Rockwell Automation Allen-Bradley MagneMover LITE Manuals

Manuals and User Guides for Rockwell Automation Allen-Bradley MagneMover LITE. We have 1 Rockwell Automation Allen-Bradley MagneMover LITE manual available for free PDF download: User Manual

Rockwell Automation Allen-Bradley MagneMover LITE User Manual (370 pages)

Brand: Rockwell Automation | Category: Industrial Equipment | Size: 10 MB

Table of Contents
3
Preface
13
Audience
13
Prerequisites
13
Notes, Safety Notices, and Symbols
13
Notes
13
Safety Notices
13
Additional Resources
15
Introduction
17
Magnemover LITE Overview
17
Magnemover LITE Transport System Components
19
Magnemover Transport System Options
21
Precision Rails
21
Precision Locator
22
Transport System Components Overview
23
Transport System Software Overview
25
Utilities
26
File Types
26
Getting Started with the Magnemover LITE Transport System
27
Safety Guidelines
29
Regulatory Compliance
29
Safety Considerations
30
Personnel Safety Guidelines
30
Equipment Safety Guidelines
31
Magnemover LITE Transport System Hazard Locations
32
Precision Rail Option Hazard Locations
33
Precision Locator Option Hazard Locations
34
Puck/Vehicle Hazard Locations
35
Symbol Identification
36
Labels
38
Mechanical Hazards
38
Electrical Hazards
39
Pneumatic Hazards
39
Magnetic Hazards
40
Handling Magnet Arrays
41
Shipping Magnet Arrays
42
Recycling and Disposal Information
42
Rohs and WEEE
42
Magnemover LITE Transport System
42
Motors
42
Vehicles
43
Magnet Arrays
43
Vehicle Body
43
Glide Pucks
43
Wheeled Pucks
43
Precision Rail Vehicles
43
System Options
43
Precision Locator
43
Precision Rail Lubrication Pump
44
Power Supplies
44
Packaging
44
Design Guidelines
45
Transport System Layout
45
Transport System Overview
45
Motors, Switches, and Vehicles (Pucks)
46
Paths
46
Nodes
47
Node Controllers
48
Additional Connections
49
Transport System Design
50
Overview
50
Design Guidelines
51
Motors
51
Motor Types
52
Available Thrust
53
Required Thrust
53
Motor Gap
53
Downstream Gap
54
Motor Cogging
54
Motor Controllers
54
Electrical Wiring
55
Power Wiring
55
Signal Wiring
56
Ground
56
Ethernet Motor Communication Recommendations
59
Ethernet Motor Connection Examples
60
Using both RS-422 and Ethernet Motors
63
Ethernet Motor MICS File
65
Magnet Arrays
66
High Flux Magnet Arrays
66
Magnet Array Length and Attractive Force
67
Magnet Array Use
68
Available Magnet Arrays
68
Vehicles
68
Vehicle Gap
69
Vehicle Design
70
Mounting Magnet Arrays to Vehicles
71
Pucks
71
Single Array Glide Puck
71
Dual Array (Tandem) Glide Puck
73
Single Array 4 Wheel Puck
74
Dual Array (Tandem) Wheeled Puck
76
Precision Rail Vehicles
78
Single Array Vehicle
78
Dual Array Vehicle
78
Guideways
80
Custom Guideway Design
80
Guideway and Support Materials
81
Motor Mounts
81
Motor Mounting Methods
82
System Stands
85
Custom Motor Mounting
86
Puck Limits
88
Cantilevered Payloads
88
High Inertia Payloads
88
Transport System Options
89
Precision Rail
89
Precision Rails
90
Spine Plates
91
Support Post Assembly
92
Precision Rail Vehicles
93
Precision Rail Installation
94
Precision Rail Lubrication
95
Precision Locator
97
Precision Locators
97
Locator Stand
97
Pallet
98
Pallet Design
98
Precision Locator Installation
100
Transport System Configuration
101
Straight Track Configuration
102
Curve Track Configuration
102
Switch Configuration
103
Specifications and Site Requirements
105
Motor Types
105
Magnemover LITE G4 Motors
105
Mechanical Specifications
107
1000 Millimeter Motors
108
250 Millimeter Motors
116
125 Millimeter Radius 90° Curve Motors
124
90° Left Switches
132
90° Right Switches
135
Standard Motor Mount Bracket
138
V-Brace Kits
139
Stand System
140
Glide Pucks
142
Wheeled Pucks
143
Tandem Glide Pucks
145
Tandem Wheeled Pucks
146
Magnet Arrays
147
MM LITE Power Supply
148
Precision Rail Option
149
Precision Rails
149
Precision Rail Single Array Vehicle
150
Precision Rail Dual Array Vehicle
151
Precision Rail Support Post Assembly
152
Spine Plates
153
Precision Rail Lubrication System
157
Precision Locator Option
158
Actuator Assembly
158
Stand Assembly
159
Adjustable Motor Mount Bracket
161
Pallet
162
Electrical Specifications
164
Motors and Switches
164
Straight and Curve Motors
166
Switches
170
MM LITE Power Supply
173
AC Power Cable
175
Motor Power Cables
176
DC Enable
177
DC Enable Jumper Plug
177
Precision Rail Lubrication Pump
178
Precision Rail Lubrication Pump Connector
178
Precision Rail Lubrication Pump Controls and Indicators
179
Precision Locator
179
Pneumatic Specifications
180
Air-Cooled Motors
180
Air Cooling
181
Pressurizing
181
Precision Locator
181
Communication
182
Ethernet Connection
182
TCP/IP Communication - Host Controller to HLC
182
TCP/IP Communication - Node Controller to Motor
183
TCP/IP Communication - Motor to Motor
183
Ethernet/Ip Communication - Host Controller to HLC
183
RS-232 Serial Interface Connection
183
Node Controller to Motor
183
Motor to Motor
184
Ethernet Interface Connection
185
Sync Connection
185
Site Requirements
186
Environment
186
Motors
186
MM LITE Power Supply
186
Precision Locator
186
Magnet Arrays, Pucks, Precision Rail Vehicles
186
Derating at High Altitude
186
Lighting, Site
187
Floor Space and Loading
187
Facilities
187
Service Access
187
Installation
189
Unpacking and Inspection
189
Unpacking and Moving
190
Required Tools and Equipment
190
Unpacking and Moving Instructions
190
Transport System Installation
191
Installing Hardware
191
Required Tools and Materials
191
Installation Overview - User-Supplied Mounting
191
Installation Overview - Supplied Mounting
192
Installation Overview - Precision Rails
193
Installation Overview - Precision Locator
194
Stand System Installation
195
Assembling Beams
195
Installing System Legs
195
Leveling the Magnemover LITE
199
Securing the Transport System
200
Motor Installation
201
Installing Cable Chase Cover Brackets
201
Installing Motor Mounts on Motors and Switches
202
Mounting Motors and Switches
202
Align and Secure Motors and Switches
204
Align and Secure Railless Motors
207
Verify Motor and Switch Installation
208
Installing Electronics
208
Installing Electronics on the Transport System
208
Mounting Power Supplies
209
Mounting Magnemover LITE Power Supplies
209
Mounting Allen-Bradley Power Supplies
210
Connecting Motors and Electronics
211
RS-422 Motor Communication
211
Ethernet Motor Communication
215
Digital I/O
217
Installing Motor Power Cables
218
Installing Magnet Arrays/Pucks
219
Magnet Array Installation
220
Puck Installation
220
Installing Cable Chase Covers
220
Option Installation
223
Precision Rail Installation
223
Assemble Precision Rail Support Posts
224
Attach Precision Rail Support Posts to the Beam
225
Attach Rails to Spine Plates
226
Align and Secure Rails to Spine Plates
228
Secure Spine Plates to Support Posts
231
Install the Precision Rail Vehicles
232
Lubricate the Precision Rails
232
Install the Optional Precision Rail Lubrication Pump System
232
Initial Lubrication Using the Pump System
234
Lubrication Using the Pump System During Normal Operation
235
Precision Locator Installation
235
Install Pallets and Pucks
236
Install the Precision Locators on the Stands
236
Install the Precision Locator Assemblies
237
Install the Motors
237
Install the Pneumatic Controls
238
Install the Covers
239
Teach the Precision Locator Position
239
Facilities Connections
239
Network Connections
239
Electrical Connections
240
E-Stop Circuit
242
Interlock Circuit
242
Light Stack Circuit
242
General Purpose Digital I/O
242
Software
242
Software Overview
243
Software Configuration
243
Node Controller Software Installation
243
Motor Software Installation
243
Check-Out and Power-Up
244
System Check-Out
244
Mechanical Checks
244
Facility Checks
244
Pre-Operation Checks
244
System Power-Up
244
System Testing
247
Operation
249
Theory of Operation
249
Magnemover LITE Transport System Advantages
250
Motion Control
250
Motor Topology
250
Motor Operation
251
Motor Cogging
251
Motor Blocks
252
Block Acquisition
252
Block Ownership
252
Block Release
253
Anti-Collision
253
Safe Stopping Distance
253
Thrust Limitations
254
Vehicles in Queue
254
Vehicle Length through Curves and Switches
255
Locating Vehicles During Startup
255
Moving Vehicles by Hand
255
Electrical System
256
Power-Related Faults
257
Power-Related Fault Resolution
258
Node Controllers
258
Node Controller Communication
258
Controls and Indicators
259
Track Display
259
Synchronization
260
E-Stops
260
Interlocks
261
Faststop
261
Light Stacks
261
Digital I/O
261
Transport System Simulation
262
Configuring a Simulation
262
Running a Simulation
263
Stopping a Simulation
264
Return the System to Normal Operation
264
Precision Rail Operation
265
Setup
265
Operation
265
Precision Locator Operation
265
Basic Operation
266
Operation Using Cylinder Position Sensors
266
Transport System Operation
266
Power-Up
266
Normal Running
267
Shutdown
267
Maintenance
269
Preventive Maintenance
269
General Cleaning
270
Spray Cleaning
270
Glide Puck Cleaning
271
Puck Wear Surface Maintenance
272
Wheeled Puck Cleaning
274
Wheeled Puck Wear Surface Maintenance
275
Cable Connection Inspection
278
Hardware Inspection
278
Transfer Log Files
278
Cleaning Magnet Arrays
279
Clean or Replace the MM LITE Power Supply Air Filter
280
Manually Lubricate the Precision Rails
281
Refill the Lubricator on Precision Rail Vehicles
281
Refill the Lubrication Pump Reservoir for Precision Rail Systems
284
Adjust Vehicle Bearings
284
Concentric Bearings
285
Eccentric Bearings
285
Precision Locator Maintenance
287
Troubleshooting
287
Initial Troubleshooting
287
Power-Related Troubleshooting
288
Node Controller Troubleshooting
289
Communication Troubleshooting
289
Motion Control Troubleshooting
289
Precision Rail Option Troubleshooting
291
Light Stack Troubleshooting
291
Contact Rockwell Automation Technical Support
291
Repair
292
Replace RS-422 Motors
293
Remove the Existing Motor
293
Install the New Motor
294
Program RS-422 Motors
294
Replace RS-422 Motors with Ethernet Motors
295
Remove Existing RS-422 Motors
295
Install New Ethernet Motors
296
Create/Revise Configuration Files
296
Upload Configuration Files and Restart
296
Replace Ethernet Motors
297
Remove the Existing Motor
297
Install the New Motor
297
Program Ethernet Motors
298
Replace Motor Rails
299
Replace Switch Rails
300
Separating Magnet Arrays
301
Replace Pucks
302
Remove Pucks
303
Install Pucks
303
Replace Glide Puck Wear Surfaces
304
Replace Tandem Glide Puck Wear Surfaces
308
Disassemble Tandem Puck Assembly
309
Reassemble Tandem Puck Assembly
311
Replace Wheeled Puck Wear Surfaces, 4-Wheel Pucks
314
Replace Wheeled Puck Wear Surfaces, 2-Wheel Pucks
317
Replace Tandem Wheeled Puck Wear Surfaces
319
Disassemble Tandem Puck Assembly
321
Reassemble Tandem Puck Assembly
323
Replace MM LITE Power Supply Fuses
326
AC Fuse
327
DC Fuses
328
Replace Precision Rail Vehicles
328
Vehicle Orientation
329
Removing Vehicles by Removing Rails
329
Installing Vehicles with Rails Removed
330
Removing Vehicles Without Removing Rails
330
Installing Vehicles Without Removing Rails
332
Install/Replace the Lubricators on Precision Rail Vehicles
333
Replace Magnet Arrays on Precision Rail Vehicles
335
Dual Array Vehicles
338
Replace Bearings on Precision Rail Vehicles
340
Replace Concentric Bearings
341
Replace Eccentric Bearings
342
Replace Wear Surfaces on Pallet
345
Replace Bushings on Pallet
347
Replace Pins on Precision Locator Arms
349
Replace Z-Datums on Precision Locator Stand
351
Ordering Parts
352
Shipping
352
Packing Procedure
353
Shipping Components
354
Shipping Systems or System Sections
354
History of Changes
355
Rev. a
355
Rev. B
355
Rev. C
356
Rev. D
356
Rev. E
357
Rev. F
358
Rev. G
360

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