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MagneMotion MagneMover Lite User Manual

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  • Page 1 MagneMover LITE User Manual...
  • Page 2 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.

  • Page 3: Table Of Contents

    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 MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...
  • Page 4 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...
  • Page 5 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 MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...
  • Page 6 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 MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...
  • Page 7 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...
  • Page 8 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 MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...
  • Page 9 Contents 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...
  • Page 10 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...
  • Page 11 File Maintenance......................A-2 Backup Files ......................A-2 Creating Backup Files.....................A-2 Restoring from Backup Files ..................A-2 Additional Documentation....................A-3 Release Notes......................A-3 Upgrade Procedure ....................A-3 Transport System Limits....................A-4 Glossary ......................G-1 Index ........................ I-1 MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...
  • Page 12 Contents This page intentionally left blank. MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 13: Figures

    Locations of Hazardous Points on the Precision Rail Option .........2-8 Locations of Hazardous Points on the Precision Locator Option ......2-9 Locations of Labels on the MagneMover LITE Straight and Curve Motors ..2-12 Locations of Labels on the MagneMover LITE Switches ........2-13 Locations of Labels on the MagneMover LITE Magnet Arrays and Pucks ...2-14...
  • Page 14 4-28 Precision Rail Straight to Curve, Spine Plates, Mechanical Drawing ....4-30 4-29 Precision Rail Curve to Curve, Spine Plates, Mechanical Drawing .......4-31 4-30 Precision Rail Straight, No Joint, Spine Plate, Mechanical Drawing .....4-32 MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...
  • Page 15 4-34 Standard Precision Locator Stand Mechanical Drawing ........4-35 4-35 Adjustable Motor Mount Bracket Mechanical Drawing ........4-36 4-36 Precision Locator Basic Pallet Mechanical Drawing ..........4-37 4-37 MagneMover LITE Motor Electrical Connections ..........4-40 4-38 MagneMover LITE Switch Electrical Connections ..........4-42 4-39 MM LITE Power Supply Electrical Connections ...........4-45 4-40 MM LITE DC Power Cables ..................4-47...
  • Page 16 5-41 Precision Locator Pneumatic Connections .............5-58 5-42 Network Cable Connections ...................5-60 Linear Synchronous Motor Derived From Rotary Motor ........6-2 Representation of Stationary Vehicles Per MagneMover LITE Motor Block ..6-4 Representation of Moving Vehicles Per MagneMover LITE Motor Block ...6-4 Vehicle Movement Profile ..................6-7 The Graphics Window ....................6-11...
  • Page 17 7-28 Remove Precision Locator Pallet from Magnet Assembly ........7-65 7-29 Replace Bushings on Precision Locator Pallet ............7-68 7-30 Replace Pins on Precision Locator Arms ...............7-69 7-31 Replace Z-Datum on Precision Locator Stand ............7-71 MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...
  • Page 18 Figures This page intentionally left blank. MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 19: Tables

    Mandatory Action Symbol Identification ...............2-11 Prohibited Action Symbol Identification ..............2-11 Labels Used on the MagneMover LITE Straight and Curve Motors .....2-12 Labels Used on the MagneMover LITE Switches ..........2-13 Labels Used on the MagneMover LITE Magnet Arrays and Pucks .......2-14 Labels Used on the NC-12 Node Controller ............2-15...
  • Page 20 4-29 Precision Locator Sensor Pinout ................4-60 4-30 Precision Locator Pneumatic Requirements ............4-61 4-31 Precision Locator Connections ................4-61 4-32 RS-422 Cable Pinouts .....................4-64 MagneMover LITE Component Packing Checklist Reference ......5-2 Motor Mount Reference ..................5-21 Precision Rail to Spine Plate Attachment Screws ..........5-49 Startup Indicators ....................5-68 Simulated Operation Differences ................6-21...

  • Page 21: Changes

    Updated trademark information. Changed all figures to show the new frame mounting system. Changed all MagneMover LITE abbreviations from ‘ML’ to ‘MM LITE’. Corrected the names of all referenced MagneMotion manuals. Updated the descriptions of all system soft- ware.

  • Page 22: Rev. C

    G4.3 pucks. Added mechanical drawings for the G4.2 and G4.3 tandem pucks. Added the mechanical drawing for the G4.2 magnet array. Added Loctite curing requirement to installa- tion procedures. Added Magnet Array Installation. Added a description of Block Acquisition. MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 23: Rev. E

    Updated the Transport System Software Overview to include the Virtual Scope. Clarified the description of Gateway Node. Moved the Magnet Array Types information from Specifications and Site MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...
  • Page 24 Updated the Transport System Installation procedures. Moved MagneMover LITE Transport System Advantages forward in Theory of Operation. Updated the descriptions of In Queue Vehicle Length Through Curves and Switches.

  • Page 25: About This Manual

    MagneMotion, Inc. to design, install, configure, test, and operate an MM LITE transport system. Audience This manual is intended for all users of MagneMover LITE transport systems and provides information on how to install, configure, and operate the MM LITE transport system. Prerequisites ®...

  • Page 26: Magnemotion Documentation

    The examples in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any linear motor transport system installa- tion, MagneMotion, Inc. cannot assume responsibility or liability for actual use based on these examples.

  • Page 27: Notes, Safety Notices, And Symbols

    Examples of the standard safety notices used in this manual are provided below and include a description of hazard level indicated by each type of notice. DANGER Danger indicates a hazardous situation which, if not avoided, will result in death or serious injury. MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 28: Manual Structure

    This manual contains the following chapters: • Introduction: Provides an overview of the MagneMover LITE components and their use in a transport system. The MM LITE motors are used to provide fast, precise movement, positioning, and tracking of loads up to 2 kg [4.4 lb].

  • Page 29: Related Documentation

    NOTE: Distribution of this manual and all addendums and attachments are not controlled. Changes may have been made to this manual or additional documents added to the MagneMover LITE document set at any time. To identify the current revisions or to obtain a current set of documents, contact MagneMotion Customer Support.
  • Page 30 About This Manual This page intentionally left blank. xxviii MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 31: Introduction

    MM LITE motors in a transport system. Use this manual to install, test, and debug the MagneMover LITE components in a transport system. Note that some procedures may vary based on the transport system configuration, communications, and other variables.

  • Page 32: Magnemover Lite Overview

    MagneMover LITE Overview MagneMover LITE Overview The MagneMover LITE (MM LITE) is an intelligent transport system specifically developed for fast, precise movement, positioning, and tracking of small, light loads in a transport sys- tem. The MM LITE transport system is a configuration of linear synchronous motors and...

  • Page 33: Magnemover Lite Transport System Components

    Standard Motor Mount Connector Plate System Leg (Stand System) Figure 1-1: Detailed View of MagneMover LITE Transport System Components • Beam – The structure mounted to the transport system legs that provides a rigid mounting system for the motors. •...

  • Page 34: Magnemover Transport System Options

    The Precision Rail option provides customized stainless steel precision ground rails in place of the integral rails on the standard MagneMover LITE motors. When using the Precision Rail option, MM LITE railless motors are used with the precision rail aligned above the motors and supporting vehicles using precision sealed bearings.

  • Page 35: Detailed View Of Magnemover Lite Precision Rail Option Components

    Spine Plate Support Post Post Mount Railless Motor V-Brace Figure 1-2: Detailed View of MagneMover LITE Precision Rail Option Components • V-Brace – Used for align and secure adjacent railless motors to each other. • Railless Motor – The MagneMover LITE motor without integral rails.

  • Page 36: Precision Locator

    • Pallet – Carries the user’s payload. Replaces the standard puck’s top plate. May be provided by MagneMotion or custom designed by the user for their application. • Precision Locator – Pneumatic mechanism used to fully constrain the pallet at the sta- tion.

  • Page 37: Transport System Overview

    Introduction Transport System Overview Transport System Overview This section identifies the components of a MagneMover LITE transport system as shown in Figure 1-4 and described after the figure. DC Power Cables Vehicles (Pucks) Power Supply Motors Host Controller (PC or PLC)

  • Page 38: Transport System Software Overview

    Introduction Transport System Software Overview Transport System Software Overview Several software applications are used to configure, test, and administer a MagneMover LITE transport system as shown in Figure 1-5 and described after the figure. Refer to Related Docu- mentation on page xxvii for the reference manuals for these applications.
  • Page 39 MagneMotion ML Configurator (Configurator) – A Windows software application supplied by MagneMotion to create or change the Node Controller Configuration File, the Track File, and Track Layout File for MagneMover LITE transport systems, with- out editing the files directly. •...

  • Page 40: Getting Started With The Magnemover Lite Transport System

    Getting Started with the MagneMover LITE Transport System Getting Started with the MagneMover LITE Transport System Use this manual as a guide and reference when installing the MagneMover LITE motors in a transport system. Follow the steps in this section to get the entire transport system operational...
  • Page 41 NOTE: The NCHost TCP Interface Utility is for test and verification trials only. The user’s Host Controller must be used to control the MagneMover LITE trans- port system after verification of functionality.
  • Page 42 Introduction This page intentionally left blank. MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 43: Safety

    Regulatory Compliance information. • Personnel and Equipment safety guidelines. • Symbol identification. • Label identification and locations. • Identification of Mechanical, Electrical, and Magnetic hazards. • Recycling and Disposal Information. MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 44: Regulatory Compliance

    EU RoHS and EU WEEE Compliance MagneMotion products are considered parts of a Large-scale Fixed Installation and as a Large-scale Stationary Industrial Tool for purposes of the European Union's RoHS and WEE Directives and are therefore exempt from mandatory compliance. The CE Marking on the DoC does not include reference to the RoHS Directive for that reason.
  • Page 45 Regulatory Compliance • Contact MagneMotion Customer Support for information regarding repair and mainte- nance service policies, both during the production of the MagneMover LITE compo- nents and after production is discontinued. • Any user-caused damage during integration of the MagneMover LITE components into their equipment is the user’s responsibility.

  • Page 46: Safety Considerations

    Personnel operating or servicing the MagneMover LITE transport system should be properly trained. • Be aware of the hazardous points of the MagneMover LITE transport system as described in this chapter. • High strength Neodymium Iron Boron magnets are used in the MagneMover LITE transport system.

  • Page 47: Equipment Safety Guidelines

    Do not place the MagneMover LITE transport system’s connections (power and com- munications cables) where they could cause a trip hazard. • Do not place the MagneMover LITE transport system in a location where it may be subject to physical damage. •...
  • Page 48 Always operate the MagneMover LITE transport system with appropriate barriers in place to prevent contact with moving objects by personnel. • Do not install or operate the MagneMover LITE transport system if any of the compo- nents have been dropped, damaged, or are malfunctioning. •...

  • Page 49: Magnemover Lite Transport System Hazard Locations

    Guideway (typical) Mechanical Hazard – Pinch Point Vehicle/Puck (typical) Mechanical Hazard – Pinch Point Magnetic Field Hazard Figure 2-1: Locations of Hazardous Points on the MagneMover LITE Transport System MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 50: Precision Rail Option Hazard Locations

    Mechanical Hazard – Pinch Point Vehicle (typical) Mechanical Hazard – Pinch Point Magnetic Field Hazard Rail Mounting (typical) Mechanical Hazard – Pinch Point Figure 2-2: Locations of Hazardous Points on the Precision Rail Option MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 51: Precision Locator Option Hazard Locations

    Locator Arm Mechanical Hazard – Pinch Point Cover Removed Locator Drive Mechanical Hazard - Pinch Point (normally covered) Figure 2-3: Locations of Hazardous Points on the Precision Locator Option MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 52: Symbol Identification

    Safety Symbol Identification Symbol Identification Symbols are used in this manual and on the MagneMotion products to identify hazards, man- datory actions, and prohibited actions. The symbols used in this manual and their descriptions are provided below. Table 2-2: Hazard Alert Symbol Identification...

  • Page 53: Mandatory Action Symbol Identification

    Pacemakers or Medical Implants Prohibited – Indicates that persons with medical implants are not allowed in the specified area due to the possibility of personal injury. MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 54: Label Identification And Location

    NOTE: Label placement may cause labels to be visible only during maintenance operations. The following tables list the labels that are affixed to the individual MagneMover LITE com- ponents. These labels are used to alert personnel to hazards on or within the MM LITE com- ponents and to provide information about the components.

  • Page 55: Locations Of Labels On The Magnemover Lite Switches

    Hazard Type: Pinch/Crush Possible injuries: Pinch between vehicle (puck) and switch rail Pinch Hazard Label Information Label MAC ID Label Figure 2-5: Locations of Labels on the MagneMover LITE Switches MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 56: Locations Of Labels On The Magnemover Lite Magnet Arrays And Pucks

    Hazard Type: Magnetic field Possible injuries: Pinch between magnet arrays, danger to pacemakers and other electronics Magnet Hazard Label Serial Number Label Figure 2-6: Locations of Labels on the MagneMover LITE Magnet Arrays and Pucks MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 57: Locations Of Labels On The Nc-12 Node Controller

    - 4 D 0 9 0 - 3 C : 1 3 - 2 B S / N MAC ID Label Figure 2-7: Locations of Labels on the NC-12 Node Controller MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 58: Locations Of Labels On The Node Controller Lite

    S/N:????????? MAC: 1A-2B-3C-4D-5E-6F Qty: 1 Location: On the top of the Node Controller LITE Information Label O N L MAC ID Label Figure 2-8: Locations of Labels on the Node Controller LITE MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 59: Locations Of Labels On The Mm Lite Power Supply

    Location: On the bottom of the power supply X110400001 100-240 VAC~, 50-60 Hz, 8.5A T, 250V, 10A Fuse Made in USA www.magnemotion.com Information Label Figure 2-9: Locations of Labels on the MM LITE Power Supply MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 60: Precision Rail Option Components

    Possible injuries: Pinch between magnet arrays, danger to pacemakers and other electronics Vehicle Serial Number Label Magnet Hazard Label Magnet Array Serial Number Label Figure 2-10: Locations of Labels on the Precision Rail Vehicles (single array shown) MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 61: Locations Of Labels On The Precision Rail Spine Plates

    Location: On the top surface of the Spine Plate Hazard Type: Pinch/Crush Possible injuries: Pinch between vehicle and spine plate, post, or rail Pinch Hazard Label Figure 2-11: Locations of Labels on the Precision Rail Spine Plates MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 62: Precision Locator Option Components

    Location: On the front of the housing Hazard Type: Pinch/Crush Possible injuries: Pinch between rocker arms and housing or pallet. Pinch Hazard Label Serial Number Label Figure 2-12: Locations of Labels on the Precision Locator MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 63: Locations Of Labels On The Precision Locator Puck

    Hazard Type: Magnetic field Possible injuries: Pinch between magnet arrays, danger to pacemakers and other electronics Serial Number Label Magnet Hazard Label Figure 2-13: Locations of Labels on the Precision Locator Puck MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 64: Mechanical Hazards

    MM LITE transport sys- tem. All facilities to the MagneMover LITE transport system must be disconnected as outlined in the facility’s lockout/tagout procedure before servicing, or injury may result from the auto- matic operation of the equipment.

  • Page 65: Electrical Hazards

    Safety Electrical Hazards Electrical Hazards The MagneMover LITE components are classified as low voltage devices, no additional safety precautions are required. The power supplies, Node Controllers, network switches, and power modules are connected to the facility’s AC Mains and are capable of generating hazardous energy. The proper precau- tions for operating and servicing electrical equipment must be observed.

  • Page 66: Pneumatic Hazards

    These precautions include following facility lockout/tagout pro- cedures, and any other specified action within the facility where the Precision Locator is being used. The MagneMover LITE Precision Locator option is a low energy device, no additional pneu- matic safety precautions are required. CAUTION...

  • Page 67: Magnetic Hazards

    Safety Magnetic Hazards Magnetic Hazards The MagneMover LITE transport systems use high strength Neodymium Iron Boron (NdFeB) magnets in the magnet arrays attached to the vehicles (pucks). The proper precautions for using high strength magnets must be observed. WARNING Magnetic Field Hazard Strong magnets in use.

  • Page 68: Handling Magnet Arrays

    (e.g., disks, credit cards, cell phones). • Pinch/Crush – The magnet arrays used with the MagneMotion linear motors are very strong. The magnet arrays have a very high attractive force to each other and ferro- magnetic materials like steel, iron, some stainless steels, and nickel. Pinching will hap- pen if the magnet arrays are allowed to come together against a body part.

  • Page 69: Shipping Magnet Arrays

    Magnetic Hazards • Use – The magnet arrays should never be used to lift any objects. The MagneMotion magnet arrays should only be used for propulsion in conjunction with an MMI motor by attaching the array to a vehicle (puck).

  • Page 70: Recycling And Disposal Information

    The MagneMover LITE transport systems use the following items that may require special handling for disposal or recycling. MagneMover LITE Transport System No hazardous materials, other than those identified below, are used in the MagneMover LITE components. Node Controllers A Lithium battery is located in the Node Controllers to maintain the clock when power is removed.

  • Page 71: Design Guidelines

    This chapter provides guidelines for designing a transport system using the MagneMover LITE components. Included in this chapter are: • Design guidelines for laying out the MagneMover LITE transport system and creating interfaces to the system. • Design guidelines for using MagneMover LITE motors and magnet arrays.

  • Page 72: Transport System Layout

    Transport System Overview The MagneMover LITE components consist of a set of basic building-blocks that provides an easy to assemble and implement transport system. The modular nature of the MM LITE com- ponents makes it easy to implement layout or control changes. An example of how the basic building-blocks are used is provided in the following sections: •...

  • Page 73: Motors, Switches, And Vehicles (Pucks)

    Transport System Layout Motors, Switches, and Vehicles (Pucks) The transport system layout is a plan view layout of the MagneMover LITE transport system. This drawing identifies each motor and switch (if required) in the transport system (refer to Figure 3-1 for an example), how they are physically located, and any interfaces to other equip- ment in the facility.

  • Page 74: Paths

    Design Guidelines Transport System Layout Paths Once all motors have been identified on the MagneMover LITE transport system layout, the individual Paths must be defined (refer to Figure 3-2 for an example). This includes identify- ing all motors on the Path and the direction of forward (downstream) movement.

  • Page 75: Nodes

    Design Guidelines Transport System Layout Nodes Once all Paths have been identified on the MagneMover LITE transport system layout, the Nodes connecting those Paths must be defined (refer to Figure 3-3 for an example). This includes identifying the type of Node being used.

  • Page 76: Node Controllers

    Transport System Layout Node Controllers Once all Paths and Nodes have been identified on the MagneMover LITE transport system layout, the Node Controllers and their connections to the motors at the Nodes must be defined. This typically includes identifying the type of Node Controllers being used (the example in Figure 3-4 shows Node Controller LITEs being used).

  • Page 77: Additional Connections

    Transport System Layout Additional Connections The remaining components and connections must be defined on the MagneMover LITE trans- port system layout. The components include power supplies for the motors and network switches for communication with the Node Controllers and Host Controller (refer to...

  • Page 78: Transport System Design

    Transport System Layout on page 3-2 layout guidelines). One advantage of the MagneMover LITE transport system is that it is possible to have vehi- cles move at different rates of speed in the same direction, or in opposite directions without a collision.

  • Page 79: Motors

    Off-centered and/or large payloads can affect system performance. Motors The MagneMover LITE motors can be mounted either right side up or upside down. Other orientations may be possible, please contact MMI Technical Support for additional informa- tion. MM LITE motors do not have a required direction, the upstream and downstream ends are automatically defined during configuration.

  • Page 80: Motor Types

    Refer to Figure 4-33 on page 4-34 for the Precision Locator option mechanical drawing. • The MagneMover LITE transport system allows only one vehicle (puck) at a time on a motor block (see Table 3-2). Table 3-2: MagneMover LITE Motor Blocks...

  • Page 81: Required Thrust

    • Required acceleration. Motor Gap For MagneMover LITE motors installed in a transport system where V-Braces are used to lock the motors together, there will always be a space (Motor Gap) between motors, as shown Figure 3-6, with the required Motor Gap being 1 mm, which places MM LITE motors on a 1 meter pitch.

  • Page 82: Motor Cogging

    Node Controller via RS-422 serial communication. Electrical Wiring The MagneMover LITE motors are designed to operate at a nominal +36 VDC. A block dia- gram of a MM LITE transport system schematic is provided in Figure 3-7.

  • Page 83: Signal Wiring

    Having separate power busses also allows the motors to be programmed and configured without enabling the propulsion power. NOTE: The standard wiring provided as part of a MagneMover LITE transport system pro- vides this separation of power busses.

  • Page 84: System Wiring Block Diagram

    Design Guidelines Transport System Design Figure 3-7: System Wiring Block Diagram MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 85: Magnet Arrays

    Design Guidelines Transport System Design Magnet Arrays The amount of linear thrust that a MagneMover LITE motor provides is primarily a function of magnet array length. High Flux Magnet Arrays The high flux magnet array for the MagneMover LITE motors is an arrangement of neodym-...

  • Page 86: Magnet Array Length And Attractive Force

    The amount of thrust force is reported as force per magnet array cycle. The more cycles in the magnet array, the greater the thrust force. All MagneMover LITE magnet arrays are one cycle long and have a cycle length of 54.5 mm as shown in Figure 3-8.

  • Page 87: Magnet Array Use

    Magnet Array Use The MagneMover LITE high flux magnet arrays are intended for use as the MM LITE motor secondary as part of the vehicle (puck) only and should not used for any other purpose.

  • Page 88: Vehicles

    Design Guidelines Transport System Design Vehicles Vehicles (pucks) carry payloads through the MagneMover LITE transport system as directed. A high-strength magnet array, described in Magnet Arrays on page 3-15, is mounted to the surface of the vehicle closest to the motors. The magnet array interacts with the motors, which moves the vehicle.

  • Page 89: Single Array Puck

    Design Guidelines Transport System Design A variety of materials may be used to construct the vehicles in a MagneMover LITE transport system, provided the material can carry the payload without deflecting while supporting the magnet array in the correct relationship to the motors. In general, use a lighter weight vehicle to maximize the acceleration capability of the system for moving the payload.

  • Page 90: Vehicle Gap

    Figure 3-12, is the distance maintained between the magnet array and the MagneMover LITE motor. This gap should be maintained throughout the transport system to ensure consistent operation of the vehicle (the larger the gap the lower the thrust). Magnet Array...

  • Page 91: Vehicle Design

    • The vehicle should be longer than the magnet array to protect the array from impacts. MagneMotion recommends a minimum of 1 mm extra length at the front and back of the vehicle. •...

  • Page 92: Mounting Magnet Arrays To Vehicles

    Magnet arrays are provided with locating features to ensure consistent mounting to the user’s vehicles and threaded standoffs for attachment. Arrays should be attached using stainless steel hardware that fully engages the threads provided in the array mounting standoffs. MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 93: Guideways

    V-Brace Motor Mount Wheel Guide Plate Figure 3-13: MagneMover LITE Railless Transport System, Single Vehicle Basic guideway design guidelines and considerations: • The guideway can have any orientation in relation to the motors and vehicles as long as the magnet array on the vehicle is held in position next to the top of the motor.

  • Page 94: Guideway And Support Materials

    • Available in a variety of weights, thicknesses, and prices. Motor Mounts The MagneMover LITE motors provide mounting features on the bottom for a simple mount- ing scheme (refer to Mechanical Specifications on page 4-3). The following guidelines are provided for designing custom motor mounts.

  • Page 95: Motor Mounting Methods

    MM LITE 1000 mm Motor Mounting Plate Clearance Holes for Motor Connections M6 Mounting Hardware Figure 3-14: Motor Mounting to Flat Surface MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 96: Motor Mounting Using Custom Brackets

    Note that this mounting method provides easy adjustment of the motor position once the motor is installed. MM LITE 1000 mm Motor Mounting Bracket Hardware Track Motor Mounting Bracket M6 Mounting Hardware Figure 3-15: Motor Mounting Using Custom Brackets MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 97: Motor Mounting Using Motor Mount Brackets

    Ensure the top surface of all motors are coplanar to each other. Treating each motor to motor interface as a separate operation, tighten the motor mounts. Refer to Align and Secure Motors and Switches for details of the mounting procedure. MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 98: System Stands

    Transport System Design System Stands The MagneMover LITE transport system stand consists of the leg assemblies and the beams the motors are mounted on. The legs are available in different lengths, which provides differ- ent system heights as shown in...

  • Page 99: Custom Motor Mounting

    Custom Motor Mounting The following motor mounting guidelines are provided when designing a custom motor mounting surface (replacing the MagneMotion leg and beam system) or custom motor mounts (replacing the MagneMotion motor mounts) for the MagneMover LITE motors instead of using the MagneMotion motor mounting system.
  • Page 100 Once all motor mounts are secured to the motor mounting surface make sure the vehi- cle (puck) is able to travel across all motors and joints with no apparent binding. If binding is detected, make adjustments as required to eliminate the binding. MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 101: Puck Carrier

    Cantilevered Loads The following guidelines are provided when designing offset material carriers that are mounted on the puck for straight track applications using standard MagneMover LITE motors. Contact MagneMotion for design guidelines for applications using curves or switches. Note that the maximum load indicated in...
  • Page 102 Design Guidelines Puck Carrier Table 3-6: Puck Carrier Overhang Limits (Continued) Overhang Length (mm) Maximum Load (g) MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 103: Transport System Options

    Precision Rails Spine Plate Support Post Post Mount Figure 3-20: Precision Rail Option MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 104: Support Post Assembly

    Rail sections attach to the spine plates at the top of the support post assemblies, as shown in Figure 3-21. Curve Rail Section Adjustment Key Straight Rail Section Support Post Assembly Figure 3-21: Precision Rails MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 105: Precision Rail Types And Lengths

    1250 mm 1500 mm 1750 mm 2000 mm 2250 mm 2500 mm 2750 mm 3000 mm 3250 mm 3500 mm Curved Rail 90° 175.5 mm R 180° 175.5 mm R MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 106: Precision Rail Spine Plates

    Left Joint Straight to Curve Right Joint Curve to Curve Left Joint Curve to Curve Right Joint Straight, Joint Straight, No Joint 180º Curve No Joint Figure 3-22: Precision Rail Spine Plates MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 107: Precision Rail Support Post

    3-23, provides a mounting surface for the spine plates as shown in Figure 3-20 Figure 3-21 and is used to ensure the precision rails are held the correct distance from the MagneMover LITE railless motors. Spine Plate Mounting Surface Support Post Support Post Mount...

  • Page 108: Vehicles

    2.5 kilogram, the dual array vehicle can carry payloads up to 5 kilograms. Mounting Plate Vehicle Body Bearings Magnet Array Figure 3-24: Precision Rail Single Array Vehicle Mounting Plate Vehicle Body Bearings Magnet Array Figure 3-25: Precision Rail Dual Array Vehicle MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 109: Precision Rail Installation

    49.00 [1.929] Single Array Vehicle 1.50 [0.059] Rail Array Motor Support Post Assembly Motor Mount All Dimensions in Millimeters [Inches] Figure 3-26: Precision Rail to Motor Reference Diagram MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 110: Precision Locator

    Figure 3-27 shows the basic structure of the Precision Locator. The Precision Locator can be mounted either to the MagneMover LITE stand beam or to a user-supplied custom mounting surface. In each case, the adjustable motor mounts should be used.

  • Page 111: Pallet

    (refer to Figure 1-3 on page 1-6) and has a pair of replaceable skis attached to its bottom sur- face to allow it to ride on the MagneMover LITE motor rails. Pallet Design Basic pallet design guidelines and considerations (refer to...

  • Page 112: Precision Locator Pallet Design Details

    SECTION C-C BUSHING MOUNT FEATURES ROTATED 90° CW SKI MOUNT FEATURES Ø9.10 30.00 90° (2.3) 3.25 Ø4.5 Ø8.50 SECTION B-B ROTATED 90° CW MAGNET ARRAY FEATURES Figure 3-28: Precision Locator Pallet Design Details MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 113: Precision Locator Installation

    A pneumatic block diagram for the Precision Locator using a 5/2 valve is provided in Figure 3-30. MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 114: Precision Locator Pneumatic Block Diagram

    Design Guidelines Transport System Options Retracted Extended Pallet Released Pallet Engaged Figure 3-30: Precision Locator Pneumatic Block Diagram MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 115: Transport System Configuration

    Motor Gap Top View Figure 3-31: Straight Track Configuration • Node Types at beginning of Path: Simple, Relay, Terminus, Gateway. • Node Types at end of Path: Relay, Terminus, Gateway. MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 116: Curve Track Configuration

    MM LITE Curve Motor Motor Gap Top View Figure 3-32: Curve Track Configuration • Node Types at beginning of Path: Simple, Relay, Terminus, Gateway. • Node Types at end of Path: Relay, Terminus, Gateway. MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 117: Switch Configuration

    Provides a diverge from one Path into two (single entry, curve exit, straight exit). • Provides a merge of two Paths into one (straight entry, curve entry, merged exit). MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...
  • Page 118 Design Guidelines This page intentionally left blank. MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 119: Specifications And Site Requirements

    This chapter describes specifications for the MagneMover LITE transport system compo- nents and the requirements for installation. Included in this chapter are: • Mechanical specifications for all MagneMover LITE components, including dimen- sions. • Electrical specifications for power and communications, including connector pinouts. •...

  • Page 120: Motor Types

    MagneMover LITE G4 Motors The MagneMover LITE motor bodies are available in two styles; motors with integral rails and railless motors. Both body styles perform the same and have the same operating specifica- tions. Note that switches are only available with integral rails. The integral rails are available in either aluminum or stainless steel.

  • Page 121: Mechanical Specifications

    Mechanical Specifications Mechanical Specifications All drawings within this manual are generic and may not reflect specific configurations of the MagneMover LITE components. To obtain a complete and current set of drawings and docu- ments contact MagneMotion Technical Support. 1000 Millimeter Motor 3.75...

  • Page 122: 1000 Millimeter Railless Motor

    Refer to Motors and Switches on page 4-38 for the electrical specifications. Exposed Materials • 316/316L Stainless Steel. • EPDM (synthetic rubber). ® • Dow Corning Silicone 737 and 734. MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 123: 250 Millimeter Motor

    304L Stainless Steel with Electroless Nickel plating (SS rails). • 6061-T6 Aluminum (Al rails). • 6063-T5 Aluminum (Al rails). • EPDM (synthetic rubber). ® • Dow Corning Silicone 737 and 734. MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 124: 250 Millimeter Railless Motor

    Refer to Motors and Switches on page 4-38 for the electrical specifications. Exposed Materials • 316/316L Stainless Steel. • EPDM (synthetic rubber). ® • Dow Corning Silicone 737 and 734. MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 125: 125 Millimeter Radius 90° Curve

    316/316L Stainless Steel. • 303 Stainless Steel with Electroless Nickel plating (SS rails). • 6061-T6 Aluminum (Al rails). • EPDM (synthetic rubber). ® • Dow Corning Silicone 737 and 734. MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 126: 125 Millimeter Radius 90° Curve Railless Motor

    Refer to Motors and Switches on page 4-38 for the electrical specifications. Exposed Materials • 316/316L Stainless Steel. • EPDM (synthetic rubber). ® • Dow Corning Silicone 737 and 734. MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 127: 90° Left Switch

    303 Stainless Steel with Electroless Nickel plating (SS rails). • 6061-T6 Aluminum (Al rails). • EPDM (synthetic rubber). ® • Viton ® • Igus L280. ® • Dow Corning Silicone 737 and 734. MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 128: 90° Right Switch

    303 Stainless Steel with Electroless Nickel plating (SS rails). • 6061-T6 Aluminum (Al rails). • EPDM (synthetic rubber). ® • Viton ® • Igus L280. ® • Dow Corning Silicone 737 and 734. MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 129: Standard Motor Mount Bracket

    9.00[0.354] THRU .625 15.88 All Dimensions in Millimeters [Inches] Figure 4-9: Standard Motor Mount Bracket Mechanical Drawing (G4) Exposed Materials • 6063-T5 Aluminum, black anodized. • 304 Stainless Steel. MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 130: Stand System

    Table 3-4 60 ±12 All Dimensions in Millimeters Figure 4-10: Stand System Mechanical Drawing Exposed Materials • Galvanized Steel. • Zinc, Electrophoretic coated. • 6060 T66 Anodized Aluminum. • PA6 Nylon. • Rubber. MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 131: Pucks

    Mechanical Specifications Pucks The pucks are used on standard MagneMover LITE transport systems with either aluminum or stainless steel integral rails. Each puck can carry a 1 kg [2.2 lb] load. The MM LITE G3 series pucks have been replaced by the G4 series pucks. The G4 series pucks are fully back- ward compatible with the G3 series.

  • Page 132: Puck Mechanical Drawing (G4.2)

    All Dimensions in Millimeters [Inches] Figure 4-12: Puck Mechanical Drawing (G4.2) NOTE: Replaced by the G4.3 Puck, refer to Figure 4-13. Exposed Materials • Stainless Steel. • 316/316L/316L #2 Stainless Steel. • PEEK/PTFE. • UHMW Polyethylene. MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 133: Puck Mechanical Drawing (G4.3)

    Weight: 0.43 kg [0.9 lb] All Dimensions in Millimeters [Inches] Figure 4-13: Puck Mechanical Drawing (G4.3) Exposed Materials • Stainless Steel. • 316/316L/316L #2 Stainless Steel. • PEEK/PTFE. • UHMW Polyethylene. MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 134: Tandem Pucks

    Mechanical Specifications Tandem Pucks The tandem pucks are used on standard MagneMover LITE transport systems with either alu- minum or stainless steel integral rails. Each tandem puck can carry a 2 kg [4.4 lb] load. The MM LITE G3 series tandem pucks have been replaced by the G4 series tandem pucks. The G4 series tandem pucks are fully backward compatible with the G3 series.

  • Page 135: Tandem Puck Mechanical Drawing (G4.2)

    NOTE: Replaced by the G4.3 Tandem Puck, refer to Figure 4-16. Exposed Materials • Stainless Steel. • 316/316L/316L #2 Stainless Steel. • PEEK/PTFE. • UHMW Polyethylene. ® • Delrin FG150. • Acetal. MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 136: Tandem Puck Mechanical Drawing (G4.3)

    All Dimensions in Millimeters [Inches] Figure 4-16: Tandem Puck Mechanical Drawing (G4.3) Exposed Materials • Stainless Steel. • 316/316L/316L #2 Stainless Steel. • PEEK/PTFE. • UHMW Polyethylene. ® • Delrin FG150. • Acetal. MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 137: Magnet Arrays

    Mechanical Specifications Magnet Arrays The stand-alone magnet arrays are used on custom MagneMover LITE transport systems where a user-designed track system with user-designed vehicles are being used. The MM LITE G3 series magnet arrays have been replaced by the G4 series arrays. The G4 series arrays are fully backward compatible with the G3 series.

  • Page 138: Magnet Array Mechanical Drawing (G4.2)

    .657±.012 16.7±0.3 Weight: 0.43 kg [0.9 lb] All Dimensions in Millimeters [Inches] Figure 4-18: Magnet Array Mechanical Drawing (G4.2) Exposed Materials • Stainless Steel. • 316L/316L #2 Stainless Steel. • UHMW Polyethylene. MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 139: Node Controller

    NC-12 Node Controller on page 4-49 for the electrical specifications. Exposed Materials The Node Controller provides openings for airflow and should not be located in an area where harsh conditions exist. MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 140: Rack Mounting Bracket

    [2.00] 114.5 [4.51] 25.4 [1.00] 86.9 [3.42] [0.28] [0.13] All Dimensions in Millimeters [Inches] Figure 4-20: Rack Mounting Bracket Mechanical Drawing Exposed Materials • Carbon Steel. • 1018 Steel. • Anodized Aluminum. MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 141: Node Controller Lite

    Node Controller LITE on page 4-54 for the electrical specifications. Exposed Materials The Node Controller has unprotected openings and should not be located in an area where harsh conditions exist. MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 142: Electronics Mounting Plate

    2.68 6.69 15.00 68.18 170.00 All Dimensions in Millimeters [Inches] Figure 4-22: Electronics Mounting Plate Mechanical Drawing Exposed Materials • 5052-H32 Aluminum. • 300 Series Stainless Steel. • A-286 Hardened Stainless Steel. MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 143: Mm Lite Power Supply

    MM LITE Power Supply on page 4-44 for the electrical specifications. Exposed Materials The power supply provides openings for airflow and should not be located in an area where harsh conditions exist. MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 144: Precision Rail Option

    Mechanical Specifications Precision Rail Option Precision Rails THEORETICAL THEORETICAL APEX APEX 25.74±0.025 10.0±0.1 5.4±0.1 10.0±0.025 5.5±0.1 All Dimensions in Millimeters Figure 4-24: Precision Rail Mechanical Drawing Exposed Materials • 420 Series Stainless Steel. MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 145: Precision Rail Single Array Vehicle

    Figure 4-25: Precision Rail Single Array Vehicle Mechanical Drawing Exposed Materials • Stainless Steel. • 316L/316L #2 Stainless Steel. • 440C Stainless Steel. • UHMW Polyethylene. • Nitrile. • Plastic. ™ • Mobilgear 600 XP Oil. MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 146: Precision Rail Dual Array Vehicle

    Figure 4-26: Precision Rail Dual Array Vehicle Mechanical Drawing Exposed Materials • Stainless Steel. • 316L/316L #2 Stainless Steel. • 440C Stainless Steel. • UHMW Polyethylene. • Nitrile. • Plastic. ™ • Mobilgear 600 XP Oil. MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 147: Precision Rail Support Post Assembly

    Exposed Materials • Galvanized Steel. • Zinc, Electrophoretic coated. • 6060 T66 Anodized Aluminum. • PA6 Nylon. • 6061 T6 Aluminum. • Zinc plated Steel. • 304 Stainless Steel. MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 148: Spine Plates

    6X R4 125.0° 2X 54.98 64.98 141.5° 94.99 114.98 R169.88 Left 138.90 150.0 128.5° [0.25] 6.35 Right All Dimensions in Millimeters Figure 4-28: Precision Rail Straight to Curve, Spine Plates, Mechanical Drawing MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 149: Precision Rail Curve To Curve, Spine Plates, Mechanical Drawing

    98.92 2X 95.00 76.40 75.00 141.5° R169.88 35.00 11.08 Left 128.5° [0.25] 6.35 Right All Dimensions in Millimeters Figure 4-29: Precision Rail Curve to Curve, Spine Plates, Mechanical Drawing MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 150: Precision Rail Straight, No Joint, Spine Plate, Mechanical Drawing

    Figure 4-30: Precision Rail Straight, No Joint, Spine Plate, Mechanical Drawing 125.0° 2X 54.98 64.98 73.58 141.5° 124.98 132.0 [0.25] 6.35 All Dimensions in Millimeters Figure 4-31: Precision Rail Straight, With Joint, Spine Plate, Mechanical Drawing MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 151: Precision Rail Curve, 180°, No Joint, Spine Plate, Mechanical Drawing

    Mechanical Specifications 114.2° 110.30 100.42 2X 95.00 76.40 141.5° R169.88 9.58 128.5° [0.25] 6.35 All Dimensions in Millimeters Figure 4-32: Precision Rail Curve, 180°, No Joint, Spine Plate, Mechanical Drawing MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 152: Precision Locator Option

    Exposed Materials • 6061-T6 Aluminum. • Aluminum, Hard Anodize. • Zinc Chromated Steel. • 18-8 (A2) Stainless Steel. • 18-8 (A2) Hardened Stainless Steel with Thin Dense Chrome plating. • SBR Rubber. MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 153: Stand Assembly

    All Dimensions in Millimeters [inches] Figure 4-34: Standard Precision Locator Stand Mechanical Drawing Exposed Materials • 6061-T6 Aluminum, anodized. • TIVAR HOT. • 18-8 (A2) Stainless Steel. • 304 (A4) Stainless Steel. MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 154: Adjustable Motor Mount Bracket

    [0.625] 15.88 All Dimensions in Millimeters [Inches] Figure 4-35: Adjustable Motor Mount Bracket Mechanical Drawing Exposed Materials • 6063-T5 Aluminum, black anodized. • 304 Stainless Steel. • 18-8 Stainless Steel. • Nylon. MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 155: Pallet

    Figure 4-36: Precision Locator Basic Pallet Mechanical Drawing Exposed Materials • Aluminum, Hard Anodize. • 18-8 (A2) Hardened Stainless Steel with Thin Dense Chrome plating. • Stainless Steel. • 316/316L/316L #2 Stainless Steel. • PEEK/PTFE. MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 156: Electrical Specifications

    When using separate power sources for logic and propulsion power, the propulsion power return should be tied to ground while the logic return can be left floating. Table 4-1: MagneMover LITE Motor and Switch Power Requirements Component Maximum Power...
  • Page 157 Specifications and Site Requirements Electrical Specifications Table 4-1: MagneMover LITE Motor and Switch Power Requirements (Continued) Component Maximum Power † Vehicle, Single Array 15 - 35 W † Vehicle, Dual Array 30 W Control power. † Additional power drawn by the motor per magnet array when the vehicle (puck) is moving.

  • Page 158: Straight And Curve Motors

    Communication Connector Communication Connector Power Connector Sync Option Bottom View Connector Figure 4-37: MagneMover LITE Motor Electrical Connections Table 4-2: MagneMover LITE Motor Connections Label Description Connector Type RS-422 communications M8 Nano-Mizer, 4-Pin, Male RS-422 communications M8 Nano-Mizer, 4-Pin, Male Power 36 VDC ±10%...

  • Page 159: Magnemover Lite Motor Rs-422 Pinouts

    Specifications and Site Requirements Electrical Specifications Table 4-3: MagneMover LITE Motor RS-422 Pinouts M8 Nano-Mizer, 4-Pin, Male RxD+ RxD- TxD+ TxD- Table 4-4: MagneMover LITE Motor Power Pinouts Keyway Mini-Conn-X, 4-Pin, Male V+ Propulsion V+ Logic V- Return Table 4-5: MagneMover LITE Sync Pinouts...

  • Page 160: Switches

    Connector Straight Section Communication Straight Section Connector Communication Connector Bottom View (Left Switch Shown) Figure 4-38: MagneMover LITE Switch Electrical Connections Table 4-6: MagneMover LITE Switch Connections Label Description Connector Type RS-422 communications M8 Nano-Mizer, 4-Pin, Male RS-422 communications M8 Nano-Mizer, 4-Pin, Male...

  • Page 161: Magnemover Lite Switch Rs-422 Pinouts

    Specifications and Site Requirements Electrical Specifications Table 4-7: MagneMover LITE Switch RS-422 Pinouts M8 Nano-Mizer, 4-Pin, Male RxD+ RxD- TxD+ TxD- Table 4-8: MagneMover LITE Switch Power Pinouts Keyway Mini-Conn-X, 4-Pin, Male V+ Propulsion V+ Logic V- Return Table 4-9: MagneMover LITE Switch Ethernet Pinout LAN –...

  • Page 162: Mm Lite Power Supply

    MagneMover LITE transport system is identified. NOTE: MagneMotion recommends that no more than 20 motors be powered from a single MM LITE Power supply (10 per 300W DC output). NOTICE The MM LITE Power Supply uses an internal NRTL/ATL approved power source.

  • Page 163: Mm Lite Power Supply Electrical Connections

    Table 4-11: MM LITE Power Supply Indicators Label Description Indicator Type LOGIC ON – Indicates motor logic power is on. Green LED PROPULSION ON – Indicates motor propulsion power is on. Green LED MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 164: Ac Power Cable

    The sinking current is 20mA max. AC Power Cable The MM LITE Power Supply is supplied with a power cable. Contact MagneMotion for replacement cables. The AC power cable plugs directly into the power supply. NOTE: There is no need for the user to construct the power cables as all cabling is supplied with the transport system.

  • Page 165: Motor Power Cable

    The MM LITE Power Supply is supplied with a Motor Power cable, which provides power to the MagneMover LITE motors and switches. Contact MagneMotion for replacement cables. The Motor Power cable connects directly to the power supply. Each wire in the cable is labeled for identification.

  • Page 166: Dc Enable

    The DC Enable jumper plug is used when remote control and monitoring of the motor propul- sion power is not required. This jumper (provided by MagneMotion) is used in place of the DC Enable cable and is permanently plugged into J4 on the MM LITE power supply.

  • Page 167: Node Controller

    Connecting with the power supply on may cause a short circuit at the connector, which may damage the power supply or any other equipment being powered by that power supply. MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...
  • Page 168 M6 threaded stud IP-67 mating connector is not required. † MagneMotion recommends that the odd number connectors be used for upstream connections and the even number connectors be used for downstream connections. ‡ MagneMotion requires grounding the NC-12 through the ground stud.
  • Page 169 Electrical Specifications Table 4-17: NC-12 Node Controller Console Pinout DE-9, Male — — — — — — Table 4-18: NC-12 Node Controller Ethernet Pinout RJ-45, Female — — — — MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...
  • Page 170 — — — — Table 4-20: NC-12 Node Controller RS-422 Pinouts M8 Nano-Mizer, 4-Pin, Male RxD+ RxD- TxD+ TxD- Table 4-21: NC-12 Node Controller Power Pinout Sleeve 2.0 mm Coax, Male Sleeve MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 171: Ac Power Cable

    Electrical Specifications AC Power Cable The NC-12 Node Controller optional remote power supply is supplied with a power cable. Contact MagneMotion for replacement cables. The AC power cable plugs directly into the power supply. MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 172: Node Controller Lite

    The Node Controller LITE can be powered by the MMI custom Power over Ethernet (PoE) switch or by a compatible PoE network. The remote power supply is not required in these cases. MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 173: Node Controller Lite Electrical Connections

    RS-422 RS-422 motor communications DE-9, Male & Female MagneMotion recommends that the odd number (male) connectors be used for upstream connections and the even number (female) connectors be used for downstream connections. Table 4-23: Node Controller LITE Power Pinout Sleeve 2.0 mm Coax, Male...

  • Page 174: Node Controller Lite Lan Pinout

    Specifications and Site Requirements Electrical Specifications Table 4-24: Node Controller LITE LAN Pinout RJ-45, Female +18 VDC +18 VDC Table 4-25: Node Controller LITE Console Pinout DE-9, Male — — — — — — MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 175: Node Controller Lite Rs-422 Pinouts

    The Node Controller LITE optional remote power supply is supplied with a power cable. Con- tact MagneMotion for replacement cables. The AC power cable plugs directly into the power supply. The remote power supply and AC cable for the Node Controller LITE is not required if Power over Ethernet is being used.

  • Page 176: Ethernet Switch With Power Over Ethernet Injector

    AC Power Cable The Ethernet Switch with PoE power supply is supplied with a power cable. Contact Magne- Motion for replacement cables. The AC power cable plugs directly into the power supply. MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 177: Precision Locator

    M8 Locking, 3-Pin, Male — Cylinder Down Sensor Connection M8 Locking, 3-Pin, Male Table 4-28: Precision Locator Sensor Indicators Label Description Indicator Type — ON – Indicates sensor is active. Red LED MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 178: Precision Locator Sensor Pinout

    Specifications and Site Requirements Electrical Specifications Table 4-29: Precision Locator Sensor Pinout Pin 3 Pin 1 Pin 4 M8, 3-Pin, Male DC (+) DC (-) Output +24 VDC max @ 40 mA max. MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 179: Pneumatic Specifications

    Open Close Figure 4-46: Precision Locator Pneumatic Connections Table 4-31: Precision Locator Connections Label Description Connector Type — Close Rc 1/8 in Thread — Open Rc 1/8 in Thread MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 180: Communications

    Only communications addressed to a specific device through the net- work are received by that device. The Ethernet connection provided by the Node Controllers supports both of MagneMotion’s proprietary TCP/IP and EtherNet/IP communication protocols. Typically, TCP/IP is used by PC-based Host Controllers and EtherNet/IP is used by PLC-based Host Controllers.

  • Page 181: Ethernet/Ip Communication

    NC-12 Node Controller at any of the RS-422 ports. The RS-422 serial cables connect to the MagneMover LITE motor using a 4-pin female M8 connector on the cable plugs into the first motor on the Path at the upstream communication port.
  • Page 182 NC-12 Node Controller at any RS-422 ports. The RS-422 serial cables connect to the MagneMover LITE motor using a 4-pin female M8 connector on the end that plugs into the last motor in the chain at the downstream communication port.

  • Page 183: Sync Connection

    NOTE: There is no need to construct the sync cables as all cabling is supplied with the trans- port system. Contact MagneMotion for additional or replacement cables. Digital I/O Connection The NC-12 Node Controller provides 16 optically isolated digital input bits and 16 optically isolated digital output bits.

  • Page 184: Site Requirements

    Operating: 0° C to 50° C [32° F to 122° F] Shipping: -18° C to 50° C [0° F to 122° F] Storage: -18° C to 50° C [0° F to 122° F] Humidity: 85% Maximum (relative, non-condensing) MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 185: Precision Locator

    Humidity: 85% Maximum (relative, non-condensing) Lighting, Site: No special lighting is required for proper operation of the MagneMover LITE transport sys- tem. Maintenance may require a user-supplied service lamp (e.g., flashlight). Floor Space and Loading The site for the MagneMover LITE transport system must meet the minimum space require-...

  • Page 186: Service Access

    LSM Synchronization Option User’s Manual for the service space required for the SYNC IT Controller. Ensure that the MagneMover LITE transport system is installed so that it provides access to items required for service after installation, such as power and communication connections.

  • Page 187: Installation

    ® MagneMover LITE components and transport systems. Included in this chapter are: • Unpacking and inspection of the MagneMover LITE transport system components. • MagneMover LITE component installation including: hardware installation, facilities connections, and software installation and configuration. • Initial power-up and check-out.

  • Page 188: Unpacking And Inspection

    Installation Unpacking and Inspection Unpacking and Inspection The MagneMover LITE transport system components are shipped in separate packages. Open each package carefully following the steps provided in Unpacking and Moving on page 5-3; inspect and verify the contents against the shipping documents. Report any damage immedi- ately to the shipper and to MagneMotion.

  • Page 189: Unpacking And Moving

    Metric Hex wrenches. Unpacking and Moving Instructions The MagneMover LITE transport system may arrive from the factory as a set of pre-assem- bled components or as a set of individual components ready for final installation. The infor- mation required to install these components is provided in...
  • Page 190 MagneMotion of any inspection discrepancy. Open each shipping package and verify the contents against the shipping documents. Carefully inspect the MagneMover LITE components and all additional items for signs of damage that may have occurred during shipping.

  • Page 191: Transport System Installation

    Transport System Installation Transport System Installation The MagneMover LITE transport system must be properly located in the facility so that other equipment can interface to it as required. The location must also ensure that there is adequate space for service access and for proper operation. Ensure that installation of the MagneMover LITE components provides access to items required for service after installation, such as con- nection panels.

  • Page 192: Installation Overview - User-Supplied Mounting

    Installation Transport System Installation Installation Overview – User-Supplied Mounting This provides an overview of the installation of the MagneMover LITE motors, switches, and other components on user equipment or a custom stand system. NOTICE Ensure the equipment or stand system where the MagneMover LITE motors will be mounted and the motor mounting surfaces are properly grounded to safety ground (earth).

  • Page 193: Installation Overview - Mmi Supplied Mounting

    Installation Transport System Installation Installation Overview – MMI Supplied Mounting This provides an overview of the installation of the MagneMover LITE transport system using the MM LITE transport system components, including stand, beam, and motor mounts. NOTICE Ensure the stand system where the MagneMover LITE motors will be mounted is properly grounded to safety ground (earth).

  • Page 194: Installation Overview - Mmi Precision Rails

    LITE transport system using railless motors. NOTICE Ensure the stand system where the MagneMover LITE motors will be mounted is properly grounded to safety ground (earth). Assemble a complete section of the system stand, including the stand and beam (refer...

  • Page 195: Installation Overview - Mmi Precision Locator

    MM LITE transport system. NOTICE Ensure the stand system where the MagneMover LITE motors will be mounted is properly grounded to safety ground (earth). Install the pallets on the pucks and install the pucks on the transport system (refer to Install Pallets and Pucks on page 5-55).
  • Page 196 Install the pneumatic controls for the Precision Locators (refer to Install the Pneumatic Controls on page 5-58). Install the covers on the Precision Locators (refer to Install the Covers on page 5-59). MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 197: Stand System Installation

    NOTE: The Loctite must cure for 2 hours at 22° C [72° F] before using the transport system. Repeat Step 4 Step 5 as needed to completely assemble the beams into a section of the system layout. MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 198: Installing System Legs

    26 N-m [230 in-lb] using a 6 mm Hex bit. NOTE: The Loctite must cure for 2 hours at 22° C [72° F] before using the transport system. MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 199: Legs On A Parallel Path Beam Assembly

    NOTE: Ensure the angle bracket is configured for 50 mm use by placing the inserts into the bracket with the hole in the insert to the outside of the bracket as shown in Figure 5-4. MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 200: Angle Bracket Assembly

    NOTE: The Loctite must cure for 2 hours at 22° C [72° F] before using the transport system. Verify that all legs are perpendicular to the beams using a machinist square. Once the stand assembly is complete ensure the transport system is properly located. MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 201: Leveling The Magnemover Lite

    Installation Transport System Installation Leveling the MagneMover LITE Once the stand assembly is complete and the transport system is properly located ensure all sections of the beam are level. Establish a datum for the system (interface to existing equipment, etc.).

  • Page 202: Securing The Transport System

    Ensure the transport system is properly grounded to safety ground (earth). Tie-down Using Brackets The legs of the MagneMover LITE frame should be secured to the facility floor to prevent system movement by installing tie-down brackets and installing an appropriate fastener.

  • Page 203: Foot Tie-Down

    Secure the bracket to the floor. Tie-down Using Feet The feet on the MagneMover LITE should be secured to the facility floor to prevent system movement by drilling a hole through each of the indicated locations on the feet that will be secured and installing an appropriate fastener.

  • Page 204: Motor Installation

    1.6 N-m [14 in-lb] using a Phillips bit. Install a switch bracket to the other side of the switch motor mount using two M5 screws and tighten to 1.6 N-m [14 in-lb] using a Phillips bit. MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 205: Installing Motor Mounts On Motors And Switches

    When using adjustable motor mounts, ensure the lock nut on the set screws is loose. Secure the motor mount to the motor using an M6 x 20 mm bolt and M6 split lock washer as shown in Figure 5-9 and finger tighten. MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 206: Mounting Motors And Switches

    Insert an M8 T-nut in the top channel of the beam at the approximate location for each motor mount, refer to Table 5-2 for quantities and locations (T-nuts must be inserted so that the spring steel tabs are facing toward the beam then rotated clockwise into place). MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 207: Motor Mount Reference

    M8 bolt securing the motor mount to the beam to 26 N-m [230 in-lb] using a 13 mm Hex socket. Motor Alignment Fixture Figure 5-11: Positioning Motors and Switches MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...
  • Page 208 Once all motors are mounted on the system, adjust any motors as necessary to ensure consistent spacing between the motors and to ensure the top surface of all motors are coplanar to each other. MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 209: Align And Secure Motors And Switches

    Using fingers, align the rails at the motor joints as shown in Figure 5-12. Tighten the two M6 x 12 mm screws on each V-brace at that motor joint to 3.4 N-m [30 in-lb] using a T30 Torx bit. MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...
  • Page 210 NOTE: For stainless steel rails the Loctite must cure for 2 hours at 22° C [72° F] before using the transport system. Repeat Step 3 at all motor and switch joints. Repeat Step 4 at all motors and switches. MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 211: Align And Secure Railless Motors

    Tighten the two M6 x 10 mm screws on each V-brace at that motor joint to 3.4 N-m [30 in-lb] using a T30 Torx bit. MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 212: Verify Motor And Switch Installation

    Once all motors and switches are installed the guideway must be checked to ensure proper movement of the vehicles (pucks) throughout the transport system. Run a vehicle (puck) through the system to verify proper movement with no binding. MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 213: Installing Electronics

    Installation Transport System Installation Installing Electronics The electronics for the MagneMover LITE transport system can be attached to the transport system stands or positioned elsewhere in the facility in an appropriate location. NOTICE Ensure all mounting surfaces and mounting hardware provide a conductive path to the transport system ground connection.
  • Page 214 The power supply may be oriented in any direction required. NOTICE The Node Controller LITE only supports MagneMotion’s custom Power over Ethernet (PoE). Never connect the Node Controller LITE to a standard PoE network as damage to internal components may result.
  • Page 215 Install an M5 T-nut and secure a nylon cable tie holder to it using an M5 x 12 mm screw on the leg as required to secure the cables running to the Node Controller using cable ties. MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...
  • Page 216 Locate the Node Controller in the rack and secure it using four screws (two per mount- ing bracket) as specified by the rack manufacturer. Install cable management as required to secure the cables running to the Node Con- troller. MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...
  • Page 217 Insert two M8 T-nuts and rotate into position in the appropriate channel(s) of the frame. Remove the six screws on each end of the bottom using a Phillips bit. MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 218: Connecting Motors And Electronics

    Connecting Motors and Electronics The MagneMover LITE transport system uses daisy-chained communication with all motors in the transport system. All motors in a specific Path are chained together with the upstream end of the chain always connected to a Node Controller and the downstream end connected to a Node Controller if it terminates in a Node.

  • Page 219: Simplified Representation Of Motor Connections

    Downstream (Straight or Curve) (Straight or Curve) (Merge) (Straight or Curve) From previous motor in Path To next motor in Path Figure 5-19: Simplified Representation of Merge Switch Connections MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 220: Communication Cable Connections

    Figure 4-43 Figure 4-44 for the communication con- nection locations on the Node Controllers in the MagneMover LITE transport system. Refer Figure 5-18 Figure 5-19 for simplified diagrams of the wiring and to...
  • Page 221 Node Controller. Bundle and dress all cables (use nylon cable-ties) as needed to ensure clean cable rout- ing. Refer to Facilities Connections on page 5-60 for external communications connec- tions. MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...
  • Page 222 Figure 4-44 for the network connection locations on the Node Controllers in the MagneMover LITE transport system. Refer to Figure 5-42 a simplified diagram of the network wiring. NOTE: The transport system’s network should be a dedicated, separate subnet to eliminate any extra network traffic.

  • Page 223: Digital I/O Connections

    Note, ensure the connector blades are making direct contact with the wire and not contacting the insulation. Connector Release Connector Connector Release Connector Figure 5-21: Digital I/O Connections MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 224: Power Connections

    (600 W). MagneMotion recommends a maximum of 10 motors be connected to J1 or J2 on the power supply at one time (20 motors per power supply).
  • Page 225 Connect the Ground stud on all NC-12 Node Controllers to GND (PE). Bundle and dress all cables (use nylon cable-ties) as needed to ensure clean cable rout- ing. Refer to Facilities Connections on page 5-60 for external power connections. MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 226: Installing Pucks/Magnet Arrays

    4-20). Mount the magnet arrays to the vehicles as defined by the design of the vehicle. Puck Installation Pucks (the vehicle used to transport material through the MagneMover LITE transport sys- tem) can easily be added or removed as needed once the MM LITE transport system is com- pletely installed.

  • Page 227: Installing Cable Chase Covers

    Install two M5 x 8 mm screws per mount to secure the cover. Tighten the M5 screws to 1.6 N-m [14 in-lb] using a Phillips bit. • 4 screws per 250 mm motor. • 8 screws per 1000 mm motor. MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...
  • Page 228 Locate an outer curve cover against the motor mount on the outside of the curve. Install two M5 x 8 mm screws to secure the cover. Tighten the four M5 screws to 1.6 N-m [14 in-lb] using a Phillips bit. MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...
  • Page 229 Locate two inner covers against the bracket on the inside of the switch. Install two M5 x 8 mm screws each to secure each cover. Tighten the six M5 screws to 1.6 N-m [14 in-lb] using a Phillips bit. MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 230: Option Installation

    (Straight) Railless Motor (Curve) Figure 5-26: MagneMover LITE Railless Motor System NOTE: When installing the Precision Rail structural components they should be loosely fas- tened (finger-tighten then back off one half turn) to provide the parts a small amount of movement relative to each other to allow for final adjustments once the entire pre- cision rail system is in place.

  • Page 231: Assemble Precision Rail Support Posts

    Position the support post base 38 mm [1.50 in] from the end of the connector plate on the post mount as shown in Figure 5-28 and tighten the M8 screws to 26 N-m [230 in-lb] using 6 mm Hex wrench. MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 232: Attach Precision Rail Support Posts To The Beam

    Locate each support post assembly at the appropriate position on the transport system. Remove the M8 T-nuts from the connecting plate and install them into the channel on the outside of the beam at the support post’s location and rotate into position. MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 233: Attach Rails To Spine Plates

    In this case, during alignment and adjustment it may be nec- essary to hone the ends of the mismatched rails to achieve the proper align- ment and performance. Engraved Letters Figure 5-30: Precision Rail End Identification MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...
  • Page 234 Prior to attaching the final rail within a closed loop system, all vehicles should be installed onto the rails. Refer to Replace Precision Rail Vehicles on page 7-45. MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 235: Precision Rail To Spine Plate Attachment Screws

    The number of screws required for each spine plate attachment is identified in Table 5-3. Table 5-3: Precision Rail to Spine Plate Attachment Screws Spine Plate Type Screws Joint, Straight-to-Straight Joint, Straight-to-Curve Joint, Curve-to-Curve No Joint, Straight No Joint, Curve MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 236: Align And Secure Rails To Spine Plates

    Once the rails are aligned, tighten each screw to 1.8 N-m [16 in-lb], using the sequence shown in Figure 5-33. Repeat Step 1 through Step 2 for all straight rail to curved rail joints within the system. MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 237: Tightening Sequence, Curve To Curve Precision Rail Spine Plate

    Once the rails are aligned, tighten each screw to 1.8 N-m [16 in-lb], using the sequence shown in Figure 5-35. Repeat Step 1 through Step 2 for all curved rail to curved rail joints in the system. MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 238: Tightening Sequence, 180° Curve No Joint Precision Rail Spine Plate

    Figure 5-37. Repeat Step 1 for all points on the rail. Repeat Step 1 Step 2 for all straight rail segments that are greater than 500 mm in length. MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 239: Secure Spine Plates To Support Posts

    (refer Installing Vehicles with Rails Removed on page 7-46. If all rail segments have been installed, refer to Installing Vehicles Without Removing Rails on page 7-47. MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 240: Precision Locator Installation

    Stand Rib M8 x 30 mm Bolt (1X per Rib) M8 Lock Washer (1X per Rib) Pneumatic M6 x 25 mm Screw Connections (4X) Figure 5-39: MagneMover LITE Precision Locator Option, Standard MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 241: Install Pallets And Pucks

    (2X per Rib) Connections M6 x 25 mm Screw (4X) Figure 5-40: MagneMover LITE Precision Locator Option, Alternate Install Pallets and Pucks The pucks with pallets should be installed on the system before installing the motors to allow easy installation.

  • Page 242: Install The Precision Locators On The Stands

    Mounting Motors and Switches on page 5-20 Align and Secure Motors and Switches on page 5-23). NOTE: The Loctite must cure for 2 hours at 22° C [72° F] before using the transport system. MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...
  • Page 243 With the puck manually pinned into position on the stand, verify proper access to the pallet by the remote equipment. Tighten the M8 bolts securing the stand ribs to the beam to 26 N-m [230 in-lb]. MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 244: Install The Pneumatic Controls

    Connect the pneumatic valve’s exhaust #5 to a muffler. If using the optional cylinder position sensors: • If installing user-supplied sensors, install them into position and secure as directed by the manufacturer. MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 245: Install The Covers

    Option Installation • If the sensors were pre-installed by MagneMotion, verify they are in the cor- rect positions and adjust if necessary by loosening the 2.5 mm set screw, adjusting the position of the sensor, and tightening the set screw.

  • Page 246: Facilities Connections

    Network Connections The MagneMover LITE transport system uses communication over an Ethernet network with a Host Controller for transport system control and communication between Node Controllers. The following procedure provides the information required to make all network communica-...

  • Page 247: Electrical Connections

    Web Interface User’s Manual for more details. Electrical Connections Electrical power is connected to the MagneMover LITE transport system for operation of the motors and other subsystems. An AC electrical connection is provided on those components that require facility power. Refer to the...

  • Page 248: E-Stop Circuit

    4-39. E-Stop Circuit The MagneMover LITE transport system can use Digital I/O, provided through an NC-12 Node Controller, for monitoring and control of local options such as an E-Stop. The optional E-Stop circuit is the responsibility of the user and requires a user-supplied E-Stop button and +3 - 24 VDC power supply for the Digital Input.

  • Page 249: Light Stack Circuit

    Facilities Connections Light Stack Circuit The MagneMover LITE transport system can use Digital I/O, provided through an NC-12 Node Controller, for monitoring and control of local options such as a Light Stack. The optional Light Stack circuit is the responsibility of the user and requires a user-supplied 3-color light tower and a user-supplied +5 - 35 VDC power supply (sized for the Light Stack) for the Digital Outputs.

  • Page 250: Software

    Software Overview Node Controllers supplied with the MagneMover LITE transport system ship with just a basic NC software image installed. All Node Controller related files (NC image, motor images and type files, and magnet array type files) must be uploaded to the Node Controller and activated before using the transport system.

  • Page 251: Node Controller Software Installation

    NOTE: Restart the Node Controller for the changes to take effect. Reset the Paths where the motors were programmed (e.g., use the NCHost TCP Inter- face Utility, refer to the NCHost TCP Interface Utility User’s Manual for details). MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 252: Check-Out And Power-Up

    Check-out and Power-up System Check-out Before the MagneMover LITE transport system is started for the first time, or after servicing the transport system, it is necessary to check all operating and safety features. The following start-up procedure is used to apply power to the MagneMover LITE transport system in an orderly manner to ensure all components are in known conditions.

  • Page 253: System Power-Up

    Check-out and Power-up System Power-up After the MagneMover LITE transport system has been installed, all connections should be checked and an initial power up should be performed before proceeding any further with the installation process. This section describes the procedure for the initial installation check-out.

  • Page 254: Startup Indicators

    Installation Check-out and Power-up Perform a Ground Continuity check from the surfaces of the MagneMover LITE trans- port system to a known good ground. Apply power to the MagneMover LITE transport system. CAUTION Automatic Movement The Host Controller initiates all motion control to the MagneMover LITE transport system.

  • Page 255: System Testing

    System Testing System Testing Test the MagneMover LITE transport system to verify proper operation of all Nodes, Paths, and vehicles. This can be accomplished using the NCHost application supplied by MagneMo- tion to move vehicles without the Host Controller to verify proper operation before integrating a transport system into a production environment.
  • Page 256 Installation This page intentionally left blank. MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 257: Operation

    Included in this chapter are: • Theory of operation of the MagneMotion linear synchronous motors and the Magne- Mover LITE transport system. • Controls and indicators provided on the system.

  • Page 258: Theory Of Operation

    The MagneMover LITE motors are similar in operation to a brushless DC rotary motor, with its stator (motor primary) and rotor or armature (motor secondary) ‘unrolled’ to allow linear...

  • Page 259: Motion Control

    Paths (either direct or through one or more Paths) through a Node (or multiple Nodes). The design and operation of the MagneMover LITE transport system uses a minimum of moving parts to ensure minimal maintenance requirements. Position monitoring circuits in all motors ensure accurate tracking and positioning of all vehicles in the transport system.

  • Page 260: Motor Operation

    Figure 6-3: Representation of Moving Vehicles Per MagneMover LITE Motor Block Motor Operation The MagneMover LITE motors provide asynchronous control of vehicles (pucks) on the transport system as directed by the Host Controller. This method minimizes the load on the Host Controller with the transport system’s Node Controllers and motors performing all rout-...

  • Page 261: Motor Cogging

    MagneMotion’s MagneMover LITE linear motors do not utilize an iron core. As such, they do not exhibit any cogging forces. Motor Blocks A motor block is a discrete motor section within each MagneMover LITE motor or switch as shown in Figure 6-2 Figure 6-3.

  • Page 262: Block Acquisition

    Anti-Collision The MagneMover LITE transport system allows only one vehicle per motor block; this is the basic rule on which the anti-collision feature of the MM LITE transport system controls is founded on. Since two vehicles are not allowed to be in the same motor block, they will not collide.

  • Page 263: Safe Stopping Distance Movement

    All of the vehicles in the queue will report being obstructed. MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 264: Vehicle Length Through Curves And Switches

    Path the vehicle is on. Moving Vehicles by Hand Vehicles on the MagneMover LITE transport system should only be moved by the MM LITE motors in the system. If there is an event that requires moving the vehicles by hand, the guide- lines provided below should be followed.
  • Page 265 Vehicles that have been moved too far can be recovered by deleting the moved vehicles and restarting the section of the transport system where they are located to detect them. MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 266: Electrical System

    Under normal operating condition these fluctua- tions are minimal and can be ignored. The power supplies and wiring for the system must be designed to minimize these fluctuations (refer to Electrical Wiring on page 3-12). MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 267: Controls And Indicators

    The user’s application running on their Host Controller should provide any needed controls or indicators related to transport system operation. Additional controls and indicators can be con- figured as described in this section. The controls and indicators of the MagneMover LITE components are identified in the Electrical Specifications on page 4-38.

  • Page 268: Synchronization

    For synchronization, a SYNC IT controller is required for every three motors that are being synchronized as shown in Figure 6-6. Refer to the LSM Synchronization Option User’s Man- ual for configuration and operation details to use the Sync option with the MagneMover LITE transport system. Sync Motor Sync Motor...

  • Page 269: E-Stops

    E-Stop bit. Refer to the MagneMover LITE Configurator User’s Manual to configure the MagneMover LITE transport system to use an E-Stop. NOTE: An external power supply for the E-Stop circuit must be provided by the user.

  • Page 270: E-Stop Wiring Diagram, Single Node Controller

    NC-12 Node Controller (8 max) Digital In Digital In +3 - 24 VDC Power Supply Figure 6-8: E-Stop Wiring Diagram, Multiple Node Controllers In this configuration other Digital I/O functions may not be available. MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 271: Interlocks

    Interlock bit. Refer to the MagneMover LITE Configurator User’s Manual to configure the MagneMover LITE transport system to use an Interlock. NOTE: An external power supply for the Interlock circuit must be provided by the user.

  • Page 272: Faststop

    Refer to the Host Con- troller TCP/IP Communication Protocol User’s Manual or the Host Controller EtherNet/IP Communication Protocol User’s Manual for details on the use of the FastStop command. MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 273: Light Stacks

    Standard three color light stacks (typically green, yellow, and red) are sup- ported by the MagneMover LITE transport system. The Light Stack may be used to monitor the status of any, or all, Paths on the Node Controller where it is connected. Refer to the Mag- ®...

  • Page 274: Digital I/O

    User’s Manual for details on the use of the Digital I/O commands. NOTE: An external power supply for the Digital I/O circuits must be provided by the user (refer to Figure 4-48 on page 4-65). MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 275: Transport System Simulation

    Transport System Simulation Transport System Simulation The MagneMover LITE transport system can be simulated to verify proper configuration of all Nodes and Paths and proper movement of commanded vehicles within the transport sys- tem. Running a simulation can be useful to test and observe system behavior without physi- cally moving vehicles on the Transport System.
  • Page 276 (refer to Node Controller Web Interface User’s Manual). Select Reboot Controller on the Main Menu. Select Restart Services. The restart status is temporarily displayed, then the General Status page is displayed once the Node Controller has restarted. MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 277: Running A Simulation

    Path has been reset will add new simulated vehicles to that Path either at the location specified in the Configuration File or in the next available space downstream. MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 278: Stopping A Simulation

    Select Reboot Controller on the Main Menu. The Reboot Controller page is displayed. Select Reboot Controller. The reboot status is temporarily displayed, then the General Status page is dis- played once the Node Controller has rebooted. MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...
  • Page 279 Demo Script for repetitive testing (refer to the NCHost TCP Interface Utility User’s Manual). • Use the application developed for the Host Controller to run the system as required. MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 280: Precision Rail Operation

    The Precision Rail option provides customized stainless steel precision ground rails in place of the integrated rails on the standard MagneMover LITE motors. When using the Precision Rail option, MM LITE railless motors are used with the precision rail aligned above the motors and supporting vehicles using precision sealed bearings.

  • Page 281: Precision Locator Operation

    Release the vehicle to allow the locator to precisely position it. Perform the appropriate action to the load mounted on the pallet. Command the Precision Locator to open. Command the vehicle to its next location. MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 282: Transport System Operation

    Normal Running Normal operation of the MagneMover LITE transport system is controlled by the user’s Host Controller. The exact usage of the MM LITE transport system must be determined by the user. Refer to the Host Controller TCP/IP Communication Protocol User’s Manual or the Mitsubi- shi PLC TCP/IP Library User’s Manual for details of each command to use Host Controller...

  • Page 283: Safe Shut-Down

    Transport System Operation Safe Shut-down The following shut-down procedure is used to remove power from the MagneMover LITE transport system in an orderly manner and place the components in safe conditions. This pro- cedure is used to prepare the components for removal, replacement, or maintenance.
  • Page 284 Operation This page intentionally left blank. MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 285: Maintenance

    LITE components. Only trained, qualified personnel should attempt to perform maintenance or ® troubleshooting on the MM LITE transport system. MagneMotion provides training in the troubleshooting and repair of the MM LITE transport system. Included in this chapter are: •...

  • Page 286: Preventive Maintenance

    Preventive Maintenance Preventive Maintenance The motors, Node Controllers, and power supplies that make up the MagneMover LITE trans- port system are self contained components designed for use in a clean, inert environment and require no maintenance other than that described here. Any deviation from this basic environ- ment may affect the maintenance requirements, contact MagneMotion Technical Support for additional information.

  • Page 287: General Cleaning

    • Isopropyl alcohol (optional). Procedure Stop all motion on the sections of the MagneMover LITE transport system to be cleaned. While wearing gloves, clean all exposed transport system surfaces and cables with a clean microfiber cloth slightly dampened with deionized water or isopropyl alcohol.

  • Page 288: Puck Cleaning

    Maintenance Preventive Maintenance Puck Cleaning The pucks used on the MagneMover LITE transport system may need to be cleaned to remove any particulate buildup on the wear surfaces of the pucks. Required Tools and Equipment • Disposable gloves. • Microfiber cleaning cloth.

  • Page 289: Puck Wear Surface Maintenance

    Preventive Maintenance Puck Wear Surface Maintenance The pucks used on the MagneMover LITE transport system may need to be rotated to ensure even wear on the wear surfaces of the pucks. This is especially true for pucks used in a trans- port system where all motion is in a single direction, for pucks in a tandem puck configura- tion, or for pucks that have a cantilevered load.

  • Page 290: Transfer Log Files

    Log files may be transferred from the Node Controller or SysLog server to a CD or external USB device so they can be archived or e-mailed to MagneMotion Support, refer to the Node Controller Web Interface User’s Manual.

  • Page 291: Lubricating The Precision Rails

    • 68 viscosity EP mineral oil. Procedure Stop all motion on the sections of the MagneMover LITE transport system to be lubri- cated. While wearing gloves, wipe the precision rail with a clean microfiber cloth slightly dampened with mineral oil. Wipe in the direction of the rail.

  • Page 292: Refilling A Precision Rail Vehicle's Lubricating Applicator

    • Syringe or other injector. Procedure Stop all motion on the section of the MagneMover LITE transport system where the vehicle is located. Locate the lubricating applicator under the Precision Rail vehicle. The applicators are located on the underside of the vehicle and can be mounted...

  • Page 293: Precision Rail Vehicle Lubricating Applicator (Front And Rear)

    NOTE: On single array vehicles, if the applicator is located between the concentric bearings (on the magnet array side of the vehicle), use the lubrication portal shown in Figure 7-4 to access the oil refill hole on the applicator. MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 294: Precision Rail Single Array Vehicle Lubrication Portal

    Oil Fill Portal Figure 7-4: Precision Rail Single Array Vehicle Lubrication Portal Replenish the oil in the applicator. Do not overfill the reservoir. Return the MM LITE transport system to normal operation. MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 295: Adjusting Vehicle Bearings

    To avoid damage to watches, instruments, electronics, and magnetic media, keep metal tools, metal objects, magnetic media (memory disks/chips, credit cards, and tapes) and elec- tronics away from the magnet arrays. MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 296: Concentric Bearings

    Dual Array 5.86 N [21.1 ozf] Stop all motion on the section of the MagneMover LITE transport system where the vehicle will be adjusted. Using a socket wrench, loosen the nut on the eccentric bearing to be adjusted on the...

  • Page 297: Troubleshooting

    Motors report power related faults. Vehicles do not seem to move as fast as when Power Related Troubleshooting on page 7-14 the MagneMover LITE transport system was Motion Control Troubleshooting on page 7-19 initially installed. Precision Rail Option Troubleshooting on...

  • Page 298: Power Related Troubleshooting

    Verify the facility’s power to the MagneMover LITE transport sys- tem is the correct power rating. Power supply main fuses are Verify power supply main fuses blown. are not blown. Replace if neces- sary and determine cause to pre- vent reoccurrence.
  • Page 299 Verify all power wiring is suffi- cient to carry all loads and deliver the proper power to the motors. The fault will clear once the power bus rises above +28 VDC. MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...
  • Page 300 Verify the voltage output from the fault. motor is above +42 VDC. power supply. Verify the voltage at the motor. The fault will clear once the power bus drops below +38 VDC. MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 301: Node Controller Troubleshooting

    Node Controller has lost its time the Node Controller is pow- charge. ered up or return the Node Con- troller to MagneMotion for repair. Use the Node Controller Web Interface Set Clock function to set the time (refer to the Node Controller Web Interface User’s...

  • Page 302: Communications Troubleshooting

    Mover LITE transport system. Table 7-6: Communications Related Troubleshooting Symptom Problem Description Corrective Action MagneMover LITE motors are Communication to the affected Verify all communications cables powered but there is no response motors is lost or intermittent. are fully seated and secure.

  • Page 303: Motion Control Troubleshooting

    Ensure the vehicle and/or track wear is within tolerance. Thrust lost when the vehicle Ensure the Downstream Gap does moves from motor to motor. not exceed 10% of the magnet array length. MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 304: Precision Rail Option Troubleshooting

    Vehicle bearings are not set cor- Ensure the bearing adjustment on rectly (log messages indicate the the vehicles is correct (refer to motors are overheating) Replace Precision Rail Vehicles on page 7-45). MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 305: Light Stack Troubleshooting

    Red light does not turn off. Light indicates vehicles stopped. Send a move vehicle command to any vehicle on the Paths or Nodes being monitored by the light stack. MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 306: Contact Magnemotion Technical Support

    Contact MagneMotion Technical Support Contact MagneMotion Technical Support To help you receive the most value from the MagneMotion Support Specialists, have the fol- lowing information ready before contacting MagneMotion Technical Support. Download and save the Node Controller and High Level Controller logs.

  • Page 307: Repair

    7-22. Once the failed unit has been identified, a replacement unit can be ordered and installed as directed in Installation on page 5-1. NOTE: The components of the MagneMover LITE transport system are designed for easy replacement. Motors, controllers, and other modules do not contain any user service- able parts. NOTICE Only a qualified service representative can service the components of the MagneMover LITE transport system.
  • Page 308 Maintenance Repair Table 7-10: MagneMover LITE Repair Procedures (Continued) Component Maintenance Action Page # Precision Locator Replacing Wear Surfaces on Pallet 7-64 Replacing Bushings on Pallet 7-67 Replacing Pins on Precision Locator Arms 7-69 Replacing Z-Datums on Precision Locator Stand...

  • Page 309: Adjust G3 Motors To Eliminate Rail Binding

    Maintenance Repair Adjust G3 Motors to Eliminate Rail Binding If binding is detected during vehicle (puck) motion on the MagneMover LITE G3 motors the rails on the motors may be adjusted. Required Tools and Equipment • 000-0614-00 – Rail Spreader, ML (G3 motors only).

  • Page 310: Adjust Rails - G3 Motors

    Maintenance Repair Rail Spreader Rail Post Rail Post Figure 7-7: Adjust Rails – G3 Motors Return the MM LITE transport system to normal operation. MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 311: Connect And Secure G3 Motors And G3 Switches

    (2X per V-Brace) Figure 7-8: Align and Secure Rails – G3 Motors Stop all motion on the sections of the MagneMover LITE transport system to be ser- viced. Loosen the M8 bolt securing the motor to the motor mount for all motors or switches being adjusted.
  • Page 312 Tighten the M8 bolt securing the motor to the motor mount to 12 N-m [106 in-lb] using a 13 mm Hex socket. Repeat Step 2 through Step 5 at all motor and switch joints. Return the MM LITE transport system to normal operation. MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 313: Connect G3 Motors And G4 Motors

    Connect G3 Motors and G4 Motors When a MagneMover LITE G3 motor is replaced by an MM LITE G4 motor a special V-brace is used to connect the rails of the G4 motor to the rails of the existing G3 motors.
  • Page 314 Maintenance Repair Stop all motion on the sections of the MagneMover LITE transport system to be ser- viced. Loosen the M8 bolt securing the G3 motor to the motor mount for the G3 motors or G3 switches connecting to the G4 motor or G4 switch.

  • Page 315: Replacing Motors

    Remove the Existing Motor All material transfers should be completed (move all material to the appropriate loca- tions) on the section of the MagneMover LITE transport system where the motor will be replaced. Command all vehicles to known safe positions off of the Path where the motor will be replaced.

  • Page 316: Install The New Motor

    Program the new motor’s masters and slaves with the current Motor image files (refer Programming Motors on page 7-33). Resume motion on the section of the MM LITE transport system where the motor was replaced. MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 317: Programming Motors

    Maintenance Repair Programming Motors When a new MagneMover LITE motor is installed, either as part of a new system installation or as a replacement for an existing motor it must be programmed with the appropriate Motor ERF image (motor_image.erf). NOTE: MagneMover LITE motors are shipped from the factory with just a basic motor soft- ware image installed.

  • Page 318: Separating Magnet Arrays

    • Magnet arrays that become stuck to each other should only be separated by trained personnel. MagneMotion recommends returning stuck magnet arrays to MagneMotion for separation. • Magnet arrays stuck to a surface can be removed by sliding the array to the edge of the surface it is stuck to.

  • Page 319: Replace Pucks

    Required Tools and Equipment • Torque wrench with the following bits: • 4 mm Hex. • T30 Torx. • Loctite 243, Thread locker, Anaerobic Adhesive, Blue. MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 320: Remove Pucks

    (2X) Figure 7-10: Remove Curve Motor Guide Rail Remove Pucks Stop all motion on the section of the MagneMover LITE transport system where the puck will be removed. Remove the inside guide rail from a curve motor. Remove the two screws securing the V-braces to the guide rail.

  • Page 321: Install Pucks

    Maintenance Repair Install Pucks Stop all motion on the section of the MagneMover LITE transport system where the puck will be installed. Remove the inside guide rail from a curve motor. Remove the two screws securing the V-braces to the guide rail.

  • Page 322: Replace Puck Wear Surfaces

    100-2067-46 – Screw, FHC, M4 X 22 mm L, A4 SS, w/Dri-Loc 204, 5 mm DL (2X). • 200-2202-00 – Preload Spacer, Compliant, Puck Center Plate, ML. • 200-2155-01 – Strip, Protective, Puck Bottom, Wide, UHMW. • 200-2205-00 – Center Plate, Puck, Ribs, G5, ML. MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...
  • Page 323 Threaded Standoff Magnet Assembly Protective Strip Figure 7-11: Remove Plates from Magnet Assembly Remove the puck from the MagneMover LITE transport system (refer to Replace Pucks on page 7-35). Place the puck on a non-metallic work surface with the magnet array down. Keep the magnet array at least three feet away from metal objects and tools.
  • Page 324 Align the top plate with the center plate and press together as shown in Figure 7-12. Center Plate G5 Spacer Glue Dot Top Plate Figure 7-12: Adhere Preload Spacer to Underside of Top Plate MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...
  • Page 325 NOTE: Once the screws have been installed, the Loctite must cure for 2 hours at 22° C [72° F] before using the puck. Replace the puck on the MM LITE transport system (refer to Replace Pucks on page 7-35). MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 326: Replace Power Supply Fuses

    Figure 7-13: Power Supply Fuse Locations CAUTION High Voltage Hazard 100 - 240 VAC, 8.5 A AC power must be disconnected before servicing. CAUTION Double Pole/Neutral Fused AC power must be disconnected before servicing. MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 327: Ac Fuse

    Insert the fuse module into the PEM ensuring that it is oriented correctly. NOTICE Never force the Fuse Module when inserting. Ensure it is not at an angle prior to inserting and slides straight in. MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 328: Dc Fuses

    Fuse Type Fuse Location T, 250V, 10A Single fuse per fuse holder. Insert the fuse holder and turn the fuse holder clockwise until fully seated. Return the power supply to normal operation. MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 329: Replace Precision Rail Vehicles

    This locates the magnet array over the motors and positions the bearings to allow motion through the curves. Figure 7-25 shows the orientation of the bearings on a Precision Rail vehicle in relationship to the track system. MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 330: Installing Vehicles With Rails Removed

    7-11. • If the vehicle can be noticeably rocked from side to side or front to back, then there is too much movement between the bearings and the rail and the bearings MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 331: Installing Vehicles Without Removing Rails

    For proper vehicle orientation, see Figure 7-16. Stop all motion on the section of the MagneMover LITE transport system where the vehicle will be installed. If a lubricant applicator is attached to the underside of the vehicle, remove the applica- tor and set it aside for reinstallation after the vehicle is installed.

  • Page 332: Removing Vehicles By Removing Rails

    The single or dual array vehicles can be removed from the Precision Rail system by removing a precision rail section. Stop all motion on the section of the MagneMover LITE transport system where the vehicle will be removed. Remove a small section of the precision rail by removing the M5 screws securing it to the spine plates.

  • Page 333: Removing Vehicles Without Removing Rails

    Note that removing vehicles in this manner will require adjustment of the vehicle’s bearings after it is re-installed on the rail. Stop all motion on the section of the MagneMover LITE transport system where the vehicle will be removed.

  • Page 334: Replacing Lubricating Applicators On Vehicles

    To avoid damage to watches, instruments, electronics, and magnetic media, keep metal tools, metal objects, magnetic media (memory disks/chips, credit cards, and tapes) and elec- tronics away from the magnet arrays. MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 335: Precision Rail Vehicle Lubricating Applicator Location

    M3 x 8 mm screws into the appropriate holes on the top of the vehicle as shown in Figure 7-22. Mounting holes at Concentric Bearings Mounting holes at Eccentric Bearings Figure 7-22: Installing or Removing a Precision Rail Felt Applicator MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...
  • Page 336 Note, do not over-tighten the screws or they will strip the holes on the applicators. Apply lubricant to the applicator, refer to Refilling a Precision Rail Vehicle’s Lubricat- ing Applicator on page 7-8. MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 337: Replacing Magnet Arrays On Precision Rail Vehicles

    To avoid damage to watches, instruments, electronics, and magnetic media, keep metal tools, metal objects, magnetic media (memory disks/chips, credit cards, and tapes) and elec- tronics away from the magnet arrays. MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 338: Single Array Vehicles

    Remove the shims from the top of the magnet array and store them in a safe location for reuse. MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...
  • Page 339 NOTE: The Loctite must cure for 2 hours at 22° C [72° F] before using the vehicle. Replace the vehicle, refer to Replace Precision Rail Vehicles on page 7-45. Restart the Path. Dispose of the removed magnet array appropriately. MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 340: Dual Array Vehicles

    Maintenance Repair Dual Array Vehicles M4 x 12mm Screw (4X) Dual Array Carriage Magnet Array Shim, 1mm (2X) Assembly Fixture Figure 7-24: Dual Array Precision Rail Vehicle Assembly MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...
  • Page 341 Place the mounting holes on the vehicle over the array posts. Realign the shims if nec- essary to ensure they line up with the vehicle. MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...
  • Page 342 NOTE: The Loctite must cure for 2 hours at 22° C [72° F] before using the puck. Replace the vehicle, refer to Replace Precision Rail Vehicles on page 7-45. Restart the Path. Dispose of the removed magnet array appropriately. MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 343: Replacing Bearings On Precision Rail Vehicles

    To avoid damage to watches, instruments, electronics, and magnetic media, keep metal tools, metal objects, magnetic media (memory disks/chips, credit cards, and tapes) and elec- tronics away from the magnet arrays. MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 344: Replacing Concentric Bearings

    Bearing (2X) Figure 7-26: Precision Rail Vehicle Concentric Bearings Disassembly/Assembly Stop all motion on the section of the MagneMover LITE transport system where the vehicle is located. Remove the vehicle from the Precision Rail (refer to Replace Precision Rail Vehicles on page 7-45).
  • Page 345 If eccentric bearings are to be replaced on this vehicle, refer to Replacing Eccentric Bearings on page 7-62. If the vehicle is ready to be installed on the rail, refer to Replace Precision Rail Vehi- cles on page 7-45. MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 346: Replacing Eccentric Bearings

    Bearing (2X) Figure 7-27: Precision Rail Vehicle Eccentric Bearings Disassembly/Assembly Stop all motion on the section of the MagneMover LITE transport system where the vehicle is located. Remove the vehicle from the Precision Rail (refer to Replace Precision Rail Vehicles on page 7-45).
  • Page 347 Repeat this procedure on the companion eccentric bearing, if it is also being replaced. Refer to Replace Precision Rail Vehicles on page 7-45 to return the vehicle to the rail. MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 348: Replacing Wear Surfaces On Pallet

    • 200-2324-00 – Spacer, Magnet Array, ML-PL (2X). • 200-2155-01 – Strip, Protective, Puck Bottom, Wide, UHMW (Optional). • Isopropyl Alcohol. • Torque wrench with the following bits: • 2.5 mm Hex. MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...
  • Page 349 Magnet Assembly Protective Strip Figure 7-28: Remove Precision Locator Pallet from Magnet Assembly Remove the puck with pallet from the MagneMover LITE transport system (refer to Replace Pucks on page 7-35). Remove the two M4 screws securing the pallet and center plate to the magnet assem- bly using a 2.5 mm Hex wrench and lift the pallet and center plate off the magnet...
  • Page 350 NOTE: The Loctite must cure for 2 hours at 22° C [72° F] before using the puck. Replace the puck on the MM LITE transport system (refer to Replace Pucks on page 7-35). MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 351: Replacing Bushings On Pallet

    100-2457-01 – Pin, Dowel, Ø2 mm X 5 mm L, 18-8 SS, per DIN 7-M6 (2X). • 100-2202-05 – Nut, Jam, Hex, M6x1, 18-8 (A2) SS, per DIN 439B (2X). • Isopropyl Alcohol. • Torque wrench with the following bits: • 6 mm. MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...
  • Page 352 M6 Nut (2X) Figure 7-29: Replace Bushings on Precision Locator Pallet Remove the puck with pallet from the MagneMover LITE transport system (refer to Replace Pucks on page 7-35). Remove the M6 nuts securing the bushings to the pallet as shown in Figure 7-29.

  • Page 353: Replacing Pins On Precision Locator Arms

    Isopropyl Alcohol. • Torque wrench with the following bits: • 000-0772-04 – Pinning Locator, Installation Tool, ML-PL Procedure Spherical Contact Pin (2X) Figure 7-30: Replace Pins on Precision Locator Arms MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...
  • Page 354 Maintenance Repair Stop all motion on the section of the MagneMover LITE transport system where the Precision Locator will be serviced. Remove the pin from the Precision Locator arm as shown in Figure 7-30. Slide the 2 mm pin from the Installation Tool into the hole on the Spherical Contact Pin.

  • Page 355: Replacing Z-Datums On Precision Locator Stand

    100-0117-01 – Screw, SHC, Full Thd, M4 X 6 mm L, A2 SS (6X - 12X). • Isopropyl Alcohol. • Torque wrench with the following bits: • 3 mm. Procedure Z-Datum (2X) M4 Screw (4X) Figure 7-31: Replace Z-Datum on Precision Locator Stand MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...
  • Page 356 Maintenance Repair Stop all motion on the section of the MagneMover LITE transport system where the Precision Locator stand z-datums will be replaced. Remove the M4 screws securing the z-datums to the inner and outer supports as shown Figure 7-31 and remove the z-datums.

  • Page 357: Ordering Parts

    Maintenance Ordering Parts Ordering Parts If new or replacement parts are needed contact MagneMotion Sales: Main Office MagneMotion, Inc. 139 Barnum Road Devens, MA 01434 Phone: +1 978-757-9100 Fax: +1 978-757-9200 MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 358: Shipping

    Shipping Shipping If a component of the MagneMover LITE transport system must be shipped, either for return to MagneMotion or to another location, it must be packaged properly to ensure it arrives undamaged. The following procedure provides the correct method for handling and packaging MM LITE components for shipment.

  • Page 359: Packing Procedure

    Shipping Packing Procedure When any of the components of the MagneMover LITE transport system are shipped, either for return to MagneMotion for service or to another location, they must be properly packaged to ensure they arrive undamaged. The following procedure provides the correct method of handling and packaging the MagneMover LITE components for shipment.

  • Page 360: Shipping Components

    When shipping pucks or magnet arrays ensure the shipping container properly isolates the magnets and identifies the Magnetic Field Hazard. When shipping to MagneMotion, ensure the SRO number is clearly visible on the out- side of the box. Shipping Systems or System Sections Bolt the feet to the bottom of the crate.
  • Page 361 Add tip indicators, shock indicators, moisture indicators, etc. to the outside of the ship- ping container as desired to verify proper handling during shipment. When shipping to MagneMotion, ensure the SRO number is clearly visible on the out- side of the crate.
  • Page 362 Maintenance This page intentionally left blank. MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 363: Appendix

    The following appendices are included to provide the user with a single location for additional ® information related to the MagneMover LITE transport system. Included in this appendix are: • File maintenance. • Additional documentation. • Transport system configuration limits. MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...

  • Page 364: File Maintenance

    File Maintenance File Maintenance Backup Files MagneMotion recommends regular backups of all files that may have been changed. Copies of all original and backup files should be kept at a remote location for safety. Creating Backup Files Backup files are not created automatically. It is the user’s responsibility to create backups of all files by copying them to a safe location and naming them appropriately.

  • Page 365: Additional Documentation

    The Release Notes for MagneMotion software include special instructions, identification of software versions, identification of new features and enhancements, and a list of known issues. The Release Notes are supplied with the software. MagneMotion recommends that this file be read before using the software.

  • Page 366: Transport System Limits

    Limited by the length of the Path and the length of the vehicles. † Limited by the number of RS-422 connections on the Node Controller (NC LITE – 4, NC-12 – 12). Table A-2: MagneMotion Transport System Motion Limits Acceleration Velocity Thrust Payload ®...

  • Page 367: Glossary

    (‘hits a brick wall’). Byte: A single octet of data (8 bits). Component: The main parts that form a MagneMotion transport system. Also called system components, these include Motors and Controllers. Configurator:...
  • Page 368 Vehicle, either through wheels or low friction runners on the vehi- cle, to ensure the vehicles are maintained in the proper relationship to the motors. In the MagneMover LITE transport system this is the integral rails mounted on the motors.
  • Page 369 LITE QuickStick ® MagneMover LITE: A MagneMotion linear synchronous motor with integrated guideways and vehicles (pucks) that enables quick, efficient conveyance of loads up to 1 kg on a single vehicle (2 kg on a tandem puck). Magnet Array: The magnets attached to the Vehicle. It is the motor secondary, moved by the primary in the motor.
  • Page 370 I/O modules that provides control, sequencing, and safety interlock logic for the operation of the transport system. Propulsion Power: The power used for vehicle movement. See also, Logic Power. Puck: A pre-configured vehicle for use on MagneMover LITE transport systems. See also, Vehicle. ® QuickStick ® QuickStick A MagneMotion linear synchronous motor that enables quick, efficient con- veyance of large loads using user-designed guideways and vehicles.

  • Page 371: Vehicle Gap

    Controllers. The vehicle typically exits the motor or Path on the Downstream end. V-Brace: The mechanical fixture used to align and secure MagneMover LITE guide rail sections. Vehicle: The independently controlled moving element in a MagneMotion transport system. The vehicle consists of a platform that carries the payload and a pas- sive magnet array to provide the necessary propulsion and position sensing.
  • Page 372 Vehicle Spacing: The distance between two vehicles on the same Path. Zero Point: The position on the Upstream end of a Path that denotes the first part on which Vehicle travels. MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...
  • Page 373 Node Controller LITE, 5-27 Console Interface, description, Node Controller, NC-12, 5-29 Contact MagneMotion, xxvii, 7-22, 7-73 power supply, 5-31 Curve Track, configuration, 3-46 Brick-wall Headway, Custom Guideway design, 3-23 MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...
  • Page 374 Equipment Safety, Humidity E-Stop magnet array, 4-67 connection, 5-62 motor, 4-66 operation, 6-13 NC LITE, 4-66 Ethernet Cable, 4-62 NC-12, 4-66 Ethernet TCP/IP power supply, 4-66 connections, 5-60 Precision Locator, 4-67 description, 4-62 MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...
  • Page 375 Magnet Array description, 3-15 dimensions, 4-19, 4-20 disposal, 2-28 Jam, vehicle, humidity, 4-67 installation, 5-40 labels, 2-14 Labels motor secondary, magnet arrays, 2-14 overview, 1-4, motors, 2-12 temperature, 4-67 MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...
  • Page 376 5-19 related documents, xxvii motors, 3-25 safety notices, motors and switches, 5-20 MM LITE, see MagneMover LITE NC LITE power supply, 5-28 MMConfigTool.exe, see MagneMotion Configu- NC-12 Node Controller, 5-29 rator network switch, 5-28 Motor network switch power supply,...
  • Page 377 Node Controller overview, Configuration File power, 4-44 Nodes temperature, 4-66 connections, 5-34 transport system layout, limits, Precision Locator Option transport system layout, connections, 4-59, 4-61, 5-58 Notes, dimensions, 4-34 MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...
  • Page 378 7-74 humidity, 4-67 Shut Down, 6-27 installation, 7-45 Simulation lubricating applicator installation, 7-50 configure, 6-19 lubricating applicator refilling, run, 6-21 replacing magnet arrays, 7-53 stop, 6-22 single array, 3-38, 4-27 temperature, 4-67 MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...
  • Page 379 Host Controller, labels, 2-13 motors, mounting, 5-20 network, overview, Node Controllers, positioning, 5-21 Nodes, transport system layout, Paths, SYNC IT Controller, 6-12 power supplies, switches, Transport System, see MagneMover LITE MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...
  • Page 380 1-4, simulated, 6-20 single magnet array, 3-19 Vehicle, Precision Rail Option adjusting bearings, 7-11 dual array, 4-28 orientation on rail, 7-45 replacing bearings, 7-53 single array, 4-27 Virtual Scope Utility, description, MagneMotion Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...
  • Page 381 Notes: MagneMover LITE User Manual Rockwell Automation Publication MMI-UM002E-EN-P - March 2016...
  • Page 382 Trademarks not belonging to Rockwell Automation are property of their respective companies. Rockwell Otomasyon Ticaret A.Ş., Kar Plaza İş Merkezi E Blok Kat:6 34752 İçerenköy, İstanbul, Tel: +90 (216) 5698400 Copyright © 2011–2016 MagneMotion, A Rockwell Automation Company. All Rights Reserved. 139 Barnum Road, Devens, MA 01434, USA...

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