Rockwell Automation 700-1616-03 Manuals

Manuals and User Guides for Rockwell Automation 700-1616-03. We have 2 Rockwell Automation 700-1616-03 manuals available for free PDF download: User Manual

Rockwell Automation 700-1616-03 User Manual (344 pages)

Brand: Rockwell Automation | Category: Accessories | Size: 7 MB

Table of Contents
3
Figures

11
Tables

15
Changes

19
- Overview
  19
  - Rev. a
    19
  - Rev. B
    19
  - Rev. C
    19
  - Ver. 04
    20
  - Rev. E
    21
  - RS-422 Cable Pinouts
    21
  - Rev. F
    22
About this Manual

23
- Overview
  23
  - Purpose
    23
  - Audience
    23
  - Prerequisites
    23
- Magnemotion Documentation
  24
  - Manual Conventions
    24
  - Notes, Safety Notices, and Symbols
    25
    
    Notes
    25
    
    Safety Notices
    25
  - Manual Structure
    27
  - Related Documentation
    27
- Contact Information
  28
1 Introduction

29
2 Safety Guidelines

39
- Overview
  39
- Regulatory Compliance
  40
  - EU Rohs and EU WEEE Compliance
    40
  - Regulatory Information
    40
  - Agency Compliance
    41
  - Equipment Regulatory Guidelines
    42
- Safety Considerations
  43
- Locations of Hazardous Points on the Quickstick HT Transport System
  45
  - Symbol Identification
    46
  - Hazard Alert Symbol Identification
    46
  - Mandatory Action Symbol Identification
    47
  - Prohibited Action Symbol Identification
    47
  - Labels
    48
  - Mechanical Hazards
    49
  - Electrical Hazards
    50
  - Magnetic Hazards
    51
    
    Handling Magnet Arrays
    52
    
    Shipping Magnet Arrays
    53
  - Recycling and Disposal Information
    54
    
    Motor Stators
    54
    
    QSMC Motor Controllers
    54
    
    Quickstick HT Transport System
    54
    
    Magnet Arrays
    55
    
    Packaging
    55
    
    QSHT 5700 Inverters
    55
3 Design Guidelines

57
- Overview
  57
- Transport System Layout
  58
  - Transport System Overview
    58
  - Motors, Motor Drives, Switches, and Vehicles
    59
- Sample QSHT Transport System Layout Showing Motors
  59
  - Paths
    60
- Sample QSHT Transport System Layout Showing Paths
  60
  - Motor Assignments
    60
    
    Nodes
    61
- Sample QSHT Transport System Layout Showing Nodes
  61
  - Node Controllers
    62
- Sample QSHT Transport System Layout Showing Node Controllers
  63
  - Additional Connections
    64
- Sample QSHT Transport System Layout Showing Additional Connections
  64
  - Transport System Design
    65
    
    Design Guidelines
    65
    
    Overview
    65
- Quickstick HT System, Single Array Vehicle
  65
  - Motors
    66
    
    Motor Blocks
    67
    
    Thrust and Attractive Force, High Flux Magnet Array
    67
    
    Available Thrust
    68
    
    Required Thrust
    69
- Available Thrust Examples
  69
  - Motor Gap
    70
  - Downstream Gap
    70
- Motor Gaps
  70
  - Motor Cogging
    71
- Downstream Gaps
  71
  - Motors on a Curve
    72
- Motors on Curves
  72
  - Motor Drives
    73
  - Electrical Wiring
    73
    
    Wiring QSHT Motors Using QSMC Controllers
    73
    
    Power Wiring
    74
    
    Wiring QSHT Motors Using QSHT 5700 Inverters
    74
    
    Signal Wiring
    75
    
    Ground
    76
- System Wiring Block Diagram, QSMC Connections
  77
- System Wiring Block Diagram, QSHT 5700 Inverter Connections
  78
  - Ethernet Motor Communication Recommendations
    79
  - Ethernet Motor Connection Examples
    80
- Ethernet Wiring - Power Supply In-Line with Inverters
  80
- Ethernet Wiring - Power Supply Separate from Inverters
  80
- Ethernet Motor Wiring - One Path, One Ethernet Chain
  81
- Ethernet Motor Wiring - One Path, Two Ethernet Chains
  81
- Ethernet Motor Wiring - One Path, Ethernet Star
  81
- Ethernet Motor Wiring - One Path, Ethernet Star, Multiple Ethernet Switches
  82
- Ethernet Motor Wiring - Two Paths, Ethernet Star, Multiple Node Controllers
  82
- Ethernet Motor Wiring - One Path, One Ethernet Chain
  83
- Ethernet Motor Wiring - One Path, Two Ethernet Chains
  84
- Ethernet Motor Wiring - One Path, Ethernet Star
  84
- Ethernet Motor Wiring - Three Paths, Two Ethernet Chains, Main Loop and Spur
  85
- Ethernet Motor Wiring - Three Paths, One Ethernet Chain, Main Loop and Spur
  85
  - Using both RS-422 and Ethernet Motors
    86
- Ethernet Motor Wiring - Two Paths, Ethernet Chain and RS-422 Chain
  86
- Ethernet Motor Wiring - Two Paths, Ethernet Chain and RS-422 Chain
  87
- Ethernet Motor Wiring - Three Paths, Ethernet Chain Main Loop, RS-422 Spur
  88
  - Ethernet Motor MICS File
    89
    
    MICS File Format
    90
    
    MICS File Protocol
    91
    
    MICS File XML Elements
    91
    
    MICS File XML Reference
    91
    
    XML Declaration
    92
    
    Mics_Motor_Data
    93
    
    Motor
    94
    
    Mac_Addr
    95
    
    Ip_Addr
    96
    
    Track_Location
    97
    
    Orientation
    98
    
    MICS File Example
    99
- System Layout for MICS File Example
  99
  - Magnet Arrays
    102
    
    High Flux Magnet Arrays
    102
- High Flux Magnet Array, 3 Cycles, 7 Poles
  102
  - Magnet Array Length and Attractive Force
    103
  - Number of Cycles
    103
  - Magnet Array Forces
    104
  - Magnet Array Use
    104
  - Vehicles
    106
- Typical Vehicle on Guideway
  106
- Magnet Array to Motor Alignment
  107
  - Vehicle Gap
    108
  - Single Array Vehicle
    108
  - Dual Array Vehicle
    109
- Single Array Vehicle Configuration
  109
- Dual Array Vehicle Configuration
  109
  - Vehicle Design
    110
  - Mounting Magnet Arrays to Vehicles
    111
- Magnet Array Mounting
  111
  - Guideways
    112
    
    Guideway Design
    112
- Guideway Detail
  112
  - Guideway and Support Materials
    113
  - Motor Mounts
    113
  - Motor Mounting Methods
    114
- Motor Mounting to Flat Surface
  114
- Motor Mounting Using Brackets
  115
  - Guideway Examples
    116
- Guideway Example #1
  116
- Guideway Example #2
  117
- Guideway Example #3
  118
  - Transport System Configuration
    119
    
    Straight Track Configuration
    119
    
    Curve Track Configuration
    120
    
    Switch Configuration
    121
    
    Moving Path Configuration
    122
4 Specifications and Site Requirements

123
- Overview
  123
- Mechanical Specifications
  124
  - Meter Motor
    124
- Meter Motor Mechanical Drawing
  124
  - 1/2 Meter Motor
    125
  - 1/2 Meter Double-Wide Motor
    126
  - QSMC Motor Controller
    127
- QSMC Motor Controller Mechanical Drawing
  127
  - QSMC-2 Motor Controller
    128
- QSMC-2 Motor Controller Mechanical Drawing
  128
  - QSMC Rack Mounting Bracket
    129
- Rack Mounting Bracket Mechanical Drawing
  129
  - Quickstick HT 5700 Inverter
    130
- Quickstick HT 5700 Inverter Mechanical Drawing
  130
  - Magnet Array, High Flux
    131
- High Flux Magnet Array Mechanical Drawing
  131
  - High Flux Magnet Array Weights
    131
  - Electrical Specifications
    133
    
    Motors (Stators)
    133
- Motor Electrical Connections
  133
  - Motor Connections
    133
    
    Stator Drive Connector Pinout
    134
    
    Stator Sense Connector Pinout
    134
    
    Motor/Qsmc Power Cable
    135
    
    Motor/Qsmc Sense Cable
    137
- QSMC to Stator Sense Cable
  137
  - QSMC to Stator Sense Cable Pinouts
    137
    
    Stator Sense Cable Wire Gauge Chart
    138
    
    Motor/Qsht 5700 Inverter Drive Cable
    139
    
    Motor/Qsht 5700 Inverter Sense Cable
    141
- QSHT 5700 Inverter to Stator Sense Cable
  141
  - QSHT 5700 Inverter to Stator Sense Cable Pinouts
    141
    
    QSMC Motor Controller
    142
- QSMC Motor Controller Electrical Connections
  143
  - QSMC Motor Controller Connections
    143
    
    QSMC Motor Controller Ethernet Pinout
    144
    
    QSMC Motor Controller Indicators
    144
    
    QSMC Motor Controller Stator Sense Connector Pinout
    144
    
    QSMC Motor Controller LVDC Power Pinout
    145
    
    QSMC Motor Controller RS-422 Connector Pinouts
    145
    
    QSMC Motor Controller HVDC Power Connector Pinout
    146
    
    QSMC Motor Controller Stator Drive Connector Pinout
    146
    
    QSMC-2 Motor Controller
    147
- QSMC-2 Motor Controller Electrical Connections
  148
  - QSMC-2 Motor Controller Connections
    148
    
    QSMC-2 Motor Controller Ethernet Pinout
    149
    
    QSMC-2 Motor Controller Indicators
    149
    
    QSMC-2 Motor Controller Stator Sense Connector Pinout
    149
    
    QSMC-2 Motor Controller LVDC Power Pinout
    150
    
    QSMC-2 Motor Controller RS-422 Connector Pinouts
    150
    
    QSMC-2 Motor Controller HVDC Power Connector Pinout
    151
    
    QSMC-2 Motor Controller Stator Drive Connector Pinout
    151
    
    QSMC HVDC Power Cable
    152
    
    QSMC HVDC Power Cable Pinouts
    152
    
    QSMC DC Power Cable Pinouts
    153
    
    QSMC LVDC Power Cable
    153
    
    QSHT 5700 Inverter/Motor Power Requirements
    154
    
    Quickstick HT 5700 Inverter
    154
- QSHT 5700 Inverter Connections, Controls, and Indicators
  155
  - QSHT 5700 Inverter Connections
    155
    
    QSHT 5700 Inverter Controls
    156
    
    QSHT 5700 Inverter Indicators
    156
    
    QSHT 5700 Inverter 24V DC Control Power Connector Pinout
    157
    
    QSHT 5700 Inverter DC Power Bus Pinout
    157
    
    Quickstick HT 5700 Inverter Connectors
    157
    
    QSHT 5700 Inverter Safety Connector Pinout
    158
    
    QSHT 5700 Inverter Ethernet Connector Pinout
    159
    
    QSHT 5700 Inverter Stator Sense Connector Pinout
    159
    
    QSHT 5700 Inverter Digital Input Connector Pinout
    160
    
    QSHT 5700 Inverter Connector Pinout
    161
    
    Quickstick HT 5700 Wiring Requirements
    162
    
    Module Status Indicator
    163
    
    Network Status Indicator
    163
    
    Quickstick HT 5700 Inverter Controls and Indicators
    163
- Main Menu Page and Layout Description
  164
  - Ethernet Link Speed Status Indicator
    164
  - Ethernet Link/Activity Status Indicator
    164
  - Home Screen Functions
    164
  - Soft Menu Functions
    165
  - Communications
    168
    
    Ethernet Connection
    168
    
    TCP/IP Communication - Host Controller to HLC
    168
    
    Ethernet/Ip Communication - Host Controller to HLC
    169
    
    TCP/IP Communication - Motor Drive to Motor Drive
    169
    
    TCP/IP Communication - Node Controller to Motor Drive
    169
    
    Node Controller to Motor Drive
    170
    
    RS-232 Serial Interface Connection
    170
    
    Motor Drive to Motor Drive
    171
    
    Ethernet Interface Connection
    172
  - Site Requirements
    173
    
    Derating at High Altitude
    173
    
    Environment
    173
    
    Magnet Arrays
    173
    
    Motors
    173
    
    QSHT 5700 Inverters
    173
    
    QSMC Motor Controllers
    173
    
    Facilities
    174
    
    Floor Space and Loading
    174
    
    Lighting, Site
    174
    
    Service Access
    174
5 Installation

175
- Overview
  175
- Unpacking and Inspection
  176
  - Quickstick HT Packing Checklist Reference
    176
  - Unpacking and Moving
    177
    
    Required Tools and Equipment
    177
    
    Unpacking and Moving Instructions
    177
- Transport System Installation
  179
  - Installing Hardware
    179
    
    Required Tools and Materials
    179
    
    Installation Overview
    180
  - System Installation
    181
    
    Assembling the Guideway
    181
    
    Leveling the Transport System
    181
    
    Mounting the Motors
    181
    
    Securing the Transport System
    181
  - Installing Electronics
    183
    
    Installing Electronics on the Transport System
    183
    
    Mounting QSMC Motor Controllers
    184
- QSMC and QSMC-2 Motor Controller Mounting Brackets
  184
  - Mounting the Quickstick HT 5700 Inverters
    185
- QSHT 5700 Inverter Mounting
  185
- Install the QSHT 5700 Inverter Ground Screw
  188
  - QSHT 5700 Inverter Ground Screw Configurations
    189
    
    Connecting Motors and Electronics
    190
    
    Wire Routing
    190
    
    RS-422 Motor Communications
    192
- Simplified Representation of RS-422 Motor Connections
  192
- QSHT Motor and QSMC RS-422 Communications Connections
  193
  - Ethernet Motor Communications
    196
- Simplified Representation of Ethernet Motor Connections
  196
  - QSHT Motor and QSHT 5700 Inverter Communications Connections
    197
  - QSHT 5700 Inverter Cable Clamp
    198
    
    Digital I/O
    201
  - Feedback Cable
    202
  - Wiring the Connector Kit
    202
  - Connector Kit Pinout
    203
    
    Universal Feedback Connector Kit Wiring Requirements
    204
    
    Installing QSMC Motor Controller Power Cables
    205
  - QSHT Power Connections
    205
    
    Installing QSHT 5700 Inverter Power Cables
    208
  - QSHT Power Connections
    208
  - QSHT 5700 Inverter Grounding
    210
    
    Magnet Array Installation
    211
    
    Installing Vehicles
    213
  - Facilities Connections
    214
    
    Network Connections
    214
  - Network Cable Connections
    214
    
    Electrical Connections
    215
    
    E-Stop Circuit
    217
    
    General Purpose Digital I/O
    217
    
    Interlock Circuit
    217
    
    Light Stack Circuit
    217
    
    Node Electronics
    218
    
    QSHT 5700 Inverter Digital Input Configurable Functions
    218
  - Software
    219
    
    Software Configuration
    219
    
    Software Overview
    219
    
    Motor Software Installation
    220
    
    Node Controller Software Installation
    220
  - Check-Out and Power-Up
    221
    
    Facility Checks
    221
    
    Mechanical Checks
    221
    
    Pre-Operation Checks
    221
    
    System Check-Out
    221
    
    System Power-Up
    222
    
    Startup Indicators
    223
  - System Testing
    225
6 Operation

227
- Overview
  227
- Theory of Operation
  228
  - Quickstick HT Transport System Advantages
    228
- Linear Synchronous Motor Derived from Rotary Motor
  228
  - Motion Control
    229
  - Motor Topology
    229
  - Motor Operation
    230
- Representation of Stationary Vehicles Per Motor Block
  230
- Representation of Moving Vehicles Per Motor Block
  230
  - Motor Cogging
    231
  - Motor Blocks
    232
    
    Block Acquisition
    232
    
    Block Ownership
    233
    
    Block Release
    233
  - Anti-Collision
    233
- Representation of Block Ownership by Vehicle
  233
  - Safe Stopping Distance
    234
  - Thrust Limitations
    234
- Vehicle Motion Profile
  234
  - In Queue
    235
- Vehicle Motion Profile Showing Thrust Limitations
  235
- Power Cycle Timing
  240
  - Power-Related Warnings and Faults When Using QSHT 5700 Inverters
    241
- Individual Block Current Vs. Internal Propulsion Bus Voltage
  241
- Power Dissipation Per Block Vs. Internal Propulsion Bus Voltage
  241
- Individual Block Current Vs. Internal Propulsion Bus Voltage
  242
- Power Dissipation Per Block Vs. Internal Propulsion Bus Voltage
  242
- Controls and Indicators
  250
  - Track Display
    250
- The Graphics Window
  250
  - E-Stops
    251
  - Interlocks
    251
  - Light Stacks
    252
  - Faststop
    252
  - Digital I/O
    252
  - Software Status Indicators
    253
  - QSHT Faults Status
    253
- Transport System Simulation
  254
  - Configuring a Simulation
    254
  - Running a Simulation
    256
  - Simulated Operation Differences
    256
  - Stopping a Simulation
    258
  - Return the System to Normal Operation
    258
- Transport System Operation
  260
  - Power-Up
    260
  - Normal Running
    260
  - Shut-Down
    261
7 QSHT 5700 Inverter Safe Torque-Off Function

263
8 Maintenance

281
- Overview
  281
- Preventive Maintenance
  282
  - Quickstick HT Transport System Preventive Maintenance Schedule
    282
  - Cleaning
    283
  - Wear Surface Maintenance
    283
  - Cable Connection Inspection
    284
  - Hardware Inspection
    284
  - Transfer Log Files
    284
  - Cleaning Magnet Arrays
    285
- Troubleshooting
  286
- Contact ICT Customer Support
  300
- Repair
  301
  - Quickstick HT Transport System Repair Procedures
    301
  - Replacing Motors
    302
    
    Remove the Existing Motor
    302
    
    Install the New Motor
    303
  - Replacing Motor Drives
    304
    
    Install the New Motor Drive
    304
    
    Remove the Existing Motor Drive
    304
  - Programming Motors
    306
  - Separating Magnet Arrays
    307
  - Cleaning or Replacing the Motor Controller Fan Filter
    308
- Replacing QSMC Fan Filter
  308
- Ordering Parts
  309
- Shipping
  310
  - Required Tools and Equipment
    310
  - Packing Procedure
    311
  - Shipping Components
    312
Appendix

313
- Overview
  313
- Interconnect Diagrams
  314
  - Interconnect Diagram Notes
    314
  - Power Wiring Examples
    316
- DC-Bus Power Supply (Single Converter) Configuration
  316
  - Data for Transport System Design Calculations
    317
    
    Thrust Force Data
    318
    
    Thrust Force Data, High Flux Magnet Array
    318
- Thrust Force Vs. Magnet Array Cycles, High Flux Magnet Array
  319
- Thrust Force Vs. Vehicle Gap, High Flux Magnet Array
  319
  - Attractive Force Data
    320
- Attractive Force Data Curves, High Flux Magnet Array
  320
  - Attractive Force Data, High Flux Magnet Array
    320
    
    Determining Thrust Force
    321
    
    Determining Attractive Force
    322
  - File Maintenance
    323
    
    Backup Files
    323
    
    Creating Backup Files
    323
    
    Restoring from Backup Files
    323
  - Additional Documentation
    324
    
    Release Notes
    324
    
    Upgrade Procedure
    324
  - Transport System Limits
    325
  - Magnemotion Transport System Limits
    325
  - Magnemotion Transport System Motion Limits
    325
Glossary

327
Index

335

Rockwell Automation 700-1616-03 User Manual (228 pages)

Brand: Rockwell Automation | Category: Industrial Equipment | Size: 13 MB

Table of Contents
3
Preface
11
About this Publication
11
Prerequisites
11
Notes, Safety Notices, and Symbols
11
Notes
11
Safety Notices
11
Additional Resources
13
Additional Documentation
14
Release Notes
14
Upgrade Procedure
14
Creating Backup Files
14
Introduction
15
How to Define Your Quickstick HT
15
Quickstick HT Transport System Overview
15
QSHT Transport System Components
17
Transport System Components Overview
18
Transport System Software Overview
19
Getting Started with the Quickstick HT Transport System
19
Safety Guidelines
21
Regulatory Compliance
21
Agency Compliance
22
Safety Considerations
22
Personnel Safety Guidelines
22
Equipment Safety Guidelines
23
QSHT Transport System Hazard Locations
24
Symbol Identification
24
Labels
25
Mechanical Hazards
26
Electrical Hazards
26
Magnetic Hazards
27
Handling Magnet Arrays
28
Shipping Magnet Arrays
29
Recycling and Disposal Information
29
Waste Electrical and Electronic Equipment (WEEE)
29
Quickstick HT Transport System
29
Motor Stators
29
QSHT Gen 2 (QSMC-1/QSMC-2) Motor Controllers
29
QSHT 5700 Motor Controllers
30
Magnet Arrays
30
Design Guidelines
31
Transport System Layout
31
Transport System Overview
31
Motors, Motor Drives, Switches, and Vehicles
32
Paths
32
Nodes
33
Node Controllers
34
Additional Connections
35
Transport System Design
36
Design Guidelines
37
Motors
38
Available Thrust
38
Required Thrust
39
Motor Gap
40
Downstream Gap
40
Motor Cogging
41
Motors on a Curve
42
Motor Controller
42
Electrical Wiring
43
Wiring QSHT Motors Using QSHT Gen 2 Controllers
43
Wiring QSHT Motors Using QSHT 5700 Motor Controllers
43
Power Wiring
43
Signal Wiring
44
Ground
44
Ethernet Motor Communication Recommendations
47
Ethernet Motor Connection Examples
47
Using both RS-422 and Ethernet Motors
53
Ethernet Motor MICS File
56
Magnet Arrays
56
High Flux Magnet Arrays
56
Magnet Array Length and Attractive Force
57
Number of Cycles
58
Magnet Array Forces
58
Magnet Array Use
58
Vehicles
59
Vehicle Gap
60
Single Array Vehicle
61
Dual Array Vehicle
61
Vehicle Design
62
Mounting Magnet Arrays to Vehicles
63
Guideways
63
Guideway Design
64
Guideway and Support Materials
64
Motor Mounts
65
Motor Mounting Methods
65
Guideway Examples
66
Transport System Configuration
69
Straight Track Configuration
70
Curve Track Configuration
71
Switch Configuration
72
Moving Path Configuration
73
Specifications and Site Requirements
75
Mechanical Specifications
75
1.0 M Motor
75
0.5 M Motor
76
0.5 M Double-Wide Motor
77
QSMC-1 Motor Controller
78
QSMC-2 Motor Controller
79
QSHT Gen 2 Rack Mounting Bracket
80
Quickstick HT 5700 Motor Controller
81
QSHT Gen 2 to 1.0 M Motor Drive Cable
82
QSHT Gen 2 to 0.5 M Motor Drive Cable
83
QSHT Gen 2 to Motor Sense Cable
84
QSHT Gen 2 HVDC Power Cable
85
QSHT Gen 2 LVDC Power Cable
86
QSHT 5700 Motor Controller to 1.0 M Motor Drive Cable
87
QSHT 5700 Motor Controller to 0.5 M Motor Drive Cable
88
QSHT 5700 Motor Controller to Motor Sense Cable
89
Magnet Array, High Flux
90
Electrical Specifications
91
Motors (Stators)
91
QSHT Gen 2 to 1.0 M Motor Drive Cable
92
QSHT Gen 2 to 0.5 M Motor Drive Cable
93
QSHT Gen 2 to Motor Sense Cable
95
QSHT 5700 Motor Controller to 1.0 M Motor Drive Cable
96
QSHT 5700 Motor Controller to 0.5 M Motor Drive Cable
97
QSHT 5700 Motor Controller to Motor Sense Cable
98
QSMC-1 Motor Controller
99
QSMC-2 Motor Controller
103
QSHT Gen 2 HVDC Power Cable
107
QSHT Gen 2 LVDC Power Cable
108
QSHT 5700 Motor Controller
109
Quickstick HT 5700 Motor Controller Connectors
111
Quickstick HT 5700 Motor Controller Controls and Indicators
114
Communication
117
Ethernet Connection
117
TCP/IP Communication - Host Controller to HLC
118
TCP/IP Communication - Node Controller to Motor Drive
118
TCP/IP Communication - Motor Drive to Motor Drive
118
Ethernet/Ip Communication - Host Controller to HLC
118
RS-232 Serial Interface Connection
119
Node Controller to Motor Drive
119
Motor Drive to Motor Drive
120
Ethernet Interface Connection
120
Site Requirements
121
Environment
121
Derating at High Altitude
121
Lighting, Site
121
Floor Space and Loading
121
Facilities
122
Service Access
122
Installation
123
Unpacking and Inspection
123
Unpacking and Moving
124
Required Tools and Equipment
124
Unpacking and Moving Instructions
124
Transport System Installation
125
Installing Hardware
125
Required Tools and Materials
125
Installation Overview
125
System Installation
126
Assembling the Guideway
126
Leveling the Transport System
126
Securing the Transport System
126
Mounting the Motors
126
Installing Electronics
127
Installing Electronics on the Transport System
127
Mounting QSHT Gen 2 Motor Controllers
128
Mounting the Quickstick HT 5700 Motor Controllers
128
Mounting the 2198-Pxxx DC-Bus Power Supplies
129
Connecting Motors and Electronics
132
Wire Routing
133
RS-422 Motor Communication
133
Digital I/O
140
Installing QSHT Gen 2 Motor Controller Power Cables
144
Installing QSHT 5700 Motor Controller Power
146
Installing Magnet Arrays/Vehicles
148
Magnet Array Installation
149
Installing Vehicles
150
Facilities Connections
150
Network Connections
150
Electrical Connections
151
E-Stop Circuit
152
Interlock Circuit
153
Light Stack Circuit
153
General Purpose Digital I/O
153
Node Electronics
153
Software
153
Software Overview
154
Software Configuration
154
Node Controller Software Installation
154
Motor Software Installation
154
Check-Out and Power-Up
155
System Check-Out
155
Mechanical Checks
155
Facility Checks
155
Pre-Operation Checks
155
System Power-Up
155
System Testing
157
Operation
159
Theory of Operation
159
Quickstick HT Transport System Advantages
160
Motion Control
160
Motor Topology
160
Motor Operation
161
Motor Cogging
161
Motor Blocks
162
Block Acquisition
162
Block Ownership
162
Block Release
163
Anti-Collision
163
Safe Stopping Distance
163
Thrust Limitations
164
Vehicles in Queue
164
Vehicle Length through Curves and Switches
165
Locating Vehicles During Startup
165
Moving Vehicles by Hand
165
Power Regenerated by a Vehicle
166
Power Management Within the Motor
167
QSHT Gen 2 Motor Controller Power-Related Warnings and Faults
167
QSHT Gen 2 Power-Related Warnings and Faults
169
QSHT Gen 2 Power-Related Fault Resolution
170
QSHT 5700 Motor Controller Power-Related Warnings and Faults
171
QSHT 5700 Motor Controller Power-Related Warnings and Faults
172
QSHT 5700 Motor Controller Power-Related Power-Related Fault Resolution
173
Node Controllers
173
Node Controller Communications
174
Controls and Indicators
174
Track Display
174
E-Stops
175
Interlocks
175
Light Stacks
175
Faststop
175
Digital I/O
176
Software Status Indicators
176
Transport System Simulation
176
Configuring a Simulation
177
Running a Simulation
178
Stopping a Simulation
179
Return the System to Normal Operation
179
Transport System Operation
179
Power-Up
179
Normal Running
180
Shut-Down
180
QSHT 5700 Motor Controller Safe Torque-Off Function
181
Introduction
181
Certification
181
Important Safety Considerations
181
Stop Category Definition
181
Performance Level (PL) and Safety Integrity Level (SIL)
182
Average Frequency of a Dangerous Failure
182
Safe Torque-Off Feature
182
Safe Torque-Off Status
183
Hardwired Safe Torque-Off
184
Description of Operation
184
Troubleshoot the Safe Torque-Off Function
186
Safe Torque-Off Connector Data
188
Wire the Safe Torque-Off Circuit
188
Install the Safety Connector Plug
189
Safe Torque-Off Wiring Requirements
189
Safe Torque-Off Feature Bypass
190
Cascade the Safe Torque-Off Signal
191
Hardwired Safe Torque-Off Electrical Specifications
192
Maintenance
193
Preventive Maintenance
193
Cleaning
194
Wear Surface Maintenance
194
Cable Connection Inspection
195
Hardware Inspection
195
Transfer Log Files
195
Cleaning Magnet Arrays
196
Troubleshooting
196
Initial Troubleshooting
197
Power-Related Troubleshooting
197
Node Controller Troubleshooting
199
Communication Troubleshooting
199
Motion Control Troubleshooting
199
Light Stack Troubleshooting
200
QSHT 5700 Motor Fault Troubleshooting
201
Repair
201
Replacing Motors
201
Remove the Existing Motor
201
Install the New Motor
202
Replacing Motor Controllers
202
Remove the Existing Motor Drive
202
Install the New Motor Drive
203
Programming Motors
203
Separating Magnet Arrays
203
Cleaning or Replacing the Motor Controller Fan Filter
204
Ordering Parts
205
Shipping
205
Required Tools and Equipment
206
Packing Procedure
206
Shipping Components
207
Appendix
209
Interconnect Diagrams
209
Interconnect Diagram Notes
209
Power Wiring Examples
211
Data for Transport System Design Calculations
211
Thrust Force Data
212
Attractive Force Data
213
Determining Thrust Force
214
Determining Attractive Force
215
Summary of Changes
217
Rev. a
217
Rev. B
217
Rev. C
217
Rev D
218
Rev. E
218
Rev. F
219
Rev. G
219
Rev. H
220
Rev. I
220
Rev. J
220
Index
221

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Rockwell Automation 700-1616-03 Manuals

Rockwell Automation 700-1616-03 User Manual (344 pages)

Table of Contents

Figures

Tables

Changes

About this Manual

1 Introduction

2 Safety Guidelines

3 Design Guidelines

4 Specifications and Site Requirements

5 Installation

6 Operation

7 QSHT 5700 Inverter Safe Torque-Off Function

8 Maintenance

Appendix

Glossary

Index

Rockwell Automation 700-1616-03 User Manual (228 pages)

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