ..........................................................................................................6-6
Safe Stopping Distance Movement....................................................................6-7In Queue.............................................................................................................6-7Vehicle Length Through Curves and Switches .................................................6-8
Locating Vehicles During Startup ...........................................................................6-8Moving Vehicles by Hand .................................................................................6-8
Electrical System .....................................................................................................6-10Controls and Indicators ..................................................................................................6-11
Track Display...........................................................................................................6-11Synchronization .......................................................................................................6-12E-Stops.....................................................................................................................6-13Interlocks .................................................................................................................6-15FastStop ...................................................................................................................6-16Light Stacks .............................................................................................................6-17Digital I/O ................................................................................................................6-18
Transport System Simulation.........................................................................................6-19Configuring a Simulation.........................................................................................6-19Running a Simulation ..............................................................................................6-21Stopping a Simulation..............................................................................................6-22Return the System to Normal Operation..................................................................6-22
Precision Rail Operation ................................................................................................6-24Setup ........................................................................................................................6-24Operation .................................................................................................................6-24
Precision Locator Operation ..........................................................................................6-25Setup ........................................................................................................................6-25Operation .................................................................................................................6-25
Transport System Operation ..........................................................................................6-26Power-up..................................................................................................................6-26Normal Running ......................................................................................................6-26Safe Shut-down........................................................................................................6-27
7 MaintenanceOverview........................................................................................................................7-1Preventive Maintenance.................................................................................................7-2
General Cleaning .....................................................................................................7-3Spray Cleaning.........................................................................................................7-3Puck Cleaning ..........................................................................................................7-4
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Puck Wear Surface Maintenance .............................................................................7-5Cable Connection Inspection ...................................................................................7-5Hardware Inspection ................................................................................................7-5Cleaning Magnet Arrays ..........................................................................................7-5Transfer Log Files....................................................................................................7-6Clean Power Supply Air Filter.................................................................................7-6Lubricating the Precision Rails................................................................................7-7Refilling a Precision Rail Vehicle’s Lubricating Applicator...................................7-8Adjusting Vehicle Bearings .....................................................................................7-11
Concentric Bearings...........................................................................................7-12Eccentric Bearings .............................................................................................7-12
Troubleshooting .............................................................................................................7-13Initial Troubleshooting ............................................................................................7-13Power Related Troubleshooting...............................................................................7-14Node Controller Troubleshooting............................................................................7-17Communications Troubleshooting...........................................................................7-18Motion Control Troubleshooting .............................................................................7-19Precision Rail Option Troubleshooting ...................................................................7-20Light Stack Troubleshooting ...................................................................................7-21
Contact MagneMotion Technical Support.....................................................................7-22Repair.............................................................................................................................7-23
Adjust G3 Motors to Eliminate Rail Binding ..........................................................7-25Connect and Secure G3 Motors and G3 Switches ...................................................7-27Connect G3 Motors and G4 Motors ........................................................................7-29Replacing Motors.....................................................................................................7-31
Remove the Existing Motor ...............................................................................7-31Install the New Motor ........................................................................................7-32
Programming Motors ...............................................................................................7-33Separating Magnet Arrays .......................................................................................7-34Replace Pucks ..........................................................................................................7-35
Remove Pucks....................................................................................................7-36Install Pucks .......................................................................................................7-37
Replace Puck Wear Surfaces ...................................................................................7-38Replace Power Supply Fuses ...................................................................................7-42
AC Fuse .............................................................................................................7-43DC Fuses............................................................................................................7-44
Replace Precision Rail Vehicles ..............................................................................7-45Vehicle Orientation............................................................................................7-45Installing Vehicles with Rails Removed............................................................7-46Installing Vehicles Without Removing Rails ....................................................7-47Removing Vehicles by Removing Rails ............................................................7-48Removing Vehicles Without Removing Rails...................................................7-49
Replacing Lubricating Applicators on Vehicles ......................................................7-50Replacing Magnet Arrays On Precision Rail Vehicles............................................7-53
Single Array Vehicles ........................................................................................7-54Dual Array Vehicles ..........................................................................................7-56
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MagneMover LITE User Manual ixRockwell Automation Publication MMI-UM002E-EN-P - March 2016
Replacing Bearings On Precision Rail Vehicles......................................................7-59Replacing Concentric Bearings .........................................................................7-60Replacing Eccentric Bearings ............................................................................7-62
Replacing Wear Surfaces on Pallet..........................................................................7-64Replacing Bushings on Pallet ..................................................................................7-67Replacing Pins on Precision Locator Arms .............................................................7-69Replacing Z-Datums on Precision Locator Stand....................................................7-71
Ordering Parts ................................................................................................................7-73Shipping .........................................................................................................................7-74
Packing Procedure ...................................................................................................7-75Shipping Components..............................................................................................7-76Shipping Systems or System Sections .....................................................................7-76
AppendixOverview.......................................................................................................................A-1File Maintenance...........................................................................................................A-2
Backup Files ...........................................................................................................A-2Creating Backup Files.............................................................................................A-2Restoring from Backup Files ..................................................................................A-2
Additional Documentation............................................................................................A-3Release Notes..........................................................................................................A-3Upgrade Procedure .................................................................................................A-3
Transport System Limits...............................................................................................A-4
Glossary ......................................................................................................... G-1
Index ................................................................................................................ I-1
Contents
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MagneMover LITE User Manual xiRockwell Automation Publication MMI-UM002E-EN-P - March 2016
Figures
1-1 Detailed View of MagneMover LITE Transport System Components ..................1-31-2 Detailed View of MagneMover LITE Precision Rail Option Components ............1-51-3 Detailed View of MagneMover LITE Precision Locator Components ..................1-61-4 Simplified View of MagneMover LITE Transport System Components ...............1-71-5 Simplified View of Transport System Software Relationships ..............................1-8
2-1 Locations of Hazardous Points on the MagneMover LITE Transport System .......2-72-2 Locations of Hazardous Points on the Precision Rail Option .................................2-82-3 Locations of Hazardous Points on the Precision Locator Option ...........................2-92-4 Locations of Labels on the MagneMover LITE Straight and Curve Motors ..........2-122-5 Locations of Labels on the MagneMover LITE Switches ......................................2-132-6 Locations of Labels on the MagneMover LITE Magnet Arrays and Pucks ...........2-142-7 Locations of Labels on the NC-12 Node Controller ...............................................2-152-8 Locations of Labels on the Node Controller LITE .................................................2-162-9 Locations of Labels on the MM LITE Power Supply ............................................2-172-10 Locations of Labels on the Precision Rail Vehicles (single array shown) .............2-182-11 Locations of Labels on the Precision Rail Spine Plates ..........................................2-192-12 Locations of Labels on the Precision Locator ........................................................2-202-13 Locations of Labels on the Precision Locator Puck ...............................................2-21
3-1 Sample MM LITE Transport System Layout Showing Motors .............................3-33-2 Sample MM LITE Transport System Layout Showing Paths ................................3-43-3 Sample MM LITE Transport System Layout Showing Nodes ...............................3-53-4 Sample MM LITE Transport System Layout Showing Node Controllers .............3-63-5 Sample MM LITE Transport System Layout Showing Additional Connections ...3-73-6 MagneMover LITE Motor Gaps .............................................................................3-113-7 System Wiring Block Diagram ...............................................................................3-143-8 Standard MagneMover LITE Magnet Array, 1 Cycle, 3 Poles ..............................3-153-9 Typical Vehicle on Guideway ................................................................................3-183-10 Standard Puck Configuration ..................................................................................3-193-11 Tandem Puck Configuration ...................................................................................3-193-12 Vehicle Gap ............................................................................................................3-203-13 MagneMover LITE Railless Transport System, Single Vehicle ............................3-233-14 Motor Mounting to Flat Surface .............................................................................3-253-15 Motor Mounting Using Custom Brackets ...............................................................3-263-16 Motor Mounting Using Motor Mount Brackets .....................................................3-273-17 System Stand ...........................................................................................................3-28
Figures
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3-18 Custom Motor Mounting ........................................................................................3-293-19 Puck Carrier Overhang ...........................................................................................3-313-20 Precision Rail Option ..............................................................................................3-333-21 Precision Rails ........................................................................................................3-343-22 Precision Rail Spine Plates .....................................................................................3-363-23 Precision Rail Support Post ....................................................................................3-373-24 Precision Rail Single Array Vehicle .......................................................................3-383-25 Precision Rail Dual Array Vehicle .........................................................................3-383-26 Precision Rail to Motor Reference Diagram ...........................................................3-393-27 Precision Locator Option ........................................................................................3-403-28 Precision Locator Pallet Design Details .................................................................3-423-29 Precision Locator Installation Dimensions .............................................................3-433-30 Precision Locator Pneumatic Block Diagram .........................................................3-443-31 Straight Track Configuration ..................................................................................3-453-32 Curve Track Configuration .....................................................................................3-463-33 Switch Configuration ..............................................................................................3-47
4-1 1000 Millimeter Motor Mechanical Drawing (G4) ................................................4-34-2 1000 Millimeter Railless Motor Mechanical Drawing (G4) ..................................4-44-3 250 Millimeter Motor Mechanical Drawing (G4) ..................................................4-54-4 250 Millimeter Railless Motor Mechanical Drawing (G4) ....................................4-64-5 125 Millimeter Radius 90° Curve Mechanical Drawing (G4) ................................4-74-6 125 Millimeter Radius 90° Railless Curve Mechanical Drawing (G4) ..................4-84-7 Left Switch Mechanical Drawing (G4) ..................................................................4-94-8 Right Switch Mechanical Drawing (G4) ................................................................4-104-9 Standard Motor Mount Bracket Mechanical Drawing (G4) ...................................4-114-10 Stand System Mechanical Drawing ........................................................................4-124-11 Puck Mechanical Drawing (G4) .............................................................................4-134-12 Puck Mechanical Drawing (G4.2) ..........................................................................4-144-13 Puck Mechanical Drawing (G4.3) ..........................................................................4-154-14 Tandem Puck Mechanical Drawing (G4) ...............................................................4-164-15 Tandem Puck Mechanical Drawing (G4.2) ............................................................4-174-16 Tandem Puck Mechanical Drawing (G4.3) ............................................................4-184-17 Magnet Array Mechanical Drawing (G4) ...............................................................4-194-18 Magnet Array Mechanical Drawing (G4.2) ............................................................4-204-19 NC-12 Node Controller Mechanical Drawing ........................................................4-214-20 Rack Mounting Bracket Mechanical Drawing .......................................................4-224-21 Node Controller LITE Mechanical Drawing ..........................................................4-234-22 Electronics Mounting Plate Mechanical Drawing ..................................................4-244-23 MM LITE Power Supply Mechanical Drawing .....................................................4-254-24 Precision Rail Mechanical Drawing .......................................................................4-264-25 Precision Rail Single Array Vehicle Mechanical Drawing ....................................4-274-26 Precision Rail Dual Array Vehicle Mechanical Drawing .......................................4-284-27 Precision Rail Support Post Assembly ...................................................................4-294-28 Precision Rail Straight to Curve, Spine Plates, Mechanical Drawing ....................4-304-29 Precision Rail Curve to Curve, Spine Plates, Mechanical Drawing .......................4-314-30 Precision Rail Straight, No Joint, Spine Plate, Mechanical Drawing .....................4-32
Figures
MagneMover LITE User Manual xiiiRockwell Automation Publication MMI-UM002E-EN-P - March 2016
4-31 Precision Rail Straight, With Joint, Spine Plate, Mechanical Drawing ..................4-324-32 Precision Rail Curve, 180°, No Joint, Spine Plate, Mechanical Drawing ..............4-334-33 Precision Locator Actuator Mechanical Drawing ..................................................4-344-34 Standard Precision Locator Stand Mechanical Drawing ........................................4-354-35 Adjustable Motor Mount Bracket Mechanical Drawing ........................................4-364-36 Precision Locator Basic Pallet Mechanical Drawing .............................................4-374-37 MagneMover LITE Motor Electrical Connections .................................................4-404-38 MagneMover LITE Switch Electrical Connections ................................................4-424-39 MM LITE Power Supply Electrical Connections ...................................................4-454-40 MM LITE DC Power Cables ..................................................................................4-474-41 DC Enable Circuit ...................................................................................................4-484-42 DC Enable Jumper ..................................................................................................4-484-43 NC-12 Node Controller Electrical Connections and Indicators .............................4-504-44 Node Controller LITE Electrical Connections .......................................................4-554-45 Precision Locator Electrical Connections ...............................................................4-594-46 Precision Locator Pneumatic Connections .............................................................4-614-47 RS-422 Cables ........................................................................................................4-644-48 Digital I/O Equivalent Circuits ...............................................................................4-65
5-1 Connecting Beam Sections .....................................................................................5-115-2 Leg on a Single Path Beam Assembly ....................................................................5-125-3 Legs on a Parallel Path Beam Assembly ................................................................5-135-4 Angle Bracket Assembly ........................................................................................5-145-5 System Leveling .....................................................................................................5-155-6 Bracket Tie-down ...................................................................................................5-165-7 Foot Tie-down .........................................................................................................5-175-8 Installing Cable Chase Cover Mounting Brackets ..................................................5-185-9 Installing Motor Mounts on Motors and Switches .................................................5-195-10 Installing Motors and Switches ...............................................................................5-205-11 Positioning Motors and Switches ...........................................................................5-215-12 Align and Secure Rails – G4 Motors ......................................................................5-235-13 Align and Secure Railless Motors ..........................................................................5-255-14 Node Controller LITE Mounting ............................................................................5-275-15 NC-12 Node Controller Mounting Plates ...............................................................5-295-16 NC-12 Node Controller Mounting Brackets ...........................................................5-305-17 Power Supply Mounting .........................................................................................5-315-18 Simplified Representation of Motor Connections ..................................................5-335-19 Simplified Representation of Merge Switch Connections ......................................5-335-20 Communication Cable Connections .......................................................................5-345-21 Digital I/O Connections ..........................................................................................5-375-22 Power Connections .................................................................................................5-385-23 Installing Straight Motor Cable Chase Covers .......................................................5-415-24 Installing Curved Motor Cable Chase Covers ........................................................5-425-25 Installing Switch Cable Chase Covers ....................................................................5-435-26 MagneMover LITE Railless Motor System ............................................................5-445-27 Precision Rail Support Post Assembly ...................................................................5-455-28 Precision Rail Support Post to Post Mount Spacing ...............................................5-46
Figures
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5-29 Attach Precision Rail Support Post Assemblies to Beam .......................................5-465-30 Precision Rail End Identification ............................................................................5-475-31 Attaching Straight Precision Rails to Curved Rails with Adjustment Key ............5-485-32 Attaching Precision Rail to Spine Plates ................................................................5-495-33 Tightening Sequence, Straight to Curve Precision Rail Spine Plate ......................5-505-34 Tightening Sequence, Curve to Curve Precision Rail Spine Plate .........................5-515-35 Tightening Sequence, Straight to Straight Precision Rail Spine Plate ...................5-515-36 Tightening Sequence, 180° Curve No Joint Precision Rail Spine Plate .................5-525-37 Tightening Sequence, Straight Rail No-Joint Precision Rail Spine Plate ...............5-525-38 Securing Precision Rail Spine Plates to Support Posts ...........................................5-535-39 MagneMover LITE Precision Locator Option, Standard .......................................5-545-40 MagneMover LITE Precision Locator Option, Alternate .......................................5-555-41 Precision Locator Pneumatic Connections .............................................................5-585-42 Network Cable Connections ...................................................................................5-60
6-1 Linear Synchronous Motor Derived From Rotary Motor .......................................6-26-2 Representation of Stationary Vehicles Per MagneMover LITE Motor Block .......6-46-3 Representation of Moving Vehicles Per MagneMover LITE Motor Block ...........6-46-4 Vehicle Movement Profile ......................................................................................6-76-5 The Graphics Window ............................................................................................6-116-6 Transport System Wiring Diagram with Synchronization .....................................6-126-7 E-Stop Wiring Diagram, Single Node Controller ...................................................6-146-8 E-Stop Wiring Diagram, Multiple Node Controllers ..............................................6-146-9 Interlock Wiring Diagram .......................................................................................6-156-10 Light Stack Wiring Diagram ...................................................................................6-17
7-1 Puck Cleaning .........................................................................................................7-47-2 Precision Rail Vehicle Lubricating Applicator Location .......................................7-97-3 Precision Rail Vehicle Lubricating Applicator (Front and Rear) ...........................7-97-4 Precision Rail Single Array Vehicle Lubrication Portal .........................................7-107-5 Precision Rail Vehicle Bearing Adjustment ...........................................................7-117-6 Rail Adjustment Points – G3 Motors ......................................................................7-257-7 Adjust Rails – G3 Motors .......................................................................................7-267-8 Align and Secure Rails – G3 Motors ......................................................................7-277-9 Align and Secure Rails – G3 to G4 Motors ............................................................7-297-10 Remove Curve Motor Guide Rail ...........................................................................7-367-11 Remove Plates from Magnet Assembly ..................................................................7-397-12 Adhere Preload Spacer to Underside of Top Plate .................................................7-407-13 Power Supply Fuse Locations .................................................................................7-427-14 Open the Power Entry Module ...............................................................................7-437-15 Remove the PEM Fuse Module ..............................................................................7-437-16 Precision Rail Vehicle to Rail Orientation .............................................................7-467-17 Precision Rail Vehicle Eccentric Bearings .............................................................7-477-18 Install Precision Rail Vehicle on Rail .....................................................................7-487-19 Remove Precision Rail Vehicle From Rail .............................................................7-497-20 Precision Rail Vehicle Lubricating Applicator .......................................................7-507-21 Precision Rail Vehicle Lubricating Applicator Location .......................................7-51
Figures
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7-22 Installing or Removing a Precision Rail Felt Applicator ........................................7-517-23 Single Array Precision Rail Vehicle Assembly ......................................................7-547-24 Dual Array Precision Rail Vehicle Assembly ........................................................7-567-25 Precision Rail Vehicle Bearing Locations ..............................................................7-597-26 Precision Rail Vehicle Concentric Bearings Disassembly/Assembly ....................7-607-27 Precision Rail Vehicle Eccentric Bearings Disassembly/Assembly .......................7-627-28 Remove Precision Locator Pallet from Magnet Assembly .....................................7-657-29 Replace Bushings on Precision Locator Pallet .......................................................7-687-30 Replace Pins on Precision Locator Arms ...............................................................7-697-31 Replace Z-Datum on Precision Locator Stand .......................................................7-71
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Tables
2-1 Regulatory Information ...........................................................................................2-22-2 Hazard Alert Symbol Identification ........................................................................2-102-3 Mandatory Action Symbol Identification ...............................................................2-112-4 Prohibited Action Symbol Identification ................................................................2-112-5 Labels Used on the MagneMover LITE Straight and Curve Motors .....................2-122-6 Labels Used on the MagneMover LITE Switches ..................................................2-132-7 Labels Used on the MagneMover LITE Magnet Arrays and Pucks .......................2-142-8 Labels Used on the NC-12 Node Controller ...........................................................2-152-9 Labels Used on the Node Controller LITE .............................................................2-162-10 Labels Used on the MM LITE Power Supply ........................................................2-172-11 Labels Used on the Precision Rail Vehicles ...........................................................2-182-12 Labels Used on the Precision Rail Spine Plates .....................................................2-192-13 Labels Used on the Precision Locator ....................................................................2-202-14 Labels Used on the Precision Locator Pucks ..........................................................2-21
3-1 Motor Assignments .................................................................................................3-43-2 MagneMover LITE Motor Blocks ..........................................................................3-103-3 MagneMover Light Thrust Force Guideline ...........................................................3-103-4 Stand System Heights .............................................................................................3-283-5 Stand System Widths ..............................................................................................3-283-6 Puck Carrier Overhang Limits ................................................................................3-313-7 Precision Rail Types and Lengths ..........................................................................3-35
4-1 MagneMover LITE Motor and Switch Power Requirements .................................4-384-2 MagneMover LITE Motor Connections .................................................................4-404-3 MagneMover LITE Motor RS-422 Pinouts ............................................................4-414-4 MagneMover LITE Motor Power Pinouts ..............................................................4-414-5 MagneMover LITE Sync Pinouts ...........................................................................4-414-6 MagneMover LITE Switch Connections ................................................................4-424-7 MagneMover LITE Switch RS-422 Pinouts ...........................................................4-434-8 MagneMover LITE Switch Power Pinouts .............................................................4-434-9 MagneMover LITE Switch Ethernet Pinout ...........................................................4-434-10 MM LITE Power Supply Connections ...................................................................4-454-11 MM LITE Power Supply Indicators .......................................................................4-454-12 MM LITE Power Supply DC Power Pinouts .........................................................4-464-13 MM LITE Power Supply DC Enable .....................................................................4-464-14 DC Power Cable Pinouts ........................................................................................4-47
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4-15 NC-12 Node Controller Connections .....................................................................4-504-16 NC-12 Node Controller Indicators .........................................................................4-504-17 NC-12 Node Controller Console Pinout .................................................................4-514-18 NC-12 Node Controller Ethernet Pinout ................................................................4-514-19 NC-12 Node Controller RS-232 Pinouts ................................................................4-524-20 NC-12 Node Controller RS-422 Pinouts ................................................................4-524-21 NC-12 Node Controller Power Pinout ....................................................................4-524-22 Node Controller LITE Connections ........................................................................4-554-23 Node Controller LITE Power Pinout ......................................................................4-554-24 Node Controller LITE LAN Pinout ........................................................................4-564-25 Node Controller LITE Console Pinout ...................................................................4-564-26 Node Controller LITE RS-422 Pinouts ..................................................................4-574-27 Precision Locator Connections ...............................................................................4-594-28 Precision Locator Sensor Indicators .......................................................................4-594-29 Precision Locator Sensor Pinout .............................................................................4-604-30 Precision Locator Pneumatic Requirements ...........................................................4-614-31 Precision Locator Connections ...............................................................................4-614-32 RS-422 Cable Pinouts .............................................................................................4-64
5-1 MagneMover LITE Component Packing Checklist Reference ..............................5-25-2 Motor Mount Reference ..........................................................................................5-215-3 Precision Rail to Spine Plate Attachment Screws ..................................................5-495-4 Startup Indicators ....................................................................................................5-68
6-1 Simulated Operation Differences ............................................................................6-21
7-1 MagneMover LITE Preventive Maintenance Schedule ..........................................7-27-2 Precision Rail Vehicle Drag ...................................................................................7-127-3 Initial Troubleshooting ...........................................................................................7-137-4 Power Related Troubleshooting ..............................................................................7-147-5 Node Controller Related Troubleshooting ..............................................................7-177-6 Communications Related Troubleshooting ............................................................7-187-7 Motion Control Related Troubleshooting ...............................................................7-197-8 Precision Rail Option Troubleshooting ..................................................................7-207-9 Light Stack Related Troubleshooting .....................................................................7-217-10 MagneMover LITE Repair Procedures ...................................................................7-237-11 MM LITE Rail Adjustment ....................................................................................7-25
A-1 MagneMotion Transport System Limits ................................................................A-4A-2 MagneMotion Transport System Motion Limits ...................................................A-4
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Changes
Overview
Changes may be made to this manual to ensure that it continues to provide the most complete documentation possible for the MagneMover® LITE transport system. This section provides a brief description of each change.
NOTE: Distribution of this manual and all addendums and attachments is not controlled. Changes may have been made at any time. To identify the current revision, contact MagneMotion Customer Support.
Rev. A
Initial release.
Rev. B
Added this Changes section. Added regulatory information and updated all figures to show current labeling. Added a figure showing hazardous points on the MM LITE® transport sys-tem. Added the Design Guidelines chapter, moved the system layout guidelines to it and added power wiring. Added guidelines for motor mounting on custom motor mounts and added puck loading information. Added mechanical 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 Power over Ethernet connection information and cautions. Provided additional informa-tion on network and external communications connections including PoE. Added a descrip-tion of motor operation. Added spray cleaning and puck maintenance procedures. Added packing and shipping procedures and information. Added an Appendix with information about additional documentation and transport system limits.
Updated trademark information. Changed all figures to show the new frame mounting system. Changed all MagneMover LITE abbreviations from ‘ML’ to ‘MM LITE’. Corrected the names of all referenced MagneMotion manuals. Updated the descriptions of all system soft-ware. Updated the system specification. Updated all mechanical drawings. Updated service
ChangesOverview
xx MagneMotionRockwell Automation Publication MMI-UM002E-EN-P - March 2016
and exclusion zone information. Updated the unpacking, installation overview, and installa-tion procedures. Updated the information on the Synchronization option. Updated the descrip-tions for the Standard Node Controller E-Stop and Interlock. Updated the start-up procedure. Updated, and moved to Chapter 7, the puck replacement procedure. Updated the fuse replace-ment procedures. Updated the Glossary.
Removed all references to ‘physical’ and ‘virtual’ components. Removed unsupported RS-232 communication information. Removed hot plug warnings.
Rev. C
Added Symbol Identification. Added motor programming to the Getting Started section. Added information on the NC-12 Node Controller. Added notice that using custom vehicles with user-supplied rails requires all vehicles are grounded to the guideway. Added a Transport System Design for designing transport systems using MM LITE railless motors. Added an overview of Motor Types and added mechanical drawings for the MM LITE G4 motors, switches, pucks, magnet array, and NC-12 Node Controller. Added new information to the existing motor operation section. Added a procedure for Puck Cleaning. Added Node Control-ler Troubleshooting. Added a procedure for Programming Motors. Added information on Ordering Parts.
Updated the Overview Note in this section. Updated the list of Related Documentation. Updated all figures to show MM LITE 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 Con-trollers. Consolidated connector location, exclusion zone, and mechanical drawings for all components. Updated the electrical specifications for all components to include connector pinouts and corrected connector identification. Updated the environmental specifications. Moved the rail adjustment procedure to the Repair section. Simplified the network switch mounting information. Updated Software installation and configuration information. Updated the Safe Shut-down procedure. Updated the General Cleaning procedure to allow cleaning while the system is energized. Updated the Replace Puck Wear Surfaces procedure for G4 pucks. Updated the Shipping procedures. Updated the Transport System Limits. Updated the Glossary.
Rev. D
Added UL Registration information. Added Recycling and Disposal Information for the Mag-neMover LITE system. Added the recommendation to use a low friction barrier on the magnet array or motor to the Vehicle Design section. Added mechanical drawings for the G4.2 and G4.3 pucks. Added mechanical drawings for the G4.2 and G4.3 tandem pucks. Added the mechanical drawing for the G4.2 magnet array. Added Loctite curing requirement to installa-tion procedures. Added Magnet Array Installation. Added a description of Block Acquisition.
ChangesOverview
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Added File Maintenance instructions. Added mechanical drawings for the railless motors. Added railless motors to the Stand System Installation section. Added information and proce-dures for the Precision Rail option, including; Precision Rail Option Components overview, Precision Rail Option Hazard Locations, Label Identification and Location on the precision rail components, design information for the Transport System Options, Precision Rail Instal-lation information including Replace Precision Rail Vehicles, and Preventive Maintenance, Troubleshooting, and Repair procedures.
Updated the Regulatory Compliance and Safety Considerations sections. Updated the Puck description in the Transport System Layout section. Updated the System Design Overview and Design Guidelines. Updated the description of attractive force in the Design Guidelines. Cor-rected the Magnet Arrays description. Updated all mechanical drawings to show both milli-meters and inches. Corrected the power supply connections and indicators tables for the Power Supply and the NC-12 Node Controller. Corrected the NC-12 Node Controller connec-tions and indicators tables. Updated the Magnet Hazard Warnings throughout the manual. Updated the list of Required Tools and Materials for installation. Updated the communica-tions and power cable connection illustrations. Updated the Transport System Limits. Updated the Replace Puck Wear Surfaces procedure.
Removed all references to the Standard Node Controller, which has been replaced by the NC-12 Node Controller. Support for the 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 including software, spare parts, technical support, and service continues to be available.
Rev. E
Added information about the Precision Locator option. Added Pneumatic Hazards, Handling Magnet Arrays, and Shipping Magnet Arrays to Safety. Added Motor Cogging, Electrical Wiring, Magnet Array Use, Motor Mounting Methods, System Stands, and Transport System Configuration to the Transport System Design section. Added exposed materials identification to the Mechanical Specifications. Added the operating voltage range for the motors, updated the motor power requirements, and added a note about the PTC (positive temperature coeffi-cient) resistor used in the motors to the Electrical Specifications. Added cable sizing and grounding to Installing Motor Power Cables. Added descriptions of Motor Cogging, Safe Stopping Distance Movement, Moving Vehicles by Hand, and the Electrical System to the The-ory of Operation section. Added Transport System Simulation, Precision Rail Operation, and Precision Locator Operation to the Operation chapter. Added Cleaning Magnet Arrays to the Preventive Maintenance section. Added Light Stack Troubleshooting. Added Separating Mag-net Arrays to the Repair section.
Restructured the manual to clearly identify the Precision Rails as an option. Updated the Transport System Software Overview to include the Virtual Scope. Clarified the description of the Gateway Node. Moved the Magnet Array Types information from Specifications and Site
ChangesOverview
xxii MagneMotionRockwell Automation Publication MMI-UM002E-EN-P - March 2016
Requirements to Design Guidelines. Corrected the NC-12 Node Controller input power to 22 - 30 VDC. Updated the description of the DC Enable Circuit for the MM LITE Power Supply. Updated the Site Requirements to show the environmental requirements 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. Updated the MagneMotion Transport System Motion Limits table.
Removed HLC VM Slaves per Master reference from the Transport System Limits.
MagneMover LITE User Manual xxiiiRockwell Automation Publication MMI-UM002E-EN-P - March 2016
About This Manual
Overview
This section provides information about the use of this manual, including the manual struc-ture, related documentation, format conventions, and safety conventions.
Purpose
This manual explains how to install, operate, and maintain the MagneMover® LITE (MM LITE®) transport system. This manual also provides basic troubleshooting information.
Use this manual in combination with the 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
This manual assumes a basic familiarity with personal computers and with the Windows® operating system. This manual also assumes that the personnel installing and operating the MagneMover LITE transport system have been properly trained on MM LITE transport sys-tem installation and operation.
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xxiv MagneMotionRockwell Automation Publication MMI-UM002E-EN-P - March 2016
MagneMotion Documentation
The documentation provided with the MagneMover LITE transport system includes this man-ual, which provides complete documentation for the installation, operation, and use of the MM LITE components as a transport system. Other manuals in the document set, listed in the Related Documentation section, support configuration and operation of the transport system.
The examples in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any linear motor transport system installa-tion, MagneMotion, Inc. cannot assume responsibility or liability for actual use based on these examples.
Manual Conventions
• Dialog Box – A window that solicits a user response.
• Click or Left-click – Press and release the left mouse button1.
• Right-click – Press and release the right mouse button.
• Double-click – Press and release the left mouse button twice 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 and are capitalized exactly as they appear in the software. Examples: Add to End..., Paths, Path Details, OK.
• Dialog box titles or headers are shown in bold type, capitalized exactly as they appear in the software. Example: the Open XML Configuration File dialog box.
• Keyboard keys and key combinations (pressing more than one key at a time) are shown enclosed in angle brackets. Examples: <F2>, <Enter>, <Ctrl>, <Ctrl-x>.
• Responses to user actions are shown in italics. Example: Motion on all specified Paths is enabled.
• Data Entry – There are several conventions for data entry:
• Exact – The text is shown in quotes. Example: Enter the name ‘Origin’ in the text field.
• Variable – The text is shown in italics. Example: Save the file as file_name.xml.
• Code Samples – Shown in monospaced text. Example: Paths.
1. Mouse usage terms assumes typical ‘right-hand’ mouse configuration.
About This ManualMagneMotion Documentation
MagneMover LITE User Manual xxvRockwell Automation Publication MMI-UM002E-EN-P - March 2016
• Numbers – All numbers are assumed to be decimal unless otherwise noted and use US number formatting (i.e., one thousand = 1,000.00). Non-decimal numbers (binary or hexadecimal) are explicitly stated.
• Binary – Followed by 2, e.g., 1100 0001 01012, 1111 1111 1111 11112.
• Hex – Followed by 16, e.g., C1516, FFFF16. Note that hexadecimal numbers displayed in the software are preceded by 0x, e.g., 0xC15, 0xFFFF.
• Measurements – All measurements are SI (International System of Units). The for-mat for dual dimensions is SI_units [English_units]; e.g., 250 mm [9.8 in].
• Text in blue is a hyperlink. These links are active when viewing the manual as a PDF. Selecting a hyperlink changes the manual view to the page of the item referenced. Note that in some cases the item referenced is on the same page, so no change in the view will occur.
Notes, Safety Notices, and Symbols
Notes, Safety Notices, and 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 standard type as shown below.
NOTE: A note provides additional or explanatory information.
Safety Notices
Safety Notices are set apart from other text. The color of the panel at the top of the notice and the text in the panel indicates the severity of the hazard, the symbol on the left of the notice identifies the type of hazard (refer to Symbol Identification on page 2-10 for symbol descrip-tions), and the text in the message panel identifies the hazard, methods to avoid the hazard, and the consequences of not avoiding the hazard.
Examples of the standard safety notices used in this manual are provided below and include a description of hazard level indicated by each type of notice.
DANGER
Danger indicates a hazardous situation which, if not avoided,will result in death or serious injury.
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xxvi MagneMotionRockwell Automation Publication MMI-UM002E-EN-P - March 2016
Manual Structure
This manual contains the following chapters:
• Introduction: Provides an overview of the MagneMover LITE components and their use in a transport system. The MM LITE motors are used to provide fast, precise movement, positioning, and tracking of loads up to 2 kg [4.4 lb].
• Safety: Identifies safety concerns and requirements for the MagneMover LITE compo-nents and the personnel operating and servicing the MM LITE motors and the trans-port system where they are installed.
• Design Guidelines: Provides guidelines for designing a MagneMover 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 schedules and procedures for the MM LITE com-ponents.
• Appendix: Provides additional information related to MM LITE transport systems.
WARNING
Warning indicates a hazardous situation which, if notavoided, could result in death or serious injury.
CAUTION
Caution indicates a hazardous situation, which if notavoided, could result in minor or moderate injury.
NOTICE
Notice indicates practices not related to personal injury that could result inequipment or property damage.
About This ManualContact Information
MagneMover LITE User Manual xxviiRockwell Automation Publication MMI-UM002E-EN-P - March 2016
• Glossary: A list of terms and definitions used in this manual and for the transport sys-tem and its components.
• Index: A cross-reference to this manual organized by subject.
Related Documentation
Before configuring or running the MagneMover LITE components, consult the following doc-umentation:
• MagneMover® LITE Configurator User’s Manual, 990000558.
• Node Controller Web Interface User’s Manual, 990000377.
• NCHost TCP Interface Utility User’s Manual, 990000562.
• Host Controller TCP/IP Communication Protocol User’s Manual, 990000436.Host Controller EtherNet/IP Communication Protocol User’s Manual, 990000437.orMitsubishi 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. Changes may have been made to this manual or additional documents added to the MagneMover LITE document set at any time. To identify the current revisions or to obtain a current set of documents, contact MagneMotion Customer Support.
Contact Information
Main Office Customer Support
MagneMotion, Inc.139 Barnum RoadDevens, MA 01434USAPhone: +1 978-757-9100Fax: +1 978-757-9200
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MagneMover LITE User Manual 1Rockwell Automation Publication MMI-UM002E-EN-P - March 2016
Introduction 1
Overview
This chapter provides an overview of the MagneMover® LITE (MM LITE®) component hardware and software, and the basic set of tasks needed to install and use the MM LITE motors in a transport 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 components.
• The transport system software.
• Getting started with the MagneMover LITE transport system.
IntroductionMagneMover LITE Overview
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MagneMover LITE Overview
The MagneMover LITE (MM LITE) is an intelligent transport system specifically developed for fast, precise movement, positioning, and tracking of small, light loads in a transport sys-tem. The MM LITE transport system is a configuration of linear synchronous motors and related control electronics that move small independently commanded material carriers (vehi-cles/pucks) in a controlled manner at various acceleration/deceleration and velocity profiles while carrying a wide range of payloads with high precision. The MM LITE transport system consists of the following components:
• MagneMover LITE motors.
• Vehicles (pucks) with Magnet Arrays.
• Node Controllers.
• Power Supplies.
• Paths and Nodes.
• User-supplied Host Controller.
• Optional user-designed and supplied guideway and track system.
Using MagneMotion’s proven linear synchronous motor (LSM) and control technology, Mag-neMover LITE transport systems offer a superior alternative to conventional belt and chain conveyors for OEM/in-machine applications and for demanding product conveyance require-ments.
• MagneMover LITE 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 motors only, does not include the gap between motors, calibrated vehicles (pucks) required, may require physical attachment of the motor to the process station).
• Vehicles (pucks) are controlled individually allowing the Host Controller to prioritize the routing of individual vehicles over different Paths.
• Motion is provided through the use of small pre-configured vehicles (pucks) or user-designed vehicles with magnet arrays attached to the surface closest to the motor.
• Up to nine (9) 62 mm vehicles (pucks) in motion1 per meter with speeds to 2 m/s [4.5 mph], accelerations to 2 m/s2 [0.2 g].
• Up to ten (10) 62 mm vehicles (pucks) in a queue1 per meter standard, up to twelve (12) vehicles in queue per meter depending upon application.
• Payloads up to 1 kilogram (2 kilograms with tandem puck).
1. Maximum number of vehicles (pucks) per meter is determined using the standard single array puck on a straight motor. Using a dual array (tandem) vehicle or a curved motor will decrease the number of vehicles allowed per meter.
IntroductionMagneMover LITE Overview
MagneMover LITE User Manual 3Rockwell Automation Publication MMI-UM002E-EN-P - March 2016
• Configuration and Simulation software tools simplify transport system design and optimization.
• Versions designed for use in cleanrooms and IP65 wash-down environments (motors and pucks/magnet arrays only).
• Less wear and tear – no belts, chains, gears, or external sensors required – few moving parts means less maintenance.
• Standard industrial communication protocols, PC or PLC controlled, and software configured move 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 mounting system for the motors.
• Cable Chase with Covers – The area between the motor and the beam. Used to run all motor power and communications cables. Covers are provided to enclose all cabling.
Guide Rail
V-Brace Motor
Beam
Cable Chase Cover(2X)
Connector Plate
Standard
(250 mm Shown)
Vehicle
System Leg
Cable Chase
(Puck)
(Stand System)
Motor Mount
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• Connector Plate – Bracket used to secure sections of the beam to each other.
• Guide Rail – Ensures vehicles (pucks) are maintained in the proper relationship to the motors.
• Motor – The MagneMover LITE linear synchronous motor (LSM) with integral rails.
• Standard Motor Mount – Used to mount the motor to the top of the beam support structure. Serves as a conduit for cable management and for fastening cable chase cov-ers (not shown).
• Vehicle (Puck) with Magnet Array – Rides on the integral rails and carries the user’s payload through the MM LITE transport system as directed. The magnet array is mounted to the vehicle (puck) and interacts with the motors, which moves each vehi-cle independently.
• Switch – (not shown) One straight 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 stainless steel precision ground rails in place of the integral 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.
Precision Rail option specifications:
• Maximum acceleration: Up to 4 m/s2 in straights; payload dependent.
• Maximum velocity: 2 m/s.
• Maximum payload: Up to 2.5 kg (5 kg with dual array vehicle).
• Location repeatability: ±0.5 mm.
• Station repeatability: ±0.1 mm with calibration.
The Precision Rail option does not support the use of the MM LITE switches.
IntroductionMagneMover LITE Overview
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Figure 1-2: Detailed View of MagneMover LITE Precision Rail Option Components
• V-Brace – Used for align and secure adjacent railless motors to each other.
• Railless Motor – The MagneMover LITE motor without integral rails.
NOTE: Switches and ‘S’ turns are not supported on Precision Rail systems.
• Post Mount – Attaches to the beam support structure (or user-supplied base) provid-ing a structural interconnecting point between the motor system and the Precision Rail System.
• Support Post – Pre-assembled post assembly consisting of a spine plate, support post, and post mount. The spine plate, 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 Rail – Single, interconnected mono-rail, which ensures the vehicles are maintained in the proper relationship to the motors.
• Vehicle with Magnet Arrays – Rides on the precision rail and carries the user’s pay-load through the MM LITE transport system as directed. The magnet array is mounted to the vehicle and interacts with the motors, which moves each vehicle independently.
Vehicle
Support Post
Railless Motor V-Brace
Railless Motor
Post Mount
Spine Plate
(Dual Array Shown)
Precision Rail
(1000 mm shown)
IntroductionMagneMover LITE Overview
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Precision Locator
The Precision Locator option provides a small pneumatic powered fixture for precisely locat-ing the carrier mounted on a puck at a process station. When using the Precision Locator option, standard MM LITE motors are used with the Precision Locator positioned on straight motors.
Precision Locator option specifications:
• Single Puck Exchange Time: 0.8 seconds with 1 kg load.
• X/Y Repeatability: ±0.05 mm.
• Z Repeatability: +0.0/-0.05 mm.
• Vertical load on the pallet while secured 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 fully constrain the pallet at the sta-tion.
• Locator Stand – Attaches to the beam support structure (or user-supplied motor mounting system) providing support and positioning for the Precision Locator.
• Adjustable Motor Mount – Provides fine adjustment of the motor when positioning within the Precision Locator Stand.
Locator Stand
Pallet
Motor(250 mm Shown)
Precision Locator
Puck
AdjustableMotor Mount
IntroductionTransport System Overview
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Transport System Overview
This section identifies the components of a MagneMover LITE transport system as shown in Figure 1-4 and described after the figure.
Figure 1-4: Simplified View of MagneMover LITE Transport System Components
• DC Power Cables and Communication Cables – Distributes DC power to the motors of the transport system and carries communications between the components.
• High Level Controller (HLC) – Software application running on one Node Controller that handles all communication with the user-supplied Host Controller and directs communication as appropriate to individual Node Controllers.
• Host Controller – Provides user control and monitoring of the MM LITE transport system. Supplied 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 available:
• NC-12 Node Controller (not shown) – Provides one network port, two RS-232 ports, 12 RS-422 ports, 16 digital inputs, and 16 digital outputs.
• Node Controller LITE – Provides one network port and four RS-422 ports.
• Power Supply – Provides DC power to the motors.
• Vehicle (Puck) with Magnet Array – Carries a payload through the MM LITE trans-port system as directed. The magnet array is mounted to the vehicle (puck) and inter-acts with the motors, which move each vehicle independently.
Host Controller(PC or PLC)
DC Power Cables
Power SupplyMotors
Communication Cables
Node Controller LITE(and High Level Controller)
Vehicles (Pucks)
Network
IntroductionTransport System Software Overview
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Transport System Software Overview
Several software applications are used to configure, test, and administer a MagneMover LITE transport system as shown in Figure 1-5 and described after the figure. Refer to Related Docu-mentation on page xxvii for the reference manuals for these applications.
Figure 1-5: Simplified View of Transport System Software Relationships
• Node Controller Web Interface – A web-based software application supplied by MagneMotion, resident on the Node Controllers, for administration of the parts of the transport system.
• Node Controller Console Interface – A serial communication software application supplied by MagneMotion, 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 TCP/IP)
MagneMotion Configurator
Node Controller
Node Controller
NCHost TCP Interface Utility
Motor
Node Controller Software Image(controller_image)
Motor Image Files(motor_image.erf)
Motor Type Files(motor_type.xml)
Magnet Array Type File(magnet_array_type.xml)
Node Controller Configuration File(node_configuration.xml)
node_configuration.xml
Node ControllerAdministration
System Control
System Testing(NCHost.exe)
(MMConfigTool.exe)
track_file.mmtrkdemo_script.txt
track_layout.ndx
(Web and Console Interfaces)
Virtual Scope UtilityPerformanceMonitoring
IntroductionTransport System Software Overview
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• MagneMotion ML Configurator (Configurator) – A Windows software application supplied by MagneMotion to create or change the Node Controller Configuration File, the Track File, and Track Layout File for MagneMover LITE transport systems, with-out editing the files directly.
• Virtual Scope Utility – A Windows software application supplied by MagneMotion to monitor and record the change of performance parameters displayed as waveforms to analyze the performance of the transport system.
• Demonstration Script (Demo Script) – A text file (demo_script.txt) uploaded to the NCHost TCP Interface Utility to move vehicles (pucks) on the transport system for test or demonstration purposes.
• Node Controller Image File (IMG file) – The software files for the Node Controllers (controller_image), includes the Node Controller and High Level Controller applica-tions. The Node Controller Image File is uploaded to all Node Controllers in the trans-port system.
• Motor Image Files (ERF file) – The software files for the motors (motor_image.erf). The Motor Image Files are uploaded to all Node Controllers in the transport system and then programmed into all motors.
• Motor Type Files – 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 system. The Magnet Array Type File is uploaded to all Node Controllers in the transport system.
• Node Controller Configuration File (Configuration File) – An XML file (node_con-figuration.xml) that contains all of the parameters for the components in the transport system. The Node Controller Configuration File is uploaded to all Node Controllers in the transport system.
• Track Layout File – An XML file (track_layout.ndx) that contains all of the parame-ters for the graphical representation of a MagneMover LITE transport system. The Track Layout File can be used by the Configurator to generate the Node Controller Configuration File and the Track File.
• Track File – A text file (track_file.mmtrk) that contains graphical path and motor information about the transport system. The Track File is used by the NCHost TCP Interface Utility to provide a graphical representation of the transport system. The Track File is created for MagneMover LITE transport systems using the MagneMotion Configurator.
NOTICE
Modifying the Image or Type files could cause improper operation of thetransport system.
IntroductionGetting Started with the MagneMover LITE Transport System
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Getting Started with the MagneMover LITE Transport System
Use this manual as a guide and reference when installing the MagneMover LITE motors in a transport system. Follow the steps in this section to get the entire transport system operational quickly with the aid of the other MagneMotion manuals (refer to Related Documentation on page xxvii).
NOTE: Ensure that all components and complete design specifications, including the physi-cal layout of the transport system, are available before starting to install or test the MM LITE transport system’s operation.
To get started quickly with the transport system:
1. Save the files and folders from the MagneMotion System Software that came with the MagneMover LITE transport system to a folder on a computer for user access.
NOTE: The minimum computer requirements for running MagneMotion software applications 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 Inspection on page 5-2.
• Transport System Installation on page 5-5.
3. Install the MagneMotion Configurator on a computer for user access (refer to Software Configuration on page 5-64 and the MagneMover® LITE Configurator User’s Man-ual).
A. Create the Track Layout File (track_layout.ndx) to define the components and their relationships in the transport system.
B. Create the Node Controller Configuration File (node_configuration.xml) to define the components and operating parameters of the transport system.
4. Verify the installation is complete and the system is ready for use:
• System Check-out on page 5-66.
• System Power-up on page 5-67.
5. Set the Node Controller IP addresses, specify the Node Controller to be used as the High Level Controller, and upload the configuration, image, and type files to each
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MagneMover LITE User Manual 11Rockwell Automation Publication MMI-UM002E-EN-P - March 2016
Node Controller (refer to Node Controller Software Installation on page 5-65 and the Node Controller Web Interface User’s Manual).
6. Program the motors using the Motor Image Files (refer to Node Controller Software Installation on page 5-65 and the Node Controller Web Interface User’s Manual and NCHost TCP Interface Utility User’s Manual).
7. Test and debug the transport system by using the NCHost TCP Interface Utility and Demo Scripts (refer to Check-out and Power-up on page 5-66 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 Controller (either PC or PLC based) to control the MM LITE transport system as required to meet the material movement needs of the facility where the system is installed (refer to either the Host Controller TCP/IP Communication Protocol User’s Manual, the Host Controller EtherNet/IP Communication Protocol User’s Manual, or the Mitsubishi PLC TCP/IP Library User’s Manual). Refer to:
• Transport System Operation on page 6-26.
• Safe Shut-down on page 6-27.
Introduction
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Safety 2
Overview
This chapter describes safety guidelines for the MagneMover® LITE components and their use in a transport system. All personnel involved in the operation or maintenance of the MM LITE® components and the transport system must be familiar with the safety precautions out-lined in this chapter.
NOTE: These safety recommendations are basic guidelines. If the 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.
Included in this chapter are:
• Regulatory Compliance information.
• Personnel and Equipment safety guidelines.
• Symbol identification.
• Label identification and locations.
• Identification of Mechanical, Electrical, and Magnetic hazards.
• Recycling and Disposal Information.
SafetyRegulatory Compliance
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Regulatory Compliance
The MagneMover LITE components are CE compliant. To determine if a specific component is CE compliant, check for the CE mark on the compo-nent. If necessary, request the official Declaration of Conformity (DoC) from MagneMotion.
The MagneMover LITE components are UL Recognized in Canada and the United States. To determine if a specific component is UL Recognized, check for the UL Recognized Mark on the component. Note that some examples of the Mark may not display the ‘C’ and ‘US’.
In addition to this section, other sections may include regulatory information. These compo-nents comply with the regulations from the organizations indicated in Table 2-1.
NOTE: It is the responsibility of the end user/third party integrator to ensure the compliance 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 Marking on the DoC does not include reference to the RoHS Directive for that reason.
However, MagneMotion has taken voluntary steps to ensure its products comply with the requirements of EU RoHS.
Equipment Regulatory Guidelines
The following regulatory guidelines are provided to aid in the use and service of the Magne-Mover LITE components in a transport systems.
• MagneMotion Technical Support will issue a Technical Advisory to notify the owners of record of any field retrofits.
Table 2-1: Regulatory Information
Organization Regulation(s)
CE (Conformité Européenne) – The European safety requirements
• Machinery Directive• Low Voltage Directive• EMC Directive
UL • 61010-1
SafetyRegulatory Compliance
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• Contact MagneMotion Customer Support for information regarding repair and mainte-nance service policies, both during the production of the MagneMover LITE compo-nents and after production is discontinued.
• Any user-caused damage during integration of the MagneMover LITE components into their equipment is the user’s responsibility.
• MagneMotion’s responsibility 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 integrated into a transport system. Only qualified, properly trained personnel should perform any procedures on the MagneMover LITE components. Damage resulting from improp-erly performing a procedure or not following cautions is not covered under warranty or service agreements.
SafetySafety Considerations
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Safety Considerations
Personnel Safety Guidelines
MagneMover LITE components and transport systems may provide several direct safety haz-ards to personnel if not properly installed or operated. General safety guidelines are provided below, specific cautions are provided as needed (refer to Mechanical Hazards on page 2-22, Electrical Hazards on page 2-23, and Magnetic Hazards on page 2-25).
• Personnel operating or servicing the MagneMover LITE transport system should be properly trained.
• Be aware of the hazardous points of the MagneMover LITE transport system as described in this chapter.
• High strength Neodymium Iron Boron magnets are used in the MagneMover LITE transport system.
• To avoid severe injury, people with pacemakers and other medical electronic implants must not handle or approach the magnet arrays. These 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 magnetic attrac-tive forces.
• Vehicles (pucks) and magnet arrays not on the MagneMover LITE transport system should be secured individually in isolated packaging.
• Moving mechanisms have no obstruction sensors and can cause personal injury.
• Know the location of the following:
• Fire extinguisher.
• First Aid Station.
• Emergency eyewash and/or shower.
• Emergency exit.
• The following safety equipment, used according to the manufacturer’s instructions, should be donned prior to installing, testing, or servicing the MagneMover LITE trans-port system:
• Eye protectionBreaking material may produce flying shards. When running a setup or test procedure, protective eye wear must be worn at all times to guard against pos-sible eye injuries.
SafetySafety Considerations
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• Safety ShoesShoes with protective toes should be worn to protect feet from dropping tools or parts.
• Observe the facility guidelines pertaining to loose clothing while working around or operating the MagneMover LITE transport system.
• It may be recommended that the use of hazardous materials, such as cleaning fluids, be used during routine maintenance procedures. Read and understand the facility’s haz-ardous materials policies and the MSDS (provided by the manufacturer) for each sub-stance.
• Whenever power is applied, the possibility of automatic movement of the vehicles (pucks) or user-supplied equipment in the MagneMover LITE transport system exists. It is the user’s responsibility to provide appropriate safeguards.
• Ensure propulsion power is disabled when performing maintenance on the vehicles (pucks), track system, or motors.
• Ensure the MagneMover LITE motors and related components are properly decontam-inated before performing any service following the facilities’ decontamination proce-dures. 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 to be present, users must observe the proper safety precau-tions and ensure that the material used is compatible with those from which the Mag-neMover LITE components are fabricated.
• Determine if the MagneMover LITE transport system will be employed in an earth-quake prone environment and install the equipment accordingly.
• The MagneMover LITE components are not provided with an Emergency Off (EMO) circuit. The user is responsible for an EMO circuit (refer to E-Stops on page 6-13 for more information).
• Do not place the MagneMover LITE transport system’s connections (power and com-munications cables) where they could cause a trip hazard.
• Do not place the MagneMover LITE transport system in a location where it may be subject to physical damage.
• Ensure that all electrical and pneumatic connections to the MagneMover LITE compo-nents are made in accordance with the appropriate facility, local, and national regula-tions.
SafetySafety Considerations
6 MagneMotionRockwell Automation Publication MMI-UM002E-EN-P - March 2016
• Ensure that the MagneMover LITE components receive proper air flow for cooling.
• Do not remove safety labels or equipment identification labels.
• Turn OFF power before inserting or removing power cables.
• Use of the MagneMover LITE components 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 have been dropped, damaged, or are malfunctioning.
• Keep cables and connectors away from heated surfaces.
• Do not modify the connectors or ports.
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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 PointMagnetic Field Hazard
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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 PointMagnetic Field Hazard
SafetySafety Considerations
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Precision Locator Option Hazard Locations
Figure 2-3: Locations of Hazardous Points on the Precision Locator Option
Locator ArmMechanical Hazard
Cover Removed
Locator DriveMechanical Hazard - Pinch Point(normally covered)
– Pinch Point
SafetySymbol Identification
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Symbol Identification
Symbols are used in this manual and on the MagneMotion products to identify hazards, man-datory actions, and prohibited actions. The symbols used in this manual and their descriptions are provided below.
Table 2-2: Hazard Alert Symbol Identification
Symbol Description
General Hazard Alert – Indicates that failure to follow recommended pro-cedures can result in unsafe conditions, which may cause injury 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 avoidmuscle 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 couldcause personal injury.
Magnetic Field Hazard – Indicates a strong magnetic field is present thatcould cause personal injury.
Pinch Point Hazard – Indicates that there are exposed moving parts thatcould cause personal injury from the squeezing or compression of fingers,hands, or other body parts between moving mechanisms.
kg
SafetySymbol Identification
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Table 2-3: Mandatory Action Symbol Identification
Symbol Description
Eye Protection Required – Indicates that appropriate eyewear must beworn to prevent injury to eyes from flying shards.
Foot Protection Required – Indicates that appropriate footwear must beworn to prevent injury to feet from falling objects.
.
Lockout Required – Indicates that all power must be disconnected using amethod 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 specifiedarea due to the possibility of damage to the media.
Metal Parts or Watches Prohibited – Indicates that watches, instruments,electronics, metal tools, and metal objects are not allowed in the specifiedarea due to the possibility of damage.
Pacemakers or Medical Implants Prohibited – Indicates that persons withmedical implants are not allowed in the specified area due to the possibilityof personal injury.
SafetyLabel Identification and Location
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Label Identification and Location
Safety labels and identification labels are placed on those MagneMover LITE components that require them to provide operators and service personnel with hazard identification and information about the MM LITE components at the point of use. This section describes each label, identifies its location, and for safety labels gives instructions on how to avoid the haz-ard.
NOTE: Label placement may cause labels 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 damaged label, contact MagneMotion and refer to its name.
Standard MagneMover LITE Components
Figure 2-4: Locations of Labels on the MagneMover LITE Straight and Curve Motors
Table 2-5: Labels Used on the MagneMover LITE Straight and Curve Motors
Product Information Label
Qty: 1
Location: On the bottom of the motor
ATE
PUCK
B-IN
TESTED
Information Label
SafetyLabel Identification and Location
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Figure 2-5: Locations of Labels on the MagneMover LITE Switches
Table 2-6: Labels Used on the MagneMover LITE Switches
Product Information Label
Qty: 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-6FMAC:
ATEINTEG
BURN
TESTED
?????????
Made in USA
www.magnemotion.com
XX VDC, X.X A Typ, X.X A Max
S/N:
P/N:700-1308-XX
S/N: 130901234
MAC: 1A-2B-3C-4D-5E-6F
Information LabelPinch Hazard Label
MAC ID Label
SafetyLabel Identification and Location
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Figure 2-6: Locations of Labels on the MagneMover LITE Magnet 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
SafetyLabel Identification and Location
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Figure 2-7: Locations 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-6FMAC:
ATE
BURN
TESTED
S/N: 130901234
MAC: 1A-2B-3C-4D-5E-6F Information Label
MAC ID Label
SafetyLabel Identification and Location
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Figure 2-8: 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-6FMAC:
PWR
LAN
18 VDC PoE ONLY
Information Label
MAC ID Label
SafetyLabel Identification and Location
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Figure 2-9: Locations of Labels on the MM LITE Power 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: X110400001100-240 VAC~, 50-60 Hz, 8.5AT, 250V, 10A Fusewww.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
www.magnemotion.com
Made in US A
Information Label
SafetyLabel Identification and Location
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Precision Rail Option Components
Figure 2-10: Locations of Labels on the Precision Rail Vehicles (single array shown)
Table 2-11: Labels Used on the 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
Magnet ArraySerial Number Label
VehicleSerial Number Label
SafetyLabel Identification and Location
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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
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Precision Locator Option Components
Figure 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
SafetyLabel Identification and Location
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Figure 2-13: Locations of Labels on the 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
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Mechanical Hazards
The MagneMover LITE transport system is a complex electromechanical system. Only per-sonnel with the proper training should install, operate, or service the MM LITE transport sys-tem.
All facilities to the MagneMover LITE transport system must be disconnected as outlined in the facility’s lockout/tagout procedure before servicing, or injury may result from the auto-matic operation of the equipment. The proper precautions for operating and servicing remotely controlled electromechanical equipment must be observed. These precautions include wearing safety glasses, safety shoes, and any other precautions 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 withoutbarriers in place or personal injury could result in the squeez-ing or compression of fingers, hands, or other body partsbetween moving mechanisms.
CAUTION
Automatic Movement Hazard
Whenever power is applied, the possibility of automaticmovement of the vehicles (pucks) on a MagneMover LITEtransport system exists, which could result in personal injury.
CAUTION
Heavy Lift Hazard
Some of the MagneMover LITE components can weigh asmuch as 14.5 kg [32 lb].
Failure to take the proper precautions before moving themcould result in personal injury.
Use proper lifting techniques when moving any Magne-Mover LITE components. Steel toe shoes should be worn atall times when working on the MagneMover LITE transportsystem.
kg
SafetyElectrical Hazards
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Electrical Hazards
The MagneMover LITE components are classified as low voltage devices, no additional safety precautions are required.
The power supplies, Node Controllers, network switches, and power modules are connected to the facility’s AC Mains and are capable of generating hazardous energy. The proper precau-tions for operating and servicing electrical equipment must be observed. These precautions include following facility lockout/tagout procedures, and any other specified action within the facility where the MagneMover LITE components are being used.
WARNING
Electrical Hazard
All electrical power to the MagneMover LITE transport sys-tem must be disconnected per the facility’s lockout/tagoutprocedure before servicing to prevent the risk of electricalshock.
CAUTION
Electrical Hazard
To avoid electric shock, do not open any MagneMover LITEcomponent. Motors, controllers, and other components donot contain any user-serviceable parts.
Do not turn on electrical power to the power supplies,motors, and Node Controllers until after connecting all othertransport system components.
NOTICE
To avoid equipment damage:
• Ensure the transport system is properly grounded.
• When using custom vehicles with user-supplied rails, ensure all vehicles are grounded to the guideway using conductive wheels or static brushes.
• Do not connect or disconnect any components while the transport sys-tem has power.
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Pneumatic Hazards
The Precision Locator is connected to the facility’s compressed air system, which is capable of generating hazardous energy. The proper precautions for operating and servicing pneumatic equipment must be observed. These precautions include following facility 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 transportsystem must be disconnected per the facility’s lockout/tagoutprocedure before servicing to prevent the risk of mechanicalmovement.
Do not turn on power to the pneumatic system until after con-necting all other transport system components.
SafetyMagnetic Hazards
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Magnetic Hazards
The MagneMover LITE transport systems use high strength Neodymium Iron Boron (NdFeB) magnets in the magnet arrays attached to the vehicles (pucks). The proper precautions for using high strength magnets must be observed.
WARNING
Magnetic Field Hazard
Strong magnets in use.
To avoid severe injury, people with pacemakers and othermedical electronic implants must stay away from the magnetarray 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 should be secured individually in isolated packaging.
NOTICE
Magnetic Fields
Strong magnets in use.
To avoid damage to watches, electronic instruments, andmagnetic media (e.g., cell phones, memory disks/chips,credit cards, and tapes) keep these items away from the mag-net arrays.
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Handling Magnet Arrays
The Neodymium Iron Boron (NdFeB) magnets used in the MMI magnet arrays require special handling. General handling guidelines and cautions are provided below. It is the responsibility of the user to define and implement their own handling guidelines in accordance with the applicable facility, local, and national safety codes for the installation site.
• Pacemakers and other Medical Implants – Individuals with pacemakers or internal medical devices should use caution when handling the magnet arrays as the magnetic fields may affect the operation of these devices. These individuals should consult their physician and the manufacturer of their medical device to determine its susceptibility to static magnetic fields prior to handling the magnet arrays and to determine the safe distance from the arrays, or if they should not handle the arrays.
• Electronic Equipment Damage – Do not allow any magnet arrays near sensitive electronics, equipment with cathode ray tubes (CRTs) or other displays, or magnetic storage media (e.g., disks, credit cards, cell phones).
• Pinch/Crush – The magnet arrays used with the MagneMotion linear motors are very strong. The magnet arrays have a very high attractive force to each other and ferro-magnetic materials like steel, iron, some stainless steels, and nickel. Pinching will hap-pen if the magnet arrays are allowed to come together against a body part. 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 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, or ferromagnetic materials. The magnets in the arrays are brittle, and if allowed to collide the magnets in the arrays can shatter and break, possibly sending particles flying at high speed.
• Debris Accumulation – If debris is accumulated, it can get caught between the mag-net array and the motor, which will affect system performance and can damage the cover of the motor.
• Corrosion – The magnets in all MagneMotion magnet arrays are protected against corrosion. However, damage (e.g., scratches, chips) to the magnet array or the magnets creates the potential for corrosion. NdFeB rare-earth magnets that have corroded have changed their physical properties. The Safety Data Sheets (SDS) for the component materials (Iron, Neodymium, Boron, Nickel, and Copper) should be consulted prior to the use, handling, or transportation of corroded magnets.
• Machining – Do not drill, grind, machine, or sand the magnets or the magnet arrays. The magnets may shatter and break when drilled or machined. The magnet dust cre-ated by machining is hazardous and can be harmful if inhaled or allowed to get into eyes. Drilling, grinding, and machining may produce metal powder which is flamma-ble and can ignite and burn at high intensity creating toxic fumes. Additionally, machining may cause high heat to develop resulting in demagnetization.
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• Use – The magnet arrays should never be used to lift any objects. The MagneMotion magnet arrays should only be used for propulsion in conjunction with an MMI motor by attaching the array to a vehicle (puck).
• Storage – Store magnet arrays in appropriate storage or shipping containers (shielded with steel or isolated). Never leave magnet arrays unattended outside the storage con-tainers. If this is unavoidable, the area should be marked with a Magnetic Hazard Sign in accordance with the applicable facility, local, and national safety codes for the installation site.
• Handling – Appropriate 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. 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 field strength. MMI recommends a maximum operating temperature of 50° C [122° F] and a maximum storage and shipping temperature of 60° C [140° F].
• Signage – Ensure appropriate cautionary signage is in place in all locations where the arrays are located in accordance with the applicable facility, local, and national safety codes for the installation site.
Shipping Magnet Arrays
Magnet arrays being shipped, for return to MMI or to another facility, must be shipped per U.S. Department of Transportation and The International Air Transport Association (IATA) Dangerous Goods Regulations.
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Recycling and Disposal Information
The MagneMover LITE transport systems use the following items that may require special handling for disposal or recycling.
MagneMover LITE Transport System
No hazardous materials, other than those identified below, are used in the MagneMover LITE components.
Node Controllers
A Lithium battery is located in the Node Controllers to maintain the 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 be handled in the following manner:
• Follow all safety procedures for the handling of high strength magnets (refer to Mag-netic Hazards).
• Follow all facility, local, and national procedures for the disposal of hazardous materi-als. All strong permanent magnets should be demagnetized prior to disposal.
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Design Guidelines 3
Overview
This chapter provides guidelines for designing a transport system using the MagneMover® LITE 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 configuration.
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Transport System Layout
Before installing a MagneMover LITE transport system, a transport system layout must be created that defines the following:
• Type and location of all motors and switches (all motors and switches provide bidirec-tional movement).
• The number of vehicles (pucks) on the transport system.
• Locations of all interfaces to other equipment in the facility.
• All Paths and the direction of forward motion (downstream).
• All Nodes and the type of the Nodes.
• All Node Controllers, their type, and connections.
• Identification of the Node Controller assigned as the High Level Controller (HLC).
• Additional connections such as motor communications, power, and network.
• Additional functions such as E-Stop, Interlock, and Light Stack.
The transport system layout is 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 a Host Application must be created that will run on the end-user’s Host Controller. This application provides all monitoring and control of the trans-port system.
Transport System Overview
The MagneMover LITE components consist of a set of basic building-blocks that provides an easy to assemble and implement transport system. The modular nature of the MM LITE com-ponents makes it easy to implement layout or control changes. An example of how the basic building-blocks are used is provided in the following sections:
• Motors, Switches, and Vehicles (Pucks) on page 3-3
• Paths on page 3-4
• Nodes on page 3-5
• Node Controllers on page 3-6
• Additional Connections on page 3-7
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Motors, Switches, and Vehicles (Pucks)
The transport system layout is a plan view layout of the MagneMover LITE transport system. This drawing identifies each motor and switch (if required) in the transport system (refer to Figure 3-1 for an example), how they are physically located, and any interfaces to other equip-ment in the facility.
Motors are used to move the vehicles (pucks) on the transport system. When using multiple motors, they must be installed so that the end of one motor is physically connected to the end of the next motor in the same Path (refer to Paths on page 3-4).
Switches connect multiple Paths and direct the vehicles (pucks) from one Path on the trans-port system to another Path. All MagneMover LITE switch modules can only be used with pucks on a standard MM LITE transport system with integral rails.
NOTE: MagneMover LITE switch modules are not 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, however vehicles can move backwards (downstream to upstream) if required. The transport system assigns a unique ID to each vehicle at startup, which is retained until the transport system is restarted, the vehicle is removed through a Ter-minus or Gateway Node, or the vehicle is deleted. Additionally, the transport system ensures vehicles do not collide with each other by implementing anti-collision algorithms. Note that it is not necessary to show the vehicles (pucks) on the transport system layout.
NOTE: It may be useful to show facility features on the drawing.
Figure 3-1: Sample MM LITE Transport System Layout Showing Motors
250 mm Motor
1000 mm Motor
90° Curve Motor
Right Switch
3 1000 mm motor6 250 mm motor5 90° curve motor2 Right switch
Qty Description
(typical)
(typical)
(typical) (typical)
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Paths
Once all motors have been identified on the MagneMover LITE transport system layout, the individual Paths must be defined (refer to Figure 3-2 for an example). This includes identify-ing all motors on the Path and the direction of forward (downstream) movement.
Paths define the routes for vehicle (puck) motion. All Paths include one or more motors arranged end to end. All Paths must begin at a Node and may end at a second Node based on the use of the Path. Paths are unique and do not overlap. Each Path is provided a unique iden-tifier in the Node Controller Configuration File and each motor is identified as belonging to a specific Path and provided a unique identifier 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 Paths.
Figure 3-2: Sample MM LITE Transport System Layout Showing Paths
NOTE: MagneMover LITE switches are not available for systems using railless motors.
Table 3-1: Motor Assignments
Path Motors
1 4 - 250 mm straight, 3 - 90° curve, 1 - 1000 mm straight
2 1 - 250 mm straight1 - 250 mm straight part of switch, 1 - 90° curve part of switch
3 1 - 250 mm straight, 2 - 90° curve, 2 - 1000 mm straight1 - 250 mm straight part of switch, 1 - 90° curve part of switch
3 1000 mm motor6 250 mm motor5 90° curve motor2 Right switch
Qty Description
Path 3
3 Paths
NOTE: Arrows indicate direction of forward motion.
Pat
h 1
Pat
h 2
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Nodes
Once all Paths have been identified on the MagneMover LITE transport system layout, the Nodes connecting those Paths must be defined (refer to Figure 3-3 for an example). This includes identifying the type of Node being used.
Nodes define the beginning of all Paths and the connections between Paths. Refer to the Mag-neMover® LITE Configurator User’s Manual for a detailed description of Nodes and all Node types. The Node types supported by the MM LITE transport system include:
• Simple Node – Defines the beginning of a Path (i.e., there is no other Path connecting at this point).
• Relay Node – Connects the 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 – Connects the end of one Path to the beginning of two other Paths.
• Merge-Diverge Node – Connects the ends of two Paths to the beginning of two other Paths.
NOTE: The connections to the motors at the ends of all Paths meeting in a Node must be made to the same Node Controller.
Figure 3-3: Sample MM LITE Transport System Layout Showing Nodes
3 1000 mm motor6 250 mm motor5 90° curve motor2 Right switch
Qty Description
Diverge3 Paths
2 Nodes
Merge
1 Diverge 1 Merge
NOTE: Arrows indicate direction of forward motion.
Path 3
Pat
h 1
Pat
h 2
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Node Controllers
Once all Paths and Nodes have been identified on the MagneMover LITE transport system layout, the Node Controllers and their connections to the motors at the Nodes must be defined. This typically includes identifying the type of Node Controllers being used (the example in Figure 3-4 shows Node Controller LITEs being used).
Node Controllers coordinate all motor operations and communicate with the High Level Con-troller. In all MagneMover LITE transport systems one Node Controller is designated as the High Level Controller (HLC). The HLC manages the communication between all Node Con-trollers in the transport system and the user’s Host Controller. The Node Controller types sup-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 16 Digital Outputs. This Node Controller can support multiple Nodes (e.g., Merge, Diverge, and Relay) and additional functions (e.g., E-Stop, Interlocks).
Motor Communications – Identifies the communications connections between motors on the same Path.
NOTE: All motor connections at a Node must be made to the same Node Controller.
Figure 3-4: Sample MM LITE Transport System Layout Showing Node Controllers
3 1000 mm motor6 250 mm motor5 90° curve motor2 Right switch
Qty Description
3 Paths
NC 1 NC 2 & HLC
2 Nodes 1 Diverge 1 Merge
NOTE: Arrows indicate direction of forward motion.
Diverge
Merge
2 Node Controller LITEs (NCn)
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Additional Connections
The remaining components and connections must be defined on the MagneMover LITE trans-port system layout. The components include power supplies for the motors and network switches for communication with the Node Controllers and Host Controller (refer to Fig-ure 3-5 for an example). If NC-12 Node Controllers (with digital I/O) are being used, E-Stop buttons, Interlocks, and Light Stacks can be configured and their locations should be identi-fied.
Power Supplies – The MM LITE Power Supply provides two 300W DC outputs for 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 the transport system.
Power Wiring – Identifies the power connections between motors connected to the same power supply.
Figure 3-5: Sample MM LITE Transport System Layout Showing Additional Connections
3 1000 mm motors6 250 mm motors5 90° curve motors2 Right switches
Qty Description
3 Paths
NC1 NC2
SW1
PS1
Host
& HLC
2 Nodes 1 Diverge 1 Merge
NOTE: Arrows indicate direction of forward motion.
Diverge
Merge
2 Node Controller LITEs (NCn)
1 Network Switch (SW1)
1 Power Supply (PS1)
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Transport System Design
Overview
This section describes some of the basic considerations for designing a track system for a MagneMover LITE transport system. The track system includes the guideway, the guideway supports, the MM LITE railless motors, the vehicles with magnet arrays, and the mechanism for mounting the motors to the guideway (refer to Transport System Layout on page 3-2 for layout guidelines).
One advantage of the MagneMover LITE transport system is that it is possible to have vehi-cles move at different rates of speed in the same direction, or in opposite directions without a collision. The control software ensures that the minimum distance between vehicles (pucks) when not moving is 3 mm [0.1 in] (refer to Motor Topology on page 6-3).
Design Guidelines
Use standard engineering practices to reduce torque, vibration, and other stresses on the guideway and other parts of the system. Factors specific to MagneMover LITE transport sys-tems to consider include:
• 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 the vehicle over the gap.
• Process stations should not be located where the center of the magnet array would be within the Downstream Gap between motors as settling time and repeatability may be negatively affected.
• Ensure the track system configuration accounts for power and communication connec-tions and all cables.
• Ensure the transport system configuration accounts for points for grounding the track to the facility’s earth ground and for grounding of all motors.
• When choosing vehicle and guideway materials, consider the stresses applied to the vehicle and guideway during use.
• When choosing vehicle and guideway materials, consider those that provide low fric-tion and low wear.
• When choosing vehicle and guideway materials, consider static electricity dissipation between the vehicles and the guideway.
• The vehicle must remain centered over the motors throughout the system.
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• When choosing wheel materials, consider the life expectancy of the wheel material and the noise level as they move on the guideway (e.g., across the joints in a straight/curved guideway).
• Off-centered and/or large payloads can affect system performance.
Motors
The MagneMover LITE motors can be mounted either right side up or upside down. Other orientations may be possible, please contact MMI Technical Support for additional informa-tion. MM LITE motors do not have a required direction, the upstream and downstream ends are automatically defined during configuration. Forward vehicle (puck) motion using the MM LITE motors is from upstream to downstream, however vehicles can move backwards (down-stream to upstream) if required.
NOTE: If the motor is mounted on an incline or vertically, the motor will not hold a vehicle (puck) in place 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 on page 4-8 for Magne-Mover LITE motor mechanical drawings.
• Refer to Figure 4-7 on page 4-9 and Figure 4-8 on page 4-10 for MagneMover LITE switch mechanical drawings (the MM LITE switches are not available in railless versions).
• Refer to Figure 4-9 on page 4-11 and Figure 4-10 on page 4-12 for mounting bracket and stand mechanical drawings.
• Refer to Figure 4-11 on page 4-13 through Figure 4-13 on page 4-15 for puck mechanical drawings. Refer to Figure 4-14 on page 4-16 through Figure 4-16 on page 4-18 for tandem puck mechanical drawings.
• Refer to Figure 4-17 on page 4-19 and Figure 4-18 on page 4-20 for magnet array mechanical drawings.
• Refer to Figure 4-24 on page 4-26 through Figure 4-32 on page 4-33 for Preci-sion Rail option mechanical drawings.
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• Refer to Figure 4-33 on page 4-34 for the Precision Locator option mechanical drawing.
• The MagneMover LITE transport system allows only one vehicle (puck) at a time on a motor block (see Table 3-2).
• The thrust available per magnet cycle must be taken into account when designing with the MagneMover LITE motors (see Table 3-3).
Motor Types
The MagneMover LITE motor bodies are available in two styles; motors with integral rails and railless motors (refer to Mechanical Specifications on page 4-3). Both body styles per-form the same and have the same operating specifications.
Available Thrust
The thrust available from the MagneMover LITE motor to move a vehicle (puck) is deter-mined by several variables:
• Magnet array length (in cycles). Note that the MM LITE always uses 1 cycle arrays.
• Vehicle 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 3-6. Using custom motor mounts that change the default spacing between motors is not recommended.
At the nominal Vehicle Gap of 1 mm [0.04 in] for G3 magnet arrays and 1.5 mm [0.06 in] for G4.2 and later magnet arrays (gap between the magnet array and the top of the MagneMover
Table 3-2: MagneMover LITE Motor Blocks
Motor TypeMotor Block
LengthNo. Blocks
Array Cycle Length
1000 mm 16.47 mm 60 54.5 mm
250 mm 16.47 mm 15 54.5 mm
Table 3-3: MagneMover Light Thrust Force Guideline
1.5 mm Magnetic Vehicle Gap (G4 Motor and Magnet Array) Force
Thrust per cycle @ 100% duty cycle 6 N/cycle*
* Thrust at 100% duty cycle must be limited to prevent overheating of the motor.
Thrust per cycle @ 25% duty cycle 10 N/cycle
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LITE motor) the MM LITE motors provide approximately 6 N [1.3 lbf] thrust per magnet array cycle (see Table 3-3). The magnet array comes in one length (1 cycle), however two arrays can be used in a dual array vehicle effectively doubling the length of the magnet array.
Required Thrust
The thrust required to move a vehicle (puck) is determined by several variables:
• Friction or drag between the vehicle and the guideway.
• Mass to be moved.
• Required acceleration.
Motor Gap
For MagneMover LITE motors installed in a transport system where V-Braces are used to lock the motors together, there will always be a space (Motor Gap) between motors, as shown in Figure 3-6, with the required Motor Gap being 1 mm, which places MM LITE motors on a 1 meter pitch.
Figure 3-6: MagneMover LITE Motor Gaps
Downstream Gap
An additional measurement between motors is the distance from the last block of the stator in 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 will cause greater loss of thrust. Please contact MMI Technical Support for additional information.
The Downstream Gap affects the force available for moving vehicles between motors. There is a certain amount of thrust available per magnet array cycle, providing that the magnet array cycle is located above the motor (magnet array coverage). There must be enough thrust to move the vehicle past the gap between motors. Note that process stations should not be located within the gap between motors as settling time and repeatability may be negatively affected.
NOTE: The MagneMover LITE motors do not compensate for the amount of thrust lost when the magnet array is over the Downstream Gap. This means that if the array
Motor Gap (1 mm)
Downstream GapMagneMover LITE 1 m Motor
Motor Block Vehicle Gap
(Motor Gap + 2 mm)(side view)
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only has half coverage, the effective PID values and peak thrust are halved, and the system will not perform as well as it does with full coverage.
It is important to note that the Downstream Gap measurement is added to the last motor block of all MagneMover LITE motors in the transport system. This is important when considering the motor blocks that a vehicle (puck) owns (refer to Block Acquisition on page 6-6) and also for determining when vehicles are considered to be at the end of a Path or cleared of a Node boundary (such as a Terminus Node).
Motor Cogging
Due to the use of epoxy cores in the motor windings, there is no cogging between the Magne-Mover LITE motor and the magnet array (refer to Motor Cogging on page 6-5).
Motor Controllers
The motor controller for each MagneMover LITE motor is located inside the MM LITE motor. Each MM LITE motor has one motor controller, also referred to as the master.
The motor controller is responsible for controlling the thrust applied to each vehicle (puck) by the motor and reading sensors in the motor to determine vehicle position. The motor control-lers communicate with each other and a Node Controller via RS-422 serial communication.
Electrical Wiring
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 to support power regeneration due to the active braking or deceleration of vehicles. The preferred architecture for the power bus in a MagneMover LITE transport system is a number of T-splitters or junction boxes (shown in Figure 3-7) connected in series to form a single, low resistance, power bus with a tap to each motor.
Vehicle motion will consume power when the vehicle accelerates and regenerate power when it decelerates. While the vehicle is accelerating, the motor is drawing power from the motor power supply system, including any excess power being generated from regeneration in other parts of the transport system connected to the same power supply system. In the worst case, a single motor can draw up to the value for peak power per vehicle while the vehicle is finishing its acceleration. In addition to providing the power used to accelerate a vehicle, the wiring must also be designed to manage power regenerated by a vehicle as it stops. In general, if a system is designed to support supplying power during acceleration, it will also support excess power created by regeneration during deceleration.
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MagneMover LITE User Manual 13Rockwell Automation Publication MMI-UM002E-EN-P - March 2016
Methods to Reduce Voltage Drop
There are two methods 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 motors by either shortening the length of the cables or increasing the conductor gauge of the cables. This will reduce the voltage difference between the power supply and the motor. The second method is to limit the number of motors connected to a single power supply.
Methods to Reduce Voltage Increase
There are two methods that can be used to reduce the voltage increase in the system during deceleration. The first method is to decrease the cable resistance between motors by either shortening the length of the cables or increasing the conductor gauge of the cables. This will reduce the voltage difference between the motor regenerating power and the motors consum-ing or dissipating power and allow the voltage at the regenerating motor to be lower. The sec-ond method is to install a voltage clamp 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, vehicle data, fault information, etc.). Having separate power busses also allows the motors to be programmed and configured without enabling the propulsion power.
NOTE: The standard wiring provided as part of a MagneMover LITE transport system pro-vides this separation of power busses.
Ground
Proper grounding of the MagneMover LITE transport system is required to ensure proper operation and to minimize electrical safety issues.
• The bodies of the motors are grounded through the GND connection on the power connector.
• The NC LITE and SYNC IT modules are not grounded through their power connec-tions. The cases of these modules must be grounded to an electrical safety ground (PE) through their mounting features.
• The NC-12 is grounded through the GND stud on the Node Controller.
• All power supplies must be grounded to an electrical safety ground (PE) via the safety ground in the AC input connector.
• All junction boxes must be grounded to an electrical safety ground (PE).
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14 MagneMotionRockwell Automation Publication MMI-UM002E-EN-P - March 2016
Figure 3-7: System Wiring Block Diagram
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MagneMover LITE User Manual 15Rockwell Automation Publication MMI-UM002E-EN-P - March 2016
Magnet Arrays
The amount of linear thrust that a MagneMover LITE motor provides is primarily a function of magnet array length.
High Flux Magnet Arrays
The high flux magnet array for the MagneMover LITE motors is an arrangement of neodym-ium iron boron (NdFeB) permanent magnets in a Halbach-type array that augments 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 Figure 3-8.
Figure 3-8: Standard MagneMover LITE Magnet Array, 1 Cycle, 3 Poles
NOTICE
Even though the magnet arrays are covered the magnets can still be dam-aged and are subject to corrosion if scratched or cracked.
1 Cycle
54.5
N S N
Direction of Motion
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16 MagneMotionRockwell Automation Publication MMI-UM002E-EN-P - March 2016
Physical Length
The physical length, measured in millimeters, can be measured using a non-ferrous measuring tool such as a ruler or measuring tape. The physical length can also be calculated, if the num-ber of cycles is known.
The equation to calculate the physical length of a high flux magnet array is:
MagnetArrayLength = (Cycles x 54.5) - 6.6 mm
Where:
MagnetArrayLength is the length of the array, in millimeters.
Cycles is the number of cycles in the array.
6.6 mm is the additional length of the cover.
Magnet Array Length and Attractive Force
There is no magnetic attractive force present between the magnet array and the MagneMover LITE motor.
Magnet array length is measured in three ways:
• Number of cycles.
• Physical length in mm.
• Number 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 oriented magnet as shown in Figure 3-8.
• With a 1 cycle G3 magnet array, the maximum Motor Gap is 1.0 mm.With a 1 cycle G4.2 and later magnet array, the maximum Motor Gap is 1.5 mm.
• Two magnet arrays may be used in a dual array configuration to increase the thrust available (refer to Dual Array (Tandem) Puck on page 3-19).
Number of Poles
The number of poles in a magnet array is simply the number of North and South oriented poles in the magnet array. The number of poles will always be an odd number (see Figure 3-8) as it includes the half magnets at each end of the array. The number of poles can also be calcu-lated from the number of cycles (cycles * 2 + 1).
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Magnet Array Width
Magnet arrays are available in one width. The width is designed to fit within the rails on the MagneMover LITE motors.
Magnet Array Forces
As mentioned previously, there is a certain amount of thrust force available per magnet array cycle; however, the number of cycles is not the only variable that affects available thrust. Other variables are the Vehicle 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 motor. Any accumulated debris will affect the performance and can damage the cover of the motor or the magnet array.
Available Magnet Arrays
The magnet array is only available in the one size used on the pucks and precision rail vehi-cles (refer to Figure 4-17 on page 4-19 and Figure 4-18 on page 4-20).
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Vehicles
Vehicles (pucks) carry payloads through the MagneMover LITE transport system as directed. A high-strength magnet array, described in Magnet Arrays on page 3-15, is mounted to the surface of the vehicle closest to the motors. The magnet array interacts with the motors, which moves the vehicle.
The vehicle is passive with no electronics on the vehicle and no power or signal connections are required. A vehicle can be of almost any size and shape, it depends on the requirements of the application, however it must be designed to hold the mass of the payload and to 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 least as long, and preferably longer than the magnet array.
• Vehicles must be grounded to the guideway using conductive materials such as wheels, skids, or static brushes.
• The vehicle must have low friction with the guideway.
• All vehicles (pucks) on connected guideways must be the same size and use the same type of magnet array.
Figure 3-9: Typical Vehicle on Guideway
Motor
Vehicle
Payload Mounting Surface
Guideway
Vehicle
Vehicle
Magnet Array
Motor Mount
Guidance
SuspensionWheel
V-Brace
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A variety of materials may be used to construct the vehicles in a MagneMover LITE transport system, provided the material can carry the payload without deflecting while supporting the magnet array in the correct relationship to the motors. In general, use a lighter weight vehicle to maximize the acceleration capability of the system for moving the payload.
Wheels or rollers are used to support the vehicle(s) on the guideway while allowing the vehi-cles to move freely upstream and downstream. They also maintain a consistent space between the magnet array attached to the vehicle and the MagneMover LITE motors (Vehicle Gap). Wheel and roller materials affect the frictional resistance, which affects the amount of thrust needed 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 Figure 3-11.
Single Array Puck
Pucks with single magnet arrays are used in MagneMover LITE transport systems where all material being moved weighs less than 1 kg.
Figure 3-10: Standard Puck Configuration
Dual Array (Tandem) Puck
Tandem pucks consist of two independent pucks connected to a mounting plate by pivots, where each puck has its own magnet array. Tandem pucks are typically used in MagneMover LITE transport systems where the material being moved weighs between 1 kg and 2 kg.
Figure 3-11: Tandem Puck Configuration
DIRECTION OF TRAVEL
Puck Body
Wear Surfaces
Magnet Array
DIRECTION OF TRAVEL
Puck Pivot
Puck Body
Wear Surfaces
Magnet Array
Mounting Plate
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Vehicle Gap
The Vehicle Gap, shown in Figure 3-12, is the distance maintained between the magnet array and the MagneMover LITE motor. This gap should be maintained throughout the transport system to ensure consistent operation of the vehicle (the larger the gap the lower the thrust).
Figure 3-12: Vehicle Gap
Standard MM LITE motors have integral rails that ensure a Vehicle Gap of 1 mm ±0.5 mm for G3 pucks and 1.5 mm ±0.5 mm for G4.2 and later pucks is maintained throughout the Magne-Mover LITE transport system. When designing a guideway to be used with the MagneMover LITE railless motors the same gap and tolerance must be maintained to meet the standard thrust requirements.
The guide rails on which the vehicles move should typically be held flat to within ±0.5 mm, with a Vehicle Gap of 1 - 2 mm more than the tolerance of the track and 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, with a total gap range of 1.0 to 2.0 mm.
NOTE: The Vehicle Gap must be such that any deviations in the flatness of the guide rails will not allow the magnet array on the vehicle to touch down on either the guide rails or the motors.
The Vehicle Gap recommendations shown are for reference only. Using a smaller minimum Vehicle Gap or a larger maximum Vehicle Gap may be possible. However, exceeding the Vehicle Gap recommendations may make it difficult for the position sensors in the motor to precisely locate the vehicles. Please contact MMI Technical Support for additional informa-tion.
• Minimum Vehicle Gap is 0.5 mm, 1.0 mm is the recommended minimum.
• Maximum Vehicle Gap is 2.0 mm, 1.5 mm is the recommended maximum.
Magnet Array
MM LITE Motor
Vehicle Gap
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Vehicle Design
When designing custom vehicles for use with the MagneMover LITE the following vehicle design guidelines and considerations should be taken into account:
• The vehicle should be longer than the magnet array to protect the array from impacts. MagneMotion recommends a minimum of 1 mm extra length at the front and back of the vehicle.
• The quantity and locations of suspension and guidance wheels or other suspension and guidance features is determined by the vehicle design.
• MagneMotion recommends the use of a low friction barrier, such as UHMW material, to prevent damage to either the magnet array or the motor in the event of contact between the magnet array and the motor. Note that for the standard pucks and magnet arrays this UHMW material is already provided 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 or separate the payload from the magnet array by 50 - 100 mm.
• When using curve motors or guideways with curves, ensure the vehicle design is able to negotiate the curves.
Vehicle Materials
Some examples of commonly used vehicle materials and considerations:
Steel:
• Good strength properties.
• High density yields heavier vehicles.
• Caution is required when using carbon steel (a ferromagnetic material).
• 300 series stainless steel is suitable.
Aluminum:
• Good combination of comparatively high strength and low mass.
• Less caution required because of no magnetic 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.
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Wheel Materials
Some examples of commonly used wheel materials and key considerations:
Steel:
• Very durable, typically used in systems moving heavy payloads or for difficult envi-ronmental conditions.
• Low rolling resistance.
• When used on a metal guideway are typically noisier than plastics.
Plastic, Teflon, or Urethane:
• Plastics with a high durometer number (hardness) are a good choice of wheel material for many applications, particularly for systems with 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 vehicle be grounded to the guideway using static brushes.
Mounting Magnet Arrays to Vehicles
Magnet arrays are provided with locating features to ensure consistent mounting to the user’s vehicles and threaded standoffs for attachment. Arrays should be attached using stainless steel hardware that fully engages the threads provided in the array mounting standoffs.
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Guideways
Just as with any conveyance technology, vehicle motion imparts dynamic loads on the guide-way system. Ensure the guideway is adequately secured to a rigid, permanent structure, such as the equipment the guideway is associated with or the floor, wall, or ceiling which will reduce vibrations and other stresses on the system.
Custom Guideway Design
Figure 3-13: MagneMover LITE Railless Transport System, Single Vehicle
Basic guideway design guidelines and considerations:
• The guideway can have any orientation in relation to the motors and vehicles as long as the magnet array on the vehicle is held in position 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 mm. This allows the Vehicle Gap to be as small as possible, maximizing vehicle thrust.
• The guideway must provide features to allow the vehicle maintain its position on the guideway (see Figure 3-9).
• The joints between sections of the guideway should be as smooth as possible to mini-mize noise and wear.
• The payload, vehicle mass, and as applicable, the motor mass must be within the limits of the guideway.
• The guideway must provide proper grounding to ensure static dissipation.
Motor
Wheel
Guideway
Motor Mount
Magnet Array
Vehicle
Guide Plate
V-Brace
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Guideway and Support Materials
As with any installation, the operational environment should be considered when choosing compatible support structure materials. Some examples of commonly used guideway structure materials and key considerations follow:
Steel:
• Good strength properties.
• Strong and provides a stable platform for vehicle movement.
• Can be heavier than is necessary.
• Caution is required when using carbon steel (a ferromagnetic material).
• Can be more expensive than other alternatives.
Aluminum:
• Good combination of comparatively high strength and low mass.
• Less caution required because of no magnetic 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 guidelines are provided for designing custom motor mounts.
• Mounts should allow the motors to have a small amount of movement relative to each other to allow adjustment of the motor to motor gap during installation.
• Mounts should ensure consistent spacing between the motors to simplify the creation of the Node Controller Configuration File and to ensure consistent thrust.
• Mounts should ensure the top surface of all motors are coplanar to each other.
• Mounts should ensure the motor is securely fastened and can not move.
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Motor Mounting Methods
The following motor mounting guidelines are provided when designing 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 forMotor Connections
M6 Mounting Hardware
MM LITE 1000 mm Motor
Mounting Plate
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• When attaching custom mounting brackets to the motors and securing 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
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MagneMover LITE User Manual 27Rockwell Automation Publication MMI-UM002E-EN-P - March 2016
• The standard or adjustable motor mounts may be used to secure the motors to a surface as shown in Figure 3-16. The motor mounts provide clearance for all cable routing. Note that this mounting method may not provide for any adjustment of the motor posi-tion once the motor is installed.
Figure 3-16: Motor Mounting 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 operation, tighten the motor mounts. Refer to Align and Secure Motors and Switches for details of the mounting procedure.
Standard Mounting Bracket
M8 Bolt
M6 x 20 mm Bolt
MM LITE 1000 mm Motor
M8 Mounting Hardware
M8 Lock Washer
M6 Lock Washer
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System Stands
The MagneMover LITE transport system stand consists of the leg assemblies and the beams the motors are mounted on. The legs are available in different lengths, which provides differ-ent system heights as shown in Table 3-4 and Figure 3-17. The legs are also 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 spacing is 250 mm cen-ter-to-center.
Stand Widths
1 50 mm
2 300 mm
3 550 mm
4 800 mm
5 1050 mm
6 1300 mm
Leg Height
System Height
240.5
Puck Top
±12Floor
Stand Width
Beam
Motor Mount
Motor
Design GuidelinesCustom Motor Mounting
MagneMover LITE User Manual 29Rockwell Automation Publication MMI-UM002E-EN-P - March 2016
Custom Motor Mounting
The following motor mounting guidelines are provided when designing a custom motor mounting surface (replacing the MagneMotion leg and beam system) or custom motor mounts (replacing the MagneMotion motor mounts) for the MagneMover LITE motors instead of using the MagneMotion motor mounting system.
Figure 3-18: Custom Motor Mounting
1. Mount the motors to the custom motor mounts (or MagneMotion motor mounts) using M6 screws. The motor to motor mount hardware and the motor mount to custom motor mounting surface should be loosely attached. 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. For straight motors, the V-braces are attached to both sides of the motor. For curve motors the V-braces are only attached to the outside of the motor.
5. Treating each motor to motor interface as a separate operation, the associated V-brace is tightened to lock in the guide rails between both motors. As this operation is per-formed, visual and tactile sensing of the guide rail joints is performed and based on
M6 x 12 mm ScrewV-Brace
Guide Rail
Motor Mount Consistent Motor Gap(M6 screw)
Design GuidelinesCustom Motor Mounting
30 MagneMotionRockwell Automation Publication MMI-UM002E-EN-P - March 2016
this, manual pressure is used to affect alignment (note that this is a very fine adjust-ment method). Refer to Connect and Secure G3 Motors and G3 Switches on page 7-27 for details of the alignment procedure.
Once the V-braces are firmly secured, the joint should be as perfect as possible and biased to minimize noise for bidirectional vehicle travel. It is prudent once this opera-tion is complete to check that no issues are present by making sure a vehicle (puck) is able to travel across this joint with no apparent binding.
6. Once the V-brace is 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 made and it should be verified that the vehicles (pucks) can go around the track with no binding on the guide-way. Refer to Verify Motor and Switch Installation on page 5-26 for details of the veri-fication procedure.
8. Once all motor mounts are secured to the motor mounting surface make sure the vehi-cle (puck) is able to travel across all motors and joints with no apparent binding. If binding is detected, make adjustments as required to eliminate the binding.
Design GuidelinesPuck Carrier
MagneMover LITE User Manual 31Rockwell Automation Publication MMI-UM002E-EN-P - March 2016
Puck Carrier
Cantilevered Loads
The following guidelines are provided when designing offset material carriers that are mounted on the puck for straight track applications using standard MagneMover LITE motors. 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 Limits
Overhang Length (mm) Maximum Load (g)
<10 1000
10 964
20 750
30 614
40 519
50 450
60 397
70 355
80 321
LoadOverhang Length
Carrier
Design GuidelinesPuck Carrier
32 MagneMotionRockwell 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)
Design GuidelinesTransport System Options
MagneMover LITE User Manual 33Rockwell Automation Publication MMI-UM002E-EN-P - March 2016
Transport System Options
Precision Rail
This section provides an overview of the Precision Rail option for use with the MagneMover LITE railless motors. The motor and rail configuration when using this option is different from the standard MM LITE configuration, where the rails are integral to the motors. When using this option, railless motors are used and the rails are independent from the motors.
Figure 3-20 shows the basic structure of a Precision Rail system configured as a loop. The rails in a Precision Rail system are supported by a 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 mount located at the bottom of each support post attaches directly to the beam supporting the motors to provide structural integrity throughout the system.
NOTE: Post mounts can be excluded from the support post assemblies to accommodate installations that provide their own underlying support structure and only require the support post and spine plate components to hold the precision rail.
Figure 3-20: Precision Rail Option
Spine Plate
Support Post
Post Mount
Precision Rails
Design GuidelinesTransport System Options
34 MagneMotionRockwell Automation Publication MMI-UM002E-EN-P - March 2016
Precision Rails
The precision rails are stainless steel precision ground rails and are available in straight 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 Rail Section
Adjustment Key
Design GuidelinesTransport System Options
MagneMover LITE User Manual 35Rockwell 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
Design GuidelinesTransport System Options
36 MagneMotionRockwell Automation Publication MMI-UM002E-EN-P - March 2016
Spine Plates
Seven different spine plates, shown in Figure 3-22, are available for supporting and connect-ing rails within a Precision Rail system as shown in Figure 3-20 and Figure 3-21. 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 CurveLeft Joint
Curve to CurveLeft Joint
180º Curve
Straight to CurveRight Joint
Curve to Curve
No Joint
Right Joint
Straight, Joint
Design GuidelinesTransport System Options
MagneMover LITE User Manual 37Rockwell Automation Publication MMI-UM002E-EN-P - March 2016
Support Post Assembly
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 PlateMounting Surface
Design GuidelinesTransport System Options
38 MagneMotionRockwell Automation Publication MMI-UM002E-EN-P - March 2016
Vehicles
Two types of vehicles are available for the Precision Rail option. A single array vehicle, shown in Figure 3-24, and a dual array 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 Motion
Vehicle Body
Magnet Array
Mounting Plate
Bearings
Design GuidelinesTransport System Options
MagneMover LITE User Manual 39Rockwell Automation Publication MMI-UM002E-EN-P - March 2016
Precision Rail Installation
Figure 3-26 shows the standard dimensions 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
MotorMount
SupportPost
Assembly
Array
SingleArray
Vehicle
Rail
All Dimensions in Millimeters [Inches]
[0.059]
Design GuidelinesTransport System Options
40 MagneMotionRockwell Automation Publication MMI-UM002E-EN-P - March 2016
Precision Locator
This section provides an overview of the Precision Locator option for use with the Magne-Mover LITE motors. The precision locator provides a method to rapidly secure a pallet mounted to an MM LITE puck to a specific location with a repeatability of ±0.05 mm. The standard motor and rail configuration must be used when using this option.
Figure 3-27 shows the basic structure of the Precision Locator. The Precision Locator can be mounted either to the MagneMover 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 precision bushings in the pallet to lock the pallet into position.
Locator Stand
The locator stand provides a method to secure the Precision Locator to a specific location and provides a pallet clamping surface. The stand is supplied in a standard version (shown in Fig-
Locator Stand
Pallet
Motor(250 mm Shown)
PrecisionLocator
PuckRocker Arm
AdjustableMotor Mount
Beam
Shown with Cover Removed
Design GuidelinesTransport System Options
MagneMover LITE User Manual 41Rockwell Automation Publication MMI-UM002E-EN-P - March 2016
ure 3-27 and Figure 5-39), which is designed to be mounted on the standard MM LITE stand assembly to the beams or on any other surface. The alternate version of the stand (shown in Figure 5-40) is designed to mount to custom fixturing on a plate only. All versions of the stand are available in versions to support multiple Precision Locators.
When placing a large vertical load on the pallet in the Precision Locator the locator stand may need to be located directly above a vertical support member (leg) for the transport system stand.
Pallet
The pallet is used to carry the user’s payload and provides precision locating features that align with the pins in the rocker arms on the Precision Locator. The pallet replaces the stan-dard puck top plate. MagneMotion sells a standard pallet (refer to Figure 4-36, Precision 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 rails.
Pallet Design
Basic pallet design guidelines and considerations (refer to Figure 3-28):
• Bushing mount feature location tolerances to be included in pallet to pallet positional repeatability tolerance stackup.
• Plate thickness tolerance to be included in pallet to pallet height repeatability tolerance stackup.
• Material: Aluminum (alternate material allowed per MagneMotion approval).
• Thickness: 8.0 mm [0.315 in].
• Finish: Hard anodize per MIL-A-8625, TYPE III - all dimensions are after plating.
• Vertical load on the pallet while clamped in the Precision Locator is limited only by the physical properties of the materials of the pallet and stand and not by the locating mechanism.
NOTE: Contact MagneMotion Technical Support for detailed pallet drawings.
Design GuidelinesTransport System Options
42 MagneMotionRockwell Automation Publication MMI-UM002E-EN-P - March 2016
Figure 3-28: Precision Locator Pallet Design Details
90°
XPAYLOAD
18.5
(50.0)
2X 6.20
62.0 MIN 0 3
X 12
.5
2X
37.5
0
3X
62.5
25.0
B
B C
CA
A
CL
2X FOR Ø2.0 PIN(BUSHING ANTI-ROTATION)
BUSHING MOUNTFEATURES
MAGNET ARRAYFEATURES
112 MIN
8MM[0.313]
8MM [0.313] THICKROCKER ARM
KEEP-OUT AREA PLATE THICKNESS TOLERANCETO BE INCLUDED IN PALLET TOPALLET HEIGHT REPEATABILITY
TOLERANCE STACKUP
THIS AREA OF PALLET ALLOWED TO BE THICKER
0.1
SKI MOUNTFEATURES
Ø9.10
Ø9.10
3.25
Ø4.5Ø8.50
(2.3)
30.00
SECTION B-BROTATED 90° CW
MAGNET ARRAY FEATURES
SECTION A-AROTATED 90° CW
BUSHING MOUNT FEATURES
(Ø9.50)
Ø AND TOLERANCE HOLE FOR BUSHINGMASKED COUNTERBORE DIAMETER &LIGHT PRESS FIT RECOMMENDED
Ø8.5 3.04.8
(0.88)Ø14.75
MIN
Ø7.5
50.0
Ø5.502X
2X 2.5 4.3
Ø6.0
25.00±0.05
SECTION C-CROTATED 90° CW
SKI MOUNT FEATURES
BUSHING MOUNT FEATURES (2) LOCATION TOLERANCESTO BE INCLUDED IN PALLET TO PALLET POSITIONAL
REPEATABILITY TOLERANCE STACKUP
90° 25.00±0.05
Ø9.2Ø9.1
60°
Design GuidelinesTransport System Options
MagneMover LITE User Manual 43Rockwell Automation Publication MMI-UM002E-EN-P - March 2016
Precision Locator Installation
The Precision Locator is designed to be installed using the locator stand. Figure 3-29 shows the critical dimensions for the installation.
Figure 3-29: Precision Locator Installation Dimensions
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 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 compressed air system and piping to the locator(s) must be designed to support this requirement. A pneumatic block diagram for the Precision Locator using a 5/2 valve is provided in Figure 3-30.
182.1
FIXTURE PLATETHICKNESS
8MM (5/16")
2X 37.5
Locator Stand
Adjustable Motor Mount
Design GuidelinesTransport System Options
44 MagneMotionRockwell Automation Publication MMI-UM002E-EN-P - March 2016
Figure 3-30: Precision Locator Pneumatic Block Diagram
1
2
3
4
51
2
3
4
51
2
3
4
5 1
2
3
4
5
Pallet Released Pallet Engaged
ExtendedRetracted
Design GuidelinesTransport System Configuration
MagneMover LITE User Manual 45Rockwell Automation Publication MMI-UM002E-EN-P - March 2016
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.
RailsMM LITE Straight Motor
Top View
Motor Gap
Design GuidelinesTransport System Configuration
46 MagneMotionRockwell Automation 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
RailsMM LITE Straight Motor
Motor Gap
MM LITE Curve Motor
Design GuidelinesTransport System Configuration
MagneMover LITE User Manual 47Rockwell Automation Publication MMI-UM002E-EN-P - March 2016
Switch Configuration
Figure 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
RailsMM LITE
MM LITE
Motor Gap
Straight Motor
Right Switch
Design Guidelines
48 MagneMotionRockwell Automation Publication MMI-UM002E-EN-P - March 2016
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MagneMover LITE User Manual 1Rockwell Automation Publication MMI-UM002E-EN-P - March 2016
Specifications and Site Requirements 4
Overview
This chapter describes 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.
Specifications and Site RequirementsMotor Types
2 MagneMotionRockwell Automation Publication MMI-UM002E-EN-P - March 2016
Motor Types
MagneMover LITE G3 Motors
The MM LITE G3 series motors and switches have been replaced by the G4 series motors and switches. The G4 series motors and switches are fully backward compatible with the G3 series.
MagneMover LITE G4 Motors
The MagneMover LITE motor bodies are available in two styles; motors with integral rails and railless motors. Both body styles perform the same and have the same operating specifica-tions. Note that switches are only available with integral rails. The integral rails 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-2 on page A-4 for acceleration, velocity, thrust, and payload limits.
1. Maximum number of vehicles (pucks) per meter is determined using the standard single array puck on a straight motor. Using a dual array (tandem) vehicle or a curved motor will decrease the number of vehicles allowed per meter.
2. Nominal Vehicle Gap (distance between the magnet array and the motor) is 1 mm for G3 magnet arrays and 1.5 mmfor G4.2 and later magnet arrays.
Specifications and Site RequirementsMechanical Specifications
MagneMover LITE User Manual 3Rockwell Automation Publication MMI-UM002E-EN-P - March 2016
Mechanical Specifications
All drawings within this manual are generic and may not reflect specific configurations of the MagneMover LITE components. To obtain a complete and current set of drawings and docu-ments contact MagneMotion Technical Support.
1000 Millimeter Motor
Figure 4-1: 1000 Millimeter Motor Mechanical Drawing (G4)
NOTE: Aluminum rails shown. Dimensions are the same for stainless steel rail version.
The Sync cable connection is only present if the Synchronization option is installed.
The exclusion zones shown are for the 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 and 734.
All Dimensions in Millimeters [Inches]Weight: 7.3 kg [16 lb]
3.7595.3
98.1±0.753.86±.03
2.3660.0
14.20.56
66.1±0.752.60±.03
4X1.1830
4X2.9575
39.35999.5
4X CLEARANCE NEEDED FORCONNECTOR & WIRE BEND RADIUS
999.039.33
0 223.
008.
780
27.6
3870
2.00
28.4
6572
3.00
7.95
320
2.00
19.6
8550
0.00
COMMUNICATION CABLECONNECTOR
POWER CONNECTOR(SYNC MOTOR ONLY)SYNC CABLE CONNECTOR
CONNECTORCOMMUNICATION CABLE
2X M6X1.0 7mmMOUNTING HOLEMAX ALLOWABLE TORQUE = 5.5 Nm
1.6943.0
3.3986.0
Specifications and Site RequirementsMechanical Specifications
4 MagneMotionRockwell Automation Publication MMI-UM002E-EN-P - March 2016
1000 Millimeter Railless Motor
Figure 4-2: 1000 Millimeter Railless Motor Mechanical Drawing (G4)
NOTE: The Sync cable connection is only present if the Synchronization option is installed.
The exclusion zones shown are for the 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.
• EPDM (synthetic rubber).
• Dow Corning® Silicone 737 and 734.
All Dimensions in Millimeters [Inches]Weight: 6.9 kg [15.2 lb]
019.6
8550
0.00
223.
008.
780
28.4
6572
3.00
7.95
320
2.00
27.6
3870
2.00
POWER CONNECTOR
CONNECTOR
SYNC CABLE CONNECTOR
CONNECTOR
(SYNC MOTOR ONLY)
COMMUNICATION CABLE
COMMUNICATION CABLE
2X M6X1.0 7mmMOUNTING HOLEMAX ALLOWABLE TORQUE = 5.5 Nm
43.11.70
3.4086.3
4X1.1830
4X2.9575
CLEARANCE NEEDED FORCONNECTOR & WIRE BEND RADIUS
39.33999.0
2.60±.0366.1±0.7 5
4.06103.3
Specifications and Site RequirementsMechanical Specifications
MagneMover LITE User Manual 5Rockwell Automation Publication MMI-UM002E-EN-P - March 2016
250 Millimeter Motor
Figure 4-3: 250 Millimeter Motor Mechanical Drawing (G4)
NOTE: Aluminum rails shown. Dimensions are the same for stainless steel rail version.
The Sync cable connection is only present if the Synchronization option is installed.
The exclusion zones shown are for the 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 and 734.
All Dimensions in Millimeters [Inches]Weight: 2 kg [4.4 lb]
03.03
77.0
0
3.86
98.0
0
3.03
77.0
0
3.86
98.0
0
COMMUNICATION CABLECONNECTOR
POWER CONNECTOR
COMMUNICATION CABLECONNECTOR
SYNC CABLE CONNECTOR(SYNC MOTOR ONLY)
1.6943.0
3.3986.0
M6X1.0 7mmMOUNTING HOLEMAX ALLOWABLE TORQUE = 5.5 Nm
4X1.1830
4X2.9575
9.82249.5
9.80249.0
4X CLEARANCE NEEDED FORCONNECTOR & WIRE BEND RADIUS
3.7595.3
3.86±.0398.1±0.75
2.3660.0
0.5614.2
2.60±.0366.1±0.75
Specifications and Site RequirementsMechanical Specifications
6 MagneMotionRockwell Automation Publication MMI-UM002E-EN-P - March 2016
250 Millimeter Railless Motor
Figure 4-4: 250 Millimeter Railless Motor Mechanical Drawing (G4)
NOTE: The Sync cable connection is only present if the Synchronization option is installed.
The exclusion zones shown are for the 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.
• EPDM (synthetic rubber).
• Dow Corning® Silicone 737 and 734.
All Dimensions in Millimeters [Inches]Weight: 1.9 kg [4.2 lb]
03.03
77.0
0
3.86
98.0
0
3.03
77.0
0
3.86
98.0
0
COMMUNICATION CABLE
SYNC CABLE CONNECTOR
CONNECTOR
POWER CONNECTOR
(SYNC MOTOR ONLY)
COMMUNICATION CABLE
CONNECTOR
M6X1.0 7mmMOUNTING HOLEMAX ALLOWABLE TORQUE = 5.5 Nm
43.21.70
3.483.3988.586.0
4X1.1830
4X2.9575
4X CLEARANCE NEEDED FORCONNECTOR & WIRE BEND RADIUS
9.849.78
250.0248.5
ENCLSOURE
66.2±0.752.61±.03
4.07103.3
Specifications and Site RequirementsMechanical Specifications
MagneMover LITE User Manual 7Rockwell Automation Publication MMI-UM002E-EN-P - March 2016
125 Millimeter Radius 90° Curve
Figure 4-5: 125 Millimeter Radius 90° Curve Mechanical Drawing (G4)
NOTE: Aluminum rails shown. Dimensions are the same for stainless steel rail version.
The Sync cable connection is only present if the Synchronization option is installed.
The exclusion zones shown are for the 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.
• 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 TRAVELPATH
3.3986.0
77.63.05
3.0577.6
4.92R125.0
3.3986.0
167.56.59
6.59167.5
0
0
1.28
32.3
9
.17
4.38 1.87
47.6
1
2.12
53.8
8
1.2832.39
.174.38
1.8747.61
2.1253.88
SYNC CABLE CONNECTOR(SYNC MOTOR ONLY)
CABLE CONNECTOR
CABLE CONNECTOR
COMMUNICATION
COMMUNICATION
POWER CONNECTOR
M6X1.0 7mmMOUNTING HOLE
MAX ALLOWABLE TORQUE = 5.5 Nm
4X1.1830
4X2.9575
60.02.36
98.1±0.753.86±.03
6.77171.9
66.1±0.752.60±.03
4X CLEARANCE NEEDED FORCONNECTOR & WIRE BEND RADIUS
Specifications and Site RequirementsMechanical Specifications
8 MagneMotionRockwell Automation Publication MMI-UM002E-EN-P - March 2016
125 Millimeter Radius 90° Curve Railless Motor
Figure 4-6: 125 Millimeter Radius 90° Railless Curve Mechanical Drawing (G4)
NOTE: The Sync cable connection is only present if the Synchronization option is installed.
The exclusion zones shown are for the 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.
• EPDM (synthetic rubber).
• Dow Corning® Silicone 737 and 734.
All Dimensions in Millimeters [Inches]Weight: 1.7 kg [3.7 lb]
3.4086.3
3.4086.3
3.0677.7
4.92R125.0
3.0677.7
3.7394.8
3.7394.8
6.61167.9
6.61167.9
0
01.
2832
.39
.17
4.38 1.87
47.6
1
2.12
53.8
8
1.2832.39
.174.38
1.8747.61
2.1253.88
CABLE CONNECTOR
CABLE CONNECTOR
COMMUNICATION
POWER CONNECTOR
SYNC CABLE CONNECTOR(SYNC MOTOR ONLY)
COMMUNICATION
M6X1.0 7mmMOUNTING HOLE
MAX ALLOWABLE TORQUE = 5.5 Nm
4X 301.18
4X2.9575
CLEARANCE NEEDED FORCONNECTOR & WIRE BEND RADIUS
2.61±.0366.2±0.75
Specifications and Site RequirementsMechanical Specifications
MagneMover LITE User Manual 9Rockwell Automation Publication MMI-UM002E-EN-P - March 2016
90° Left Switch
Figure 4-7: Left Switch Mechanical Drawing (G4)
NOTE: Aluminum rails shown. Dimensions are the same for stainless steel rail version.
The exclusion zones shown are for the MM LITE switch only. Additional exclusion zones may be required based on the material being transported by the motor.
The noise of the switching mechanism is minimal and may vary from switch to switch.
Refer to Motors 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).
• Viton®.
• Igus® L280.
• Dow Corning® Silicone 737 and 734.
All Dimensions in Millimeters [Inches]Weight: 4.1 kg [9 lb]
0
0
2X3.
8698
.0
2.28
58.0
3.03
77.0
3.86
98.0
.5915.0
.5915.0
2.2858.0
3.8698.0
POWERCONNECTOR
CABLE CONNECTORCOMMUNICATION
CABLE CONNECTORCOMMUNICATION COMMUNICATION
CABLE CONNECTOR
ETHERNETCONNECTOR
M6 X 1.00 7mmMOUNTING HOLEMAX ALLOWABLE TORQUE = 5.5 Nm
6X1.1830.0
6X2.9575
6X CLEARANCE NEEDED FORCONNECTOR & WIRE BEND RADIUS
3X3.86±.0398.1±0.75
7.92201.1
2.3660.0
4.92R125.0
3.3685.3
7.74196.5
3.3685.3 3.36
85.3
9.80249.0
Specifications and Site RequirementsMechanical Specifications
10 MagneMotionRockwell Automation Publication MMI-UM002E-EN-P - March 2016
90° Right Switch
Figure 4-8: Right Switch Mechanical Drawing (G4)
NOTE: Aluminum rails shown. Dimensions are the same for stainless steel rail version.
The exclusion zones shown are for the MM LITE switch only. Additional exclusion zones may be required based on the material being transported by the motor.
The noise of the switching mechanism is minimal and may vary from switch to switch.
Refer to Motors 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).
• Viton®.
• Igus® L280.
• Dow Corning® Silicone 737 and 734.
All Dimensions in Millimeters [Inches]Weight: 4.1 kg [9 lb]
0
0
COMMUNICATIONCABLE CONNECTOR
COMMUNICATIONCABLE CONNECTOR
COMMUNICATIONCABLE CONNECTOR
POWERCONNECTOR
M6 X 1.00 7mmMOUNTING HOLEMAX ALLOWABLE TORQUE = 5.5 Nm
ETHERNETCONNECTOR
3.86
98.0
3.03
77.0
2.28
58.0
3.8698.0
2.2858.0
.5915.0
.5915.0
2X3.
8698
.0
2.3660.0
3X3.86±.0398.1±0.75
7.92201.1
6X1.1830
6X2.9575
6X CLEARANCE NEEDED FORCONNECTOR & WIRE BEND RADIUS
7.74196.5
9.80249.0
3.3685.3
3.3685.3
3.3685.3
4.92R125.0
Specifications and Site RequirementsMechanical Specifications
MagneMover LITE User Manual 11Rockwell Automation Publication MMI-UM002E-EN-P - March 2016
Standard Motor Mount Bracket
Figure 4-9: Standard Motor Mount Bracket Mechanical Drawing (G4)
Exposed Materials
• 6063-T5 Aluminum, black anodized.
• 304 Stainless Steel.
CL
46.981.850
9.00[0.354] THRU
.62515.88
3.20081.3
±.0053.150±0.1380.00
13.95.549
±0.05±.002
80.03.150
2.03.080
2X 90°±1°
31.81.250
6.50 THRU.256
.62515.88
INSERT, TANGED, HLCL,SLF-LKG, Ø5mm [Ø0.2in] X 5.00mm [0.200in] L
All Dimensions in Millimeters [Inches]
Specifications and Site RequirementsMechanical Specifications
12 MagneMotionRockwell 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
Specifications and Site RequirementsMechanical Specifications
MagneMover LITE User Manual 13Rockwell Automation Publication MMI-UM002E-EN-P - March 2016
Pucks
The pucks are used on standard MagneMover LITE transport systems with either aluminum or stainless steel integral rails. Each puck can carry a 1 kg [2.2 lb] load. The MM LITE G3 series pucks have been replaced by 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±.01020±0.25
.787±.01020±0.25
.787±.01020±0.25
.787±.01020±0.25
431.701
.488±.01012.40±0.25
(0.3MM TYPICAL WEARNOT INCLUDED)
CL
CL
(TORQUE SCREWS TO 8 IN-LBS MAX)6.3 MAX5X M4 X0.7
2.43362
2.42162
RUNNING SURFACES
DIRECTION OF TRAVEL
All Dimensions in Millimeters [Inches]Weight: 0.43 kg [0.9 lb]
Specifications and Site RequirementsMechanical Specifications
14 MagneMotionRockwell Automation Publication MMI-UM002E-EN-P - March 2016
Figure 4-12: Puck Mechanical Drawing (G4.2)
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.
DIRECTION OF TRAVEL
RUNNING SURFACES
CL
CL
62.0
R2.079
4X
CLABOUTSYMMETRIC
40±0.151.575±.006
CLABOUTSYMMETRIC
40±0.151.575±.006
2.441
5X M4x0.7 6.3 MAX(TORQUE SCREWS TO 8 IN-LBS MAX)
IF REPLACING WEAR PARTSRE-TORQUE SCREWS TO 13 IN-LBS (WET) WITHTHREAD LOCKER LOCTITE 243, OR EQUIV.ALLOW TO CURE FOR 12 HR BEFORE USE.
12.40+-0.13
.488 -.005.020
0.50
+
1.68942.89
62.02.440
All Dimensions in Millimeters [Inches]Weight: 0.43 kg [0.9 lb]
Specifications and Site RequirementsMechanical Specifications
MagneMover LITE User Manual 15Rockwell Automation Publication MMI-UM002E-EN-P - March 2016
Figure 4-13: Puck Mechanical Drawing (G4.3)
Exposed Materials
• Stainless Steel.
• 316/316L/316L #2 Stainless Steel.
• PEEK/PTFE.
• UHMW Polyethylene.
RUNNING SURFACES
THREAD LOCKER LOCTITE 243 OR EQUIV
IF REPLACING WEAR COMPONENTSRE-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±.01020±0.25
622.440
622.441
20±0.25.787±.010
2X 20±0.25.787±.010
2X
2X.787±.01020±0.25
43.021.694
.488±.01012.40±0.25
(0.3MM TYPICAL WEARNOT INCLUDED)
DIRECTION OF TRAVEL
All Dimensions in Millimeters [Inches]Weight: 0.43 kg [0.9 lb]
Specifications and Site RequirementsMechanical Specifications
16 MagneMotionRockwell Automation Publication MMI-UM002E-EN-P - March 2016
Tandem Pucks
The tandem pucks are used on standard MagneMover LITE transport systems with either alu-minum or stainless steel integral rails. Each tandem puck can carry a 2 kg [4.4 lb] load. The MM LITE G3 series tandem pucks have been replaced by the G4 series tandem pucks. The G4 series tandem pucks are fully backward 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+-0.180.55
.39410.00
2X.039
R1(ALL AROUND)
2.10553.46
CL
CL
CL CL
4X1.575±.006
40±0.15SYMMETRICAL
ABOUT CL
2X1.575±.006
40±0.15SYMMETRICAL
ABOUT CL2X
1.575±.00640±0.15 2X
1.575±.00640±0.15
5.906150.0
2.44162.0
8X M4X0.7 6.3 MAX(TORQUE SCREWSTO 8 IN-LBS MAX)
4X.079R2
[3.425]87.00
DIRECTIONOF TRAVEL
Weight: 1 kg [2.2 lb]
Specifications and Site RequirementsMechanical Specifications
MagneMover LITE User Manual 17Rockwell Automation Publication MMI-UM002E-EN-P - March 2016
Figure 4-15: Tandem Puck Mechanical Drawing (G4.2)
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
.39410.00
2X.039
R1(ALL AROUND)
.882+-.007.022
22.40+-0.180.55
2.08252.89
CL
CL
8X M4 X 0.7 6.3 MAX(TORQUE SCREWSTO 8 IN-LBS MAX)
5.906150.0
2.44162.0
4X1.575±.006
40±0.15SYMMETRICABOUT CL
2X1.575±.006
40±0.15SYMMETRICABOUT CL
2X1.575±.006
40±0.15 2X1.575±.006
40±0.154X.079R2
DIRECTIONOF TRAVEL
CL CL[3.425]87.00
Weight: 1 kg [2.2 lb]
Specifications and Site RequirementsMechanical Specifications
18 MagneMotionRockwell Automation Publication MMI-UM002E-EN-P - March 2016
Figure 4-16: Tandem Puck Mechanical Drawing (G4.3)
Exposed Materials
• Stainless Steel.
• 316/316L/316L #2 Stainless 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)
4X1.575±.006
40±0.15SYMMETRICABOUT CL
2X
CL CL
1.575±.00640±0.15
2X1.575±.006
40±0.15SYMMETRICABOUT CL
2X1.575±.006
40±0.15
5.906150.0
2.44162.0
.079R2 TYP
[3.425]87.00
2X.882±.02022.40±0.50
(0.3MM TYPICAL WEARNOT INCLUDED)
.39410.0
2.08753.02
RUNNING SURFACES
DIRECTION OF TRAVEL
Weight: 1 kg [2.2 lb]
Specifications and Site RequirementsMechanical Specifications
MagneMover LITE User Manual 19Rockwell Automation Publication MMI-UM002E-EN-P - March 2016
Magnet Arrays
The stand-alone magnet arrays are used on custom MagneMover LITE transport systems where a user-designed track system with user-designed vehicles are being used. The MM LITE G3 series magnet arrays have 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.
CL
CL
DIRECTION OF TRAVEL
7.122X.280
1.181±.01030.00±0.25
MAX62.202.449
MAX52.802.079
2X M.157
4 X 0.7 4 MAX(TORQUE SCREWS TO 13 IN-LB MAX)
1.000.97025.4024.64
0.7300.69318.5517.61
0.2770.2737.036.85
All Dimensions in Millimeters [Inches]Weight: 0.43 kg [0.9 lb]
Specifications and Site RequirementsMechanical Specifications
20 MagneMotionRockwell Automation Publication MMI-UM002E-EN-P - March 2016
Figure 4-18: Magnet Array Mechanical Drawing (G4.2)
Exposed Materials
• Stainless Steel.
• 316L/316L #2 Stainless Steel.
• UHMW Polyethylene.
2X M4 X 0.7-6H4.5 MIN
RECOMMENDED TORQUE:13 IN-LB WITH LOCTITE 243 THREADLOCKER
CL
2.417±.01661.4±0.4
CLSYMMETRIC ABOUT30.0±0.13
1.181±.005
52.6±0.42.070±.016
2X.315±.005
8.0±0.13
.2927.4
24.1±0.4.950±.016
2X
16.7±0.3.657±.012
.3158.0
All Dimensions in Millimeters [Inches]Weight: 0.43 kg [0.9 lb]
Specifications and Site RequirementsMechanical Specifications
MagneMover LITE User Manual 21Rockwell Automation Publication MMI-UM002E-EN-P - March 2016
NC-12 Node Controller
Figure 4-19: NC-12 Node Controller Mechanical Drawing
NOTE: A minimum of 50% of each vent must be clear for unobstructed air flow.
A mounting kit is 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
[0.77]19.50
[3.44]87.3
[2.5]63.5
[2.5]63.5
[2.5]63.5
[8.75]222.3
[0.62]15.6
[1.34]33.9
[4.34]110.2
[0.12]3.10
[9.98]253.5
[10.2]260.0
Specifications and Site RequirementsMechanical Specifications
22 MagneMotionRockwell Automation Publication MMI-UM002E-EN-P - March 2016
Rack 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]
Specifications and Site RequirementsMechanical Specifications
MagneMover LITE User Manual 23Rockwell Automation Publication MMI-UM002E-EN-P - March 2016
Node Controller LITE
Figure 4-21: Node Controller LITE Mechanical Drawing
NOTE: A plate is available for mounting (refer to Electronics Mounting Plate on page 4-24).
Refer to Node Controller LITE 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 SLIDINGMOUNTING BRACKETS
MOUNTING PLATE REQUIREDON CROSSHATCHED AREA
2X
CABLE CONNECTOREXCLUSION AREA
CABLE CONNECTOREXCLUSION AREA
PWRLAN
18 VDC PoE ONLY CONSOLE
[0.17]4.3
[1.75]44.5
[4.27]108.5
[4.88]124.0
[5.52]140.2
[2.5]63.5
[2.5]63.5
[0.19]4.8
2X[3.13]79.5
[0.220]5.59
[9.19]233.4
[8.84]224.5
All Dimensions in Millimeters [Inches]Weight: 0.7 kg [1.5 lb]
Specifications and Site RequirementsMechanical Specifications
24 MagneMotionRockwell Automation Publication MMI-UM002E-EN-P - March 2016
Electronics Mounting Plate
The Electronics Mounting Plate can be used for mounting the Node Controller LITE, the SYNC IT controller, 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
28.1
81.
11
91.1
83.
59
97.9
33.
86
153.
186.
03
208.
428.
21
215.
188.
47
278.
1810
.95
13.00.51
75.002.95
101.744.01
137.005.39
5.91150.00
2X 10.00[0.39]
4X M5 THRU2X M4 THRU
M5 X 12 MM STUD
TYP3.2R306.3512.06
2.6868.18
6.69170.0015.00
.59
3.2.13
Specifications and Site RequirementsMechanical Specifications
MagneMover LITE User Manual 25Rockwell Automation Publication MMI-UM002E-EN-P - March 2016
MM LITE Power Supply
Figure 4-23: MM LITE Power Supply Mechanical Drawing
NOTE: All of the vents must be clear for unobstructed air flow.
Refer to MM 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
[2.5]63.5
6X TOP SURFACE MOUNTING LOCATION
All Dimensions in Millimeters [Inches]Weight: 2.4 kg [5.3 lb]
Specifications and Site RequirementsMechanical Specifications
26 MagneMotionRockwell Automation 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
THEORETICALAPEX
CL
A
A
THEORETICALAPEX
5.4±0.1
10.0±0.1
5.5±0.1
All Dimensions in Millimeters
Specifications and Site RequirementsMechanical Specifications
MagneMover LITE User Manual 27Rockwell Automation Publication MMI-UM002E-EN-P - March 2016
Precision Rail Single Array Vehicle
Figure 4-25: Precision Rail 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 MillimetersWeight: 0.8 kg [1.6 lb]
LOCKING HELICOIL INSERTS
DIRECTION OF MOTION
CL
[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]28.81[1.201]
30.51
Specifications and Site RequirementsMechanical Specifications
28 MagneMotionRockwell Automation Publication MMI-UM002E-EN-P - March 2016
Precision Rail Dual Array Vehicle
Figure 4-26: Precision Rail Dual 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 MillimetersWeight: 1.2 kg [2.6 lb]
[1.937]49.21
[1.201]30.51
[1.134]28.81
LOCKING HELICOIL INSERTS
DIRECTION OF MOTION
CL
[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
[4.553]115.64
[3.46]88.0
Specifications and Site RequirementsMechanical Specifications
MagneMover LITE User Manual 29Rockwell Automation Publication MMI-UM002E-EN-P - March 2016
Precision Rail Support Post Assembly
Precision Rail support posts are assembled prior to shipment and consist of a post mount, sup-port 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 plated Steel.
• 304 Stainless Steel.
217
10.3
167.1166.6
38.0
104
All Dimensions in Millimeters
Specifications and Site RequirementsMechanical Specifications
30 MagneMotionRockwell Automation Publication MMI-UM002E-EN-P - March 2016
Spine Plates
Spine plates 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
26.6
3
50.6
3
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
Specifications and Site RequirementsMechanical Specifications
MagneMover LITE User Manual 31Rockwell Automation Publication MMI-UM002E-EN-P - March 2016
Figure 4-29: Precision Rail Curve to Curve, Spine Plates, Mechanical Drawing
0
0
17.3
7
41.3
7
2X63
.70
2X68
.35
78.0
11.08
35.00
75.0076.40
2X 95.0098.92
110.30
[0.25]6.35
141.5°
128.5°
R169.88
114.2°
Right
Left
All Dimensions in Millimeters
Specifications and Site RequirementsMechanical Specifications
32 MagneMotionRockwell Automation Publication MMI-UM002E-EN-P - March 2016
Figure 4-30: Precision Rail Straight, 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
4X5.
62
26.6
3
50.6
3
68.0
0
2X 125.0°
2X 145.0°
6X R4
[0.25]6.35
All Dimensions in Millimeters
0
0
2X5.
62
26.6
3
50.6
3
68.0
0
2X 54.98
64.98
73.58
124.98132.0
141.5°
125.0°
[0.25]6.35
All Dimensions in Millimeters
Specifications and Site RequirementsMechanical Specifications
MagneMover LITE User Manual 33Rockwell Automation Publication MMI-UM002E-EN-P - March 2016
Figure 4-32: Precision Rail Curve, 180°, No Joint, Spine Plate, Mechanical Drawing
0
0
17.3
7
41.3
7
2X68
.35
78.0
0
9.58
76.40
2X 95.00100.42
110.30
128.5°
141.5°
R169.88
114.2°
[0.25]6.35
All Dimensions in Millimeters
Specifications and Site RequirementsMechanical Specifications
34 MagneMotionRockwell Automation Publication MMI-UM002E-EN-P - March 2016
Precision Locator Option
Actuator Assembly
Figure 4-33: 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.
106.590.0
128.6
All Dimensions in Millimeters [inches]Weight: 0.9 kg [2.0 lb]
Specifications and Site RequirementsMechanical Specifications
MagneMover LITE User Manual 35Rockwell Automation 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.
159.8112.0
182.1
96.0
All Dimensions in Millimeters [inches]Weight: 1.1 kg [2.5 lb]
Specifications and Site RequirementsMechanical Specifications
36 MagneMotionRockwell Automation Publication MMI-UM002E-EN-P - March 2016
Adjustable Motor Mount Bracket
Figure 4-35: Adjustable Motor Mount Bracket Mechanical Drawing
Exposed Materials
• 6063-T5 Aluminum, black anodized.
• 304 Stainless Steel.
• 18-8 Stainless Steel.
• Nylon.
CL
[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]
Specifications and Site RequirementsMechanical Specifications
MagneMover LITE User Manual 37Rockwell Automation Publication MMI-UM002E-EN-P - March 2016
Pallet
Figure 4-36: Precision 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.
62.0MIN
2X18.5
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
CL
PAYLOAD
0.1
4X FORSKI MOUNT
8.0
All Dimensions in Millimeters
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38 MagneMotionRockwell Automation Publication MMI-UM002E-EN-P - March 2016
Electrical Specifications
Motors and Switches
250 mm Motor (Rail and Railless) – 36 VDC ±10%, 0.4 A typ, 1.2 A max.Refer to 250 Millimeter Motor on page 4-5 and 250 Millimeter Railless Motor on page 4-6 for the mechanical drawings.
1000 mm Motor (Rail and Railless) – 36 VDC ±10%, 1.5 A typ, 5.0 A max.Refer to 1000 Millimeter Motor on page 4-3 and 1000 Millimeter Railless Motor on page 4-4 for the mechanical drawings.
125 mm R 90° Curve Motor (Rail and Railless) – 36 VDC ±10%, 0.4 A typ, 1.2 A max.Refer to 125 Millimeter Radius 90° Curve on page 4-7 and 125 Millimeter Radius 90° Curve Railless Motor on page 4-8 for the mechanical drawings.
Switch (Rail only) – 36 VDC ±10%, 1.5 A typ, 5.0 A max.Refer to 90° Left Switch on page 4-9 and 90° Right Switch on page 4-10 for the mechanical drawings.
NOTE: The motors and switches 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 limit inrush current upon application of power. Limit cycling of the propulsion power to three times or less per minute to allow the PTC to cool-down. The PTC is only used for inrush current limiting and is bypassed in nor-mal operation.
Providing a separate power source for the logic power allows the motors to be pro-grammed and configured without enabling the propulsion power.
When using separate power sources for logic and propulsion power, the propulsion power return should be tied to ground while the logic return can be left floating.
Table 4-1: MagneMover LITE Motor and Switch Power Requirements
Component Maximum Power
250 mm Motor 5 W*
1000 mm Motor 10 W*
125 mm R 90° Curve Motor 5 W*
Left Switch 10 W*
Right Switch 10 W*
Specifications and Site RequirementsElectrical Specifications
MagneMover LITE User Manual 39Rockwell Automation Publication MMI-UM002E-EN-P - March 2016
To remove propulsion power to the motors, the MM LITE power supply (refer to MM LITE Power Supply on page 4-44) has a propulsion power DC Enable input which turns the propul-sion power on/off on the DC side. If the DC Enable is not used, MMI recommends removing power from the AC side of the power supplies. However, if power must be switched on the DC side of the power supply because AC power cannot be turned on/off, then it is acceptable to switch the DC power using appropriately rated solid-state relays.
Vehicle, 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 atmaximum acceleration the additional power drawn can be asmuch as 35 W per magnet array. When multiple magnet arraysare on the motor at the same time the amount of power drawnper array will increase as the arrays get closer to each other.
NOTICE
Never disable propulsion power by switching the propulsion input pin of themotor from the DC power source directly to ground as this will producelarge current spikes that will damage the electronics.
NOTICE
Any user-supplied power supply must be NRTL/ATL approved.
NOTICE
Hot-plugging of either power source to the motors is not recommended.
Table 4-1: MagneMover LITE Motor and Switch Power Requirements (Continued)
Component Maximum Power
Specifications and Site RequirementsElectrical Specifications
40 MagneMotionRockwell Automation Publication MMI-UM002E-EN-P - March 2016
Straight and Curve Motors
Refer to 1000 Millimeter Motor through 125 Millimeter Radius 90° Curve Railless Motor for mechanical drawings.
NOTE: The motors draw an additional 15 W of power per vehicle (puck) when the vehicle is moving at maximum acceleration or velocity (refer to Table 4-1).
Figure 4-37: MagneMover LITE Motor Electrical Connections
Table 4-2: 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.
External Synchronization Micro-Mizer, 8-Pin, Male
Power
Communication
Sync Option
Power
Sync Option
Straight Motor Sections
Curve Motor Sections
Bottom View
Bottom View
CommunicationConnector
Connector
Connector
Connector
Connector
CommunicationConnector
Connector
CommunicationConnector
Specifications and Site RequirementsElectrical Specifications
MagneMover LITE User Manual 41Rockwell Automation Publication MMI-UM002E-EN-P - March 2016
Table 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
12Keyway
Specifications and Site RequirementsElectrical Specifications
42 MagneMotionRockwell Automation Publication MMI-UM002E-EN-P - March 2016
Switches
Refer to 90° Left Switch on page 4-9 and 90° Right Switch on page 4-10 for mechanical draw-ings.
NOTE: The switches draw an additional 15 W of power per vehicle (puck) when the vehicle is moving at maximum acceleration or velocity (refer to Table 4-1).
Figure 4-38: MagneMover LITE Switch Electrical 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, Female, IP-67
Power
Curve Section
Bottom View (Left Switch Shown)
Communication
Straight SectionCommunication
Connector
Connector
Connector
Curve SectionCommunicationConnector
Straight SectionCommunicationConnector
EthernetConnector
Specifications and Site RequirementsElectrical Specifications
MagneMover LITE User Manual 43Rockwell Automation Publication MMI-UM002E-EN-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
Specifications and Site RequirementsElectrical Specifications
44 MagneMotionRockwell Automation Publication MMI-UM002E-EN-P - March 2016
MM LITE Power Supply
100 - 240 VAC @ 50 - 60 Hz, single phase (phase to phase or phase to neutral), 8.5 A based on configuration and operating mode. Inrush current 35 A/110 VAC, 70 A/220 VAC max. Refer to MM LITE Power Supply on page 4-25 for the mechanical drawing.
The actual power being drawn depends upon operations being performed, however all power wiring must be capable of carrying the full load.
Each MM LITE Power Supply 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 300W DC output).
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.
NOTICE
The MM LITE Power Supply uses an internal NRTL/ATL approved powersource. If a user-supplied power supply is used in its place it must beNRTL/ATL approved.
Specifications and Site RequirementsElectrical Specifications
MagneMover LITE User Manual 45Rockwell Automation Publication MMI-UM002E-EN-P - March 2016
Figure 4-39: MM LITE Power Supply Electrical Connections
Table 4-10: MM LITE Power Supply Connections
Label Description Connector Type
J1 Motor power• V+ Propulsion – 36 VDC ±1%, 300W• V+ Logic – 36 VDC ±1%
Screw terminals
J2
J3 100 - 240 VAC~, 50 - 60 Hz, 8.5 A 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 VDC300W / 8A MAX
36 VDC300W / 8A MAX
J1 J2
GND
V+PROPULSION
V+LOGIC
V-RETURN
V+LOGIC
V-RETURN
V+PROPULSION
AC Power
DC Enable
Motor Power
Motor Power
Front View
F3LOGIC
T, 250V, 10A
F1PROPULSION 1
T, 250V, 10ALOGIC
PROPULSIONF2
PROPULSION 2T, 250V, 10A
SEE
MAN
UAL
FOR
FILT
ER M
AINT
ENAN
CELOGIC
Rear View
PROPULSION
J3
J1
J2
J4
Specifications and Site RequirementsElectrical Specifications
46 MagneMotionRockwell Automation Publication MMI-UM002E-EN-P - March 2016
AC Power Cable
The MM LITE Power Supply is supplied with a power cable. Contact MagneMotion for replacement cables. The AC power cable plugs directly into the power supply.
NOTE: There is no need for the user to construct the 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-rent is 10mA max.
2 RTN
3 +Bus Enable†
† Can be shorted via a transistor to enable propulsionpower. The sinking current is 20mA max.
4 -Bus Enable†
5 —
6 —
7 —
8 —
9 —
78
23
Specifications and Site RequirementsElectrical Specifications
MagneMover LITE User Manual 47Rockwell Automation Publication MMI-UM002E-EN-P - March 2016
Motor Power Cable
The MM LITE Power Supply is supplied with a Motor Power cable, which provides power to the MagneMover LITE motors and switches. Contact MagneMotion for replacement cables. The Motor Power 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 Green 4 4 4
Mini-MizerFemale
Mini-MizerFemale
Mini-Mizer
Mini-Conn X
Mini-Mizer
Female
MaleFemale
Mini-MizerMale
4
3
1
2
Keyway
1
2
4
3
Key
4
3
1
2
Keyway
Specifications and Site RequirementsElectrical Specifications
48 MagneMotionRockwell Automation Publication MMI-UM002E-EN-P - March 2016
DC Enable
The DC Enable connector (J4) is used to monitor the status of the power supply and to control the motor propulsion power from the MM LITE power supply to the motors remotely. Refer to Figure 4-39 on page 4-45 for the location of this connection.
A user-supplied cable can be used to provide remote DC Enable functionality. This functions to enable or remove propulsion power. If vehicles are moving on the system and propulsion power is removed, the vehicle motion is longer be controlled by the system, and vehicles will glide to a stop depending on their payload and motion prior to the loss of power. The 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 be constructed using 22 AWG wire for each pin on the connector that is wired, with a maximum length of 10 meters.
Figure 4-41: DC Enable Circuit
DC Enable Jumper Plug
The DC Enable jumper plug is used when remote control and monitoring of the motor propul-sion power is not required. This jumper (provided by MagneMotion) is used in place of the DC Enable cable and is permanently plugged into J4 on the MM LITE power supply.
Figure 4-42: DC Enable Jumper
DC-OK
RTN
+Propulsion Bus Enable
–Propulsion Bus Enable
DC Motor Power Monitor
Power Supply1
2
3
4
1
Specifications and Site RequirementsElectrical Specifications
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NC-12 Node Controller
22 - 30 VDC, 20 W maximum based on configuration and operating mode. Refer to NC-12 Node Controller on page 4-21 for the mechanical drawing.
AC Power Option
The optional remote power supply for the NC-12 Node Controller requires 90 - 264 VAC @ 47 - 63 Hz, single phase (phase to phase or phase to neutral), 0.7 A at 100 VAC (25 W max), based 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 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 power must be disconnected before servicing.
NOTICE
Any user-supplied power supply must be NRTL/ATL approved.
NOTICE
The NC-12 Node Controller does not support Power over Ethernet (PoE).Connecting the controller to a powered Ethernet network may damage it.
NOTICE
Connecting to the DC power connector on the NC-12 Node Controller mustbe done with the power supply off. Connecting with the power supply onmay cause a short circuit at the connector, which may damage the powersupply or any other equipment being powered by that power supply.
Specifications and Site RequirementsElectrical Specifications
50 MagneMotionRockwell Automation Publication MMI-UM002E-EN-P - March 2016
Figure 4-43: NC-12 Node Controller Electrical Connections and Indicators
Table 4-15: NC-12 Node Controller Connections
Label Description Connector Type
CONSOLE External terminal DE-9, Male
ETHERNET Ethernet – 10/100/1000 BaseTx RJ-45, Female, IP-67*
* IP-67 mating connector is not required.
DIGITAL I/O Digital I/O, refer to Digital I/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 evennumber 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‡
‡ MagneMotion requires grounding the NC-12 through the ground stud.
Table 4-16: NC-12 Node Controller Indicators
Label Description Indicator Type
PWR ON – Indicates DC power is on. Green LED
EthernetConsole
RS-422Digital I/ORS-232
Front View
Ground
PowerIndicator
DC Power
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MagneMover LITE User Manual 51Rockwell 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 53
8 1
Specifications and Site RequirementsElectrical Specifications
52 MagneMotionRockwell Automation Publication MMI-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 53
3
4
1
2
Pin
Sleeve
Specifications and Site RequirementsElectrical Specifications
MagneMover LITE User Manual 53Rockwell 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.
Specifications and Site RequirementsElectrical Specifications
54 MagneMotionRockwell Automation Publication MMI-UM002E-EN-P - March 2016
Node Controller LITE
7 - 18 VDC, 5 W maximum based on configuration and operating mode. Refer to Node Con-troller LITE on page 4-23 for the mechanical drawing.
AC Power Option
The optional remote power supply for the Node Controller LITE (NC LITE) requires 90 - 264 VAC @ 47 - 63 Hz, single phase (phase to phase or phase to neutral), 0.7 A at 100 VAC (25 W max), based 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 the MMI custom Power over Ethernet (PoE) switch or by a compatible PoE network. The remote power supply is not required in these cases.
CAUTION
High Voltage Hazard
90 - 264 VAC, 25 W
AC power must be disconnected before servicing.
NOTICE
Any user-supplied power supply must be NRTL/ATL approved.
Specifications and Site RequirementsElectrical Specifications
MagneMover LITE User Manual 55Rockwell Automation Publication MMI-UM002E-EN-P - March 2016
Figure 4-44: Node Controller LITE Electrical Connections
Table 4-22: Node Controller LITE Connections
Label Description Connector Type
LAN Ethernet – 10/100 BaseTx(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 andthe even number (female) connectors be used for downstream connections.
Table 4-23: Node Controller LITE Power Pinout
2.0 mm Coax, Male
PWR Pin
RTN Sleeve
PWRLAN
18 VDC PoE ONLY CONSOLE
Power
RS-422
LAN
Front View
Back View
(18 VDC PoE)Console
Pin
Sleeve
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56 MagneMotionRockwell 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 53
Specifications and Site RequirementsElectrical Specifications
MagneMover LITE User Manual 57Rockwell Automation Publication MMI-UM002E-EN-P - March 2016
AC Power Cable
The Node Controller LITE optional remote power supply is supplied 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
TxD- 8 RxD- 8
— 9 — 9
2 3
7 8 78
23
Specifications and Site RequirementsElectrical Specifications
58 MagneMotionRockwell Automation Publication MMI-UM002E-EN-P - March 2016
Ethernet Switch with Power over Ethernet Injector
The remote power supply for the Ethernet switch requires 85 - 264 VAC @ 47 - 63 Hz, single phase (phase to phase or phase to neutral), <1.0 A rms (100 W max), based on configuration and operating mode. Inrush current <37 A at 230 VAC cold start.
The actual power being drawn 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 power supply.
NOTICE
The voltage provided by the Power over Ethernet switch is non-standard(18 VDC) and the switch does not disable power at any port.
Connecting any device other than a Node Controller LITE to the PoE switchmay damage the device.
Specifications and Site RequirementsElectrical Specifications
MagneMover LITE User Manual 59Rockwell Automation Publication MMI-UM002E-EN-P - March 2016
Precision Locator
There is no electrical power requirement for the Precision Locator, refer to Pneumatic Specifi-cations for the pneumatic power requirements. Refer to Precision Locator Option 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 Sensor Indicators
Label Description Indicator Type
— ON – Indicates sensor is active. Red LED
Cylinder Up
Cylinder Down
Sensor Connection
Sensor Connection
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60 MagneMotionRockwell 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
Specifications and Site RequirementsPneumatic Specifications
MagneMover LITE User Manual 61Rockwell Automation Publication MMI-UM002E-EN-P - March 2016
Pneumatic Specifications
Precision Locator
2.03 cc3/sec @ 0.41 mPa [0.0043 scfm @ 60 psi] per cycle @ 21° C [70° F] @ sea level based on configuration and operating mode. Refer to Precision Locator Option on page 4-34 for the mechanical 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 toarm 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 [0.315 in]
Vertical Clamping Force 330 N [74 lbf]
Table 4-31: Precision Locator Connections
Label Description Connector Type
— Close Rc 1/8 in Thread
— Open Rc 1/8 in Thread
Open
Close
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Communications
Ethernet Connection
The NC LITE Node Controller supports Ethernet connections of 10/100 Mb/s (auto-negotia-tion supported). The NC12 Node Controller supports Ethernet connections of 10/100/1000 Mb/s (auto-negotiation supported). Network communications provides the abil-ity to connect a number of different devices to a factory controller using a single communica-tions cable, which simplifies wiring. Each device connected to the network has a unique network device address. Only communications addressed to a specific device through the net-work are received by that device.
The Ethernet connection provided by the Node Controllers supports both of MagneMotion’s proprietary TCP/IP and EtherNet/IP communication protocols. Typically, TCP/IP is used by PC-based Host Controllers and EtherNet/IP is used by PLC-based Host Controllers. Note that the Node Controllers always use TCP/IP for communication between Node Controllers. In sit-uations where the Host Controller is unavailable, a personal computer running a network com-munications application, such as MagneMotion’s NCHost, may be connected to the transport system network.
NOTE: While both TCP/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 the LAN port. Refer to Figure 4-43 and Figure 4-44 for the locations of these connections.
NOTE: To establish a direct communications link from a PC to any Node Controller using Ethernet, a standard Ethernet cable may be used (auto-MDIX is supported).
TCP/IP Communication
TCP/IP communication is supported for use when the Host Controller is PC-based or for some PLCs that use TCP/IP. TCP/IP communications allows the Host Controller to communicate with the High Level Controller (HLC) using the commands detailed in the Host Controller TCP/IP Communication Protocol User’s Manual and the Mitsubishi PLC TCP/IP Library User’s Manual. TCP/IP communications is also used between the Node Controllers and the Node Controller designated as the High Level Controller.
NOTE: There is one Host control connection and four Host status connections on the HLC. If a second Host attempts to connect to the Host control TCP/IP port, it will cause the first Host to be disconnected. If a fifth connection to the status TCP/IP port is attempted, it will cause the first status connection to be disconnected.
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The connection to all Node Controllers uses standard Ethernet network wiring. Note that if more than one Node Controller is connected to the same network the IP address of each addi-tional Node Controller must be changed to a unique address to avoid IP conflicts. The TCP/IP address used on the Node Controller(s) must be configured as specified in the Node Controller Web Interface User’s Manual.
EtherNet/IP Communication
EtherNet/IP communication is supported for use when the Host Controller is PLC-based. Eth-erNet/IP communications allows the Host Controller to communicate with the High Level Controller using the memory-mapped tags detailed in the Host Controller EtherNet/IP Com-munication Protocol User’s Manual.
The connection to the Node Controller acting as the High Level Controller from the Host Controller uses standard Ethernet network wiring. The EtherNet/IP address used on the Node Controller configured as the High Level Controller must be configured as specified in the Node Controller Web Interface User’s Manual.
RS-232 Serial Interface Connection
RS-232 serial communications on 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 locations of these connections on the motors and switches. Refer to Figure 4-43 through Figure 4-44 for the locations of these connections on the Node Controllers.
NOTE: There is no need to construct the RS-422 cables as all cabling is supplied with the transport system. Contact MagneMotion for additional or replacement cables.
The RS-422 serial cables for upstream connections connect to the Node Controller using either a 9-pin female ‘D’ connector on the end that plugs into the Node Controller LITE at any of the odd numbered RS-422 ports or a 4-pin female M8 connector on the end that plugs into the NC-12 Node Controller at any of the RS-422 ports. The RS-422 serial cables connect to the MagneMover LITE motor using a 4-pin female M8 connector on the cable plugs into the first motor on the Path at the upstream communication port.
The RS-422 daisy-chain cables use a 4-pin female M8 connector that plugs into one motor at the downstream end and another 4-pin female M8 connector that plugs into the next motor in the chain at the upstream end.
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The RS-422 serial cables for downstream connections connect to the Node Controller using either a 9-pin male ‘D’ connector on the end that plugs into the Node Controller LITE at any of the even numbered RS-422 ports or a 4-pin female M8 connector on the end that plugs into the NC-12 Node Controller at any RS-422 ports. The RS-422 serial cables connect to the MagneMover LITE motor using a 4-pin female M8 connector on the end that plugs into the 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 LITE Node Controller.
Figure 4-47: RS-422 Cables
Table 4-32: RS-422 Cable Pinouts
M8 Nano-Mizer, 4-Pin, Female
DE-9, Male DE-9, FemaleM8 Nano-Mizer,
4-Pin, Female
End ‘A’ End ‘B’ End ‘B’ End ‘B’
RxD+ 1 TxD+ 3 7 3
RxD- 2 TxD- 8 2 4
TxD+ 3 RxD+ 7 3 1
TxD- 4 RxD- 2 8 2
DE-9M
DE-9F
Nano-Mizer FNano-Mizer F
Nano-Mizer F
Nano-Mizer F
End ‘A’ End ‘B’(Motor) (Node Controller)
1
2
3
42 3
7 8 78
23
1
2
3
4
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Sync Connection
The optional Sync connection provides a method to directly connect a motor to the Host Con-troller to allow the controller to synchronize the positioning of vehicles (pucks) on the motor with an external mechanism. Refer to the LSM Synchronization Option User’s Manual for cable and connection details.
NOTE: There is no need to construct the sync cables as all cabling is supplied with the trans-port system. Contact MagneMotion for additional or replacement cables.
Digital I/O Connection
The NC-12 Node Controller provides 16 optically isolated digital input bits and 16 optically isolated digital output bits. These signals can be used as required. Typical applications include wiring E-Stops and Light Stacks.
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 digital inputs can also be wired as a source where +3 - 24 VDC is wired to the COM and the appropriate input is wired through the signal to ground as shown in Fig-ure 4-48.
NOTE: The GND pin on the Node Controllers is not used for the digital inputs even though there is a spring clamp on the “Inputs” side for GND.
The digital outputs can only be wired as a sink where a +5 - 35 VDC supply is wired through a load and sunk when the digital output in use is turned on by the Node Controller as shown in Figure 4-48.
1.2K Ohm
1.2K Ohm
Signal
COM
+3 - 24 VDCSignal
+3 - 24 VDCCOM
RTN
RTN
Digital Inputs Digital Outputs
+DC (5-35V)
Load
VDD
DOn
DarlingtonSink Driver
PC 817
V5V
RTN
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Site Requirements
Environment
Motors
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 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° 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)
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Precision Locator
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)
Magnet Arrays, Pucks, Precision Rail Vehicles
Temperature:
Operating: 0° C to 50° C [32° F to 122° F]Shipping: -18° C to 60° C [0° F to 140° F]Storage: -18° C to 60° C [0° F to 140° F]
Humidity:
85% Maximum (relative, non-condensing)
Lighting, Site:
No special lighting is required for proper operation of the MagneMover LITE transport sys-tem. Maintenance may require a user-supplied service lamp (e.g., flashlight).
Floor Space and Loading
The 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 motors and components only. It is the user’s responsibility to ensure adequate space around the equipment for operation and service based on their needs and any vehicle overhang.
Facilities
The user is responsible for providing the facilities specified in Electrical Specifications on page 4-38 and Pneumatic Specifications on page 4-61 to ensure proper operation of the Mag-neMover LITE motors and other components. Refer to Facilities Connections on page 5-60 for the connection of all facilities to the MagneMover LITE transport system.
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The facility is responsible for the main disconnect device between the MagneMover LITE transport system and the facility’s power source, ensuring it complies with the appropriate facility, local, and national electrical codes. Service to the MagneMover LITE transport sys-tem should have the appropriate circuit breaker rating.
Service Access
The MagneMover LITE transport system requires adequate space for service access and for proper operation. 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 installed so that it provides access to items required for service after installation, such as power and communication connections.
NOTE: The Exclusion Zones shown are for the MagneMover LITE transport system compo-nents only. Additional exclusion zones may be required based on the design of a cus-tom vehicle and the material being transported on the MM LITE transport system.
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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.
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Unpacking and Inspection
The MagneMover LITE transport system components are shipped in separate packages. Open each package carefully following the steps provided in Unpacking and Moving on page 5-3; inspect and verify the contents against the shipping documents. Report any damage immedi-ately to the shipper and to MagneMotion.
One set of shipping documents is attached to the outside of the main shipping crate for easy access.
NOTE: The number and contents of the shipping packages depends on the items purchased and their configuration (i.e., shipped as components or shipped as a system). Refer to the shipping documents for 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
MagneMover LITE pucks/magnet arrays for moving material on the transport system.
Node Controllers MagneMotion Node Controllers for managing the Nodes in the transport system.
Power Supplies MagneMotion power supplies to provide logic and propulsion power to the MagneMover LITE motors.
Installation Kit • Miscellaneous hardware.• Cables.• User’s Manuals, drawings, etc.
Precision Rail Option • Straight and Curve Rails.• Post and Post/Mount Assemblies.• Spine Plates.• Vehicles.
Precision Locator Option • Precision Locator.• Locator Stand.• Adjustable Motor Mount(s).
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Unpacking and Moving
Required Tools and Materials
• Open End Wrench, Adjustable.
• Metric Hex wrenches.
Unpacking and Moving Instructions
The MagneMover LITE transport system may arrive from the factory as a set of pre-assem-bled components or as a set of individual components ready for final installation. The infor-mation required to install these components is provided in Transport System Installation on page 5-5.
CAUTION
Strong Magnets
To avoid severe injury, people with pacemakers and othermedical electronic implants must stay away from the magnetarray 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 damage to watches, electronic instruments, andmagnetic media (e.g., cell phones, memory disks/chips,credit cards, and tapes) keep these items away from the mag-net arrays.
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NOTE: Save the shipping packaging for possible future use. If any part of the MagneMover LITE components are shipped, the original shipping packaging must be used. If the original packaging has become lost or damaged, contact MagneMotion for replace-ments.
1. Upon receiving the packages, visually verify the packaging is not damaged. Inform the freight carrier and MagneMotion of 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 can weigh asmuch as 14.5 kg [32 lb]. Failure to take the proper precau-tions before moving them could result in personal injury.
Use proper lifting techniques when moving any Magne-Mover LITE components. Steel toe shoes should be worn atall times when installing the MagneMover LITE.
kg
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Transport System Installation
The MagneMover LITE transport system must be properly located in the facility so that other equipment can interface to it as required. The location must also ensure that there is adequate space for service access and for proper operation. Ensure that installation of the MagneMover LITE components provides access to items required for service after installation, such as con-nection panels. Once properly located, the MagneMover LITE transport system should be lev-eled and secured to the floor or other rigid mounting points designed as part of the system to prevent any movement.
Installing Hardware
These hardware installation procedures assume use of the MagneMover LITE stand system to support the motors and switches.
To install 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 to the appropriate torque specification and do not need to be tightened during installation.
When performing any of the following procedures, adhere to and follow all safety warnings and instructions.
Required Tools and Materials
• Metric Hex wrench set.
• Torque wrench (0.9 - 26 N-m [8 - 230 in-lb] range) with metric and Torx bits.
• Screwdriver, Small flat blade.
• Screwdriver, Phillips.
• 12” Machinist Square.
• Laser level, rotary.
• Digital Multimeter.
• Loctite 243, Thread locker, Anaerobic Adhesive, Blue.
• Loctite 290, Thread locker, Wicking Grade, Green (Precision Rail option only).
• Open end wrench, 13 mm, thin (Precision Rail option only).
• Ratcheting Hex wrenches; 10 mm, 13 mm, 14 mm, 17 mm.
• 000-0616-00 – Motor Alignment Fixture, ML.
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Installation Overview – User-Supplied Mounting
This provides an overview of the installation of the MagneMover LITE motors, switches, and other components on user equipment or a custom stand system.
1. Assemble a complete section of the track, including guideway, motor mounts, and stand.
2. Level the section of the track where the motors will be mounted (refer to Leveling the MagneMover LITE on page 5-15).
3. Secure the track to the floor or other equipment as required (refer to Securing the Transport System on page 5-16).
4. Install the motors and switches ensuring the guide rails are colinear to each other and the tops 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 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 installing the last motor to eliminate the need to remove a guide rail.
7. Make all communications, network, and power connections (refer to Facilities Con-nections on page 5-60).
8. Assemble the next section of the system following Step 1 through Step 7 and connect it to the previously installed section ensuring both sections are in the same plane and level to each other.
9. Continue assembling and installing sections until the system is complete.
10. Create the Node Controller Configuration File and install software (refer to Software on page 5-64).
11. Power up the system and check all operating features, safety features, and connections (refer to System Check-out on page 5-66 and System Power-up on page 5-67).
NOTICE
Ensure the equipment or stand system where the MagneMover LITE motorswill be mounted and the motor mounting surfaces are properly grounded tosafety ground (earth).
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Installation Overview – MMI Supplied Mounting
This provides an overview of the installation of the MagneMover LITE transport system using the MM LITE transport system components, including stand, beam, and motor mounts.
1. Assemble a complete section of the system stand, including the stand and beam (refer to Assembling Beams on page 5-11 and Installing System Legs on page 5-12).
2. Adjust the feet on the stand section 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 and switch motor mounts (refer to Install-ing Cable Chase Cover Brackets on page 5-18).
5. Attach the motor mounts to all motors and switches (refer to Installing Motor Mounts on Motors and Switches on page 5-19).
6. Install the motors and switches ensuring the guide rails are colinear to each other and the tops 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. Install the power supplies, Node Controllers, network switches, and cables (refer to Installing Electronics on page 5-27).
8. Make all communications, network, and power connections (refer to Connecting Motors and Electronics on page 5-32 and Network Connections on page 5-60).
9. Assemble the next section of the system following Step 1 through Step 8 and connect it to the previously installed section ensuring both sections are in the same plane and level to each other.
10. Continue assembling and installing sections until the system is complete.
11. Install the vehicles (pucks) on the system (refer to Installing Pucks/Magnet Arrays on page 5-40).
NOTE: Vehicles (pucks) should be installed on closed loop systems before installing the last motor to eliminate the need to remove a guide rail.
NOTICE
Ensure the stand system where the MagneMover LITE motors will bemounted is properly grounded to safety ground (earth).
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12. Install cable chase covers once all wiring is complete and has been tested (refer to Installing Cable Chase Covers on page 5-41).
13. Install the user-supplied electrical power and communications connections (refer to Facilities Connections on page 5-60).
14. Create the Node Controller Configuration File and install software (refer to Software on page 5-64).
15. Power up the system and check all operating, safety features, and connections (refer to System Check-out on page 5-66 and System Power-up on page 5-67).
Installation Overview – MMI Precision Rails
This provides an overview of the installation of the Precision Rail option on a MagneMover LITE transport system using railless motors.
1. Assemble a complete section of the system stand, including the stand and beam (refer to Assembling Beams on page 5-11 and Installing System Legs on page 5-12).
2. Adjust the feet on the stand section 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 Mounts on Motors and Switches on page 5-19).
6. Install the motors ensuring the motors are colinear to each other and the tops of all motors are coplanar to each other and tighten the V-braces (refer to Align and Secure Railless Motors on page 5-25).
NOTE: If motors are installed in a CIP or wash-down environment it must not exceed IP65.
7. Attach the precision rail support post assemblies to the beam (refer to Attach Precision Rail Support Posts to the Beam on page 5-46).
NOTE: All precision rail hardware should be loosely fastened (finger-tighten then back off one half turn) allowing for alignment and final adjustments once all components within the system have been assembled.
NOTICE
Ensure the stand system where the MagneMover LITE motors will bemounted is properly grounded to safety ground (earth).
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8. Attach the precision rails to the support posts (refer to Attach Rails to Spine Plates on page 5-47).
9. Install the vehicles on the system (refer to Replace Precision Rail Vehicles on page 7-45).
NOTE: Vehicles should be installed on closed loop systems before installing the last rail segment to eliminate the need to remove a guide rail or change the fac-tory settings on the vehicles.
10. Once all components are loosely fastened together make final adjustments and tighten (refer to Align and Secure Rails to Spine Plates on page 5-50 and Secure Spine Plates to Support Posts on page 5-53).
11. Install the power supplies, Node Controllers, network switches, and cables (refer to Installing Electronics on page 5-27).
12. Make all communications, network, and power connections (refer to Connecting Motors and Electronics on page 5-32 and Network Connections on page 5-60).
13. Install cable chase covers once all wiring is complete and has been tested (refer 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 System Power-up on page 5-67).
Installation Overview – MMI Precision Locator
This provides an overview of the installation of the Precision Locator option on a Magne-Mover LITE transport system. Note that the Precision Locators are typically installed on a section of the transport system, refer to Installation Overview – MMI Supplied Mounting on page 5-7 for installation of the complete MM LITE transport system.
1. Install the pallets on the pucks and install the pucks on the transport system (refer to Install Pallets and Pucks on page 5-55).
2. Install the Precision Locators on their stands (refer to Install the Precision Locators on the Stands on page 5-56).
3. Install the Precision Locators (refer to Install the Precision Locator Assemblies on page 5-56).
NOTICE
Ensure the stand system where the MagneMover LITE motors will bemounted is properly grounded to safety ground (earth).
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4. Attach the adjustable 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).
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Stand System Installation
Assembling Beams
Each beam section must be connected to the beam sections on either side of it to form the complete system layout. The layout may be broken into sections for ease of assembly. When breaking the layout into sections, ensure that each section is as self-contained as possible.
1. Place two beam sections end-to-end, ensuring that both beam sections are colinear to each other as shown in Figure 5-1.
2. The beam section for the curve motors is not symmetrical, there is a top (empty T groove) and a bottom (T groove has hardware securing 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 assembled sections, ensuring that both the new beam section and the assembled sections are colinear to each other.
5. 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.
6. Repeat Step 4 and Step 5 as needed to completely assemble the beams into a section of the system layout.
Existing Beam
New Beam Section
Connector Plate
M8 x 25 mm Screw(2X)
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Installing System Legs
Once the beam sections are assembled the legs must be attached.
1. Invert the beam and place on a clean work surface.
NOTE: Ensure the beam is inverted as some sections have an orientation and must be installed correctly to enable mounting of the motors.
2. Attach the Single Path Legs at the appropriate locations (if not already installed) as 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 over the T-nuts, 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.
Leg Stand Assembly
Beam
M8 T-Nut(2X)
M8 x 25 mm Screw(2X)
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3. Attach the Parallel Path Legs at the appropriate locations (if not already installed) as shown in Figure 5-3.
Figure 5-3: Legs on a Parallel Path Beam Assembly
A. Insert one M8 T-nut and rotate into position in the channel on the side of each 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. 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 bracket while still allowing it to move.
NOTE: Ensure the angle bracket is configured for 50 mm use by placing the inserts into the bracket with the hole in the insert to the outside of the bracket as shown in Figure 5-4.
Leg Stand Assembly
M8 T-Nut(4X)
M8 x 25 mm Screw(4X)
Beam
Angle Bracket(2X)
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14 MagneMotionRockwell Automation Publication MMI-UM002E-EN-P - March 2016
Figure 5-4: Angle Bracket Assembly
E. 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.
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MagneMover LITE User Manual 15Rockwell Automation Publication MMI-UM002E-EN-P - March 2016
Leveling the MagneMover LITE
Once the stand assembly is complete and the transport system is properly located ensure all sections of the beam are level.
1. Establish a datum for the system (interface to existing equipment, etc.).
2. Use a laser level 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 using a 14 mm Hex wrench.
C. Lock the feet into position by tightening the jam nut against the leg using a 17 mm Hex wrench.
D. Repeat for each foot.
Laser Level
12” Machinist Square
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Securing the Transport System
The MagneMover LITE transport system should be secured to the floor to prevent system movement. Two methods are available; securing the feet or using brackets to secure the legs. Additionally, the beam on the MagneMover LITE should be secured to the equipment it is interfacing with to prevent movement at the interface location by securing it directly to the equipment.
NOTE: Tie-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 leg.
2. Apply Loctite 243 to two M8 x 16 mm screws and secure the bracket to the leg using the screws and M8 washers. Tighten enough to secure the bracket while still allowing it to move vertically.
NOTICE
Ensure the transport system is properly grounded to safety ground (earth).
Leg Stand AssemblyM8 T-Nut(2X)
M8 Screw(2X)
Bracket
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3. Slide the bracket down until it makes positive contact with the floor 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. 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.
Figure 5-7: Foot Tie-down
Tie-down Location(2X)
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Motor Installation
Installing Cable Chase Cover Brackets
If cable chase covers will be used, the brackets for attaching the covers to the standard motor mounts for the curve motors and switches must be installed on all motor mounts for the curved motors and switches before installing the mounts on the motors and 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 switch motor mount using two M5 screws and tighten to 1.6 N-m [14 in-lb] using a Phillips bit.
Switch Bracket
M5 x 8 mm Screw
Curve BracketM5 x 8 mm Screw
Curve Bracket
M5 x 8 mm Screw(2X)
(2X)
(2X)
Curve Motor Mounts (typ) Switch Mounts (typ)
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Installing Motor Mounts on Motors and Switches
The motor mounts should be installed on the motors before installing the motors in the trans-port system to provide ease of installation. This procedure applies to both the standard motor mount bracket, shown in Figure 5-9, and the adjustable motor mount bracket.
NOTE: Installing the motor mounts is the same for motors with rails and for railless motors.
Figure 5-9: Installing Motor Mounts on Motors and Switches
1. Place a motor or switch upside down on a clean work surface.
2. Locate the flat end of the motor mount against the motor at the mounting hole (for adjustable 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 lock washer as shown in Figure 5-9 and finger tighten.
ATE
INTEGBURN
TESTED
?????????
Made in USA
www.magnemotion.com
XX VDC, X.X A Typ, X.X A Max
S/N:
P/N:700-1308-XX
ATE
PUCKB-IN
TESTED
?????????
www.magnemotion.com
XX VDC, X.X A Typ, X.X A Max
Power:
S/N:
P/N:
700-1308-XX
Made in USA
?????????
www.magnemotion.com
XX VDC, X.X A Typ, X.X A Max
Power:
S/N:
P/N:
700-1308-XX
Made in USA
ATE
PUCK
B-IN
TESTED
M6 x 20 mm BoltM6 Lock Washer
Straight Motors (typ) Curve Motors (typ)
Switches (typ)
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Mounting Motors and Switches
All motors and switches, with their motor mounts pre-attached, must be attached to the beam sections. Starting at one end of the system install all switches, then fill in the space between the switches with the motors.
NOTE: If Precision Locators are being used, install the locator stands before installing the motors at those locations (refer to Precision Locator Installation).
If motors or switches are being mounted to supports other than the 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 Motors and Switches
1. Insert an M8 T-nut in the top channel of the beam at the approximate location for each motor mount, refer to Table 5-2 for quantities and locations (T-nuts must be inserted so that the spring steel tabs are facing toward the beam then rotated clockwise into place).
Locating Boss
M8 x 20 mm Bolt
M8 Lock Washer
M8 T-Nut
Straight Motors (typ) Curve Motors (typ) Switches (typ)
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2. Locate the motor or switch so that the protruding boss on the standard motor mount is keyed into the beam and aligned to the T-nut, install an M8 x 20 mm bolt and M8 split lock washer as shown in Figure 5-10 and finger tighten.
3. Using the Motor Alignment Fixture adjust the position of the motor or switch along the beam so it is properly centered on the beam as 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 TypeMotor Mount
Qty Location
250 mm Motor 1 Center of beam
1000 mm Motor 2 25 cm from each end of beam
125 mm R 90° Curve Motor 1 Center of beam*
* Ensure the beam is oriented so that all internal fastening hardware in located on thebottom of the beam.
Left or Right Switch 1 Center of beam
Motor Alignment Fixture
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4. Continue 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.
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Align and Secure Motors and Switches
Once all motors and switches are properly located, either after initial installation or after maintenance or replacement, the rails on the motors must be aligned from motor to motor (or switch). When aligning and securing the ends of the rails together, a V-brace is attached over the alignment blocks on both rails on each motor.
NOTE: To align and secure railless motors, refer to Align and Secure Railless Motors on page 5-25.
Figure 5-12: Align and Secure 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 tightening.
For stainless steel rails, install the V-braces at all guide rail joints using M6 x 12 mm screws with Loctite 243 and tighten finger-tight to pull the rails together.
3. Using fingers, align the rails at the motor joints as shown in Figure 5-12. 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.
M6 x 12 mm Screw
V-Brace
(2X per V-Brace)M6 Bolt(Under Motor)
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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.
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Align and Secure Railless Motors
Once all motors are properly located, either after initial installation or after maintenance or replacement, the motors must be aligned from motor to motor. When aligning and securing the ends of two straight motors together, a V-brace is attached over the alignment blocks on both inner and outer surfaces of the motors. When aligning and securing the ends of two curved motors, or a straight motor to a curved motor, the V-brace is only attached at the outer surface of the motors.
NOTE: To align and secure motors with rails, refer to Align and 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 the top sur-face of the motors are flush with one another and the motors are coplanar. Tighten the two M6 x 10 mm screws on each V-brace at that motor joint to 3.4 N-m [30 in-lb] using a T30 Torx bit.
4. Align the straight to curve motor joints ensuring the top surface of the motors are flush with one another and the motors are coplanar. Tighten the two M6 x 10 mm screws on each V-brace at that motor joint to 3.4 N-m [30 in-lb] using a T30 Torx bit.
M6 x 10 mm Screw
V-Brace
(2X per V-Brace)
M6 Bolt(Under Motor)
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5. Align the curve to curve motor joints ensuring the top surface of the motors are flush with one another and the motors are coplanar. Tighten the two M6 x 10 mm screws on each V-brace at that motor joint to 3.4 N-m [30 in-lb] using a T30 Torx bit.
6. Tighten the M6 bolt securing the motor to the motor 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 motors and switches are installed the guideway must be checked to ensure proper movement of the vehicles (pucks) throughout the transport system. Run a vehicle (puck) through the system to verify proper movement with no binding.
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Installing Electronics
The electronics for the MagneMover LITE transport system can be attached to the transport system stands or positioned elsewhere in the facility in an appropriate location.
Installing Electronics on the Transport System
The MagneMover LITE motor stands are designed to accept mounting of all the electronic components of the transport system (Node Controllers, network switches, and power sup-plies).
Mounting Node 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 horizontally between two parallel track sections as shown in Figure 5-14.
Figure 5-14: Node Controller LITE Mounting
NOTICE
Ensure all mounting surfaces and mounting hardware provide a conductivepath to the transport system ground connection.
PWR
LAN
18 VDC PoE ONLY
M8 Lock Washer
M8 T-Nut(2X)
M8 Screw(2X)
M5 Screw(2X)
(2X)
M5 T-NutCable Tie Holder
M5 Screw
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1. Insert two M8 T-nuts and rotate into position in the appropriate channel(s) of the frame.
2. Secure the bracket (refer to Figure 4-22 on page 4-24) to the T-nuts, apply Loctite 243 to two M8 screws and install with M8 split lock washers and tighten the screws to 26 N-m [230 in-lb] using a 6 mm Hex bit.
3. Install the mounting flanges onto the NC LITE, if not already installed.
4. Orient the NC LITE as required and secure it to the bracket, apply Loctite 243 to two M5 x 10 mm screws and install and tighten the screws to 2.7 N-m [24 in-lb] using a 4 mm Hex bit.
NOTE: The Loctite must cure for 2 hours at 22° C [72° F] before using the transport system.
5. Install an M5 T-nut in the appropriate channel of the frame and secure a nylon cable tie holder to it using an M5 x 12 mm screw on the leg as required to secure the cables run-ning to the NC LITE using cable ties.
Mounting Node Controller LITE and NC-12 Power Supplies
If the Node Controller is powered 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 connecting to minimize the length of all wiring. The switch can be mounted to the same bracket used for the NC LITE (see Figure 5-14) and may be oriented in any direction required.
Mounting Network Switch Power Supplies
If the Network Switch is powered using the remote power supply (instead of using PoE) the power supply should be located on the transport system stand close to the switch it is power-ing to minimize the length of all wiring. The power supply may be oriented in any direction required.
NOTICE
The Node Controller LITE only supports MagneMotion’s custom Powerover Ethernet (PoE). Never connect the Node Controller LITE to a standardPoE network as damage to internal components may result.
The NC-12 Node Controller does not support Power over Ethernet (PoE).Never connect these Node Controllers to a PoE network as damage to inter-nal components may result.
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Mounting NC-12 Node Controllers
The Node Controller should be located 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 ser-vice and exclusion zones identified in Figure 4-19 on page 4-21 are maintained.
Mounting Plates
The typical method for mounting the Node Controller is vertically on one of the transport sys-tem legs by attaching the optional mounting plates as shown in Figure 5-15.
Figure 5-15: NC-12 Node Controller Mounting Plates
1. Insert two M8 T-nuts 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 and install with M8 split lock washers 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.
4. Install an M5 T-nut and secure a nylon cable tie holder to it using an M5 x 12 mm screw on the leg as required to secure the cables running to the Node Controller using cable ties.
M8 Screw(2X)
1/4-20 Flat Head Screw(4X)
Mounting Plate(2X)
M8 T-Nut(2X)
M8 Lock Washer(2X)
M5 T-Nut
Cable Tie HolderM5 Screw
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Mounting Brackets
The NC-12 may be mounted in a standard 19 inch rack by attaching the optional rack mount-ing brackets as shown in Figure 5-16.
Figure 5-16: NC-12 Node Controller Mounting Brackets
Install the mounting brackets 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 cable management as required to secure the cables running to the Node Con-troller.
Attachment Screw(4X)
Mounting Bracket(2X)
M5 x 10 mm(4X)
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Mounting Power Supplies
The power supply should be located on the transport system stand close to the Paths it is pro-viding power for to minimize the length of all wiring. The power supply may be oriented in any direction required 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 screws on each end of the bottom using a Phillips bit.
Bracket
M8 T-Nut(2X)
M8 Screw(2X)
Power Supply Screw(6X)
M8 Lock Washer(2X)
(2X)
M5 T-NutCable Tie Holder
M5 Screw
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3. Install the mounting flanges onto the power supply using the screws from the bottom using Loctite 243 and tighten the screws to 0.9 N-m [8 in-lb] using a Phillips bit.
4. Orient the power supply as required and secure it to the T-nuts, apply Loctite 243 to two M8 screws and install with M8 split lock washers 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.
5. Install an M5 T-nut and secure a nylon cable tie holder to it using an M5 x 12 mm screw on the leg as required to secure the cables running to the power supply using cable ties.
Connecting Motors and Electronics
The MagneMover LITE transport system uses daisy-chained communication with all motors 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 provides the information required to make all motor connec-tions as shown in Figure 4-1 through Figure 4-8 and Figure 4-43 and Figure 4-44.
NOTICE
Never connect or disconnect the power lines with power applied to theMagneMover LITE transport system as damage to internal components mayresult.
NOTICE
The Node Controller LITE only supports MagneMotion’s custom Powerover Ethernet (PoE). Never connect the Node Controller LITE to a standardPoE network as damage to internal components may result.
The NC-12 Node Controller does not support Power over Ethernet (PoE).Never connect these Node Controllers to a powered Ethernet network asdamage to internal components may result.
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Figure 5-18: Simplified Representation of Motor Connections
Figure 5-19: Simplified Representation of Merge Switch Connections
To next motorin Path
NC PS
DownstreamUpstream(Simple
Node)
Power Connection
Communication Connection
Motor Section(Straight or Curve)
Motor Section(Straight or Curve)
DownstreamUpstream
PS
Upstream
Upstream
Motor Section(Straight or Curve)Motor Section(Straight or Curve)
Switch Section(Merge)
Mot
or S
ectio
n(S
trai
ght o
r C
urve
)
From previous
From previousmotor in Path
motor in PathTo next motorin Path
Motor Section(Straight or Curve)
Switch Configuration
Downstream
NC
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Installing Motor Communications Cables
Refer to Figure 4-1 on page 4-3 through Figure 4-8 for the communication connection loca-tions on the motors and switches and Figure 4-43 and Figure 4-44 for the communication con-nection locations on the Node Controllers in the MagneMover LITE transport system. Refer to Figure 5-18 and Figure 5-19 for simplified diagrams of the wiring and to Figure 5-20 for a detailed example. Note that the connections for a diverge switch are different than the connec-tion shown in Figure 5-19 for a merge switch.
NOTE: Both ends of a Path do not need to connect 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 upstream end of the first motor in a Path (as defined in the transport system layout drawing) and route the cable in the cable chase (refer to Figure 5-20).
• For an NC-12 Node Controller, connect to any RS-422 port, finger tighten only.
Upstream
Upstream
Downstream
Upstream
Downstream Connection
External Communications Cable(typical)
Downstream
Connection
Connection
Node Controller
1 meter Motor
1/4 meterMotor
Downstream
Upstream
Connection
Connection
(NC-12 Shown)
Connection
Internal Communications Cable(typical)
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• For a Node Controller LITE, typically connect to either J1 or J3 using a small screwdriver - do not overtighten.
• Record the Node Controller number from the transport system layout and the Port number from the Node Controller for entry into the Node Controller Con-figuration File.
NOTE: When using an NC LITE, a custom cross-over gender changer may be used when connecting the upstream end of a Path to one of the Node Controller’s even (downstream) ports.
2. Connect a communication cable from the downstream end of the motor to the upstream end of the next motor in the Path; finger-tighten – do not use tools to tighten, and route the cable in the cable chase.
3. Continue to connect the remaining motors in the Path using the communication cables.
4. Connect an external communications 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.
• Record the Node Controller number from the transport system layout and the Port number from the Node Controller for entry into the Node Controller Con-figuration File.
NOTE: When using an NC LITE, a custom cross-over gender changer may be used when connecting the downstream end of a Path to one of the Node Controller’s odd (upstream) ports.
5. Repeat Step 1 through Step 4 for each Path in the MM LITE transport system.
NOTE: The motors at the ends of all Paths connected in a Node must be connected to the same Node Controller.
6. Bundle and dress all cables (use nylon cable-ties) as needed to ensure clean cable rout-ing.
7. Refer to Facilities Connections on page 5-60 for external communications connec-tions.
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Installing Network Communications Cables
Refer to Figure 4-43 on page 4-50 through Figure 4-44 for the network connection locations on the Node Controllers in the MagneMover LITE transport system. Refer to Figure 5-42 for a simplified diagram of the network wiring.
NOTE: The transport system’s network should be a dedicated, separate subnet to eliminate any extra network traffic.
1. Connect a Category 5 (Cat 5) network cable for network communications from a dedi-cated standard Ethernet switch to ETHERNET on each NC-12 Node Controller (auto-MDIX and auto-negotiation are 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, connect a Cat 5 network cable for network communications from a dedicated standard Ethernet switch to LAN on each Node Controller LITE.
3. Bundle and dress all cables (use nylon cable-ties) as needed to ensure clean cable rout-ing.
4. Refer to Facilities Connections on page 5-60 for external network connections.
NOTICE
The NC-12 Node Controller does not support Power over Ethernet(PoE). Never connect these Node Controllers to a standard PoE net-work as damage to internal components may result.
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Installing Digital I/O Wiring
Wiring for discrete digital inputs and outputs can be connected to the NC-12 Node Controllers and used for E-Stops, Interlocks, Light Stacks, and general purpose I/O. Refer to Figure 4-43 for the Digital I/O connection locations on the NC-12 Node Controller.
To make Digital 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 seated, release and remove the screwdriver. Note, ensure the connector blades are making direct contact with the wire and not contacting the insulation.
Figure 5-21: Digital I/O Connections
Connector Release
Connector
Connector Release
Connector
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38 MagneMotionRockwell Automation Publication MMI-UM002E-EN-P - March 2016
Installing Motor Power Cables
Refer to Figure 4-1 on page 4-3 through Figure 4-8 for the power connection locations on the motors and switches in the MagneMover LITE transport system and Figure 4-39 for the power connection locations on the power supply. Refer to Figure 5-18 and Figure 5-19 for simplified diagrams of the wiring. Figure 5-22 shows the power connections being made to the bottom of the motor.
Figure 5-22: Power Connections
NOTE: The AC power connections will 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 the power supply at one time (20 motors per power supply).
NOTICE
If a user-supplied power supply is used it must be NRTL/ATL approved.
J1
J2
GNDJ4 DC ENABLE
(SEE MANUAL FOR PINOUT)
36 VDC 300W
36 VDC 300W
GND
V+PROPULSION
V+LOGIC
V-RETURN
V+
LOGIC
V-
RETURN
V+
PROPULSION
J3
Motor Power Connector
Power
Power Bus Cable
T-Splitter Power Cable
Power Bus End Cap
Power Cable
SupplyGround
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1. Connect a power cable to either the J1 or J2 terminals on the power supply. Refer to the labels on the wires to identify the correct connections (refer to Figure 4-39 on page 4-45 and Figure 4-40).
2. Run the power cable from the power supply to the first motor in the Path, routing the cable in the cable chase.
3. Connect a T-splitter power cable to the motor; finger-tighten – do not use tools to tighten.
4. Connect the power cable to the T-splitter power cable; finger-tighten – do not use tools to tighten.
5. Connect a power bus cable to 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 connect all of the motors on a Path to the same power supply or to connect a power supply to only one Path.
9. Install a power bus end cap at the end of each power run to seal the cable; fin-ger-tighten – do not use tools to tighten.
10. Connect the Ground stud on all NC-12 Node Controllers to GND (PE).
11. Bundle and dress all cables (use nylon cable-ties) as needed to ensure clean cable rout-ing.
12. Refer to Facilities Connections on page 5-60 for external power connections.
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Installing Pucks/Magnet Arrays
Magnet Array Installation
The magnet arrays are supplied with threaded standoffs for locating and securing to the mounting surface of the vehicle (refer to Figure 4-17 on page 4-19 and Figure 4-18 on page 4-20). Mount the magnet arrays to the vehicles as defined by the design of the vehicle.
Puck Installation
Pucks (the vehicle used to transport material through the MagneMover LITE transport sys-tem) can easily be added or removed as needed once the MM LITE transport system is com-pletely installed.
NOTE: MagneMotion recommends installing all pucks before completing motor installation on a closed-loop system by sliding them onto the transport system at the end of an installed motor and then sliding 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 severe injury, people with pacemakers and othermedical electronic implants must stay away from the magnetarray 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 damage to watches, electronic instruments, andmagnetic media (e.g., cell phones, memory disks/chips,credit cards, and tapes) keep these items away from the mag-net arrays.
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Installing Cable Chase Covers
The cable chase covers provide protection to all of the cables routed under the motors and ensure that all cabling remains neatly organized.
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-lb] using a Phillips bit.
• 4 screws per 250 mm motor.
• 8 screws per 1000 mm motor.
Cover
M5 Screw(4X)
(2X)
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Curved Motors
Figure 5-24: Installing Curved Motor Cable 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 CoverM5 Screw
(4X)
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Switches
Figure 5-25: Installing Switch Cable Chase 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)
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Option Installation
Precision Rail Installation
When installing the optional precision rails, ensure all previous installation steps have been completed using railless motors. A typical 2 meter loop using railless 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 the entire pre-cision rail system is in place.
Beam
Motor Mounts
V-Brace
Railless Motor(Curve)
Railless Motor(Straight)
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Assemble Precision Rail Support Posts
The precision rail support posts should be loosely assembled as shown Figure 5-27.
NOTE: This step may be skipped if the support posts are supplied pre-assembled.
Figure 5-27: Precision Rail Support Post Assembly
1. Insert two M8 T-nuts into the channel on the top of the post mount and rotate into posi-tion.
2. Loosely attach the support post to the post mount using two M8 x 16 mm SHC screws and M8 washers (finger-tighten then back off one half turn) to provide 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 con-nector plate on the post mount.
4. Position the support post base 38 mm [1.50 in] from the end of the connector plate on the post mount as shown in Figure 5-28 and tighten the M8 screws to 26 N-m [230 in-lb] using 6 mm Hex wrench.
Spine Plate
Support Post
Connector Plate
M6 x 10 mmLow Head Socket
Cap Screw (2X)
M8 x 16 mm SHC Screw(2X)
M8 T-Nut(2X)
M8 Flat Washer(2X)
Post Mount CapPost Mount
M8 T-NutM8 x 20 SHC Screw(2X)
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Figure 5-28: Precision Rail Support Post to Post Mount Spacing
Attach Precision Rail Support Posts to the Beam
Once all of the support posts are assembled they 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-NutM8 x 20 Screw
Motor
Motor Mount
Beam
Support PostAssembly
(2X)(2X)
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3. Loosely secure each support post assembly to the T-nuts using the M8 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 motor.
Attach Rails to Spine Plates
The precision rails are provided as a matched set with adjoining rail ends lettered (engraved) at the factory as A to A, B to B, C to C, etc. as shown in Figure 5-30. Rails typically attach to spine plates at a joint where two rail ends meet, as shown in Figure 5-31. However, some rails may attach to spine plates along the mid-point of a single 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 section of rail (refer to Replace Precision Rail Vehicles on page 7-45).
Ensure all rails on parallel paths are parallel.
1. Identify the letters engraved on the end of each rail segment (see Figure 5-30) and lay-out the rails so matching letters (A to A, B to B, C to C etc.) align.
NOTE: If a rail segment is not used or is mislocated, the letters between the joints will not match. In this case, during alignment and adjustment it may be nec-essary to hone the ends of the mismatched rails to achieve the proper align-ment and performance.
Figure 5-30: Precision Rail End Identification
Engraved Letters
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2. When connecting a straight rail section to a curved rail section an adjustment key is used to ensure proper alignment between the sections as shown in Figure 5-31.
NOTE: The adjustment key is inserted for connecting straight rail to curved rail sec-tions only. The adjustment key is not required for other rail to rail connec-tions.
Figure 5-31: Attaching Straight Precision Rails to Curved Rails with Adjustment Key
A. Back-out the jacking screws on both sides of the curved rail.
B. Insert the large end of the adjustment key into the end of the curved 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 plate holes as shown in Figure 5-32.
NOTE: During rail adjustment and alignment, the spine plates must be loosely attached to the support post assembly to provide the parts a small amount of movement relative to each other to allow adjustment.
Prior to attaching the final rail within a closed loop system, all vehicles should be installed onto the rails. Refer to Replace Precision Rail Vehicles on page 7-45.
Straight Rail
Jacking Screw
Curved Rail
Adjustment Key
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Figure 5-32: Attaching Precision Rail to Spine Plates
4. Adjust the position of the support post assemblies as required.
5. Loosely secure the rails to the corresponding spine 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, Curve-to-Curve 4
No Joint, Straight 2
No Joint, Curve 2
Spine Plate
M5 Screw
Precision Rail
(typical)
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Align and Secure Rails to Spine Plates
Once all rails have been loosely attached to the spine plates they must be aligned and secured to the plates. The alignment sequence is:
1. Straight Rail to Curved Rail Joints
2. Curved Rail to Curved Rail Joints
3. Straight Rail to Straight Rail Joints
4. Curved Rail, No Joint Locations
5. Straight, No Joint Locations
Straight Rail to Curved Rail Joints
Refer to Figure 5-34 when aligning and securing all 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 screw on the other side of the rail to align the two rail section.
2. Once the rails are aligned, tighten each screw to 1.8 N-m [16 in-lb], using the sequence shown in Figure 5-33.
3. Repeat Step 1 through Step 2 for all straight rail to curved rail joints within the system.
1
12
2
3
3
Straight to Curve, Left Joint
Straight to Curve, Right JointM5 Screw(4X)
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Curved Rail to Curved Rail Joints
Refer to Figure 5-34 when aligning and securing all curved rail to curved rail joints.
Figure 5-34: Tightening Sequence, Curve to Curve Precision Rail Spine Plate
1. Use fingers to align the ends of the curved rails.
2. Once the rails are aligned, tighten each screw to 1.8 N-m [16 in-lb], using the sequence shown 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, tighten each screw to 1.8 N-m [16 in-lb], using the sequence shown in Figure 5-35.
3. Repeat Step 1 through Step 2 for all curved rail to curved rail joints in the system.
1
1
2
2
3
3
4
4
Curve to Curve, Left Joint
Curve to Curve, Right JointM5 Screw(4X)
1
2
M5 Screw(2X)
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Curved Rail, No Joint Locations
Refer to Figure 5-36 when aligning and securing all 180° curved rails at mid-point locations.
Figure 5-36: Tightening Sequence, 180° Curve No Joint Precision Rail Spine Plate
1. Once the rail is aligned, tighten each screw to 1.8 N-m [16 in-lb], using the same sequence shown in Figure 5-36.
2. Repeat Step 1 for all 180° curved rails 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 aligned, tighten each screw to 1.8 N-m [16 in-lb], using the same sequence shown in Figure 5-37.
2. Repeat Step 1 for all points on the rail.
3. Repeat Step 1 and Step 2 for all straight rail segments that are greater than 500 mm in length.
1
2
M5 Screw(2X)
1
2
M5 Screw(2X)
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Secure Spine Plates to Support Posts
Once all rails have been properly aligned and secured to the spine plates, the spine plates must be firmly secured to the top of each support post as shown in Figure 5-38.
Figure 5-38: Securing Precision Rail Spine Plates to Support Posts
1. Starting with the M6 x 10 mm low head socket cap screw closest to the rail, tighten it to 3.2 N-m [28 in-lb] using a 5 mm Hex wrench.
2. Check 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 before installing the last rail segment to eliminate the need to remove a guide rail or change the factory settings on the vehicles (refer to Installing Vehicles with Rails Removed on page 7-46. If all rail segments have been installed, refer to Installing Vehicles Without Removing Rails on page 7-47.
Spine Plate
Support Post
M6 Low Head SCS(2X)
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Precision Locator Installation
When installing the optional Precision Locator, ensure all previous installation steps except mounting the motor(s) where the Precision Locator(s) will be installed 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
PrecisionLocator
Puck
Adjustable Motor Mount
M6 x 20 mm BoltM6 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)
M6 x 12 mm Screw(2X per Rib)
PneumaticConnections
Stand Rib
Cover
M3 x 6 mm Screw(2 + 1X per Locator)
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Figure 5-40: MagneMover LITE Precision Locator Option, Alternate
Install Pallets and Pucks
The pucks with pallets should be installed on the system before installing the motors to allow easy installation.
1. Mount the pallet on the custom puck if not already installed (refer 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
PrecisionLocator
Puck
Adjustable Motor Mount
M6 x 20 mm BoltM6 Lock Washer
M8 x 20 mm Bolt
M8 Lock Washer
M6 x 25 mm Screw(4X)
M6 x 12 mm Screw(2X per Rib)
PneumaticConnections
Stand Rib
Cover
M3 x 6 mm Screw(2 + 1X per Locator)
M8 x 30 mm Bolt
M8 Lock Washer(2X per Rib)
(2X per Rib)
Locating Pin
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Install the Precision Locators on the Stands
The Precision Locators are installed on the stands before installing the stands for ease of assembly. The Precision Locators can be removed or installed on the stands once the stand is installed in the transport system, however it is more difficult to access the locator’s mounting screws.
1. Install the pneumatic fittings on the Precision Locator cylinder using Teflon™ tape.
2. Install each Precision Locator on the stand and secure using four M6 x 25 mm screws then tighten to 4.5 N-m [40 in-lb] using a 5 mm Hex wrench.
Install the Precision Locator Assemblies
The stands are installed loosely to allow final positioning with the equipment that will be accessing the pallet.
1. Remove the back plate from the stand by removing the M6 x 12 mm screws securing it and store the screws in a safe location.
2. Install the 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, install an M8 x 30 mm bolt and M8 split lock washer for each rib and finger-tighten.
Mounting the Alternate Precision Locator Stand (refer to Figure 5-40)
A. Position the locator stand onto the locating pins on the custom fixturing.
B. Install an M8 x 30 mm bolt and M8 split lock washer for each rib and fin-ger-tighten.
Install the Motors
Once the motors are installed and properly positioned the Precision Locator can be secured in its final position.
1. Install the adjustable motor mounts on the motor (refer to Installing Motor Mounts on Motors and Switches).
2. Install the motor (refer to Mounting Motors and Switches on page 5-20 and Align and Secure Motors and Switches on page 5-23).
NOTE: The Loctite must cure for 2 hours at 22° C [72° F] before using the transport system.
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3. Verify proper clearances between the puck and the Precision Locator and adjust the set screws on the motor mount as required.
• With the puck manually pinned into position on the stand (press down on both arms at the same time to secure the puck), verify 0.13 mm [0.005 in] clearance between the top of the rail and the skis on the pallet.
• With the puck manually pinned into position on the stand, verify 0.13 mm [0.005 in] clearance between the bottom of the rail and the center plate on the puck.
• With the puck manually pinned into position on the stand, verify 0.13 mm [0.005 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 screws that were removed from the back plate and replace the back plate on the stand. Tighten the screws to 5 N-m [45 in-lb] using a 5 mm Hex wrench.
6. Adjust the position of the locator stand as required.
• Ensure proper alignment between the bushings on the puck and the pins on the Precision Locator.
• With the puck manually pinned into position on the stand, verify proper access to the pallet by the remote equipment.
7. Tighten the M8 bolts securing the stand ribs to the beam to 26 N-m [230 in-lb].
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Install the Pneumatic Controls
The pneumatic fittings on the Precision Locator’s cylinder should be installed before the loca-tor is mounted on the stand to allow ease of access (refer to Install the Precision Locators on the Stands).
Figure 5-41: Precision Locator Pneumatic Connections
1. Install the pneumatic valve that will control the Precision Locator. This procedure assume the use of a 5/2 valve as described in Precision Locator Installation on page 3-43.
A. Connect the pneumatic valve control lines to 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 be adjusted to limit the pinning time to 100 ms or greater. Please note that all life estimates are based on a pinning time of at least 100 ms.
F. Connect the pneumatic valve’s exhaust #5 to a muffler.
2. If using the optional cylinder position sensors:
• If installing user-supplied sensors, install them into position and secure as directed by the manufacturer.
Open Locator
Close Locator(Extend Cylinder)
(Retract Cylinder)
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• If the sensors were pre-installed by MagneMotion, verify they are in the cor-rect positions and adjust if necessary by loosening the 2.5 mm set screw, adjusting the position of the sensor, and tightening the set screw.
Install the Covers
Install the cover(s) over the Precision Locator Assembly(s).
1. Position the cover over the Precision Locator Assembly(s) ensuring the holes in the cover align with the holes on the Locator(s).
2. Apply Loctite 243 to one M3x0.5 x 6 mm screw per Locator, install through the top of the cover into the Locator, and tighten the screws to 0.68 N-m [6 in-lb] using a 2 mm Hex wrench.
3. Apply Loctite 243 to two M3x0.5 x 6 mm screws, install through the sides of the cover into the 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 pallet while it is secured must be taught to the interfacing equipment.
1. Command the puck to the Precision Locator station.
2. Manually pin the puck into position (press down on both arms at the same time to secure the puck) and verify the arms fully seat into the pallet.
3. Pin the puck into position by commanding the locator to close and verify the arms fully seat into the pallet.
4. Using the NCHost utility read the position of the puck.
5. Adjust the position of the commanded position of the vehicle (station) to match the value from NCHost.
6. With the puck pinned into position teach the pallet location to the remote equipment.
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Facilities Connections
The standard configuration of the MagneMover LITE transport system requires user-supplied electrical power and communications connections. Refer to the Electrical Specifications on page 4-38 for descriptions and specifications of all required facilities.
Network Connections
The MagneMover LITE transport system uses communication over an Ethernet network with a Host Controller for transport system control and communication between Node Controllers. The following procedure provides the information required 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 network switch.
NOTICE
The Ethernet cable connecting a PoE switch to the Host Controller orother switches must connect to the Uplink port, otherwise damage tothe switches or other devices connected to the switches may occur.
Host
NC LITE
NetworkSwitch(PoE)
NC-12
NetworkSwitch
ControllerSYNC IT(optional)
TCP/IP or ENet/IPEtherNet/IP N
etw
ork
Sw
itch
Upl
ink
Upl
ink
Uplink
Upl
ink
NC LITE
NetworkSwitch(PoE)
NC LITE. . . NC LITE. . . NC-12 . . .
SYNC IT(optional)
. . .
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NOTE: When using multiple network switches to connect all Node Controllers, use one switch as a master and connect all other switches to it as shown in Fig-ure 5-42.
When using multiple MMI PoE network switches, connect the Uplink from each switch to a master switch as shown in Figure 5-42, do not daisy chain the PoE switches.
When using the optional SYNC IT controllers, use a switch dedicated to those controllers connected directly to the EtherNet/IP port on the PLC dedi-cated to synchronization as shown in Figure 5-42.
2. Connect a cable for network communications from the switch to each Node Controller.
• For NC-12 Node Controllers, connect to ETHERNET as shown in Figure 4-43.
• For Node Controller LITEs, connect to LAN as shown in Figure 4-44.
3. Set the IP address for each Node Controller. Refer to the Node Controller Web Inter-face 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 operation of the motors and other subsystems. An AC electrical connection is provided on those components that require facility power. Refer to the Electrical Specifications on page 4-38 for electrical requirements. Ensure that all electrical connections are for the appropriate voltage and power rating.
1. Connect power to each NC-12:
• Connect the AC power cable from either the optional remote power supply or a user-supplied power supply to the power distribution from the facility’s main
NOTICE
Do not turn on facility power until all installation procedures have beencompleted.
NOTICE
The NC-12 Node Controller does not support Power over Ethernet(PoE). Never connect these Node Controllers to a powered Ethernetnetwork as damage to internal components may result.
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power disconnect. Then, connect the DC power cable to the power connector on each NC-12 Node Controller as shown in Figure 4-43.
2. Connect power to each Node Controller LITE:
• When supplying Power over Ethernet to the NC LITE, ensure the Ethernet connection goes to a PoE enabled switch then plug the switch power supply into the power distribution from the facility’s main power disconnect. Then, connect the cable from the switch power supply to the switch.
• When supplying power directly to each NC LITE, plug the NC LITE power supply into the power distribution from the facility’s main power disconnect. Then, connect the cable from the NC LITE power supply to the NC LITE as shown in Figure 4-44.
3. Connect an AC power cable from the power distribution on the facility’s main power disconnect to the power connector on the MM LITE Power Supply as shown in Fig-ure 4-39.
E-Stop Circuit
The MagneMover LITE transport 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 the E-Stop circuit. Refer to the MagneMover® LITE Configurator User’s Manual for information on configuring an E-Stop.
Interlock Circuit
The MagneMover LITE transport system can use Digital I/O, provided through an NC-12 Node Controller, for monitoring and control of local options such as a Interlocks. The optional Interlock circuit is the responsibility of the user and requires a user-supplied +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 Interlocks on page 6-15 for the Interlock circuit. Refer to the MagneMover® LITE Configurator User’s Manual for information on configuring an Inter-lock.
CAUTION
High Voltage Hazard
The E-Stop is not the same as an EMO (Emergency Off),which removes power to the MagneMover LITE transportsystem.
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Light Stack Circuit
The MagneMover LITE transport system can use Digital I/O, provided through an NC-12 Node Controller, for monitoring and control of local options such as a Light Stack. The optional Light Stack circuit is the responsibility of the user and requires a user-supplied 3-color light tower and a user-supplied +5 - 35 VDC power supply (sized for the Light Stack) for the Digital Outputs. 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 monitor and control Digital Inputs and Out-puts. Refer to Figure 4-48 on page 4-65 for the Digital I/O Equivalent Circuits. Refer to the Host Controller TCP/IP Communication Protocol User’s Manual or the Host Controller Eth-erNet/IP Communication Protocol User’s Manual for the command details on performing these operations.
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Software
The MagneMover LITE transport system requires user-creation of the Node Controller Con-figuration File and creation of Host Controller software to direct vehicle movement for the particular application and monitor transport system performance. MagneMotion provides a number of software tools to simplify the creation of the Node Controller Configuration File, for testing system operation, and for monitoring system operation. Refer to Transport System Software Overview on page 1-8 for identification and descriptions of all software components.
Software Overview
Node Controllers supplied with the MagneMover LITE transport system ship with just a basic NC software image installed. All Node Controller related files (NC image, motor images and type files, and magnet array type files) must be uploaded to the Node Controller and activated before using the transport system. Refer to the Node Controller Web Interface User’s Manual for details.
All MagneMover LITE motors ship with just a basic motor software image installed. The motor image files must be uploaded to the 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 software running on the MagneMover LITE transport system must be part of the same release. Refer to the Release Notes provided with the software for additional information.
Alterations or changes to the software should only be made by qualified MagneMo-tion personnel or as directed by MagneMotion.
Software Configuration
Create the Node Controller Configuration File (node_configuration.xml) using the Configura-tor to define the components of the transport system and their relationship to each other. Refer to Design Guidelines on page 3-1 and the MagneMover® LITE Configurator User’s Manual for more details. The Configuration File must then must be uploaded to each Node Controller in the transport system before using the system. Refer to the Node Controller Web Interface User’s Manual for details.
Configure the Host Controller to control the transport system. Refer to the Host Controller TCP/IP Communication Protocol User’s Manual, the Host Controller EtherNet/IP Communi-
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cation Protocol User’s Manual, or the Mitsubishi PLC TCP/IP Library User’s Manual depending on the Host Controller type.
Node Controller Software Installation
1. Upload the Node Controller image files to each Node Controller using the Node Con-troller Web Interface. Refer to the Node Controller Web Interface User’s Manual for details.
NOTE: Activate the image and reboot the Node Controller for the changes to take effect.
2. Upload 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 and slaves. Refer to Programming Motors on page 7-33 and the Node Controller Web Interface User’s Manual for details.
NOTE: Restart the Node Controller for the changes to take effect.
2. Reset the Paths where the motors were programmed (e.g., use the NCHost TCP Inter-face Utility, refer to the NCHost TCP Interface Utility User’s Manual for details).
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Check-out and Power-up
System Check-out
Before the MagneMover LITE transport system is started for the first time, or after servicing the transport system, it is necessary to check all operating and safety features.
The following start-up procedure is used to apply power to the MagneMover LITE transport system in an orderly manner to ensure all components are in known conditions. This proce-dure is used to prepare the transport system for full operation.
Mechanical Checks
• Verify all shipping brackets have been removed.
• Ensure that all MagneMover LITE components are properly and 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 on page 4-38 and Site Requirements on page 4-66.
• Ensure that the power and communications connections have been completed.
• Check all cables. Verify the connectors are fully seated and screws/locks are secured to ensure good continuity.
• Verify all cables are routed in a safe place and away from any travel areas.
• Inspect all cables for restricting bend radii, excessive tension, or physical damage.
Pre-operation Checks
• Ensure that there are no obstructions in the travel path of the vehicles (pucks).
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System Power-up
After the MagneMover LITE transport system has been installed, all connections should be checked and an initial power up should be performed before proceeding any further with the installation process. This section describes the procedure for the initial installation check-out.
1. Ensure that all of the installation procedures previously described in this chapter have been completed.
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 noobstruction sensors.
Do not operate the MagneMover LITE transport systemwithout barriers in place or personal injury could result in thesqueezing or compression of fingers, hands, or other bodyparts between moving mechanisms.
CAUTION
Automatic Movement
Whenever power is applied, the possibility of automaticmovement of the vehicles (pucks) on the MagneMover LITEexists, which could result in personal injury.
CAUTION
High Voltage Hazard
110 VAC @ 8.5 A (220 VAC @ 5 A).
The AC circuit must be properly protected.
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4. Perform a Ground Continuity check from the surfaces of the MagneMover LITE trans-port system to a known good ground.
5. Apply power to the MagneMover LITE transport system.
The indicators on the components of the MagneMover LITE transport system will be lit as shown in Table 5-4.
6. If power-up was successful, the MagneMover LITE transport system is ready to accept commands. If, however, the power-up sequence was unsuccessful, refer to Trouble-shooting on page 7-13.
7. Create the Node Controller Configuration File for the transport system (refer to Soft-ware Configuration on page 5-64 and to the MagneMover® LITE Configurator User’s Manual).
8. Set the Node Controller IP 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 pro-grammed and configured properly (refer to the Node Controller Web Interface User’s Manual).
CAUTION
Automatic Movement
The Host Controller initiates all motion control to theMagneMover LITE transport system. It is the user’sresponsibility to initiate a safe start-up of all MMLITE components.
Do not attempt to operate the MagneMover LITEtransport system until all setup procedures describedin this chapter have been completed.
Table 5-4: Startup Indicators
Component Indicator Status
MM LITE Power Supply Logic Enabled On
Propulsion Enabled On
Node Controller, NC-12 Power On
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System Testing
Test the MagneMover LITE transport system to verify proper operation of all Nodes, Paths, and vehicles. This can be accomplished using the NCHost application supplied by MagneMo-tion to move vehicles without the Host Controller to verify proper operation before integrating a transport system into a production environment. Create Demo Scripts to perform repetitive testing throughout the transport system. Refer to the NCHost TCP Interface Utility User’s Manual for details. If any problems are encountered, refer to Troubleshooting on page 7-13.
1. Ensure the transport system is fully configured.
2. Ensure the Node Controller Configuration File is fully defined and has been uploaded to all Node Controllers (refer to the Node Controller Web Interface User’s Manual).
3. Ensure that each the NC Web 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 Paths is enabled, all vehicles on the Paths are identified and located, and the Paths become operational.
7. Verify the Host Controller has identified all vehicles in the transport system (refer to the NCHost TCP Interface Utility User’s Manual).
8. Move vehicles individually or create a Demo Script for repetitive testing (refer to the NCHost TCP Interface Utility User’s Manual).
9. Monitor transport system operation using the NCHost TCP Interface Utility.
CAUTION
Crush Hazard
Moving mechanisms have no obstruction sensors.
Do not operate the MagneMover LITE transport systemwithout barriers in place or personal injury could result in thesqueezing or compression of fingers, hands, or other bodyparts between moving mechanisms.
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Operation 6
Overview
This chapter provides an overview of operation for the MagneMover® LITE transport 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.
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Theory of Operation
The MagneMover LITE is a new approach to linear synchronous motor (LSM) technology, which provides a faster, cleaner, and more advanced alternative to conventional propulsion and conveyor methods. With a scalable, adaptable, and innovative design, the MM LITE pro-vides the ability to achieve various acceleration and velocity profiles while moving a wide range of payloads with high precision.
The MagneMover LITE motors are similar in operation to a brushless DC rotary motor, with its stator (motor primary) and rotor or armature (motor secondary) ‘unrolled’ to allow linear movement as shown in Figure 6-1. The motor primary is a series of coils that generate a mag-netic field, within the MagneMover LITE motor. The motor secondary 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 Advantages
An advantage of the MagneMover LITE transport system is that the motor secondary (vehi-cle) is not connected or tethered to the motor primary, allowing the vehicle to travel further and faster than connection cables allow. Another advantage is unlimited travel length. The result is a propulsion solution that is efficient, reliable, quiet, and clean. The MM LITE trans-
Rotary Motor
‘Unrolling’ a Rotary Motor
Motor Secondary MovementVehicle (Puck)
MagneMover LITE Linear Synchronous Motor
Motor Secondary
Motor Primary
Motor Primary
Motor Secondary
MotorSecondaryMovement
(Perm Magnets)
(Coils)
Motor Secondary(Perm Magnets)
Motor Primary(Coils)
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port system also provides high reliability because it does not require frequent replacement of power transmission parts.
A summary of MagneMover LITE transport system benefits include:
• Less maintenance than conventional belt conveyors.
• No moving parts within the straight and curve motor modules.
• Passive vehicles (pucks) that do not require batteries, wires, or power.
• Bidirectional movement.
• Variable transport system layout, including curves, switches, and horizontal guide-ways.
• Anti-collision feature.
• Automated move profiles.
• Independent vehicle movement.
Motion Control
The MagneMover LITE transport system provides an integrated transport system for material movement along one axis. Motors are linked together in Paths that define the individual movement routes. The Host Controller can then direct movement and positioning of the vehi-cles (pucks) anywhere along the length of 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 positioning of all vehicles in the transport system.
Motor Topology
Each MagneMover LITE motor is constructed as a series of blocks (refer to Table 3-2 on page 3-10 and Figure 6-2). Each block is a discrete motor primary section within the motor that is energized over its whole length. Varying the magnetic force within a block and its neighbors causes the vehicle to move in the desired direction and provides precise positioning of the vehicles.
The control software ensures that the minimum distance between vehicles on adjacent motor blocks is 3 mm [0.1 in] when not moving. However, this dimension can be larger depending upon the vehicle edge location relative to the block boundary.
NOTE: The MagneMover LITE anti-collision feature prevents two vehicles from occupying the same motor block.
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Figure 6-2: Representation of Stationary Vehicles Per MagneMover LITE Motor Block
Figure 6-3: Representation of Moving Vehicles Per MagneMover LITE Motor Block
Motor Operation
The MagneMover LITE motors provide asynchronous control of vehicles (pucks) on the transport system as directed by the Host Controller. This method minimizes the load on the Host Controller with the transport system’s Node Controllers and motors performing all rout-ing and vehicle control operations (positioning, acceleration, deceleration, and collision avoidance) as described below.
1. The Host Controller generates an asynchronous movement order to move a vehicle (puck) to a specific location from the beginning of a Path using either a position or sta-tion command 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 where the vehicle is currently located).
4. The vehicle master generates a movement profile based on the order. Every update period (~1 ms) a new position, velocity, and acceleration set point (Pset, Vset, and Aset) are calculated.
• As the vehicle moves, the master acquires empty blocks ahead of the vehicle that the vehicle can move into based on the vehicle’s current movement order. A ‘block’ is defined as an independently controlled coil or set of coils (refer to Table 3-2 on page 3-10 for details), no two vehicles are allowed to occupy the same block.
Vehicle (Puck)
Motor
BlockMagnet Array
Downstream
Vehicle (Puck)
Motor
Block
Magnet ArrayDownstream Motion
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• The vehicle master will use the position of the most recently acquired block farthest from the vehicle as an interim destination (target) to calculate the next profile set point (Pset, Vset, Aset).
• The vehicle master handles all collision avoidance ensuring brick-wall head-way is maintained between vehicles.
5. The vehicle master controls the vehicle based on the profile set points as inputs.
During the move, vehicle data such as actual position, velocity, and interim destination are sent back to the Node Controller, typically every 100-200 ms, to provide the Host Controller some level of feedback as to where the vehicle is located.
6. The vehicle master continues to generate updated movement profiles based on the order and continues to control the vehicle based on the new profile set points until the vehicle is handed off to the next vehicle master or it reaches its destination.
The vehicle master hands-off vehicle control to the motor controller in the next motor as the vehicle moves across motor boundaries. The new master ‘picks up’ where the old one left off for profile generation. 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 nature. The periodicity in this case would be expressed in degrees and the mag-nitude and direction of this cogging force would vary as a function of shaft position.
Linear motors that utilize a iron core also exhibit cogging forces. The main difference between rotary motors and linear motors is that in linear motors these forces are periodic as a function of distance versus angle. In the linear motor these forces will tend to pull the vehicle forward or backward at specified intervals along the motor.
MagneMotion’s MagneMover LITE linear motors do not utilize an iron core. As such, they do not exhibit any cogging forces.
Motor Blocks
A motor block is a discrete motor section within each MagneMover LITE motor or switch as shown in Figure 6-2 and Figure 6-3. It is an independently controlled linear motor driven by one inverter. This is the stator (motor primary) and consists of copper windings. There is no iron core to the motor, which eliminates the attractive force between the magnet array and motor.
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Block Acquisition
The master controller for each motor takes ownership of vehicles (pucks) when they enter the motor and maintains that ownership the entire time the vehicle is on the motor. Ownership includes identification of the final destination, maximum acceleration, and maximum velocity as defined in the current movement order and determination of the vehicle’s interim destina-tion and current acceleration and velocity set points.
The master ensures that the vehicle has acquired sufficient empty blocks ahead of the vehicle in the direction of movement to ensure brick-wall headway is maintained based on the current motion profile. This is done by defining new interim destinations and communicating with the motors ahead of the vehicle to ensure sufficient blocks can be acquired.
• The vehicle master uses the position of the most recently acquired block farthest from the vehicle as an interim destination (target) to calculate the next profile set point (Pset, Vset, Aset).
• A new interim destination (target) block is only granted if the block has not been allo-cated to another vehicle (i.e., permission is granted for only one vehicle per motor block).
• A new target is requested only immediately before 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-Collision
The MagneMover LITE transport system allows only one vehicle per motor block; this is the basic rule on which the anti-collision feature of the MM LITE transport system controls is founded on. Since two vehicles are not allowed to be in the same motor block, they will not collide. Note that this affects how many vehicles can fit on a motor or path.
Also, the magnet arrays on the vehicles have a slight repulsive force which causes them to passively separate from each other a short distance when they are manually pushed together and not being servoed (actively controlled). The distance they will passively separate will vary based on vehicle (puck) and track conditions which are impacted by friction but it will typically be about 30 mm. Therefore, the passively parked center-to-center spacing (or pitch) is about 90 mm.
The vehicles can be servoed to a tighter spacing but they need to be forced to do so by con-stantly driving the motor. They can be driven to a pitch where they are practically in contact with each other but if this constant, close position condition is held for a period of time the
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motors will reach a thermal limit and shut down. This tight spacing may be done on occasion but it should not be a standard part of a process.
Safe Stopping Distance Movement
Standard vehicle control ensures vehicles (pucks) always have a safe stopping distance (brick-wall headway). Figure 6-4 shows acceleration, velocity, and position versus time for the standard vehicle movement profile. Movement permission for a vehicle is granted as needed to keep a vehicle on its movement profile (solid 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 obstructs or jams the route. Obstructions are normal occurrences, jams are not. While in queue, the vehicles can be as close together as permitted by the system and the amount of space in between the carriers mounted on the vehicles depends on the defined length of the vehicle. All of the vehicles in the queue will report being obstructed.
Destination
Vlimit
-Alimit
+Alimit
Time
Time
Time
Pos
ition
Vel
ocity
Acc
eler
atio
n
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An obstruction indicates that another vehicle, or a Node not ready for a vehicle, is preventing the vehicle from completing its current movement order. Once the obstructing vehicle moves, or the Node is ready, the obstructed vehicle is free to complete its order.
A jam indicates that there is no known obstruction preventing vehicle movement, but the vehi-cle is not making progress towards its destination. This is typically due to something having fallen onto the track or friction within the system cannot be overcome. Once the jam has been cleared, typically by outside intervention, the jammed vehicle is free to complete its order and any vehicles it has obstructed are free to complete their orders.
Vehicle Length Through Curves and Switches
The width of the vehicles is not defined in the Node Controller Configuration File. In order to ensure multiple vehicles can move on curved sections of the transport system without collid-ing the vehicle length must be defined longer than it actually is to account for the vehicle’s width in a curve. The value of the defined length must be calculated using basic trigonometry.
NOTE: If the actual length and width 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 the Path. When the NC detects a magnet array (vehicle) it assigns the vehicle (puck) a Vehicle ID. The NC will continue scan-ning for vehicles until it locates a new one.
The NC will continue to scan until all vehicles detected have been assigned a vehicle ID. This could take several seconds to several minutes depending on how many vehicles are on a Path.
Once a vehicle ID is assigned, it will remain with that vehicle until the vehicle is either removed from the MagneMover LITE transport system via a Terminus Node, the vehicle is explicitly deleted with a Delete Vehicle command from the Host Controller, or a Reset is issued for the Path the vehicle is on.
Moving Vehicles by Hand
Vehicles on the MagneMover LITE transport system should only be moved by the MM LITE motors in the system. If there is an event that requires moving the vehicles by hand, the guide-lines provided below should be followed.
NOTE: Moving vehicles by hand will produce eddy currents in the stators of the motors where the vehicle is being moved, which will put power on the propulsion bus.
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If both propulsion power and logic power to the transport system are removed there is no tracking of vehicles being provided. Once power is restored the transport system must be restarted, which will detect all vehicles at their current locations.
If propulsion power to the transport system is removed while logic power is maintained and a vehicle is moved manually, its position will be tracked by the transport system unless the cen-ter of the magnet array on the vehicle crosses a motor boundary (moves off the end of a motor), which will generate an Unlocated Vehicle Fault. Vehicles that have crossed a motor boundary will be shown as having lost signal (Vehicle Signal = 0) when monitoring vehicle status through the Host Communication Protocols (refer to either the Host Controller TCP/IP Communication Protocol User’s Manual, the Host Controller EtherNet/IP Communication Protocol User’s Manual, or the Mitsubishi PLC TCP/IP Library User’s Manual).
A vehicle that has been manually moved, bumped, or dislodged, and lost its signal, is able to re-acquire its signal once manually relocated 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 are identified as Suspect require a restart of the Path where they are located to clear the Suspect bit. In some cases the vehicle can be commanded, but it will continue to show as Suspect.
If both propulsion power and logic power are maintained and a vehicle is moved manually, the motor will resist the vehicle’s movement. Once the vehicle is released it will snap 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 vehicle crosses a motor boundary.
Vehicles that have been moved too far can be recovered by deleting the moved vehicles and restarting the section of the transport system where they are located to detect them.
WARNING
Crush Hazard
Moving mechanisms have no obstruction sensors.
Do not attempt to manually move any vehicles while propul-sion power is supplied to the transport system or personalinjury could result in the squeezing or compression of fin-gers, hands, or other body parts between moving mecha-nisms.
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Electrical System
Voltage drops in the power distribution system when the motors 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).
OperationControls and Indicators
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Controls and Indicators
The user’s application running on their Host Controller should provide any needed controls or indicators related to transport system operation. Additional controls and indicators can be con-figured as described in this section. The controls and indicators of the 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 configuration has been created. Refer to the NCHost TCP Interface Utility User’s Manual to use the Graphics Window and the MagneMover® LITE Configurator User’s Man-ual to create the Track File.
Figure 6-5: The Graphics Window
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Synchronization
The Synchronization option for the MagneMover LITE transport system provides the ability for the end user to more accurately control movement of individual vehicles (pucks) within a specified zone. More elaborate movement profiles can be implemented, such as jerk control. It also provides the ability to co-ordinate vehicle motion to that of an external moving element, (e.g. robot, filler, etc). Only those motors that are in a location where vehicle movement must be synchronized with an external mechanism should use the Sync option.
In normal asynchronous operation, the Node Controllers route the orders from the Host to the motors and the motors control the profiles (position, velocity, and acceleration) for the vehi-cles. All asynchronous control is handled through the Node Controller’s RS-422 interface to the motors.
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 collision avoidance functions. The vehicle IDs assigned to the vehi-cles by the transport system are preserved across non-Sync and Sync regions.
For synchronization, a SYNC IT controller is required for every three motors that are being synchronized as shown in Figure 6-6. Refer to the LSM Synchronization Option User’s Man-ual for configuration and operation details to use the Sync option with the MagneMover LITE transport system.
Figure 6-6: Transport System Wiring Diagram with Synchronization
NOTE: The SYNC IT controller is powered through its connection to the motors and does not require any external source of power.
PLC
Sync Motor
SYNC IT
Power
Sync Motor Sync Motor Motor Motor
TCP/IP or ENet/IP
EtherNet/IP
NCController
Motor
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E-Stops
When using an NC-12 Node Controller, the Node Controller’s Digital I/O can be connected directly to an E-Stop circuit. An E-Stop is a user-supplied button (typically locking) that can be pressed by an operator if an emergency situation arises to halt all motion on the specified Paths. When the Node Controller detects that the E-Stop button is activated, it commands all Paths associated with that E-Stop to suspend vehicle (puck) movement. All motors on those Paths suspend vehicle target requests and permissions and all vehicles come to a controlled stop and are held in position by the motors. Stopping time for each vehicle is dependent on the vehicle’s load and the acceleration setting of the vehicle’s current movement command.
Multiple E-Stop circuits may be connected to a single NC-12 Node Controller. Each Path can 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 series as shown in Fig-ure 6-7 so that pressing any button will initiate an E-Stop. The same E-Stop circuit may be used for multiple Paths on different Node Controllers by wiring the E-Stop circuit to each Node Controller in series as shown in Figure 6-8 to a maximum of eight Node Controllers and referencing the appropriate Digital Input Bit on each Path. The E-Stop is cleared by releasing the button that was pressed and issuing a Resume command.
NOTE: Motion will not resume until the button is released and the Host Controller issues a Resume command to the Paths associated with the E-Stop.
CAUTION
Electrical Hazard
The E-Stop only executes the actions described, it is not thesame as an EMO (Emergency Off), which removes power tothe transport system.
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Figure 6-7: E-Stop Wiring Diagram, Single Node Controller
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 VDCPower 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 VDCPower Supply
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Interlocks
When using an NC-12 Node Controller, the Node Controller’s Digital I/O can be connected directly to an Interlock circuit. An Interlock is a user-installed circuit that can be activated by another piece of equipment in the facility to temporarily halt all motion on the specified Paths. When the Node Controller detects that the Interlock circuit is activated, it commands all Paths associated with that Interlock to suspend vehicle (puck) movement. All motors suspend vehi-cle target requests and permissions and all vehicles come to a controlled stop and are held in position by the motors. Stopping time for each vehicle is dependent on the vehicle’s load and the acceleration setting of 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 external power supply for the Interlock circuit must be provided by the user.
The Interlock circuit, shown in Figure 6-9, is connected to a digital output on the Host Con-troller such that breaking the circuit will activate the Interlock. The Interlock is cleared by tak-ing the Interlock signal High.
Figure 6-9: Interlock Wiring Diagram
CAUTION
Automatic Movement Hazard
When the Interlock is cleared movement of the vehicles onthe MagneMover LITE transport system is automaticallyresumed, which could result in personal injury.
+3 - 24 VDCPower Supply
Digital In
Digital In
NC-12 Node Controller
COM
+V -V
User-installed Circuit
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FastStop
The Host Controller can send a FastStop command to the Node Controller, on a per-Path basis. This command suspends all movement on the specified 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 User’s Manual for details on the use of the FastStop command.
OperationControls and Indicators
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Light Stacks
When using an NC-12 Node Controller, Light Stacks can be wired directly to the Digital I/O as shown in Figure 6-10. A Light Stack is a user-installed visual signal used to provide trans-port system status. Standard three color light 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 provided by the user.
Figure 6-10: Light Stack Wiring Diagram
Digital Out n
Digital Out n+1
Digital Out n+2
Light Stack NC-12 Node Controller
RTN
+V -V
Power Supply+5 - 35 VDC
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Digital I/O
When using an NC-12 Node Controller, digital inputs and outputs may be monitored and con-trolled, respectively. These circuits can be wired directly to the Digital 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 Digital I/O circuits must be provided by the user (refer to Figure 4-48 on page 4-65).
OperationTransport System Simulation
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Transport System Simulation
The MagneMover LITE transport system can be simulated to verify proper configuration of all Nodes and Paths and proper movement of commanded vehicles within the transport sys-tem. Running a simulation can be useful to test and observe system behavior without physi-cally moving vehicles on the Transport System. Note that in order to run a simulation the system must be fully defined in a Node Controller Configuration File (refer to the Magne-Mover® LITE Configurator User’s Manual) and that file must be loaded onto the Node Con-troller that will be used for simulation (refer to the Node Controller Web Interface User’s Manual).
Simulated vehicles can be moved during the simulation to verify basic functionality. Note that the movement profile of all simulated vehicles is an ideal profile, which assumes that there is no friction between the vehicle and the guideway and that 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 controller or the NCHost TCP Interface Utility).
Configuring a Simulation
1. Configure a Node Controller to run in Simulation Mode.
A. Run the Node Controller Web Interface (refer to Node Controller Web Inter-face User’s Manual).
B. Select IP Settings on the Main Menu.
C. In the Configured Functions section, ensure This box is a High Level Con-troller Simulator is selected.
D. In the Configured Functions section, ensure This box is a Node Controller is cleared.
E. In the Configured Functions section, ensure This box is the High Level Controller is cleared.
F. Select Apply Changes.
The selected changes are applied.
G. Select Reboot Controller on the Main Menu.
The Reboot Controller page is displayed.
H. Select Reboot Controller.
The reboot status is temporarily displayed, then the General Status page is dis-played once the Node Controller has rebooted.
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2. Download the current Node Controller Configuration File from the Node Controller. If a Configuration File does not exist, refer to the MagneMover® LITE Configurator User’s Manual to create one.
A. Using the Node Controller Web Interface, select Configuration Files on the Main Menu.
B. Under Node Controller Configuration File, select Download.
C. Specify a location for the file download, change the file name as appropriate, and select Save.
The file is named and saved as specified.
3. Edit the Node Controller Configuration File to add simulated vehicles.
NOTE: The Simulated Vehicle is a simulated version of the vehicle defined in the Vehicle section of the Motor Defaults.
A. Open the copy of the current Configuration File in the Configurator (refer to the MagneMover® LITE Configurator User’s Manual).
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 vehicle just added and specify its starting location.
5. Repeat Step 2 through Step 4 for each vehicle to be added.
D. Save the updated Node Controller Configuration File file.
4. Update the Node Controller with the latest file versions.
A. Upload the updated Configuration File file to the Node Controller (refer to Node Controller Web Interface User’s Manual).
B. Ensure the latest version of the motor type files are installed and upload new files if necessary (refer to Node Controller Web Interface User’s Manual).
C. Select Reboot Controller on the Main Menu.
D. Select Restart Services.
The restart status is temporarily displayed, then the General Status page is displayed once the Node Controller has restarted.
OperationTransport System Simulation
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Running a Simulation
Not all features of the transport system can be simulated. The differences between physical operation and simulated operation are detailed in Table 6-1.
1. Connect to the Node Controller to run the simulation.
• Use the NCHost TCP Interface Utility to manually run the system (refer to the NCHost TCP Interface Utility User’s Manual).
• Use the application developed for the Host Controller to run the system as planned for production.
2. Issue a Reset command for all Paths.
All of the motors on the Paths in the transport system are simulated.
3. Issue a Startup command to all Paths.
Motion on all Paths is enabled, all simulated vehicles on the Paths are identified and located as specified in the Node Controller Configuration File, and the Paths become operational.
NOTE: Resetting a Path where simulated vehicles are located will delete those vehi-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 defined, con-nected to the Node Controller, and operational.
All motors must be defined. Motors do not need to be connected to the Node Controller.
Node Control-lers
All Node Controllers in the transport system must be operational.
One Node Controller must be opera-tional and configured as a Simulator.
Nodes All Nodes must be defined. All Nodes must be defined.• Gateway Nodes are not simulated.
Paths All Paths must be defined. All Paths must be defined.
Stations Any stations must be defined. Any stations must be defined.
Vehicles The vehicle properties must be defined in the Configuration File. All vehicles being used must be installed in the transport system.
The vehicle properties must be defined in the Configuration File. All vehicles being simulated must be defined in the Configuration File.
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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 the Host Controller to run the system as planned for production.
Stopping a Simulation
1. Issue a Suspend Movement command for all Paths.
All vehicles come to a controlled stop.
2. Once 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 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 Configured Functions section, ensure This box is a Node Controller is selected as appropriate.
E. In the Configured Functions section, ensure This box is the High Level Controller is selected as appropriate.
F. Select Apply Changes.
The selected changes are applied.
G. Select Reboot Controller on the Main Menu.
The Reboot Controller page is displayed.
H. Select Reboot Controller.
The reboot status is temporarily displayed, then the General Status page is dis-played once the Node Controller has rebooted.
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2. Using the host interface, issue a Reset command for all Paths.
All of the 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 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 the Host Controller to run the system as required.
OperationPrecision Rail Operation
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Precision Rail Operation
The Precision Rail option provides customized stainless steel precision ground rails in place of the integrated 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 vehicles using the standard integrated rails.
OperationPrecision Locator Operation
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Precision Locator Operation
The Precision Locator option provides a small pneumatic fixture for precisely locating and securing a puck at a process station.
Setup
Install the Precision Locator as described in Precision Locator Installation on page 5-54.
Operation
Operation of the Precision Locator is controlled by the Host Controller. There 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 the user-supplied pneumatic valve for the locator.
3. Release the vehicle to allow the locator to precisely position it.
4. Perform the appropriate action to the load mounted on the pallet.
5. Command the Precision Locator to open.
6. Command the vehicle to its next location.
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Transport System Operation
Power-up
The MagneMover LITE transport system is started by applying power as previously specified (refer to Check-out and Power-up on page 5-66). Once this is done, the MM LITE compo-nents are ready to operate. If the Host Controller is in control of the transport system, the MM LITE transport system will accept commands from the Host Controller through the network connection.
Normal Running
Normal operation of the MagneMover LITE transport system is controlled by the user’s Host Controller. The exact usage of the 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 Host Control-ler EtherNet/IP Communications.
NOTICE
All switch settings, communication connections, and power connectionsmust be made before power is applied.
CAUTION
Crush Hazard
Moving mechanisms (vehicles and switches) have noobstruction sensors.
Do not operate the MagneMover LITE transport systemwithout barriers in place or personal injury could result in thesqueezing or compression of fingers, hands, or other bodyparts between moving mechanisms.
OperationTransport System Operation
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Safe Shut-down
The following shut-down procedure is used to remove power from the MagneMover LITE transport system in an orderly manner and place the components in safe conditions. This pro-cedure is used to prepare the components for removal, replacement, or maintenance.
The MagneMover LITE transport system requires no special shut-down procedures. When the Host Controller is to be shut down, the MM LITE components should be shut down first.
1. All material transfers should be completed (move all material to appropriate loca-tions).
2. Command all vehicles (pucks) to known safe positions.
3. Issue a Suspend Movement 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 for the MagneMover LITE transport system.
NOTE: This procedure only shuts down facilities to the MagneMover LITE motors, their subsystems, and the Host Controller. Any user equipment will remain powered up.
CAUTION
Electrical Hazard
The shut-down procedure is used in the normal shut-down ofthe MagneMover LITE transport system. This procedurecompletely removes the power source and all other facilitiesto the components and provides guidelines for lock-out/tagout. This procedure is NOT the same as an EMO cir-cuit or other safety interlock.
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Maintenance 7
Overview
This chapter provides maintenance schedules and procedures for the MagneMover® LITE components. Only 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 procedures.
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Preventive Maintenance
The motors, Node Controllers, and power supplies that make up the MagneMover LITE trans-port system are self contained components designed for use in a clean, inert environment and require no maintenance other than that described here. Any deviation from this basic environ-ment may affect the maintenance requirements, contact MagneMotion Technical Support for additional information. Refer to Troubleshooting on page 7-13 if any problems are detected.
Table 7-1: MagneMover LITE Preventive Maintenance Schedule
Component Maintenance Action Frequency*
* The specified 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
7-5
Cable Connection Inspection 3 months or as required
7-5
Hardware Inspection 3 months or as required
7-5
Cleaning Magnet Arrays 3 months or as required
7-5
Node Controllers Transfer Log Files 3 months or as required
7-6
Power Supplies Clean Power Supply Air Filter 12 months or as required
7-6
Precision Rail Option Lubricating the Precision Rails As required 7-7
Refilling a Precision Rail Vehi-cle’s Lubricating Applicator
As required 7-8
Adjusting Vehicle Bearings As required 7-11
MaintenancePreventive Maintenance
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General Cleaning
General cleaning of the MagneMover LITE transport system consists of cleaning transport system surfaces as described below.
Required Tools and Equipment
• Disposable gloves.
• Microfiber cleaning cloth.
• Deionized water.
• Isopropyl alcohol (optional).
Procedure
1. Stop all motion on the sections of the MagneMover LITE transport system to be cleaned.
2. While wearing gloves, clean all exposed transport system surfaces and cables with a clean microfiber cloth slightly dampened with deionized water or isopropyl alcohol. Wipe in the direction of the grain on all surfaces that have a grain.
3. Ensure all components are dry.
4. Resume motion on the sections of the MM LITE transport system that were stopped.
Spray Cleaning
Spray cleaning the MagneMover 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 cleaned, motion does not need to be stopped and the speed should be adjusted to ensure proper cleaning of the material.
3. Initiate the IP65 washdown of compatible components (motors, switches) or material in transport.
• Maximum water volume: 12.5 liter [0.26 gallon] per minute.
• Maximum pressure: 30 kN/m2 [6.14 psf] at distance of 3 m [9.8 ft].
4. If the only the motors are being cleaned, ensure all components are dry and return the MagneMover LITE transport system to normal operation.
NOTICE
Only the motors, pucks, and magnet arrays are IP65 washdown compatible.
Ensure all components that are not IP65 washdown compatible (power sup-plies, Node Controllers, etc.) are not exposed to water spray.
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Puck Cleaning
The pucks used on the MagneMover LITE transport system may need to be cleaned to remove any particulate buildup on the wear surfaces of the pucks.
Required Tools and Equipment
• Disposable gloves.
• Microfiber cleaning cloth.
• Deionized water.
• Isopropyl alcohol.
Procedure
1. Remove the puck from the MagneMover LITE transport system (refer to Replace Pucks on page 7-35).
2. While wearing gloves, clean internal puck wear surfaces with a clean cotton tipped swab slightly 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 should not cause any alcohol to drip) by running the cloth over the surfaces in the direction of travel (refer to Figure 7-1).
4. While wearing gloves, dry all cleaned puck surfaces with a clean dry clean cotton tipped swab and a clean dry microfiber cloth.
5. Replace the puck on the MM LITE transport system (refer to Replace Pucks on page 7-35).
Internal Wear
External WearSurfaces
Surfaces
MaintenancePreventive Maintenance
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Puck Wear Surface Maintenance
The pucks used on the MagneMover LITE transport system may need to be rotated to ensure even wear on the wear surfaces of the pucks. This is especially true for pucks used in a trans-port system where all motion is in a single direction, for pucks in a tandem puck configura-tion, or for pucks that have a cantilevered load.
1. Remove the pucks from the MagneMover LITE transport system (refer to Replace Pucks on page 7-35).
2. Rotate the pucks 180° and replace the pucks on the MM LITE transport system (refer to Replace Pucks on page 7-35).
Cable Connection Inspection
1. Stop all motion on the sections of the MM LITE transport system to be inspected.
2. Verify all cable connectors are fully seated and screws/locks are secured to ensure good continuity.
3. Inspect all cables for 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. Ensure all guideway mounting hardware is secure.
6. Ensure all vehicle hardware, especially the hardware securing the magnet array, is secure.
7. Ensure the Vehicle Gap (distance between the magnet array on the vehicle and the motor) is within tolerance for all vehicles on all motors.
8. Return the MM LITE transport system to normal operation.
Cleaning Magnet Arrays
The magnet arrays will attract ferrous particles from the air and surrounding surfaces. These particles will accumulate and appear as small “hairs” on the surface of the array.
• Using adhesive tape to capture the ferrous particles is a simple way to clean the mag-net arrays.
• To combat accumulated debris, magnet arrays not being used should be kept in their original container.
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Transfer Log Files
The log files for each Node Controller and the High Level Controller should be reviewed peri-odically to look for unexpected messages.
Log files may be transferred from the Node Controller or SysLog server to a CD or external USB device so they can be archived or e-mailed to MagneMotion 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 MagneMotion for a replacement.
4. Clean the air filter using warm soapy water, rinse thoroughly with clean water, and let dry.
5. Replace the air filter in the power supply.
6. Return the power supply to normal operation.
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Lubricating the Precision Rails
Precision rails should have a very thin coat of oil across the entire rail system. This provides both lubrication and environmental protection.
To determine if the precision rails require lubrication, use a clean, dry wipe and run it lightly over different sections of the rail. If very little or no oil appears on the wipe, then the rails require lubrication. 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 transport system to be lubri-cated.
2. While wearing gloves, wipe the precision rail with a clean microfiber cloth slightly dampened with mineral oil. Wipe in the direction of the rail.
3. Ensure all components are free of any oil puddles.
4. Resume motion on the sections of the MM LITE transport system that were stopped.
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Refilling a Precision Rail Vehicle’s Lubricating Applicator
If the rails require lubrication and there are lubricating applicators attached to the underside of the vehicles, they should be refilled.
NOTE: The lubricating applicators only lubricate the running surfaces of the rails, to lubri-cate the entire rail refer to Lubricating the Precision Rails on page 7-7.
The frequency of lubrication depends on the distance traveled.
Required Tools and Equipment
• 68 viscosity EP mineral oil.
• Syringe or other injector.
Procedure
1. Stop all motion on the section of the MagneMover LITE transport system where the vehicle 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 othermedical electronic implants must stay away from the magnetarray 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 be secured individually in isolated packaging.
To avoid damage to watches, instruments, electronics, andmagnetic media, keep metal tools, metal objects, magneticmedia (memory disks/chips, credit cards, and tapes) and elec-tronics away from the magnet arrays.
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Some systems may have applicators mounted in both locations on the same vehicle. The felt end of the applicator is always pointed inwards toward the rail with the refill access portal at the opposite end of the reservoir. See Figure 7-3 for illustration 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 lubrication portal shown in Figure 7-4 to access the oil refill hole on the applicator.
Applicator
ConcentricBearings
Applicator EccentricBearings
Oil RefillFelt Applicator
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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
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Adjusting Vehicle Bearings
Properly adjusted bearings enable the vehicle to move easily along both straight and curve rails with very little movement between the bearings and the rail. Improperly adjusted bear-ings can cause motor overheating if they are too tight on the rail or loss of precision if they are too loose.
Figure 7-5: Precision Rail Vehicle Bearing Adjustment
CAUTION
Strong Magnets
To avoid severe injury, people with pacemakers and othermedical electronic implants must stay away from the magnetarray 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 be secured individually in isolated packaging.
To avoid damage to watches, instruments, electronics, andmagnetic media, keep metal tools, metal objects, magneticmedia (memory disks/chips, credit cards, and tapes) and elec-tronics away from the magnet arrays.
EccentricBearing
Bearing Nut
Motor Side of Vehicle
ConcentricBearing
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Concentric Bearings
Concentric bearings are not adjustable and should be tightened to 19 N-m [14 ft-lb] at all times. Once tightened, apply Loctite 290 to the nuts on the top of the carriage and allow the Loctite to cure for 3 hours at 22° C [72° F] before using the vehicle.
Eccentric Bearings
Eccentric bearings are adjustable, enabling them to be rotated either closer to or further away from the rail. If the vehicle can be rocked from side to side or front to back, then there is too much movement and one or both bearings will need to be readjusted and rotated closer to the rail until the movement is eliminated. If the vehicle does not move easily along the rails, rotate one or both bearings further away from the rails.
Adjustments made to a vehicle’s eccentric bearings, in relationship to the rail, will dictate how easily the vehicle moves along the rail. Note that when the bearings are adjusted the drag force for the vehicle must not exceed the limits shown in Table 7-2. Refer 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 rotate the eccentric bearing either closer to (counter-clockwise) or further away from (clockwise) the rail.
4. Test the bearing’s position by moving the vehicle on the rail.
• If the vehicle can be rocked from side to side or front to back, rotate the bear-ing CCW (closer to the rail) until the excess movement is eliminated.
• If the vehicle does not move easily along the rail, rotate the bearing CW (fur-ther away from the rail) until the binding is eliminated.
5. Secure the bearing in place by holding the bearing nut firmly with a thin open ended wrench while tightening the nut on the top of bearing to 19 N-m [14 ft-lb].
6. Apply Loctite 290 to the threads on the nut on the top of the carriage.
NOTE: The Loctite must cure for 3 hours at 22° C [72° F] before using the transport system.
Table 7-2: Precision Rail Vehicle Drag
Vehicle Type Maximum Drag
Single Array 2.80 N [10.7 ozf]
Dual Array 5.86 N [21.1 ozf]
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Troubleshooting
This section describes the common difficulties that may be encountered with the Magne-Mover LITE transport system and software components.
For assistance, refer to Contact MagneMotion Technical Support on page 7-22.
Initial Troubleshooting
This section covers the initial determination of the problem area within the MagneMover LITE transport system and provides direction to the second step of the troubleshooting pro-cess. If a specific problem is suspected, refer to that problem in Table 7-3. If the problem has not been identified, review each of the symptoms identified in Table 7-3 to help determine the problem area.
Table 7-3: Initial 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 Troubleshooting on page 7-19
See Precision Rail Option Troubleshooting on page 7-20
Node Controller logs do not indicate correct time.
See Node Controller Troubleshooting on page 7-17
MagneMover LITE transport system does not respond to the Host Controller.
See Communications Troubleshooting on page 7-18
See Motion Control Troubleshooting on page 7-19
Vehicle movement is noisy. See Motion Control Troubleshooting on page 7-19
See Precision Rail Option Troubleshooting on page 7-20
The Light Stack does not function as expected. See Light Stack Troubleshooting on page 7-21
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Power Related Troubleshooting
This section covers the determination of power related problems within the MagneMover LITE transport system.
Table 7-4: Power Related Troubleshooting
Symptom Problem Description Corrective Action
Lights on power supplies do not turn on.
No power or incorrect power being supplied.
Verify the Power Cable from the facility’s power is fully seated and secured.
Verify the facility’s power to the MagneMover LITE transport sys-tem is the correct power rating.
Power supply main fuses are blown.
Verify power supply main fuses are not 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 7-19.
One or more motors do not oper-ate.
Power or communication to the affected motors is lost or intermit-tent.
Verify cables to the affected motor(s) are fully seated and secured.
Power supply is not providing full power.
Verify power supply for the affected motor is operating prop-erly.
Verify voltage output from the power supply.
Verify power supply Logic and Propulsion fuses are not blown. Replace if necessary and deter-mine cause to prevent reoccur-rence.
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After power cycling the propul-sion power line multiple times the motor controller will not clear the under-voltage fault.
The PTC used to limit inrush cur-rent eventually heats up enough that it goes to a high resistance state and does not allow the motor controller to power up enough to clear the under-voltage.
Turn off the power supply for a few minutes to allow the PTC to cool down sufficiently to allow proper resumption of operation upon re-application of the propul-sion power source.
Motor reports ‘Not in operational mode’.
All motors currently enter this state for 100 ms, and then auto-matically exit. This is to let sam-pled A/D inputs and observers settle before using this data. There is currently no lockout of behav-ior based on this fault, this fault is informational only.
Wait 100 ms after reset or power on before 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 failed so they can complete including the homing of the switch’s flipper.
The motor reports a soft start not complete fault
The motor’s internal power bus is below +27 VDC.
The fault will clear once the power bus rises above +32 VDC.
The motor reports an under-volt-age fault.
Power being supplied to the motor is below +27 VDC.
Verify the voltage output from the power supply.
Reduce power cable resistance between motors that share a com-mon +36 VDC power supply.
Verify the voltage at the motor.
Verify all power wiring is suffi-cient to carry all loads and deliver the proper power to the motors.
The fault will clear once the power bus rises above +28 VDC.
Table 7-4: Power Related Troubleshooting (Continued)
Symptom Problem Description Corrective Action
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The motor 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
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Node Controller Troubleshooting
This section covers the determination of problems within the Node Controllers.
Table 7-5: 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 Con-troller to MagneMotion for repair.
Use the Node Controller Web Interface Set Clock function to set the time (refer to the Node Controller Web Interface User’s Manual).
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Communications Troubleshooting
This section covers the determination of communications related problems within the Magne-Mover LITE transport system.
Table 7-6: Communications Related Troubleshooting
Symptom Problem Description Corrective Action
MagneMover LITE motors are powered but there is no response to the Host Controller.
Communication to the affected motors is lost or intermittent.
Verify all communications cables are fully seated and secure.
Check for proper 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.
MagneMover LITE motors respond to the Host Controller but motors do not operate.
Power to the affected motors is lost or intermittent.
Ensure power cables to all motors are properly seated.
Ensure propulsion power is enabled.
E-Stop or Interlock circuit is acti-vated.
Ensure any E-Stops or Interlocks configured for the Paths the motors are on are in the operate state.
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Motion Control Troubleshooting
This section covers the determination of motion related problems within the MagneMover LITE transport system.
Table 7-7: Motion Control Related Troubleshooting
Symptom Problem Description Corrective Action
Material slipping on the vehicles. Vehicle not designed to carry that specific material.
Ensure the vehicle design is cor-rect.
Vehicle is not holding the material securely.
Ensure all material contact sur-faces are clean.
Motion configuration issue. Ensure the vehicle acceleration is correct.
Ensure the vehicle speed is cor-rect.
Ensure the PID values are correct.
Vehicles not moving smoothly or movement 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.
Excessive noise when the vehicle moves from motor to motor.
Ensure the motors are properly mounted and the transition from the rails on one motor to the rails on the next motor is smooth (rails should be at the same height).
Vehicles loosing thrust. Misalignment or wear of sections of the guideway.
Ensure the Vehicle Gap is consis-tent at all locations in the trans-port system.
Ensure the vehicle and/or track wear is within tolerance.
Thrust lost when the vehicle moves from motor to motor.
Ensure the Downstream Gap does not exceed 10% of the magnet array length.
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Precision Rail Option Troubleshooting
This section contains troubleshooting tips specific to the Precision Rail option.
Table 7-8: Precision Rail Option Troubleshooting
Symptom Problem Description 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 adjustment on the vehicles is correct (refer to Replace Precision Rail Vehicles on page 7-45).
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Light Stack Troubleshooting
This section covers the determination of light stack related problems within the MagneMover LITE transport system.
Table 7-9: Light Stack Related Troubleshooting
Symptom Problem Description Corrective Action
Lights do not turn on. Power to the light stack is lost or intermittent.
Ensure all wiring to the light stack is properly seated.
Verify voltage output 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 off. Light indicates one or more faults. Review the log file to determine the fault (refer to the Node Con-troller Web Interface User’s Man-ual).
Red light does not turn off. Light indicates vehicles stopped. Send a move vehicle command to any vehicle on the Paths or Nodes being monitored by the light stack.
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Contact MagneMotion Technical Support
To help you receive the most value from the MagneMotion Support Specialists, have the fol-lowing information ready before contacting MagneMotion Technical Support.
1. Download and save the Node Controller and High Level Controller logs.
2. Record the serial numbers from the motors and Node Controllers.
3. Provide the location of the MagneMover LITE transport system.
4. 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 error was performed. What were the results of those actions?
• Is there any other information that may assist our Specialist?
7. Contact MagneMotion Technical Support:
Main Office Technical Support
MagneMotion, Inc.139 Barnum RoadDevens, MA 01434USAPhone: +1 978-757-9100Fax: +1 978-757-9200
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Repair
If a component of the MagneMover LITE transport system malfunctions, refer to Trouble-shooting on page 7-13 in this manual for diagnostic procedures. If these procedures are not adequate to determine the source of the problem, refer to Contact MagneMotion Technical Support on page 7-22. Once the failed unit has been identified, a replacement unit can be ordered and installed as directed in Installation on page 5-1.
NOTE: The components of the MagneMover LITE transport system are designed for easy replacement. Motors, controllers, and other modules do not contain any user service-able parts.
NOTICE
Only a qualified service representative can service the components of theMagneMover 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 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
Programming Motors 7-33
Separating Magnet Arrays 7-34
Puck Replace Pucks 7-35
Replace Puck Wear Surfaces 7-38
Power Supply Replace Power Supply Fuses 7-42
Precision Rail Vehicles Replace Precision Rail Vehicles 7-45
Replacing Lubricating Applicators on Vehicles 7-50
Replacing Magnet Arrays On Precision Rail Vehi-cles
7-53
Replacing Bearings On Precision Rail Vehicles 7-59
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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 #
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Adjust G3 Motors to Eliminate Rail Binding
If binding is detected during vehicle (puck) motion on the MagneMover LITE G3 motors the rails on the motors may be adjusted.
Required Tools and Equipment
• 000-0614-00 – Rail Spreader, ML (G3 motors only).
Procedure
1. Stop all motion on the sections of the MagneMover LITE transport system to be ser-viced.
2. Insert the Rail Spreader at the rail posts on the straight motor 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 eliminate the binding. Remove the Rail Spreader and verify the vehicle (puck) moves through the area without binding.
Table 7-11: MM LITE Rail Adjustment
Minimal Binding 1 turn minimum
Noticeable Binding 1 ½ turns
Severe Binding 2 turns maximum
Do Not Adjust Do Not Adjust
For Bindingin this Area
Adjust at These Locations
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Figure 7-7: Adjust Rails – G3 Motors
4. Return the MM LITE transport system to normal operation.
Rail Post
Rail Spreader
Rail Post
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Connect and Secure G3 Motors and G3 Switches
Once the MagneMover LITE G3 motors and switches are properly located, either after initial installation or after maintenance or replacement, the rails must be aligned from motor to motor (or switch).
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 the motor mount for all motors or switches being adjusted.
M6 x 12 mm Screw
V-Brace
(2X per V-Brace)
Rail Alignment Fixture
M8 x 20 mm Bolt(1X per Bracket)
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3. Loosen the V-braces at all guide rail joints and tighten finger-tight to pull the rails together.
4. Use the Rail Alignment Fixture to align the rails at the motor joints as shown 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 and switch joints.
7. Return the MM LITE transport system to normal operation.
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Connect G3 Motors and G4 Motors
When a MagneMover LITE G3 motor is replaced by an MM LITE G4 motor a special V-brace is used to connect the rails of the G4 motor to the rails of the existing G3 motors.
NOTE: When G3 and G4 motors are being used in the same transport 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 Adhesive, Blue.
Procedure
Figure 7-9: Align and Secure Rails – G3 to G4 Motors
M6 x 12 mm Screw
V-Brace
(2X per V-Brace)
G4 Motor
G3 Motor
M6 Screw(Under Motor)
M8 Bolt(Under Motor)
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1. Stop all motion on the sections of the MagneMover LITE transport system to be ser-viced.
2. Loosen the M8 bolt securing the G3 motor to the motor mount for the G3 motors or G3 switches connecting to the G4 motor or G4 switch.
3. Loosen the M6 bolt securing the G4 motor to the motor mount for the G4 motors or G4 switches connecting to the G3 motor or G3 switch.
4. 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-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: The Loctite must cure for 2 hours at 22° C [72° F] before using the transport system.
6. Tighten the M8 bolt securing the G3 motors to the motor mounts to 12 N-m [106 in-lb] using a 13 mm Hex socket.
7. Tighten the M6 bolt securing the G4 motors to the motor mounts to 5.5 N-m [49 in-lb] using a 10 mm Hex socket.
8. Repeat Step 2 through Step 7 at all motor and switch joints.
9. Return the MM LITE transport system to normal operation.
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Replacing Motors
The MagneMover LITE motors can typically be replaced very easily depending upon the location and mounting method for the motor.
Remove the Existing Motor
1. All material transfers should be completed (move all material to the appropriate loca-tions) on the section of the MagneMover LITE transport system where the motor will be replaced.
2. Command all vehicles to known safe positions off of the Path where the motor will be replaced.
3. Issue a Suspend Movement command for the Path where the motor will be replaced.
All 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 securing the motor.
9. Remove the motor from the transport system.
10. Store the motor in a secure location.
11. Refer to Shipping on page 7-74 to return the motor to MagneMotion.
CAUTION
Heavy Lift Hazard
The MagneMover LITE motors can weigh as much as7.3 kg [16 lb]. Failure to take the proper precautionsbefore moving them could result in personal injury.
Use proper lifting techniques and steel toe shoeswhen moving any MagneMover LITE motors.
kg
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Install the New Motor
1. Refer to Stand System Installation on page 5-11 for detailed installation instructions.
2. Reconnect 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 was replaced.
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Programming Motors
When a new MagneMover LITE motor is installed, either as part of a new system installation or as a replacement for an existing motor it must be programmed with the appropriate Motor ERF image (motor_image.erf).
NOTE: MagneMover LITE motors are shipped from the factory with just a basic 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 Controller Web Interface User’s Manual for details.
2. Reset the Paths where the motors were programmed (e.g., use the NCHost TCP Inter-face Utility, refer to the NCHost TCP Interface Utility User’s Manual for details).
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Separating Magnet Arrays
Magnet arrays can become stuck to each other or to any ferrous materials through improper handling. It is the responsibility of the user to define and implement their own separation pro-cedures. Note that it may be impossible to separate very large magnet arrays.
• Magnet arrays that become stuck to each other should only be separated by trained personnel. MagneMotion recommends returning stuck magnet arrays to MagneMotion for separation.
• Magnet arrays stuck to a surface can be removed by sliding the array to the edge of the surface it is stuck 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 othermedical electronic implants must stay away from the magnetarray 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 damage to watches, instruments, electronics, andmagnetic media, keep metal tools, metal objects, magneticmedia (memory disks/chips, credit cards, and tapes) and elec-tronics away from the magnet arrays.
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Replace Pucks
Pucks should be replaced if they become damaged or worn. Additionally, pucks may be added to, or removed from, the transport system if the quantity of pucks in use is not correct. If the transport system does not contain an open spur that can be used to insert or remove pucks, use the following procedure to replace pucks.
Required Tools and Equipment
• Torque wrench with the following bits:
• 4 mm Hex.
• T30 Torx.
• Loctite 243, Thread locker, Anaerobic Adhesive, Blue.
CAUTION
Strong Magnets
To avoid severe injury, people with pacemakers and othermedical electronic implants must stay away from the magnetarray 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 damage to watches, instruments, electronics, andmagnetic media, keep metal tools, metal objects, magneticmedia (memory disks/chips, credit cards, and tapes) and elec-tronics away from the magnet arrays.
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Procedure
Figure 7-10: Remove Curve Motor Guide Rail
Remove Pucks
1. Stop all motion on the section of the MagneMover LITE transport system where the puck will be removed.
2. Remove the inside guide rail from a curve motor.
A. Remove the two screws 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. 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 the V-brace hardware to 3.4 N-m [30 in-lb].
NOTE: The Loctite must cure for 2 hours at 22° C [72° F] before using the transport system.
5. Return the MM LITE transport system to normal operation.
V Brace Screw
Guide Rail
(2X)
Mounting Screws(2X)
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Install Pucks
1. Stop all motion on the section of the MagneMover LITE transport system where the puck will be installed.
2. Remove the inside guide rail from a curve motor.
A. Remove the two screws 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 at 22° C [72° F] before using the transport system.
5. Return the MM LITE transport system to normal operation.
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Replace Puck Wear Surfaces
The various wear surfaces on the pucks should be replaced once they have become worn due to extended use (typically greater than 16 km travel or 2 years, whichever occurs first). This procedure provides instructions for replacing worn wear surfaces on the following pucks:
• 700-1339-00: ML Gen 4 Puck Assy.
• 700-1440-00: ML Gen 4.1 Puck Assy.
• 700-1441-00: ML Gen 4.2 Puck Assy with PTFE Strip.
• 700-1441-01: ML Gen 4.2 Puck Assy with UHMW Strip.
• 700-1540-00: ML Gen 4.3 Puck Assy.
• 700-1560-00: ML G5 Puck Assy.
Required Tools and Equipment
• 100-2067-46 – Screw, FHC, M4 X 22 mm L, A4 SS, w/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 othermedical electronic implants must stay away from the magnetarray 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 damage to watches, instruments, electronics, andmagnetic media, keep metal tools, metal objects, magneticmedia (memory disks/chips, credit cards, and tapes) and elec-tronics away from the magnet arrays.
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• 700-1385-00 – Assy, Top Plate, Puck, Gen 4, ML.
• 100-2378-00 - Glue Dot, Adhesive, Hi-Tack, Semi-Perm, Lo-Profile, 0.250.
• Isopropyl Alcohol.
• Torque wrench with the following bits:
• 2.5 mm Hex.
Procedure
Figure 7-11: Remove Plates from Magnet Assembly
1. Remove the puck from the MagneMover LITE transport system (refer to Replace 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 there are o-rings on the threaded standoffs on the magnet assembly, remove the o-rings and dispose of properly.
M4 Screw(2X)
Magnet Assembly
Top Plate
Center Plate
Protective Strip
G5 Spacer
Threaded Standoff
Glue Dot
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OPTIONAL
A. Remove the protective strip from the magnet assembly.
B. Clean the magnet assembly using isopropyl alcohol to remove any residue.
C. Place the new protective strip on a flat surface with the adhesive side up and remove the adhesive protective backing from the strip.
NOTE: If a PTFE protective strip was used it will be replaced with the new UHMW protective strip.
D. Carefully center the magnet array over the center of the adhesive strip. Fold both ends of the strip over the sides of the array. 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 preload spacer as shown in Figure 7-12.
6. Locate the preload spacer on the center hole on the underside of the top plate, ensuring the surface with the glue dot is fully seated and adhered to the top plate.
7. Align the top plate with the center plate and press together as shown in Figure 7-12.
Figure 7-12: Adhere Preload Spacer to Underside of Top Plate
Center Plate
G5 Spacer
Glue Dot
Top Plate
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8. Locate the plate assembly over 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).
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Replace Power Supply Fuses
Fuses must be replaced if they become damaged.
Required Tools and Equipment
• Small flat blade screwdriver.
• T, 250V, 2A Fuses.
• T, 250V, 10A Fuses.
Procedure
Figure 7-13: Power Supply Fuse Locations
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.
F3LOGIC
T, 250V, 10A
F1PROPULSION 1
T, 250V, 10ALOGIC
PROPULSIONF2
PROPULSION 2T, 250V, 10A
SEE
MAN
UAL
FOR
FILT
ER M
AINT
ENAN
CE
GND
J4 DC ENABLE(SEE MANUAL FOR PINOUT)
36 VDC300W / 8A MAX
36 VDC300W / 8A MAX
J1 J2
GND
V+PROPULSION
V+LOGIC
V-RETURN
V+LOGIC
V-RETURN
V+PROPULSION
Power Entry Module
DC Fuse
Rear View
Front View
Holders
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AC Fuse
1. Turn off power to the MM LITE Power Supply and unplug the power cable.
2. Open the Power Entry Module (PEM), shown in Figure 7-13, by inserting a small flat blade screwdriver into the slot at the top and pressing outward as shown in Fig-ure 7-14.
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 side.Single fuse on the left-hand side.
NOTICE
Never force the Fuse Module when inserting. Ensure it is not at anangle prior to inserting and slides straight in.
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7. Close the power entry module and ensure that the cover snaps into place.
8. Return the power supply to normal operation.
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 holder.
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Replace Precision Rail Vehicles
Precision Rail vehicles should be replaced if they become damaged or worn. Additionally, vehicles may be added to, or removed from, the transport system if the quantity of vehicles in use is not correct. If the transport system does not contain an open end that can be used to insert or remove the vehicles, use the following procedure to replace the vehicles.
Required Tools and Equipment
• Open end wrench, 13 mm, thin.
• Socket wrench, 13 mm.
• Torque wrench (0.9 - 26 N-m [8 - 230 in-lb] range) with the following socket:
• 13 mm Hex.
Vehicle Orientation
When installing the Precision Rail vehicles they must be installed with the eccentric bearings 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 othermedical electronic implants must stay away from the magnetarray 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 packaging.
To avoid damage to watches, instruments, electronics, andmagnetic media, keep metal tools, metal objects, magneticmedia (memory disks/chips, credit cards, and tapes) and elec-tronics away from the magnet arrays.
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Figure 7-16: Precision Rail Vehicle to Rail Orientation
Installing Vehicles with Rails Removed
The bearings on Precision Rail vehicles are pre-set at the factory prior to shipment. The rec-ommended, and easiest method for installing vehicles on a Precision Rail system is with one rail removed, or during installation prior to fastening the last rail onto the system. This enables all vehicles to slide onto the rail system without having to make major adjustments to the bearings. For proper vehicle orientation, see Figure 7-16.
1. Slide the felt tip of the lubricating applicator into the body of the applicator so it can clear the rail (refer to Replacing Lubricating Applicators on Vehicles on page 7-50).
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 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 little or no front-to-back or side-to-side rocking or binding felt between the vehicle bearings and the rail.
NOTE: Each vehicle’s factory pre-load (eccentric bearing settings) will vary slightly and may or may not be appropriate out of the box for a particular transport system. If a vehicle’s eccentric bearings require adjustment to improve the vehicle’s movement along the rail, see Adjusting Vehicle Bearings on page 7-11.
• If the vehicle can be noticeably rocked from side to side or front to back, then there is too much movement between the bearings and the rail and the bearings
Concentric
Motor Side
Eccentric
Stand Sideof Rail
BearingsEccentricBearings
BearingsConcentric
Bearings
of Rail
Single Array VehicleDual Array Vehicle
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must be adjusted for a tighter fit with the rails, see Adjusting Vehicle Bearings on page 7-11.
• If the vehicle appears to bind, then the bearings must be adjusted for a looser fit with the rails, see Adjusting Vehicle Bearings on page 7-11.
Installing Vehicles Without Removing Rails
If it is not possible or practical to remove a rail to install a vehicle onto the Precision Rail sys-tem the eccentric bearings may be loosened to allow the vehicle to be inserted onto the rail. Note that installing vehicles in this manner will require adjustment of the vehicle’s bearings after it is installed on the rail. For proper vehicle orientation, see Figure 7-16.
1. Stop all motion on the section 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 (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. Tilt the vehicle at an angle, with the eccentric bearings positioned down and the mag-net arrays upward, as shown in Figure 7-17.
Figure 7-17: Precision Rail Vehicle Eccentric Bearings
6. Touch the inside edges of the eccentric bearings to the outside edge of the rail, then slowly roll the magnet side of the vehicle onto the rail bringing the concentric bearings and magnet arrays to a horizontal position.
EccentricBearing
Bearing Nut
Motor Side of Vehicle
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Figure 7-18: Install Precision Rail Vehicle on Rail
7. To adjust both eccentric bearings, refer to Adjusting Vehicle Bearings on page 7-11.
8. Re-attach the lubricating applicator to bottom of the vehicle. See Replacing Lubricat-ing Applicators on Vehicles on page 7-50.
9. Return the MM LITE transport system to normal operation.
Removing Vehicles by Removing Rails
The single or dual array vehicles can be removed from the Precision Rail system by removing a precision rail section.
1. Stop all motion on the section of the MagneMover LITE transport system 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 section.
A. Position the rail over the edge of the spine plates, aligning the letters engraved on the end of each rail segment and the mounting holes in the rail over the spine plate holes.
B. Secure the rail to the corresponding spine plates using M5 SHC screws, tighten each screw to 1.8 N-m [16 in-lb], using the sequence shown in Figure , Align and Secure Rails to Spine Plates, on page 5-50.
5. Return the MM LITE transport system to normal operation.
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Removing Vehicles Without Removing Rails
The single or dual array vehicles can be removed from the Precision Rail system without removing any of the precision rail sections. Note that removing vehicles in this manner will require adjustment of the vehicle’s bearings after it is re-installed on the rail.
1. Stop all motion on the section of the MagneMover LITE transport system where the vehicle will be removed.
2. Remove 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 vehicle up and off of the rail as shown in Fig-ure 7-19.
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.
Figure 7-19: Remove Precision Rail Vehicle From Rail
6. Return the MM LITE transport system to normal operation.
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Replacing Lubricating Applicators on Vehicles
To help extend bearing and rail life, felt tipped lubricating applicators should be attached to the underside of each vehicle. Each applicator (see Figure 7-20) consists of an impact resistant plastic housing, and a spring loaded, oil impregnated felt wiper designed to apply a constant film of oil to the working surfaces of the rail without imposing undue friction.
NOTE: The frequency of lubrication depends on the distance traveled, duty, and environ-mental factors. Replenish lubricant as necessary using a 68 viscosity EP mineral oil (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 othermedical electronic implants must stay away from the magnetarray 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 packaging.
To avoid damage to watches, instruments, electronics, andmagnetic media, keep metal tools, metal objects, magneticmedia (memory disks/chips, credit cards, and tapes) and elec-tronics away from the magnet arrays.
Felt Tip
Mounting Holes
Oil Refill Port
(2X)
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Required Tools and Equipment
• Screwdriver, Phillips #1.
• Loctite 243, Thread locker Anaerobic Adhesive, Blue.
Procedure
The lubricating applicators are attached to the underside of the vehicle between either the con-centric bearings or the eccentric bearings as shown in Figure 7-21. To maintain consistency between vehicles, and to apply lubricant evenly to both sides of the rail system, MMI recom-mends that half the vehicles be installed with the applicator between the concentric bearings and the other half between the eccentric bearings.
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 freely along the rail.
1. Install the applicator at either the eccentric bearing or concentric bearing location by inserting two M3 x 8 mm screws into the appropriate holes on the top of the vehicle as shown in Figure 7-22.
Figure 7-22: Installing or Removing a Precision Rail Felt Applicator
ConcentricBearings
Applicator
Applicator
EccentricBearings
Felt Tip
Felt Tip
Mounting holes atEccentric Bearings
Mounting holes atConcentric Bearings
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2. Position the applicator on the underside of the vehicle, below the two corresponding screw holes. Make 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.
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Replacing Magnet Arrays On Precision Rail Vehicles
Magnet arrays can be removed and replaced if they become damaged. Or, if the Precision Rail Vehicle becomes damaged, the magnet array can be removed and installed on a new vehicle.
CAUTION
Strong Magnets
To avoid severe injury, people with pacemakers and othermedical electronic implants must stay away from the magnetarray 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 packaging.
To avoid damage to watches, instruments, electronics, andmagnetic media, keep metal tools, metal objects, magneticmedia (memory disks/chips, credit cards, and tapes) and elec-tronics away from the magnet arrays.
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Single Array Vehicles
Figure 7-23: Single Array Precision Rail Vehicle Assembly
Required Tools and Equipment
• Hex wrench, 2.5 mm.
• Loctite 243, Thread locker Anaerobic Adhesive, Blue.
Procedure
1. Stop all motion on the Path where the vehicle to be removed is located.
2. Remove the vehicle as described in 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. 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, lift the vehicle off of the array and place the array in the original shipping container, or in an isolated container.
6. Remove the shims from the top of the magnet array and store them in a safe location for reuse.
Single ArrayCarriage
Shim, 1mm(2X)
Magnet Array
M4 x 12mm Screw(2X)
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7. Locate the replacement magnet array and place flat on the work surface away from the vehicle.
8. Place the previously removed shim(s) on the top surface of the replacement magnet array. Slide the shims around the array posts but do not allow the ends to extend beyond the outer edges of the array.
NOTE: 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 must cure for 2 hours at 22° C [72° F] before using the vehicle.
11. Replace the vehicle, refer to Replace Precision Rail Vehicles on page 7-45.
12. Restart the Path.
13. Dispose of the removed magnet array appropriately.
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Dual Array Vehicles
Figure 7-24: Dual Array Precision Rail Vehicle Assembly
Dual ArrayCarriage
Shim, 1mm(2X)
Magnet Array
M4 x 12mm Screw(4X)
AssemblyFixture
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Required Tools and Equipment
• Hex wrench; 2.5 mm Hex.
• Assembly fixture.
• Loctite 243, Thread locker Anaerobic Adhesive, Blue.
Procedure
1. Stop all motion on the Path where the vehicle to be removed is located.
2. Remove the vehicle as described in Replace Precision Rail Vehicles on page 7-45.
3. Place the vehicle on a non-metallic work surface with the magnet arrays down. Keep the magnet arrays 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. Place the vehicle in the assembly fixture on a non-metallic work surface with the bear-ings and magnet arrays facing downward. Keep the magnet arrays at least three feet away from metal objects and tools. For safety reasons, only service one vehicle at a time.
NOTE: The fixture holds the magnet arrays in place and helps to prevent them from being attracted to each other.
5. Remove the four M4 x 12 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 in the orig-inal shipping container, or in isolated containers. Do not move one magnet array over, or near the other magnet array.
9. Locate the replacement magnet arrays and place the first array in the assembly fixture.
10. Hold the first array in place and place the second array in the assembly fixture. Do not move the magnet array over, or near the other magnet array.
11. Place the previously removed shim(s) on the top surface of the replacement magnet arrays. Slide the shims around the array posts but do not allow the ends to extend beyond the outer edges of the array.
NOTE: If the shims are removed, or additional shims added, the length of the screws must be adjusted appropriately.
12. 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.
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13. Secure the array to the vehicle 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.
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Replacing Bearings On Precision Rail Vehicles
Bearings can be removed and replaced if they become damaged. Figure 7-25 shows the loca-tion of each set of eccentric bearings and concentric bearings for both the single array and dual array vehicles. The concentric bearings are located closest to the magnet arrays and the eccentric bearings are located furthest from the magnet arrays.
Figure 7-25: Precision Rail Vehicle Bearing Locations
CAUTION
Strong Magnets
To avoid severe injury, people with pacemakers and othermedical electronic implants must stay away from the magnetarray 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 packaging.
To avoid damage to watches, instruments, electronics, andmagnetic media, keep metal tools, metal objects, magneticmedia (memory disks/chips, credit cards, and tapes) and elec-tronics away from the magnet arrays.
Concentric
Motor Side
Eccentric
Stand Sideof Rail
BearingsEccentricBearings
BearingsConcentric
Bearings
of Rail
Single Array VehicleDual Array Vehicle
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Required Tools and Equipment
• Open end wrench, 13 mm, thin.
• Socket wrench, 13 mm.
• Torque wrench (0.9 - 26 N-m [8 - 230 in-lb] range) with the following socket:
• 13 mm Hex.
• Loctite 290, Thread locker, Wicking 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 Vehicles on page 7-45).
Concentric
Washer
Bearing
Bearing Nut
(2X)
Top Nut
(2X)
(2X)
(2X)
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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 remove the nut and washer for the concentric bearing being removed (located on the top of the carriage) and store them in a safe location for reuse.
5. Remove the concentric bearing from the bottom of carriage and discard appropriately.
6. Insert the replacement concentric bearing from the bottom of the carriage.
7. 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 wrench to tighten the nut on the top of the carriage to 19 N-m [14 ft-lb] and apply Loctite 290.
NOTE: The Loctite must cure for 3 hours at 22° C [72° F] before using the vehicle.
10. Repeat this procedure on the companion concentric bearing, if it is also being replaced.
11. If eccentric bearings are to be replaced on this vehicle, refer to Replacing Eccentric Bearings on page 7-62.
12. If the vehicle is ready to be installed on the rail, refer to Replace Precision Rail Vehi-cles on page 7-45.
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Replacing Eccentric Bearings
If concentric bearings are to be replaced on this vehicle, perform that procedure first (refer to Replacing Concentric Bearings). Figure 7-27 shows a dual array vehicle, however the same process is used for single array vehicles.
Figure 7-27: Precision Rail Vehicle Eccentric 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 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 remove the nut and washer for the eccentric bearing being removed (located on the top of the carriage) and store them in a safe location for reuse.
5. Remove the eccentric bearing from the bottom of carriage and discard appropriately.
Concentric
Washer
Bearing
Bearing Nut
(2X)
Top Nut
(2X)
(2X)
(2X)
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6. Insert the replacement eccentric bearing from the bottom of the carriage.
7. 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 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 adjustments are complete.
10. Repeat this procedure on the companion eccentric bearing, if it is also being replaced.
11. Refer to Replace Precision Rail Vehicles on page 7-45 to return the vehicle to the rail.
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Replacing Wear Surfaces on Pallet
The various wear surfaces on the pallet used with the Precision Locator should be replaced once they have become worn due to extended use. This procedure provides instructions for replacing worn wear surfaces on the pallet or replacing a pallet if it has become damaged.
Required Tools and Equipment
• 100-0097-30 – Loctite 243, Thread locker Anaerobic Adhesive, Blue.
• 100-2067-01 – Screw, Flat Head, M4 X 8 mm L, A4 SS, per DIN 7991 (2X).
• 100-2067-05 – Screw, Flat 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 bits:
• 2.5 mm Hex.
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 any ferrous material or another magnet array to avoid injury from strong magnetic attractive forces.
• Pucks or magnet arrays not being used should be secured individually in isolated packaging.
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Procedure
Figure 7-28: Remove Precision Locator Pallet from Magnet Assembly
1. Remove the puck with pallet from the MagneMover LITE transport system (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
Glue Dot
Preload Spacer
M4 x 8 mm Screw(2X)
(2X)
Spacer(2X)
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B. Clean the magnet assembly using isopropyl alcohol to remove any residue.
C. Remove the backing from the new protective strip and place it on the magnet assembly by centering the round hole at the end of the strip over one of the threaded standoffs and folding the strip around the bottom of the magnet assembly and over the other standoff as shown in Figure 7-28. Press the strip into place using a burnisher, ensuring there are no bubbles.
3. If a new center plate is being installed, remove the backing and apply the glue dot to the depression in the middle of the septum on the center plate as shown in Figure 7-28.
4. If necessary, replace the spacers in the center plate as shown 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 mm flat head screw. Secure the skis to the pallet using the two M4 x 8 mm flat head screws, and tighten to 1.5 N-m [13 in-lb].
6. Align the pallet with the spacers on the center plate and seat it into place.
7. Place two to three drops of Loctite 243 on the threads of each M4 x 20 mm flat head screw. Secure the pallet to the magnet array using the two M4 x 20 mm flat head screws, and tighten 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.
8. Replace the puck on the MM LITE transport system (refer to Replace Pucks on page 7-35).
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Replacing Bushings on Pallet
The bushings used to locate the pallet 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.
• 200-2342-00 – Tapered Bushing, Hole, Pallet, 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 any ferrous material or another magnet array to avoid injury from strong magnetic attractive forces.
• Pucks or magnet arrays not being used should be secured individually in isolated packaging.
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Procedure
Figure 7-29: Replace Bushings on Precision Locator Pallet
1. Remove the puck with pallet from the MagneMover LITE transport system (refer to Replace Pucks on page 7-35).
2. Remove the M6 nuts securing the bushings to the pallet as shown in Figure 7-29.
3. Remove the bushings from the pallet using an arbor press.
4. If necessary, remove the dowel pins from the pallet using an arbor press.
5. Clean the surfaces of the pallet using isopropyl 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 threads of each M6 nut. Secure the bush-ings to the pallet using the two M6 nuts, and tighten to 2.3 N-m [20 in-lb].
NOTE: 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).
M6 Nut(2X)
Pallet
2 mm Dowel Pin(2X)
Bushing, Hole
Bushing, Slot
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Replacing Pins on Precision Locator Arms
The pins used to locate 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)
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1. Stop all motion on the section of the MagneMover LITE transport system where the Precision Locator will be serviced.
2. Remove the pin from the Precision Locator arm as shown in Figure 7-30.
A. Slide the 2 mm pin from the Installation Tool into the hole on the Spherical Contact 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. Engage the 2 mm pin with the Installation Tool socket and tighten the Spheri-cal Contact Pin to 2.3 N-m [20 in-lb].
5. Return the MM LITE transport system to normal operation.
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Replacing Z-Datums on Precision Locator Stand
The z-datums used to support the pallet while it is being secured by the 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 Stand
Z-Datum(2X)
M4 Screw(4X)
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1. Stop all motion on the section of the MagneMover LITE transport system where the Precision Locator stand z-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 operation.
MaintenanceOrdering Parts
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Ordering Parts
If new or replacement parts are needed contact MagneMotion Sales:
Main Office
MagneMotion, Inc.139 Barnum RoadDevens, MA 01434USAPhone: +1 978-757-9100Fax: +1 978-757-9200
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Shipping
If a component of the MagneMover LITE transport system must be shipped, either for return to MagneMotion or to another location, it must be packaged properly to ensure it arrives undamaged. The following procedure provides the correct method for handling and packaging MM LITE components for shipment.
Required Tools and Equipment
• Metric Hex wrenches.
• English Hex wrenches.
• Open end wrench, adjustable.
• Fork truck or appropriate lift as required.
CAUTION
Electrical Hazard
Before beginning this procedure the MagneMover LITEtransport system must be shut down following the procedureprovided in Safe Shut-down on page 6-27.
CAUTION
Heavy Lift Hazard
Some of the MagneMover LITE components can weigh asmuch as 14.5 kg [32 lb]. Failure to take the proper precau-tions before moving them could result in personal injury.
Use proper lifting techniques when moving any Magne-Mover LITE components. Steel toe shoes should be worn atall times when packing and shipping any MagneMover LITEcomponents.
kg
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Packing Procedure
When any of the components of the MagneMover LITE transport system are shipped, either for return to MagneMotion for service or to another location, they must be properly packaged to ensure they arrive undamaged. The following procedure provides the correct method of handling and packaging the MagneMover LITE components for shipment.
NOTE: The original shipping packaging must be used when shipping MagneMover LITE components. If the original packaging has become lost or damaged, contact Magne-Motion for replacements.
CAUTION
Strong Magnets
To avoid severe injury, people with pacemakers and othermedical electronic implants must stay away from the magnetarray 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 damage to watches, electronic instruments, andmagnetic media, keep metal tools, metal objects, magneticmedia (memory disks/chips, credit cards, and tapes) and elec-tronics away from the magnet arrays.
CAUTION
Heavy Lift Hazard
Some of the MagneMover LITE components can weigh asmuch as 14.5 kg [32 lb]. Failure to take the proper precau-tions before moving them could result in personal injury.
Use proper lifting techniques when moving any Magne-Mover LITE components. Steel toe shoes should be worn atall times when packing and shipping the MagneMover LITEcomponents.
kg
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76 MagneMotionRockwell Automation Publication MMI-UM002E-EN-P - March 2016
1. Turn off and disconnect all electrical and pneumatic power as detailed in Safe Shut-down on page 6-27.
2. Disconnect all communications connections as detailed in Safe Shut-down on page 6-27.
3. Ensure the system or component has been properly decontaminated following the facilities decontamination procedures. Follow all facility, local, and national proce-dures for the disposal of any hazardous materials.
4. When shipping individual components, remove all components that will be shipped (refer to the Transport System Installation on page 5-5 and reverse the sequence to remove components) and refer to Shipping Components on page 7-76.
When shipping systems, refer to Shipping 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, Caution - Heavy, etc.) and all shipping documents are attached to the outside of the container.
5. When shipping to MagneMotion, ensure the SRO number is clearly visible on the out-side of the box.
Shipping Systems or System Sections
1. Bolt the feet to the bottom of the crate.
2. Install brackets to secure the leg outriggers to the bottom of the crate.
3. Ensure all hardware on the system is properly secured.
CAUTION
Magnetic Field Hazard
When shipping pucks or magnet arrays ensure theshipping container properly isolates the magnets andidentifies the Magnetic Field Hazard.
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4. Secure any loose wires to the system frame using plastic shipping film.
5. Secure any vehicles (pucks) on the system by moving them to one section of the sys-tem and wrapping them and the motors they are on in plastic shipping film.
6. Ensure the 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 as desired to verify proper handling during shipment.
10. When shipping to MagneMotion, ensure the SRO number is clearly visible on the out-side of the crate.
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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.
AppendixFile Maintenance
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File Maintenance
Backup Files
MagneMotion recommends regular backups of all files that may have been changed. Copies of all 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 to their original name.
AppendixAdditional Documentation
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Additional Documentation
Release Notes
The Release Notes for MagneMotion software include special instructions, identification of software versions, identification 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 associated with the software. The Upgrade Procedure is supplied with the software.
AppendixTransport System Limits
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Transport System Limits
Table A-1: MagneMotion Transport System Limits
Path Node Controller System
Motors 20 240†
† Limited by the number of RS-422 connections on the Node Controller (NC LITE – 4, NC-12 – 12).
1,280
Node Controllers – – 64
Nodes 2 –† 128
Paths – –† 64
Stations 255 255 255
Vehicles (Pucks) –*
* Limited by the length of the Path and the length of the vehicles.
384 2,560
Table A-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 stator current with a nominal Vehicle Gap of 3 mm using a standard magnet array.
100 kg [220 lb]
QuickStick® HT 60 m/s2 [6.1g] 2.5 m/s [5.6 mph] 182.0 N/cycle‡
‡ QSHT thrust at 10.9 A stator current with a nominal Vehicle Gap of 12 mm using a high flux magnet array.
4500 kg [9900 lb]
MagneMover LITE User Manual 1Rockwell Automation Publication MMI-UM002E-EN-P - March 2016
Glossary
Block: See Motor Block.
Bogie: A structure underneath a vehicle to which a magnet array is attached. The structure is then attached to the vehicle. For vehicles traveling over curves the attachment is through a bearing allowing independent rotation.
Brick-wall Headway: Space maintained between vehicles to ensure that a trailing vehicle is able to stop safely if the leading vehicle stops suddenly (‘hits a brick wall’).
Byte: A single octet of data (8 bits).
Component: The main parts that form a MagneMotion transport system. Also called system components, these include Motors and Controllers.
Configurator: The application used to define and edit the basic operating parameters of the transport system stored in the Node Controller Configuration File.
Controller: A device that 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 or demon-stration purposes to move vehicles on the transport system. Also called a Demo Script.
Design Specifications: The unique parameters for a specific MagneMotion transport system.
Downstream: The end of a motor or Path where a vehicle exits if it is travelling in the default forward direction. The vehicle typically enters the motor or Path on the Upstream end.
Downstream Gap: The physical distance from the end of the stator in one motor to the beginning of the stator in the next motor downstream on the same Path. This includes the Motor Gap.
E-Stop: See Emergency Stop.
Emergency Off: A user-supplied device that disconnects AC power to the transport system.
GlossaryEmergency Stop
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Emergency Stop: A user-supplied circuit with a locking button that anyone can press to stop motion in the transport system. It may be wired through the Digital I/O ports on the NC-12 Node Controller.
EMO: See Emergency Off.
Forward Direction: The default direction of movement, from Upstream to Downstream, on a Mag-neMotion transport system.
Global Directives: The Demonstration Script commands that define the general operating charac-teristics for all vehicles specified. See also Vehicle Directives.
Ground: The reference point in an electrical circuit from which voltages are measured. This is typically a common return path for electric current. See also PE.
Guideway: A component of the Track System that consists of rails or other devices in con-tact with the Vehicle, either through wheels or low friction runners on the vehi-cle, to ensure the vehicles are maintained in the proper relationship to the motors. In the MagneMover LITE transport system this is the integral rails mounted on the motors.
High Level Controller: The application in a Node Controller that communicates with the Host Con-troller. In a transport system with only one Node Controller, 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 the transport system. The con-troller may be either a PC-Based Controller or a Programmable Logic Con-troller.
Host Control Session: A user session between an application running on the Host Controller (such as the NCHost TCP Interface Utility) and a High Level Controller that allows the user to issue commands to control all aspects of Transport System opera-tion as well as to actively monitor Transport System status.
Host Status Session: A user session between an application running on the Host Controller (such as the NCHost TCP Interface Utility) and a High Level Controller that only allows the user to actively monitor Transport System status.
ID: The software labels used to uniquely identify various components of the trans-port system to ensure proper execution of commands involving vehicle posi-tion, vehicle destination, and transport system configuration. ID types include vehicle and Path.
Interlock: A user-supplied circuit used to stop motion in the transport system. It is wired through the Digital I/O ports on the NC-12 Node Controller.
GlossaryPath
MagneMover LITE User Manual 3Rockwell Automation Publication MMI-UM002E-EN-P - March 2016
Keepout Area: An area of a Path where the motors will not allow a vehicle to enter unless it has permission from the motors to move past the area.
Logic Power: The power used for the controllers and signals. See also, Propulsion Power.
LSM: Linear Synchronous Motor. See MagneMover® LITE and QuickStick®.
MagneMover® LITE: A MagneMotion linear synchronous motor with integrated guideways and vehicles (pucks) that enables quick, efficient conveyance of loads up to 1 kg on a single vehicle (2 kg on a tandem puck).
Magnet Array: The magnets attached to the Vehicle. It is the motor secondary, moved by the primary in the motor.
MM LITE: See MagneMover® LITE.
Motor: See LSM.
Motor Block: A discrete motor primary section (coil or set of coils) within a motor that can be energized independently. This section can contain only one vehicle during transport system operation.
Motor Controller: The controller for each motor that communicates vehicle positions and other information to the Node Controller. It is internal to the motor on MagneMover LITE and QuickStick 100 motors and external on QuickStick HT motors.
Motor Gap: The physical 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 system containing the basic operating parameters of the transport system. A copy of the Configura-tion File is uploaded to each Node Controller in the transport system.
Node Controller: The controller that coordinates vehicle movements along a Path or Paths of motors. The Node Controller is responsible for the motors on all Paths origi-nating from Nodes that the Node Controller is responsible for.
There can be multiple Node Controllers in a transport system each responsible for a subset of the Nodes within the transport system.
NRTL/ATL: Nationally Recognized Test Lab/Accredited Test Lab.
NRTL organizations have been recognized by OSHA in accordance with 29 CFR 1910.7 to test and certify equipment or materials (products).
ATL organizations have been evaluated by Accreditation bodies to ISO/IEC 17025 for testing and calibration laboratories.
Path: A designation for one or more motors placed end to end, which defines a linear route for vehicle travel. A Path begins at the Upstream end of the first motor in
GlossaryPC-Based Controller
4 MagneMotionRockwell Automation Publication MMI-UM002E-EN-P - March 2016
the series and ends at the Downstream end of the last motor in the series. All Paths must begin at a Node and the beginning of a Path is always the zero posi-tion for determining vehicle positions along that Path.
PC-Based Controller: The user-supplied computer that provides control and sequencing for the operation of the transport system.
PE: Protective Earth. A conductor that is provided for safety purposes (e.g. against the risk of electric shock) and which also provides a conductive path to earth. See also, Ground.
PLC: See Programmable Logic Controller.
Position: A specific location on a Path, measured from the beginning of that Path, used as a vehicle destination. Position zero on any Path is defined as the leading edge of the first LSM in the Path.
A vehicle at a specific position has its midpoint over that location on the Path.
Power Supply: The equipment used to convert facility AC power to the correct voltages for the transport system.
Programmable Logic Controller: The user-supplied dedicated controller consisting of Processor and I/O modules that provides control, 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 guideways and vehicles. Quick-Stick 100 (QS 100) motors move loads up to 100 kg [220 lb] per vehicle and QuickStick High Thrust (QSHT) motors move loads up to 4,500 kg [9,900 lb] per vehicle.
QuickStick® System: A group of specific components that contribute to a Transport System. These components include QuickStick® motors, Node Controllers, Motor Controllers (if applicable), Magnet Arrays, and other parts available from MagneMotion.
Single Vehicle Area: An area of a Path where only one vehicle may move at any time. Other vehi-cles on the Path must form a queue and wait before entering this area until the previous vehicle leaves the area. This option allows one vehicle to move back-ward and forward along a portion of a Path without interfering with any other vehicles.
Station: A specific location on a Path, measured from the beginning of that Path and identified with a unique ID, used as a vehicle destination.
Stator: The stationary part of the motor over which the magnet array is moved.
GlossaryVehicle Master
MagneMover LITE User Manual 5Rockwell Automation Publication MMI-UM002E-EN-P - March 2016
Switch: The mechanical guide for positioning a vehicle through merging or diverging guideway sections.
Sync Zone: An area where vehicle motion may be synchronized with other moving sys-tems through direct control of the motor by the Host Controller.
System Component: The main parts that form a Transport System. Also called components, these include Motors and Controllers.
Tandem Vehicle: A vehicle designed to carry larger loads that uses dual bogies (two magnet arrays on pivoting carriers linked to the vehicle) to provide enough thrust.
Track System: The components that physically support and move vehicles. For a QuickStick transport system, this includes a Guideway, one or more QuickStick® motors, mounting hardware, and a stand system. For a MagneMover LITE transport system this includes the MagneMover® LITE components and stands.
Transport System: The components that collectively move user material. This includes the Motors, external Motor Controllers (if applicable), Track System, Node Con-trollers, Vehicles, cables, and hardware.
Upstream: The end of a motor or Path where a vehicle enters if it is travelling in the default forward direction. The upstream end of all Paths are connected to Node Controllers. 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. All vehicles on Paths connected through Nodes must be of the same length.
The transport system constantly monitors and controls vehicle position and velocity for the entire time the vehicle is on the transport system. All vehicles are assigned a unique ID at startup and retain that ID until the transport system is restarted or the vehicle is removed or deleted.
Vehicle Directives: The Demonstration Script commands that define the individual movement characteristics for a specific vehicle. See also Global Directives.
Vehicle Gap: The distance between the bottom of the magnet array attached to a vehicle and the top surface of a motor.
Vehicle ID Master Database: The database maintained by the High Level Controller for the assign-ment and tracking of Vehicle IDs in the transport system. When using HLC Control Groups, this database is maintained by the Master HLC.
Vehicle ID Slave Database: The database used by Slave HLCs when using HLC Control Groups to track the Vehicle IDs assigned by the Vehicle ID Master Database within the Slave’s HLC Control Group.
Vehicle Master: The motor controlling the vehicle.
GlossaryVehicle Signal
6 MagneMotionRockwell Automation Publication MMI-UM002E-EN-P - March 2016
Vehicle 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.
MagneMover LITE User Manual 1Rockwell Automation Publication MMI-UM002E-EN-P - March 2016
Index
AAC Power Requirements
Ethernet Switch, 4-58Node Controller LITE, 4-54Node Controller, NC-12, 4-49power supply, 4-44
Adjust RailsG3 motors, 7-25G4 motors, 5-23precision rails, 5-50
Adjustable Motor Mountdimensions, 4-36installation, 5-19overview, 1-6
BBackup, A-2Battery Disposal, 2-28Beam
installation, 5-11overview, 1-3
Block Length, 3-10Bogie, see Dual Magnet Array VehicleBracket
electronics mounting, 4-24floor mounting, 5-16install onto NC-12, 5-30motor mounting, adjustable, 4-36motor mounting, standard, 4-11NC-12 rack mounting, 4-22network switch, 5-28Node Controller LITE, 5-27Node Controller, NC-12, 5-29power supply, 5-31
Brick-wall Headway, 6-7
CCable Chase
cover installation, 5-41cover mounting bracket, 5-18overview, 1-3
CablesAC power, 4-46, 4-53, 4-57, 4-58DC Enable, 4-48DC power, 4-47design, 3-12, 3-43Ethernet, 4-62RS-422, 4-63
Carrier Design, 3-31Cleaning, 7-3Communication Cables
digital I/O, 4-65Ethernet, 4-62identification, 1-7installation, 5-34, 5-36, 5-37RS-422, 4-63Sync option, 4-65
Computer Requirements, 1-10Configuration File, see Node Controller Config-
uration FileConfigurator, see MagneMotion ConfiguratorConnections
communications, 5-34motor power, 5-38motor to motor, 5-32network, 5-60power, 5-61RS-422, 5-34
Console Interface, description, 1-8Contact MagneMotion, xxvii, 7-22, 7-73Curve Track, configuration, 3-46Custom Guideway
design, 3-23
IndexD
2 MagneMotionRockwell Automation Publication MMI-UM002E-EN-P - March 2016
Custom Guideway (Continued)installation, 5-6materials, 3-24
Cycle Length, 3-10, 3-16
DDC Enable
cable, 4-48jumper, 4-48use of, 4-39
DC Power Requirementsmotors, 4-38NC-12 Node Controller, 4-49Node Controller LITE, 4-54
Demonstration Scriptcreate, 1-11overview, 1-9
Designcarriers, 3-31custom guideway, 3-23pallet, 3-41transport system, 3-2vehicles, 3-18
Digital I/Ocircuits, 4-65E-Stop, 5-62interlock, 5-62light stack, 5-63operation, 6-18wiring, 5-37
Downstreamconnection, 4-64gap, 3-11
Dual Magnet Arraymotor downstream gap, 3-11Precision Rail Vehicle, 3-38vehicle, 3-19
EEquipment Safety, 2-5E-Stop
connection, 5-62operation, 6-13
Ethernet Cable, 4-62Ethernet TCP/IP
connections, 5-60description, 4-62
EtherNet/IPconfiguration, 5-61connections, 5-60description, 4-63
FFastStop, 6-16
GGap
downstream, 3-11motor, 3-11vehicle, 3-20
Gender Changer, 4-64, 5-35Getting Started, 1-10Guide Rail
alignment, G3 motors, 7-25alignment, G4, 5-23precision, overview, 1-5standard, overview, 1-4
Guidewaydesign, 3-8
HHazards
electrical, 2-23locations on system, 2-7magnetic, 2-25mechanical, 2-22pneumatic, 2-24
High Level Controllerconfigure, 5-61overview, 1-7transport system layout, 3-6
Host Controllercontrol connection, 4-62overview, 1-7status connection, 4-62transport system layout, 3-7
Humiditymagnet array, 4-67motor, 4-66NC LITE, 4-66NC-12, 4-66power supply, 4-66Precision Locator, 4-67
IndexM
MagneMover LITE User Manual 3Rockwell Automation Publication MMI-UM002E-EN-P - March 2016
Humidity (Continued)Precision Rail Vehicle, 4-67puck, 4-67
IImage Files
motor, 1-9Node Controller, 1-9
Inspectioncables, 7-5hardware, 7-5
Installationbeam, 5-11cable chase covers, 5-18check-out, 5-66connections, 5-32electronics, 5-27leveling, 5-15magnet arrays, 5-40motor mount, adjustable, 5-19motor mount, standard, 5-19motors with rails, 5-20overview, 5-7power cables, 5-38Precision Locator Option, 5-54Precision Rail Option, 5-44pucks, 5-40railless motors, 5-25software, 5-64stand system, 5-12switches, 5-20tie-downs, 5-16
Interlockconnection, 5-62operation, 6-15
IP65cleaning, 7-3compatibility, 1-3
JJam, vehicle, 6-8
LLabels
magnet arrays, 2-14motors, 2-12
Labels (Continued)Node Controller LITE, 2-16Node Controller, NC-12, 2-15power supply, 2-17Precision Locator Puck, 2-20precision rail vehicle, 2-18pucks, 2-14, 2-21spine plates, 2-19switches, 2-13
Leg, see Stand SystemLight Stack
connection, 5-63operation, 6-17troubleshooting, 7-21
Lighting, site, 4-67Linear Synchronous Motor, 6-2LSM, see Linear Synchronous MotorLubricating Applicator for Precision Rails
installation, 7-50refilling, 7-8
MMagneMotion
contact, xxvii, 7-22, 7-73Customer Support, 7-22Sales, 7-73
MagneMotion Configurator, overview, 1-9MagneMover LITE
benefits, 6-3components, 1-7description, 1-2installation, 5-5service access, 4-68shipping, 7-74site lighting, 4-67software, 1-8start up, 6-26
Magnet Arraydescription, 3-15dimensions, 4-19, 4-20disposal, 2-28humidity, 4-67installation, 5-40labels, 2-14motor secondary, 6-2overview, 1-4, 1-7temperature, 4-67
IndexN
4 MagneMotionRockwell Automation Publication MMI-UM002E-EN-P - March 2016
Maintenanceair filter, 7-6cleaning, 7-3fuses, 7-42inspection, cables, 7-5inspection, hardware, 7-5log files, 7-6lubricating applicator refill, 7-8magnet arrays, 7-5pallet, 7-64, 7-67Precision Locator, 7-69Precision Locator stand, 7-71puck, 7-38transport system, 7-2
Manualchapter descriptions, xxviconventions, xxivprerequisites, xxiiirelated documents, xxviisafety notices, xxv
MM LITE, see MagneMover LITEMMConfigTool.exe, see MagneMotion Configu-
ratorMotor
block, 6-5block acquisition, 6-6cable chase covers, curve, 5-42cable chase covers, straight, 5-41cable chase covers, switch, 5-43communication connections, 5-34connection locations, 4-40custom mounting, 3-29dimensions, 1 m, 4-3, 4-4dimensions, 250 mm, 4-5, 4-6dimensions, 90° curve, 4-7, 4-8gap, 3-11humidity, 4-66installation, 5-20labels, 2-12limits, A-4mounting, 5-20mounting methods, 3-25overview, 1-4, 1-7positioning, 5-21primary, 6-2programming, 7-33secondary, 6-2
Motor (Continued)temperature, 4-66theory of operation, 6-2transport system layout, 3-3
Motor Mount Design, 3-24Motor Mount, Adjustable
dimensions, 4-36installation, 5-19overview, 1-6
Motor Mount, Standarddimensions, 4-11installation, 5-19overview, 1-4
Mountingalign motors and switches, 5-23G3 motors and switches, 7-27G3 motors to G4 motors, 7-29motor mounts, 5-19motors, 3-25motors and switches, 5-20NC LITE power supply, 5-28NC-12 Node Controller, 5-29network switch, 5-28network switch power supply, 5-28Node Controller LITE, 5-27power supply, 5-31railless motors, 5-25system to floor, 5-16verification, 5-26
Mounting Precision Locator, 5-54Movement Order, 6-4Movement Profile, 6-4
NNCHost TCP Interface Utility
overview, 1-8using, 5-65, 7-33
NCHost.exe, see NCHost TCP Interface UtilityNetwork
cables, 5-36identification, 1-7transport system layout, 3-7
Network Switchconnections, 5-60mounting, 5-28power, 4-58
IndexP
MagneMover LITE User Manual 5Rockwell Automation Publication MMI-UM002E-EN-P - March 2016
Node Controllerconnecting, 5-34identification, 1-7IP Address, 1-10limits, A-4NC LITE
connections, 4-55, 5-34description, 3-6dimensions, 4-23exclusion zones, 4-23humidity, 4-66labels, 2-16mounting, 5-27power, 4-54temperature, 4-66
NC-12connections, 4-50, 5-34description, 3-6dimensions, 4-21exclusion zones, 4-21humidity, 4-66labels, 2-15mounting, 5-29power, 4-49temperature, 4-66
set IP Address, 5-68transport system layout, 3-6troubleshooting, 7-17
Node Controller Configuration Filecreate, 1-10define, 3-2Node Controller port, 5-35overview, 1-9
Node Controller Console Interface, see ConsoleInterface
Node Controller Web Interfacefile upload, 5-65program motors, 5-65upload motor files, 7-33
Node Controller Web Interface, see Web Interfacenode_configuration.xml, see Node Controller
Configuration FileNodes
connections, 5-34limits, A-4transport system layout, 3-5
Notes, xxv
OObstruction, vehicle, 6-8Operation
monitoring, 6-11shut down, 6-27start up, 6-26, 7-2
PPallet
bushing replacement, 7-67design, 3-41extended use, 7-64maintenance, 7-64, 7-67
Pathsconnections, 5-34limits, A-4transport system layout, 3-4
Personnel Safety, 2-4Pneumatic Connections, Precision Locator, 5-58Post Mount, overview, 1-5Power Cables
AC power, 4-46, 4-53, 4-57, 4-58connection, 5-61DC cable, 4-47DC Enable, 4-48identification, 1-7installation, 5-38T, 5-39
Power over EthernetNC LITE, 4-54Network switch, 4-58wiring diagram, 5-60
Power Supplyconnections, 4-45DC enable, 4-48dimensions, 4-25exclusion zones, 4-25humidity, 4-66labels, 2-17mounting, 5-28, 5-31overview, 1-7power, 4-44temperature, 4-66transport system layout, 3-7
Precision Locator Optionconnections, 4-59, 4-61, 5-58dimensions, 4-34
IndexR
6 MagneMotionRockwell Automation Publication MMI-UM002E-EN-P - March 2016
Precision Locator Option (Continued)humidity, 4-67labels, 2-20locator maintenance, 7-69operation, 6-25pallet maintenance, 7-64, 7-67pin replacement, 7-69stand maintenance, 7-71stand z-datum replacement, 7-71system components, 3-40temperature, 4-67
Precision Rail Optionadjusting vehicle bearings, 7-11hazard points, 2-8, 2-9install vehicles with rails removed, 7-46install vehicles without rails removed, 7-47installation overview, 5-8, 5-9lubricating applicator refill, 7-8lubricating rails, 7-7rail, 4-26rail installation, 5-47rails, 3-34, 4-26reference diagram, 3-39remove vehicles with rails removed, 7-48remove vehicles without rails removed, 7-49spine plates, 3-36, 4-30support post assembly, 5-45support post dimensions, 4-29support post installation, 5-46support posts, 3-37system components, 3-33troubleshooting, 7-20vehicle installation, 7-45vehicle orientation, 7-45vehicle repair, 7-23vehicles, 3-38
Precision Rail Vehiclebearing replacement, 7-59dimensions, dual array, 4-28dimensions, single array, 4-27dual array, 3-38, 4-28humidity, 4-67installation, 7-45lubricating applicator installation, 7-50lubricating applicator refilling, 7-8replacing magnet arrays, 7-53single array, 3-38, 4-27temperature, 4-67
Pucksee also Vehiclecleaning, 7-4configuration, single, 3-19configuration, tandem, 3-19dimensions, single, 4-13, 4-14, 4-15dimensions, tandem, 4-16, 4-17, 4-18extended use, 7-38, 7-64humidity, 4-67installation, 5-40labels, 2-14, 2-21limits, A-4maintenance, 7-38replacement, 7-35single magnet array, 3-19temperature, 4-67wear surfaces, 7-5
RRailless Motors, installation, 5-25Rails, installation, 5-47Recycling, 2-28Regulatory Guidelines, 2-2Repair, 7-23Replacement, 7-23Roller, see WheelRS-422
cable, 4-63connections, 5-34
SSafe Stopping Distance, 6-7Safety
alert types, xxvequipment, 2-5hazardous points, 2-7personnel, 2-4symbols, 2-10
Scope, see Virtual Scope UtilityShipping, 7-74Shut Down, 6-27Simulation
configure, 6-19run, 6-21stop, 6-22
IndexT
MagneMover LITE User Manual 7Rockwell Automation Publication MMI-UM002E-EN-P - March 2016
Single Magnet Arraymotor downstream gap, 3-11Precision Rail Vehicle, 3-38vehicle (puck), 3-19
Softwareconfiguration, 5-64installation, motors, 5-65installation, Node Controller, 5-65programming motors, 7-33types, 1-8
Spine Plateoverview, 1-5Precision Rail mounting, 3-36
Stand Systembeam installation, 5-11dimensions, 4-12installation, 5-11leg installation, 5-12leveling, 5-15
Standard Motor Mountdimensions, 4-11installation, 5-19overview, 1-4
Start Up, 6-26Stations
limits, A-4location restrictions, 3-11
Straight Track, configuration, 3-45Support Post
assembly, 4-29installation, 5-46overview, 1-5
Switchcable chase covers, 5-43configuration, 3-47connection locations, 4-42dimensions, left, 4-9dimensions, right, 4-10installation, 5-20labels, 2-13mounting, 5-20overview, 1-4positioning, 5-21transport system layout, 3-3
SYNC IT Controller, 6-12
Synchronization Optionconnection, 4-65connection location, 4-40operation, 6-12
System Configurator, see MagneMotion Config-urator
System Leg, see Stand System
TT cable, 5-39Tandem Vehicle, see Dual Magnet Array VehicleTemperature
magnet array, 4-67motor, 4-66NC LITE, 4-66NC-12, 4-66power supply, 4-66Precision Locator, 4-67Precision Rail Vehicle, 4-67puck, 4-67
Text FilesDemo Script, 1-9Track File, 1-9
Toolsinstallation, 5-5packing, 7-74unpacking, 5-3
Trackcurve, 3-46design, 3-8straight, 3-45switch, 3-47
Track File, overview, 1-9Track Layout File, overview, 1-9track_file.mmtrk, see Track Filetrack_layout.ndx, see Track Layout FileTransport System Layout
High Level Controller, 3-6Host Controller, 3-7motors, 3-3network, 3-7Node Controllers, 3-6Nodes, 3-5Paths, 3-4power supplies, 3-7switches, 3-3
Transport System, see MagneMover LITE
IndexU
8 MagneMotionRockwell Automation Publication MMI-UM002E-EN-P - March 2016
Troubleshootingcommunications, 7-18initial, 7-13light stack, 7-21motion, 7-19Node Controller, 7-17power, 7-14precision rail, 7-20Precision Rail vehicles, 7-20
Type Filesmagnet array, 1-9motor, 1-9
UUnpacking, 5-3Upstream, 4-64
VV-Brace
installation, 3-29, 5-23, 5-25, 7-28, 7-30overview, 1-4
Vehiclesee also Puckanti-collision, 6-6design, 3-18detected, 6-8dual bogie, 3-19dual magnet array, 3-19gap, 3-20jammed, 6-8labels, 2-18limits, A-4locating during startup, 6-8materials, 3-21obstructed, 6-8overview, 1-4, 1-5simulated, 6-20single magnet array, 3-19
Vehicle, Precision Rail Optionadjusting bearings, 7-11dual array, 4-28orientation on rail, 7-45replacing bearings, 7-53single array, 4-27
Virtual Scope Utility, description, 1-9
WWeb Interface, description, 1-8Wheel Materials, 3-22Wiring
motor communications, 5-34motor power, 5-38network communications, 5-36power, 3-12signal, 3-13transport system layout, 3-7
XXML Files
magnet array type file, 1-9motor type file, 1-9Node Controller Configuration File, 1-9Track Layout File, 1-9
MagneMover LITE User Manual 501Rockwell Automation Publication MMI-UM002E-EN-P - March 2016
Notes:
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Copyright © 2011–2016 MagneMotion, A Rockwell Automation Company. All Rights Reserved.139 Barnum Road, Devens, MA 01434, USA+1 978-757-9100Publication MMI-UM002E-EN-P - March 2016 DIR 990000410Supersedes 990000410 Rev. D www.rockwellautomation.com
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