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