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Manuals and User Guides for Rockwell Automation MagneMotion QuickStick HT. We have
1
Rockwell Automation MagneMotion QuickStick HT manual available for free PDF download: User Manual
Rockwell Automation MagneMotion QuickStick HT User Manual (344 pages)
Brand:
Rockwell Automation
| Category:
Accessories
| Size: 7 MB
Table of Contents
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
Overview
29
Quickstick HT Transport System Overview
30
QSHT Transport System Components
32
Detailed View of Quickstick HT Transport System Components
32
Transport System Components Overview
34
Simplified View of the Quickstick HT Transport System Components
34
Transport System Software Overview
35
Simplified View of Transport System Software Relationships
35
Getting Started with the Quickstick HT Transport System
37
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
Personnel Safety Guidelines
43
Equipment Safety Guidelines
44
QSHT Transport System Hazard Locations
45
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
Mounting the 2198-Pxxx DC-Bus Power Supplies
186
Ground Screw/Jumper Setting for the DC-Bus Power Supply
186
Ground Screw/Jumper Setting for the QSHT 5700 Inverter
187
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
Vehicle Length through Curves and Switches
236
Locating Vehicles During Startup
236
Moving Vehicles by Hand
237
Electrical System
239
Power Management Within the Motor
239
Power Regenerated by a Vehicle
239
Power-Related Warnings and Faults When Using QSMC Motor Controllers
240
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
QSMC Power-Related Warnings and Faults
243
Propulsion Voltage Range- QSMC Controllers
243
Power-Related Fault Resolution
245
QSHT Inverter Power-Related Warnings and Faults
246
Propulsion Voltage Range- QSHT 5700 Inverter
246
Power-Related Fault Resolution
247
Node Controllers
249
Node Controller Communications
249
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
Overview
263
Introduction
264
Certification
264
Important Safety Considerations
264
Stop Category Definition
264
Performance Level (PL) and Safety Integrity Level (SIL)
265
Average Frequency of a Dangerous Failure
265
Safety Circuit Relevant Parameters
265
Safe Torque-Off Feature
266
Safe Torque-Off Status
267
Safety-Related Axis Tags - Mmi_Path_Qs_Ht_Faults_Status
268
Hardwired Safe Torque-Off
269
Description of Operation
269
Normal System Operation
271
Normal System Operation (Legend)
271
Troubleshoot the Safe Torque-Off Function
272
System Operation in the Event of STO Inputs Discrepancy (Fault Case 1)
272
System Operation in the Event of STO Inputs Discrepancy (Fault Case 2)
272
System Operation in the Event of STO Inputs Discrepancy (Fault Case 3)
273
Safe Torque-Off Connector Data
274
Pin Orientation for 16-Pin Safe Torque-Off (STO) Connector
274
Safe Torque-Off Connector Pinouts
274
Wire the Safe Torque-Off Circuit
275
Install the Safety Connector Plug
275
Insert the Safety Connector Plug
275
Safe Torque-Off Wiring Requirements
276
Safe Torque-Off (STO) Terminal Plug
276
Safe Torque-Off (STO) Connector Plug Wiring
276
Safe Torque-Off Feature Bypass
277
Safe Torque-Off Bypass Wiring
277
Cascade the Safe Torque-Off Signal
278
Cascaded STO Wiring - Dual Inverters with Two Safety Devices
278
Cascaded STO Wiring - Dual Inverter with Single Safety Device
278
Hardwired Safe Torque-Off Electrical Specifications
279
Hardwired STO Electrical Specifications
279
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
Initial Troubleshooting
286
Power-Related Troubleshooting
287
Node Controller Troubleshooting
292
Node Controller Related Troubleshooting
292
Communication Troubleshooting
293
Communication-Related Troubleshooting
293
Motion Control Troubleshooting
294
Motion Control Related Troubleshooting
294
Light Stack Troubleshooting
295
Light Stack Related Troubleshooting
295
QSHT 5700 Inverter Fault Troubleshooting
296
Quickstick HT Mmi_Path_Qs_Ht_Faults_Status Motor Faults
296
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
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