Rockwell Automation QuickStick 100 Manuals

Manuals and User Guides for Rockwell Automation QuickStick 100. We have 1 Rockwell Automation QuickStick 100 manual available for free PDF download: User Manual

Rockwell Automation QuickStick 100 User Manual

Rockwell Automation QuickStick 100 User Manual (232 pages)

Brand: Rockwell Automation | Category: Accessories | Size: 2 MB

Table of Contents

Table of Contents
3
Figures

11
Tables

13
Changes

15
- Overview
  15
  - Rev. a
    15
  - Rev. B
    15
  - Rev. C
    16
  - Rev. D
    17
  - Ver. 05
    18
  - Ver. 06
    18
  - Rev. G
    18
About this Manual

21
- Overview
  21
  - Purpose
    21
  - Audience
    21
  - Prerequisites
    21
- Magnemotion Documentation
  22
  - Manual Conventions
    22
  - Notes, Safety Notices, and Symbols
    23
    
    Notes
    23
    
    Safety Notices
    23
  - Manual Structure
    24
  - Related Documentation
    25
- Contact Information
  26
1 Introduction

27
2 Safety

35
3 Design Guidelines

55
- Overview
  55
- Transport System Layout
  56
- Transport System Design
  62
  - Overview
    62
  - Design Guidelines
    62
  - Quickstick 100 System, Single Array Vehicle
    62
  - Motors
    63
    
    Motor Blocks
    64
    
    Thrust and Attractive Force, Standard Magnet Array
    64
    
    Available Thrust
    65
    
    Available Thrust Examples
    66
    
    Motor Gap
    66
    
    Required Thrust
    66
    
    Downstream Gap
    67
    
    Motor Cogging
    67
    
    Motor Gaps
    67
    
    Motors on a Curve
    68
    
    Motors on Curves
    68
    
    Motor Controllers
    69
  - Electrical Wiring
    69
    
    Power Wiring
    69
    
    Signal Wiring
    70
    
    Ground
    71
  - Magnet Arrays
    73
    
    Magnet Array Length and Attractive Force
    73
    
    Magnet Array Width
    74
    
    Magnet Array Use
    74
    
    Standard Magnet Arrays
    74
    
    Standard Potted Magnet Array, 5 Cycles, 11 Poles
    75
    
    Standard Covered Magnet Array, 5 Cycles, 11 Poles
    76
  - Vehicles
    78
    
    Vehicle Gap
    80
    
    Single Array Vehicle
    80
    
    Dual Array Vehicle
    81
    
    Single Array Vehicle Configuration
    81
    
    Dual Array Vehicle Configuration
    81
    
    Vehicle Design
    82
    
    Mounting Magnet Arrays to Vehicles
    83
    
    Magnet Array Mounting
    83
  - Guideways
    84
    
    Guideway Design
    84
    
    Quickstick 100 Transport System, Guideway Detail
    84
    
    Guideway and Support Materials
    85
    
    Motor Mounts
    85
    
    Motor Mounting Methods
    86
    
    Motor Connections
    86
    
    Guideway Examples
    88
    
    Guideway Example #1
    88
    
    Guideway Example #2
    89
    
    Guideway Example #3
    90
- Transport System Configuration
  91
  - Straight Track Configuration
    91
  - Curve Track Configuration
    92
  - Switch Configuration
    93
  - Moving Path Configuration
    94
4 Specifications and Site Requirements

95
- Overview
  95
- Mechanical Specifications
  96
- Electrical Specifications
  103
  - QS 100 Motors
    103
    
    Quickstick 100 Motor Power Requirements
    103
    
    Motor Electrical Connections
    104
    
    Power Connector Pinout
    105
    
    Sync Connector Pinout
    105
    
    Motor Power Cable
    106
    
    Motor Power Drop Cable
    106
    
    Motor Power Drop Cable Pinouts
    106
  - QS 100 Power Supply
    107
    
    QS 100 Power Supply Connections
    108
    
    QS 100 Power Supply DC Power Pinout
    108
    
    QS 100 Power Supply Electrical Connections
    108
    
    QS 100 Power Supply Indicators (Per PS Module)
    108
    
    QS 100 Power Supply Control and Monitoring Pinout
    109
    
    Control Cable
    110
    
    QS 100 Power Supply Control and Monitoring Cable
    110
    
    QS 100 Power Supply Control and Monitoring Cable Pinouts
    110
- Communications
  111
  - Ethernet Connection
    111
    
    TCP/IP Communication - Host Controller to HLC
    111
    
    Ethernet/Ip Communication - Host Controller to HLC
    112
  - RS-232 Serial Interface Connection
    112
    
    Node Controller to Motor
    112
    
    Motor to Motor
    114
  - Sync Connection
    114
- Site Requirements
  115
  - Environment
    115
    
    Motors
    115
    
    QS 100 Power Supply
    115
    
    Magnet Arrays, Potted and Covered
    115
    
    Derating at High Altitude
    115
  - Lighting, Site
    115
  - Floor Space and Loading
    116
  - Facilities
    116
  - Service Access
    116
5 Installation

117
- Overview
  117
- Unpacking and Inspection
  118
  - Packing Checklist Reference
    118
  - Unpacking and Moving
    119
    
    Required Tools and Equipment
    119
    
    Unpacking and Moving Instructions
    119
- Transport System Installation
  121
  - Installing Hardware
    121
    
    Required Tools and Materials
    121
    
    Installation Overview
    122
  - System Installation
    124
    
    Assembling the Guideway
    124
    
    Leveling the Transport System
    124
    
    Securing the Transport System
    124
    
    Mounting the Motors
    124
  - Installing Electronics
    126
    
    Installing Electronics on the Transport System
    126
  - Connecting Motors and Electronics
    127
    
    Motor Communications
    127
    
    Simplified Representation of RS-422 Motor Connections
    127
    
    Simplified Representation of RS-422 Motor Connections in a Merge Switch
    128
    
    Digital I/O
    131
    
    Installing Motor Power Cables
    132
    
    Power Connections
    132
  - Magnet Array Installation
    134
  - Vehicle Installation
    136
- Facilities Connections
  137
  - Network Connections
    137
  - Network Cable Connections
    137
  - Electrical Connections
    138
    
    E-Stop Circuit
    139
    
    Interlock Circuit
    139
    
    Light Stack Circuit
    140
    
    General Purpose Digital I/O
    140
    
    Node Electronics
    140
- Software
  141
  - Software Overview
    141
  - Software Configuration
    141
    
    Node Controller Software Installation
    142
    
    Motor Software Installation
    142
- Check-Out and Power-Up
  143
  - System Check-Out
    143
    
    Mechanical Checks
    143
    
    Facility Checks
    143
    
    Pre-Operation Checks
    143
  - System Power-Up
    144
  - Startup Indicators
    145
- System Testing
  147
6 Operation

149
- Overview
  149
- Theory of Operation
  150
  - Quickstick 100 Transport System Advantages
    150
  - Linear Synchronous Motor Derived from Rotary Motor
    150
  - Motion Control
    151
  - Motor Topology
    151
  - Motor Operation
    152
    
    Representation of Moving Vehicles Per Motor Block
    152
    
    Representation of Stationary Vehicles Per Motor Block
    152
    
    Motor Cogging
    153
  - Motor Blocks
    154
    
    Block Acquisition
    154
    
    Block Ownership
    155
    
    Block Release
    155
  - Anti-Collision
    155
    
    Representation of Block Ownership by Vehicle
    155
    
    Safe Stopping Distance
    156
    
    Thrust Limitations
    156
    
    Vehicle Motion Profile
    156
    
    In Queue
    157
    
    Vehicle Movement Profile Showing Thrust Limitations
    157
    
    Vehicle Length through Curves and Switches
    158
  - Locating Vehicles During Startup
    158
    
    Moving Vehicles by Hand
    159
  - Electrical System
    161
    
    Power Regenerated by a Vehicle
    161
    
    Power Management Within the QS 100 Motor
    161
    
    Power-Related Warnings and Faults
    161
    
    Power Cycle Timing
    162
    
    Individual Block Current Vs. Internal Propulsion Bus Voltage
    163
    
    Power Dissipation Per Block Vs. Internal Propulsion Bus Voltage
    163
    
    Power Related Warnings and Faults
    164
    
    Power Dissipation by 10 Ohm Resistor Vs. Internal Propulsion Bus Voltage
    164
    
    Propulsion Voltage Range
    164
    
    Power Related Fault Resolution
    166
  - Node Controllers
    168
    
    Node Controller Communications
    168
- Controls and Indicators
  169
  - Track Display
    169
  - The Graphics Window
    169
  - Synchronization
    170
  - Transport System Wiring Diagram with Synchronization
    170
  - E-Stops
    171
  - Interlocks
    171
  - Light Stacks
    172
  - Faststop
    172
  - Digital I/O
    172
- Transport System Simulation
  173
  - Configuring a Simulation
    173
  - Running a Simulation
    175
  - Simulated Operation Differences
    175
  - Stopping a Simulation
    177
  - Return the System to Normal Operation
    177
- Transport System Operation
  179
  - Power-Up
    179
  - Normal Running
    179
  - Safe Shut-Down
    180
7 Maintenance

181
- Overview
  181
- Preventive Maintenance
  182
  - Quickstick 100 Transport System Preventive Maintenance Schedule
    182
  - Cleaning
    183
  - Wear Surface Maintenance
    183
  - Cable Connection Inspection
    184
  - Cleaning Magnet Arrays
    184
  - Hardware Inspection
    184
  - Transfer Log Files
    185
- Troubleshooting
  186
  - Initial Troubleshooting
    186
  - Power-Related Troubleshooting
    186
  - Power-Related Troubleshooting
    187
  - Node Controller Troubleshooting
    190
  - Node Controller Related Troubleshooting
    190
  - Communication Troubleshooting
    191
  - Communication-Related Troubleshooting
    191
  - Motion Control Troubleshooting
    192
  - Motion Control Related Troubleshooting
    192
  - Light Stack Troubleshooting
    193
  - Light Stack Related Troubleshooting
    193
- Contact ICT Customer Support
  194
- Repair
  195
  - Quickstick 100 Transport System Repair Procedures
    195
  - Replacing Motors
    196
    
    Remove the Existing Motor
    196
    
    Install the New Motor
    197
  - Programming Motors
    198
  - Separating Magnet Arrays
    199
- Ordering Parts
  200
- Shipping
  201
  - Packing Procedure
    202
  - Shipping Components
    203
Appendix

205
- Overview
  205
- Data for Transport System Design Calculations
  206
- File Maintenance
  213
  - Backup Files
    213
  - Creating Backup Files
    213
  - Restoring from Backup Files
    213
- Additional Documentation
  214
  - Release Notes
    214
  - Upgrade Procedure
    214
- Transport System Limits
  215
- Magnemotion Transport System Limits
  215
- Magnemotion Transport System Motion Limits
  215
Glossary

217
Index

225

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