Rockwell Automation MagneMotion MagneMover LITE User manual

MagneMover LITE
User Manual
Catalog numbers: 700-1308-xx, MMI-MML-1000M-NR-SER-SYNCAC, MMI-MML-250M-NR-SER-SYNCAC,
MMI-MML-CURV-NR-SER-SYNCAC, 700-1708-xx, 700-1560-00, 700-1458-01, 700-1663-00, 700-1561-00,
700-1664-00, 700-1738-02, 700-1740-03, 700-1525-00, 700-1528-00, C920600, 110-0001-00, 700-1670-xx
Original Instructions

2MagneMotion
Rockwell Automation Publication MMI-UM002F-EN-P - October 2022
Although every effort is made to keep this manual accurate and up-to-date, MagneMotion®assumes no responsibility for
any errors, omissions, or inaccuracies. Information that is provided in this manual is subject to change without notice. Any
sample code that is referenced in this manual or included with MagneMotion software is included for illustration only and
is, therefore, unsupported.
This product is protected under one or more U.S. and International patents. Additional U.S. and International patents
pending.
The information that is included in this manual is proprietary or confidential to MagneMotion, Inc. Any disclosure,
reproduction, use, or redistribution of this information by or to an unintended recipient is prohibited. In no event will
MagneMotion, Inc. be responsible or liable for indirect or consequential damage that results from the use or application of
this equipment.
Rockwell Automation recognizes that some of the terms that are currently used in our industry and in this publication are
not in alignment with the movement toward inclusive language in technology. We are proactively collaborating with
industry peers to find alternatives to such terms and making changes to our products and content. Please excuse the use of
such terms in our content while we implement these changes.
MagneMotion, Inc.
A Rockwell Automation Company
139 Barnum Road
Devens, MA 01434
USA
Phone: [phone]
Fax: [phone]
rok.auto/ict
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 3
Rockwell Automation Publication MMI-UM002F-EN-P - October 2022
Contents
Figures ............................................................................................................... 13
Tables................................................................................................................. 19
Changes
Overview............................................................................................................................21
Rev. A ..........................................................................................................................21
Rev. B ..........................................................................................................................21
Rev. C ..........................................................................................................................22
Rev. D ..........................................................................................................................23
Rev. E...........................................................................................................................24
Rev. F...........................................................................................................................26
About This Manual
Overview............................................................................................................................29
Purpose.........................................................................................................................29
Audience ......................................................................................................................29
Prerequisites.................................................................................................................29
MagneMotion Documentation...........................................................................................30
Manual Conventions ....................................................................................................30
Notes, Safety Notices, and Symbols............................................................................31
Notes ......................................................................................................................31
Safety Notices ........................................................................................................31
Manual Structure..........................................................................................................33
Related Documentation................................................................................................33
1 Introduction
Overview............................................................................................................................35
MagneMover LITE Overview ...........................................................................................36
MagneMover LITE Transport System Components ...................................................38
MagneMover Transport System Options.....................................................................41
Precision Rails .......................................................................................................41
Precision Locator ...................................................................................................43
Transport System Components Overview .........................................................................44
Transport System Software Overview...............................................................................45

Contents
4MagneMotion
Rockwell Automation Publication MMI-UM002F-EN-P - October 2022
Utilities.........................................................................................................................45
File Types ....................................................................................................................46
Getting Started with the MagneMover LITE Transport System .......................................48
2 Safety Guidelines
Overview............................................................................................................................51
Regulatory Compliance .....................................................................................................52
Safety Considerations ........................................................................................................53
Personnel Safety Guidelines ........................................................................................53
Equipment Safety Guidelines ......................................................................................54
MagneMover LITE Transport System Hazard Locations ...........................................55
Precision Rail Option Hazard Locations .....................................................................56
Precision Locator Option Hazard Locations................................................................57
Puck/Vehicle Hazard Locations...................................................................................58
Symbol Identification ........................................................................................................60
Labels.................................................................................................................................62
Mechanical Hazards...........................................................................................................63
Electrical Hazards ..............................................................................................................64
Pneumatic Hazards ............................................................................................................65
Magnetic Hazards ..............................................................................................................66
Handling Magnet Arrays .............................................................................................67
Shipping Magnet Arrays..............................................................................................68
Recycling and Disposal Information .................................................................................69
RoHS and WEEE.........................................................................................................69
MagneMover LITE Transport System.........................................................................69
Motors..........................................................................................................................69
Vehicles .......................................................................................................................70
System Options ............................................................................................................71
Power Supplies ............................................................................................................71
Packaging.....................................................................................................................71
3 Design Guidelines
Overview............................................................................................................................73
Transport System Layout...................................................................................................74
Transport System Overview ........................................................................................74
Motors, Switches, and Vehicles (Pucks) .....................................................................75
Paths.............................................................................................................................76
Nodes ...........................................................................................................................77
Node Controllers..........................................................................................................78
Additional Connections ...............................................................................................79
Transport System Design...................................................................................................80
Overview......................................................................................................................80
Design Guidelines........................................................................................................80
Motors..........................................................................................................................81
Motor Types...........................................................................................................83
Available Thrust ....................................................................................................83

Contents
MagneMover LITE User Manual 5
Rockwell Automation Publication MMI-UM002F-EN-P - October 2022
Required Thrust .....................................................................................................84
Motor Gap..............................................................................................................84
Downstream Gap ...................................................................................................85
Motor Cogging.......................................................................................................85
Motor Controllers ..................................................................................................85
Electrical Wiring..........................................................................................................86
Power Wiring.........................................................................................................86
Signal Wiring.........................................................................................................87
Ground ...................................................................................................................87
Ethernet Motor Communication Recommendations .............................................90
Ethernet Motor Connection Examples...................................................................91
Using Both RS-422 and Ethernet Motors ..............................................................95
Ethernet Motor MICS File...........................................................................................97
Magnet Arrays .............................................................................................................98
High Flux Magnet Arrays ......................................................................................98
Magnet Array Length and Attractive Force...........................................................99
Magnet Array Use................................................................................................100
Available Magnet Arrays.....................................................................................100
Vehicles .....................................................................................................................101
Vehicle Gap .........................................................................................................102
Vehicle Design.....................................................................................................103
Mounting Magnet Arrays to Vehicles .................................................................104
Pucks..........................................................................................................................105
Single Array Glide Puck ......................................................................................105
Dual Array (Tandem) Glide Puck........................................................................107
Single Array 4 Wheel Puck .................................................................................109
Dual Array (Tandem) Wheeled Puck ..................................................................111
Precision Rail Vehicles..............................................................................................113
Single Array Vehicle ...........................................................................................113
Dual Array Vehicle..............................................................................................114
Guideways .................................................................................................................115
Custom Guideway Design ...................................................................................115
Guideway and Support Materials ........................................................................116
Motor Mounts ......................................................................................................116
Motor Mounting Methods....................................................................................117
System Stands ............................................................................................................120
Custom Motor Mounting .................................................................................................122
Puck Limits ......................................................................................................................124
Cantilevered Payloads................................................................................................124
High Inertia Payloads.................................................................................................125
Transport System Options ...............................................................................................126
Precision Rail.............................................................................................................126
Precision Rails .....................................................................................................127
Spine Plates..........................................................................................................128
Support Post Assembly........................................................................................129
Precision Rail Vehicles........................................................................................130
Precision Rail Installation....................................................................................131

Contents
6MagneMotion
Rockwell Automation Publication MMI-UM002F-EN-P - October 2022
Precision Rail Lubrication ...................................................................................132
Precision Locator .......................................................................................................134
Precision Locators................................................................................................134
Locator Stand.......................................................................................................135
Pallet ....................................................................................................................135
Pallet Design ........................................................................................................135
Precision Locator Installation ..............................................................................137
Transport System Configuration......................................................................................139
Straight Track Configuration .....................................................................................139
Curve Track Configuration........................................................................................140
Switch Configuration.................................................................................................141
4 Specifications and Site Requirements
Overview..........................................................................................................................143
Motor Types.....................................................................................................................144
MagneMover LITE G4 Motors..................................................................................144
Mechanical Specifications ...............................................................................................148
1000 Millimeter Motors.............................................................................................148
250 Millimeter Motors...............................................................................................156
125 Millimeter Radius 90° Curve Motors .................................................................164
90° Left Switches.......................................................................................................172
90° Right Switches.....................................................................................................175
Standard Motor Mount Bracket .................................................................................178
V-brace Kits...............................................................................................................179
Stand System..............................................................................................................180
Glide Pucks ................................................................................................................182
Wheeled Pucks...........................................................................................................183
Tandem Glide Pucks..................................................................................................185
Tandem Wheeled Pucks.............................................................................................186
Magnet Arrays ...........................................................................................................187
MM LITE Power Supply ...........................................................................................188
Precision Rail Option.................................................................................................189
Precision Rails .....................................................................................................189
Precision Rail Single Array Vehicle....................................................................191
Precision Rail Dual Array Vehicle ......................................................................192
Precision Rail Support Post Assembly ................................................................193
Spine Plates..........................................................................................................194
Precision Rail Lubrication System ......................................................................198
Precision Locator Option ...........................................................................................199
Actuator Assembly ..............................................................................................199
Stand Assembly ...................................................................................................201
Adjustable Motor Mount Bracket ........................................................................203
Pallet ....................................................................................................................204
Electrical Specifications ..................................................................................................206
Motors and Switches..................................................................................................206
Straight and Curve Motors...................................................................................208
Switches ...............................................................................................................213

Contents
MagneMover LITE User Manual 7
Rockwell Automation Publication MMI-UM002F-EN-P - October 2022
MM LITE Power Supply ...........................................................................................217
AC Power Cable ..................................................................................................220
Motor Power Cables ............................................................................................221
DC Enable............................................................................................................222
DC Enable Jumper Plug.......................................................................................222
Precision Rail Lubrication Pump...............................................................................223
Precision Rail Lubrication Pump Connector .......................................................224
Precision Rail Lubrication Pump Controls and Indicators ..................................224
Precision Locator .......................................................................................................225
Pneumatic Specifications.................................................................................................227
Air-cooled Motors......................................................................................................227
Air Cooling ..........................................................................................................227
Pressurizing..........................................................................................................227
Precision Locator .......................................................................................................228
Communication................................................................................................................229
Ethernet Connection ..................................................................................................229
TCP/IP Communication – Host Controller to HLC.............................................229
TCP/IP Communication – Node Controller to Motor .........................................230
TCP/IP Communication – Motor to Motor..........................................................230
EtherNet/IP Communication – Host Controller to HLC .....................................230
RS-232 Serial Interface Connection ..........................................................................231
RS-422 Serial Interface Connection ..........................................................................231
Node Controller to Motor ....................................................................................231
Motor to Motor ....................................................................................................232
Ethernet Interface Connection ...................................................................................233
Sync Connection ........................................................................................................233
Site Requirements ............................................................................................................234
Environment...............................................................................................................234
Motors..................................................................................................................234
MM LITE Power Supply .....................................................................................234
Precision Locator .................................................................................................234
Magnet Arrays, Pucks, Precision Rail Vehicles ..................................................234
Derating at High Altitude ....................................................................................235
Lighting, Site .............................................................................................................235
Floor Space and Loading ...........................................................................................235
Facilities.....................................................................................................................235
Service Access ...........................................................................................................236
5 Installation
Overview..........................................................................................................................237
Unpacking and Inspection ...............................................................................................238
Unpacking and Moving .............................................................................................239
Required Tools and Equipment ...........................................................................239
Unpacking and Moving Instructions....................................................................239
Transport System Installation ..........................................................................................241
Installing Hardware....................................................................................................241
Required Tools and Materials..............................................................................241

Contents
8MagneMotion
Rockwell Automation Publication MMI-UM002F-EN-P - October 2022
Installation Overview – User-Supplied Mounting...............................................242
Installation Overview – MagneMotion Supplied Mounting................................243
Installation Overview – MagneMotion Precision Rails.......................................244
Installation Overview – MagneMotion Precision Locator ..................................246
Stand System Installation...........................................................................................247
Assembling Beams ..............................................................................................247
Installing System Legs.........................................................................................248
Leveling the MagneMover LITE.........................................................................251
Securing the Transport System ............................................................................252
Motor Installation ......................................................................................................254
Installing Cable Chase Cover Brackets ...............................................................254
Installing Motor Mounts on Motors and Switches ..............................................255
Mounting Motors and Switches...........................................................................256
Align and Secure Motors and Switches...............................................................258
Align and Secure Railless Motors .......................................................................261
Verify Motor and Switch Installation ..................................................................262
Installing Electronics .................................................................................................263
Installing Electronics on the Transport System ...................................................263
Mounting Power Supplies....................................................................................264
Mounting MagneMover LITE Power Supplies ...................................................264
Mounting Allen-Bradley Power Supplies............................................................265
Connecting Motors and Electronics...........................................................................266
RS-422 Motor Communication ...........................................................................267
Ethernet Motor Communication ..........................................................................270
Digital I/O ............................................................................................................273
Installing Motor Power Cables ............................................................................274
Installing Magnet Arrays/Pucks.................................................................................276
Magnet Array Installation....................................................................................276
Puck Installation ..................................................................................................277
Installing Cable Chase Covers...................................................................................278
Option Installation ...........................................................................................................281
Precision Rail Installation..........................................................................................281
Assemble Precision Rail Support Posts ...............................................................282
Attach Precision Rail Support Posts to the Beam................................................284
Attach Rails to Spine Plates.................................................................................285
Align and Secure Rails to Spine Plates................................................................288
Secure Spine Plates to Support Posts...................................................................291
Install the Precision Rail Vehicles .......................................................................291
Lubricate the Precision Rails ...............................................................................292
Install the Optional Precision Rail Lubrication Pump System ............................293
Initial Lubrication Using the Pump System.........................................................295
Lubrication Using the Pump System During Normal Operation.........................295
Precision Locator Installation ....................................................................................296
Install Pallets and Pucks ......................................................................................297
Install the Precision Locators on the Stands ........................................................298
Install the Precision Locator Assemblies.............................................................298
Install the Motors .................................................................................................298

Contents
MagneMover LITE User Manual 9
Rockwell Automation Publication MMI-UM002F-EN-P - October 2022
Install the Pneumatic Controls.............................................................................299
Install the Covers .................................................................................................301
Teach the Precision Locator Position ..................................................................301
Facilities Connections......................................................................................................302
Network Connections ................................................................................................302
Electrical Connections ...............................................................................................303
E-stop Circuit.......................................................................................................305
Interlock Circuit...................................................................................................305
Light Stack Circuit...............................................................................................306
General Purpose Digital I/O ................................................................................306
Software ...........................................................................................................................307
Software Overview ....................................................................................................307
Software Configuration..............................................................................................307
Node Controller Software Installation.................................................................308
Motor Software Installation .................................................................................308
Check-out and Power-up .................................................................................................309
System Check-out ......................................................................................................309
Mechanical Checks ..............................................................................................309
Facility Checks ....................................................................................................309
Pre-operation Checks...........................................................................................309
System Power-up .......................................................................................................310
System Testing.................................................................................................................313
6 Operation
Overview..........................................................................................................................315
Theory of Operation.........................................................................................................316
MagneMover LITE Transport System Advantages...................................................316
Motion Control ..........................................................................................................317
Motor Topology.........................................................................................................317
Motor Operation ........................................................................................................318
Motor Cogging.....................................................................................................319
Motor Blocks .............................................................................................................319
Block Acquisition ................................................................................................319
Block Ownership .................................................................................................320
Block Release ......................................................................................................320
Anti-Collision ............................................................................................................321
Safe Stopping Distance........................................................................................321
Thrust Limitations................................................................................................322
Vehicles In Queue................................................................................................322
Vehicle Length Through Curves and Switches ...................................................323
Locating Vehicles During Startup .............................................................................323
Moving Vehicles by Hand ...................................................................................323
Electrical System .......................................................................................................326
Power-Related Faults...........................................................................................327
Power-Related Fault Resolution ..........................................................................328
Node Controllers........................................................................................................329
Node Controller Communication.........................................................................329

Contents
10 MagneMotion
Rockwell Automation Publication MMI-UM002F-EN-P - October 2022
Controls and Indicators....................................................................................................330
Track Display.............................................................................................................330
Synchronization .........................................................................................................331
E-stops .......................................................................................................................332
Interlocks ...................................................................................................................332
FastStop .....................................................................................................................333
Light Stacks ...............................................................................................................333
Digital I/O ..................................................................................................................333
Transport System Simulation...........................................................................................334
Configuring a Simulation...........................................................................................334
Running a Simulation ................................................................................................336
Stopping a Simulation................................................................................................338
Return the System to Normal Operation....................................................................338
Precision Rail Operation..................................................................................................340
Setup ..........................................................................................................................340
Operation ...................................................................................................................340
Precision Locator Operation ............................................................................................341
Setup ..........................................................................................................................341
Basic Operation..........................................................................................................341
Operation Using Cylinder Position Sensors ..............................................................341
Transport System Operation ............................................................................................343
Power-up....................................................................................................................343
Normal Running ........................................................................................................343
Shutdown ...................................................................................................................344
7 Maintenance
Overview..........................................................................................................................345
Preventive Maintenance...................................................................................................346
General Cleaning .......................................................................................................348
Spray Cleaning...........................................................................................................348
Glide Puck Cleaning ..................................................................................................350
Puck Wear Surface Maintenance...............................................................................352
Wheeled Puck Cleaning.............................................................................................354
Wheeled Puck Wear Surface Maintenance................................................................356
Cable Connection Inspection .....................................................................................359
Hardware Inspection ..................................................................................................359
Transfer Log Files......................................................................................................359
Cleaning Magnet Arrays............................................................................................360
Clean or Replace the MM LITE Power Supply Air Filter.........................................361
Manually Lubricate the Precision Rails.....................................................................362
Refill the Lubricator on Precision Rail Vehicles .......................................................363
Refill the Lubrication Pump Reservoir for Precision Rail Systems ..........................366
Adjust Vehicle Bearings ............................................................................................367
Concentric Bearings.............................................................................................368
Eccentric Bearings ...............................................................................................368
Precision Locator Maintenance .................................................................................370
Troubleshooting ...............................................................................................................371

Contents
MagneMover LITE User Manual 11
Rockwell Automation Publication MMI-UM002F-EN-P - October 2022
Initial Troubleshooting ..............................................................................................371
Power-Related Troubleshooting ................................................................................372
Node Controller Troubleshooting..............................................................................375
Communication Troubleshooting ..............................................................................376
Motion Control Troubleshooting ...............................................................................377
Precision Rail Option Troubleshooting .....................................................................380
Light Stack Troubleshooting .....................................................................................381
Contact Rockwell Automation Technical Support ..........................................................382
Repair...............................................................................................................................383
Replace RS-422 Motors.............................................................................................385
Remove the Existing Motor.................................................................................385
Install the New Motor ..........................................................................................386
Program RS-422 Motors............................................................................................387
Replace RS-422 Motors with Ethernet Motors..........................................................388
Remove Existing RS-422 Motors ........................................................................388
Install New Ethernet Motors................................................................................389
Create/Revise Configuration Files.......................................................................389
Upload Configuration Files and Restart ..............................................................390
Replace Ethernet Motors ...........................................................................................391
Remove the Existing Motor.................................................................................391
Install the New Motor ..........................................................................................392
Program Ethernet Motors...........................................................................................393
Replace Motor Rails ..................................................................................................394
Replace Switch Rails .................................................................................................396
Separating Magnet Arrays .........................................................................................398
Replace Pucks ............................................................................................................399
Remove Pucks......................................................................................................400
Install Pucks.........................................................................................................401
Replace Glide Puck Wear Surfaces ...........................................................................402
Replace Tandem Glide Puck Wear Surfaces .............................................................406
Disassemble Tandem Puck Assembly .................................................................407
Reassemble Tandem Puck Assembly ..................................................................409
Replace Wheeled Puck Wear Surfaces, 4-Wheel Pucks............................................412
Replace Wheeled Puck Wear Surfaces, 2-Wheel Pucks............................................416
Replace Tandem Wheeled Puck Wear Surfaces........................................................419
Disassemble Tandem Puck Assembly .................................................................420
Reassemble Tandem Puck Assembly ..................................................................422
Replace MM LITE Power Supply Fuses ...................................................................425
AC Fuse ...............................................................................................................426
DC Fuses..............................................................................................................427
Replace Precision Rail Vehicles ................................................................................428
Vehicle Orientation..............................................................................................429
Removing Vehicles by Removing Rails..............................................................429
Installing Vehicles with Rails Removed..............................................................430
Removing Vehicles Without Removing Rails.....................................................430
Installing Vehicles Without Removing Rails ......................................................431
Install/Replace the Lubricators on Precision Rail Vehicles.......................................433

Contents
12 MagneMotion
Rockwell Automation Publication MMI-UM002F-EN-P - October 2022
Replace Magnet Arrays on Precision Rail Vehicles..................................................436
Single Array Vehicles..........................................................................................437
Dual Array Vehicles ............................................................................................439
Replace Bearings on Precision Rail Vehicles............................................................442
Replace Concentric Bearings...............................................................................444
Replace Eccentric Bearings .................................................................................446
Replace Wear Surfaces on Pallet ...............................................................................448
Replace Bushings on Pallet........................................................................................451
Replace Pins on Precision Locator Arms ..................................................................453
Replace Z-Datums on Precision Locator Stand.........................................................455
Ordering Parts ..................................................................................................................457
Shipping ...........................................................................................................................458
Packing Procedure .....................................................................................................459
Shipping Components................................................................................................460
Shipping Systems or System Sections .......................................................................461
Appendix
Overview..........................................................................................................................463
File Maintenance..............................................................................................................464
Backup Files ..............................................................................................................464
Creating Backup Files................................................................................................464
Restoring from Backup Files .....................................................................................464
Additional Documentation...............................................................................................465
Release Notes.............................................................................................................465
Upgrade Procedure ....................................................................................................465
Transport System Limits..................................................................................................466
Glossary ........................................................................................................... 467
Index ................................................................................................................ 475

MagneMover LITE User Manual 13
Rockwell Automation Publication MMI-UM002F-EN-P - October 2022
Figures
1-1 Detailed View of MagneMover LITE Transport System Components ......................38
1-2 Detailed View of MagneMover LITE Glide Puck ......................................................39
1-3 Detailed View of MagneMover LITE Wheeled Puck ................................................39
1-4 Detailed View of MagneMover LITE Precision Rail Option Components ................41
1-5 Detailed View of MagneMover LITE Precision Rail Vehicle ...................................42
1-6 Detailed View of MagneMover LITE Precision Locator Components ......................43
1-7 Simplified View of the MagneMover LITE Transport System Components .............44
1-8 Simplified View of Transport System Software Organization ...................................45
2-1 Locations of Hazardous Points on the MagneMover LITE Transport System ...........55
2-2 Locations of Hazardous Points on the Precision Rail Option .....................................56
2-3 Locations of Hazardous Points on the Precision Locator Option ...............................57
2-4 Locations of Hazardous Points on the Glide Puck .....................................................58
2-5 Locations of Hazardous Points on the Wheeled Puck ................................................58
2-6 Locations of Hazardous Points on the Precision Rail Vehicle ...................................59
3-1 Sample MM LITE Transport System Layout Showing Motors .................................75
3-2 Sample MM LITE Transport System Layout Showing Paths ....................................76
3-3 Sample MM LITE Transport System Layout Showing Nodes ...................................77
3-4 Sample MM LITE Transport System Layout Showing Node Controllers .................78
3-5 Sample MM LITE Transport System Layout Showing Additional Connections .......79
3-6 MagneMover LITE System, Single Array Glide Puck ...............................................80
3-7 MagneMover LITE Motor Gaps .................................................................................84
3-8 System Wiring Block Diagram, RS-422 Motor Communication ...............................88
3-9 System Wiring Block Diagram, Ethernet Motor Communication .............................89
3-10 Ethernet Motor Wiring – One Path, One Ethernet Chain ...........................................91
3-11 Ethernet Motor Wiring – One Path, Two Ethernet Chains .........................................91
3-12 Ethernet Motor Wiring – One Path, Ethernet Star ......................................................92
3-13 Ethernet Motor Wiring – One Path, Ethernet Star, Multiple Ethernet Switches ........92
3-14 Ethernet Motor Wiring – Two Paths, Ethernet Star, Multiple Node Controllers .......92
3-15 Ethernet Motor Wiring – One Path, One Ethernet Chain ...........................................93
3-16 Ethernet Motor Wiring – One Path, Two Ethernet Chains .........................................93
3-17 Ethernet Motor Wiring – One Path, Ethernet Star ......................................................93
3-18 Ethernet Motor Wiring – Five Paths, Two Ethernet Chains, Main Loop and Spur ....94
3-19 Ethernet Motor Wiring – Three Paths, One Ethernet Chain, Main Loop and Spur ....94
3-20 Ethernet Motor Wiring – Two Paths, Ethernet Chain and RS-422 Chain ..................95
3-21 Ethernet Motor Wiring – Two Paths, Ethernet Chain and RS-422 Chain ..................95

14 MagneMotion
Rockwell Automation Publication MMI-UM002F-EN-P - October 2022
3-22 Ethernet Motor Wiring – Three Paths, Ethernet Chain Main Loop, RS-422 Spur .....96
3-23 Standard MagneMover LITE Magnet Array, 1 Cycle, 3 Poles ..................................98
3-24 Typical Vehicle on Guideway ..................................................................................101
3-25 Vehicle Gap ..............................................................................................................102
3-26 Single Array Glide Puck ...........................................................................................105
3-27 Single Array Glide Puck Payload Envelope .............................................................105
3-28 Single Array Glide Puck Payload vs. Velocity .........................................................106
3-29 Dual Array (Tandem) Array Glide Puck ..................................................................107
3-30 Dual Array (Tandem) Glide Puck Payload Envelope ...............................................107
3-31 Tandem Array Glide Puck Payload vs. Velocity ......................................................108
3-32 Single Array 4 Wheel Puck ......................................................................................109
3-33 Single Array 4 Wheel Puck Payload Envelope ........................................................109
3-34 Single Array 4 Wheel Puck Payload vs. Velocity ....................................................110
3-35 Dual Array (Tandem) Wheeled Puck .......................................................................111
3-36 Dual Array (Tandem) Wheeled Puck Payload Envelope .........................................111
3-37 Dual Array (Tandem) Wheeled Puck Payload vs. Velocity .....................................112
3-38 Single Array 2 Wheel Puck ......................................................................................112
3-39 Single Array Precision Rail Vehicle .........................................................................113
3-40 Single Array Precision Rail Vehicle Payload vs. Velocity .......................................113
3-41 Dual Array Precision Rail Vehicle ...........................................................................114
3-42 Dual Array Precision Rail Vehicle Payload vs. Velocity .........................................114
3-43 MagneMover LITE Railless Transport System, Single Vehicle ..............................115
3-44 Motor Mounting to Flat Surface ...............................................................................117
3-45 Motor Mounting Using Custom Brackets .................................................................118
3-46 Motor Mounting Using Motor Mount Brackets .......................................................119
3-47 System Stand .............................................................................................................120
3-48 Typical Leg Installation ............................................................................................121
3-49 Custom Motor Mounting ..........................................................................................122
3-50 Puck Carrier Overhang .............................................................................................124
3-51 Precision Rail Option ................................................................................................126
3-52 Precision Rails ..........................................................................................................127
3-53 Precision Rail Spine Plates .......................................................................................128
3-54 Precision Rail Support Post ......................................................................................129
3-55 Precision Rail Single Array Vehicle .........................................................................130
3-56 Precision Rail Dual Array Vehicle ...........................................................................130
3-57 Precision Rail to Motor Reference Diagram .............................................................131
3-58 Lubricator on Single Array Vehicle ..........................................................................132
3-59 Precision Rail System with Lubrication Pump System ............................................133
3-60 Precision Locator Option ..........................................................................................134
3-61 Precision Locator Pallet Design Details ...................................................................136
3-62 Precision Locator Installation Dimensions ...............................................................137
3-63 Precision Locator Pneumatic Block Diagram ...........................................................138
3-64 Straight Track Configuration ....................................................................................139
3-65 Curve Track Configuration .......................................................................................140
3-66 Switch Configuration ................................................................................................141
4-1 1000 mm RS-422 Motor Mechanical Drawing ........................................................148

MagneMover LITE User Manual 15
Rockwell Automation Publication MMI-UM002F-EN-P - October 2022
4-2 1000 mm RS-422 Air-cooled Motor Mechanical Drawing ......................................149
4-3 1000 mm Railless RS-422 Motor Mechanical Drawing ...........................................150
4-4 1000 mm Railless RS-422 Air-cooled Motor Mechanical Drawing ........................151
4-5 1000 mm Ethernet Motor Mechanical Drawing .......................................................152
4-6 1000 mm Ethernet Air-cooled Motor Mechanical Drawing .....................................153
4-7 1000 mm Railless Ethernet Motor Mechanical Drawing .........................................154
4-8 1000 mm Railless Ethernet Air-cooled Motor Mechanical Drawing .......................155
4-9 250 mm RS-422 Motor Mechanical Drawing ..........................................................156
4-10 250 mm RS-422 Air-cooled Motor Mechanical Drawing ........................................157
4-11 250 mm Railless RS-422 Motor Mechanical Drawing .............................................158
4-12 250 mm Railless RS-422 Air-cooled Motor Mechanical Drawing ..........................159
4-13 250 mm Ethernet Motor Mechanical Drawing .........................................................160
4-14 250 mm Ethernet Air-cooled Motor Mechanical Drawing .......................................161
4-15 250 mm Railless Ethernet Motor Mechanical Drawing ...........................................162
4-16 250 mm Railless Ethernet Air-cooled Motor Mechanical Drawing .........................163
4-17 125 mm R 90° Curve RS-422 Motor Mechanical Drawing .....................................164
4-18 125 mm R 90° Curve RS-422 Air-cooled Motor Mechanical Drawing ...................165
4-19 125 mm R 90° Curve Railless RS-422 Motor Mechanical Drawing ........................166
4-20 125 mm R 90° Curve Railless RS-422 Air-cooled Motor Mechanical Drawing .....167
4-21 125 mm R 90° Curve Ethernet Motor Mechanical Drawing ....................................168
4-22 125 mm R 90° Curve Ethernet Air-cooled Motor Mechanical Drawing ..................169
4-23 125 mm R 90° Railless Curve Ethernet Motor Mechanical Drawing ......................170
4-24 125 mm R 90° Railless Curve Ethernet Air-cooled Motor Mechanical Drawing ....171
4-25 Left RS-422 Switch Mechanical Drawing ................................................................172
4-26 Left Ethernet Switch Mechanical Drawing ..............................................................173
4-27 Left Ethernet High Payload Switch Mechanical Drawing ........................................174
4-28 Right RS-422 Switch Mechanical Drawing ..............................................................175
4-29 Right Ethernet Switch Mechanical Drawing ............................................................176
4-30 Right Ethernet High Payload Switch Mechanical Drawing .....................................177
4-31 Standard Motor Mount Bracket Mechanical Drawing .............................................178
4-32 Standard V-braces .....................................................................................................179
4-33 Stand System Mechanical Drawing ..........................................................................180
4-34 Glide Puck Mechanical Drawing (G5) .....................................................................182
4-35 4 Wheel Puck Mechanical Drawing .........................................................................183
4-36 2 Wheel Puck Mechanical Drawing .........................................................................184
4-37 Tandem Glide Puck Mechanical Drawing (G5) .......................................................185
4-38 Tandem Wheeled Puck Mechanical Drawing ..........................................................186
4-39 Magnet Array Mechanical Drawing (G4.2) ..............................................................187
4-40 MM LITE Power Supply Mechanical Drawing .......................................................188
4-41 Precision Rail Mechanical Drawing .........................................................................189
4-42 Precision Rail Single Array Vehicle Mechanical Drawing ......................................191
4-43 Precision Rail Dual Array Vehicle Mechanical Drawing .........................................192
4-44 Precision Rail Support Post Assembly .....................................................................193
4-45 Precision Rail Straight to Curve, Spine Plates, Mechanical Drawing ......................194
4-46 Precision Rail Curve to Curve, Spine Plates, Mechanical Drawing .........................195
4-47 Precision Rail Straight, No Joint, Spine Plate, Mechanical Drawing .......................196
4-48 Precision Rail Straight, With Joint, Spine Plate, Mechanical Drawing ....................196

16 MagneMotion
Rockwell Automation Publication MMI-UM002F-EN-P - October 2022
4-49 Precision Rail Curve, 180°, No Joint, Spine Plate, Mechanical Drawing ................197
4-50 Precision Rail Support Lubricator Pump ..................................................................198
4-51 Precision Locator Actuator Mechanical Drawing ....................................................199
4-52 Standard Precision Locator Stand Mechanical Drawing ..........................................201
4-53 Adjustable Motor Mount Bracket Mechanical Drawing ..........................................203
4-54 Precision Locator Glide Puck with Basic Pallet Mechanical Drawing ....................204
4-55 Precision Locator Tandem Glide Puck with Basic Pallet Mechanical Drawing ......205
4-56 MagneMover LITE RS-422 Motor Electrical Connections .....................................208
4-57 MagneMover LITE Ethernet Motor Electrical Connections ....................................210
4-58 MagneMover LITE RS-422 Switch Electrical Connections ....................................213
4-59 MagneMover LITE Ethernet Switch Electrical Connections ...................................215
4-60 MM LITE Power Supply Electrical Connections and Indicators .............................218
4-61 MM LITE DC Power Cables ....................................................................................221
4-62 DC Enable Circuit .....................................................................................................222
4-63 DC Enable Jumper ....................................................................................................222
4-64 Precision Rail Optional Lubricator Pump Connections ............................................223
4-65 Precision Locator Electrical Connections .................................................................225
4-66 Air-cooled Motor Pneumatic Connections ...............................................................227
4-67 Precision Locator Pneumatic Connections ...............................................................228
4-68 RS-422 Cables ..........................................................................................................232
5-1 Connecting Beam Sections .......................................................................................247
5-2 Leg on a Single Path Beam Assembly ......................................................................248
5-3 Legs on a Parallel Path Beam Assembly ..................................................................249
5-4 Angle Bracket Assembly ..........................................................................................250
5-5 System Leveling .......................................................................................................251
5-6 Bracket Tie-down .....................................................................................................252
5-7 Foot Tie-down ...........................................................................................................253
5-8 Installing Cable Chase Cover Mounting Brackets ....................................................254
5-9 Installing Motor Mounts on Motors and Switches ...................................................255
5-10 Installing Motors and Switches .................................................................................256
5-11 Positioning Motors and Switches .............................................................................257
5-12 Align and Secure Rails .............................................................................................258
5-13 Install Standard Switch .............................................................................................259
5-14 Install High Payload Switch .....................................................................................260
5-15 Align and Secure Railless Motors ............................................................................261
5-16 Power Supply Mounting ...........................................................................................264
5-17 Fusing for Allen-Bradley Power Supplies ................................................................265
5-18 Simplified Representation of RS-422 Motor Connections .......................................267
5-19 Simplified Representation of RS-422 Merge Switch Connections ..........................267
5-20 RS-422 Motor Communication Cable Connections .................................................268
5-21 Simplified Representation of Ethernet Motor Connections ......................................270
5-22 Simplified Representation of Ethernet Merge Switch Connections .........................270
5-23 Ethernet Motor Communication Cable Connections ................................................271
5-24 Power Connections ...................................................................................................274
5-25 Installing Straight Motor Cable Chase Covers .........................................................278
5-26 Installing Curved Motor Cable Chase Covers ..........................................................279

MagneMover LITE User Manual 17
Rockwell Automation Publication MMI-UM002F-EN-P - October 2022
5-27 Installing Switch Cable Chase Covers ......................................................................280
5-28 MagneMover LITE Railless Motor System ..............................................................281
5-29 Precision Rail Support Post Assembly .....................................................................282
5-30 Precision Rail Support Post to Post Mount Spacing .................................................283
5-31 Attach Precision Rail Support Post Assemblies to Beam .........................................284
5-32 Precision Rail End Identification ..............................................................................285
5-33 Attaching Straight Precision Rails to Curved Rails with Adjustment Key ..............286
5-34 Attaching Precision Rail to Spine Plates ..................................................................287
5-35 Tightening Sequence, Straight to Curve Precision Rail Spine Plate ........................288
5-36 Tightening Sequence, Curve to Curve Precision Rail Spine Plate ...........................289
5-37 Tightening Sequence, Straight to Straight Precision Rail Spine Plate .....................289
5-38 Tightening Sequence, 180° Curve No Joint Precision Rail Spine Plate ...................290
5-39 Tightening Sequence, Straight Rail No-Joint Precision Rail Spine Plate .................290
5-40 Securing Precision Rail Spine Plates to Support Posts .............................................291
5-41 Precision Rail Lubricator System .............................................................................293
5-42 Lubricator System Pump Clearance Distances .........................................................294
5-43 MagneMover LITE Precision Locator Option, Standard .........................................296
5-44 MagneMover LITE Precision Locator Option, Alternate .........................................297
5-45 Precision Locator Pneumatic Connections ...............................................................300
5-46 Network Cable Connections .....................................................................................302
6-1 Linear Synchronous Motor Derived From Rotary Motor .........................................316
6-2 Representation of Stationary Vehicles and Motor Blocks ........................................317
6-3 Representation of Moving Vehicles Per Motor Block ..............................................320
6-4 Representation of Block Ownership by Vehicle .......................................................320
6-5 Vehicle Movement Profile ........................................................................................321
6-6 Vehicle Movement Profile Showing Thrust Limitations ..........................................322
6-7 Power Cycle Timing .................................................................................................326
6-8 The Graphics Window ..............................................................................................330
6-9 Transport System Wiring Diagram with Synchronization .......................................331
7-1 Glide Puck Cleaning .................................................................................................351
7-2 Glide Puck Wear Indicator .......................................................................................353
7-3 Wheeled Puck Cleaning ............................................................................................355
7-4 Wheeled Puck Wear Point Inspection ......................................................................357
7-5 Tandem Wheeled Puck Wear Point Inspection ........................................................358
7-6 Replacing MM LITE Power Supply Fan Filter ........................................................361
7-7 Precision Rail Vehicle Lubricator Location .............................................................364
7-8 Precision Rail Vehicle Lubricator (Front and Rear) .................................................364
7-9 Precision Rail Single Array Vehicle Lubrication Portal ...........................................365
7-10 Precision Rail Vehicle Bearing Adjustment .............................................................368
7-11 Eccentric Bearing Position ........................................................................................369
7-12 Basic RS-422 Loop ...................................................................................................388
7-13 Basic RS-422 Loop with Motors Removed ..............................................................388
7-14 Basic RS-422 Loop With Ethernet Motors Added ...................................................389
7-15 Replace Motor Guide Rails .......................................................................................394
7-16 Replace Switch Guide Rails .....................................................................................396

18 MagneMotion
Rockwell Automation Publication MMI-UM002F-EN-P - October 2022
7-17 Remove Curve Motor Guide Rail .............................................................................400
7-18 Remove Plates from Magnet Assembly ....................................................................404
7-19 Adhere Preload Spacer to Underside of Top Plate ...................................................405
7-20 Place Tandem Glide Puck in Fixture ........................................................................407
7-21 Remove Tandem Glide Puck Linkage Plate Assembly ............................................408
7-22 Place First Glide Puck in Fixture ..............................................................................409
7-23 Place Second Glide Puck in Fixture .........................................................................410
7-24 Attach Tandem Glide Puck Linkage Plate Assembly ...............................................411
7-25 Replace 4-Wheel Puck Wear Points .........................................................................413
7-26 Replace 2-Wheel Puck Wear Points .........................................................................417
7-27 Place Tandem Wheeled Puck in Fixture ...................................................................420
7-28 Remove Tandem Wheeled Puck Linkage Plate Assembly .......................................421
7-29 Place First Wheeled Puck in Fixture .........................................................................422
7-30 Place Second Wheeled Puck in Fixture ....................................................................423
7-31 Attach Tandem Wheeled Puck Linkage Plate Assembly .........................................424
7-32 MM LITE Power Supply Fuse Locations .................................................................425
7-33 Open the Power Entry Module .................................................................................426
7-34 Remove the PEM Fuse Module ................................................................................426
7-35 Precision Rail Vehicle to Rail Orientation ...............................................................429
7-36 Remove Precision Rail Vehicle From Rail ...............................................................431
7-37 Precision Rail Vehicle Eccentric Bearings ...............................................................432
7-38 Install Precision Rail Vehicle on Rail .......................................................................432
7-39 Precision Rail Vehicle Lubricator Locations ............................................................434
7-40 Precision Rail Vehicle Lubricator .............................................................................434
7-41 Installing or Removing a Precision Rail Lubricator .................................................435
7-42 Single Array Precision Rail Vehicle Assembly ........................................................437
7-43 Dual Array Precision Rail Vehicle Assembly ..........................................................439
7-44 Precision Rail Vehicle Bearing Locations ................................................................443
7-45 Precision Rail Vehicle Concentric Bearings Disassembly/Assembly ......................444
7-46 Precision Rail Vehicle Eccentric Bearings Disassembly/Assembly .........................446
7-47 Eccentric Bearings Orientation .................................................................................447
7-48 Remove Precision Locator Pallet from Magnet Assembly .......................................449
7-49 Replace Bushings on Precision Locator Pallet .........................................................452
7-50 Replace Pins on Precision Locator Arms .................................................................453
7-51 Replace Z-Datum on Precision Locator Stand .........................................................455

MagneMover LITE User Manual 19
Rockwell Automation Publication MMI-UM002F-EN-P - October 2022
Tables
2-1 Regulatory Information ...............................................................................................52
2-2 Hazard Alert Symbol Identification ............................................................................60
2-3 Mandatory Action Symbol Identification ...................................................................61
2-4 Prohibited Action Symbol Identification ....................................................................61
3-1 Motor Assignments .....................................................................................................76
3-2 MagneMover LITE Motor Blocks ..............................................................................82
3-3 MagneMover LITE Thrust Force Guidelines .............................................................82
3-4 Single Glide Puck Carrier Overhang Limits .............................................................124
4-1 MagneMover LITE Gen 4 Motors Using RS-422 Communication .........................145
4-2 MagneMover LITE Gen 4 Motors Using Ethernet Communication ........................146
4-3 V-brace Kit Configurations ......................................................................................179
4-4 Stand System Heights ...............................................................................................181
4-5 Stand System Widths ................................................................................................181
4-6 Precision Rail Types and Lengths ............................................................................190
4-7 Precision Locator Actuator .......................................................................................200
4-8 Precision Locator Stand ............................................................................................202
4-9 MagneMover LITE Motor and Switch Power Requirements ...................................206
4-10 MagneMover LITE RS-422 Motor Electrical Connections .....................................208
4-11 MagneMover LITE Motor RS-422 Pinouts ..............................................................209
4-12 MagneMover LITE Motor Power Pinouts ................................................................209
4-13 MagneMover LITE Sync Pinouts .............................................................................209
4-14 MagneMover LITE Ethernet Motor Electrical Connections ....................................210
4-15 MagneMover LITE Motor Ethernet Pinout ..............................................................211
4-16 MagneMover LITE Motor Power Pinouts ................................................................211
4-17 MagneMover LITE Sync Pinouts .............................................................................212
4-18 MagneMover LITE RS-422 Switch Electrical Connections ....................................213
4-19 MagneMover LITE Switch RS-422 Pinouts .............................................................214
4-20 MagneMover LITE Switch Power Pinouts ...............................................................214
4-21 MagneMover LITE Switch Ethernet Pinout .............................................................214
4-22 MagneMover LITE Ethernet Switch Electrical Connections ...................................215
4-23 MagneMover LITE Switch Power Pinouts ...............................................................215
4-24 MagneMover LITE Switch Ethernet Pinout .............................................................216
4-25 MM LITE Power Supply Electrical Connections .....................................................218
4-26 MM LITE Power Supply Indicators .........................................................................218
4-27 MM LITE Power Supply Fuses ................................................................................219

20 MagneMotion
Rockwell Automation Publication MMI-UM002F-EN-P - October 2022
4-28 MM LITE Power Supply DC Power Pinouts ...........................................................219
4-29 MM LITE Power Supply DC Enable .......................................................................219
4-30 DC Power Cable Pinouts ..........................................................................................221
4-31 Precision Rail Optional Lubricator Pump Electrical Connections ...........................223
4-32 Precision Rail Optional Lubricator Pump Controls ..................................................223
4-33 Precision Rail Optional Lubricator Pump Indicators ................................................223
4-34 Precision Rail Optional Lubricator Pump Control Pinout ........................................224
4-35 Precision Locator Connections .................................................................................225
4-36 Precision Locator Sensor Indicators .........................................................................225
4-37 Precision Locator Sensor Pinout ...............................................................................226
4-38 Air-cooled Motor Pneumatic Connectors .................................................................227
4-39 Precision Locator Pneumatic Requirements .............................................................228
4-40 Precision Locator Connections .................................................................................228
4-41 RS-422 Cable Pinouts ...............................................................................................232
5-1 MagneMover LITE Component Packing Checklist Reference ................................238
5-2 Motor Mount Reference ............................................................................................257
5-3 Allen-Bradley Power Supplies ..................................................................................265
5-4 Precision Rail to Spine Plate Attachment Screws ....................................................287
5-5 Startup Indicators ......................................................................................................311
6-1 Propulsion Voltage Range ........................................................................................327
6-2 Simulated Operation Differences ..............................................................................336
7-1 MagneMover LITE Preventive Maintenance Schedule ............................................346
7-2 Precision Rail Vehicle Drag .....................................................................................368
7-3 Initial Troubleshooting .............................................................................................371
7-4 Power-Related Troubleshooting ...............................................................................372
7-5 Node Controller Related Troubleshooting ................................................................375
7-6 Communication-Related Troubleshooting ................................................................376
7-7 Motion Control Related Troubleshooting .................................................................377
7-8 Precision Rail Option Troubleshooting ....................................................................380
7-9 Light Stack Related Troubleshooting .......................................................................381
7-10 MagneMover LITE Repair Procedures .....................................................................383
A-1 MagneMotion Transport System Limits ...................................................................466
A-2 MagneMotion Transport System Motion Limits ......................................................466