QuickStick 100 User s Manual

Transcription

1 QuickStick 100 User s Manual Rev. D

2 Although every effort is made to ensure the accuracy of this document, 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. MagneMotion, MagneMover, QuickStick, MM LITE, and SYNC IT are trademarks or registered trademarks of All other trademarks are properties of their respective owners. This product is protected under one or more U.S. and International patents. Additional U.S. and International patents pending All Rights Reserved. The information included in this manual is proprietary information and is provided for the use of customers only and cannot be used for distribution, reproduction, or sale without the express written permission of In no event will be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment. 139 Barnum Road Devens, MA USA Phone: Fax: This technology is subject to United States Export Administration Regulations and authorized to the destination only; diversion contrary to U.S. law is prohibited. Printed in the U.S.A Rev. D

3 Contents Figures... ix Tables... xiii Changes Overview... xv Rev. A... xv Rev. B... xv Rev. C... xvi Rev. D... xvi About This Manual Overview... xvii Purpose... xvii Audience... xvii Prerequisites... xvii MagneMotion Documentation... xviii Manual Conventions... xviii Notes, Safety Notices, and Symbols... xix Manual Structure... xx Related Documentation... xxi Contact Information... xxi 1 Introduction Overview QuickStick 100 Transport System Overview QS 100 Transport System Components Transport System Components Overview Transport System Software Overview Getting Started with the QuickStick 100 System Safety Overview Regulatory Compliance EU RoHS and EU WEEE Compliance QuickStick 100 User s Manual i

4 Contents Equipment Regulatory Guidelines Safety Considerations Personnel Safety Guidelines Equipment Safety Guidelines QuickStick 100 Transport System Hazard Locations Symbol Identification Label Identification and Location Mechanical Hazards Electrical Hazards Magnetic Hazards Handling Magnet Arrays Shipping Magnet Arrays Recycling and Disposal Information QuickStick 100 Transport System Node Controllers Magnet Arrays Design Guidelines Overview Transport System Layout Transport System Overview Motors, Switches, and Vehicles Paths Nodes Node Controllers Additional Connections Transport System Design Overview Design Guidelines Motors Available Thrust Required Thrust Motor Gap Downstream Gap Motor Cogging Motors on a Curve Motor Controllers Electrical Wiring Power Wiring Signal Wiring Ground Magnet Arrays Magnet Array Length and Attractive Force Magnet Array Width Magnet Array Use Standard Magnet Arrays High Flux Magnet Arrays ii Rev. D

5 Contents Vehicles Single Array Vehicle Dual Array Vehicle Vehicle Gap Vehicle Design Mounting Magnet Arrays to Vehicles Guideways Guideway Design Guideway and Support Materials Motor Mounts Motor Mounting Methods Guideway Examples Transport System Configuration Straight Track Configuration Curve Track Configuration Switch Configuration Shuttle Configuration Moving Path Configuration Specifications and Site Requirements Overview Mechanical Specifications Millimeter Motor Millimeter Motor Magnet Array, Standard Magnet Array, High Flux NC-12 Node Controller Rack Mounting Bracket Node Controller LITE Electronics Mounting Plate QS 100 Power Supply Electrical Specifications QS 100 Motors Motor Power Cable NC-12 Node Controller AC Power Option DC Power Option AC Power Cable Node Controller LITE AC Power Option DC Power Option QS 100 Power Supply Control Cable Ethernet Switch with Power over Ethernet Injector Communications Ethernet Connection TCP/IP Communication QuickStick 100 User s Manual iii

6 Contents EtherNet/IP Communication RS-232 Serial Interface Connection RS-422 Serial Interface Connection Sync Connection Digital I/O Connection Site Requirements Environment Motors NC LITE NC Power Supply Magnet Arrays Lighting, Site Floor Space and Loading Facilities Service Access Installation Overview Unpacking and Inspection Unpacking and Moving Required Tools and Equipment Unpacking and Moving Instructions Transport System Installation Installing Hardware Required Tools and Materials Installation Overview System Installation Assembling the Guideway Leveling the Transport System Securing the Transport System Mounting the Motors Installing Electronics Mounting NC-12 Node Controllers Connecting Motors and Electronics Installing Vehicles Magnet Array Installation Vehicle Installation Facilities Connections Network Connections Electrical Connections E-Stop Circuit Interlock Circuit Light Stack Circuit General Purpose Digital I/O Node Electronics iv Rev. D

7 Contents Software Software Overview Software Configuration Node Controller Software Installation Motor Software Installation Check-out and Power-up System Check-out Mechanical Checks Facility Checks Pre-operation Checks System Power-up System Testing Operation Overview Theory of Operation QuickStick 100 Transport System Advantages Motion Control Motor Topology Motor Operation Motor Cogging Motor Blocks Block Acquisition Anti-Collision Safe Stopping Distance Movement In Queue Vehicle Length Through Curves and Switches Locating Vehicles During Startup Moving Vehicles by Hand Electrical System Power Regenerated by a Vehicle Power Management Within the QS 100 Motor Power Related Warnings and Faults Power Related Fault Resolution Controls and Indicators System Display Synchronization E-Stops Interlocks FastStop Light Stacks Digital I/O Transport System Simulation Configuring a Simulation Running a Simulation Stopping a Simulation Return the System to Normal Operation QuickStick 100 User s Manual v

8 Contents Transport System Operation Power-up Normal Running Safe Shut-down Maintenance Overview Preventive Maintenance Wear Surface Maintenance Cleaning Cable Connection Inspection Hardware Inspection Cleaning Magnet Arrays Transfer Log Files Troubleshooting Initial Troubleshooting Power Related Troubleshooting Node Controller Troubleshooting Communications Troubleshooting Motion Control Troubleshooting Light Stack Troubleshooting Contact MagneMotion Technical Support Repair Replacing Motors Remove the Existing Motor Install the New Motor Programming Motors Separating Magnet Arrays Ordering Parts Shipping Packing Procedure Shipping Components Appendix Overview...A-1 Data for Transport System Design Calculations...A-2 Thrust Force Data...A-3 Attractive Force Data...A-7 Determining Thrust Force...A-11 Determining Attractive Force...A-11 File Maintenance...A-13 Backup Files...A-13 Creating Backup Files...A-13 Restoring from Backup Files...A-13 Additional Documentation...A-14 Release Notes...A-14 vi Rev. D

9 Contents Upgrade Procedure...A-14 Transport System Limits...A-15 Glossary... G-1 Index...I-1 QuickStick 100 User s Manual vii

10 Contents This page intentionally left blank. viii Rev. D

11 Figures 1-1 Detailed View of QuickStick 100 Transport System Components Simplified View of the QuickStick 100 Transport System Components Simplified View of Transport System Software Relationships Locations of Hazardous Points on the QuickStick 100 Transport System Locations of Labels on the QuickStick 100 Motors Locations of Labels on the QuickStick 100 Standard Magnet Arrays Locations of Labels on the QuickStick 100 High Flux Magnet Arrays Locations of Labels on the NC-12 Node Controller Locations of Labels on the Node Controller LITE Locations of Labels on the QuickStick 100 Power Supply Sample QS 100 Transport System Layout Showing Motors Sample QS 100 Transport System Layout Showing Paths Sample QS 100 Transport System Layout Showing Nodes Sample QS 100 Transport System Layout Showing Node Controllers Sample QS 100 Transport System Layout Showing Additional Connections Available Thrust Examples Motor Gaps Motors on Curves System Wiring Block Diagram Standard Magnet Array, 5 Cycles, 11 Poles High Flux Magnet Array, 5 Cycles, 11 Poles Typical Vehicle on Guideway Magnet Array to Motor Alignment Single Array Vehicle Configuration Dual Array Vehicle Configuration Vehicle Gap QuickStick 100 Transport System, Guideway Detail Motor Mounting to Flat Surface Motor Mounting Using Brackets Guideway Example # Guideway Example # Guideway Example # Straight Track Configuration Curve Track Configuration Switch Configuration QuickStick 100 User s Manual ix

12 Figures 3-26 Shuttle Configuration Moving Path Configuration Millimeter Motor Mechanical Drawing Millimeter Motor Mechanical Drawing Standard F Magnet Array Mechanical Drawing High Flux E Magnet Array Mechanical Drawing NC-12 Node Controller Mechanical Drawing Rack Mounting Bracket Mechanical Drawing Node Controller LITE Mechanical Drawing Electronics Mounting Plate Mechanical Drawing QS 100 Power Supply Mechanical Drawing Motor Electrical Connections Motor Power Drop Cable NC-12 Node Controller Electrical Connections and Indicators Node Controller LITE Electrical Connections QS 100 Power Supply Electrical Connections QS 100 Power Supply Control and Monitoring Cable RS-422 Cables Digital I/O Equivalent Circuits NC-12 Node Controller Mounting Plates NC-12 Node Controller Mounting Brackets Node Controller LITE Mounting Simplified Representation of Motor Connections Simplified Representation of Motor Connections in a Merge Switch Communications Connections Digital I/O Connections Power Connections Network Cable Connections Linear Synchronous Motor Derived From Rotary Motor Representation of Stationary Vehicles Per Motor Block Representation of Moving Vehicles Per Motor Block Vehicle Movement Profile Individual Block Current vs. Internal Propulsion Bus Voltage Power Dissipation Per Block vs. Internal Propulsion Bus Voltage Power Dissipation by 10 Ohm Resistor vs. Internal Propulsion Bus Voltage The Graphics Window Transport System Wiring Diagram with Synchronization E-Stop Wiring Diagram, Single Node Controller E-Stop Wiring Diagram, Multiple Node Controllers Interlock Wiring Diagram Light Stack Wiring Diagram A-1 Thrust Force vs. Magnet Array Cycles, Standard Magnet Array...A-4 A-2 Thrust Force vs. Vehicle Gap, Standard Magnet Array...A-4 x Rev. D

13 Figures A-3 Thrust Force Data Curves, High Flux Magnet Array...A-6 A-4 Attractive Force Data Curves, Standard Magnet Array...A-8 A-5 Attractive Force Data Curves, High Flux Magnet Array...A-10 QuickStick 100 User s Manual xi

14 Figures This page intentionally left blank. xii Rev. D

15 Tables 2-1 Regulatory Information Hazard Alert Symbol Identification Mandatory Action Symbol Identification Prohibited Action Symbol Identification Labels Used on the QuickStick 100 Motors Labels Used on the QuickStick 100 Standard Magnet Arrays Labels Used on the QuickStick 100 High Flux Magnet Arrays Labels Used on the NC-12 Node Controller Labels Used on the Node Controller LITE Labels Used on the QuickStick 100 Power Supply Motor Assignments Motor Blocks Thrust and Attractive Force, Standard Magnet Array Standard Magnet Array Weights QuickStick 100 Motor Power Requirements Motor Connections RS-422 Pinouts Power Connector Pinout Sync Connector Pinout Motor Power Drop Cable Pinouts NC-12 Node Controller Connections NC-12 Node Controller Indicators NC-12 Node Controller Console Pinout NC-12 Node Controller Ethernet Pinout NC-12 Node Controller RS-232 Pinouts NC-12 Node Controller RS-422 Pinouts NC-12 Node Controller Power Pinout Node Controller LITE Connections Node Controller LITE Power Pinout Node Controller LITE LAN Pinout Node Controller LITE Console Pinout Node Controller LITE RS-422 Pinouts QS 100 Power Supply Connections QS 100 Power Supply Indicators (per PS Module) QS 100 Power Supply DC Power Pinout QuickStick 100 User s Manual xiii

16 Tables 4-23 QS 100 Power Supply Control and Monitoring Pinout QS 100 Power Supply Control and Monitoring Cable Pinouts RS-422 Cable Pinouts Packing Checklist Reference Startup Indicators Propulsion Voltage Range Simulated Operation Differences QuickStick 100 Transport System Preventive Maintenance Schedule Initial Troubleshooting Power Related Troubleshooting Node Controller Related Troubleshooting Communications Related Troubleshooting Motion Control Related Troubleshooting Light Stack Related Troubleshooting QuickStick 100 Transport System Repair Procedures A-1 Thrust Force Data, Standard Magnet Array...A-3 A-2 Thrust Force Data, High Flux Magnet Array...A-5 A-3 Attractive Force Data, Standard Magnet Array...A-7 A-4 Attractive Force Data, High Flux Magnet Array...A-9 A-5 MagneMotion Transport System Limits...A-15 A-6 MagneMotion Transport System Motion Limits...A-15 xiv Rev. D

17 Changes Overview Changes may be made to this manual to ensure that it continues to provide the most complete documentation possible for the QuickStick transport system. This section provides a brief description of each change. NOTE: Distribution of this manual and all addendums and attachments is not controlled. Changes may have been made at any time. To identify the current revision, contact MagneMotion Customer Support. Rev. A Initial release. Rev. B Added UL Registered Component, EU RoHS and EU WEEE Compliance, and Symbol Identification information. Added information on the QS 100 Power Supply. Added Wear Surface Maintenance, Replacing Motors, and Programming Motors procedures. Added information about File Maintenance. Updated all figures to QS 100 only. Updated product specifications. Updated software descriptions and figures. Updated Safety Considerations and Recycling and Disposal Information. Updated the Transport System Layout, Transport System Design, and Transport System Configuration sections to focus on QS 100. Update pinouts of RS-422 Cables. Updated Digital I/O Equivalent Circuits. Updated the Check-out and Power-up and System Testing procedures. Updated the Theory of Operation, to include more details on Motor Topology and Block Acquisition. Updated the tables and charts for Thrust Force Data and Attractive Force Data. Updated the Transport System Limits information. Updated the Glossary. Removed all references to QuickStick High Thrust, which has a separate manual ( ). Removed all references to the Standard Node Controller, which has been replaced by the NC-12 Node Controller. Support for the Standard Node Controller including software, spare parts, technical support, and service continues to be available. Removed refer- QuickStick 100 User s Manual xv

18 Changes Overview ences to unsupported Node types (Turntable and Host Switch). Removed unused RS-232 communications support. Rev. C Added Handling Magnet Arrays to Safety. Added Motor Cogging, Electrical Wiring, and Magnet Array Use to the Transport System Design section. Added exposed materials identification to the Mechanical Specifications. Added the operating voltage range for the motors and a note about the PTC (positive temperature coefficient) resistor used in the motors to the Electrical Specifications. Added rack mounting for the NC-12 to Mounting NC-12 Node Controllers. Added cable sizing and grounding to Installing Motor Power Cables. Added descriptions of Motor Cogging, Safe Stopping Distance Movement, Moving Vehicles by Hand, and the Electrical System to the Theory of Operation section. Added Transport System Simulation to the Operation chapter. Added Cleaning Magnet Arrays to the Preventive Maintenance section. Added Light Stack Troubleshooting. Added Separating Magnet Arrays to the Repair section. Clarified description of Gateway Node. Moved the Magnet Array Types information from Specifications and Site Requirements to Design Guidelines. Corrected motor thrust per magnet array cycle to 15.9 N at 4.0 A stator current. Updated figures to show the static brush used for grounding vehicles. Changed the Power Connector Pinout to reflect proper use. Updated the Motor Power Cable to the current cable design. Corrected the NC-12 Node Controller input power to VDC. Updated the Digital I/O Connection description. Updated Magnet Array Installation. Corrected the temperature range for the magnet arrays. Moved Quick- Stick 100 Transport System Advantages forward in the Theory of Operation. Updated the descriptions of In Queue and Vehicle Length Through Curves and Switches. Updated all troubleshooting tables. Updated the Data for Transport System Design Calculations. Corrected the thrust spec in the Transport System Limits. Removed HLC VM Slaves per Master reference from the Transport System Limits. Rev. D Added information about Overtravel and Moving Path Nodes. Added description of Magnet Array Use. Updated Simplified View of Transport System Software Relationships. Corrected Locations of Labels on the QuickStick 100 High Flux Magnet Arrays. Corrected description of Ground for NC LITE and SYNC IT modules. Moved figure from Transport System Design Overview to Guideway Design. Updated the Site Requirementsto show the environmental requirements for each component. Updated Thrust equations to provide results in both N and Lb. Updated QSHT velocity in the Transport System Limits. Removed references to Merge and Diverge Nodes from Configuring a Simulation. xvi Rev. D

19 About This Manual Overview This section provides information about the use of this manual, including the manual structure, related documentation, format conventions, and safety conventions. Purpose This manual explains how to install, operate, and maintain the MagneMotion QuickStick 100 (QS 100) transport system. This manual also provides basic troubleshooting information. Use this manual in combination with the other manuals and documentation that accompanies the transport system and with the training classes offered by to design, install, configure, test, and operate a QS 100 transport system. Audience This manual is intended for all users of QuickStick 100 (QS 100) transport systems and provides information on how to install, configure, and operate the QS 100 transport system. Prerequisites This manual assumes a basic familiarity with personal computers and with the Windows operating system. This manual also assumes that the personnel installing and operating the QuickStick 100 transport system have been properly trained on QuickStick 100 transport system installation and operation. QuickStick 100 User s Manual xvii

20 About This Manual MagneMotion Documentation MagneMotion Documentation The documentation provided with the QuickStick 100 transport system includes this manual, which provides complete documentation for the installation, operation, and use of the QS 100 components as a transport system. Other manuals in the document set, listed in the Related Documentation section, support configuration and operation of the transport system. 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 installation, cannot assume responsibility or liability for actual use based on these examples. Manual Conventions Dialog Box A window that solicits a user response. Click or Left-click Press and release the left mouse button 1. Right-click Press and release the right mouse button. Double-click Press and release the left mouse button twice in quick succession. Control-click Hold down <Ctrl> and press and release the left mouse button. Click-and-hold Press down the left mouse button and hold it down while moving the mouse. Select Highlight a menu item with the mouse or the tab or arrow keys. Selectable menu choices, option titles (button, check box, and text box), function titles, and area or field titles in dialog boxes are shown in bold type and are capitalized exactly as they appear in the software. Examples: Add to End..., Paths, Path Details, OK. Dialog box titles or headers are shown in bold type, capitalized exactly as they appear in the software. Example: the Open XML Configuration File dialog box. Keyboard keys and key combinations (pressing more than one key at a time) are shown enclosed in angle brackets. Examples: <F2>, <Enter>, <Ctrl>, <Ctrl-x>. Responses to user actions are shown in italics. Example: Motion on all specified Paths is enabled. Data Entry There are several conventions for data entry: Exact The text is shown in quotes. Example: Enter the name Origin in the text field. Variable The text is shown in italics. Example: Save the file as file_ name.xml. Code Samples Shown in monospaced text. Example: Paths. 1. Mouse usage terms assumes typical right-hand mouse configuration. xviii Rev. D

21 About This Manual MagneMotion Documentation Numbers All numbers are assumed to be decimal unless otherwise noted and use US number formatting (i.e., one thousand = 1,000.00). Non-decimal numbers (binary or hexadecimal) are explicitly stated. Binary Followed by 2, e.g., , Hex Followed by 16, e.g., C15 16, FFFF 16. Note that hexadecimal numbers displayed in the software are preceded by 0x, e.g., 0xC15, 0xFFFF. Measurements All measurements are SI (International System of Units). The format for dual dimensions is SI_units [English_units]; e.g., 250 mm [9.8 in]. Text in blue is a hyperlink. These links are active when viewing the manual as a PDF. Selecting a hyperlink changes the manual view to the page of the item referenced. Note that in some cases the item referenced is on the same page, so no change in the view will occur. Notes, Safety Notices, and Symbols Notes Notes, Safety Notices, and Symbols used within this manual have very specific meanings and formats. Examples of notes and the different types of safety notices and their general meanings are provided below. Adhere to all safety notices provided throughout this manual to ensure safe installation and use. Notes are set apart from other text and provide additional or explanatory information. The text for Notes is in standard type as shown below. NOTE: A note provides additional or explanatory information. Safety Notices Safety Notices are set apart from other text. The color of the panel at the top of the notice and the text in the panel indicates the severity of the hazard, the symbol on the left of the notice identifies the type of hazard (refer to Symbol Identification on page 2-7 for symbol descriptions), and the text in the message panel identifies the hazard, methods to avoid the hazard, and the consequences of not avoiding the hazard. 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. QuickStick 100 User s Manual xix

22 About This Manual MagneMotion Documentation WARNING Warning indicates a hazardous situation which, if not avoided, could result in death or serious injury. CAUTION Caution indicates a hazardous situation, which if not avoided, could result in minor or moderate injury. NOTICE Notice indicates practices not related to personal injury that could result in equipment or property damage. Manual Structure This manual contains the following chapters: Introduction: Provides an overview of the QuickStick 100 components and their use in a transport system. The QuickStick 100 motors are used to provide fast, precise movement, positioning, and tracking of loads up to 100 kg [220 lb]. Safety: Identifies safety concerns and requirements for the QuickStick 100 components and the personnel operating and servicing the QuickStick 100 motors and the transport system where they are installed. Design Guidelines: Provides guidelines for designing a QuickStick 100 transport system. Specifications and Site Requirements: Provides specifications and the requirements for installation of the QuickStick 100 components as a transport system. Installation: Provides complete installation procedures for the QS 100 components. Operation: Provides complete operation directions for the QS 100 components as part of a transport system. Maintenance: Provides maintenance schedules and procedures for the QuickStick 100 components. Appendix: Provides additional information related to QuickStick 100 transport systems. xx Rev. D

23 About This Manual Contact Information Glossary: A list of terms and definitions used in this manual and for the transport system and its components. Index: A cross-reference to this manual organized by subject. Related Documentation Before configuring or running the QuickStick 100 components, consult the following documentation: QuickStick Configurator User s Manual, Node Controller Interface User s Manual, NCHost TCP Interface Utility User s Manual, Host Controller TCP/IP Communication Protocol User s Manual, Host Controller EtherNet/IP Communication Protocol User s Manual, or Mitsubishi PLC TCP/IP Library User s Manual, QuickStick 100 User s Manual, (this manual). LSM Synchronization Option User s Manual, Virtual Scope Utility User s Manual, 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 QuickStick 100 document set at any time. To identify the current revisions or to obtain a current set of documents, contact MagneMotion Customer Support. Contact Information Main Office 139 Barnum Road Devens, MA USA Phone: Fax: Customer Support customersupport@magnemotion.com QuickStick 100 User s Manual xxi

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25 Introduction 1 Overview This chapter provides an overview of the QuickStick 100 (QS 100) component hardware and software, and the basic set of tasks needed to install and use the QS 100 motors in a transport system. Use this manual to install, test, and debug the QuickStick 100 components in a transport system. Note that some procedures may vary based on the transport system configuration, communications, and other variables. This manual supports: QuickStick 100 transport systems. Included in this chapter are overviews of: The QuickStick 100 components in a transport system. The transport system components. The transport system software. Getting started with the QuickStick 100 transport system. QuickStick 100 User s Manual 1-1

26 Introduction QuickStick 100 Transport System Overview QuickStick 100 Transport System Overview The QuickStick 100 (QS 100) is an intelligent transport system specifically developed for fast, precise movement, positioning, and tracking of loads in a transport system. The QS 100 transport system is a configuration of linear synchronous motors and related control electronics that move independently commanded material carriers (vehicles) in a controlled manner at various acceleration/deceleration and velocity profiles while carrying a wide range of payloads with high precision. The QS 100 transport system consists of the following components: QuickStick 100 motors. User-designed and supplied vehicles with QuickStick 100 Magnet Arrays. Node Controllers. Power Supplies. Paths and Nodes. User-supplied Host Controller. User-designed and supplied track system. Using MagneMotion s proven linear synchronous motor (LSM) and control technology, QuickStick 100 transport systems offer a superior alternative to conventional belt and chain conveyors for OEM/in-machine applications and for demanding product conveyance requirements. QuickStick 100 motors provide repeatable positioning with no hard stops required, bidirectional travel, smooth motion, and continuous vehicle tracking and reporting. Motor, drive, controller, positioning, and guidance built into the motor. Servo repeatability at any position: ± 0.5 mm [0.02 in.] (dependent on the size of the gap between the motor and the vehicle-mounted magnet array and may vary based on guideway and vehicle design/structure, not applicable over the gaps between motors). Vehicles are controlled individually allowing the Host Controller to prioritize the routing of individual vehicles over different Paths. Motion is provided through the use of user-designed vehicles with magnet arrays attached to the surface closest to the motor. Up to five (5) vehicles in queue or in motion per meter 1 (150 mm [5.9 in] vehicle length) with speeds up to 2.5 m/s [5.6 mph] and acceleration up to 9.8 m/s 2 [1.0g]. QuickStick 100 motors are capable of moving payloads up to 100 kg [220 lb] (the vehicle and track system must be designed to support the load). Minimum magnet array length is 150 mm [5.9 in]. Configuration and simulation software tools simplify transport system design and optimization. 1. Maximum number of vehicles per meter is determined using the shortest magnet array allowed on a straight guideway. Using a longer magnet array or a curved guideway will decrease the number of vehicles allowed per meter Rev. D

27 Introduction QuickStick 100 Transport System Overview Versions designed for use in cleanrooms and IP54 environments (motors and magnet arrays only). Less wear and tear no belts, chains, gears, or external sensors required few moving parts means less maintenance. Standard industrial communication protocols, PC or PLC controlled, and software configured move profiles (PID control loop) for fast and easy changeovers to new configurations. Standard motor and configuration elements provide plug-and-play capability and make it easy to implement layout changes. QS 100 Transport System Components Guideway Vehicle Magnet Array Motor Motor Mount Track System Figure 1-1: Detailed View of QuickStick 100 Transport System Components Track System The components that physically support and move vehicles, this includes the support structure, the guideway, one or more QuickStick 100 motors, and mounting hardware. Guideway Used to ensure the vehicles are maintained in the proper relationship to the motors. Straight and Curve Motors placed end-to-end to provide a continuous Path of motion. Switch (not shown) Three motors configured to provide either a merge of two Paths into one or a diverge from one Path into two. Motor The QuickStick 100 linear synchronous motor (LSM). Motor Mount Used to mount the motor to the guideway. Vehicle with Magnet Array Carries the user s payload through the QS 100 transport system as directed. The motors interact with the magnet array mounted to each vehicle, moving the vehicles as required. QuickStick 100 User s Manual 1-3

28 Introduction Transport System Components Overview Transport System Components Overview This section identifies the components of a QuickStick 100 transport system as shown in Figure 1-2 and described after the figure. DC Power Cables Motors Vehicles Power Supply Host Controller (PLC or PC) Network (Ethernet) Communication Cables Figure 1-2: Simplified View of the QuickStick 100 Transport System Components DC Power Cables and Communication Cables Distributes DC power to the motors of the transport system and carries communications between the components. High Level Controller (HLC) Software application running on one Node Controller that handles all communication with the user-supplied Host Controller and directs communication as appropriate to individual Node Controllers. Host Controller Provides user control and monitoring of the QuickStick 100 transport system. Supplied by the user, it can be either PC-based or a PLC. Motor Refers to the QuickStick 100 linear synchronous motor (LSM). Network Ethernet network providing communications (TCP/IP or EtherNet/IP) between the Host Controller and the HLC (TCP/IP is used between Node Controllers). Node Controller (NC) Coordinates motor operations and communicates with the High Level Controller. Two types of Node Controllers are available: NC-12 Node Controller (not shown) Provides one network port, two RS-232 ports, 12 RS-422 ports, 16 digital inputs, and 16 digital outputs. Node Controller LITE Provides one network port and four RS-422 ports. Power Supply Provides DC power to the motors. Node Controller (and High Level Controller) Vehicle with Magnet Array Carries a payload through the QS 100 transport system as directed. The magnet array is mounted to the vehicle and interacts with the motors, which move each vehicle independently Rev. D

29 Introduction Transport System Software Overview Transport System Software Overview Several software applications are used to configure, test, and administer a QuickStick 100 transport system as shown in Figure 1-3 and described after the figure. Refer to Related Documentation on page xxi for the reference manuals for these applications. User s Host Controller (EtherNet/IP or TCP/IP) Node Controller (Web and Console Interfaces) Virtual Scope Utility NCHost TCP Interface Utility (NCHost.exe) System Control Node Controller Administration Performance Monitoring System Testing Node Controller Node Controller Software Image (controller_image) Motor Image Files (motor_image.erf) Motor Type Files (motor_type.xml) Magnet Array Type File (magnet_array_type.xml) Node Controller Configuration File (node_configuration.xml) demo_script.txt track_file.mmtrk node_configuration.xml Motor MagneMotion Configurator (MMConfigTool.exe) Figure 1-3: Simplified View of Transport System Software Relationships Node Controller Web Interface A web-based software application supplied by MagneMotion, resident on the Node Controllers, for administration of the parts of the transport system. Node Controller Console Interface A serial communication software application supplied by MagneMotion, resident on the Node Controllers, for administration of the Node Controller. NCHost TCP Interface Utility A Windows software application supplied by MagneMotion to move vehicles for test or demonstration purposes without the Host Controller to verify that vehicles move correctly before integrating a transport system into a production environment. MagneMotion QS Configurator (Configurator) A Windows software application supplied by MagneMotion to create or change the Node Controller Configuration File without editing the file directly. QuickStick 100 User s Manual 1-5

30 Introduction Transport System Software Overview Virtual Scope A Windows software application supplied by MagneMotion to monitor and record the change of performance parameters displayed as waveforms to analyze the performance of the transport system. Demonstration Script (Demo Script) A text file (demo_script.txt) uploaded to the NCHost TCP Interface Utility to move vehicles on the transport system for test or demonstration purposes. Node Controller Image File (IMG file) The software files for the Node Controllers (controller_image), includes the Node Controller and High Level Controller applications. The Node Controller Image File is uploaded to all Node Controllers in the transport system. Motor Image Files (ERF file) The software files for the motors (motor_image.erf). The Motor Image Files are uploaded to all Node Controllers in the transport system and then programmed into all motors. Motor Type Files XML files (motor_type.xml) that contain basic information about the specific QuickStick 100 motor types being used. The Motor Type Files are uploaded to all Node Controllers in the transport system. Magnet Array Type Files XML files (magnet_array_type.xml) that contain basic information about the specific MagneMotion magnet array type used on the vehicles in the QuickStick 100 transport system. The Magnet Array Type File is uploaded to all Node Controllers in the transport system. Node Controller Configuration File (Configuration File) An XML file (node_configuration.xml) that contains all of the parameters for the components in the transport system. The Node Controller Configuration File is uploaded to all Node Controllers in the transport system. Track File A text file (track_file.mmtrk) that contains graphical path and motor information about the transport system. The Track File is used by the NCHost TCP Interface Utility to provide a graphical representation of the transport system. Contact MagneMotion Customer Support for the development of a Track File for QuickStick 100 transport systems. NOTICE Modifying the Image or Type files could cause improper operation of the transport system Rev. D

31 Getting Started with the QuickStick 100 System Introduction Getting Started with the QuickStick 100 System Use this manual as a guide and reference when installing the QuickStick 100 motors in a transport system. Follow the steps in this section to get the entire transport system operational quickly with the aid of the other MagneMotion manuals (refer to Related Documentation on page xxi). NOTE: Ensure that all components and complete design specifications, including the physical layout of the transport system, are available before starting to install or test the QS 100 transport system s operation. To get started quickly with the transport system: 1. Save the files and folders from the MagneMotion System Software that came with the QuickStick 100 transport system to a folder on a computer for user access. NOTE: The minimum computer requirements for running MagneMotion software applications are a PC running either Windows XP or Windows 7 with.net 4.0 and an Ethernet port. 2. Install the components of the QS 100 transport system as described in the following sections of this manual: A. Prepare the facility for the installation: Safety Considerations on page 2-4. Design Guidelines on page 3-1. Site Requirements on page B. Prepare the components for installation and install: Unpacking and Inspection on page 5-2. Transport System Installation on page Install the MagneMotion Configurator on a computer for user access (refer to Software Configuration on page 5-26 and the QuickStick Configurator User s Manual). A. Create the Node Controller Configuration File (node_configuration.xml) to define the components and operating parameters of the transport system. 4. Verify the installation is complete and the system is ready for use: System Check-out on page System Power-up on page Set the Node Controller IP addresses, specify the Node Controller to be used as the High Level Controller, and upload the configuration, image, and type files to each Node Controller (refer to Node Controller Software Installation on page 5-27 and the Node Controller Interface User s Manual). QuickStick 100 User s Manual 1-7

32 Introduction Getting Started with the QuickStick 100 System 6. Program the motors using the Motor Image Files (refer to Motor Software Installation on page 5-27 and the Node Controller Interface User s Manual and the NCHost TCP Interface Utility User s Manual). 7. Test and debug the transport system by using the NCHost TCP Interface Utility and Demo Scripts (refer to Check-out and Power-up on page 5-28 and the NCHost TCP Interface Utility User s Manual). This provides an easy method to verify proper operation and make adjustments such as refining the control loop tuning. NOTE: The NCHost TCP Interface Utility is for test and verification trials only. The user s Host Controller must be used to control the QS 100 transport system after verification of functionality. 8. Configure the Host Controller (either PC or PLC based) to control the QS 100 transport system as required to meet the material movement needs of the facility where the system is installed (refer to either the Host Controller TCP/IP Communication Protocol User s Manual, the Host Controller EtherNet/IP Communication Protocol User s Manual, or the Mitsubishi PLC TCP/IP Library User s Manual). Refer to: Transport System Operation on page Safe Shut-down on page Rev. D

33 Safety 2 Overview This chapter describes safety guidelines for the QuickStick 100 components and their use in a transport system. All personnel involved in the operation or maintenance of the QS 100 components and the transport system must be familiar with the safety precautions outlined in this chapter. NOTE: These safety recommendations are basic guidelines. If the facility where the Quick- Stick 100 components are installed in a transport system has additional safety guidelines they should be followed as well, along with the applicable local and national safety codes. If any additional safety-related upgrades or newly identified hazards associated with the QuickStick 100 components are identified, the Technical Support group will notify the owner of record. Included in this chapter are: 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. QuickStick 100 User s Manual 2-1

34 Safety Regulatory Compliance Regulatory Compliance The QuickStick 100 components are CE compliant. To determine if a specific component is CE compliant, check for the CE mark on the component. If necessary, request the official Declaration of Conformity (DoC) from MagneMotion. The QuickStick 100 components are UL Recognized in Canada and the United States. To determine if a specific component is UL Recognized, check for the UL Recognized Mark on the component. Note that some examples of the Mark may not display the C and US. In addition to this section, other sections may include regulatory information. These components comply with the regulations from the organizations indicated in Table 2-1. Table 2-1: Regulatory Information Organization Regulation(s) CE (Conformité Européenne) The European safety requirements UL Machinery Directive Low Voltage Directive EMC Directive NOTE: It is the responsibility of the end user/third party integrator to ensure the compliance of the installed QuickStick 100 transport system with the appropriate facility, local, and national regulations. 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. However, MagneMotion has taken voluntary steps to ensure its products comply with the requirements of EU RoHS. Equipment Regulatory Guidelines The following regulatory guidelines are provided to aid in the use and service of the Quick- Stick 100 components in a transport system. MagneMotion Technical Support will issue a Technical Advisory to notify the owners of record of any field retrofits Rev. D

35 Safety Regulatory Compliance Contact MagneMotion Customer Support for information regarding repair and maintenance service policies, both during the production of the QuickStick 100 components and after production is discontinued. Any user-caused damage during integration of the QuickStick 100 components into their equipment is the user s responsibility. MagneMotion s responsibility for work performed by MagneMotion authorized technicians or for equipment transported or resold by the owner of record is determined on a case-by-case basis by MagneMotion Technical Support. Any parts being returned to MagneMotion should be packaged according to the instructions provided in the Packing Procedure on page MagneMotion provides training for the QuickStick 100 components as integrated into a transport system. Only qualified, properly trained personnel should perform any procedures on the QS 100 components. Damage resulting from improperly performing a procedure or not following cautions is not covered under warranty or service agreements. QuickStick 100 User s Manual 2-3

36 Safety Safety Considerations Safety Considerations Personnel Safety Guidelines QuickStick 100 components and transport systems may provide several direct safety hazards to personnel if not properly installed or operated. General safety guidelines are provided below, specific cautions are provided as needed (refer to Mechanical Hazards on page 2-15, Electrical Hazards on page 2-16, and Magnetic Hazards on page 2-17). Personnel operating or servicing the QuickStick 100 transport system should be properly trained. Be aware of the hazardous points of the QuickStick 100 transport system as described in this chapter. High strength Neodymium Iron Boron magnets are used with the QuickStick 100 motors. To avoid severe injury, people with pacemakers and other medical electronic implants must not handle or approach the magnet arrays. These individuals must consult their physician to determine their device s susceptibility to static magnetic fields and to determine a safe distance between themselves and the magnet array. Handle only one vehicle/magnet array at a time. Do not place any body parts, such as fingers, between the magnet array being handled and any QuickStick 100 motors, ferrous material, or another magnet array to avoid injury from strong magnetic attractive forces. Vehicles and magnet arrays not on the QuickStick 100 transport system should be secured individually in isolated packaging. Moving mechanisms have no obstruction sensors and can cause personal injury. Know the location of the following: Fire extinguisher. First Aid Station. Emergency eyewash and/or shower. Emergency exit. The following safety equipment, used according to the manufacturer s instructions, should be donned prior to installing, testing, or servicing the QuickStick 100 transport system: Eye protection Breaking material may produce flying shards. When running a setup or test procedure, protective eye wear must be worn at all times to guard against possible eye injuries Rev. D

37 Safety Safety Considerations Safety Shoes Shoes with protective toes should be worn to protect feet from dropping tools or parts. Observe the facility guidelines pertaining to loose clothing while working around or operating the QuickStick 100 transport system. It may be recommended that the use of hazardous materials, such as cleaning fluids, be used during routine maintenance procedures. Read and understand the facility s hazardous materials policies and the MSDS (provided by the manufacturer) for each substance. Whenever power is applied, the possibility of automatic movement of the vehicles or user-supplied equipment in the QuickStick 100 transport system exists. It is the user s responsibility to provide appropriate safeguards. Ensure propulsion power is disabled when performing maintenance on the vehicles, track system, or motors. Ensure the QuickStick 100 motors and related components are properly decontaminated before performing any service following the facilities decontamination procedures. Follow all facility, local, and national procedures for the disposal of any hazardous materials. Ergonomic hazards may exist with certain installation or service operations pertaining to the QuickStick 100 transport system. Equipment Safety Guidelines The following safety considerations are provided to aid in the placement and use of the Quick- Stick 100 transport system. If hazardous materials are to be present, users must observe the proper safety precautions and ensure that the material used is compatible with those from which the Quick- Stick 100 components are fabricated. Determine if the QuickStick 100 transport system will be employed in an earthquake prone environment and install the equipment accordingly. The QuickStick 100 components are not provided with an Emergency Off (EMO) circuit. The user is responsible for an EMO circuit (refer to E-Stops on page 6-19 for more information). Do not place the QuickStick 100 transport system s connections (power and communications cables) where they could cause a trip hazard. Do not place the QuickStick 100 transport system in a location where it may be subject to physical damage. Ensure that all electrical connections to the QuickStick 100 components are made in accordance with the appropriate facility, local, and national regulations. Ensure that the QuickStick 100 components receive proper air flow for cooling. QuickStick 100 User s Manual 2-5

38 Safety Safety Considerations Do not remove safety labels or equipment identification labels. Turn OFF power before inserting or removing power cables. Use of the QuickStick 100 components for any purpose other than as a linear transport system is not recommended and may cause damage to the QuickStick 100 components or the equipment they are connected to. Always operate the QuickStick 100 transport system with appropriate barriers in place to prevent contact with moving objects by personnel. Do not install or operate the QuickStick 100 transport system if any of the components have been dropped, damaged, or are malfunctioning. Keep cables and connectors away from heated surfaces. Do not modify the connectors or ports. QuickStick 100 Transport System Hazard Locations Guideway (typical, user-defined) Mechanical Hazard - Pinch Point Switch (typical, user-defined) Mechanical Hazard - Pinch Point Vehicle (typical, user-defined) Mechanical Hazard - Pinch Point Magnetic Field Hazard Figure 2-1: Locations of Hazardous Points on the QuickStick 100 Transport System Rev. D

39 Safety Symbol Identification Symbol Identification Symbols are used in this manual and on the MagneMotion products to identify hazards, mandatory actions, and prohibited actions. The symbols used in this manual and their descriptions are provided below. Table 2-2: Hazard Alert Symbol Identification Symbol Description General Hazard Alert Indicates that failure to follow recommended procedures can result in unsafe conditions, which may cause injury or equipment damage. kg Lifting Hazard Indicates the specified object is heavy or awkward to handle. Personnel should use lifting aids and proper lifting techniques to avoid muscle strain or back injury. Automatic Start Hazard Indicates the possibility of machinery automatically starting or moving, which could cause personal injury. Hazardous Voltage Indicates a severe shock hazard is present that could cause personal injury. Magnetic Field Hazard Indicates a strong magnetic field is present that could cause personal injury. Pinch Point Hazard Indicates that there are exposed moving parts that could cause personal injury from the squeezing or compression of fingers, hands, or other body parts between moving mechanisms. QuickStick 100 User s Manual 2-7

40 Safety Symbol Identification Table 2-3: Mandatory Action Symbol Identification Symbol Description Eye Protection Required Indicates that appropriate eyewear must be worn to prevent injury to eyes from flying shards. Foot Protection Required Indicates that appropriate footwear must be worn to prevent injury to feet from falling objects. Lockout Required Indicates that all power must be disconnected using a method that prevents accidental reconnection.. Table 2-4: Prohibited Action Symbol Identification Symbol Description Magnetic or Electronic Media Prohibited Indicates that magnetic media (memory disks/chips, credit cards, tapes, etc.) is not allowed in the specified area due to the possibility of damage to the media. Metal Parts or Watches Prohibited Indicates that watches, instruments, electronics, metal tools, and metal objects are not allowed in the specified area due to the possibility of damage. 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 Rev. D

41 Safety Label Identification and Location Label Identification and Location Safety labels and identification labels are placed on those QuickStick 100 components that require them to provide operators and service personnel with hazard identification and information about the QS 100 components at the point of use. This section describes each label, identifies its location, and for safety labels gives instructions on how to avoid the hazard. 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 QS 100 components. These labels are used to alert personnel to hazards on or within the QS 100 components and to provide information about the components. The figure after each table shows the location of each label identified in the table. To replace a lost or damaged label, contact MagneMotion and refer to its name. Table 2-5: Labels Used on the QuickStick 100 Motors Product Information Label Qty: 1 Location: On the end of the motor Information Label Figure 2-2: Locations of Labels on the QuickStick 100 Motors QuickStick 100 User s Manual 2-9

42 Safety Label Identification and Location Table 2-6: Labels Used on the QuickStick 100 Standard Magnet Arrays P/N: S/N: ????????? Product Information Label Qty: 1 Location: On the mounting surface of the magnet array Made in USA Magnet Hazard Label Qty: 1 Location: On the mounting surface of the magnet array Hazard Type: Magnetic field Possible injuries: Pinch between magnet arrays, danger to pacemakers and other electronics Mounting Surface P/N: S/N:????????? Made in USA Information Label Magnet Hazard Label Figure 2-3: Locations of Labels on the QuickStick 100 Standard Magnet Arrays Rev. D

43 Safety Label Identification and Location Table 2-7: Labels Used on the QuickStick 100 High Flux Magnet Arrays XX????????? Product Information Label Qty: 1 Location: On the side of the magnet array Magnet Hazard Label Qty: 1 Location: On the side of the magnet array Hazard Type: Magnetic field Possible injuries: Pinch between magnet arrays, danger to pacemakers and other electronics Mounting Surface (Farside) Magnet Hazard Label Information Label Figure 2-4: Locations of Labels on the QuickStick 100 High Flux Magnet Arrays QuickStick 100 User s Manual 2-11

44 Safety Label Identification and Location Table 2-8: Labels Used on the NC-12 Node Controller Product Information Label Qty: 1 Location: On the back of the NC-12 Node Controller S/N:????????? MAC:1A-2B-3C-4D-5E-6F MAC ID Label Qty: 1 Location: On the back of the NC-12 Node Controller TESTED ATE BURN S/N: MAC: 1A-2B-3C-4D-5E-6F Information Label MAC ID Label Figure 2-5: Locations of Labels on the NC-12 Node Controller Rev. D

45 LAN PWR Safety Label Identification and Location Table 2-9: Labels Used on the Node Controller LITE Product Information Label Qty: 1 Location: On the top of the Node Controller LITE S/N:????????? MAC:1A-2B-3C-4D-5E-6F MAC ID Label Qty: 1 Location: On the top of the Node Controller LITE Information Label 18 VDC PoE ONLY MAC ID Label Figure 2-6: Locations of Labels on the Node Controller LITE QuickStick 100 User s Manual 2-13

46 Safety Label Identification and Location Table 2-10: Labels Used on the QuickStick 100 Power Supply P/N: S/N:????????? Power: VAC~, Hz 3600 W Max Product Information Label Qty: 1 Location: On the bottom of the power supply housing Information Label (on bottom) Figure 2-7: Locations of Labels on the QuickStick 100 Power Supply Rev. D

47 Safety Mechanical Hazards Mechanical Hazards The QuickStick 100 transport system is a complex electromechanical system. Only personnel with the proper training should install, operate, or service the QuickStick 100 transport system. All facilities to the QS 100 transport system must be disconnected as outlined in the facility s lockout/tagout procedure before servicing, or injury may result from the automatic operation of the equipment. The proper precautions for operating and servicing remotely controlled electromechanical equipment must be observed. These precautions include wearing safety glasses, safety shoes, and any other precautions specified within the facility where the QS 100 components are being used. WARNING Crush Hazard Moving mechanisms have no obstruction sensors. Do not operate the QuickStick 100 components without barriers in place or personal injury could result in the squeezing or compression of fingers, hands, or other body parts between moving mechanisms. WARNING Automatic Movement Hazard Whenever power is applied, the possibility of automatic movement of the vehicles on the QuickStick 100 transport system exists, which could result in personal injury. kg CAUTION Heavy Lift Hazard Some of the QuickStick 100 components can weigh as much as 13.2 kg [29.1 lb]. Failure to take the proper precautions before moving them could result in personal injury. Use proper lifting techniques when moving any QuickStick 100 components. Steel toe shoes should be worn at all times when working on the QuickStick 100 transport system. QuickStick 100 User s Manual 2-15

48 Safety Electrical Hazards Electrical Hazards The QuickStick 100 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 precautions for operating and servicing electrical equipment must be observed. These precautions include following facility lockout/tagout procedures, and any other specified action within the facility where the QS 100 components are being used. WARNING Electrical Hazard All electrical power to the QuickStick 100 transport system must be disconnected per the facility s lockout/tagout procedure before servicing to prevent the risk of electrical shock. CAUTION Electrical Hazard To avoid electric shock, do not open any QuickStick 100 component. Motors, controllers, and other components do not contain any user-serviceable parts. Do not turn on power to the power supplies, motors, and Node Controllers until after connecting all other transport system components. NOTICE To avoid equipment damage: Ensure the transport system is properly grounded. Ensure all vehicles are grounded to the guideway using conductive wheels or static brushes. Do not connect or disconnect any components while the transport system has power Rev. D

49 Safety Magnetic Hazards Magnetic Hazards The QuickStick 100 transport system uses high strength Neodymium Iron Boron (NdFeB) magnets in the magnet arrays attached to the vehicles. The proper precautions for using high strength magnets must be observed. Strong magnets in use. WARNING Magnetic Field Hazard To avoid severe injury, people with pacemakers and other medical electronic implants must stay away from the magnet arrays. WARNING Crush Hazard Strong magnets in use. To avoid severe injury: Handle only one vehicle or magnet array at a time. Do not place any body parts (e.g., fingers) between a magnet array and any QuickStick 100 motors, ferrous material, or another magnet array to avoid injury from strong magnetic attractive forces. Vehicles and magnet arrays not being used should be secured individually in isolated packaging. Strong magnets in use. NOTICE Magnetic Fields To avoid damage to watches, electronic instruments, and magnetic media (e.g., cell phones, memory disks/chips, credit cards, and tapes) keep these items away from the magnet arrays. QuickStick 100 User s Manual 2-17

50 Safety Magnetic Hazards Handling Magnet Arrays The Neodymium Iron Boron (NdFeB) magnets used in the MMI magnet arrays require special handling. General handling guidelines and cautions are provided below. It is the responsibility of the user to define and implement their own handling guidelines in accordance with the applicable facility, local, and national safety codes for the installation site. Pacemakers and other Medical Implants Individuals with pacemakers or internal medical devices should use caution when handling the magnet arrays as the magnetic fields may affect the operation of these devices. These individuals should consult their physician and the manufacturer of their medical device to determine its susceptibility to static magnetic fields prior to handling the magnet arrays and to determine the safe distance from the arrays, or if they should not handle the arrays. Electronic Equipment Damage Do not allow any magnet arrays near sensitive electronics, equipment with cathode ray tubes (CRTs) or other displays, or magnetic storage media (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 ferromagnetic materials like steel, iron, some stainless steels, and nickel. Pinching will happen if the magnet arrays are allowed to come together against a body part. Do not try to stop moving objects or magnet arrays that have been attracted to each other. Impact Do not strike the magnet arrays as the magnets within them may shatter and break. The magnets within the magnet arrays may spark on impact. Handle carefully in explosive atmospheres. Sharp Fragments The magnet arrays are very strong and unsecured magnet arrays can accelerate toward other magnets, magnet arrays, or ferromagnetic materials. The magnets in the arrays are brittle, and if allowed to collide the magnets in the arrays can shatter and break, possibly sending particles flying at high speed. Debris Accumulation If debris is accumulated, it can get caught between the magnet array and the motor, which will affect system performance and can damage the cover of the motor. Corrosion The magnets in all MagneMotion magnet arrays are protected against corrosion. However, damage (e.g., scratches, chips) to the magnet array or the magnets creates the potential for corrosion. NdFeB rare-earth magnets that have corroded have changed their physical properties. The Safety Data Sheets (SDS) for the component materials (Iron, Neodymium, Boron, Nickel, and Copper) should be consulted prior to the use, handling, or transportation of corroded magnets. Machining Do not drill, grind, machine, or sand the magnets or the magnet arrays. The magnets may shatter and break when drilled or machined. The magnet dust created by machining is hazardous and can be harmful if inhaled or allowed to get into eyes. Drilling, grinding, and machining may produce metal powder which is flammable and can ignite and burn at high intensity creating toxic fumes. Additionally, machining may cause high heat to develop resulting in demagnetization Rev. D

51 Safety 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. Storage Store magnet arrays in appropriate storage or shipping containers (shielded with steel or isolated). Never leave magnet arrays unattended outside the storage containers. If this is unavoidable, the area should be marked with a Magnetic Hazard Sign in accordance with the applicable facility, local, and national safety codes for the installation site. Handling Appropriate handling is required. Handle only one magnet array at a time. If an array is attracted to another object, DO NOT attempt to stop it. MagneMotion recommends wearing gloves and safety glasses when handling the magnet arrays. Inspect the area prior to handling the magnet arrays and ensure it is free of other magnet arrays or ferromagnetic materials. Temperature If the temperature of the magnet arrays gets over approximately 80 C [176 F], the magnets will begin to irreversibly loose field strength. MMI recommends a maximum operating temperature of 50 C [122 F] and a maximum storage and shipping temperature of 60 C [140 F]. Signage Ensure appropriate cautionary signage is in place in all locations where the arrays are located in accordance with the applicable facility, local, and national safety codes for the installation site. Shipping Magnet Arrays Magnet arrays being shipped, for return to MMI or to another facility, must be shipped per U.S. Department of Transportation and The International Air Transport Association (IATA) Dangerous Goods Regulations. QuickStick 100 User s Manual 2-19

52 Safety Recycling and Disposal Information Recycling and Disposal Information The QuickStick 100 transport systems use the following items that may require special handling for disposal or recycling. QuickStick 100 Transport System No hazardous materials, other than those identified below, are used in the QuickStick 100 components. Node Controllers A Lithium battery is located in the Node Controllers to maintain the clock when power is removed. If this battery is being removed or disposed of, it must be handled in the following manner: Follow all facility, local, and national procedures for the disposal of hazardous materials. Magnet Arrays Neodymium Iron Boron (NdFeB) magnets are used in the magnet arrays attached to the user s vehicles as the motor secondary. If these magnets are being removed or replaced, they must be handled in the following manner: Follow all safety procedures for the handling of high strength magnets (refer to Magnetic Hazards). Follow all facility, local, and national procedures for the disposal of hazardous materials. All strong permanent magnets should be demagnetized prior to disposal Rev. D

53 Design Guidelines 3 Overview This chapter provides guidelines for designing a transport system using the QuickStick 100 components. Included in this chapter are: Design guidelines for laying out the QuickStick100 transport system and creating interfaces to the system. Design guidelines for using QuickStick 100 motors and magnet arrays. Guidelines for electrical wiring. Design guidelines for the vehicles and guideways. Guidelines for motor mounting. Guidelines for transport system configuration. QuickStick 100 User s Manual 3-1

54 Design Guidelines Transport System Layout Transport System Layout Before installing a QuickStick 100 transport system, a transport system layout must be created that defines the following: Type and location of all motors and switching mechanisms (all motors provide bidirectional movement). The number of vehicles on the transport system. Locations of all interfaces to other equipment in the facility. All Paths and the direction of forward motion (downstream). All Nodes and the type of the Nodes. All Node Controllers, their type, and connections. Identification of the Node Controller assigned as the High Level Controller (HLC). Additional connections such as motor communications, power, and network. Additional functions such as E-Stop, Interlock, and Light Stack. The transport system layout is used to physically locate the motors and other transport system components in the facility. It is also used as a reference when connecting the components of the transport system and defining the elements of the Node Controller Configuration File (refer to the QuickStick Configurator User s Manual). Refer to Table A-5 on page A-15 for a list of system limits. To use the installed transport system a Host Application must be created that will run on the end-user s Host Controller. This application provides all monitoring and control of the transport system. Transport System Overview The QuickStick 100 components consist of a set of basic building-blocks that provides an easy to assemble and implement transport system. The modular nature of the QS 100 components 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: Motors, Switches, and Vehicles on page 3-3 Paths on page 3-4 Nodes on page 3-5 Node Controllers on page 3-6 Additional Connections on page Rev. D

55 Design Guidelines Transport System Layout Motors, Switches, and Vehicles The transport system layout is a plan view layout of the QS 100 transport system. This drawing identifies each motor and switching mechanism (if required) in the transport system (refer to Figure 3-1), how they are physically located, the space between each motor, and any interfaces to other equipment in the facility. Motors are used to move the vehicles on the transport system. When using multiple motors, they must be installed such that the downstream end of one motor is followed by the upstream end of the next motor in the same Path (refer to Paths on page 3-4). Switches connect multiple Paths and direct the vehicles from one Path on the transport system to another Path. The switch mechanism is defined and supplied by the user. Vehicles are independent platforms designed by the user with integral magnet arrays used on QuickStick 100 transport systems. Each vehicle is independently controlled and provides a platform for securing and carrying the payload in transit. Forward vehicle motion is from upstream to downstream, however vehicles can move backwards (downstream to upstream) if required. The transport system assigns a unique ID to each vehicle at startup, which is retained until the transport system is restarted, the vehicle is removed through a Terminus or Gateway Node, or the vehicle is deleted. Additionally, the transport system ensures vehicles do not collide with each other by implementing anti-collision algorithms. Note that it is not necessary to show the vehicles on the transport system layout. NOTE: It may be useful to show facility features on the drawing mm motor Qty Description mm motor 500 mm Motor (typical) User-supplied Switching Mechanism (typical) Motor Gap (typical) 1000 mm Motor (typical) Figure 3-1: Sample QS 100 Transport System Layout Showing Motors QuickStick 100 User s Manual 3-3

56 Design Guidelines Transport System Layout Paths Once all motors have been identified on the QS 100 transport system layout, the individual Paths must be defined (refer to Figure 3-2). This includes identifying all motors on the Path and the direction of forward (downstream) movement. Paths define the routes for vehicle motion. All Paths include one or more motors arranged end to end. All Paths must begin at a Node and may end at a second Node based on the use of the Path. Paths are unique and do not overlap. Each Path is provided a unique identifier in the Node Controller Configuration File and each motor is identified as belonging to a specific Path and provided a unique identifier in the Configuration File. Paths are controlled by the Node Controller connected to the Path s upstream end. Paths must have a connection to a Node Controller at their downstream end if a vehicle moves off the downstream end of the Path, either onto another Path or onto another type of transport system. Refer to the QuickStick Configurator User s Manual for a detailed description of Paths. Qty Description mm motor mm motor 3 Paths Path 2 Path 1 Path 3 NOTE: Arrows indicate direction of forward motion. Figure 3-2: Sample QS 100 Transport System Layout Showing Paths Table 3-1: Motor Assignments Path Motors mm, mm mm mm, mm Rev. D

57 Design Guidelines Transport System Layout Nodes Once all Paths have been identified on the QS 100 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. Nodes define the beginning of all Paths and the connections between Paths. Refer to the QuickStick Configurator User s Manual for a detailed description of Nodes and all Node types. The Node types supported by the QS 100 transport system include: Simple Node Defines the beginning of a Path (i.e., there is no other Path connecting at this point). Relay Node Connects the end of a Path to the beginning of a Path. Terminus Node Defines the end or beginning of a Path where vehicles move to or from the QuickStick 100 transport system. Gateway Node Connects a Path in one Control Group in a transport system to a Path in another Control Group within the same transport system. Merge Node Connects the ends of two Paths to the beginning of another Path. Diverge Node Connects the end of one Path to the beginning of two other Paths. Shuttle Node Connects the ends of multiple Paths to the beginning of other Paths using a linear indexer constructed of QS 100 motors. Overtravel Node Permits a vehicle to move past the end of the motor at the end of a Path. Moving Path Node Connects the ends of multiple Paths to the beginning of other Paths using a Host-controlled mechanism. NOTE: The connections to the motors at the ends of all Paths meeting in a Node must be made to the same Node Controller. Qty Description mm motor mm motor 3 Paths 2 Nodes 1 Diverge 1 Merge Diverge Path 2 Path 1 Path 3 NOTE: Arrows indicate direction of forward motion. Merge Figure 3-3: Sample QS 100 Transport System Layout Showing Nodes QuickStick 100 User s Manual 3-5

58 Design Guidelines Transport System Layout Node Controllers Once all Paths and Nodes have been identified on the QS 100 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 an NC-12 Node Controller being used). Node Controllers coordinate all motor operations and communicate with the High Level Controller. In all QS 100 transport systems one Node Controller is designated as the High Level Controller (HLC). The HLC manages the communication between all Node Controllers in the transport system and the user s Host Controller. The Node Controller types supported by the QS 100 transport system are: Node Controller LITE (NC LITE) Compact Node Controller with four RS-422 ports. This Node Controller typically supports one Node (e.g., Merge). However, some configurations of Nodes will allow the Node Controller to support multiple Nodes (e.g., Simple and Relay). NC-12 Node Controller Full-size Node Controller with 12 RS-422 ports, two RS-232 ports, 16 Digital Inputs, and 16 Digital Outputs. This Node Controller can support multiple Nodes (e.g., Merge, Diverge, and Relay) and additional functions (e.g., E-Stop, Interlocks). Motor Communications Identifies the communications connections between motors on the same Path. NOTE: All motor connections at a Node must be made to the same Node Controller. Qty Description mm motor mm motor 3 Paths 2 Nodes 1 Diverge 1 Merge 1 Node Controller (NC) NC & HLC Diverge Path 2 Path 1 Path 3 NOTE: Arrows indicate direction of forward motion. Merge Figure 3-4: Sample QS 100 Transport System Layout Showing Node Controllers Rev. D

59 Design Guidelines Transport System Layout Additional Connections The remaining components and connections must be defined on the QuickStick 100 transport system layout. The components include power supplies for the motors and network switches for communication with the Node Controllers and Host Controller (refer to Figure 3-5 for an example). If NC-12 Node Controllers (with Digital I/O) are being used, E-Stop buttons, Interlocks, and Light Stacks can be configured and their locations should be identified. Power Supplies DC power supplies providing +48 VDC are required for powering the QS 100 motors. Refer to Table 4-2 on page 4-12 for power supply sizing. Network Switches Ethernet switches provide signal routing from the Host Controller to the Node Controllers and between Node Controllers. All Node Controllers must be on the same Local Area Network subnet. Host Controller User-supplied controller running the user s application for monitoring and control of the transport system. Power Wiring Identifies the power connections between motors connected to the same power supply. Qty Description Host SW mm motor mm motor NC 3 Paths & HLC 2 Nodes 1 Diverge 1 Merge 1 1 Node Controller (NC) Power Supply (PS1) (48 VDC) Diverge Path 2 Path 1 PS1 Path 3 NOTE: Arrows indicate direction of forward motion. Merge Figure 3-5: Sample QS 100 Transport System Layout Showing Additional Connections QuickStick 100 User s Manual 3-7

60 Design Guidelines Transport System Design Transport System Design Overview This section describes some of the basic considerations for designing a track system for a QuickStick 100 transport system. The track system includes the guideway, the guideway supports, the QS 100 motors, the vehicles with magnet arrays, and the mechanism for mounting the motors to the guideway (refer to Transport System Layout on page 3-2 for layout guidelines). One advantage of the QuickStick 100 system is that it is possible to have vehicles move at different rates of speed in the same direction, or in opposite directions without a collision. The control software ensures that the minimum distance between vehicles when not moving is 3 mm [0.1 in] (refer to Motor Topology on page 6-3). Design Guidelines Use standard engineering practices to reduce torque, vibration, and other stresses on the guideway and other parts of the system. Factors specific to QuickStick 100 transport systems to consider include: Vehicles are not held in place if power is removed. The magnetic attractive force between the magnet array and the QuickStick 100 motors is constant (assuming the Vehicle Gap is maintained) regardless of the power applied to the motors. The Vehicle Gap (distance between magnet array and motor, see Figure 3-16) must be maintained throughout the system. The Downstream Gap (distance between motors, see Figure 3-7) should be as small as possible to ensure there is enough thrust to move the vehicle over the gap. Process stations should not be located where the center of the magnet array would be within the Downstream Gap between motors as settling time and repeatability may be negatively affected. Ensure the track system configuration accounts for power and communication connections and all cables. Ensure the transport system configuration accounts for points for grounding the track to the facility s earth ground and for grounding of all motors. When choosing vehicle and guideway materials, consider the stresses applied to the vehicle and guideway during use. When choosing vehicle and guideway materials, consider those that provide low friction and low wear Rev. D

61 Design Guidelines Transport System Design When choosing vehicle and guideway materials, consider static electricity dissipation between the vehicles and the guideway. The vehicle must remain centered over the motors throughout the system. When choosing wheel materials, consider the life expectancy of the wheel material and the noise level as they move on the guideway (e.g., across the joints in a straight/curved guideway or into a switch). Off-centered and/or large payloads can affect system performance. Motors The QuickStick 100 motors can be mounted in any orientation: right side up, sideways, upside down, and vertically. QS 100 motors have a required direction, with an upstream end and a downstream end (refer to Mechanical Specifications on page 4-2 for identification). The QuickStick 100 motors must always be installed with the upstream end of one motor following the downstream end of the previous motor. Forward vehicle motion using the QS 100 motors is from upstream to downstream, however vehicles can move backwards (downstream to upstream) if required. NOTE: If the motor is mounted on an incline or vertically, the motor will not hold a vehicle in place during startup, restarts, or if power is lost. Before designing a QuickStick 100 transport system, review the following information: Desired throughput. Maximum payload. Total transport length. Transport topography. Move time. Vehicle length. Once these characteristics are known, identify additional requirements: Accommodations for vehicles less than 0.5 meter [19.7 in] in length. Accommodations for track length and topology. Refer to Figure 4-1 on page 4-2 and Figure 4-2 on page 4-3 for QuickStick 100 motor mechanical drawings. Refer to Figure 4-3 on page 4-4 and Figure 4-4 on page 4-6 for typical Quick- Stick 100 magnet array mechanical drawings. Perform the calculations as shown in Determining Thrust Force on page A-11 to determine the optimal thrust force, Vehicle Gap, and magnet array size. QuickStick 100 User s Manual 3-9

62 Design Guidelines Transport System Design The QuickStick 100 transport system allows only one vehicle at a time on a motor block (see Table 3-2). Table 3-2: Motor Blocks Motor Type Motor Block Length No. Blocks Array Cycle Length No. Cycles QS 100, 1000 mm 96 mm mm 20 QS 100, 500 mm 96 mm 5 48 mm 10 The magnetic attractive force are available in Data for Transport System Design Calculations on page A-2. Table 3-3: Thrust and Attractive Force, Standard Magnet Array Force * Thrust per 4 A stator current Attractive force per cycle 15.9 N/cycle 58.8 N/cycle * 3 mm Vehicle Gap. Available Thrust The thrust available from the QuickStick 100 motors to move a vehicle is determined by several variables: Magnet array length (in cycles). Vehicle Gap (distance between the magnet array attached to the vehicle and the motor). Friction between the vehicle and the guideway. Motor Gap (physical distance between motors) and Downstream Gap (actual distance between motor blocks in adjacent motors), refer to Figure 3-7. The effect of the first two variables, the number of cycles of magnet array and the Vehicle Gap are shown best in Data for Transport System Design Calculations on page A-2. Equations that use all of these variables are provided in Determining Thrust Force on page A-11. At the nominal Vehicle Gap of 3 mm [0.12 in] (gap between the magnet array and the top of the QuickStick 100 motor) the QS 100 motors provide approximately 15.9 N thrust per magnet array cycle at 4 A stator current (see Table 3-3). The magnet arrays are available in various lengths to provide the appropriate thrust for the application. By increasing the length of the magnet arrays the number of motors in the system can be decreased, however the loss of thrust in the gaps between the motors must be taken into account (refer to Figure 3-6) Rev. D

63 Design Guidelines Transport System Design 100% Coverage 100% Thrust 50% Coverage 50% Thrust 25% Coverage 25% Coverage 50% Thrust 12.5% Coverage 12.5% Coverage 25% Thrust Figure 3-6: Available Thrust Examples Required Thrust Motor Gap The thrust required to move a vehicle is determined by several variables: Required acceleration. Mass to be moved. Friction between the vehicle and the guideway. For QuickStick 100 motors installed in a transport system in a straight line, there will always be a space (Motor Gap) between motors, as shown in Figure 3-7, with the minimum space being 2 mm (for thermal expansion) and a typical space being 22 mm, which places 1 m QuickStick 100 motors on a 1 meter pitch. QuickStick 100 User s Manual 3-11

64 Design Guidelines Transport System Design Motor Block Motor Gap Vehicle Gap Upstream QuickStick Motor (side view) Figure 3-7: Motor Gaps Downstream Gap (Motor Gap + 18 mm) Downstream Downstream Gap An additional measurement between motors is the distance from the last block of the stator in one motor to the first block of the stator in the next motor downstream, which is referred to as the Downstream Gap (shown in Figure 3-7 and is equivalent to the Motor Gap plus 18 mm). NOTE: MagneMotion recommends that the maximum Downstream Gap between motors is 10% of the magnet array length, when a dual-array vehicle is used it s 10% of the length of one of the arrays. Larger gaps may be possible, but will cause greater loss of thrust. Please contact MMI Technical Support for additional information. The Downstream Gap affects the force available for moving vehicles between motors. There is a certain amount of thrust available per magnet array cycle, providing that the magnet array cycle is located above the motor (magnet array coverage). There must be enough thrust to move the vehicle past the gap between motors. Note that process stations should not be located within the gap between motors as settling time and repeatability may be negatively affected. NOTE: The QuickStick 100 motors do not compensate for the amount of thrust lost when the magnet array is over the Downstream Gap. This means that if the array only has half coverage, the effective PID values and peak thrust are halved, and the system will not perform as well as it does with full coverage. It is important to note that the Downstream Gap measurement is added to the last motor block of all QuickStick 100 motors in the transport system. This is important when considering the motor blocks that a vehicle owns (refer to Block Acquisition on page 6-6) and also for determining when vehicles are considered to be at the end of a Path or cleared of a Node boundary (such as a Terminus Node). Motor Cogging Any cogging between the QS 100 motor and the magnet array is typically not an issue unless there is a direct human interaction with the vehicle while it is being moved, in which case it might be felt (refer to Motor Cogging on page 6-5). Any cogging will not affect the positioning accuracy of the motor Rev. D

65 Cogging can be minimized by the following methods: Design Guidelines Transport System Design Placing QuickStick 100 motors at the optimal pitch on the transport system (refer to Downstream Gap). Maximizing the Vehicle Gap between the motor and the magnet array. Providing external damping between the vehicle and the payload. Motors on a Curve For motors located on a curve the distance from the center of the motor housing on one motor to the center of the housing on the next (downstream) motor is the Motor Gap, which by default defines the Downstream Gap (Motor Gap + 18 mm). Motor Motor Gap C L C L QuickStick Motor (top view) Figure 3-8: Motors on Curves Since the motors and the magnet arrays are not curved, the alignment of the magnet array over the motors is not optimal in the curve and the alignment of the magnet array changes as the vehicle moves through the curve (refer to Figure 3-13). To minimize some of this misalignment the magnet arrays used for curve geometry are wider than usual to provide more magnetic array coverage. Additionally, when a motor is located on a curve, the On Curve option for that motor in the Node Controller Configuration File may need to be selected. The On Curve option is used based on the configuration of the motors in the curve to enable the use of a correction table (supplied by MagneMotion) to locate the vehicle correctly relative to the position sensors in the motors. This is more commonly required for tight radius curves or single array vehicles. NOTE: If On Curve is selected for a motor and MagneMotion has not supplied a unique version of software with the correction table, the vehicles may not move properly and the system may not perform as expected. Motor Controllers The motor controller for each QuickStick 100 motor is located inside the QS 100 motor. Each QS 100 motor has one motor controller, also referred to as the master. QuickStick 100 User s Manual 3-13

66 Design Guidelines Transport System Design The motor controller is responsible for controlling the thrust applied to each vehicle by the motor and reading sensors in the motor to determine vehicle position. The motor controllers communicate with each other and a Node Controller via RS-422 serial communication. Electrical Wiring The QS 100 motors are designed to operate at a nominal +48 VDC. However voltage drops in the power distribution system when delivering power to the motors and voltage increases during regeneration events will lead to fluctuations in the voltages seen at the motor power terminals. The power supplies and wiring for the system must be designed to minimize these fluctuations. The acceptable voltage range for the QuickStick 100 motors is between +43 and VDC, with a nominal voltage of +48 VDC. Operating below or above this range can result in the motor turning off or being damaged. While the motor has protections in place to prevent damage, the power supply system should be designed so that the voltage limits are not exceeded during normal operating conditions. To supplement any external power management schemes for the QS 100 transport system, a means of internally consuming regenerated power within a QS 100 motor is incorporated as a product feature (refer to Electrical System on page 6-10). The QS 100 motors are enabled when the internal propulsion bus rises above +43 VDC. Until this voltage is reached, the motor will report an under-voltage fault and the motor will not allow vehicle motion to occur. Once this internal voltage is reached, the motor will support vehicle motion and operate as intended. If the internal bus voltage drops below +41 VDC during operation, the motor will report an under-voltage fault and all inverters within the motor will be disabled. Normal operation will resume once the internal propulsion bus rises back up to +43 VDC. If the internal bus voltage rises above +59 VDC during operation, the motor will report an over-voltage fault and all inverters within the motor will be disabled. Normal operation will resume once the internal propulsion bus falls below +57 VDC. Once the inverters are disabled, any vehicles in motion over the motor will no longer be under active control and as such their motion will be undefined. A block diagram of a QS 100 system schematic is provided in Figure 3-9. Note that any part numbers shown are for reference only and are subject to change. Power Wiring All power wiring must be constructed such that there is minimal loss between the power supplies and the motors. Additionally, the power wiring must be able to support power regeneration due to the active braking or deceleration of vehicles. The preferred architecture for the power bus in a QS 100 system is a number of junction boxes (shown in Figure 3-9) connected in series to form a single, low resistance, power bus with a tap to each motor. The current to each motor in a system at a given time will depend on system behavior and vehicle size. When sizing cables, the worst case power draw, current, and vehicle movement Rev. D

67 Design Guidelines Transport System Design should always be used. MagneMotion recommends designing the electrical system to keep voltage drops below 5% of the nominal voltage (+48 VDC). Vehicle motion will consume power when the vehicle accelerates and regenerate power when it decelerates. While the vehicle is accelerating, the motor is drawing power from the motor power supply system, including any excess power being generated from regeneration in other parts of the transport system connected to the same power supply system. In the worst case, a single motor can draw up to the value for peak power per vehicle while the vehicle is finishing its acceleration. In addition to providing the power used to accelerate a vehicle, the wiring must also be designed to manage power regenerated by a vehicle as it stops. In general, if a system is designed to support supplying power during acceleration, it will also support excess power created by regeneration during deceleration. Methods to Reduce Voltage Drop There are two methods that can be used to reduce the drop of voltage in the system during acceleration. The first method is to decrease the cable resistance between the power supply and the motors by either shortening the length of the cables or increasing the conductor gauge of the cables. This will reduce the voltage difference between the power supply and the motor. The second method is to limit the number of motors connected to a single power supply. Methods to Reduce Voltage Increase There are two methods that can be used to reduce the voltage increase in the system during deceleration. The first method is to decrease the cable resistance between motors by either shortening the length of the cables or increasing the conductor gauge of the cables. This will reduce the voltage difference between the motor regenerating power and the motors consuming or dissipating power and allow the voltage at the regenerating motor to be lower. The second method is to install a voltage clamp in the power supply circuit to dissipate power if the voltage on the bus goes above a certain level. Signal Wiring Ground Logic power can be provided separately or though the propulsion power pins. Logic power is a constant 10 W of power per motor. If only propulsion power is supplied to the motors, connection to logic power is automatically made within the motor. Separating the logic and propulsion power busses allows propulsion power to be removed (e.g., during an EMO event) without losing motor logic functions (configuration data, vehicle data, fault information, etc.). Having separate power busses also allows the motors to be programmed and configured without enabling the propulsion power. Proper grounding of the QuickStick 100 transport system is required to ensure proper operation and to minimize electrical safety issues. The bodies of the motors are grounded through the PE connection on the power connector. QuickStick 100 User s Manual 3-15

68 Design Guidelines Transport System Design The NC LITE and SYNC IT modules are not grounded through their power connections. The cases of these modules must be grounded to an electrical safety ground (PE) through their mounting features. The NC-12 is grounded through the GND stud on the Node Controller. All power supplies must be grounded to an electrical safety ground (PE) via the safety ground in the AC input connector. All junction boxes must be grounded to an electrical safety ground (PE) Rev. D

69 Design Guidelines Transport System Design DOWNSTREAM UPSTREAM UPSTREAM QS 100 MOTOR, 1/2M QS 100 MOTOR, 1M J1 J2 J3 J5 J1 J2 J3 J5 DC POWER CABLE (TYPICAL TO EACH MOTOR) JUNCTION BOX JUNCTION BOX RS XX RS XX RS (can be extended using XX) RS (can be extended using XX) MOTOR SYNC CABLE DC POWER BUS +24 VDC UTP-CAT5 NC LITE VDC OPTIONAL POE (+ 18 VDC) NC VDC UTP-CAT5 SYNC IT MAGNEMOTION COMPONENTS USER COMPONENTS 48 VDC POWER SUPPLY (MMI OR USER SUPPLIED) ETHERNET SWITCH HOST CONTROLLER HUMAN MACHINE INTERFACE DOWNSTREAM RS XX TO NEXT MOTOR DOWNSTREAM (J1) FROM LAST MOTOR DOWNSTREAM (J5) AC POWER LAN PWR CONSOLE USB1 ETH1 ETH0 J2 J3 J1 J1 SP3 SP2 SP1 RS-422 J DIGITAL I/O OUT 0-15 IN 0-15 ETHERNET POWER CONSOLE RS RS GND UTP-CAT5 UTP-CAT5 Figure 3-9: System Wiring Block Diagram QuickStick 100 User s Manual 3-17

70 Design Guidelines Transport System Design Magnet Arrays The amount of linear thrust that a QS 100 motor provides is primarily a function of magnet array length. Magnet Array Length and Attractive Force There is a strong magnetic attractive force present between the magnet array and the Quick- Stick 100 motor. This force is an important consideration in designing the support structure for the QuickStick 100 system and in determining the force required to move a vehicle. The magnetic attractive force is always present, even if there is no power to the motor. The amount of magnetic attractive force present is also dependant on the length of the magnet array. Based on the application, multiple magnet arrays may be used for each vehicle, side-by-side or end-to-end. Magnet array length is measured in three ways: Number of cycles. Physical length in millimeters. Number of poles. Number of Cycles The amount of thrust force and attractive force is reported as force per magnet array cycle. The more cycles in the magnet array, the greater the thrust and attractive forces. A magnet array cycle is: The distance from the edge of a half North oriented magnet to the center line of a full North oriented magnet as shown in Figure 3-10 and Figure The distance from the center line of one full North oriented magnet to the centerline of the next full North oriented magnet as shown in Figure 3-10 and Figure For QS 100 magnet arrays the cycle length is always 48 mm. The smallest magnet array available for use with QS 100 motors is 3 cycles (150 mm [5.9 in]). With a 3 cycle magnet array the recommended maximum Motor Gap (distance between motors) is 15 mm (refer to Downstream Gap on page 3-12). NOTE: When determining the number of cycles required for the magnet array be sure to account for the Downstream Gap. Number of Poles The number of poles in a magnet array is simply the number of North and South oriented poles in the magnet array. The number of poles will always be an odd number (see Figure 3-10) as it includes the half magnets at each end of the array. The number of poles can also be calculated from the number of cycles (cycles * 2 + 1) Rev. D

71 Design Guidelines Transport System Design Magnet Array Width Magnet arrays are available in several different widths. The width used is determined by the application. Regular width arrays are used in applications where the array does not need to be wider than the motor. This is typically when QS 100 motors are arranged in a straight line. Wide arrays are used in applications where the array needs to be wider than the motor to ensure coverage when there is a misalignment between the motor and the magnet array, which could lead to a loss of force. This is typically when QS 100 motors are arranged in a curve. Magnet Array Forces As mentioned previously, there is a certain amount of thrust and attractive force available per magnet array cycle; however, the number of cycles is not the only variable that affects available thrust. Other variables are the Vehicle Gap and the Downstream Gap. These other variables and their effect on available thrust are discussed later in this chapter. Magnet Array Use The QuickStick 100 magnet arrays are intended for use as the QS 100 motor secondary as part of the vehicle only and should not be used for any other purpose. NOTE: If debris is accumulated it can get caught between the magnet array and the motor. Any accumulated debris will affect the performance and can damage the cover of the motor or the magnet array. Available Magnet Arrays The magnet arrays are available in different styles, widths, and lengths (refer to Magnet Array, Standard on page 4-4 and Magnet Array, High Flux on page 4-6). QuickStick 100 User s Manual 3-19

72 Design Guidelines Transport System Design Standard Magnet Arrays The standard magnet array for the QS 100 motors is an arrangement of alternating North oriented and South oriented neodymium iron boron (NdFeB) permanent magnets placed perpendicular to the direction of motion. They come in several lengths and widths, with full magnets of alternating polarity in the middle of the array and a North oriented half magnet at each end of the array. Orientation of the magnets is referenced to the surface facing the motor as shown in Figure Cycle 1 Cycle Mounting Surface N S N S N S N S N S N Direction of Motion Figure 3-10: Standard Magnet Array, 5 Cycles, 11 Poles Physical Length NOTICE Even though the magnet arrays are potted in epoxy the magnets can still be damaged and are subject to corrosion if scratched. The physical length of the standard magnet arrays, measured in millimeters, can be measured using a non-ferrous measuring tool such as a ruler or measuring tape. The physical length can also be calculated, if the number of cycles is known. The equation to calculate the physical length of a standard magnet array is: MagnetArrayLength = (Cycles x 48) + 6 mm Rev. D

73 Where: High Flux Magnet Arrays MagnetArrayLength is the length of the array, in millimeters. Cycles is the number of cycles in the array. 6mm is the additional length of the epoxy protecting the magnets. Design Guidelines Transport System Design The high flux magnet array for the QS 100 motors is an arrangement of neodymium iron boron (NdFeB) permanent magnets in a Halbach-type array that augments the magnetic field on the side of the array facing the motor while cancelling the field to near zero on the other side, with the magnets placed perpendicular to the direction of motion. They come in several lengths and widths, with full magnets of alternating polarity in the middle of the array and a North oriented half magnet at each end of the array. Orientation of the magnets is referenced to the surface facing the motor as shown in Figure Cycle Cycle 48.0 Mounting Surface N S N S N S N S N S N Direction of Motion Figure 3-11: High Flux Magnet Array, 5 Cycles, 11 Poles NOTICE Even though the magnet arrays are covered the magnets can still be damaged and are subject to corrosion if scratched or cracked. QuickStick 100 User s Manual 3-21

74 Design Guidelines Transport System Design Physical Length The physical length of the high flux magnet arrays, in millimeters, can be measured using a non-ferrous measuring tool such as a ruler or measuring tape. The physical length can also be calculated, if the number of cycles is known. The equation to calculate the physical length of a high flux magnet array is: Where: MagnetArrayLength = (Cycles x 48) + 5 mm MagnetArrayLength is the length of the array, in millimeters. Cycles is the number of cycles in the array. 5mm is the additional length of the cover Rev. D

75 Design Guidelines Transport System Design Vehicles Vehicles carry payloads through the QuickStick 100 transport system as directed. A high-strength magnet array, described in Magnet Arrays on page 3-18, is mounted to the surface of the vehicle closest to the motors. The magnet array interacts with the motors, which moves the vehicle. The vehicle is passive with no electronics on the vehicle and no power or signal connections are required. A vehicle can be of almost any size and shape, depending on the requirements of the application, however it must be designed to hold the mass of the payload, to hold the magnet array, and to withstand the attractive force present between the magnet array and the top of the QuickStick 100 motor. There are several design elements that must be met: The vehicle supports the magnet array and its placement in the guideway must ensure the Vehicle Gap, see Figure 3-16, is maintained throughout the system. The vehicle design must provide guides to ensure the magnet array position is maintained over the center of the motor as shown in Figure The vehicle must be at least as long, and preferably longer than the magnet array. Vehicles must be grounded to the guideway using conductive materials such as wheels or static brushes. The vehicle must have low friction with the guideway. All vehicles on connected guideways must be the same size and use the same size and type of magnet array. Vehicle Suspension Wheel Vehicle Guidance Wheel Payload Mounting Surface Vehicle Motor Mount QS 100 Motor Magnet Array Figure 3-12: Typical Vehicle on Guideway Static Brush QuickStick 100 User s Manual 3-23

76 Design Guidelines Transport System Design A variety of materials may be used to construct the vehicles in a QuickStick 100 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. Wheels or rollers are used to support the vehicle(s) on the guideway while allowing the vehicles to move freely upstream and downstream. They also maintain a consistent space between the magnet array attached to the vehicle and the QuickStick 100 motors (Vehicle Gap). Wheel and roller materials affect the frictional resistance, which affects the amount of thrust needed to move a vehicle. The selected material should be hard enough to provide a low rolling resistance but, depending on the environment the system is used in, soft enough to not create excess noise when traversing joints between guideway sections. Vehicles may have one or two magnet arrays attached to the surface closest to the motors based on the use of the vehicle and the design of the guideway. Typically, when vehicles travel guideways with curves they need to have two independent magnet arrays to ensure maximum alignment of the arrays with the motors while traveling through the curve as shown in Figure Single Magnet Array Misaligned with Respect to Motors in a Curve Dual Magnet Array Aligned with Respect to Motors in a Curve Figure 3-13: Magnet Array to Motor Alignment Rev. D

77 Design Guidelines Transport System Design Single Array Vehicle Vehicles with single magnet arrays are typically used in QuickStick 100 transport systems where all motion is in a straight line. However they can be used where the guideway includes curves by using a wider magnet array to minimize thrust loss through the curve due to misalignment of the motor to the magnet array. Attributes of systems utilizing single array vehicles may include: The magnet array is typically the same width as the motor. The guideway does not have any curves or it only uses large radius curves and the magnet array is short or wider than the motor. Vehicle Body Vehicle Wheels Magnet Array Figure 3-14: Single Array Vehicle Configuration Dual Array Vehicle Vehicles with two magnet arrays are typically used in QuickStick systems where the guideway includes curves or large distances between motors. For systems where the track runs in a straight line these arrays may be mounted directly to the vehicle. For systems where the track has curves these arrays may be mounted on independent bogies. On a curve there can be misalignment between the motor and the magnet array on the vehicle, which could lead to a loss of force. The dual array vehicle for use on curves has two independent bogies connected to the vehicle by pivots, where each bogie has its own magnet array. By allowing the bogies to rotate independently of each other under the vehicle, each magnet array can stay as closely aligned to the motors as possible (as shown in Figure 3-13), minimizing the thrust loss that occurs while moving through a curve. Both magnet arrays in a dual array vehicle must be the same length and the magnet arrays must be mounted so that the gap between the arrays is a multiple of a cycle. Attributes of systems utilizing dual array vehicles may include: The magnet array needs to be longer than a standard single magnet array. The magnet array is typically wider than the motors. The guideway uses small radius curves. Vehicle Body Bogie Body Vehicle Wheels Bogie Pivot Magnet Array Figure 3-15: Dual Array Vehicle Configuration QuickStick 100 User s Manual 3-25

78 Design Guidelines Transport System Design Vehicle Gap The Vehicle Gap, shown in Figure 3-16, is the distance maintained between the magnet array and the QuickStick 100 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 or the longer the magnet array must be to achieve the same thrust). Refer to Table A-1 on page A-3 through Table A-4 on page A-9 for Vehicle Gap data. Magnet Array Vehicle Gap QuickStick 100 Motor Figure 3-16: Vehicle Gap Guide rails on which the vehicles roll are typically held as flat as is reasonable to ensure consistency in the Vehicle Gap. Allowing greater variability in the Vehicle Gap helps to minimize the rail and vehicle costs to meet the thrust requirements (refer to Determining Thrust Force on page A-11). However, the greater the tolerance on the flatness of the guideway the larger the Vehicle Gap must be to ensure the magnet array never touches the top of a motor and the larger the magnet array must be to ensure the same thrust as would be achieved from a smaller Vehicle Gap. NOTE: The Vehicle Gap must be such that any deviations in the flatness of the guide rails will not allow the magnet array on the vehicle to touch down on either the guide rails or the motors. Standard Magnet Arrays The Vehicle Gap recommendations shown are for reference only. Using a smaller minimum Vehicle Gap or larger maximum Vehicle Gap may be possible. However, exceeding the Vehicle Gap recommendations may make it difficult for the position sensors in the motor to precisely locate the vehicles. Please contact MMI Technical Support for additional information. Minimum Vehicle Gap is 1 mm, 3 mm is the recommended minimum. High Flux Magnet Arrays The Vehicle Gap recommendations shown are for reference only. Using a smaller minimum Vehicle Gap and/or larger maximum Vehicle Gap may be possible. However, using smaller minimum Vehicle Gap and/or larger maximum Vehicle Gap may cause the position sensors in the motor difficulty in precisely locating the vehicles, please contact MMI Technical Support for additional information. Minimum Vehicle Gap is 5 mm Rev. D

79 Design Guidelines Transport System Design Vehicle Design When designing vehicles for use with the QuickStick 100 motors the following vehicle design guidelines and considerations should be taken into account: MagneMotion recommends that the vehicle should be longer than the magnet array to protect the array from impacts. The quantity and locations of suspension and guidance wheels or other suspension and guidance features is determined by the vehicle design and the magnet array size. MagneMotion recommends the use of a low friction barrier, such as UHMW material, to prevent damage to either the magnet array or the motor in the event of contact between the magnet array and the motor. Up to five vehicles per meter (150 mm [5.9 in] minimum vehicle length) in motion or in queue. Note that transport systems with short vehicles with 150 mm magnet arrays may encounter startup issues if the vehicles are too close to one another. The payload, vehicle mass, and required acceleration must be within the limits of the magnet array. Vehicles that carry payloads sensitive to magnetic fields should provide shielding or separate the payload from the magnet array by mm. When using curved guideways, ensure the vehicle design is able to negotiate the curves. Vehicle Materials Some examples of commonly used vehicle materials and considerations: Steel: Good strength properties. High density yields heavier vehicles. Caution is required when using carbon steel (a ferromagnetic material). 300 series stainless steel is suitable. Aluminum: Good combination of comparatively high strength and low mass. Less caution required because of no magnetic attractive force. The area under the vehicle magnet array should be clear of aluminum as the aluminum may create eddy currents which will create a breaking force. Wheel Materials Some examples of commonly used wheel materials and key considerations: QuickStick 100 User s Manual 3-27

80 Design Guidelines Transport System Design Steel: Very durable, typically used in systems moving heavy payloads or for difficult environmental conditions. Low rolling resistance. When used on a metal guideway are typically noisier than plastics. Plastic, Teflon, or Urethane: Plastics with a high durometer number (hardness) are a good choice of wheel material for many applications, particularly for systems with moderate to low payload weights. Plastic or urethane wheels may develop a small flat area if the vehicle remains stationary for a long time period due to the vehicle mass and the magnet attractive force but in most cases the flat spots disappear after the vehicle is put in motion again. Higher rolling resistance than steel, but usually operate more quietly than steel wheels when used on a metal guideway. Typically requires the vehicle be grounded to the guideway using static brushes. 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 Rev. D

81 Design Guidelines Transport System Design Guideways Just as with any conveyance technology, vehicle motion imparts dynamic loads on the guideway system. Ensure the guideway is adequately secured to a rigid, permanent structure, such as the equipment the guideway is associated with or the floor, wall, or ceiling which will reduce vibrations and other stresses on the system. Guideway Design Vehicle Magnet Array Guideway Vehicle Guidance Surface Vehicle Suspension Surface Motor Mount Figure 3-17: QuickStick 100 Transport System, Guideway Detail Vertical Wheel Horizontal Wheel Motor 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. The guideway must hold the motors in position to ensure the motor to motor spacing does not change (see Figure 3-7). The guideway must hold the motors and support the vehicles to ensure the Vehicle Gap (see Figure 3-16) is maintained throughout the system. Guide rails on which the vehicles roll should be held as flat as possible to minimize the variation in the Vehicle Gap throughout the transport system. This allows the Vehicle Gap to be smaller, maximizing vehicle thrust. The guideway must provide features to allow the vehicle maintain its position on the guideway (see Figure 3-17). When using curved guideways ensure the guideway material will support curving. The joints between sections of the guideway should be as smooth as possible to minimize noise and wear on the wheels. The payload, vehicle mass, and as applicable, the motor mass must be within the limits of the guideway. The guideway must provide proper grounding to ensure static dissipation. QuickStick 100 User s Manual 3-29

82 Design Guidelines Transport System Design Guideway and Support Materials As with any installation, the operational environment should be considered when choosing compatible support structure materials. Some examples of commonly used guideway structure materials and key considerations follow: Steel: Good strength properties. Strong and provides a stable platform for vehicle movement. Can be heavier than is necessary. Caution is required when using carbon steel (a ferromagnetic material). Can be more expensive than other alternatives. Aluminum: Good combination of comparatively high strength and low mass. Less caution required because of no magnetic attractive force. The area under the vehicle magnet array should be clear of aluminum as the aluminum may create eddy currents which will create a breaking force. Available in a variety of weights, thicknesses, and prices. Motor Mounts The QuickStick 100 motors provide mounting features on the bottom, which provides for a simple mounting scheme (refer to Mechanical Specifications on page 4-2). The following guidelines are provided for designing the motor mounts. Mounts should allow the motors to have a small amount of movement relative to each other to allow adjustment of the motor to motor gap during installation. Mounts should ensure consistent spacing between the motors to simplify the creation of the Node Controller Configuration File and to ensure consistent thrust. Mounts should ensure the top surface of all motors are coplanar to each other. Mounts should ensure the motor is securely fastened and can not move Rev. D

83 Design Guidelines Transport System Design Motor Mounting Methods The following motor mounting guidelines are provided when designing a guideway. When attaching directly to the track or mounting plate as shown in Figure 3-18, ensure clearance holes for all motor connections are provided. Note that this mounting method may not provide for any adjustment of the motor position once the motor is installed. QS 100 Motor M8 T-Nut (in channel) Clearance Holes for Motor Connections Mounting Plate M8 Mounting Hardware Figure 3-18: Motor Mounting to Flat Surface QuickStick 100 User s Manual 3-31

84 Design Guidelines Transport System Design When attaching mounts to the motors and securing the mounts to the track as shown in Figure 3-19, ensure the mounts are located to allow access to all motor connections. Note that this mounting method provides easy adjustment of the motor position once the motor is installed. QS 100 Motor M8 T-Nut (in channel) Track Mounting Bracket Hardware Motor Mounting Bracket M8 Mounting Hardware Figure 3-19: Motor Mounting Using Brackets When using either of the mounting methods shown. 1. Loosely mount the motors to the motor mounting surface. The motor mounts should allow the motors a small amount of movement relative to each other. NOTE: The upstream end of the motor has the power connector located near it (refer to Figure 4-1 on page 4-2 and Figure 4-2 on page 4-3). 2. Ensure consistent spacing between the motors. 3. Ensure the top surface of all motors are coplanar to each other. 4. Treating each motor to motor interface as a separate operation, tighten the motor mounts. Refer to Mounting the Motors on page 5-6 for details of the mounting procedure Rev. D

85 Design Guidelines Transport System Design Guideway Examples Figure 3-20 provides an example of a guideway and vehicle where the guideway is constructed of stiff steel sides and a sheet metal base. The vehicle has flanged wheels that ride on the top of the side plates. NOTE: Vehicles are not held in place if power is removed. QS 100 Motor Vehicle Guideway Figure 3-20: Guideway Example #1 QuickStick 100 User s Manual 3-33

86 Design Guidelines Transport System Design Figure 3-21 provides an example of a guideway and vehicle where the guideway is constructed of extruded aluminum with linear bearing guide rails. The vehicle has linear bearing slides that ride on the rails. This guideway can be used in any orientation as the vehicles are captive. NOTE: Vehicles are not held in place if power is removed. Vehicle QS 100 Motor Guideway Figure 3-21: Guideway Example # Rev. D

87 Design Guidelines Transport System Design Figure 3-22 provides an example of a guideway and vehicle where the guideway is constructed of extruded aluminum with rollers mounted along the top of the guideway. The vehicle sits on the rollers and between the side plates. NOTE: Vehicles are not held in place if power is removed. QS 100 Motor Vehicle Side Plate Figure 3-22: Guideway Example #3 QuickStick 100 User s Manual 3-35

88 Design Guidelines Transport System Configuration Transport System Configuration All examples provided are for horizontal track layouts unless otherwise specified. The guideway is shown in an isometric view in Figure Straight Track Configuration Guideway Motor Mount QS 100 Motor Motor Gap Top View Figure 3-23: Straight Track Configuration Node Types at beginning of Path: Simple, Relay, Terminus, Gateway. Node Types at end of Path: Relay, Terminus, Gateway. Motor Gaps should be consistent over the length of the Path and over the entire system if possible to make creation of the Node Controller Configuration File simpler. NOTE: Different size gaps between motors must be identified in the Node Controller Configuration File (using the Configurator) Rev. D

89 Design Guidelines Transport System Configuration Curve Track Configuration QS 100 Motor Guideway Motor Mount Motor Gap Top View Figure 3-24: Curve Track Configuration Node Types at beginning of Path: Simple, Relay, Terminus, Gateway. Node Types at end of Path: Relay, Terminus, Gateway. Minimum radius determined by motor length, and magnet array/vehicle length. May require a vehicle with dual magnet arrays (refer to Figure 3-13, Magnet Array to Motor Alignment, on page 3-24). Motors may need to be configured as being On Curve in the Node Controller Configuration File. Motor Gaps should be consistent over the length of the curve in the guideway. NOTE: Different size gaps between motors must be identified in the Node Controller Configuration File (using the Configurator). QuickStick 100 User s Manual 3-37

90 Design Guidelines Transport System Configuration Switch Configuration Straight Entry/Straight Exit QS 100 Motor Guideway Curve Entry/Curve Exit Straight Motor Gap Curve Motor Gap Motor Mount Merged Exit/Single Entry Top View Figure 3-25: Switch Configuration Node Types at switch: Merge, Diverge. Provides a merge of two Paths into one (straight entry, curve entry, merged exit). Provides a diverge from one Path into two (single entry, curve exit, straight exit). Requires a switching mechanism (electromagnetic or mechanical). Minimum radius determined by motor length, and magnet array/vehicle length. May require a vehicle with dual magnet arrays (refer to Figure 3-13, Magnet Array to Motor Alignment, on page 3-24). Motors in curve section may need to be configured as being On Curve in the Node Controller Configuration File. Motor Gaps may vary from section to section of the guideway (entry, exit, curve), but should be consistent in each section of the guideway. NOTE: Different size gaps between motors must be identified in the Node Controller Configuration File (using the Configurator) Rev. D

91 Design Guidelines Transport System Configuration Shuttle Configuration Guideway Entry/Exit Entry/Exit QS 100 Motor Shuttle Motor Shuttle Drive Path Top View Motor Gap Entry/Exit Shuttle Path Shuttle QS 100 Drive Path Motor Node Type: Shuttle. Side View Figure 3-26: Shuttle Configuration Provides a dedicated moving Path (Shuttle Path). Provides multiple entries and exits (maximum of six). QuickStick 100 motor(s) (Drive Path) used to provide movement of Shuttle Path. Shuttle Path can consist of multiple motors. Motor Gaps may vary from section to section of the guideway (entry, exit), but should be consistent in each section of the guideway. NOTE: Different size gaps between motors must be identified in the Node Controller Configuration File (using the Configurator). QuickStick 100 User s Manual 3-39

92 Design Guidelines Transport System Configuration Moving Path Configuration Moving Paths Entry/Exit Moving Paths Entry/Exit QS 100 Motor Guideway Fixed Paths Entry/Exit Drive Mechanism Motor Gap Fixed Paths Entry/Exit Node Type: Moving Path. Figure 3-27: Moving Path Configuration Provides multiple entries and exits (maximum of 12). The example shown in Figure 3-27 uses two Moving Path Nodes, one for entry onto the moving Paths and one for exit from the moving Paths. Requires a Host-controlled drive mechanism to position the Moving Path(s). QuickStick 100 motor(s) may be used as the drive mechanism to provide movement of the Moving Path(s). The Moving Path can consist of multiple motors. Motor Gaps may vary from section to section of the guideway (entry, exit), but should be consistent in each section of the guideway. NOTE: Different size gaps between motors must be identified in the Node Controller Configuration File (using the Configurator) Rev. D

93 Specifications and Site Requirements 4 Overview This chapter describes specifications for the QuickStick 100 transport system components and the requirements for installation. Included in this chapter are: Mechanical specifications for all QuickStick 100 components, including dimensions. Electrical specifications for power and communications, including connector pinouts. Site requirements, including environmental and service access. QuickStick 100 User s Manual 4-1

94 J5 Downstream RS-422 (See manual for pinout) 0 J3 J2 J1 Upstream RS-422 (See manual for pinout) Specifications and Site Requirements Mechanical Specifications Mechanical Specifications All drawings within this manual are generic and may not reflect specific configurations of the QuickStick 100 components. To obtain a complete and current set of drawings and documents contact MagneMotion Technical Support Millimeter Motor MOTOR BLOCK REGIONS C L [3.78] 96.0 [3.78] 96.0 [3.78] 96.0 [3.78] 96.0 [3.78] 96.0 [3.78] 96.0 [3.78] 96.0 [3.78] 96.0 [3.78] 96.0 [3.78] 96.0 [3.25] 82.5 CLEARANCE NEEDED FOR POWER AND COMM CABLE CONN. & WIRE BEND RADIUS T-SLOT ACCOMODATES BOSCH 10MM T-SLOT HARDWARE (E.G. M8X1.25, 10MM T-BLOCK & SPRING, BOSCH P/Ns: & RESPECTIVELY.) [30.5] UPSTREAM END C L [3.4] 87.0 [0.98] 4X 25.0 [16.18] [1.69] 43.0 C L [6.93] [1.69] 43.0 [11.56] [2.52] 64.0 [16.18] [1.69] 43.0 [0.17] 4.2 DOWNSTREAM COMMUNICATION CABLE CONNECTOR Weight: 13.2 kg [29.1 lb] Figure 4-1: 1000 Millimeter Motor Mechanical Drawing NOTE: The exclusion zones shown are for the QS 100 motor only. Additional exclusion zones may be required based on the design of the vehicle and the material being transported by the motor. Exposed Materials Refer to QS 100 Motors on page 4-12 for the electrical specifications. Aluminum 6063-T Stainless Steel. TGIC powder coat. VHB conformable foam with acrylic adhesive. SYNC CABLE CONNECTOR (SYNC MOTOR ONLY) UPSTREAM COMMUNICATION CABLE CONNECTOR The motor has exposed D-style connectors and should not be located in an area where harsh conditions exist. POWER CONNECTOR All Dimensions in Millimeters [Inches] Rev. D

95 Specifications and Site Requirements Mechanical Specifications 500 Millimeter Motor MOTOR BLOCK REGIONS [3.78] 96.0 [3.78] 96.0 [3.78] 96.0 C L [3.78] 96.0 [3.78] 96.0 [3.25] 82.5 CLEARANCE NEEDED FOR POWER AND COMM CABLE CONN. & WIRE BEND RADIUS T-SLOT ACCOMODATES BOSCH 10MM T-SLOT HARDWARE (E.G. M8X1.25, 10MM T-BLOCK & SPRING, BOSCH P/Ns: & RESPECTIVELY.) [19.61] UPSTREAM END Downstream RS-422 (See manual for pinout) Upstream RS-422 (See manual for pinout) J5 J3 J2 J1 C L [3.4] 87.0 [0.98] 4X 25.0 [6.73] [1.69] 43.0 [2.52] 64.0 [1.69] C L [2.11] 53.5 [2.56] 65.0 [6.73] [1.69] 43.0 [0.17] 4.2 Figure 4-2: 500 Millimeter Motor Mechanical Drawing NOTE: The exclusion zones shown are for the QS 100 motor only. Additional exclusion zones may be required based on the design of the vehicle and the material being transported by the motor. Exposed Materials DOWNSTREAM COMMUNICATION CABLE CONNECTOR Weight: 6.6 kg [14.6 lb] Refer to QS 100 Motors on page 4-12 for the electrical specifications. Aluminum 6063-T Stainless Steel. TGIC powder coat. SYNC CABLE CONNECTOR (SYNC MOTOR ONLY) POWER CONNECTOR VHB conformable foam with acrylic adhesive. UPSTREAM COMMUNICATION CABLE CONNECTOR All Dimensions in Millimeters [Inches] The motor has exposed D-style connectors and should not be located in an area where harsh conditions exist. QuickStick 100 User s Manual 4-3

96 Specifications and Site Requirements Mechanical Specifications Magnet Array, Standard Standard magnet arrays (refer to Standard Magnet Arrays on page 3-20) are available in two widths (80.0 mm [3.15 in] ( F ) and mm [5.15 in] ( E )) and in lengths from 3 cycles to 20 cycles. Contact MagneMotion Customer Support for detailed information on specific magnet arrays. Figure 4-3 shows an 80 mm wide 3 cycle array for reference, note that the number, quantity, and locations of the mounting holes will vary based on the size of the array. 2X 9.5 M5X X DOWEL PIN C L [3.150] C L [2.362] [1.417] [1.417] [2.362] X R [0.187] 4.76 [5.905] X [0.17] 4.2 [5.118] C L Weight: see Table 4-1 All Dimensions in Millimeters [Inches] Figure 4-3: Standard F Magnet Array Mechanical Drawing Rev. D

97 Specifications and Site Requirements Mechanical Specifications Table 4-1: Standard Magnet Array Weights 80.0 mm [3.15 in] Wide (Standard F ) mm [5.15 in] Wide * (Standard E ) Cycles Length Weight Weight mm [5.90 in] 0.93 kg [2.05 lb] 1.53 kg [3.37 lb] mm [7.79 in] 1.24 kg [2.73 lb] 2.04 kg [4.50 lb] mm [9.68 in] 1.55 kg [3.42 lb] 2.55 kg [5.62 lb] mm [11.57 in] 1.86 kg [4.10 lb] 3.06 kg [6.75 lb] mm [13.46 in] 2.17 kg [4.78 lb] 3.57 kg [7.87 lb] mm [15.35 in] 2.48 kg [5.47 lb] 4.08 kg [9.00 lb] mm [17.24 in] 2.79 kg [6.15 lb] 4.59 kg [10.12 lb] mm [19.13 in] 3.10 kg [6.83 lb] 5.10 kg [11.24 lb] mm [21.02 in] 3.41 kg [7.52 lb] 5.61 kg [12.37 lb] mm [22.91 in] 3.72 kg [8.20 lb] 6.12 kg [13.49 lb] mm [24.80 in] 4.03 kg [8.88 lb] 6.63 kg [14.62 lb] mm [26.69 in] 4.34 kg [9.57 lb] 7.14 kg [15.74 lb] mm [28.58 in] 4.65 kg [10.25 lb] 7.65 kg [16.87 lb] mm [30.47 in] 4.96 kg [10.93 lb] 8.16 kg [17.99 lb] mm [32.36 in] 5.27 kg [11.62 lb] 8.67 kg [19.11 lb] mm [34.25 in] 5.58 kg [12.30 lb] 9.18 kg [20.24 lb] mm [36.14 in] 5.89 kg [12.99 lb] 9.69 kg [21.36 lb] mm [38.03 in] 6.20 kg [13.67 lb] 10.2 kg [22.49 lb] * Wide magnet arrays are typically used when QS 100 motors are arranged in a curve to ensure coverage (refer to Magnet Array Length and Attractive Force on page 3-18). Exposed Materials Low Carbon Steel. Hardened Steel. Nd-Fe-B magnets with Ni-Cu-Epoxy coating. Oxy-Cast 607. QuickStick 100 User s Manual 4-5

98 Specifications and Site Requirements Mechanical Specifications Magnet Array, High Flux High flux magnet arrays (refer to High Flux Magnet Arrays on page 3-21) are available in two widths (78.5 mm [3.09 in] ( F )) and mm [5.10 in] ( E )) and in lengths from 3 cycles (149.0 mm [5.87 in]) to 20 cycles (965.0 mm [38.00 in]). Contact MagneMotion Customer Support for detailed information on specific magnet arrays. Figure 4-4 shows a mm wide 9 cycle array for reference, note that the number, quantity, and locations of the mounting holes will vary based on the size of the array. Other widths may be available, contact MagneMotion Customer Support for more information. C L C L [5.1] [17.2] [0.87] [.197] C L 8X M5 X 0.8-6H 6.5 MAX [1.575] 4X C L 4X [1.575] [2.362] Figure 4-4: High Flux E Magnet Array Mechanical Drawing Exposed Materials Low Carbon Steel. Hardened Steel. Nd-Fe-B magnets with Ni-Cu-Ni coating. 304 Stainless Steel, 18-8 Stainless Steel. 2X [6.142] Weight: Varies by length [7.087] X Rev. D 0 2X [2.362] [6.142] X C L [7.087] All Dimensions in Millimeters [Inches]

99 Specifications and Site Requirements Mechanical Specifications NC-12 Node Controller [10.2] [9.98] [0.12] 3.10 [8.18] [7.00] [0.77] [2.5] 63.5 [2.5] 63.5 [2.5] 63.5 [3.44] 87.3 [0.62] 15.6 [8.75] [1.34] X.250 UNC-2B.310 [4.34] Weight: 3.6 kg [8 lb] Figure 4-5: NC-12 Node Controller Mechanical Drawing NOTE: A minimum of 50% of each vent must be clear for unobstructed air flow. A mounting kit is available for standard 19 in electronics rack (refer to Rack Mounting Bracket on page 4-8). Refer to NC-12 Node Controller on page 4-16 for the electrical specifications. Exposed Materials All Dimensions in Millimeters [Inches] The Node Controller provides openings for airflow and should not be located in an area where harsh conditions exist. QuickStick 100 User s Manual 4-7

100 Specifications and Site Requirements Mechanical Specifications Rack Mounting Bracket The rack mounting bracket can be used for mounting the NC-12 Node Controller in a standard 19 in electronics rack [4.51] 50.8 [2.00] 25.4 [1.00] 86.9 [3.42] 7.1 [0.28] 3.3 [0.13] All Dimensions in Millimeters [Inches] Figure 4-6: Rack Mounting Bracket Mechanical Drawing Exposed Materials Carbon Steel Steel. Anodized Aluminum Rev. D

101 Specifications and Site Requirements Mechanical Specifications Node Controller LITE CABLE CONNECTOR EXCLUSION AREA [2.5] X [0.19] 4.8 MOUNTING PLATE REQUIRED ON CROSSHATCHED AREA 2X [0.220] X [3.13] 79.5 [9.19] [8.84] ADJUSTABLE SLIDING MOUNTING BRACKETS [2.5] 63.5 [0.17] 4.3 CABLE CONNECTOR EXCLUSION AREA [4.27] [4.88] [5.52] LAN 18 VDC PoE ONLY PWR CONSOLE [1.75] 44.5 Weight: 0.7 kg [1.5 lb] Figure 4-7: Node Controller LITE Mechanical Drawing NOTE: A plate is available for mounting (refer to Electronics Mounting Plate on page 4-10). Exposed Materials All Dimensions in Millimeters [Inches] Refer to Node Controller LITE on page 4-21 for the electrical specifications. The Node Controller has unprotected openings and should not be located in an area where harsh conditions exist. QuickStick 100 User s Manual 4-9

102 Specifications and Site Requirements Mechanical Specifications Electronics Mounting Plate The Electronics Mounting Plate can be used for mounting the Node Controller LITE, the SYNC IT controller, and Ethernet Switches. 2X M4 THRU 4X M5 THRU 2X 10.00[0.39] M5 X 12 MM STUD R3.2 TYP All Dimensions in Millimeters [Inches] Figure 4-8: Electronics Mounting Plate Mechanical Drawing Exposed Materials 5052-H32 Aluminum. 300 Series Stainless Steel. A-286 Hardened Stainless Steel Rev. D

103 Specifications and Site Requirements Mechanical Specifications QS 100 Power Supply [17.32] [13.82] [15.12] [0.98] , -02, , [1.72] 43.6 [18.35] Weight: -01: 5.7 kg [12.6 lb] Figure 4-9: QS 100 Power Supply Mechanical Drawing NOTE: All of the vents must be clear for unobstructed air flow. Exposed Materials [19.0] : 7.7 kg [17.0 lb] -03: 9.7 kg [21.4 lb] All Dimensions in Millimeters [Inches] Designed for mounting in a standard 19 in electronics rack. Refer to QS 100 Power Supply on page 4-25 for the electrical specifications. The power supply provides openings for airflow and should not be located in an area where harsh conditions exist. QuickStick 100 User s Manual 4-11

104 Specifications and Site Requirements Electrical Specifications Electrical Specifications QS 100 Motors 1000 mm VDC, 48 VDC nominal at 2 A, 5 A max Refer to 1000 Millimeter Motor on page 4-2 for the mechanical drawing. 500 mm VDC, 48 VDC nominal at 1 A, 2.5 A max Refer to 500 Millimeter Motor on page 4-3 for the mechanical drawing. NOTE: The motors draw additional power when the vehicle is moving or accelerating (refer to Table 4-2). The amount of additional power drawn depends on the vehicle s velocity and acceleration, the number of vehicles that may accelerate at once, and the magnet array length. All power wiring must be capable of carrying the full load. The propulsion power input (J2) uses a PTC (positive temperature coefficient) resistor to limit inrush current upon application of power. Limit cycling of the propulsion power to three times or less per minute to allow the PTC to cool-down. The PTC is only used for inrush current limiting and is bypassed in normal operation. Providing a separate power source for the logic power allows the motors to be programmed and configured without enabling the propulsion power. If only propulsion power is supplied to the motors, connection to logic power is automatically made within the motor. 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 4-2: QuickStick 100 Motor Power Requirements Component Maximum Power QS 100 Motor, 500 mm - Control power 5 W QS 100 Motor, 1000 mm - Control power 10 W Vehicle - Propulsion power Variable * * The motor s propulsion power is fused at 15 A. Maximum power is drawn by the motor when the vehicle is moving at maximum acceleration or velocity. Contact MagneMotion for support in determining the correct power supply size based on the motor application and size of the magnet array. NOTICE Never disable propulsion power by switching the propulsion input pin of the motor from the DC power source directly to ground as this will produce large current spikes that will damage the electronics. NOTICE Any user-supplied power supply must be NRTL/ATL approved. NOTICE Hot-plugging of either power source to the motors is not recommended Rev. D

105 Specifications and Site Requirements Electrical Specifications Downstream RS-422 (See manual for pinout) Upstream RS-422 (See manual for pinout) J5 J3 J2 J1 J5 Downstream J3 Sync Bottom View J2 Power Figure 4-10: Motor Electrical Connections J1 Upstream Table 4-3: Motor Connections Label Description Connector Type J1 RS-422, Upstream communications DE-9, Female J2 Power, VDC, +48 VDC nominal 1000 mm motor - 2 A, 5 A max 500 mm motor - 1 A, 2.5 A max DB-9W4, Male J3 External Synchronization DE-9, Female J5 RS-422, Downstream communications DE-9, Male Table 4-4: RS-422 Pinouts J5 DE-9, Male (Downstream) J1 DE-9, Female (Upstream) 1 1 TxD- 2 RxD- 2 RxD+ 3 TxD TxD+ 7 RxD+ 7 RxD- 8 TxD QuickStick 100 User s Manual 4-13

106 Specifications and Site Requirements Electrical Specifications Table 4-5: Power Connector Pinout A1 1 2 A4 J2 DB-9W4, Male GND (PE) 3 A1 +48 VDC Logic A2 +48 VDC Propulsion A3 48 VDC Return A VDC Logic 2 * 3 48 VDC Logic Return 4 * GND (PE) 5 * * The motors provide connections for Logic power on Pins 2, 4, and 5. For existing installations, there is no need to change power wiring. However, for new designs MMI recommends all power connections to the motor be made to Pins A1 - A4 only. 5 Table 4-6: Sync Connector Pinout J3 DE-9, Female Signal Pin I/O Max Voltage 1 SIMO 2 Input 3.3 V SOMI 3 Output 3.3V RESET 4 Output 3.3V 5 6 CLK 7 Input 3.3 V STE 8 Input 3.3 V GND V Rev. D

107 Specifications and Site Requirements Electrical Specifications Motor Power Cable The QS 100 Motor is supplied with a 2 meter, unterminated, power drop cable, shown in Figure 4-11, which provides power to the motor. Contact MagneMotion for replacement cables. This cable connects the motor power to a nearby junction box. When installing, the cable should be cut to length to minimize the voltage drop between the motor and the junction box as specified in Cable Use. Each wire in the cable is color coded for identification. A4 A1 DB-9W4, F Figure 4-11: Motor Power Drop Cable Table 4-7: Motor Power Drop Cable Pinouts A4 2 1 A1 Wire Color DB-9W4, Female GND (PE) Grn A1 +48 VDC Logic Wht A2 +48 VDC Propulsion Red A3 48 VDC Return Blk A4 no connection 1 no connection 2 no connection 3 no connection 4 no connection 5 Cable Use 1. Cut the supplied cable to length. 2. Strip the ends of the individual wires (approx. 1/2 in). 3. Connect +48 VDC Logic, +48 VDC Propulsion, and 48 VDC Return to the Power Bus in a junction box. 4. Connect GND (PE) to the Ground stud in the same junction box. 5. Ensure all junction boxes are connected to PE. 5 3 QuickStick 100 User s Manual 4-15

108 Specifications and Site Requirements Electrical Specifications NC-12 Node Controller VDC, 20 W maximum based on configuration and operating mode. Refer to NC-12 Node Controller on page 4-7 for the mechanical drawing. AC Power Option The optional remote power supply for the NC-12 Node Controller requires Hz, single phase (phase to phase or phase to neutral), 0.7 A at 100 VAC (25 W max), based on configuration and operating mode. Inrush current 45 A/240 VAC max. Refer to the manufacturer s data sheet for mechanical information. The actual power being drawn will depend upon operations being performed, however all power wiring must be capable of carrying the full load. DC Power Option VAC, 25 W CAUTION High Voltage Hazard AC power must be disconnected before servicing. DC power from a user-supplied power supply requires VDC, 20 W. NOTICE Any user-supplied power supply must be NRTL/ATL approved. The actual power being drawn will depend upon operations being performed, however all power wiring must be capable of carrying the full load and has a limited power source or is fused to the maximum rating of the power wiring. NOTICE The NC-12 Node Controller does not support Power over Ethernet (PoE). Connecting the controller to a powered Ethernet network may damage it. NOTICE Connecting to the DC power connector on the NC-12 Node Controller must be done with the power supply off. 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 Rev. D

109 Specifications and Site Requirements Electrical Specifications Power Indicator RS-232 Digital I/O RS-422 Front View Ethernet DC Power Console Ground Figure 4-12: NC-12 Node Controller Electrical Connections and Indicators Table 4-8: NC-12 Node Controller Connections Label Description Connector Type CONSOLE External terminal DE-9, Male ETHERNET Ethernet 10/100/1000 BaseTx RJ-45, Female, IP-67 * DIGITAL I/O Digital I/O, refer to Digital I/O Connection on page 4-33 Spring-cage clamp RS-232 RS-232 external communications DE-9, Male RS-422 RS-422 motor communications M8 Nano-Mizer, 4-Pin, Male POWER VDC, 20 W DC Power Jack, 2.0 mm Coax, Male, M12 Thread Ground 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. Table 4-9: NC-12 Node Controller Indicators Label Description Indicator Type PWR ON Indicates DC power is on. Green LED QuickStick 100 User s Manual 4-17

110 Specifications and Site Requirements Electrical Specifications Table 4-10: NC-12 Node Controller Console Pinout DE-9, Male 1 Rx 2 Tx 3 4 RTN Table 4-11: NC-12 Node Controller Ethernet Pinout 8 1 RJ-45, Female TD+ 1 TD- 2 RD RD Rev. D

111 Specifications and Site Requirements Electrical Specifications Table 4-12: NC-12 Node Controller RS-232 Pinouts DE-9, Male 1 Rx 2 Tx 3 4 RTN Table 4-13: NC-12 Node Controller RS-422 Pinouts M8 Nano-Mizer, 4-Pin, Male RxD+ 1 RxD- 2 TxD+ 3 TxD- 4 Table 4-14: NC-12 Node Controller Power Pinout Sleeve Pin 2.0 mm Coax, Male PWR RTN Pin Sleeve QuickStick 100 User s Manual 4-19

112 Specifications and Site Requirements 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 Rev. D

113 Specifications and Site Requirements Electrical Specifications Node Controller LITE 7-18 VDC, 5 W maximum based on configuration and operating mode. Refer to Node Controller LITE on page 4-9 for the mechanical drawing. AC Power Option The optional remote power supply for the Node Controller LITE (NC LITE) requires Hz, single phase (phase to phase or phase to neutral), 0.7 A at 100 VAC (25 W max), based on configuration and operating mode. Inrush current 45 A/240 VAC max. Refer to the manufacturer s data sheet for mechanical information. CAUTION High Voltage Hazard VAC, 25 W AC power must be disconnected before servicing. The actual power being drawn will depend upon operations being performed, however all power wiring must be capable of carrying the full load. DC Power Option DC power from a user-supplied power supply requires 7-18 VDC, 5 W. NOTICE Any user-supplied power supply must be NRTL/ATL approved. 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. QuickStick 100 User s Manual 4-21

114 Specifications and Site Requirements Electrical Specifications LAN PWR LAN (18 VDC PoE) 18 VDC PoE ONLY CONSOLE Console Power Front View RS-422 Back View Figure 4-13: Node Controller LITE Electrical Connections LAN Table 4-15: Node Controller LITE Connections Label Description Connector Type Ethernet 10/100 BaseTx (Passive PoE, 18 VDC) RJ-45, Female PWR 7-18 VDC, 5 W DC Power Jack, 2.0 mm Coax, Male CONSOLE External terminal DE-9, Male 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 4-16: Node Controller LITE Power Pinout Sleeve Pin 2.0 mm Coax, Male PWR RTN Pin Sleeve Rev. D

115 Specifications and Site Requirements Electrical Specifications Table 4-17: Node Controller LITE LAN Pinout 8 1 RJ-45, Female TD+ 1 TD- 2 RD VDC VDC 5 RD- 6 RTN 7 RTN 8 Table 4-18: Node Controller LITE Console Pinout DE-9, Male 1 Rx 2 Tx 3 4 RTN QuickStick 100 User s Manual 4-23

116 Specifications and Site Requirements Electrical Specifications Table 4-19: Node Controller LITE RS-422 Pinouts Upstream Downstream J1, J3 - DE-9, Male J2, J4 - DE-9, Female 1 1 RxD- 2 TxD- 2 TxD+ 3 RxD RxD+ 7 TxD+ 7 TxD- 8 RxD AC Power Cable The Node Controller LITE 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. The remote power supply and AC cable for the Node Controller LITE is not required if Power over Ethernet is being used Rev. D

117 Specifications and Site Requirements Electrical Specifications QS 100 Power Supply VAC, Hz. Inrush current < 40 A per power supply module. The QS 100 Power Supply may contain up to three 1 kw power supply modules. Refer to QS 100 Power Supply on page 4-11 for the mechanical drawing. CAUTION High Voltage Hazard VAC, 1 kw per power supply module. AC power must be disconnected before servicing. The actual power being drawn depends upon operations being performed, however all power wiring must be capable of carrying the full load. NOTE: A readily accessible third-party approved branch circuit overcurrent protective device rated at 20 A must be installed for each QS 100 Power Supply. Each QS 100 Power Supply provides up to 3 kw DC for powering the QuickStick motors. The number of power supplies required for a specific QuickStick configuration can be determined from Table 4-2 where the maximum power consumption for each component within the QuickStick transport system is identified. NOTICE The QS 100 Power Supply uses internal NRTL/ATL approved power supplies. If a user-supplied power supply is used in its place it must be NRTL/ATL approved. QuickStick 100 User s Manual 4-25

118 Specifications and Site Requirements Electrical Specifications -01 (1 kw) -02 (2 kw) -03 (3 kw) DC OK DC FAIL AC OK Front View DC Output AC Input Control and Monitoring Rear View Figure 4-14: QS 100 Power Supply Electrical Connections Table 4-20: QS 100 Power Supply Connections Label Description Connector Type AC Input VAC, Hz IEC 320, Female DC Output Motor power: 48 VDC ±1%, 1-3 kw M6 Screw Terminals Control and Monitoring Power supply control and monitoring (refer to manufacturer s documentation) DB-25, Female Table 4-21: QS 100 Power Supply Indicators (per PS Module) Label Description Indicator Type DC OK ON Indicates output voltage is > 80% of rated value Green LED DC FAIL ON Indicates output voltage is < 80% of rated value Red LED AC OK ON Indicates input voltage is > 85 V rms Green LED Table 4-22: QS 100 Power Supply DC Power Pinout Individual Terminals +48 VDC V+ RTN V Rev. D

119 Specifications and Site Requirements Electrical Specifications Table 4-23: QS 100 Power Supply Control and Monitoring Pinout DB-25, Female V_TRIM_B 1 14 TEMP_ALARM_B 2 DC_OK_B 3 TEMP_ALARM_A 4 ON/OFF_A 5 DC_OK_A 6 V_TRIM_A 7 +12V_AUX 8 CS 9 V_TRIM_C 10 SIGNAL_RETURN 11 DC_OK_C 12 +SENSE 13 AC_FAIL_B 14 ON/OFF_B 15 AC_FAIL_A 16 NC 17 NC 18 NC 19 SCL 20 SDA 21 -SENSE 22 TEMP_ALARM_C 23 AC_FAIL_C 24 ON/OFF_C 25 QuickStick 100 User s Manual 4-27

120 Specifications and Site Requirements Electrical Specifications Control Cable The QS 100 Power Supply is supplied with a control cable, which provides basic ON/OFF control of the power supply. Contact MagneMotion for replacement cables. The control cable plugs directly into the power supply. Figure 4-15: QS 100 Power Supply Control and Monitoring Cable Table 4-24: QS 100 Power Supply Control and Monitoring Cable Pinouts 1 13 Individual Terminals DB-25, Male +VDC 13 -VDC 22 Internally Shorted 14 5, 11, 15, AC Power Cable The QS 100 Power Supply is supplied with a power cable. Contact MagneMotion for replacement cables. The AC power cable plugs directly into the power supply. CAUTION There is a potential shock hazard if the power supply chassis and cover are not connected to an electrical safety ground via the safety ground in the AC input connector Rev. D

121 Ethernet Switch with Power over Ethernet Injector Specifications and Site Requirements Electrical Specifications The remote power supply for the Ethernet switch requires Hz, single phase (phase to phase or phase to neutral), <1.0 A rms (100 W max), based on configuration and operating mode. Inrush current <37 A at 230 VAC cold start. The actual power being drawn will depend upon operations being performed, however all Ethernet cables used for PoE must be capable of carrying the full load. The Power over Ethernet (PoE) switch provides A max/port for the Node Controller LITE. NOTICE The voltage provided by the Power over Ethernet switch is non-standard (18 VDC) and the switch does not disable power at any port. Connecting any device other than a Node Controller LITE to the PoE switch may damage the device. AC Power Cable The Ethernet Switch with PoE power supply is supplied with a power cable. Contact MagneMotion for replacement cables. The AC power cable plugs directly into the power supply. QuickStick 100 User s Manual 4-29

122 Specifications and Site Requirements Communications Communications Ethernet Connection The NC LITE Node Controller supports Ethernet connections of 10/100 Mb/s (auto-negotiation supported). The NC12 Node Controller supports Ethernet connections of 10/100/1000 Mb/s (auto-negotiation supported). Network communications provides the ability to connect a number of different devices to a factory controller using a single communications cable, which simplifies wiring. Each device connected to the network has a unique network device address. Only communications addressed to a specific device through the network 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. Note that the Node Controllers always use TCP/IP for communication between Node Controllers. In situations where the Host Controller is unavailable, a personal computer running a network communications application, such as MagneMotion s NCHost, may be connected to the transport system network. NOTE: While both TCP/IP and EtherNet/IP use the same hardware for communication, the communication protocol itself is different. This allows both protocols to run on the same network at the same time without interfering with each other. The Ethernet cables used are standard network cable (UTP-Cat5) with an 8-pin RJ-45 connector that plugs into the NC-12 Node Controller at the ETHERNET port and the Node Controller LITE at the LAN port. Refer to Figure 4-12 and Figure 4-13 for the locations of these connections. NOTE: To establish a direct communications link from a PC to any Node Controller using Ethernet, a standard Ethernet cable may be used (auto-mdix is supported). TCP/IP Communication TCP/IP communication is supported for use when the Host Controller is PC-based or for some PLCs that use TCP/IP. TCP/IP communications allows the Host Controller to communicate with the High Level Controller (HLC) using the commands detailed in the Host Controller TCP/IP Communication Protocol User s Manual and the Mitsubishi PLC TCP/IP Library User s Manual. TCP/IP communications is also used between the Node Controllers and the Node Controller designated as the High Level Controller. NOTE: There is one Host control connection and four Host status connections on the HLC. If a second Host attempts to connect to the Host control TCP/IP port, it will cause the first Host to be disconnected. If a fifth connection to the status TCP/IP port is attempted, it will cause the first status connection to be disconnected Rev. D

123 Specifications and Site Requirements Communications The connection to all Node Controllers uses standard Ethernet network wiring. Note that if more than one Node Controller is connected to the same network the IP address of each additional Node Controller must be changed to a unique address to avoid IP conflicts. The TCP/IP address used on the Node Controller(s) must be configured as specified in the Node Controller Interface User s Manual. EtherNet/IP Communication EtherNet/IP communication is supported for use when the Host Controller is PLC-based. EtherNet/IP communications allows the Host Controller to communicate with the High Level Controller using the memory-mapped tags detailed in the Host Controller EtherNet/IP Communication Protocol User s Manual. The connection to the Node Controller acting as the High Level Controller from the Host Controller uses standard Ethernet network wiring. The EtherNet/IP address used on the Node Controller configured as the High Level Controller must be configured as specified in the Node Controller Interface User s Manual. RS-232 Serial Interface Connection RS-232 serial communication on the NC-12 Node Controller is not used with QuickStick 100 transport systems. RS-422 Serial Interface Connection RS-422 serial communication provides the ability to connect the Node Controllers to the motors in a daisy-chain using a simple 4-wire cable. Refer to Figure 4-16 for cable identification and Table 4-25 for cable pinouts. Refer to Figure 4-10 for the locations of these connections on the motors. Refer to Figure 4-12 through Figure 4-13 for the locations of these connections on the Node Controllers. NOTE: There is no need to construct the RS-422 cables as all cabling is supplied with the transport system. Contact MagneMotion for additional or replacement cables. The RS-422 serial cables for upstream connections connect to the Node Controller using either a 9-pin female D connector on the end that plugs into the Node Controller LITE at any of the odd numbered RS-422 ports or a 4-pin female M8 connector on the end that plugs into the NC-12 Node Controller at any of the RS-422 ports. The RS-422 serial cables connect to the QS 100 motor using a 9-pin male D connector on the cable plugs into the first motor in the Path at the upstream communication port. The RS-422 daisy-chain cables use a 9-pin female D connector that plugs into one motor at the downstream communication port on the motor and a 9-pin male D connector that plugs into the next motor in the chain at the upstream communication port. The RS-422 serial cables for downstream connections connect to the Node Controller using either a 9-pin male D connector on the end that plugs into the Node Controller LITE at any QuickStick 100 User s Manual 4-31

124 Specifications and Site Requirements Communications of the even numbered RS-422 ports or a 4-pin female M8 connector on the end that plugs into the NC-12 Node Controller at any of the RS-422 ports. The RS-422 serial cables connect to the QS 100 motor using a 9-pin female D connector on the end that plugs into the last QS 100 motor in the chain at the downstream communication port. NOTE: MagneMotion recommends that the upstream connection to the NC LITE Node Controller always be made to an odd numbered (male DE-9) RS-422 port and the downstream connection always be made to an even numbered (female DE-9) RS-422 port. However, a custom crossover gender changer may be used to connect an RS-422 DE-9 connector of the wrong gender to the Node Controller. End A (Motor) End B (Node Controller) Nano-Mizer, F DE-9, M Nano-Mizer, F DE-9, F DE-9, F Figure 4-16: RS-422 Cables Table 4-25: RS-422 Cable Pinouts DE-9, M M8 Nano-Mizer, 4-Pin, Female End A DE-9, Female DE-9, Male DE-9, Female End B RxD+ 1 7 TxD+ 3 7 RxD- 2 2 TxD- 8 2 TxD+ 3 3 RxD+ 7 3 TxD- 4 8 RxD Rev. D

125 Specifications and Site Requirements Communications Sync Connection The optional Sync connection provides a method to directly connect a motor to the Host Controller to allow the controller to synchronize the positioning of vehicles on the motor with an external mechanism. Refer to the LSM Synchronization Option User s Manual for cable and connection details. NOTE: There is no need to construct the sync cables as all cabling is supplied with the transport 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. These signals can be used as required. Typical applications include wiring E-Stops and Light Stacks. Digital I/O signals can be connected to the NC-12 Node Controllers only. Refer to Figure 4-12 for the location of these connections on the Node Controller VDC Signal 1.2K Ohm Load VDD DOn V5V COM RTN DC (5-35V) + RTN PC 817 Signal 1.2K Ohm Darlington Sink Driver VDC COM RTN Digital Inputs Figure 4-17: Digital I/O Equivalent Circuits Digital Outputs The digital inputs can be wired as a sink where a VDC signal is wired to the appropriate digital input and COM is connected to the return (minus) side of the signal as shown in Figure The digital inputs can also be wired as a source where VDC is wired to the COM and the appropriate input is wired through the signal to ground as shown in Figure NOTE: The GND pin on the Node Controllers is not used for the digital inputs even though there is a spring clamp on the Inputs side for GND. The digital outputs can only be wired as a sink where a VDC supply is wired through a load and sunk when the digital output in use is turned on by the Node Controller as shown in Figure QuickStick 100 User s Manual 4-33

126 Specifications and Site Requirements Site Requirements Site Requirements Environment Motors NC LITE NC-12 Temperature: Humidity: Temperature: Humidity: Temperature: Humidity: Power Supply Temperature: Humidity: 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] 85% Maximum (relative, non-condensing) 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] 85% Maximum (relative, non-condensing) Operating: 0 C to 45 C [32 F to 113 F] Shipping: -18 C to 50 C [0 F to 122 F] Storage: -18 C to 50 C [0 F to 122 F] 85% Maximum (relative, non-condensing) 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] 85% Maximum (relative, non-condensing) Rev. D

127 Specifications and Site Requirements Site Requirements Magnet Arrays Temperature: Humidity: Lighting, Site Operating: 0 C to 50 C [32 F to 122 F] Shipping: -18 C to 60 C [0 F to 140 F] Storage: -18 C to 60 C [0 F to 140 F] 85% Maximum (relative, non-condensing) No special lighting is required for proper operation of the QuickStick 100 transport system. Maintenance may require a user-supplied service lamp (e.g., flashlight). Floor Space and Loading The site for the QuickStick 100 transport system must meet the minimum space requirements defined after developing the layout as defined in Transport System Layout on page 3-2 and referencing the Mechanical Specifications on page 4-2 to ensure proper clearance for installation, operation, and servicing of the QS 100 motors and other components. Note that the dimensions given are for the QS 100 motors and other components only. It is the user s responsibility to ensure adequate space around the equipment for operation and service based on their needs and any vehicle overhang. Facilities The user is responsible for providing the facilities specified in Electrical Specifications on page 4-12 to ensure proper operation of the QuickStick 100 motors and other components. Refer to Facilities Connections on page 5-22 for the connection of all facilities to the QS 100 transport system. The facility is responsible for the main disconnect device between the QuickStick 100 transport system and the facility s power source, ensuring it complies with the appropriate facility, local, and national electrical codes. Service to the QuickStick 100 transport system should have the appropriate circuit breaker rating. Service Access The QuickStick 100 transport system requires adequate space for service access and for proper operation. Typical service space required for the QS 100 motors is shown in Figure 4-1 and Figure 4-2. Typical service space required for the Node Controllers is shown in Figure 4-5 and Figure 4-7. Refer to the LSM Synchronization Option User s Manual for the service space required for the SYNC IT Controller. QuickStick 100 User s Manual 4-35

128 Specifications and Site Requirements Site Requirements Ensure that installation of the QuickStick 100 transport system is such that it provides access to items required for service after installation, such as power and communication connections. NOTE: The Exclusion Zones shown are for the QuickStick 100 transport system components only. Additional exclusion zones may be required based on the design of the vehicle and the material being transported by the QuickStick 100 transport system Rev. D

129 Installation 5 Overview This chapter provides complete installation procedures for the QuickStick 100 components used in a transport system. Included in this chapter are: Unpacking and inspection of the QuickStick 100 transport system components. QuickStick 100 component installation including: hardware installation, facilities connections, and software installation and configuration. Initial power-up and check-out. Transport system testing using demonstration scripts. QuickStick 100 User s Manual 5-1

130 Installation Unpacking and Inspection Unpacking and Inspection The QuickStick 100 transport system components are shipped in separate packages. Open each package carefully following the steps provided in Unpacking and Moving on page 5-2; inspect and verify the contents against the shipping documents. Report any damage immediately to the shipper and to MagneMotion. One set of shipping documents is attached to the outside of the main shipping crate for easy access. NOTE: The number and contents of the shipping packages depends on the items purchased. Refer to the shipping documents for the exact contents. Table 5-1, below, is provided for reference only. Table 5-1: Packing Checklist Reference Package Contents QuickStick 100 Motors Magnet Arrays Node Controllers Power Supplies QuickStick linear synchronous motors. Magnet arrays to be attached to the vehicles for moving material on the transport system. MagneMotion Node Controllers for managing the Nodes in the transport system. Power supplies to provide DC logic and motor power to the QS 100 motors. Installation Kit Miscellaneous hardware Cables User s Manuals, drawings, etc. Unpacking and Moving Required Tools and Equipment Open End Wrench, Adjustable. Metric Hex wrenches. Unpacking and Moving Instructions The QuickStick 100 components arrive from the factory ready for installation. The information required to install these components is provided in Transport System Installation on page Rev. D

131 Installation Unpacking and Inspection WARNING Strong Magnets To avoid severe injury, people with pacemakers and other medical electronic implants must stay away from the magnet arrays. To avoid injury from strong magnetic attractive forces: Handle only one magnet array at a time. Do not place any body parts, such as fingers, between a magnet array and any QuickStick 100 motors, ferrous material, or another magnet array. Magnet arrays not being used should be secured individually in isolated packaging. To avoid damage to watches, electronic instruments, and magnetic media (e.g., cell phones, memory disks/chips, credit cards, and tapes) keep these items far away from the magnet arrays. CAUTION Heavy Lift Hazard kg Some of the QuickStick 100 components can weigh as much as 13.2 kg [29.1 lb]. Failure to take the proper precautions before moving them could result in personal injury. Use proper lifting techniques when moving any QS 100 components. Steel toe shoes should be worn at all times when installing any QS 100 components. NOTE: Save the shipping packaging for possible future use. If any of the QuickStick 100 components are shipped, the original shipping packaging must be used. If the original packaging has become lost or damaged, contact MagneMotion for replacements. 1. Upon receiving the packages, visually verify the packaging is not damaged. Inform the freight carrier and MagneMotion of any inspection discrepancy. 2. Open each shipping package and verify the contents against the shipping documents. 3. Carefully inspect the QuickStick 100 components and all additional items for signs of damage that may have occurred during shipping. 4. Move all items to their destination (refer to Transport System Installation on page 5-4). QuickStick 100 User s Manual 5-3

132 Installation Transport System Installation Transport System Installation The QuickStick 100 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 QuickStick 100 components provides access to items required for service after installation, such as connection panels. Once properly located, the QuickStick 100 transport system should be leveled and secured to the floor or other rigid mounting points designed as part of the system to prevent any movement. Installing Hardware To install the motors on user-supplied supports ensure the supports are properly prepared to receive the motors (refer to Mechanical Specifications on page 4-2). Install the motors (refer to Mounting the Motors on page 5-6) making any adjustments necessary to account for the custom supports. NOTE: Any bolts with plastic caps have been pre-tightened at the factory to the appropriate torque specification and do not need to be tightened during installation. Required Tools and Materials When performing any of the following procedures, adhere to and follow all safety warnings and instructions. Metric Hex wrench set. Torque wrench with the metric bits. Screwdriver, Small flat blade. Screwdriver, Phillips. 12 Machinist Square. Laser level, rotary. Digital Multimeter. Loctite 243, Thread locker Anaerobic Adhesive, Blue Rev. D

133 Installation Transport System Installation Installation Overview This provides an overview of the installation of the QuickStick 100 motors and other QS 100 components on user equipment or a custom track system. NOTICE Ensure the equipment or track system where the QuickStick 100 motors will be mounted and the motor mounting surfaces are properly grounded to safety ground (earth). 1. Assemble a complete section of the track, including guideway, motor mounts, and stand (refer to Figure 1-1, Assembling the Guideway on page 5-6, and Installing Vehicles on page 5-20). 2. Prepare and level the equipment where the motors will be mounted (refer to Leveling the Transport System on page 5-6). 3. Secure the track to the floor or other equipment as required (refer to Securing the Transport System on page 5-6). 4. Install the motors ensuring the motor bodies are parallel to each other and tops of all motors are coplanar to each other and tighten the motor mounting bolts (refer to Mounting the Motors on page 5-6). 5. Install the power supplies, Node Controllers, network switches, and cables (refer to Installing Electronics on page 5-7). 6. Install magnet arrays on the vehicles and install the vehicles on the system (refer to Installing Vehicles on page 5-20). 7. Make all communications, network, and power connections (refer to Facilities Connections on page 5-22). 8. Create the Node Controller Configuration File and install software tools (refer to Software on page 5-26). 9. Power up the system and check all operating features, safety features, and connections (refer to Check-out and Power-up on page 5-28). QuickStick 100 User s Manual 5-5

134 Installation Transport System Installation System Installation Assembling the Guideway The guideway with the motor mounts must be located and attached to stands or other equipment as required. Each guideway section must be connected to the guideway sections on either side of it to form the complete system layout. The layout may be broken into sections for ease of assembly. When breaking the layout into sections, ensure that each section is as self-contained as possible. NOTE: Before completing a closed guideway add the vehicles by sliding them onto a section of guideway that has been installed (refer to Installing Vehicles on page 5-20). Leveling the Transport System Once the track assembly is complete ensure that it is properly located and ensure all sections of the track are level. 1. Establish a datum for the system (interface to existing equipment, etc.). 2. Use a laser level to identify the datum throughout the installation area. 3. Ensure all sections of the track are level and correctly referenced to the datum. Make any adjustments to the track as necessary. Securing the Transport System Floor tie-downs should be used to secure the QuickStick 100 transport system to the floor to prevent system movement. Secure the transport system to the floor and to any other equipment as required. NOTE: Tie-downs for facilities requiring earthquake protection are the responsibility of the user. NOTICE Ensure the transport system is properly grounded to safety ground (earth). Mounting the Motors The motors must be attached to the motor mounts on the guideway (refer to Figure 3-17 on page 3-29 for an overview). NOTE: Ensure all motors are flat and level once mounted. 1. Locate all QS 100 motors (if not already installed) by placing the bottom of the motor on the motor mounts installed on the guideway and secure the motor using M8 bolts Rev. D

135 Installation Transport System Installation and M8 split lock washers through the motor mount to the M8 T-Blocks and finger tighten. NOTE: Locking features such as thread locker or lock washers must be used. 2. Adjust the position of all motors to ensure the motors are collinear to each other and the space between motor bodies is consistent with the system layout. 3. Ensure the tops of all motors are coplanar to each other (adjust the motor mounts as required). 4. Tighten all QS 100 motor mounting hardware (typically 25 N-m [22 ft-lb] max). NOTE: Refer to the engineering drawings for the locations, depths, and torques for all mounting features. 5. Verify all motors are properly mounted and the Motor Gap between all motors is identified and recorded, the top surface of all motors are coplanar to each other, all guide rails are collinear, and all motor mounting bolts are tightened. NOTE: The Motor Gap must be entered for the motors in the Node Controller Configuration File. If all motors on a Path have the same Motor Gap, it can be entered once in the Motor Defaults before defining all of the individual motors on the Path (refer to the QuickStick Configurator User s Manual). Installing Electronics The electronics for the QS 100 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. QuickStick 100 User s Manual 5-7

136 Installation Transport System Installation Mounting NC-12 Node Controllers The Node Controller should be located close to the Nodes it is responsible for to minimize the length of all wiring. The controller may be oriented in any direction required ensuring the service and exclusion zones identified in Figure 4-5 on page 4-7 are maintained. Mounting Plates The NC-12 may be mounted to a convenient surface by attaching the optional mounting plates as shown in Figure /4-20 Flat Head Screw (4X) Mounting Plate (2X) Figure 5-1: NC-12 Node Controller Mounting Plates Install the mounting plates onto the Node Controller, if not already installed. 1. Apply Loctite 243 to four 1/4-20 flat head screws and tighten to 10.1 N-m [90 in-lb], maximum thread length into threaded hole = 7.87 mm [0.310 in]. 2. Orient the Node Controller as required and secure it using a minimum of two M8 screws with M8 split lock washers (one per mounting plate). 3. Install cable management as required to secure the cables running to the Node Controller. NOTE: The Loctite must cure for 2 hours at 22 C [72 F] before using the transport system Rev. D

137 Installation Transport System Installation Mounting Brackets The NC-12 may be mounted in a standard 19 inch rack by attaching the optional rack mounting brackets as shown in Figure 5-2. Attachment Screw (4X) Mounting Bracket (2X) M5 x 10 mm (4X) Figure 5-2: NC-12 Node Controller Mounting Brackets Install the mounting brackets onto the Node Controller, if not already installed. 1. Remove the two M5 x 10 mm screws from the front of each side (four screws total). 2. Install two M5 X 12 mm flat head screws to secure each bracket and tighten to 2.0 N-m [18 in-lb] (four screws total). 3. Locate the Node Controller in the rack and secure it using four screws (two per mounting bracket) as specified by the rack manufacturer. 4. Install cable management as required to secure the cables running to the Node Controller. QuickStick 100 User s Manual 5-9

138 LAN PWR Installation Transport System Installation Mounting Node Controller LITEs The Node Controller LITE should be located close to the Nodes it is responsible for to minimize the length of all wiring. The controller may be oriented in any direction required ensuring the service and exclusion zones identified in Figure 4-7 on page 4-9 are maintained. Typical methods for mounting the NC LITE on the mounting plate are shown in Figure 5-3. M5 Screw (2X) M5 Screw (2X) 18 VDC PoE ON LY Figure 5-3: Node Controller LITE Mounting 1. Install the mounting flanges onto the NC LITE, if not already installed. 2. Orient the NC LITE as required and secure it to the plate, apply Loctite 243 to two M5 x 10 mm screws and install and tighten the screws to 2.7 N-m [24 in-lb]. NOTE: The Loctite must cure for 2 hours at 22 C [72 F] before using the transport system. 3. Orient the Node Controller as required and secure the plate using two M8 screws with M8 split lock washers Rev. D

139 Installation Transport System Installation Mounting Node Controller LITE and NC-12 Power Supplies If the Node Controller is powered using the remote power supply (instead of using PoE) the power supply should be located close to the Node Controller it is powering to minimize the length of all wiring. 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. The NC-12 Node Controller does not support Power over Ethernet (PoE). Never connect these Node Controllers to a PoE network as damage to internal components may result. Mounting Network Switches The network switches should be located close to the Node Controllers they are connecting to minimize the length of all wiring. The switch can be mounted to the same mounting plate used for the NC LITE (see Figure 5-3) and may be oriented in any direction required. Mounting Network Switch Power Supplies If the Network Switch is powered using the remote power supply (instead of using PoE) the power supply should be located close to the switch it is powering to minimize the length of all wiring. The power supply may be oriented in any direction required. QuickStick 100 User s Manual 5-11

140 Installation Transport System Installation Connecting Motors and Electronics The QuickStick 100 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. Power and communications cables should be run such that they are protected from damage and can be easily accessed for service. The following procedure provides the information required to make all motor and Node Controller connections. NOTICE Never connect or disconnect the power lines with power applied to the QuickStick 100 transport system as damage to internal components may result. 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. The NC-12 Node Controller does not support Power over Ethernet (PoE). Never connect these Node Controllers to a powered Ethernet network as damage to internal components may result Rev. D

141 Installation Transport System Installation Upstream (Simple Node) Motor Motor Downstream To next motor in Path NC PS Communication Connection Power Connection Junction Box Figure 5-4: Simplified Representation of Motor Connections Downstream Upstream From previous motor in Path Switch Configuration Motor Downstream Downstream Upstream Motor Downstream Motor Upstream Motor Downstream From previous motor in Path To next motor in Path PS NC Communication Connection Figure 5-5: Simplified Representation of Motor Connections in a Merge Switch QuickStick 100 User s Manual 5-13

142 Installation Transport System Installation Installing Motor Communication Cables Refer to Figure 4-10 on page 4-13 for the connection locations on the QS 100 motors and Figure 4-12 and Figure 4-13 for the connection locations on the Node Controllers in the Quick- Stick 100 system. Refer to Figure 5-4 and Figure 5-5 for simplified diagrams of the wiring and to Figure 5-6 for a detailed example. NOTE: Both ends of a Path do not need to connect to the same Node Controller. However, all connections to the motors at the ends of all Paths meeting in a Node must be made to the same Node Controller. Refer to the QuickStick Configurator User s Manual for more information about Nodes and Paths. Upstream Connector Upstream 1 meter QS 100 Downstream Connector Upstream Connector 1/2 meter QS 100 Node Controller Downstream Downstream Connector Upstream Connector Downstream Connector RS-422 Cable (typical) Figure 5-6: Communications Connections 1. Connect an external communications cable from an RS-422 connector on the Node Controller to the upstream connector of the first motor in a Path (as defined in the transport system layout drawing), routing the cable so it is protected from damage and can be easily accessed for service (refer to Figure 5-6). For an NC-12 Node Controller, connect to any RS-422 port, finger tighten only Rev. D

143 Installation Transport System Installation For a Node Controller LITE, typically connect to either J1 or J3 using a small screwdriver - do not overtighten. Record the Node Controller number from the transport system layout and the Port number from the Node Controller for entry into the Node Controller Configuration File. NOTE: When using an NC LITE, a custom cross-over gender changer may be used when connecting the upstream end of a Path to one of the Node Controller s even (downstream) ports. 2. Connect a communication cable from the downstream connector of the motor just connected to the upstream connector of the next motor in the Path, using a small screwdriver - do not overtighten, routing the cable so it is protected from damage and can be easily accessed for service. 3. Continue to connect the remaining motors in the Path using the communication cables. 4. Connect an external communications cable from the downstream connector of the last motor in the Path to an RS-422 connector on the Node Controller if that Path ends at a Node (e.g., Relay Node, Switch, Terminus Node), routing the cable so it is protected from damage and can be easily accessed for service. For an NC-12 Node Controller, connect to any RS-422 port, finger tighten only. For a Node Controller LITE, typically connect to either J2 or J4 using a small screwdriver - do not overtighten. Record the Node Controller number from the transport system layout and the Port number from the Node Controller for entry into the Node Controller Configuration File. NOTE: When using an NC LITE, a custom cross-over gender changer may be used when connecting the downstream end of a Path to one of the Node Controller s odd (upstream) ports. 5. Repeat Step 1 through Step 4 for each Path in the QS 100 transport system. NOTE: The motors at the ends of all Paths connected in the same Node must be connected to the same Node Controller. 6. Bundle and dress all cables (use nylon cable-ties) as needed to ensure clean cable routing. 7. Refer to Facilities Connections on page 5-22 for external communications connections. QuickStick 100 User s Manual 5-15

144 Installation Transport System Installation Installing Network Communications Cables Refer to Figure 4-12 on page 4-17 through Figure 4-13 for the network connection locations on the Node Controllers in the QuickStick 100 transport system. Refer to Figure 5-9 for a simplified diagram of the network wiring. NOTE: The transport system s network should be a dedicated, separate subnet to eliminate any unrelated network traffic. 1. Connect a Category 5 (Cat 5) network cable for network communications from a dedicated standard Ethernet switch to ETHERNET on each NC-12 Node Controller (auto-mdix and auto-negotiation are supported) and route the cable so it is protected from damage and can be easily accessed for service. NOTICE The NC-12 Node Controller does not support Power over Ethernet (PoE). Never connect these Node Controllers to a standard PoE network as damage to internal components may result. 2. When supplying power to the Node Controller LITE through PoE, connect a Cat 5 network cable for network communications from a dedicated Ethernet switch with 18 VDC PoE to LAN on each Node Controller LITE (auto-mdix and auto-negotiation are supported) and route the cable so it is protected from damage and can be easily accessed for service. When supplying power directly to the Node Controller LITE, connect a Cat 5 network cable for network communications from a dedicated standard Ethernet switch to LAN on each Node Controller LITE. 3. Bundle and dress all cables (use nylon cable-ties) as needed to ensure clean cable routing. 4. Refer to Facilities Connections on page 5-22 for external network connections Rev. D

145 Installation Transport System Installation Installing Digital I/O Wiring Wiring for discrete digital inputs and outputs can be connected to the NC-12 Node Controllers and used for E-Stops, Interlocks, Light Stacks, and general purpose I/O. Refer to Figure 4-12 for the Digital I/O connection locations on the NC-12 Node Controller. To make Digital I/O connections use AWG insulated wires and connect them to the appropriate input or output bits and to the respective COM, GND, or VDD connections. Insert a small (e.g., #2) flat blade screwdriver into the connector release slot above the appropriate connector (refer to Figure 5-7) and rotate it in place to open the connector while inserting the wire into the connector. Once the wire is fully seated, release and remove the screwdriver. Note, ensure the connector blades are making direct contact with the wire and not contacting the insulation. Connector Release Connector Release Connector Connector Figure 5-7: Digital I/O Connections QuickStick 100 User s Manual 5-17

146 Installation Transport System Installation Installing Motor Power Cables Refer to Figure 4-10 on page 4-13 for the power connection locations on the QS 100 motors in the QuickStick 100 transport system. Refer to Figure 5-4 and Figure 5-5 for simplified diagrams of the wiring and to Figure 5-8 for a detailed example. Motor Power Cable Upstream 1 meter QS 100 1/2 meter QS 100 Ground Power Bus Cable Downstream To Power Supply Power Junction Box Figure 5-8: Power Connections Ground NOTICE If a user-supplied power supply is used it must be NRTL/ATL approved. NOTE: The AC power connections will be made at a later time (refer to Facilities Connections on page 5-22). Refer to Electrical Wiring on page 3-14 to ensure all power wiring is properly sized. Refer to Table 4-2 on page 4-12 when connecting the power cables to the motors to ensure each chain of motors does not exceed the rated output of the power supply. 1. Connect the power cable to the terminals on the power supply. Ensure the power supply is properly grounded. Ensure the power cables are sized for the full load of all motors downstream from the connection Rev. D

147 Installation Transport System Installation 2. Run the power cable from the power supply to the junction box at the first motor in the Path, route the cable so it is protected from damage and can be easily accessed for service. Ensure the junction box is properly grounded. 3. Run a power cable from J2 on the motor, using a small screwdriver - do not overtighten, to the junction box (refer to Motor Power Cable on page 4-15), routing the cable so it is protected from damage and can be easily accessed for service. Connect +48 VDC Logic, +48 VDC Propulsion, and 48 VDC Return to the Power Bus in the junction box. Connect GND (PE) to GND (PE) in the junction box. 4. Run a power cable from the junction box to the junction box at the next motor in the Path, route the cable so it is protected from damage and can be easily accessed for service. Ensure the junction box is properly grounded. 5. Repeat Step 3 and Step 4 for each motor in the power chain. NOTE: It is not necessary to connect all of the motors on a Path to the same power supply or to connect a power supply to only one Path. 6. Connect the Ground stud on all NC-12 Node Controllers to GND (PE). 7. Bundle and dress all cables (use nylon cable-ties) as needed to ensure clean cable routing. 8. Refer to Facilities Connections on page 5-22 for external power connections. QuickStick 100 User s Manual 5-19

148 Installation Transport System Installation Installing Vehicles WARNING Strong Magnets To avoid severe injury, people with pacemakers and other medical electronic implants must stay away from the magnet arrays. To avoid injury from strong magnetic attractive forces: Handle only one magnet array at a time. Do not place any body parts, such as fingers, between a magnet array and any QuickStick 100 motors, ferrous material, or another magnet array. Magnet arrays not being used should be secured individually in isolated packaging. To avoid damage to watches, electronic instruments, and magnetic media, (e.g., cell phones, memory disks/chips, credit cards, and tapes) keep these items far away from the magnet arrays. Magnet Array Installation The magnet arrays are supplied with threaded holes and locator pins for mounting to the mounting surface of the vehicle. The number and location of the mounting holes and locator pins depends on the size and type of the magnet array (refer to the MagneMotion Interface Control Drawing for the magnet array). Refer to the MagneMotion drawing for the magnet array for mounting hole locations and torques. Mount the magnet arrays to the vehicles as defined by the design of the vehicle. Mounting A Single Array When installing a magnet array on a vehicle: 1. Work on only one vehicle at a time. 2. Ensure the vehicle is secured to a work surface that is clear of any magnet arrays or ferrous material. 3. Move only one magnet array at a time and ensure the magnet array stays as far away from all other magnets and any ferrous material as possible Rev. D

149 Installation Transport System Installation 4. Locate the magnet array on the vehicle using the locating features on the magnet array. 5. Secure the magnet array to the vehicle as defined by the vehicle s design. 6. Once the array is secured to the vehicle, install the vehicle on the guideway. Vehicle Installation Vehicles can be added or removed as needed once the QuickStick 100 transport system is completely installed. NOTE: The design of the guideway and of the vehicle will determine the ease of adding vehicles (i.e., an open guideway will allow vehicles to placed onto it, while a closed guideway will require either an opening for placement of vehicles or placement of the vehicles before closing the guideway. WARNING Crush Hazard Strong magnets in use. To avoid severe injury: Handle only one vehicle or magnet array at a time. Do not place any body parts (e.g., fingers) between a magnet array and any QuickStick 100 motors, ferrous material, or another magnet array to avoid injury from strong magnetic attractive forces. Vehicles and magnet arrays not being used should be secured individually in isolated packaging. QuickStick 100 User s Manual 5-21

150 Installation Facilities Connections Facilities Connections The standard configuration of the QuickStick 100 transport system requires user-supplied electrical power and communications connections. Refer to the Electrical Specifications on page 4-12 for descriptions and specifications of all required facilities. Network Connections The QuickStick 100 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 communications and PoE connections to the Node Controllers as shown in Figure 5-9. NOTE: The transport system s network should be a dedicated, separate subnet to eliminate any unrelated network traffic. Host Controller EtherNet/IP TCP/IP or ENet/IP Uplink Network Switch Uplink Network Switch SYNC IT (optional)... SYNC IT (optional) Uplink Network Switch (PoE) Uplink Network Switch (PoE) NC LITE... NC LITE NC LITE... NC LITE NC NC-12 Figure 5-9: Network Cable Connections 1. Connect a Cat 5 network cable for transport system network communications from the Host Controller to the Uplink connector on the network switch as shown in Figure Rev. D

151 Installation Facilities Connections NOTICE The Ethernet cable connecting a PoE switch to the Host Controller or other switches must connect to the Uplink port, otherwise damage to the switches or other devices connected to the switches may occur. NOTE: When using multiple network switches to connect all Node Controllers, use one switch as a master and connect all other switches to it as shown in Figure 5-9. When using multiple MMI PoE network switches, connect the Uplink from each switch to a master switch as shown in Figure 5-9, do not daisy chain the PoE switches. When using the optional SYNC IT controllers, use a switch dedicated to those controllers connected directly to the EtherNet/IP port on the PLC dedicated to synchronization as shown in Figure Connect a cable for network communications from the switch to each Node Controller. For NC-12 Node Controllers, connect to ETHERNET as shown in Figure For Node Controller LITEs, connect to LAN as shown in Figure Set the IP address for each Node Controller. Refer to the Node Controller Interface User s Manual for more details. If EtherNet/IP is being used refer to the QuickStick Configurator User s Manual for additional configuration information. 4. Configure one Node Controller as a High Level Controller. Refer to the Node Controller Interface User s Manual for more details. Electrical Connections Electrical power is connected to the QuickStick 100 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 Electrical Specifications on page 4-12 for electrical requirements. Ensure that all electrical connections are for the appropriate voltage and power rating. 1. Connect power to each NC-12: NOTICE Do not turn on facility power until all installation procedures have been completed. QuickStick 100 User s Manual 5-23

152 Installation Facilities Connections Connect the AC power cable from either the optional remote power supply or a user-supplied power supply to the power distribution from the facility s main power disconnect. Then, connect the DC power cable to the power connector on each NC-12 Node Controller as shown in Figure Connect power to each Node Controller LITE: When supplying Power over Ethernet to the NC LITE, ensure the Ethernet connection goes to a PoE enabled switch then plug the switch power supply into the power distribution from the facility s main power disconnect. Then, connect the cable from the switch power supply to the switch. When supplying power directly to each NC LITE, plug the NC LITE power supply into the power distribution from the facility s main power disconnect. Then, connect the cable from the NC LITE power supply to the NC LITE as shown in Figure Connect an AC power cable from the power distribution on the facility s main power disconnect to the power connector on the power supplies. E-Stop Circuit NOTICE The NC-12 Node Controller does not support Power over Ethernet (PoE). Never connect these Node Controllers to a powered Ethernet network as damage to internal components may result. The QuickStick 100 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 VDC power supply for the Digital Input. Refer to Figure 4-17 on page 4-33 for the Digital I/O Equivalent Circuits. Refer to E-Stops on page 6-19 for the E-Stop circuit. Refer to the QuickStick Configurator User s Manual for information on configuring an E-Stop. CAUTION High Voltage Hazard The E-Stop is not the same as an EMO (Emergency Off), which removes power to the Quick Stick 100 transport system Rev. D

153 Installation Facilities Connections Interlock Circuit The QuickStick 100 transport system can use Digital I/O, provided through an NC-12 Node Controller, for monitoring and control of local options such as a Interlocks. The optional Interlock circuit is the responsibility of the user and requires a user-supplied VDC power supply for the Digital Input. Refer to Figure 4-17 on page 4-33 for the Digital I/O Equivalent Circuits. Refer to Interlocks on page 6-21 for the Interlock circuit. Refer to the QuickStick Configurator User s Manual for information on configuring an Interlock. Light Stack Circuit The QuickStick 100 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 stack and a user-supplied VDC power supply (sized for the Light Stack) for the Digital Outputs. Refer to Figure 4-17 on page 4-33 for the Digital I/O Equivalent Circuits. Refer to Light Stacks on page 6-23 for the Light Stack circuit. Refer to the QuickStick Configurator User s Manual for information on configuring a Light Stack. General Purpose Digital I/O The QuickStick 100 transport system can use Digital I/O, provided through an NC-12 Node Controller, to allow the Host Controller to monitor and control Digital Inputs and Outputs, respectively. Refer to Figure 4-17 on page 4-33 for the Digital I/O Equivalent Circuits. Refer to the Host Controller TCP/IP Communication Protocol User s Manual or the Host Controller EtherNet/IP Communication Protocol User s Manual for the command details on performing these operations. Node Electronics The Merge and Diverge Nodes in the QuickStick 100 transport system rely on external devices to provide the switching. This switching mechanism may be controlled through the Digital I/O, provided through an NC-12 Node Controller. For Merge and Diverge Nodes using Digital I/O, provided through an NC-12 Node Controller, control and status signals are used for each switch position. Refer to the QuickStick Configurator User s Manual for information on configuring these Nodes. QuickStick 100 User s Manual 5-25

154 Installation Software Software The QuickStick 100 transport system requires user creation of the Node Controller Configuration File and creation of Host Controller software to direct vehicle movement for the particular application and monitor transport system performance. MagneMotion provides a number of software tools to simplify the creation of the Node Controller Configuration File, for testing system operation, and for monitoring system operation. Refer to Transport System Software Overview on page 1-5 for identification and descriptions of all software components. Software Overview Node Controllers supplied with the QuickStick 100 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. Refer to the Node Controller Interface User s Manual for details. All QuickStick 100 motors ship with just a basic motor software image installed. The motor image files must be uploaded to the motors through the Node Controller. Upgrades to the software can be uploaded through the network communications link. Refer to the Upgrade Procedure in the Release Notes supplied with the software upgrade. NOTE: Specific builds of MagneMotion s software may not implement all of the features described in this manual. Refer to the Release Notes provided with the software for additional information. All software running on the QuickStick 100 transport system must be part of the same release. Refer to the Release Notes provided with the software for additional information. Alterations or changes to the software should only be made by qualified MagneMotion personnel or as directed by MagneMotion. Software Configuration Create the Node Controller Configuration File (node_configuration.xml) using the Configurator to define the components of the transport system and their relationship to each other. Refer to Design Guidelines on page 3-1 and the QuickStick Configurator User s Manual for more details. The Configuration File must then must be uploaded to each Node Controller in the transport system before using the system. Refer to the Node Controller Interface User s Manual for details. Configure the Host Controller to control the transport system. Refer to the Host Controller TCP/IP Communication Protocol User s Manual, the Host Controller EtherNet/IP Communication Protocol User s Manual, or the Mitsubishi PLC TCP/IP Library User s Manual depending on the Host Controller type Rev. D

155 Installation Software Node Controller Software Installation 1. Upload the Node Controller image files to each Node Controller using the Node Controller Web Interface. Refer to the Node Controller Interface User s Manual for details. NOTE: Activate the image and reboot the Node Controller for the changes to take effect. 2. Upload the configuration files through the Node Controller Web Interface to each Node Controller. Refer to the Node Controller Interface User s Manual for details. Motor Software Installation NOTE: Restart the Node Controller for the changes to take effect. 1. Upload the motor ERF image files (motor_image.erf) to each Node Controller using the Node Controller Web Interface and program the motor masters and slaves. Refer to Programming Motors on page 7-16 and the Node Controller Interface User s Manual for details. NOTE: Restart the Node Controller for the changes to take effect. 2. Reset the Paths where the motors were programmed (e.g., use the NCHost TCP Interface Utility, refer to the NCHost TCP Interface Utility User s Manual for details). QuickStick 100 User s Manual 5-27

156 Installation Check-out and Power-up Check-out and Power-up System Check-out Before the QuickStick 100 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 QuickStick 100 components in an orderly manner to ensure all components are in known conditions. This procedure is used to prepare the transport system for full operation. Mechanical Checks Verify all shipping brackets have been removed. Ensure that all QuickStick 100 components are properly and securely installed in the facility. Ensure that all hardware is secure. If the optional E-Stop circuit is being used, ensure that the button is functional. Manually move a vehicle through the entire QS 100 transport system to ensure free motion (no binding). Facility Checks Ensure that all facilities are capable of meeting, or exceeding, the requirements as described in the Electrical Specifications on page 4-12 and Site Requirements on page Ensure that the power and communications connections have been completed. Check all cables. Verify the connectors are fully seated and screws/locks are secured to ensure good continuity. Verify all cables are routed in a safe place and away from any travel areas. Inspect all cables for restricting bend radii, excessive tension, or physical damage. Pre-operation Checks Ensure that there are no obstructions in the travel path of the vehicles Rev. D

157 Installation Check-out and Power-up System Power-up After the QuickStick 100 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. WARNING Crush Hazard Moving mechanisms (vehicles) have no obstruction sensors. Do not operate the QuickStick 100 transport system without barriers in place or personal injury could result in the squeezing or compression of fingers, hands, or other body parts between moving mechanisms. WARNING Automatic Movement Whenever power is applied, the possibility of automatic movement of the vehicles on the QuickStick 100 transport system exists, which could result in personal injury. 1. Ensure that all of the installation procedures previously described in this chapter have been completed. 2. Ensure the system is properly grounded. 3. Connect the QuickStick 100 transport system to the plant s electrical services. Ensure power remains off. CAUTION High Voltage Hazard Each motor can draw 48 5 A maximum. Ensure the AC circuit suppling power to the power supplies for the motors is properly sized and properly protected. QuickStick 100 User s Manual 5-29

158 Installation Check-out and Power-up 4. Perform a Ground Continuity check from the surfaces of the QuickStick 100 transport system to a known good ground. 5. Apply power to the QuickStick 100 transport system. WARNING Automatic Movement The Host Controller initiates all motion control to the QuickStick 100 transport system. It is the user s responsibility to initiate a safe start-up of all QS 100 components. Do not attempt to operate the QuickStick 100 transport system until all setup procedures described in this chapter have been completed. The indicators on the components of the QuickStick 100 transport system will be lit as shown in Table 5-2. Table 5-2: Startup Indicators Component Indicator Status Node Controller, NC-12 Power On (green) QS 100 Power Supply AC OK On (green) DC OK On (green) 6. If power-up was successful, the QuickStick 100 transport system is ready to accept commands. If, however, the power-up sequence was unsuccessful, refer to Troubleshooting on page Create the Node Controller Configuration File for the transport system (refer to Software Configuration on page 5-26 and to the QuickStick Configurator User s Manual). 8. Set the Node Controller IP addresses, specify the Node Controller to be used as the High Level Controller, and upload the configuration, image, and type files to each Node Controller (refer to the Node Controller Interface User s Manual). 9. Program the motors using the Motor Image Files (refer to the Node Controller Interface User s Manual). 10. Review the log files for each Node Controller to ensure that the system has been programmed and configured properly (refer to the Node Controller Interface User s Manual) Rev. D

159 Installation System Testing System Testing Test the QuickStick 100 transport system to verify proper operation of all Nodes, Paths, and vehicles. This can be accomplished using the NCHost application supplied by MagneMotion to move vehicles without the Host Controller to verify proper operation before integrating a transport system into a production environment. Create Demo Scripts to perform repetitive testing throughout the transport system. Refer to the NCHost TCP Interface Utility User s Manual for details. If any problems are encountered, refer to Troubleshooting on page 7-5. WARNING Crush Hazard Moving mechanisms have no obstruction sensors. Do not operate the QuickStick 100 transport system without barriers in place or personal injury could result in the squeezing or compression of fingers, hands, or other body parts between moving mechanisms. 1. Ensure the transport system is fully configured. 2. Ensure the Node Controller Configuration File is fully defined and has been uploaded to all Node Controllers (refer to the Node Controller Interface User s Manual). 3. Ensure that each the NC Web Interface for each Node Controller shows a status of running/valid (refer to the Node Controller Interface User s Manual). 4. Issue a Restart Services command for each Node Controller (refer to the Node Controller Interface User s Manual). 5. Issue a Reset command for all Paths. All of the motors on the Paths in the transport system are reset. 6. Issue a Startup command to all Paths. Motion on all Paths is enabled, all vehicles on the Paths are identified and located, and the Paths become operational. WARNING Crush Hazard The vehicles will move during the startup sequence. QuickStick 100 User s Manual 5-31

160 Installation System Testing 7. Verify the Host Controller has identified all vehicles in the transport system (refer to the NCHost TCP Interface Utility User s Manual). 8. Move vehicles individually or create a Demo Script for repetitive testing (refer to the NCHost TCP Interface Utility User s Manual). 9. Monitor transport system operation using the NCHost TCP Interface Utility Rev. D

161 Operation 6 Overview This chapter provides an overview of operation for the QuickStick 100 transport system. The operation of the QS 100 transport system is covered for both normal conditions and emergency conditions. Included in this chapter are: Theory of operation of the MagneMotion linear synchronous motors and the Quick- Stick 100 transport system. Controls and indicators provided on the system. Simulation of QS 100 transport system operation. Operational start-up and safe shut-down. QuickStick 100 User s Manual 6-1

162 Operation Theory of Operation Theory of Operation The QuickStick 100 is a new approach to linear synchronous motor (LSM) technology, which provides a faster, cleaner, and more advanced alternative to conventional propulsion and conveyor methods. With a scalable, adaptable, and innovative design, the QS 100 transport system provides the ability to achieve various acceleration and velocity profiles while moving a wide range of payloads with high precision. The QuickStick 100 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 movement as shown in Figure 6-1. The motor primary is a series of coils that generate a magnetic field within the QuickStick 100 motor. The motor secondary is an array of magnets that is attached to the object to move, referred to as a vehicle. The motor primary generates a magnetic field to move the motor secondary (vehicle) in a controlled manner. The QuickStick 100 motors also use the magnets on the vehicle to track the vehicle s position. Motor Secondary (Perm Magnets) Motor Primary (Coils) Motor Secondary Movement Rotary Motor Motor Secondary Motor Primary Unrolling a Rotary Motor Motor Secondary (Perm Magnets) Vehicle/Magnet Array Motor Secondary Movement Motor Primary (Coils) QuickStick 100 Linear Synchronous Motor Figure 6-1: Linear Synchronous Motor Derived From Rotary Motor QuickStick 100 Transport System Advantages An advantage of the QuickStick 100 transport system is that the motor secondary (vehicle) is not connected or tethered to the motor primary, allowing the vehicle to travel further and faster than connection cables allow. Another advantage is unlimited travel length. The result is a propulsion solution that is efficient, reliable, quiet, and clean. The QS 100 transport system Rev. D

163 Operation Theory of Operation also provides high reliability because it does not require frequent replacement of power transmission parts. A summary of QuickStick 100 transport system benefits include: Less maintenance than conventional belt conveyors. No moving parts within the motor modules. Passive pallets or vehicles that do not require batteries, wires, or power. Bidirectional movement. Variable guideway system layout including curves and horizontal or vertical guideways. Anti-collision feature. Automated move profiles. Independent vehicle movement. Motion Control The QuickStick 100 transport system provides an integrated transport system for material movement along one axis. Motors are linked together in Paths that define the individual movement routes. The Host Controller can then direct movement and positioning of the vehicles anywhere along the length of the Path. Vehicles can also be moved from one Path to another as long as there is a connection between the Paths (either direct or through one or more Paths) through a Node (or multiple Nodes). The design and operation of the QuickStick 100 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. Motor Topology Each QuickStick 100 motor is constructed as a series of blocks (refer to Table 3-2 on page 3-10 and Figure 6-2). Each block is a discrete motor primary section of multiple coils within the motor that is energized over its whole length. Varying the magnetic force within a block and its neighbors causes the vehicle to move in the desired direction and provides precise positioning of the vehicles. The control software ensures that the minimum distance between vehicles at the extreme ends of adjacent motor blocks is 3 mm [0.1 in] when not moving. However, this dimension is variable depending upon the vehicle edge location relative to the block boundary. This allows having a magnet array (vehicle) right justified in the 1st block of a QuickStick 100 motor with a second magnet array (vehicle) left justified in the 2nd block of the QuickStick 100 motor. NOTE: The QuickStick 100 motor s anti-collision feature prevents two vehicles from occupying the same motor block. QuickStick 100 User s Manual 6-3

164 Operation Theory of Operation Vehicle Magnet Array Block Downstream Motor Figure 6-2: Representation of Stationary Vehicles Per Motor Block Vehicle Magnet Array Downstream Motion Block Motor Figure 6-3: Representation of Moving Vehicles Per Motor Block Motor Operation The QuickStick 100 motors provide asynchronous control of vehicles 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 routing and vehicle control operations (positioning, acceleration, deceleration, and collision avoidance) as described below. 1. The Host Controller generates an asynchronous movement order to move a vehicle to a specified location from the beginning of a Path using either a position or station command and sends it to the High Level Controller (HLC). For example, the Order is to move Vehicle #1 to a Position 1.5 m on Path 1 (Pdest) at a maximum speed of 0.5 m/s (Vmax), and acceleration/deceleration of 1 m/s 2 (Amax). 2. The HLC routes the order to the appropriate Node Controller. 3. The Node Controller generates a movement order and sends it to the appropriate vehicle master (motor controller for the motor where the vehicle is currently located). 4. The vehicle master generates a movement profile based on the order. Every update period (~1 ms) a new position, velocity, and acceleration set point (Pset, Vset, and Aset) are calculated. As the vehicle moves, the master acquires empty blocks ahead of the vehicle that the vehicle can move into based on the vehicle s current movement order. A block is defined as an independently controlled coil or set of coils (refer to Table 3-2 on page 3-10 for details), no two vehicles are allowed to occupy the same block Rev. D

165 Operation Theory of Operation The vehicle master will use the position of the most recently acquired block farthest from the vehicle as an interim destination (target) to calculate the next profile set point (Pset, Vset, Aset). The vehicle master handles all collision avoidance ensuring brick-wall headway is maintained between vehicles. 5. The vehicle master controls the vehicle based on the profile set points as inputs. During the move, vehicle data such as actual position, velocity, and interim destination are sent back to the Node Controller, typically every ms, to provide the Host Controller some level of feedback as to where the vehicle is located. 6. The vehicle master continues to generate updated movement profiles based on the order and continues to control the vehicle based on the new profile set points until the vehicle is handed off to the next vehicle master or it reaches its destination. The vehicle master hands-off vehicle control to the motor controller in the next motor as the vehicle moves across motor boundaries. The new master picks up where the old one left off for profile generation. The new master is now responsible to continue the closed-loop control of the vehicle. 7. The movement order is finished when the vehicle position is equal to the ordered destination. Motor Cogging Brushless Permanent Magnet (BPM) motors that are iron core based inherently exhibit cogging forces. In traditional BPM motors, these are felt when turning the shaft of the motor and are periodic in nature. The periodicity in this case would be expressed in degrees and the magnitude and direction of this cogging force would vary as a function of shaft position. Linear motors, such as MagneMotion s QuickStick motors, that utilize an iron core to maximize thrust (equivalent to torque in a traditional rotary motor) also exhibit cogging forces. The main difference between rotary motors and linear motors is that in linear motors these forces are periodic as a function of distance versus angle. In the linear motor these forces will tend to pull the vehicle forward or backward at specified intervals along the motor. The QuickStick motors have been designed to minimize cogging as vehicles travel over the motor. Vehicles will be subjected to slightly greater cogging as they travel from motor to motor. The frequency of these cogging forces is directly proportional to vehicle speed. Although cogging forces are below 5% of the available thrust provided by the motors and do not appreciably impact acceleration and speed capabilities of the motors, they can lead to perceptible low level vibrations whose frequency are related to vehicle speed. These small vibrations have a typical frequency range of 0 Hz (at zero speed) to 30 Hz (at high vehicle speeds). For general transport and conveyance applications, cogging effects are not generally observable or perceptible provided that the vehicle, track, and payload design do not exhibit a sharp resonance within the 0-30 Hz range. However, for payloads susceptible to vibration, these QuickStick 100 User s Manual 6-5

166 Operation Theory of Operation cogging effects may have an impact and require special attention to suppress them. Refer to Motor Cogging on page 3-12 for installation methods to minimize cogging. Motor Blocks A motor block is a discrete motor section within each QuickStick 100 motor as shown in Figure 6-2 and Figure 6-3. It is an independently controlled linear motor driven by one inverter. This is the stator (motor primary) and consists of copper windings. There is an iron core to the motor, which creates an attractive force between the magnet array and motor even when the motor is not powered. Block Acquisition The master controller for each motor takes ownership of vehicles when they enter the motor and maintains that ownership the entire time the vehicle is on the motor. Ownership includes identification of the final destination, maximum acceleration, and maximum velocity as defined in the current movement order and determination of the vehicle s interim destination and current acceleration and velocity set points. The master ensures that the vehicle has acquired sufficient empty blocks ahead of the vehicle in the direction of movement to ensure brick-wall headway is maintained based on the current motion profile. This is done by defining new interim destinations and communicating with the motors ahead of the vehicle to ensure sufficient blocks can be acquired. The vehicle master uses the position of the most recently acquired block farthest from the vehicle as an interim destination (target) to calculate the next profile set point (Pset, Vset, Aset). A new interim destination (target) block is only granted if the block has not been allocated to another vehicle (i.e., permission is granted for only one vehicle per motor block). A new target is requested only immediately before the vehicle must start slowing down for its current target to minimize the number of committed blocks and to ensure brick-wall headway is maintained. Permission to enter a motor block is only granted after previous vehicles have completely exited the block. Each vehicle is controlled in such a manner that it is always able to stop in the last motor block it was granted permission to enter. Anti-Collision The QS 100 transport system allows only one vehicle per motor block; this is the basic rule on which the anti-collision feature of the QS 100 transport system controls is founded. Since two vehicles are not allowed to be in the same motor block, they will not collide. Note that this affects how many vehicles can fit on a motor or Path Rev. D

167 Operation Theory of Operation Also, the magnet arrays on the vehicles have a slight repulsive force which causes them to passively separate from each other a short distance when they are manually pushed together and not being servoed (actively controlled). The distance they will passively separate will vary based on vehicle and guideway conditions (including friction). The vehicles can be servoed to a tighter spacing but they need to be forced to do so by constantly driving the motor. They can be driven to a pitch where they are practically in contact with each other but if this constant, close position condition is held for a period of time the motors will reach a thermal limit and shut down. This tight spacing may be done on occasion but it should not be a standard part of a process. Safe Stopping Distance Movement Standard vehicle control ensures vehicles always have a safe stopping distance (brick-wall headway). Figure 6-4 shows acceleration, velocity, and position versus time for the standard vehicle movement profile. Movement permission for a vehicle is granted as needed to keep a vehicle on its movement profile (solid heavy line) and provide a safe stopping distance (dashed heavy line) based on the vehicle's current velocity and commanded acceleration. This can be found by dividing the square of a vehicle s current velocity by twice its acceleration (V 2 /2a). +Alimit Position Velocity Acceleration -Alimit Vlimit Destination Time Time Time Figure 6-4: Vehicle Movement Profile QuickStick 100 User s Manual 6-7

168 Operation Theory of Operation In Queue Typically, the vehicles will queue up while in route to a particular destination when another vehicle obstructs or jams the route. Obstructions are normal occurrences, jams are not. While in queue, the vehicles can be as close together as permitted by the system and the amount of space in between the carriers mounted on the vehicles depends on the defined length of the vehicle. All of the vehicles in the queue will report being obstructed. An obstruction indicates that another vehicle, or a Node not ready for a vehicle, is preventing the vehicle from completing its current movement order. Once the obstructing vehicle moves, or the Node is ready, the obstructed vehicle is free to complete its order. A jam indicates that there is no known obstruction preventing vehicle movement, but the vehicle is not making progress towards its destination. This is typically due to something having fallen onto the guideway or friction within the system that cannot be overcome. Once the jam has been cleared, typically by outside intervention, the jammed vehicle is free to complete its order and any vehicles it has obstructed are free to complete their orders. Vehicle Length Through Curves and Switches The width of the vehicles is not defined in the Node Controller Configuration File. In order to ensure multiple vehicles can move on curved sections of the transport system without colliding the vehicle length must be defined longer than it actually is to account for the vehicle s width in a curve. The value of the defined length must be calculated using basic trigonometry. Locating Vehicles During Startup The Node Controller scans for the magnet array on the vehicles starting from the upstream end of a Path and scanning towards the downstream end of the Path. When the NC detects a magnet array (vehicle) it attempts to precisely locate it by moving the vehicle into the adjacent motor block in the downstream direction to determine its position (using the sensors in the next motor block). If the NC is able to move the vehicle, it assigns the vehicle a Vehicle ID. If the adjacent motor block is occupied by another vehicle (or there are no more motor blocks downstream), the NC will look to the next detected vehicle and try to move it. The NC will continue scanning for vehicles until it locates a new one, or the NC will try to move an already located vehicle to make room to locate a new vehicle provided there is additional room to move the already located vehicle that is in the way. If the Node Controller comes to the end of the Path and was unable to move any detected new vehicles into a downstream motor block or the NC is unable to move existing vehicles for room, it will switch directions and begin scanning in the upstream direction from the downstream end of the Path. The NC will assign a vehicle ID to the next vehicle it can move into an adjacent upstream motor block to determine its position. NOTE: There must be at least one motor block free per Path for startup to succeed Rev. D

169 Operation Theory of Operation The NC will continue to scan back and forth in the downstream and upstream directions until all vehicles detected have been assigned a vehicle ID. This could take several seconds to several minutes depending on how many vehicles are on a Path. NOTE: If the NC scans in the downstream direction and then the upstream direction of a Path without being able to perform any moves of any type startup will fail for that Path. This could be due to either due to no space to move a detected vehicle or a jammed vehicle. Once a vehicle ID is assigned, it will remain with that vehicle until the vehicle is either removed from the QuickStick 100 transport system via a Terminus Node, the vehicle is explicitly deleted with a Delete Vehicle command, or a Reset is issued for the Path where the vehicle is located. Moving Vehicles by Hand Vehicles on the QuickStick 100 transport system should only be moved by the QS 100 motors in the system. If there is an event that requires moving the vehicles by hand, the guidelines provided below should be followed. NOTE: Moving vehicles by hand will produce eddy currents in the stators of the motors where the vehicle is being moved, which will put power on the propulsion bus. WARNING Crush Hazard Moving mechanisms have no obstruction sensors. Do not attempt to manually move any vehicles while propulsion power is supplied to the transport system or personal injury could result in the squeezing or compression of fingers, hands, or other body parts between moving mechanisms. If both propulsion power and logic power to the transport system are removed there is no tracking of vehicles being provided. Once power is restored the transport system must be restarted, which will detect all vehicles at their current locations. If propulsion power to the transport system is removed while logic power is maintained and a vehicle is moved manually, its position will be tracked by the transport system unless the center of the magnet array on the vehicle crosses a motor boundary (moves off the end of a motor), which will generate an Unlocated Vehicle Fault. Vehicles that have crossed a motor boundary will be shown as having lost signal (Vehicle Signal = 0) when monitoring vehicle status through the Host Communication Protocols (refer to either the Host Controller TCP/IP QuickStick 100 User s Manual 6-9

170 Operation Theory of Operation Communication Protocol User s Manual, the Host Controller EtherNet/IP Communication Protocol User s Manual, or the Mitsubishi PLC TCP/IP Library User s Manual). A vehicle that has been manually moved, bumped, or dislodged, and lost its signal, is able to re-acquire its signal once manually relocated to within approximately 25 mm of its original position as measured from the center of the vehicle. On return of the propulsion power, the vehicle will not be able to move unless it had been returned to the same section of the motor where it was located when the power was shut off. In this case, the vehicle will be shown as having signal (Vehicle Signal = 1) but it will also show as Suspect. Vehicles that are identified as Suspect require a restart of the Path where they are located to clear the Suspect bit. In some cases the vehicle can be commanded, but it will continue to show as Suspect. If both propulsion power and logic power are maintained and a vehicle is moved manually, the motor will resist the vehicle s movement. Once the vehicle is released it will snap back to its original position if it has not been moved vary far (less than 25 mm) unless the center of the magnet array on the vehicle crosses a motor boundary. 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. Electrical System The QS 100 motors are designed to operate at a nominal +48 VDC. The inverters that power the individual blocks within the QS 100 motor are enabled when the motor s internal propulsion bus rises above +43 VDC allowing normal motor operation and are shut down if the voltage falls below +41 VDC. The motor s inverters are also shut down when the internal propulsion bus reaches +59 VDC to protect internal circuitry and are enabled when the voltage falls below +57 VDC. The motor s logic circuits are designed to operate at a nominal +48 VDC, but will start to function once the motor s logic bus rises above +40 VDC allowing reporting of all motor warnings and faults. Voltage drops in the power distribution system when the motors consume power while moving vehicles and voltage increases during regeneration events will lead to fluctuations in the voltages seen at the motor power terminals. The power supplies and wiring for the system must be designed to minimize these fluctuations (refer to Electrical Wiring on page 3-14). Power Regenerated by a Vehicle When a vehicle slows to a stop, the mechanical energy of the vehicle is converted to electrical energy, which is applied to the motor s internal propulsion bus. This energy must then be dissipated to avoid raising the voltage of the bus beyond the acceptable limit of 56.5 VDC. Power is provided to the motor to actively slow down the vehicle so the net effective regeneration power is lower than the power required to accelerate the vehicle. The reduction is based on a number of factors, but a conservative estimate is that the net effective regeneration power is about 75% of the acceleration power. Note that as the vehicle slows down under constant deceleration, the regeneration power will drop linearly with speed Rev. D

171 Operation Theory of Operation Power Management Within the QS 100 Motor To supplement any external power management schemes applied to a QuickStick 100 transport system, several means of internally consuming regenerated power within a QS 100 motor are incorporated to protect the motor and help minimize voltage increases. These include both Block Level Power Management, where excess power is dissipated through unused motor blocks and Motor Level Power Management, where excess power is dissipated by an internal resistive load. Block Level Power Management When the internal propulsion bus reaches VDC, current will begin to ramp in the coils of blocks that are available to effectively allow the motor to absorb and dissipate unused power due to regeneration within itself or coming from other motors connected to a commonly shared +48 VDC power supply. A coil block is defined as available and will be used to dissipate power within a motor if its neighboring blocks (upstream and downstream) do not have any part of a magnet array over them. Note that a neighboring block may be within a different motor as would be the case for the first and last blocks within a given motor. The current in these available blocks ramps linearly to 5 A over a 2 volt range from VDC to VDC. The coil current remains constant at 5 A for voltages above +55 VDC and drops to zero for voltages above +59 VDC since all inverters are turned off. This behavior is shown in Figure Current (A) Internal Bus Voltage (VDC) Figure 6-5: Individual Block Current vs. Internal Propulsion Bus Voltage With a nominal block coil resistance of 1.9 Ohms, the dissipated power is 47.5 W per block when the 5 A current level is reached and will remain at this level up to +59 VDC. The dissipated power vs. the internal propulsion bus voltage is shown in Figure 6-6. QuickStick 100 User s Manual 6-11

172 Operation Theory of Operation Power Dissipated per Block (W) Internal Bus Voltage (VDC) Figure 6-6: Power Dissipation Per Block vs. Internal Propulsion Bus Voltage Motor Level Power Management When the + 48 VDC internal propulsion voltage rises above VDC, a 10 Ohm resistor within the motor is automatically switched across the +48 VDC propulsion and +48 V return lines. This internal load will remain active for voltages higher than this voltage and will be removed when the voltage goes below VDC. The power dissipated by this load, shown in Figure 6-7 (the blue line shows increasing power and the orange line shows decreasing power), is additive to any power dissipated by the coils in the blocks as previously described. Under normal use conditions, this resistor should never be activated or be relied upon to absorb regeneration power. This resistor is meant to handle anomalous high voltage transients that might otherwise lead to a catastrophic voltage induced motor failure only. Power Dissipation (W) Internal Bus Voltage (VDC) Figure 6-7: Power Dissipation by 10 Ohm Resistor vs. Internal Propulsion Bus Voltage Rev. D

173 Operation Theory of Operation Power Related Warnings and Faults The voltage drops in the power distribution system when the QS 100 motors consume power while moving vehicles and any voltage increases during regeneration events will lead to fluctuations in the voltages seen at the motor power terminals. These fluctuations can lead to the motor issuing warnings and faults and can cause motor shutdown as shown in Table 6-1. Table 6-1: Propulsion Voltage Range Voltage (VDC) Event Status 41 Soft Start Not Complete Fault Triggered 41 Under-voltage Fault Triggered, Inverters disabled 42.5 Under-voltage Warning Triggered Voltage Too Low Motor operation suspended 43 Minimum recommended Operating Voltage 51.5 Blocks begin dissipating power 53.5 Blocks reach maximum power dissipation Operating Range 56.5 Maximum Recommended Operating Voltage 57 Over-voltage Warning Triggered Voltage Too High 59 Over-voltage Fault Triggered, Inverters disabled Motor operation suspended Motor in normal operating condition. Motor in warning condition will continue to control vehicles. Motor in fault condition will not control vehicles (motion is undefined). Soft Start Not Complete Fault Upon initial power up, when the motor s internal propulsion bus is below +43 VDC, the motor will report a soft start not complete fault to the HLC. The HLC will report this to the Host Controller as a soft start not complete fault (refer to either the Host Controller TCP/IP Communication Protocol User s Manual, the Host Controller EtherNet/IP Communication Protocol User s Manual, or the Mitsubishi PLC TCP/IP Library User s Manual) and the motor will not allow vehicle motion to occur. Once +43 VDC is reached, the motor will support vehicle motion and the soft start fault message will self-clear. If the internal propulsion bus voltage drops below +41 VDC during operation, the motor will report a soft start not complete fault through the HLC to the Host Controller, all inverters within the motor will be disabled, and any vehicles in motion over the motor will no longer be under active control and as such their motion will be undefined. Normal operation will resume once the internal propulsion bus rises back up to +43 VDC. QuickStick 100 User s Manual 6-13

174 Operation Theory of Operation Under-voltage Fault Upon initial power up, when the motor s internal propulsion bus is below +43 VDC, the motor will report an under-voltage fault to the HLC. Once this fault clears, it will only re-appear if the internal propulsion bus voltage drops below +41 VDC. The HLC will report this to the Host Controller as an under-voltage fault (refer to either the Host Controller TCP/IP Communication Protocol User s Manual, the Host Controller EtherNet/IP Communication Protocol User s Manual, or the Mitsubishi PLC TCP/IP Library User s Manual). This fault self-clears when the internal propulsion bus voltages rises above +43 VDC. If the internal propulsion bus voltage drops below +41 VDC during operation, the motor will report a under-voltage fault through the HLC to the Host Controller, all inverters within the motor will be disabled, and any vehicles in motion over the motor will no longer be under active control and as such their motion will be undefined. Normal operation will resume once the internal propulsion bus rises back up to +43 VDC. This fault is likely due to excessive +48 VDC power and +48 VDC return cable resistance from the power source to the motor. Under-voltage Warning When the motor s internal propulsion bus drops below VDC the motor will report an under-voltage warning to the HLC. This warning will be logged in the HLC Log when the Log Level for Faults is set to the Warning level (refer to the Node Controller Interface User s Manual). Note that this warning is not sent to the Host Controller. When the voltage rises back up to +43 VDC this fault will self-clear. There is no voltage filtering associated with this warning since the intent is to capture minimum voltage excursions. Upon initial system power up, this fault will be present and persist until the propulsion bus reaches +43 VDC. The intent of this feature is to verify proper cabling and power distribution for new systems and to support periodic assessments of the system to make sure no degradation has occurred. A properly designed system should never exhibit this alarm following system power up. Any warnings observed as part of system commissioning need to be addressed and resolved using one or several of the resolution methods described in Power Related Fault Resolution. Over-voltage Warning When the motor detects instantaneous voltages in excess of +57 VDC on its internal propulsion bus the motor will report an over-voltage warning to the HLC. This warning will be logged in the HLC Log when the Log Level for Faults is set to the Warning level (refer to the Node Controller Interface User s Manual). Note that this warning is not sent to the Host Controller. When the propulsion bus voltage drops back below VDC this fault will self-clear. The intent of this feature is to verify proper cabling and power distribution for new systems and to support periodic assessments of the system to make sure no degradation has occurred. Any warnings observed as part of system commissioning need to be addressed and resolved using one or several of the resolution methods described in Power Related Fault Resolution Rev. D

175 Operation Theory of Operation Over-voltage Fault When the motor s internal propulsion bus rises above +59 VDC the motor will report an over-voltage fault to the HLC. The HLC will report this to the Host Controller as an over-voltage fault (refer to either the Host Controller TCP/IP Communication Protocol User s Manual, the Host Controller EtherNet/IP Communication Protocol User s Manual, or the Mitsubishi PLC TCP/IP Library User s Manual). This fault self-clears when the internal propulsion bus voltages falls below +57 VDC. To avoid issuing an over-voltage fault to the Host Controller due to spurious noise, the internal propulsion bus used to trigger this event is filtered. If the internal propulsion bus voltage reaches +59 VDC during operation, the motor will report a over-voltage fault through the HLC to the Host Controller, all inverters within the motor will be disabled, and any vehicles in motion over the motor will no longer be under active control and as such their motion will be undefined. Normal operation will resume once the internal propulsion bus falls below +57 VDC. Based on the specific system wiring and vehicle activity, it is possible for regenerated power resulting from vehicle decelerations to cause the internal propulsion bus voltage to rise to excessive levels. To protect against this, MMI has implemented protective features to guard against operating conditions that could damage the motor. Since the source of such a condition is due to regeneration effects associated with active braking or deceleration of a vehicle (loaded or unloaded), a means (among others) of eliminating such regenerated power is to shut down the inverters in the motor. Power Related Fault Resolution The power related error messages and the associated faults will persist until the voltage of the motor s internal propulsion bus is between and +57 VDC. At this time the system will attempt to resume active control of the vehicle. There are several possible solutions available to eliminate faults of these types. 1. Reduce the cable resistance between motors that share a common +48 VDC power supply if voltage drops in these cables leads to under voltage on motors accelerating vehicles or excessive voltage on motors undergoing regeneration. 2. Reduce the cable resistance between the power supply and the motors if voltage drops in these cables leads to under voltage on motors accelerating vehicles. 3. Reduce the maximum speeds and/or maximum accelerations to reduce the amount of power drawn and the regenerated power flowing back into the system. 4. Reduce the number of vehicles accelerating on motors connected to the same common +48 VDC power supply. 5. Split the power bus into smaller sections and install additional power supplies. 6. Increase the spacing between vehicles on motors sharing a common +48 VDC power supply to increase the number of blocks available to absorb power during regeneration. QuickStick 100 User s Manual 6-15

176 Operation Theory of Operation 7. Connect more motors to a common +48 VDC power supply to increase the number of blocks available to absorb regenerated power. 8. If all of the above resolution paths have been explored and excessive voltage problems still persist, add an active voltage clamp across the +48 VDC power supply local to the power supply or to the motor(s) that are exhibiting this issue. The clamping voltage should be above +51 VDC but kept as low as possible Rev. D

177 Operation Controls and Indicators 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 configured as described in this section. The controls and indicators of the QuickStick 100 components are identified in the Electrical Specifications on page System Display The NCHost TCP Interface Utility can be used to display the Graphics Window, shown in Figure 6-8, which shows the transport system layout and all vehicles in the transport system for real-time monitoring of transport system operation. This can only be used if a Track File for the specific configuration has been created by MagneMotion. Refer to the NCHost TCP Interface Utility User s Manual to use the Graphics Window. Figure 6-8: The Graphics Window QuickStick 100 User s Manual 6-17