MagneMotion MagneMover LITE User manual

MagneMover LITE
User Manual

ii MagneMotion
Rockwell 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 for
any errors, omissions, or inaccuracies. Information provided within this manual is subject to change without notice. Any
sample code referenced in this document and that may be included with MagneMotion software is included for illustration
only and is, therefore, unsupported.
MagneMotion®, MagneMover®, QuickStick®, MM LITE®, and SYNC IT™ are trademarks or registered trademarks of
MagneMotion, Inc. Microsoft®and Windows®are registered trademarks of Microsoft Corporation. All other trademarks
are properties of their respective owners.
This product is protected under one or more U.S. and International patents. Additional U.S. and International patents
pending.
©2011 - 2016 MagneMotion, Inc. All Rights Reserved. The information included in this manual is MagneMotion, Inc.
proprietary information and is provided for the use of MagneMotion, Inc. customers only and cannot be used for
distribution, reproduction, or sale without the express written permission of MagneMotion, Inc. In no event will
MagneMotion, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of
this equipment.
MagneMotion, Inc.
139 Barnum Road
Devens, MA 01434
USA
Phone: [phone]
Fax: [phone]
www.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 i
Rockwell Automation Publication MMI-UM002E-EN-P - March 2016
Contents
Figures ........................................................................................................... xi
Tables............................................................................................................. xvii
Changes
Overview...................................................................................................................... xix
Rev. A .................................................................................................................... xix
Rev. B .................................................................................................................... xix
Rev. C .................................................................................................................... xx
Rev. D .................................................................................................................... xx
Rev. E..................................................................................................................... xxi
About This Manual
Overview...................................................................................................................... xxiii
Purpose................................................................................................................... xxiii
Audience ................................................................................................................ xxiii
Prerequisites........................................................................................................... xxiii
MagneMotion Documentation..................................................................................... xxiv
Manual Conventions .............................................................................................. xxiv
Notes, Safety Notices, and Symbols...................................................................... xxv
Manual Structure.................................................................................................... xxvi
Related Documentation.......................................................................................... xxvii
Contact Information..................................................................................................... xxvii
1 Introduction
Overview........................................................................................................................1-1
MagneMover LITE Overview .......................................................................................1-2
MagneMover LITE Transport System Components ...............................................1-3
MagneMover Transport System Options.................................................................1-4
Precision Rails ...................................................................................................1-4
Precision Locator ...............................................................................................1-6
Transport System Overview ..........................................................................................1-7
Transport System Software Overview...........................................................................1-8
Getting Started with the MagneMover LITE Transport System ...................................1-10

Contents
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Rockwell Automation Publication MMI-UM002E-EN-P - March 2016
2Safety
Overview........................................................................................................................2-1
Regulatory Compliance .................................................................................................2-2
EU RoHS and EU WEEE Compliance....................................................................2-2
Equipment Regulatory Guidelines...........................................................................2-2
Safety Considerations ....................................................................................................2-4
Personnel Safety Guidelines ....................................................................................2-4
Equipment Safety Guidelines ..................................................................................2-5
MagneMover LITE Transport System Hazard Locations .......................................2-7
Precision Rail Option Hazard Locations .................................................................2-8
Precision Locator Option Hazard Locations............................................................2-9
Symbol Identification ....................................................................................................2-10
Label Identification and Location..................................................................................2-12
Standard MagneMover LITE Components..............................................................2-12
Precision Rail Option Components..........................................................................2-18
Precision Locator Option Components....................................................................2-20
Mechanical Hazards.......................................................................................................2-22
Electrical Hazards ..........................................................................................................2-23
Pneumatic Hazards ........................................................................................................2-24
Magnetic Hazards ..........................................................................................................2-25
Handling Magnet Arrays .........................................................................................2-26
Shipping Magnet Arrays..........................................................................................2-27
Recycling and Disposal Information .............................................................................2-28
MagneMover LITE Transport System.....................................................................2-28
Node Controllers......................................................................................................2-28
Magnet Arrays .........................................................................................................2-28
3 Design Guidelines
Overview........................................................................................................................3-1
Transport System Layout...............................................................................................3-2
Transport System Overview ....................................................................................3-2
Motors, Switches, and Vehicles (Pucks) .................................................................3-3
Paths.........................................................................................................................3-4
Nodes .......................................................................................................................3-5
Node Controllers......................................................................................................3-6
Additional Connections ...........................................................................................3-7
Transport System Design...............................................................................................3-8
Overview..................................................................................................................3-8
Design Guidelines....................................................................................................3-8
Motors......................................................................................................................3-9
Motor Types.......................................................................................................3-10
Available Thrust ................................................................................................3-10
Required Thrust .................................................................................................3-11
Motor Gap..........................................................................................................3-11
Downstream Gap ...............................................................................................3-11
Motor Cogging...................................................................................................3-12
Motor Controllers ..............................................................................................3-12

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Rockwell Automation Publication MMI-UM002E-EN-P - March 2016
Electrical Wiring......................................................................................................3-12
Power Wiring.....................................................................................................3-12
Signal Wiring.....................................................................................................3-13
Ground ...............................................................................................................3-13
Magnet Arrays .........................................................................................................3-15
High Flux Magnet Arrays ..................................................................................3-15
Magnet Array Length and Attractive Force.......................................................3-16
Magnet Array Use..............................................................................................3-17
Available Magnet Arrays...................................................................................3-17
Vehicles ...................................................................................................................3-18
Single Array Puck..............................................................................................3-19
Dual Array (Tandem) Puck................................................................................3-19
Vehicle Gap .......................................................................................................3-20
Vehicle Design...................................................................................................3-21
Mounting Magnet Arrays to Vehicles ...............................................................3-22
Guideways ...............................................................................................................3-23
Custom Guideway Design .................................................................................3-23
Guideway and Support Materials ......................................................................3-24
Motor Mounts ....................................................................................................3-24
Motor Mounting Methods..................................................................................3-25
System Stands ..........................................................................................................3-28
Custom Motor Mounting ...............................................................................................3-29
Puck Carrier ...................................................................................................................3-31
Cantilevered Loads ..................................................................................................3-31
Transport System Options .............................................................................................3-33
Precision Rail...........................................................................................................3-33
Precision Rails ...................................................................................................3-34
Spine Plates........................................................................................................3-36
Support Post Assembly......................................................................................3-37
Vehicles .............................................................................................................3-38
Precision Rail Installation........................................................................................3-39
Precision Locator .....................................................................................................3-40
Precision Locators..............................................................................................3-40
Locator Stand.....................................................................................................3-40
Pallet ..................................................................................................................3-41
Pallet Design ......................................................................................................3-41
Precision Locator Installation ..................................................................................3-43
Pneumatic Piping ...............................................................................................3-43
Transport System Configuration....................................................................................3-45
Straight Track Configuration ...................................................................................3-45
Curve Track Configuration......................................................................................3-46
Switch Configuration...............................................................................................3-47
4 Specifications and Site Requirements
Overview........................................................................................................................4-1
Motor Types...................................................................................................................4-2
MagneMover LITE G3 Motors................................................................................4-2
MagneMover LITE G4 Motors................................................................................4-2

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Mechanical Specifications .............................................................................................4-3
1000 Millimeter Motor ............................................................................................4-3
1000 Millimeter Railless Motor...............................................................................4-4
250 Millimeter Motor ..............................................................................................4-5
250 Millimeter Railless Motor.................................................................................4-6
125 Millimeter Radius 90° Curve............................................................................4-7
125 Millimeter Radius 90° Curve Railless Motor ...................................................4-8
90° Left Switch ........................................................................................................4-9
90° Right Switch......................................................................................................4-10
Standard Motor Mount Bracket ...............................................................................4-11
Stand System............................................................................................................4-12
Pucks........................................................................................................................4-13
Tandem Pucks..........................................................................................................4-16
Magnet Arrays .........................................................................................................4-19
NC-12 Node Controller ...........................................................................................4-21
Rack Mounting Bracket ...........................................................................................4-22
Node Controller LITE..............................................................................................4-23
Electronics Mounting Plate......................................................................................4-24
MM LITE Power Supply .........................................................................................4-25
Precision Rail Option...............................................................................................4-26
Precision Rails ...................................................................................................4-26
Precision Rail Single Array Vehicle..................................................................4-27
Precision Rail Dual Array Vehicle ....................................................................4-28
Precision Rail Support Post Assembly ..............................................................4-29
Spine Plates........................................................................................................4-30
Precision Locator Option .........................................................................................4-34
Actuator Assembly ............................................................................................4-34
Stand Assembly .................................................................................................4-35
Adjustable Motor Mount Bracket ......................................................................4-36
Pallet ..................................................................................................................4-37
Electrical Specifications ................................................................................................4-38
Motors and Switches................................................................................................4-38
Straight and Curve Motors.................................................................................4-40
Switches .............................................................................................................4-42
MM LITE Power Supply .........................................................................................4-44
AC Power Cable ................................................................................................4-46
Motor Power Cable............................................................................................4-47
DC Enable..........................................................................................................4-48
DC Enable Jumper Plug.....................................................................................4-48
NC-12 Node Controller ...........................................................................................4-49
AC Power Option...............................................................................................4-49
DC Power Option...............................................................................................4-49
AC Power Cable ................................................................................................4-53
Node Controller LITE..............................................................................................4-54
AC Power Option...............................................................................................4-54
DC Power Option...............................................................................................4-54
AC Power Cable ................................................................................................4-57

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Ethernet Switch with Power over Ethernet Injector ................................................4-58
AC Power Cable ................................................................................................4-58
Precision Locator .....................................................................................................4-59
Pneumatic Specifications...............................................................................................4-61
Precision Locator .....................................................................................................4-61
Communications ............................................................................................................4-62
Ethernet Connection ................................................................................................4-62
TCP/IP Communication...........................................................................................4-62
EtherNet/IP Communication....................................................................................4-63
RS-232 Serial Interface Connection ........................................................................4-63
RS-422 Serial Interface Connection ........................................................................4-63
Sync Connection ......................................................................................................4-65
Digital I/O Connection.............................................................................................4-65
Site Requirements ..........................................................................................................4-66
Environment.............................................................................................................4-66
Motors................................................................................................................4-66
NC LITE ............................................................................................................4-66
NC-12.................................................................................................................4-66
MM LITE Power Supply ...................................................................................4-66
Precision Locator ...............................................................................................4-67
Magnet Arrays, Pucks, Precision Rail Vehicles ................................................4-67
Lighting, Site: ....................................................................................................4-67
Floor Space and Loading .........................................................................................4-67
Facilities...................................................................................................................4-67
Service Access .........................................................................................................4-68
5 Installation
Overview........................................................................................................................5-1
Unpacking and Inspection .............................................................................................5-2
Unpacking and Moving ...........................................................................................5-3
Required Tools and Materials............................................................................5-3
Unpacking and Moving Instructions..................................................................5-3
Transport System Installation ........................................................................................5-5
Installing Hardware..................................................................................................5-5
Required Tools and Materials............................................................................5-5
Installation Overview – User-Supplied Mounting.............................................5-6
Installation Overview – MMI Supplied Mounting ............................................5-7
Installation Overview – MMI Precision Rails ...................................................5-8
Installation Overview – MMI Precision Locator...............................................5-9
Stand System Installation.........................................................................................5-11
Assembling Beams ............................................................................................5-11
Installing System Legs.......................................................................................5-12
Leveling the MagneMover LITE.......................................................................5-15
Securing the Transport System ..........................................................................5-16
Motor Installation ....................................................................................................5-18
Installing Cable Chase Cover Brackets .............................................................5-18
Installing Motor Mounts on Motors and Switches ............................................5-19

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Mounting Motors and Switches.........................................................................5-20
Align and Secure Motors and Switches.............................................................5-23
Align and Secure Railless Motors .....................................................................5-25
Verify Motor and Switch Installation ................................................................5-26
Installing Electronics ...............................................................................................5-27
Installing Electronics on the Transport System .................................................5-27
Connecting Motors and Electronics.........................................................................5-32
Installing Pucks/Magnet Arrays...............................................................................5-40
Magnet Array Installation..................................................................................5-40
Puck Installation ................................................................................................5-40
Installing Cable Chase Covers.................................................................................5-41
Option Installation .........................................................................................................5-44
Precision Rail Installation........................................................................................5-44
Assemble Precision Rail Support Posts .............................................................5-45
Attach Precision Rail Support Posts to the Beam..............................................5-46
Attach Rails to Spine Plates...............................................................................5-47
Align and Secure Rails to Spine Plates..............................................................5-50
Secure Spine Plates to Support Posts.................................................................5-53
Install the Precision Rail Vehicles .....................................................................5-53
Precision Locator Installation ..................................................................................5-54
Install Pallets and Pucks ....................................................................................5-55
Install the Precision Locators on the Stands ......................................................5-56
Install the Precision Locator Assemblies...........................................................5-56
Install the Motors ...............................................................................................5-56
Install the Pneumatic Controls...........................................................................5-58
Install the Covers ...............................................................................................5-59
Teach the Precision Locator Position ................................................................5-59
Facilities Connections....................................................................................................5-60
Network Connections ..............................................................................................5-60
Electrical Connections .............................................................................................5-61
E-Stop Circuit ....................................................................................................5-62
Interlock Circuit.................................................................................................5-62
Light Stack Circuit.............................................................................................5-63
General Purpose Digital I/O ..............................................................................5-63
Software .........................................................................................................................5-64
Software Overview ..................................................................................................5-64
Software Configuration............................................................................................5-64
Node Controller Software Installation...............................................................5-65
Motor Software Installation ...............................................................................5-65
Check-out and Power-up ...............................................................................................5-66
System Check-out ....................................................................................................5-66
Mechanical Checks ............................................................................................5-66
Facility Checks ..................................................................................................5-66
Pre-operation Checks.........................................................................................5-66
System Power-up .....................................................................................................5-67
System Testing...............................................................................................................5-69

Contents
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Rockwell Automation Publication MMI-UM002E-EN-P - March 2016
6 Operation
Overview........................................................................................................................6-1
Theory of Operation.......................................................................................................6-2
MagneMover LITE Transport System Advantages.................................................6-2
Motion Control ........................................................................................................6-3
Motor Topology.......................................................................................................6-3
Motor Operation ......................................................................................................6-4
Motor Cogging...................................................................................................6-5
Motor Blocks ...........................................................................................................6-5
Block Acquisition ..............................................................................................6-6
Anti-Collision ..........................................................................................................6-6
Safe Stopping Distance Movement....................................................................6-7
In Queue.............................................................................................................6-7
Vehicle Length Through Curves and Switches .................................................6-8
Locating Vehicles During Startup ...........................................................................6-8
Moving Vehicles by Hand .................................................................................6-8
Electrical System .....................................................................................................6-10
Controls and Indicators..................................................................................................6-11
Track Display...........................................................................................................6-11
Synchronization .......................................................................................................6-12
E-Stops.....................................................................................................................6-13
Interlocks .................................................................................................................6-15
FastStop ...................................................................................................................6-16
Light Stacks .............................................................................................................6-17
Digital I/O ................................................................................................................6-18
Transport System Simulation.........................................................................................6-19
Configuring a Simulation.........................................................................................6-19
Running a Simulation ..............................................................................................6-21
Stopping a Simulation..............................................................................................6-22
Return the System to Normal Operation..................................................................6-22
Precision Rail Operation................................................................................................6-24
Setup ........................................................................................................................6-24
Operation .................................................................................................................6-24
Precision Locator Operation ..........................................................................................6-25
Setup ........................................................................................................................6-25
Operation .................................................................................................................6-25
Transport System Operation ..........................................................................................6-26
Power-up..................................................................................................................6-26
Normal Running ......................................................................................................6-26
Safe Shut-down........................................................................................................6-27
7 Maintenance
Overview........................................................................................................................7-1
Preventive Maintenance.................................................................................................7-2
General Cleaning .....................................................................................................7-3
Spray Cleaning.........................................................................................................7-3
Puck Cleaning ..........................................................................................................7-4

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Puck Wear Surface Maintenance.............................................................................7-5
Cable Connection Inspection ...................................................................................7-5
Hardware Inspection ................................................................................................7-5
Cleaning Magnet Arrays..........................................................................................7-5
Transfer Log Files....................................................................................................7-6
Clean Power Supply Air Filter.................................................................................7-6
Lubricating the Precision Rails................................................................................7-7
Refilling a Precision Rail Vehicle’s Lubricating Applicator...................................7-8
Adjusting Vehicle Bearings .....................................................................................7-11
Concentric Bearings...........................................................................................7-12
Eccentric Bearings .............................................................................................7-12
Troubleshooting .............................................................................................................7-13
Initial Troubleshooting ............................................................................................7-13
Power Related Troubleshooting...............................................................................7-14
Node Controller Troubleshooting............................................................................7-17
Communications Troubleshooting...........................................................................7-18
Motion Control Troubleshooting .............................................................................7-19
Precision Rail Option Troubleshooting ...................................................................7-20
Light Stack Troubleshooting ...................................................................................7-21
Contact MagneMotion Technical Support.....................................................................7-22
Repair.............................................................................................................................7-23
Adjust G3 Motors to Eliminate Rail Binding ..........................................................7-25
Connect and Secure G3 Motors and G3 Switches...................................................7-27
Connect G3 Motors and G4 Motors ........................................................................7-29
Replacing Motors.....................................................................................................7-31
Remove the Existing Motor...............................................................................7-31
Install the New Motor ........................................................................................7-32
Programming Motors...............................................................................................7-33
Separating Magnet Arrays .......................................................................................7-34
Replace Pucks ..........................................................................................................7-35
Remove Pucks....................................................................................................7-36
Install Pucks.......................................................................................................7-37
Replace Puck Wear Surfaces ...................................................................................7-38
Replace Power Supply Fuses...................................................................................7-42
AC Fuse .............................................................................................................7-43
DC Fuses............................................................................................................7-44
Replace Precision Rail Vehicles ..............................................................................7-45
Vehicle Orientation............................................................................................7-45
Installing Vehicles with Rails Removed............................................................7-46
Installing Vehicles Without Removing Rails ....................................................7-47
Removing Vehicles by Removing Rails............................................................7-48
Removing Vehicles Without Removing Rails...................................................7-49
Replacing Lubricating Applicators on Vehicles......................................................7-50
Replacing Magnet Arrays On Precision Rail Vehicles............................................7-53
Single Array Vehicles........................................................................................7-54
Dual Array Vehicles ..........................................................................................7-56

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Rockwell Automation Publication MMI-UM002E-EN-P - March 2016
Replacing Bearings On Precision Rail Vehicles......................................................7-59
Replacing Concentric Bearings .........................................................................7-60
Replacing Eccentric Bearings............................................................................7-62
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
Ordering Parts ................................................................................................................7-73
Shipping .........................................................................................................................7-74
Packing Procedure ...................................................................................................7-75
Shipping Components..............................................................................................7-76
Shipping Systems or System Sections .....................................................................7-76
Appendix
Overview.......................................................................................................................A-1
File Maintenance...........................................................................................................A-2
Backup Files ...........................................................................................................A-2
Creating Backup Files.............................................................................................A-2
Restoring from Backup Files ..................................................................................A-2
Additional Documentation............................................................................................A-3
Release Notes..........................................................................................................A-3
Upgrade Procedure .................................................................................................A-3
Transport System Limits...............................................................................................A-4
Glossary ......................................................................................................... G-1
Index ................................................................................................................ I-1

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Figures
1-1 Detailed View of MagneMover LITE Transport System Components ..................1-3
1-2 Detailed View of MagneMover LITE Precision Rail Option Components ............1-5
1-3 Detailed View of MagneMover LITE Precision Locator Components ..................1-6
1-4 Simplified View of MagneMover LITE Transport System Components ...............1-7
1-5 Simplified View of Transport System Software Relationships ..............................1-8
2-1 Locations of Hazardous Points on the MagneMover LITE Transport System .......2-7
2-2 Locations of Hazardous Points on the Precision Rail Option .................................2-8
2-3 Locations of Hazardous Points on the Precision Locator Option ...........................2-9
2-4 Locations of Labels on the MagneMover LITE Straight and Curve Motors ..........2-12
2-5 Locations of Labels on the MagneMover LITE Switches ......................................2-13
2-6 Locations of Labels on the MagneMover LITE Magnet Arrays and Pucks ...........2-14
2-7 Locations of Labels on the NC-12 Node Controller ...............................................2-15
2-8 Locations of Labels on the Node Controller LITE .................................................2-16
2-9 Locations of Labels on the MM LITE Power Supply ............................................2-17
2-10 Locations of Labels on the Precision Rail Vehicles (single array shown) .............2-18
2-11 Locations of Labels on the Precision Rail Spine Plates ..........................................2-19
2-12 Locations of Labels on the Precision Locator ........................................................2-20
2-13 Locations of Labels on the Precision Locator Puck ...............................................2-21
3-1 Sample MM LITE Transport System Layout Showing Motors .............................3-3
3-2 Sample MM LITE Transport System Layout Showing Paths ................................3-4
3-3 Sample MM LITE Transport System Layout Showing Nodes ...............................3-5
3-4 Sample MM LITE Transport System Layout Showing Node Controllers .............3-6
3-5 Sample MM LITE Transport System Layout Showing Additional Connections ...3-7
3-6 MagneMover LITE Motor Gaps .............................................................................3-11
3-7 System Wiring Block Diagram ...............................................................................3-14
3-8 Standard MagneMover LITE Magnet Array, 1 Cycle, 3 Poles ..............................3-15
3-9 Typical Vehicle on Guideway ................................................................................3-18
3-10 Standard Puck Configuration ..................................................................................3-19
3-11 Tandem Puck Configuration ...................................................................................3-19
3-12 Vehicle Gap ............................................................................................................3-20
3-13 MagneMover LITE Railless Transport System, Single Vehicle ............................3-23
3-14 Motor Mounting to Flat Surface .............................................................................3-25
3-15 Motor Mounting Using Custom Brackets ...............................................................3-26
3-16 Motor Mounting Using Motor Mount Brackets .....................................................3-27
3-17 System Stand ...........................................................................................................3-28

Figures
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3-18 Custom Motor Mounting ........................................................................................3-29
3-19 Puck Carrier Overhang ...........................................................................................3-31
3-20 Precision Rail Option ..............................................................................................3-33
3-21 Precision Rails ........................................................................................................3-34
3-22 Precision Rail Spine Plates .....................................................................................3-36
3-23 Precision Rail Support Post ....................................................................................3-37
3-24 Precision Rail Single Array Vehicle .......................................................................3-38
3-25 Precision Rail Dual Array Vehicle .........................................................................3-38
3-26 Precision Rail to Motor Reference Diagram ...........................................................3-39
3-27 Precision Locator Option ........................................................................................3-40
3-28 Precision Locator Pallet Design Details .................................................................3-42
3-29 Precision Locator Installation Dimensions .............................................................3-43
3-30 Precision Locator Pneumatic Block Diagram .........................................................3-44
3-31 Straight Track Configuration ..................................................................................3-45
3-32 Curve Track Configuration .....................................................................................3-46
3-33 Switch Configuration ..............................................................................................3-47
4-1 1000 Millimeter Motor Mechanical Drawing (G4) ................................................4-3
4-2 1000 Millimeter Railless Motor Mechanical Drawing (G4) ..................................4-4
4-3 250 Millimeter Motor Mechanical Drawing (G4) ..................................................4-5
4-4 250 Millimeter Railless Motor Mechanical Drawing (G4) ....................................4-6
4-5 125 Millimeter Radius 90° Curve Mechanical Drawing (G4) ................................4-7
4-6 125 Millimeter Radius 90° Railless Curve Mechanical Drawing (G4) ..................4-8
4-7 Left Switch Mechanical Drawing (G4) ..................................................................4-9
4-8 Right Switch Mechanical Drawing (G4) ................................................................4-10
4-9 Standard Motor Mount Bracket Mechanical Drawing (G4) ...................................4-11
4-10 Stand System Mechanical Drawing ........................................................................4-12
4-11 Puck Mechanical Drawing (G4) .............................................................................4-13
4-12 Puck Mechanical Drawing (G4.2) ..........................................................................4-14
4-13 Puck Mechanical Drawing (G4.3) ..........................................................................4-15
4-14 Tandem Puck Mechanical Drawing (G4) ...............................................................4-16
4-15 Tandem Puck Mechanical Drawing (G4.2) ............................................................4-17
4-16 Tandem Puck Mechanical Drawing (G4.3) ............................................................4-18
4-17 Magnet Array Mechanical Drawing (G4) ...............................................................4-19
4-18 Magnet Array Mechanical Drawing (G4.2) ............................................................4-20
4-19 NC-12 Node Controller Mechanical Drawing ........................................................4-21
4-20 Rack Mounting Bracket Mechanical Drawing .......................................................4-22
4-21 Node Controller LITE Mechanical Drawing ..........................................................4-23
4-22 Electronics Mounting Plate Mechanical Drawing ..................................................4-24
4-23 MM LITE Power Supply Mechanical Drawing .....................................................4-25
4-24 Precision Rail Mechanical Drawing .......................................................................4-26
4-25 Precision Rail Single Array Vehicle Mechanical Drawing ....................................4-27
4-26 Precision Rail Dual Array Vehicle Mechanical Drawing .......................................4-28
4-27 Precision Rail Support Post Assembly ...................................................................4-29
4-28 Precision Rail Straight to Curve, Spine Plates, Mechanical Drawing ....................4-30
4-29 Precision Rail Curve to Curve, Spine Plates, Mechanical Drawing .......................4-31
4-30 Precision Rail Straight, No Joint, Spine Plate, Mechanical Drawing .....................4-32

Figures
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4-31 Precision Rail Straight, With Joint, Spine Plate, Mechanical Drawing ..................4-32
4-32 Precision Rail Curve, 180°, No Joint, Spine Plate, Mechanical Drawing ..............4-33
4-33 Precision Locator Actuator Mechanical Drawing ..................................................4-34
4-34 Standard Precision Locator Stand Mechanical Drawing ........................................4-35
4-35 Adjustable Motor Mount Bracket Mechanical Drawing ........................................4-36
4-36 Precision Locator Basic Pallet Mechanical Drawing .............................................4-37
4-37 MagneMover LITE Motor Electrical Connections .................................................4-40
4-38 MagneMover LITE Switch Electrical Connections ................................................4-42
4-39 MM LITE Power Supply Electrical Connections ...................................................4-45
4-40 MM LITE DC Power Cables ..................................................................................4-47
4-41 DC Enable Circuit ...................................................................................................4-48
4-42 DC Enable Jumper ..................................................................................................4-48
4-43 NC-12 Node Controller Electrical Connections and Indicators .............................4-50
4-44 Node Controller LITE Electrical Connections .......................................................4-55
4-45 Precision Locator Electrical Connections ...............................................................4-59
4-46 Precision Locator Pneumatic Connections .............................................................4-61
4-47 RS-422 Cables ........................................................................................................4-64
4-48 Digital I/O Equivalent Circuits ...............................................................................4-65
5-1 Connecting Beam Sections .....................................................................................5-11
5-2 Leg on a Single Path Beam Assembly ....................................................................5-12
5-3 Legs on a Parallel Path Beam Assembly ................................................................5-13
5-4 Angle Bracket Assembly ........................................................................................5-14
5-5 System Leveling .....................................................................................................5-15
5-6 Bracket Tie-down ...................................................................................................5-16
5-7 Foot Tie-down .........................................................................................................5-17
5-8 Installing Cable Chase Cover Mounting Brackets ..................................................5-18
5-9 Installing Motor Mounts on Motors and Switches .................................................5-19
5-10 Installing Motors and Switches ...............................................................................5-20
5-11 Positioning Motors and Switches ...........................................................................5-21
5-12 Align and Secure Rails – G4 Motors ......................................................................5-23
5-13 Align and Secure Railless Motors ..........................................................................5-25
5-14 Node Controller LITE Mounting ............................................................................5-27
5-15 NC-12 Node Controller Mounting Plates ...............................................................5-29
5-16 NC-12 Node Controller Mounting Brackets ...........................................................5-30
5-17 Power Supply Mounting .........................................................................................5-31
5-18 Simplified Representation of Motor Connections ..................................................5-33
5-19 Simplified Representation of Merge Switch Connections ......................................5-33
5-20 Communication Cable Connections .......................................................................5-34
5-21 Digital I/O Connections ..........................................................................................5-37
5-22 Power Connections .................................................................................................5-38
5-23 Installing Straight Motor Cable Chase Covers .......................................................5-41
5-24 Installing Curved Motor Cable Chase Covers ........................................................5-42
5-25 Installing Switch Cable Chase Covers ....................................................................5-43
5-26 MagneMover LITE Railless Motor System ............................................................5-44
5-27 Precision Rail Support Post Assembly ...................................................................5-45
5-28 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 .......................................5-46
5-30 Precision Rail End Identification ............................................................................5-47
5-31 Attaching Straight Precision Rails to Curved Rails with Adjustment Key ............5-48
5-32 Attaching Precision Rail to Spine Plates ................................................................5-49
5-33 Tightening Sequence, Straight to Curve Precision Rail Spine Plate ......................5-50
5-34 Tightening Sequence, Curve to Curve Precision Rail Spine Plate .........................5-51
5-35 Tightening Sequence, Straight to Straight Precision Rail Spine Plate ...................5-51
5-36 Tightening Sequence, 180° Curve No Joint Precision Rail Spine Plate .................5-52
5-37 Tightening Sequence, Straight Rail No-Joint Precision Rail Spine Plate ...............5-52
5-38 Securing Precision Rail Spine Plates to Support Posts ...........................................5-53
5-39 MagneMover LITE Precision Locator Option, Standard .......................................5-54
5-40 MagneMover LITE Precision Locator Option, Alternate .......................................5-55
5-41 Precision Locator Pneumatic Connections .............................................................5-58
5-42 Network Cable Connections ...................................................................................5-60
6-1 Linear Synchronous Motor Derived From Rotary Motor .......................................6-2
6-2 Representation of Stationary Vehicles Per MagneMover LITE Motor Block .......6-4
6-3 Representation of Moving Vehicles Per MagneMover LITE Motor Block ...........6-4
6-4 Vehicle Movement Profile ......................................................................................6-7
6-5 The Graphics Window ............................................................................................6-11
6-6 Transport System Wiring Diagram with Synchronization .....................................6-12
6-7 E-Stop Wiring Diagram, Single Node Controller ...................................................6-14
6-8 E-Stop Wiring Diagram, Multiple Node Controllers ..............................................6-14
6-9 Interlock Wiring Diagram .......................................................................................6-15
6-10 Light Stack Wiring Diagram ...................................................................................6-17
7-1 Puck Cleaning .........................................................................................................7-4
7-2 Precision Rail Vehicle Lubricating Applicator Location .......................................7-9
7-3 Precision Rail Vehicle Lubricating Applicator (Front and Rear) ...........................7-9
7-4 Precision Rail Single Array Vehicle Lubrication Portal .........................................7-10
7-5 Precision Rail Vehicle Bearing Adjustment ...........................................................7-11
7-6 Rail Adjustment Points – G3 Motors ......................................................................7-25
7-7 Adjust Rails – G3 Motors .......................................................................................7-26
7-8 Align and Secure Rails – G3 Motors ......................................................................7-27
7-9 Align and Secure Rails – G3 to G4 Motors ............................................................7-29
7-10 Remove Curve Motor Guide Rail ...........................................................................7-36
7-11 Remove Plates from Magnet Assembly ..................................................................7-39
7-12 Adhere Preload Spacer to Underside of Top Plate .................................................7-40
7-13 Power Supply Fuse Locations .................................................................................7-42
7-14 Open the Power Entry Module ...............................................................................7-43
7-15 Remove the PEM Fuse Module ..............................................................................7-43
7-16 Precision Rail Vehicle to Rail Orientation .............................................................7-46
7-17 Precision Rail Vehicle Eccentric Bearings .............................................................7-47
7-18 Install Precision Rail Vehicle on Rail .....................................................................7-48
7-19 Remove Precision Rail Vehicle From Rail .............................................................7-49
7-20 Precision Rail Vehicle Lubricating Applicator .......................................................7-50
7-21 Precision Rail Vehicle Lubricating Applicator Location .......................................7-51

Figures
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7-22 Installing or Removing a Precision Rail Felt Applicator ........................................7-51
7-23 Single Array Precision Rail Vehicle Assembly ......................................................7-54
7-24 Dual Array Precision Rail Vehicle Assembly ........................................................7-56
7-25 Precision Rail Vehicle Bearing Locations ..............................................................7-59
7-26 Precision Rail Vehicle Concentric Bearings Disassembly/Assembly ....................7-60
7-27 Precision Rail Vehicle Eccentric Bearings Disassembly/Assembly .......................7-62
7-28 Remove Precision Locator Pallet from Magnet Assembly .....................................7-65
7-29 Replace Bushings on Precision Locator Pallet .......................................................7-68
7-30 Replace Pins on Precision Locator Arms ...............................................................7-69
7-31 Replace Z-Datum on Precision Locator Stand .......................................................7-71

Figures
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Tables
2-1 Regulatory Information ...........................................................................................2-2
2-2 Hazard Alert Symbol Identification ........................................................................2-10
2-3 Mandatory Action Symbol Identification ...............................................................2-11
2-4 Prohibited Action Symbol Identification ................................................................2-11
2-5 Labels Used on the MagneMover LITE Straight and Curve Motors .....................2-12
2-6 Labels Used on the MagneMover LITE Switches ..................................................2-13
2-7 Labels Used on the MagneMover LITE Magnet Arrays and Pucks .......................2-14
2-8 Labels Used on the NC-12 Node Controller ...........................................................2-15
2-9 Labels Used on the Node Controller LITE .............................................................2-16
2-10 Labels Used on the MM LITE Power Supply ........................................................2-17
2-11 Labels Used on the Precision Rail Vehicles ...........................................................2-18
2-12 Labels Used on the Precision Rail Spine Plates .....................................................2-19
2-13 Labels Used on the Precision Locator ....................................................................2-20
2-14 Labels Used on the Precision Locator Pucks ..........................................................2-21
3-1 Motor Assignments .................................................................................................3-4
3-2 MagneMover LITE Motor Blocks ..........................................................................3-10
3-3 MagneMover Light Thrust Force Guideline ...........................................................3-10
3-4 Stand System Heights .............................................................................................3-28
3-5 Stand System Widths ..............................................................................................3-28
3-6 Puck Carrier Overhang Limits ................................................................................3-31
3-7 Precision Rail Types and Lengths ..........................................................................3-35
4-1 MagneMover LITE Motor and Switch Power Requirements .................................4-38
4-2 MagneMover LITE Motor Connections .................................................................4-40
4-3 MagneMover LITE Motor RS-422 Pinouts ............................................................4-41
4-4 MagneMover LITE Motor Power Pinouts ..............................................................4-41
4-5 MagneMover LITE Sync Pinouts ...........................................................................4-41
4-6 MagneMover LITE Switch Connections ................................................................4-42
4-7 MagneMover LITE Switch RS-422 Pinouts ...........................................................4-43
4-8 MagneMover LITE Switch Power Pinouts .............................................................4-43
4-9 MagneMover LITE Switch Ethernet Pinout ...........................................................4-43
4-10 MM LITE Power Supply Connections ...................................................................4-45
4-11 MM LITE Power Supply Indicators .......................................................................4-45
4-12 MM LITE Power Supply DC Power Pinouts .........................................................4-46
4-13 MM LITE Power Supply DC Enable .....................................................................4-46
4-14 DC Power Cable Pinouts ........................................................................................4-47

Tables
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4-15 NC-12 Node Controller Connections .....................................................................4-50
4-16 NC-12 Node Controller Indicators .........................................................................4-50
4-17 NC-12 Node Controller Console Pinout .................................................................4-51
4-18 NC-12 Node Controller Ethernet Pinout ................................................................4-51
4-19 NC-12 Node Controller RS-232 Pinouts ................................................................4-52
4-20 NC-12 Node Controller RS-422 Pinouts ................................................................4-52
4-21 NC-12 Node Controller Power Pinout ....................................................................4-52
4-22 Node Controller LITE Connections ........................................................................4-55
4-23 Node Controller LITE Power Pinout ......................................................................4-55
4-24 Node Controller LITE LAN Pinout ........................................................................4-56
4-25 Node Controller LITE Console Pinout ...................................................................4-56
4-26 Node Controller LITE RS-422 Pinouts ..................................................................4-57
4-27 Precision Locator Connections ...............................................................................4-59
4-28 Precision Locator Sensor Indicators .......................................................................4-59
4-29 Precision Locator Sensor Pinout .............................................................................4-60
4-30 Precision Locator Pneumatic Requirements ...........................................................4-61
4-31 Precision Locator Connections ...............................................................................4-61
4-32 RS-422 Cable Pinouts .............................................................................................4-64
5-1 MagneMover LITE Component Packing Checklist Reference ..............................5-2
5-2 Motor Mount Reference ..........................................................................................5-21
5-3 Precision Rail to Spine Plate Attachment Screws ..................................................5-49
5-4 Startup Indicators ....................................................................................................5-68
6-1 Simulated Operation Differences ............................................................................6-21
7-1 MagneMover LITE Preventive Maintenance Schedule ..........................................7-2
7-2 Precision Rail Vehicle Drag ...................................................................................7-12
7-3 Initial Troubleshooting ...........................................................................................7-13
7-4 Power Related Troubleshooting ..............................................................................7-14
7-5 Node Controller Related Troubleshooting ..............................................................7-17
7-6 Communications Related Troubleshooting ............................................................7-18
7-7 Motion Control Related Troubleshooting ...............................................................7-19
7-8 Precision Rail Option Troubleshooting ..................................................................7-20
7-9 Light Stack Related Troubleshooting .....................................................................7-21
7-10 MagneMover LITE Repair Procedures ...................................................................7-23
7-11 MM LITE Rail Adjustment ....................................................................................7-25
A-1 MagneMotion Transport System Limits ................................................................A-4
A-2 MagneMotion Transport System Motion Limits ...................................................A-4