LSM Synchronization Option User’s Manual Synchronization Option User’s Manual i Contents Figures...

990000447 Rev. C

LSM Synchronization Option User’s Manual

MagneMotion, Inc.2 990000447 Rev. C

Although every effort is made to ensure the accuracy of this document, MagneMotion, Inc. assumes no responsibility forany errors, omissions, or inaccuracies. Information provided within this manual is subject to change without notice. Anysample code referenced in this document and that may be included with MagneMotion software is included for illustrationonly and is, therefore, unsupported.

MagneMotion®, MagneMover®, MM LITE™, QuickStick®, and SYNC IT™ are trademarks or registered trademarks ofMagneMotion, Inc. 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 patentspending.

©2011 - 2014 MagneMotion, Inc. All Rights Reserved. The information included in this manual is MagneMotion, Inc.proprietary information and is provided for the use of MagneMotion, Inc. customers only and cannot be used fordistribution, reproduction, or sale without the express written permission of MagneMotion, Inc. In no event willMagneMotion, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application ofthis equipment.

MagneMotion, Inc.139 Barnum RoadDevens, MA 01434USAPhone: +1 978-757-9100Fax: +1 978-757-9200www.magnemotion.com

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.

http://www.magnemotion.com

LSM Synchronization Option User’s Manual i

Contents

Figures ............................................................................................................. vii

Tables............................................................................................................... ix

ChangesOverview........................................................................................................................ xi

Rev. A ...................................................................................................................... xiRev. B ...................................................................................................................... xiRev. C ...................................................................................................................... xii

About This ManualOverview........................................................................................................................ xiii

Purpose..................................................................................................................... xiiiAudience .................................................................................................................. xiiiPrerequisites............................................................................................................. xiii

MagneMotion Documentation ....................................................................................... xivManual Conventions ................................................................................................ xivNotes, Safety Notices, and Symbols ........................................................................ xvManual Structure...................................................................................................... xviRelated Documentation............................................................................................ xvii

Contact Information....................................................................................................... xviii

1 IntroductionOverview........................................................................................................................1-1LSM Synchronization Option Overview .......................................................................1-2Transport System Components Overview .....................................................................1-3Transport System Software Overview...........................................................................1-4Getting Started with the LSM Synchronization Option.................................................1-6

2 SafetyOverview........................................................................................................................2-1Regulatory Compliance .................................................................................................2-2

EU RoHS and EU WEEE Compliance....................................................................2-2Equipment Regulatory Guidelines...........................................................................2-2

Contents

MagneMotion, Inc.ii 990000447 Rev. C

Safety Considerations ....................................................................................................2-4Personnel Safety Guidelines ....................................................................................2-4Equipment Safety Guidelines ..................................................................................2-5

Symbol Identification ....................................................................................................2-7Label Identification and Location..................................................................................2-8Mechanical Hazards.......................................................................................................2-9Electrical Hazards ..........................................................................................................2-10Recycling and Disposal Information .............................................................................2-11

3 Specifications and Site RequirementsOverview........................................................................................................................3-1Design Guidelines..........................................................................................................3-2

LSM Synchronization Connections .........................................................................3-2Mechanical Specifications .............................................................................................3-3

SYNC IT Controller.................................................................................................3-3Mounting Plate.........................................................................................................3-4

Electrical Specifications ................................................................................................3-5SYNC IT Controller.................................................................................................3-5Power Connection....................................................................................................3-6

MagneMover® LITE Transport Systems...........................................................3-6QuickStick® 100 Transport Systems .................................................................3-6

Ethernet Connection ................................................................................................3-6EtherNet/IP Communication....................................................................................3-7USB Serial Interface Connection.............................................................................3-7Sync Connection ......................................................................................................3-7

MagneMover LITE Transport Systems .............................................................3-8QuickStick 100 Transport Systems....................................................................3-8

Site Requirements ..........................................................................................................3-10Environment.............................................................................................................3-10Floor Space and Loading .........................................................................................3-10Facilities...................................................................................................................3-10Service Access .........................................................................................................3-10

4 InstallationOverview........................................................................................................................4-1Unpacking and Inspection .............................................................................................4-2

Unpacking and Moving ...........................................................................................4-2Unpacking and Moving Instructions..................................................................4-2

Installation Preparation ............................................................................................4-3Remove Protective Packaging ...........................................................................4-3

LSM Synchronization Option Installation.....................................................................4-4Installing Synchronization Enabled Motors ............................................................4-4Installing the SYNC IT Controller...........................................................................4-4

Installation Overview.........................................................................................4-4Installing Hardware............................................................................................4-4Connecting Motors and Electronics...................................................................4-6

Contents

LSM Synchronization Option User’s Manual iii

Software ...................................................................................................................4-8Software Installation ..........................................................................................4-8Software Configuration......................................................................................4-8

Power-up and Check-out ...............................................................................................4-9System Check-out ....................................................................................................4-9

Mechanical Checks ............................................................................................4-9Facility Checks ..................................................................................................4-9

System Power-up .....................................................................................................4-10System Testing...............................................................................................................4-11

5 OperationOverview........................................................................................................................5-1Theory of Operation.......................................................................................................5-2Configuration .................................................................................................................5-4

Configure the SYNC IT Controller .........................................................................5-4Install Configuration Application ......................................................................5-4Configure IP Address.........................................................................................5-4

Configure the PLC ...................................................................................................5-10Operation .......................................................................................................................5-15

Start-up.....................................................................................................................5-15Normal Running ......................................................................................................5-15

Safe Shut-down..............................................................................................................5-16

6 Application NotesOverview........................................................................................................................6-1Operation Overview.......................................................................................................6-2

Standard Operation ..................................................................................................6-2Synchronized Operation ..........................................................................................6-3

Sync Zones.....................................................................................................................6-4Sync Zone Offsets....................................................................................................6-4Standard Configuration............................................................................................6-5

Multi-motor Single-zone Configuration ............................................................6-5Alternate Configurations..........................................................................................6-7

Multi-motor Multi-zone Configuration .............................................................6-7Single-motor Multi-zone Configuration ............................................................6-9

Using the SYNC IT™ Motor Offset Worksheet ...........................................................6-10Examples..................................................................................................................6-11

MagneMover LITE ............................................................................................6-11QuickStick 100 ..................................................................................................6-11

Calculating Sync Motor Offsets ....................................................................................6-12MagneMover LITE ..................................................................................................6-13QuickStick 100 ........................................................................................................6-14

Communication..............................................................................................................6-16Vehicle Movement in Sync Zones.................................................................................6-17

Vehicle Introduction into Sync Zones .....................................................................6-17Vehicle Movement in Sync Zones...........................................................................6-20

Gearing...............................................................................................................6-20

Contents

MagneMotion, Inc.iv 990000447 Rev. C

Camming............................................................................................................6-20Synchronized Movement ...................................................................................6-20

Vehicle Exit from Sync Zones.................................................................................6-22MMI PLC Tools.............................................................................................................6-24

Main Task Routines .................................................................................................6-24cold_start_service ..............................................................................................6-24sync_take_control_of_puck ...............................................................................6-24utilities ...............................................................................................................6-24

Profile Task Routines...............................................................................................6-25Profiles_to_motor ..............................................................................................6-25

Add-On Instructions ................................................................................................6-25MMI_CIP_sync_conv_feedback .......................................................................6-25MMI_sync_motion_IO ......................................................................................6-25

7 Interface ReferenceOverview........................................................................................................................7-1Communications Protocol..............................................................................................7-2

Introduction..............................................................................................................7-2Motor Command Memory Interface........................................................................7-3Motor Status Memory Interface...............................................................................7-7

8 MaintenanceOverview........................................................................................................................8-1Preventive Maintenance.................................................................................................8-2

Cleaning ...................................................................................................................8-3Cable Connection Inspection ...................................................................................8-3

Troubleshooting .............................................................................................................8-4Initial Troubleshooting ............................................................................................8-4Power Related Troubleshooting...............................................................................8-5SYNC IT Controller Troubleshooting .....................................................................8-6Communications Troubleshooting...........................................................................8-7Motion Control Troubleshooting .............................................................................8-8

Contact MagneMotion Customer Support .....................................................................8-10Repair.............................................................................................................................8-11Shipping .........................................................................................................................8-12

Packing Procedure ...................................................................................................8-12

AppendixOverview.......................................................................................................................A-1Communications Protocol.............................................................................................A-2

Communications Format.........................................................................................A-2EtherNet/IP .............................................................................................................A-2

File Maintenance...........................................................................................................A-3Backup Files ...........................................................................................................A-3Creating Backup Files.............................................................................................A-3Restoring from Backup Files ..................................................................................A-3

Contents

LSM Synchronization Option User’s Manual v

Additional Documentation............................................................................................A-4Release Notes..........................................................................................................A-4Upgrade Procedure .................................................................................................A-4

Transport System Limits...............................................................................................A-5

Glossary ......................................................................................................... G-1

Index ................................................................................................................ I-1

Contents

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LSM Synchronization Option User’s Manual vii

Figures

1-1 Simplified View of MagneMotion Transport System Components with Sync ......1-31-2 Simplified View of Transport System Software Relationships ..............................1-4

2-1 Locations of Labels on the SYNC IT Controller ....................................................2-8

3-1 Sample Transport System Layout Showing Sync Option Connections .................3-23-2 SYNC IT Controller Mechanical Drawing .............................................................3-33-3 Mounting Plate Mechanical Drawing .....................................................................3-43-4 SYNC IT Controller Electrical Connectors and Indicators ....................................3-53-5 MagneMover LITE Sync Cable ..............................................................................3-83-6 QuickStick 100 Sync Cable ....................................................................................3-9

4-1 SYNC IT Controller Mounting ...............................................................................4-54-2 SYNC IT Controller Electrical Connections ..........................................................4-64-3 MagneMover LITE Motor Electrical Connections .................................................4-64-4 QuickStick 100 Motor Electrical Connections .......................................................4-74-5 Simplified Representation of QS 100 Motor Connections .....................................4-74-6 Network Cable Connections ...................................................................................4-8

5-1 Transport System Wiring Diagram with Synchronization .....................................5-35-2 SYCON.net Application .........................................................................................5-55-3 SYCON.net – Configuration File Loaded ..............................................................5-55-4 netProject – Settings – Driver .................................................................................5-65-5 netProject – Settings – netX Driver ........................................................................5-65-6 netProject – Settings – Device Assignment ............................................................5-75-7 netProject – Configuration – General .....................................................................5-85-8 netProject – Configuration – Assembly ..................................................................5-95-9 netProject - Download Warning .............................................................................5-95-10 Download Succeeded ..............................................................................................5-105-11 PLC Configuration for SYNC IT Controller, General Tab ....................................5-115-12 PLC Configuration for SYNC IT Controller, Connection Tab ..............................5-115-13 Motion Group Properties - Attribute Tab ...............................................................5-125-14 Axis Properties - Units Tab ....................................................................................5-135-15 Axis Properties - Conversion Tab ...........................................................................5-135-16 Axis Properties - Homing Tab ................................................................................5-145-17 Axis Properties - Dynamics Tab .............................................................................5-14

Figures

MagneMotion, Inc.viii 990000447 Rev. C

6-1 Multiple Motors with Single Sync Zone .................................................................6-56-2 Motor Command - Multiple Motors with Single Sync Zone (Example 1) .............6-66-3 Motor Command - Multiple Motors with Single Sync Zone (Example 2) .............6-66-4 Multiple Motors with Multiple Sync Zones ...........................................................6-76-5 Motor Command - Multiple Motors with Multiple Sync Zones (Example 1) ........6-76-6 Motor Command - Multiple Motors with Multiple Sync Zones (Example 2) ........6-86-7 Single Motor with Multiple Sync Zones .................................................................6-96-8 Motor Command - Single Motor with Multiple Sync Zones ..................................6-96-9 SYNC IT™ Motor Offset Worksheet .....................................................................6-106-10 SYNC IT™ Motor Offset Worksheet – MML Example ........................................6-116-11 SYNC IT™ Motor Offset Worksheet – QS 100 Example .....................................6-116-12 Motor Offset Calculations ......................................................................................6-126-13 Motor Offset Calculations, MML Example ............................................................6-136-14 Motor Offset Calculations, QS 100 Example 1 ......................................................6-146-15 Motor Offset Calculations, QS 100 Example 2 ......................................................6-156-16 Sync Zone Communications Timing Diagram .......................................................6-166-17 Motor Status - Vehicle Entering Sync Zone (SyncIT:I.Data) ................................6-186-18 Motor Command - Vehicle Entering Sync Zone (SyncIT:O.Data) ........................6-196-19 Motor Status – Vehicle Under Control in Sync Zone (SyncIT:I.Data) ..................6-216-20 Motor Command - Vehicle Exiting Sync Zone (SyncIT:I.Data) ............................6-226-21 Motor Status – Vehicle Leaving Sync Control (SyncIT:I.Data) ............................6-236-22 Motor Status – Vehicle Exiting Sync Zone (SyncIT:I.Data) ..................................6-23

LSM Synchronization Option User’s Manual ix

Tables

2-1 Regulatory Information ...........................................................................................2-22-2 Hazard Alert Symbol Identification ........................................................................2-72-3 Mandatory Action Symbol Identification ...............................................................2-72-4 Labels Used on the SYNC IT Controller ................................................................2-8

3-1 SYNC IT Controller Connectors ............................................................................3-53-2 SYNC IT Controller Indicators ...............................................................................3-53-3 MML Sync Cable Pin Assignments ........................................................................3-83-4 QS 100 Sync Cable Pin Assignments .....................................................................3-9

4-1 Packing Checklist Reference ..................................................................................4-2

6-1 MagneMotion Motor Lengths and Offsets .............................................................6-12

7-1 SYNC IT Controller Memory Structure .................................................................7-2

8-1 Preventive Maintenance Schedule ..........................................................................8-28-2 Initial Troubleshooting ...........................................................................................8-48-3 Power Related Troubleshooting ..............................................................................8-58-4 Controller Related Troubleshooting .......................................................................8-68-5 Communications Troubleshooting ..........................................................................8-78-6 Motion Control Troubleshooting ............................................................................8-8

A-1 MagneMotion Transport System Limits ................................................................A-5A-2 MagneMotion Transport System Motion Limits ...................................................A-5

Tables

MagneMotion, Inc.x 990000447 Rev. C


LSM Synchronization Option User’s Manual xi

Changes

Overview

Changes may be made to this manual to ensure that it continues to provide the most complete documentation possible for the MagneMotion Synchronization option. 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 to support MagneMover LITE using Version 1.

Rev. B

Updated to support QuickStick using Version 1.

Added LSM to the title of the manual. Added this Changes section. Added regulatory infor-mation. Added support for QuickStick 100 motors. Added a shipping procedure.

Updated trademark information. Corrected the names of all referenced MagneMotion manu-als. Updated the descriptions of all system software. Updated the Getting Started procedure. Updated all figures to show SYNC IT™ connector changes and current labeling. Updated the descriptions of the electrical hazards. Moved the design guidelines to Chapter 3 and updated the mechanical drawings. Updated the installation procedure. Moved the theory of operation to the beginning of Chapter 5. Updated the Troubleshooting section, the Appendix, the Glos-sary, and the Index.

Removed all references to ‘physical’ and ‘virtual’ components.

ChangesOverview

MagneMotion, Inc.xii 990000447 Rev. C

Rev. C

Added software version notice. Added additional reference documents. Added Regulatory Compliance and Symbol Identification. Added additional Personnel Safety Guidelines and Equipment Safety Guidelines. Added description of Sync Zone Offsets and process for Calcu-lating Sync Motor Offsets.

Updated trademark information. Updated the LSM Synchronization option description to include time stamping. Updated software descriptions and added missing items. Updated Electrical Hazards. Updated the Electrical Specifications and the QS 100 Sync Cable Pin Assignments. Updated the Site Requirements. Updated the SYNC IT Controller Mounting pro-cedure. Updated the Theory of Operation to include time stamping. Updated the Configure IP Address procedure to add configuration of data length. Updated the Vehicle Introduction into Sync Zones process to provide greater detail. Updated the Vehicle Exit from Sync Zones pro-cess to provide greater detail. Updated the MMI PLC Tools descriptions to include time stamping. Updated the Communications Protocol descriptions to include the time stamps. Expanded Motion Control Troubleshooting. Updated the Glossary.

Removed all references to the Standard Node Controller, which has been replaced by the NC-12 Node Controller.

LSM Synchronization Option User’s Manual xiii

About This Manual

Overview

This section provides information about the use of this manual, including the manual struc-ture, related documentation, format conventions, and safety conventions.

Purpose

This manual explains how to install, operate, and maintain the LSM Synchronization Option for use with MagneMotion transport systems. Additionally, this manual describes the protocol for communication between the SYNC IT™ controller and a Host Controller (PLC) equipped with an EtherNet/IP interface. 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 MagneMotion, Inc. to design, install, configure, test, and operate the LSM Synchronization (Sync) option in a MagneMotion transport system.

Audience

This manual is intended for all users of MagneMotion transport systems and provides infor-mation on how to install, configure, and use the Sync Option in a transport system.

NOTE: Depending on user access privileges and application configuration, certain opera-tions described within this manual may not be available.

Prerequisites

This manual assumes familiarity with Allen Bradley ControlLogix® PLC programming. Details on how to build ladder logic that utilizes the message and tag definitions defined in this manual for a production system are beyond the scope of this manual.

This manual also assumes that the hardware for the MagneMotion transport system has already been installed, that the full documentation for the transport system is available, and that personnel installing and operating the LSM Synchronization Option for the transport sys-tem have been properly trained.

About This ManualMagneMotion Documentation

MagneMotion, Inc.xiv 990000447 Rev. C

MagneMotion Documentation

The documentation provided with the MagneMotion LSM Synchronization Option includes this manual, which provides complete documentation for the installation, operation, and use of the LSM Synchronization (Sync) option. Other manuals in the document set, listed in the Related Documentation section, support installation, configuration, and operation of the trans-port 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 installa-tion, MagneMotion, Inc. 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 button1.

• 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.


LSM Synchronization Option User’s Manual xv

• Numbers – All numbers are assumed to be decimal unless otherwise noted. Non-deci-mal numbers (binary or hexadecimal) are explicitly stated.

• Binary – Followed by 2, e.g., 1100 0001 01012, 1111 1111 1111 11112.

• Hex – Followed by 16, e.g., C1516, FFFF16. 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 for-mat 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, Safety Notices, and Symbols used within this manual have very specific meanings and formats. Examples of notes, 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

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 descrip-tions), 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.


MagneMotion, Inc.xvi 990000447 Rev. C

Manual Structure

This manual contains the following chapters:

• Introduction: Provides an overview of the LSM Synchronization Option and its use with a MagneMotion transport system.

• Safety: Provides Safety concerns and requirements for the LSM Synchronization Option and the personnel operating and servicing the transport system where it is installed.

• Specifications and Site Requirements: Provides specifications and the requirements for installation of the LSM Synchronization Option.

• Installation: Provides complete installation procedures for the LSM Synchronization Option.

• Operation: Provides complete operation directions for the LSM Synchronization Option.

• Application Notes: Provides examples and step-by-step procedures related to specific tasks using the LSM Synchronization Option with a MagneMotion transport system.

• Interface Reference: Provides an overview of the Communications Protocol and details of each command.

• Maintenance: Provides complete maintenance schedules and procedures for the LSM Synchronization Option.

WARNING

Warning indicates a hazardous situation which, if notavoided, could result in death or serious injury.

CAUTION

Caution indicates a hazardous situation, which if notavoided, could result in minor or moderate injury.

NOTICE

Notice indicates practices not related to personal injury that could result inequipment or property damage.


LSM Synchronization Option User’s Manual xvii

• Appendix: Provides additional information related to the LSM Synchronization Option and MagneMotion transport systems.

• Glossary: A list of terms and definitions used in this manual and for the transport sys-tem and its components.

• Index: A cross-reference to this manual organized by subject.

NOTE: The software version of the SYCON.net application supplied on the CD-ROM may be newer than the version described in this manual. However, all features docu-mented in this manual are supported.

The software version of the Host Controller TCP/IP and EtherNet/IP Communica-tions Protocols supplied with the Node Controller Image File on the CD-ROM may be newer than the version that is described in this manual (indicated in Changes at the front of this manual). However, all features documented in this manual are sup-ported. Note that specific builds of the Host Controller TCP/IP and EtherNet/IP Communications Protocols may not implement all of the features described in this manual.

Related Documentation

Before configuring or running the LSM Synchronization Option for the MagneMotion trans-port system, consult the following documentation:

• MagneMover® LITE Configurator User’s Manual, 990000558.orQuickStick® Configurator User’s Manual, 990000559.

• Node Controller Web Interface User’s Manual, 990000377.

• NCHost TCP Interface Utility User’s Manual, 990000562.

• Host Controller TCP/IP Communication Protocol User’s Manual, 990000436.Host Controller EtherNet/IP Communication Protocol User’s Manual, 990000437.orMitsubishi PLC TCP/IP Library User’s Manual, 990000628.

• MagneMover® LITE User’s Manual, 990000410.orQuickStick® 100 User’s Manual, 990000460.

• LSM Synchronization Option User’s Manual, 990000447 (this manual).

• SYNC IT™ Motor Offset Worksheet Guide, 990000486.

• SYNC IT™ Motor Offset Worksheet, 800-0089-00.

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 document set at any time. To identify the current revisions or to obtain a current set of documents, contact MagneMotion Customer Support.

About This ManualContact Information

MagneMotion, Inc.xviii 990000447 Rev. C

Contact Information

Main Office Customer Support

MagneMotion, Inc.139 Barnum RoadDevens, MA 01434USAPhone: +1 978-757-9100Fax: +1 978-757-9200

+1 [email protected]

LSM Synchronization Option User’s Manual 1-1

Introduction 1

Overview

This chapter provides an overview of the MagneMotion LSM Synchronization option, the transport system hardware and software, and the basic set of tasks needed to install and use the LSM Synchronization option on a transport system.

Use this manual to install, test, and troubleshoot use of the LSM Synchronization option. Note that some procedures may vary based on the transport system configuration, communications, and other variables.

This manual supports:

• MagneMover® LITE (MML™) transport systems.

• QuickStick® 100 (QS 100) motors in transport systems.

Included in this chapter are overviews of:

• The LSM Synchronization option.

• The transport system hardware and software.

• Getting started with the LSM Synchronization option in a transport system.

IntroductionLSM Synchronization Option Overview

MagneMotion, Inc.1-2 990000447 Rev. C

LSM Synchronization Option Overview

The LSM Synchronization (Sync) option for MagneMotion linear synchronous motor trans-port systems is capable of synchronization with 3rd party systems. Synchronization provides a PLC controller the ability to directly control specific motors in the transport system. Only those motors located where vehicle movement must be synchronized with an external mecha-nism should use the Sync option.

NOTE: All PLC configuration and operation information provided in this manual assumes use of an Allen Bradley ControlLogix PLC using RSLogix 5000.

LSM Synchronization option:

• Provides direct control of up to 20 vehicles per SYNC IT™ controller, including:

• Groups of vehicles moving together through the Sync Zone.

• Vehicles chaining through the Sync Zone.

• Vehicles moving together on parallel Sync Zones.

• For MagneMover LITE, synchronizes up to ten pucks (vehicles) per meter.

• For QuickStick 100, synchronizes up to five 150 mm vehicles per meter.

• Each vehicle in the Sync Zone is considered an ‘Axis’ in the PLC.

• Each SYNC IT controller manages up to three Sync motors (motors may be contigu-ous, but do not need to be).

• PLC to SYNC IT controller to motor communication is time stamped and synchro-nized in both directions.

• Requires Sync enabled motors and SYNC IT controller.

SYNC IT Controller:

• For MagneMover LITE, powered by Sync enabled motors.

• For QuickStick 100, powered by a remote power supply.

• IP30 rating.

• EtherNet/IP Class 1 connectivity, I/O Adapter protocol.

• Configurable through USB port.

• Field upgradeable software via USB port.

• Up to 3 zones (motors) per controller.

IntroductionTransport System Components Overview


Transport System Components Overview

This section identifies the components of a MagneMotion transport system equipped with the LSM Synchronization (Sync) option as shown in Figure 1-1 and described after the figure.

Figure 1-1: Simplified View of MagneMotion Transport System Components with Sync

• 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 transport system. Sup-plied by the user, it can be either PC-based or a PLC. Note that a PLC must be used for the LSM Synchronization option.

• Motor – Refers to a MagneMotion 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.

• SYNC IT Controller – Provides direct control of specific motors.

• Power Supply – Provides DC power to the motors.

• Vehicle with Magnet Array – Carries a payload through the transport system as directed. The magnet array is mounted to the vehicle and interacts with the motors, which moves each vehicle independently.

Host Controller(PLC)

DC Power Cables

Power SupplyMotors

Communication Cables

Node Controller LITE(and High Level Controller)

SYNC IT Controller

Vehicles

Network (Motor Control)

Network (Synchronization)

Sync Motor Cable

IntroductionTransport System Software Overview


Transport System Software Overview

Several software applications are used to configure, test, and administer a MagneMotion transport system as shown in Figure 1-2 and described after the figure. Refer to Related Docu-mentation on page xvii for the reference manuals for these applications.

Figure 1-2: 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.

• 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 Configurator (Configurator) – A Windows software application sup-plied by MagneMotion to create or change the Node Controller Configuration File, or the Track File for MagneMover LITE transport systems, without editing the files directly.

User’s Host Controller(EtherNet/IP or TCP/IP)

MagneMotion Configurator

Node ControllerNode Controller Web Interface

NCHost TCP Interface Utility

Motor

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)

node_configuration.xml

Node Controller Administration

System Control

System Testing(NCHost.exe)

(MMConfigTool.exe)

track_file.mmtrkdemo_script.txt

track_layout.ndx

IntroductionTransport System Software Overview


• 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_version_date), includes the Node Controller and High Level Con-troller applications. The Node Controller Image File is uploaded to all Node Control-lers 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 MagneMotion 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 transport system. The Magnet Array Type File is uploaded to all Node Control-lers in the transport system.

• Node Controller Configuration File (Configuration File) – An XML file (node_con-figuration.xml) that contains all of the parameters for the components in the transport system. The Configuration File is uploaded to all Node Controllers in the transport system.

• Track Layout File – An XML file (track_layout.ndx) that contains all of the parame-ters for the graphical representation of a MagneMover LITE transport system. The Track Layout File can be used to generate the Node Controller Configuration File and the Track File.

• Track File – A text file (track_file.mmtrk) that contains parameters of the transport system. The Track File is used by the NCHost TCP Interface Utility to provide a graphical representation of the transport system.

NOTICE

Modifying the Image or Type files could cause improper operation of thetransport system.

IntroductionGetting Started with the LSM Synchronization Option


Getting Started with the LSM Synchronization Option

Use this manual as a guide and reference when installing the LSM Synchronization (Sync) option on a MagneMotion transport system. Follow the steps in this section to get Sync opera-tional quickly with the aid of the other MagneMotion manuals (refer to Related Documenta-tion on page xvii).

NOTE: Ensure that all components and complete design specifications, including the physi-cal layout of the transport system, are available before starting to install or test LSM Sync operation.

To get started quickly with the LSM Synchronization option for the transport system:

1. Save the files and folders from the MagneMotion System Software and Installation CD-ROM that came with the MagneMotion 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.

Communications for running the memory interface for the Sync option requires an Allen Bradley ControlLogix PLC using RSLogix 5000 with an EtherNet/IP connection.

2. Ensure the components of the transport system are already installed and operational as described in the MagneMover® LITE User’s Manual, the QuickStick® 100 User’s Manual, or the QuickStick® HT User’s Manual.

3. Install the components of the LSM Synchronization option on the transport system as described in the following sections of this manual:

A. Prepare the transport system for the installation:

• Safety Considerations on page 2-4.

• Design Guidelines on page 3-2.

• Site Requirements on page 3-10.

B. Prepare the components for installation and install:

• Unpacking and Inspection on page 4-2.

• LSM Synchronization Option Installation on page 4-4.

4. Verify the installation is complete and the system is ready for use:

A. Power-up and Check-out on page 4-9.

B. Operation on page 5-15.

IntroductionGetting Started with the LSM Synchronization Option


5. Configure the SYNC IT controller for operation as described in the following sections of this manual.

• Configure the SYNC IT Controller on page 5-4.

6. Configure the Host Controller to control the Synchronization zones as required to meet the material movement needs of the facility where the system is installed (refer to the Host Controller EtherNet/IP Communication Protocol User’s Manual). Refer to:

A. Configure the PLC on page 5-10.

B. Application Notes on page 6-1.

C. Safe Shut-down on page 5-16.

Introduction




Safety 2

Overview

This chapter describes safety guidelines for the MagneMotion LSM Synchronization (Sync) option on a transport system. All personnel involved in the operation or maintenance of the transport system with the Sync option must be familiar with the safety precautions outlined in this chapter.

NOTE: These safety recommendations are basic guidelines. If the facility where the LSM Synchronization option is installed has additional safety guidelines they should be followed as well, along with the applicable national and international safety codes.

If any additional safety-related upgrades or newly identified hazards associated with the LSM Synchronization option are identified, the Customer 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 and Electrical hazards.

• Recycling and Disposal Information.

SafetyRegulatory Compliance


Regulatory Compliance

The SYNC IT™ controller is CE compliant. If necessary, request the offi-cial Declaration of Conformity (DoC) from MagneMotion.

The SYNC IT™ controller is UL Recognized in Canada and the United States. 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. The SYNC IT controller complies with the regulations from the organizations indicated in Table 2-1.

NOTE: It is the responsibility of the end user/third party integrator to ensure the compliance of the installed SYNC IT controller with the appropriate national and local regula-tions.

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 SYNC IT controller.

• MagneMotion Technical Support will issue a Technical Advisory to notify the owners of record of any field retrofits.

Table 2-1: Regulatory Information

Organization Regulation(s)

CE (Conformité Européenne) – The European safety requirements

• Machinery Directive• Low Voltage Directive• EMC Directive

UL • 61010-1

SafetyRegulatory Compliance


• Contact MagneMotion Customer Support for information regarding repair and mainte-nance service policies, both during the production of the SYNC IT controller and after production is discontinued.

• Any user caused damage during integration of the SYNC IT controller into their equipment is the user’s responsibility.

• MagneMotion’s responsibility for work performed by MagneMotion authorized tech-nicians 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 Shipping on page 8-12.

• MagneMotion provides training for the SYNC IT controller as integrated into a trans-port system. Only qualified, properly trained persons should perform any procedures on the controller. Damage resulting from improperly performing a procedure or not following cautions is not covered under warranty or service agreements.

SafetySafety Considerations


Safety Considerations

Personnel Safety Guidelines

When installed on a MagneMotion transport system the LSM Synchronization option may provide several direct safety hazards to personnel if not properly installed or operated. Gen-eral safety guidelines are provided below, specific cautions are provided as needed (refer to Mechanical Hazards on page 2-9 and Electrical Hazards on page 2-10.

• Personnel operating the transport system should be properly trained.

• Be aware of the hazardous points of the transport system as described in the appropri-ate manuals.

• High strength Neodymium Iron Boron magnets are used in the transport system.

• 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 MMI motor, ferrous material, or another magnet array to avoid injury from strong magnetic attractive forces.

• Vehicles and magnet arrays not on the transport system should be secured indi-vidually 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 transport system:

• Eye protectionBreaking material may produce flying shards. When running a setup or test procedure, protective eye wear must be worn at all times to guard against pos-sible eye injuries.

• Safety ShoesShoes 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 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 haz-ardous materials policies and the MSDS (provided by the manufacturer) for each sub-stance.

• Whenever power is applied, the possibility of automatic movement of vehicles or user supplied equipment within the transport system exists. It is the user’s responsibility to provide appropriate safeguards.

• Ensure the transport system and related components are properly decontaminated before performing any service following the facilities’ decontamination procedures. Follow all national, local, and facility procedures for the disposal of any hazardous materials.

• Ergonomic hazards may exist with certain installation or service operations pertaining to the transport system.

Equipment Safety Guidelines

The following safety considerations are provided to aid in the placement and use of the LSM Synchronization option on the transport system.

• If hazardous materials are to be present, users must observe the proper safety precau-tions and ensure that the material used is compatible with those from which the SYNC IT controller is fabricated.

• Determine if the SYNC IT controller will be employed in an earthquake prone envi-ronment and install the equipment accordingly.

• The SYNC IT controller is not provided with an Emergency Off (EMO) circuit. The user is responsible for an EMO circuit (refer to the applicable system’s User’s Manual for more information).

• Do not place the SYNC IT controller’s connections (power and communications cables) where they could cause a trip hazard.

• Do not place the SYNC IT controller in a location where it may be subject to physical damage.

• Ensure that all power connections to the SYNC IT controller are made in accordance with the appropriate national and local regulations.

• Ensure that the SYNC IT controller receives proper air flow for cooling.

• Do not remove safety labels or equipment identification labels.

• Turn OFF power before inserting or removing power cables.



• Use of the SYNC IT controller for MagneMotion transport systems for any purpose other than as a direct motor control interface is not recommended and may cause dam-age to the transport system or the equipment it is connected to.

• Always operate the transport system with appropriate barriers in place to prevent con-tact with moving objects by personnel.

• Do not install or operate the transport system if any of the components of the transport system have been dropped, damaged, or are malfunctioning.

• Keep cables and connectors away from heated surfaces.

• Do not modify the connectors or ports.

SafetySymbol Identification


Symbol Identification

Symbols are used in this manual and on the MagneMotion products to identify hazards, man-datory 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 pro-cedures can result in unsafe conditions, which may cause injury or equip-ment damage.

Automatic Start Hazard – Indicates the possibility of machinery automati-cally starting or moving, which could cause personal injury.

Hazardous Voltage – Indicates a severe shock hazard is present that couldcause personal injury.

Pinch Point Hazard – Indicates that there are exposed moving parts thatcould cause personal injury from the squeezing or compression of fingers orhands between moving parts.

Table 2-3: Mandatory Action Symbol Identification

Symbol Description

. Lockout Required – Indicates that all power must be disconnected using amethod that prevents accidental reconnection.

SafetyLabel Identification and Location


Label Identification and Location

Safety labels and identification labels are placed on the LSM Synchronization controller to provide operators and service personnel with hazard identification and information about the controller at the point of use. This section describes each label and identifies its location.

NOTE: Label placement may cause labels to be visible only during maintenance operations.

The following table lists the labels that are affixed to the SYNC IT™ controller. These labels are used to provide information about the controller. The figure after the table shows the loca-tion of each label identified in the table. To replace a lost or damaged label, contact MagneMotion and refer to its name.

Figure 2-1: Locations of Labels on the SYNC IT Controller

Table 2-4: Labels Used on the SYNC IT Controller

Product Information Label

Qty: 1

Location: On top of the SYNC IT controller

MAC ID Label

Qty: 1

Location: On top of the SYNC IT controller

????????????

Product Information Label

MAC ID Label

SafetyMechanical Hazards


Mechanical Hazards

The transport system where the LSM Synchronization option is being used is a complex elec-tromechanical system. Only persons with the proper training should install, operate, or service the SYNC IT controller.

All facilities to the 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 electrome-chanical equipment must be observed. These precautions include wearing a safety glasses, safety shoes, and any other precautions specified within the facility where the transport sys-tem is being used.

CAUTION

Crush Hazard

Moving mechanisms have no obstruction sensors.

Do not operate the transport system without barriers in placeor personal injury could result in the squeezing or compres-sion of fingers or hands between moving parts.

CAUTION

Automatic Movement Hazard

Whenever power is applied, the possibility of automaticmovement of the vehicles on the transport system exists,which could result in personal injury.

SafetyElectrical Hazards


Electrical Hazards

The SYNC IT controller is classified as a low voltage device, no additional safety precautions are required.

The SYNC IT controller is powered remotely (either through the MagneMover® LITE motors or a remote power supply) and is not capable of generating hazardous energy. The remote power supply for the controller is connected to the facility’s AC Mains and as such could have hazardous energy. Additionally, when using the QuickStick HT motors the motor controller is capable of generating hazardous energy. The proper precautions for operating and servicing electrical equipment must still be observed. These precautions include following facility lock-out/tagout procedures, and any other specified action within the facility where the transport system is being used.

WARNING

Electrical Hazard

All power to the SYNC IT controller must be disconnectedper the facility’s lockout/tagout procedure before servicing toprevent the risk of electrical shock.

CAUTION

Electrical Hazard

To avoid electric shock, do not open the SYNC IT controller.The controller and other components of the transport systemdo not contain any user serviceable parts.

NOTICE

To avoid equipment damage:

• Ensure the transport system is properly grounded.

• Do not connect or disconnect any components while the transport sys-tem has power.

SafetyRecycling and Disposal Information


Recycling and Disposal Information

The SYNC IT controller contains no hazardous materials that may require special handling for disposal or recycling.

Safety




Specifications and Site Requirements 3

Overview

This chapter describes specifications for the MagneMotion LSM Synchronization option on a transport system and the requirements for installation.


• Design guidelines for creating the interface to the transport system.

• Mechanical specifications, including dimensions.

• Power and communications specifications.

• Site requirements, including environmental and service access.

Specifications and Site RequirementsDesign Guidelines


Design Guidelines

Before installing the SYNC IT™ controller to the transport system, the transport system lay-out must be updated to define the following (refer to the MagneMover® LITE User’s Manual, the QuickStick® 100 User’s Manual, or the QuickStick® HT User’s Manual).

• Location of all sync-enabled motors.

• Location of all SYNC IT controllers and their connections.

The transport system layout is used to physically locate the SYNC IT controller on the trans-port system. It is also used as a reference when connecting the SYNC IT controller.

LSM Synchronization Connections

The SYNC IT controller and its connections must be defined on the transport system layout (refer to Figure 3-1 for an example using two Sync-enabled motors).

Figure 3-1: Sample Transport System Layout Showing Sync Option Connections

NOTICE

The Host Controller must track all vehicles in the Sync Zone to ensureappropriate spacing between vehicles and for collision avoidance.

2 Node Controller LITEs (NCn)

2 Right switches

3 Paths

1 Network Switch (SW1)

1 Power Supply (PS1)

2 Nodes 1 Diverge 1 Merge

1 SYNC IT Controller (SC1)

5 90° curve motors

3 1000 mm motors

6 250 mm motors

Qty Description

NC1 NC2

SW1

PS1

Host

& HLC

SC1

Sync Enabled Motors

Eth

erN

et/IP

Eth

erN

et/IP

PS1

2 Standard 1 with Sync Option

(curve and 1 m)

4 Standard 1 with Sync Option

Specifications and Site RequirementsMechanical Specifications


Mechanical Specifications

All drawings within this manual are generic and may not reflect specific configurations of the SYNC IT™ controller. To obtain a complete and current set of drawings and documents con-tact MagneMotion Customer Support.

SYNC IT Controller

Figure 3-2: SYNC IT Controller Mechanical Drawing

[2.5]63.5

[2.5]63.5

[6.48]164.6

[1.75]44.5

ADJUSTABLE SLIDINGMOUNTING BRACKETS

MOUNTING PLATE REQUIREDON CROSSHATCHED AREA

[5.52]140.0

[4.88]123.9

[4.27]108.5

2X [0.220]5.59

2X[3.13]79.5

CABLE CONNECTOREXCLUSION AREA

CABLE CONNECTOREXCLUSION AREA

All Dimensions in Millimeters [Inches]Weight: 0.4 kg [0.9 lb]

Specifications and Site RequirementsMechanical Specifications


Mounting Plate

Figure 3-3: Mounting Plate Mechanical Drawing

0

0

28.1

81.

11

91.1

83.

59

97.9

33.

86

153.

186.

03

208.

428.

21

215.

188.

47

278.

1810

.95

13.00.51

75.002.95

101.744.01

137.005.39

5.91150.00

2X 10.00[0.39]

4X M5 THRU2X M4 THRU

M5 X 12 MM STUD

TYP3.2R306.3512.06

2.6868.18

6.69170.0015.00

.59

3.2.13

All Dimensions in [Inches] Millimeters

Specifications and Site RequirementsElectrical Specifications


Electrical Specifications

SYNC IT Controller

18 - 42 VDC, 5 W maximum.

Refer to SYNC IT Controller on page 3-3 for the mechanical drawing.

Figure 3-4: SYNC IT Controller Electrical Connectors and Indicators

Table 3-1: SYNC IT Controller Connectors

Label Description Connector Type

ETH0/ETH1 Ethernet RJ-45, Female

USB1 USB USB Type B, Female

SP1 - SP3 Sync Molex Mini-Fit Jr.

Table 3-2: SYNC IT Controller Indicators

Label Description Function

NS Red/Green Light Network Status

Solid green – Normal operationFlashing green – No established connectionSolid red – Duplicate IP addressFlashing red – Connection time-out

MS Red/Green Light Module Status

Solid green – Normal operationFlashing green – Not configuredSolid red – Major faultFlashing red – Minor fault

SYS Yellow/Green Light System Status

Solid green – Normal operationFlashing green/yellow – Firmware not loadedFlashing yellow – Software not loaded

Status EthernetUSB

Sync

Front Back



Power Connection

MagneMover® LITE Transport Systems

When used in a MagneMover LITE (MML™) system, the SYNC IT controller is powered through its connection to the motors and does not require any external source of power.

QuickStick® 100 Transport Systems

When used in a QS 100 system, the SYNC IT controller uses a remote power supply that requires 90 - 264 VAC @ 47 - 63 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. Internal power converters produce the different voltages required by the different subsystems of the SYNC IT controller.

The SYNC IT controller power supply is supplied with a power cable, which should not be substituted. Contact MagneMotion for replacement cables. The AC power cable plugs directly into the power supply.

Ethernet Connection

The SYNC IT controller supports an Ethernet connection of 10/100 Mbps (auto-negotiation supported). This connection supports the EtherNet/IP communication protocol for use with PLC-based Host Controllers.

CAUTION

High Voltage Hazard

90 - 264 VAC, 25 WAC power must be disconnected before servicing.

NOTICE

The SYNC IT controller does not support Power over Ethernet (PoE). Con-necting the controller to a powered Ethernet network may damage the con-troller.



NOTE: To ensure high speed communications over the EtherNet/IP connection to the SYNC IT controller MagneMotion recommends the use of a dedicated IEEE 1588 CIP Sync compatible connection between the Host Controller and the SYNC IT con-troller.

The Ethernet cables used are standard network cable (UTP-Cat5) with an 8-pin RJ-45 connec-tor that plugs into the SYNC IT controller at either the ETH0 or ETH1 port. Refer to Fig-ure 4-2 on page 4-6 for the locations of this connection.

NOTE: To establish a direct communications link between the Host Controller and the SYNC IT controller a standard Ethernet cable may be used (auto-MDIX is sup-ported).

EtherNet/IP Communication

EtherNet/IP allows the Host Controller to communicate with the SYNC IT controller as if it was additional I/O using the memory interface detailed in the Interface Reference on page 7-1.

The connection to the SYNC IT controller uses standard 10/100 Base-TX Ethernet network wiring. The EtherNet/IP address used on the SYNC IT controller must be configured to an address appropriate for use with the Host Controller (refer to Configure IP Address on page 5-4).

USB Serial Interface Connection

USB serial communications provides the ability to connect the SYNC IT controller to a ser-vice computer for setting the IP address and performing software upgrades using a standard USB cable with a Type B connector at the end plugging into the SYNC IT controller.

Sync Connection

The Sync connection provides the ability to connect the SYNC IT controller directly to a sync-enabled motor using an 8-wire cable. Up to three motors may by controlled through a single SYNC IT controller.



MagneMover LITE Transport Systems

For MagneMover LITE (MML) systems, the sync cable uses a male 8-pin M12 connector that plugs into the motor and a female 8-pin Molex connector that plugs into the SYNC IT control-ler. Refer to Figure 3-5 for cable identification and Table 3-3 for cable pinouts.

Figure 3-5: MagneMover LITE Sync Cable

NOTE: There is no need for the user to construct the sync cables as all cabling is supplied with the transport system. Contact MagneMotion for additional or replacement cables.

QuickStick 100 Transport Systems

For QuickStick 100 systems (QS 100) the sync cable uses a male DE-9 connector that plugs into the motor and a female 8-pin Molex connector that plugs into the SYNC IT controller. There is an additional cable branch with a female 2.1 mm Coax connector that plugs into the

Table 3-3: MML Sync Cable Pin Assignments

Male Micro-Mizer Female Mini-Fit

GND 1 1

V+ 2 2

SIMO 3 3

SCLK 4 4

SOMI 5 5

SS 6 6

Drain – 7

RESET 8 8

FemaleMini-Fit

MaleMicro-Mizer

700-1291-00

1Keyway 8

1 4

5



cable from the power supply. Refer to Figure 3-6 for cable identification and Table 3-4 for cable pinouts.

Figure 3-6: QuickStick 100 Sync Cable

NOTE: There is no need for the user to construct the sync cables as all cabling is supplied with the transport system. Contact MagneMotion for additional or replacement cables.

Table 3-4: QS 100 Sync Cable Pin Assignments

Male DE-9 Female Mini-Fit Female 2.1 mm Coax

V+ — 2 Red (Center)

SIMO 2 3 —

SOMI 3 5 —

RESET 4 8 —

not used 5 — —

not used 6 — —

SCLK 7 4 —

SS 8 6 —

GND 9 1 Blk (Shell)

Shield/Drain — 7 —

FemaleMini-Fit

MaleDE-9

FemaleCoax

700-1358-00

6

1

9

5 8

1 4

5

GND

V+

Specifications and Site RequirementsSite Requirements


Site Requirements

Environment

Temperature:

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]

Humidity:

85% Maximum (relative, non-condensing)

Lighting:

No special lighting is required for proper operation of the SYNC IT controller. Main-tenance may require a user supplied service lamp (e.g., flashlight).

Floor Space and Loading

The site for the SYNC IT controller must meet the minimum space requirements as defined in Design Guidelines on page 3-2 and referencing the Mechanical Specifications on page 3-3 to ensure proper clearance for installation, operation, and servicing. It is the user’s responsibility to ensure adequate space around the equipment for operation and service based on their needs.

Facilities

The user is responsible for providing the facilities specified in Electrical Specifications on page 3-5 to ensure proper operation of the SYNC IT controller.

The facility is responsible for the main disconnect device between the SYNC IT controller and the facility’s power source, ensuring it complies with the appropriate national and local electrical codes. Service to the SYNC IT controller should have the appropriate circuit breaker rating.

Service Access

The SYNC IT controller requires adequate space for service access and for proper operation. Typical service space required for the SYNC IT controller is shown in Figure 3-2.

Ensure that installation of the SYNC IT controller on the transport system is such that it pro-vides access to items required for service after installation, such as power and communication connections.


Installation 4

Overview

This chapter provides complete installation procedures for the LSM Synchronization option on a MagneMotion transport system.


• Unpacking and inspection.

• LSM Synchronization option setup, including: hardware installation, facilities connec-tions, and software installation and configuration.

• Initial power-up and check-out.

InstallationUnpacking and Inspection


Unpacking and Inspection

The SYNC IT™ controller is shipped in one package. Open the package carefully following the steps provided in Unpacking and Moving on page 4-2; inspect and verify the contents against the shipping documents attached to the outside of the main shipping crate. Report any damage immediately to the shipper and to MagneMotion.

NOTE: The contents of the shipping packages depends on the items purchased. Table 4-1, below, is provided for reference only.

NOTE: Save the shipping packaging for possible future use. If the SYNC IT controller is returned to MagneMotion for service, the original shipping packaging must be used. If the original packaging has become lost or damaged, contact MagneMotion for replacements.

Unpacking and Moving

Unpacking and Moving Instructions

1. Upon receiving the package, visually verify the packaging is not damaged. Inform the freight carrier and MagneMotion of any inspection discrepancy.

2. Open the shipping package and verify the contents against the shipping documents. Do not remove any protective wrapping.

3. Move all items to the depack location (refer to LSM Synchronization Option Installa-tion on page 4-4).

4. Remove all protective wrapping.

5. Carefully inspect the contents for signs of damage that may have occurred during ship-ping.

Table 4-1: Packing Checklist Reference

Package Contents

SYNC IT Controller • SYNC IT controller• Mounting bracket• Miscellaneous hardware• Cables• Power supply

InstallationUnpacking and Inspection


Installation Preparation

The SYNC IT controller arrives from the factory ready to install. The information required to install the controller is provided in the following procedures:

• Remove Protective Packaging on page 4-3.

• LSM Synchronization Option Installation on page 4-4.

Remove Protective Packaging

The SYNC IT controller and related equipment is shipped wrapped in protective packaging. This packaging must be removed before installation can be started.

• Remove any protective wrapping from the controller module.

• Remove any protective wrapping from any loose cable ends or connectors.

• Remove any protective wrapping from any other components.

InstallationLSM Synchronization Option Installation


LSM Synchronization Option Installation

The SYNC IT controller must be properly located on the transport system so that it can inter-face to the motors being controlled. The location must also ensure that there is adequate space for service access and for proper operation.

Installing Synchronization Enabled Motors

Sync motors are physically the same as standard motors with one extra connector provided on the motor. Refer to the system User’s Manual for motor installation.

Installing the SYNC IT Controller

These installation procedures assume use of the MagneMover® LITE (MML™) stand system to support the SYNC IT controller. When installing the SYNC IT controller on a QuickStick® 100 (QS 100) system the same mounting bracket may be used, location and mounting of the controller on the system is determined by the user.

To install the SYNC IT controller on user-supplied supports ensure the supports are properly prepared to receive the controller (refer to Mechanical Specifications on page 3-3). Install the controller making any adjustment necessary to account for the custom supports.

Installation Overview

1. Ensure power to the transport system is turned off.

2. Locate the bracket near the motors to be controlled and attach it to the system stand.

3. Mount the SYNC IT controller on the bracket.

4. Connect the SYNC IT controller to the motors.

5. Connect the SYNC IT controller to the Host Controller.

Installing Hardware

The SYNC IT controller should be located on the transport system close to the motors it is responsible for to minimize the length of all wiring. The controller may be mounted directly to the transport system using the supplied mounting flanges, or it may be attached to the mount-ing plate (refer to Figure 3-3 on page 3-4) if needed, ensure the service and exclusion zones identified in Figure 3-2 on page 3-3 are maintained. Standard mounting methods for using the mounting plate are shown in Figure 4-1.



Figure 4-1: SYNC IT Controller Mounting

1. Install the mounting flanges onto the SYNC IT controller, if not already installed.

2. Orient the SYNC IT controller as required and secure it to the bracket, apply Loctite 243 to two M5 x 10 mm screws and install and tighten the screws to 2.7 Nm [24 in - lb].

3. Secure the mounting plate to the transport system as required.

4. Use nylon cable ties as required to secure the cables running to the controller.

M5 Screw(2X)

M5 Screw(2X)



Connecting Motors and Electronics

The SYNC IT controller uses a discrete communications connection to each motor being con-trolled by the LSM Synchronization option. For MagneMover LITE systems these connec-tions provide power to the SYNC IT controller minimizing the amount of wiring needed.

Figure 4-2: SYNC IT Controller Electrical Connections

Figure 4-3: MagneMover LITE Motor Electrical Connections

NOTE: The Sync connection will only be present on the MML motor if the LSM Synchroni-zation option is installed.

NOTICE

Never connect or disconnect the sync cables with power applied to themotors as damage to internal components may result.

USB

Sync

Ethernet (Maintenance Only)

Front View

Back View

(2X)

(3X)

Power

Sync Option

Communications

Power

Sync Option

Straight Motor Sections Curve Motor Sections

Bottom View

Bottom View

(2X)Communications(2X)



Figure 4-4: QuickStick 100 Motor Electrical Connections

Figure 4-5: Simplified Representation of QS 100 Motor Connections

Refer to Figure 4-2, Figure 4-3, and Figure 4-4 for the sync connection location on the SYNC IT controller and the motors in the transport system. For MML systems, all cables can be run in the cable chase under the motors. Refer to Figure 4-5 for a simplified diagram of the wiring.

1. Connect the sync cable from the first Sync connector (SP1) on the SYNC IT controller to the upstream (first) motor in the Sync Zone (as defined in the transport system lay-out drawing).

NOTE: Motors should be connected to the SYNC IT controller in sequence (SP1 for the first motor in the Sync Zone, SP2 for the second, etc.) to simplify the control logic.

2. Connect sync cables from the Sync connectors on the SYNC IT controller to the remaining motors in the Sync Zone(s) (as defined in the transport system layout draw-ing).

3. Connect an Ethernet cable from the SYNC IT controller (ETH0 or ETH1) to the dedi-cated Ethernet/IP port on the Host Controller.

DownstreamRS-422

(See manualfor pinout)

J3 J1J2J5

UpstreamRS-422

(See manualfor pinout)

PowerSync OptionCommunications

Bottom View

(2X)

To next motorin Path

NC PS

DownstreamUpstream(Simple

Node)

Motor

SC

PowerConnection

SyncConnection

CommunicationConnection

Sync Motor



If more than one SYNC IT controller is being used they should be connected to a com-mon network switch and the switch should be connected to the Host Controller at the dedicated EtherNet/IP port as shown in Figure 4-6.

Figure 4-6: Network Cable Connections

4. Set the EtherNet/IP address for the SYNC IT controller (refer to Configure the SYNC IT Controller on page 5-4).

5. Repeat Step 1 through Step 4 each additional SYNC IT controller.

Software

Software Installation

The SYNC IT controller ships with the factory default version of the control software pre-loaded at the factory. Upgrades to the software can be downloaded through the USB com-munications link. Refer to the Upgrade Procedure supplied with the software upgrade.

NOTE: Alterations or changes to the software image should only be made by qualified MagneMotion personnel.

Refer to Configure the SYNC IT Controller on page 5-4 and Configure the PLC on page 5-10 before using the Sync option.

Software Configuration

For standard (asynchronous) transport system control, refer to either the Host Controller TCP/IP Communication Protocol User’s Manual, the Host Controller EtherNet/IP Communi-cation Protocol User’s Manual, or the Mitsubishi PLC TCP/IP Library User’s Manual. For control of vehicles in the Sync Zones, refer to Operation on page 5-1.

Host

NetworkSwitch

ControllerSYNC IT

ENet or ENet/IPENet/IP N

etw

ork

Sw

itch

Upl

ink Uplink

SYNC IT

. . .

To Node Controllers

InstallationPower-up and Check-out


Power-up and Check-out

System Check-out

Before the LSM Synchronization option is started for the first time, or after servicing the SYNC IT controller, it is necessary to check all operating and safety features.

The following start-up procedure is used in addition to the procedures provided in the trans-port system User’s Manuals.

Mechanical Checks

• Ensure that all new hardware is secure.

Facility Checks

• Ensure that all 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.

InstallationPower-up and Check-out


System Power-up

After the LSM Synchronization option has been installed and configured, all connections should be checked before proceeding any further with the installation process. This section describes the procedure for the initial installation check-out to be used in addition to the pro-cedures provided in the transport system User’s Manuals.

1. Ensure that all of the installation procedures previously described in this chapter have been completed.

2. Perform a Ground Continuity check from the surfaces of the SYNC IT controller to a known good ground.

3. Connect the transport system to the plant’s electrical services.

The indicators on the SYNC IT controller are lit solid green during normal operation.

4. If the initialization sequence executes without error (all indicators on the SYNC IT controller are green), then the Sync option has been properly installed, all the compo-nents are communicating successfully, and the transport system is ready for operation.

If start-up was successful, the transport system is ready to accept commands. If, how-ever, the start-up sequence was unsuccessful, refer to Troubleshooting on page 8-4.

5. Configure the transport system for synchronized operation by modifying the existing control application appropriately and creating a synchronized control application to operate the vehicles in the Sync Zones.

CAUTION

Automatic Movement

The Host Controller initiates all motion control toboth the High Level Controller and the SYNC IT con-troller on the transport system. It is the user’s respon-sibility to initiate a safe start-up of the transportsystem.

Do not attempt to operate the transport system untilall setup procedures described in this chapter havebeen completed.

InstallationSystem Testing


System Testing

Testing the transport system to verify proper operation of all Sync Zones requires the PLC responsible for monitoring and controlling the sync motors be fully configured to control those motors. This can be accomplished using the NCHost application supplied by MagneMo-tion to move vehicles without the Host Controller to verify proper functioning before integrat-ing the sync zone into a production environment. Create Demo Scripts to perform repetitive testing throughout the transport system and the sync zones. Refer to the NCHost TCP Inter-face Utility User’s Manual for details. If any problems are encountered, refer to Troubleshoot-ing on page 8-4.

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 Web Interface User’s Manual). Note that the Configuration File does not require any changes to support the Sync option.

3. Verify that each NC has a status of running/valid (refer to the Node Controller Web Interface User’s Manual).

4. Issue a Restart Services command for each Node Controller (refer to the Node Con-troller Web 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. Once all Paths have completed their reset, issue a Startup command to all Paths.

Motion on all Paths is enabled, all vehicles on the Paths are identified, and the Paths become operational.

CAUTION

Crush Hazard

Moving mechanisms have no obstruction sensors. Do notoperate the transport system without barriers in place or per-sonal injury could result in the squeezing or compression offingers or hands between moving parts.

CAUTION

Crush Hazard

The vehicles may move during the startup sequence.

InstallationSystem 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 Demonstration 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.

NOTE: All vehicle positions while under asynchronous control are measured from the beginning of the Path where the vehicle is located.

10. Run the application on the PLC to take control of, and move, the vehicles through the Sync Zones.

NOTE: All vehicle positions while under sync-control are measured from the begin-ning of the Sync Zone where the vehicle is located.

While a vehicle is under sync-control the vehicle status reported by the Node Controller will indicate the vehicle is jammed when the vehicle is not mov-ing and not within the arrival tolerance of the asynchronous order it’s cur-rently under.


Operation 5

Overview

This chapter provides complete operation directions for the LSM Synchronization option on a MagneMotion transport system.


• Theory of operation.

• Configuration of the SYNC IT™ controller and the Host Controller (PLC).

• Transport system testing.

• Operation of the transport system.

OperationTheory of Operation


Theory of Operation

From a synchronization perspective, each vehicle is considered a unique axis. At the most basic level, the vehicle’s profile (and subsequent motion) is a ‘slave’ to commands from an external ‘Master’. Most protocols use a master/slave control. That is, the ‘Master’ is what does the commanding, the ‘slave’ performs the command. For MagneMotion sync-enabled motors, each vehicle has the option to become a ‘slave’ to the PLC ‘master’.

In normal asynchronous operation (non-Sync Zones), the Node Controllers route the orders from the Host to the motors and the motors control the profiles (position, velocity, and accel-eration) for the vehicles. All asynchronous control is handled through the Node Controller’s RS-422 interface to the motors.

In Sync Zone operation, the profile (position, velocity, and acceleration) generation for indi-vidual vehicles is the responsibility of the Host Controller, which generates profiles for all vehicles under sync control in the synchronization region. This requires that the Host Control-ler be in charge of collision avoidance. Once the vehicle leaves the sync region, the MMI con-trol system picks up profile generation (and collision avoidance) functions. The Vehicle IDs are preserved across non-Sync and Sync regions. Refer to Sync Zones on page 6-4 for descrip-tions of Sync Zone configurations.

LSM Synchronization provides the ability for the end user to more accurately control move-ment of individual vehicles within a specified zone. More elaborate movement profiles can be implemented, such as jerk control. It also provides the ability to co-ordinate vehicle motion to that of an external moving element, e.g. robot, filler, etc.

Ensuring proper control of the vehicles within the Sync Zones requires ‘timely’ motion com-mands, typically on the order of 1-10ms update rates. To ensure precise control and position, all communication in the SYNC IT system is time stamped.

Key features of the LSM Synchronization option are:

• The SYNC IT controller can control up to 3 separate MagneMotion motors as shown in Figure 5-1 and must be within 2m of the motors.

• The SYNC IT controller can control up to 3 separate SYNC zones.

• Sync zones longer than three motors require additional SYNC IT controllers.

• Collision avoidance must be handled by the Host Controller (PLC).

• The Host Controller generates the vehicle movement profile in the Sync Zone.

• The motors will attempt to ‘fill in the gaps’ if the next profile is not sent in a timely manner.

OperationTheory of Operation


Figure 5-1: Transport System Wiring Diagram with Synchronization

PLC

Sync Motor

SYNC IT

Power

Sync Motor Sync Motor Sync Motor Motor

ENet or ENet/IP

EtherNet/IP

NC

Motor

SYNC IT

Switch

OperationConfiguration


Configuration

Configure the SYNC IT Controller

The SYNC IT controller is supplied with a software application (SYCON.net) for configuring the IP address. This application is run on a user-supplier computer (service computer) con-nected to the SYNC IT controller through a USB cable.

NOTE: An additional application (Ethernet Device Setup) may be supplied on the CD, but should not be used as any changes made using it will not be restored if power to the SYNC IT controller is cycled.

Install Configuration Application

Install the SYCON.net application on the service computer if not already installed.

1. Run SYCONnet netX setup.exe supplied on the MagneMotion CD-ROM.

The Windows installer runs and installs the application. An entry for the application is added to the Windows Programs list in the SYCON.net System Configurator folder.

2. The first time SYCON.net is run a SYCON.net administrator password must be cre-ated to complete the installation.

Configure IP Address

1. Connect the SYNC IT controller to the service computer using a USB cable.

2. Connect the SYNC IT controller to its power source.

• For MagneMover LITE, the controller must be connected to at least one motor and the motor must have power supplied.

• For QuickStick, the controller must be connected to its remote power supply.

3. Run the SYCON.net application.

4. Enter the administrator password created when SYCON.net was installed.

The SYCON.net application window is displayed as shown in Figure 5-2.



Figure 5-2: SYCON.net Application

5. Open the supplied configuration file (.spj extension).

The SYCON.net application window is updated with the configuration data and an icon for the SYNC IT controller is displayed as shown in Figure 5-3.

Figure 5-3: SYCON.net – Configuration File Loaded

6. Right-click on the COMX icon and select Configuration... from the short-cut menu.

The netProject - Configuration dialog box is displayed.

7. From the Navigation Area select Settings.



A. Select Driver and ensure that both drivers are selected.

Figure 5-4: netProject – Settings – Driver

B. Select netX Driver.

Figure 5-5: netProject – Settings – netX Driver



1. Ensure that Enable USB/RS232 Connector is selected.

2. In the netX Driver section ensure that the correct comm port for the USB connection is selected (refer to the service computer’s documenta-tion).

3. Select Save All.

C. Select Device Assignment.

Figure 5-6: netProject – Settings – Device Assignment

1. Select Scan to locate the SYNC IT controller.

SYCON.net scans for attached devices and displays the detected COMX devices.

2. Select the COMX device.



8. From the Navigation Area select Configuration.

A. Select General.

Figure 5-7: netProject – Configuration – General

1. Ensure Fixed Address is selected.

2. Enter the IP Address that will be used for the SYNC IT controller.

3. Select Apply.

4. Select OK.

The netProject - Configuration dialog box is closed.

B. Select Assembly.



Figure 5-8: netProject – Configuration – Assembly

1. Ensure Data length is 264 for both the IN and OUT instances.

9. Right-click on the COMX icon and select Download from the short-cut menu.

The netProject - Configuration download alert shown in Figure 5-9 is displayed.

Figure 5-9: netProject - Download Warning

10. Select Yes.

The download status is displayed. Once the download is complete the SYCON.net application window is updated to show the name of the icon for the SYNC IT control-ler in green as shown in Figure 5-10.



Figure 5-10: Download Succeeded

11. Close the SYCON.net application.

Configure the PLC

Once connected to the PLC the SYNC IT controller will appear as dedicated I/O, with 132 x 16 bit words configured as output memory and 132 x 16 bit words configured as input mem-ory (refer to the Interface Reference on page 7-1 for memory configuration).

NOTE: The following steps are for an Allen Bradley ControlLogix PLC using RSLogix 5000. If a different type of PLC is being used refer to the manufacturer’s documenta-tion for the equivalent procedure.

1. Add a dedicated Ethernet module for the SYNC IT controller.

A. Open the I/O Configuration folder from the Controller Organizer.

B. Open the Backplane folder.

C. Open the Ethernet Port folder.

D. Right-click on Ethernet and create a New Module.

E. Select the new module to display its Properties dialog box.

F. Set the IP address of the Ethernet module to the same network as the SYNC IT controller. Note that this is a closed network, only the PLC and the SYNC IT controller should be connected to it (refer to Figure 5-1).

G. Connect the SYNC IT controller as a ‘Generic Ethernet Module’ and configure it as shown in Figure 5-11 and Figure 5-12 and described below the figures. Note that the values shown must be used to ensure proper configuration of the communications with the SYNC IT controller.



Figure 5-11: PLC Configuration for SYNC IT Controller, General Tab

Figure 5-12: PLC Configuration for SYNC IT Controller, Connection Tab

2. Select Apply.

Name: as required

Comm Format: Data - INT

IP Address: as required

Input Assembly Instance: 101

Input Size: 132

Output Assembly Instance: 100

Output Size: 132

Configuration Assembly Instance: 1

Configuration Size: 0

Requested Packet Interval (RPI): 1 ms

Use Unicast Connection over EtherNet/IP: Selected



3. Select OK.

The dialog box is closed and the tag memory for the SYNC IT controller I/O is created.

4. Open MMI_sync_example_logic.ACD (provided on the CD supplied with the SYNC IT Controller).

5. Configure a virtual axis for each vehicle that will be in the Sync Zone at the same time. Note that axes only need to be configured for the number of vehicles in the Sync Zone, not all vehicles in the transport system, and that the axis can be reused by the next vehicle to enter the Sync Zone once the vehicle being controlled leaves the Sync Zone.

A. In the Motion Group Properties dialog box on the Attribute tab (shown in Fig-ure 5-13), ensure the Coarse Update Period is set to 2.0 ms.

Figure 5-13: Motion Group Properties - Attribute Tab

NOTE: A large update rate (> 8 ms) may cause erratic behavior.

A very large update rate (> 20 ms) may cause the sync motor to time out while waiting for an update and switch back to asynchronous con-trol.

B. Create a new axis.

1. Right-click on the Motion Group, select New Axis from the short-cut menu, and AXIS_VIRTUAL... from the sub-menu.

The New Tag dialog box is displayed.

2. In the New Tag dialog box, enter a name for the axis and select Create.

3. Double-click on the new axis in the Motion Group.

The Axis Properties dialog box for the selected axis is displayed.

4. In the Axis Properties dialog box on the Tag tab, change the axis name if desired.



5. In the Axis Properties dialog box on the Units tab (shown in Fig-ure 5-14), ensure the Position Units are set to ‘Meters’.

Figure 5-14: Axis Properties - Units Tab

6. In the Axis Properties dialog box on the Conversion tab (shown in Fig-ure 5-15), ensure the Positioning Mode is set to ‘Rotary’, the Conver-sion Constant is set to ‘1000000’ (one million), and the Position Unwind is set to account for the total length of the Sync Zone.

The Position Unwind setting is the total length of the Sync Zone, where a 0.25 m zone = 250000 (250 thousand), a 1 m zone = 1000000 (one million), and a 3 m zone = 3000000 (three million).

Figure 5-15: Axis Properties - Conversion Tab



7. In the Axis Properties dialog box on the Homing tab (shown in Fig-ure 5-16), ensure the Position is set to ‘0’.

Figure 5-16: Axis Properties - Homing Tab

8. In the Axis Properties dialog box on the Dynamics tab (shown in Fig-ure 5-17), ensure the settings match the values in the transports sys-tem’s Node Controller Configuration File. Select to have the system calculate the Jerk.

Figure 5-17: Axis Properties - Dynamics Tab

NOTE: For every axis created, an instance of the MMI_sync_motion_IO add-on instruction must be added to the main ladder Profiles_to_motor of the ProfileTask that comes with the MMI_sync_example_logic.ACD file.

OperationOperation


Operation

Start-up

The transport system is started by applying power as specified as in the transport system’s User’s Manual. Once this is done, the transport system is ready to operate. If the Host Control-ler is in control of the transport system, the transport system will accept commands from the Host Controller through the network connection.

Normal Running

Normal operation of the transport system and operation of the Sync Zones is controlled by the user’s Host Controller. The exact usage of the transport system must be determined by the user. For information on using the Sync Zones refer to Application Notes on page 6-1.

NOTICE

All switch settings, communication connections, and power connectionsmust be made before power is applied.

CAUTION

Crush Hazard

Moving mechanisms have no obstruction sensors.

Do not operate the transport system without barriers in placeor personal injury could result in the squeezing or compres-sion of fingers or hands between moving parts.

NOTICE

The Host Controller is in charge of collision avoidance for all vehicles undersync control.

OperationSafe Shut-down


Safe Shut-down

The following shut-down procedure is used to remove power from the transport system in an orderly manner and place the components in safe conditions. This procedure is used to prepare the components for removal, replacement, or maintenance.

NOTE: When the Host Controller is to be shut down, the transport system should be shut down first.

The transport system requires no special shut-down procedures. When the Host Controller is to be shut down, the transport system should be shut down first.

1. All material transfers should be completed (move all material to the appropriate loca-tions).

2. Command all vehicles to known safe positions.

All vehicles come to a controlled stop at their designated locations.

3. Once all motion has stopped, issue a Suspend Movement command for all Paths.

4. Issue a Reset command for all Paths.

Clears all vehicle records.

5. Turn off power to the motors (motor controllers).

6. Turn off power to the Node Controllers.

7. Turn off power to the Host Controller.

8. Turn off the main power disconnect for the QuickStick 100 transport system.

9. Remove the power cable from the source and disconnect it from the Host Controller.

10. Disconnect the communication cables to the Host Controller.

NOTE: This procedure only shuts down facilities to the transport system and its subsystems. Any user equipment will remain powered up.

CAUTION

Electrical Hazard

The shut-down procedure is used in the normal shut-down ofthe transport system. This procedure completely removes thepower source and all other facilities to the components andprovides guidelines for lockout/tagout. This procedure isNOT the same as an EMO circuit or other safety interlock.


Application Notes 6

Overview

This chapter shows how to use the features of the LSM Synchronization Option.


• Operation overview, including asynchronous and synchronous operation.

• Descriptions of Sync Zone configurations.

• Overview of SYNC IT™ controller communications.

• Vehicle movement in Sync Zones.

• Overview of the PLC Tools supplied by MagneMotion.

Application NotesOperation Overview


Operation Overview

This section provides an overview of the two methods of vehicle control within a MagneMo-tion transport system.

Standard Operation

MagneMotion transport systems provide asynchronous control of vehicles on the transport system as directed by the Host Controller. This method minimizes the load on the Host Con-troller with the transport system’s Node Controllers and motors performing all routing and vehicle control operations (positioning, acceleration, deceleration, collision avoidance) as described below.

1. The Host Controller generates an asynchronous movement order to move a vehicle to a specific location from the beginning of a Path and sends it to the High Level Control-ler (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/s2 (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 vehi-cle master (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 (a ‘block’ is defined as an independently con-trolled coil or set of coils; no two vehicles are allowed to occupy the same block).

• For MagneMover® LITE, a block is a single coil (approx. 16.43 mm).

• For QuickStick® 100, a block is a single set of coils (approx. 96 mm).

• The vehicle master will use the position of the last acquired block 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 head-way 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 100 ms, to provide the Host Con-troller some level of feedback as to where the vehicle is located.

Application NotesOperation Overview


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 next motor as the vehicle moves across motor boundaries. The new master ‘picks up’ where the old one left off for pro-file 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 within the arrival toler-ance of the destination as defined in the Node Configuration file.

Synchronized Operation

MagneMotion transport systems provide an option for direct control of individual vehicles on specific motors within the transport system as directed by the Host Controller. This method increases the load and responsibilities on the Host Controller, with the Host Controller per-forming all vehicle control operations (positioning, acceleration, deceleration, and collision avoidance) as described below.

NOTE: To eliminate the additional load on the Host Controller a dedicated PLC can be used to provide the synchronized control.

1. The Host Controller (PLC) generates a movement order to move a vehicle through a specific Sync Zone and sends it to the High Level Controller.

2. The vehicle is controlled as described in Standard Operation.

3. The Host Controller monitors the Sync Zone to detect the arrival of the vehicle in the Sync Zone.

4. Once the vehicle is in the Sync Zone the Host Controller takes control of the vehicle, generates a movement profile for the vehicle from the vehicle’s current location, and sends it to the SYNC IT controller, which sends it to the appropriate motor (vehicle master) in the Sync Zone.

5. The Host Controller updates the SYNC IT controller every 2 ms with an updated motion profile.

6. If there is more than one motor in the Sync Zone, the Host Controller instructs the SYNC IT controller to send the movement profile to the appropriate motors.

7. Once the vehicle reaches the end of the Sync Zone the Host Controller returns control of the vehicle back to the transport system.

NOTICE

The Host Controller must track all vehicles in the Sync Zone toensure appropriate spacing between vehicles and for collision avoid-ance.

Application NotesSync Zones


Sync Zones

Each sync motor provides a unique Sync Zone. These zones can be independent of each other or connected to each other to create a larger Sync Zone.

This section provides examples of the various ways to configure the sync motors to create Sync Zones.

• Figure 6-1 shows two basic configurations. Three sync motors configured as one Sync Zone and two sync motors configured as one Sync Zone.

• Figure 6-4 shows two basic configurations. Three sync motors configured as three separate Sync Zones and two sync motors configured as two separate Sync Zones sep-arated by a standard motor.

• Figure 6-7 shows one sync motor used as two separate Sync Zones. In this case the motor is divided into multiple zones in software.

Sync Zone Offsets

The MagneMotion QuickStick 100 and MagneMover LITE motors perform all position-based calculations in cycle lengths rather than meters. To control a vehicle in a Sync Zone the Host Controller (PLC) must pass fixed point position data (in cycles) to the SYNC IT controller. When there is more than one motor in a Sync Zone, the offset to the upstream end of each additional motor in the Sync Zone must be accurately represented as a 16.16 fixed point num-ber specifying the position in whole and fractional motor cycle lengths (refer to Motor Com-mand Memory Interface on page 7-3).

The fractional cycle 16-bit value is interpreted by the SYNC IT Controller as an unsigned integer. However, most PLCs support only signed integers. Therefore, if the unsigned frac-tional cycle value is greater than 32767, the high order bit, which is the sign bit in the PLC, is set. In this case, the value must be converted to a negative value when entered into the PLC. This is calculated by subtracting 65536 from the fractional cycle value if it is greater than 32767. Formulas for performing these calculations are provided in Calculating Sync Motor Offsets.

NOTE: The SYNC IT™ Motor Offset Worksheet (800-0089-00) calculates the upstream end offset values needed for the Host Controller software (refer to Using the SYNC IT™ Motor Offset Worksheet). It is critical that these values match the values used by the motor. If not, a move across multiple motors will cause accumulated position errors, which will negatively impact accuracy.



Standard Configuration

Multi-motor Single-zone Configuration

This is the typical configuration for Sync Zones, where two or more sync-enabled motors are treated as a single zone, refer to Example 1 and Example 2 in Figure 6-1. Typical Sync Motor Offsets for Example 1 are shown in Figure 6-2 and for Example 2 in Figure 6-3

Figure 6-1: Multiple Motors with Single Sync Zone

In the first example, three sync motors are treated as a single continuous Sync Zone. This allows sync control of the vehicle to be started anywhere within the Sync Zone and provides positioning anywhere along the 3 m length of the zone. Using the motors as a continuous Sync Zone provides automatic handoff between the motors as the vehicle moves from motor to motor.

The Sync Motor Offsets in the Motor Command Memory Interface, shown in Figure 6-2 are used by the SYNC IT controller to provide the transition between the motors shown in Exam-ple 1. Note that motor 1 starts at 0 as it is the beginning of the first motor, motor 2 starts at 20.25 cycles, which accounts for the gap between motors, as that is the location of the begin-ning of the second motor (1 m from the beginning of motor 1), and motor 3 starts at 40.50 cycles as that is the location of the beginning of the third motor (2 m from the beginning of motor 1).

Sync Zone 1

Example 1

Example 2

Sync Motor 1 Sync Motor 2 Sync Motor 3Sync Zone Position

Path Position3m5m

0m2m

Sync Zone 1

Sync Motor 1 Std MotorSync Zone Position

Path Position1m3m 5m

0m2m

2m4m

Sync Motor 2

1m3m

2m4m



In the second example, two sync motors are treated as a single continuous Sync Zone. This allows sync control of the vehicle to be started anywhere within the Sync Zone and provides positioning anywhere along the 2 m length of the zone. Using the motors as a continuous Sync Zone provides automatic handoff between the motors as the vehicle moves from motor to motor.

The Sync Motor Offsets shown in Figure 6-3 are used by the SYNC IT controller to provide the transition between motor 1 and motor 2. Note that no offset is provided for motor 3 as it is not being used. Note that motor 1 starts at 0 as it is the beginning of the first motor, motor 2 starts at 20.25 cycles as that is the location of the beginning of the second motor (1 m from the beginning of motor 1) and that no offset is shown for motor 3 as it is not being used.

UDT Memory Offset

Value

Sync Motor Offset

2 Motor 1 MSW 0

3 Motor 1 LSW 0

4 Motor 2 MSW 20

5 Motor 2 LSW 16384

6 Motor 3 MSW 40

7 Motor 3 LSW -32768

Figure 6-2: Motor Command - Multiple Motors with Single Sync Zone (Example 1)

UDT Memory Offset

Value

Sync Motor Offset

2 Motor 1 MSW 0

3 Motor 1 LSW 0

4 Motor 2 MSW 20

5 Motor 2 LSW 16384

6 Motor 3 MSW –

7 Motor 3 LSW –

Figure 6-3: Motor Command - Multiple Motors with Single Sync Zone (Example 2)



Alternate Configurations

Multi-motor Multi-zone Configuration

Each sync-enabled motor is treated as a separate zone. Refer to Example 1 and Example 2 in Figure 6-4. Typical Sync Motor Offsets for Example 1 are shown in Figure 6-5 and for Exam-ple 2 in Figure 6-6.

Figure 6-4: Multiple Motors with Multiple Sync Zones

In the first example, each sync motor is treated as a unique Sync Zone creating an area of three separate contiguous Sync Zones. This requires sync control of the vehicle to be started each time the vehicle moves to a new motor (Sync Zone) and stopped each time it leaves that motor. When the vehicle moves from motor to motor it must exit the Sync Zone it is in return-ing control of the vehicle to the Node Controller and then once the vehicle enters the next Sync Zone sync control must be started for that motor.

Note that the Sync Motor Offsets in the Motor Command Memory Interface, shown in Fig-ure 6-5, are all ‘0’ as each motor starts a new Sync Zone.

UDT Memory Offset

Value

Sync Motor Offset

2 Motor 1 MSW 0

3 Motor 1 LSW 0

4 Motor 2 MSW 0

5 Motor 2 LSW 0

6 Motor 3 MSW 0

7 Motor 3 LSW 0

Figure 6-5: Motor Command - Multiple Motors with Multiple Sync Zones (Example 1)

Sync Zone 1 Sync Zone 2 Sync Zone 3

Example 1

Example 2

Sync Motor 1 Sync Motor 2 Sync Motor 3Sync Zone Position

Path Position1m 0m

4m1m5m

0m2m

Sync Zone 1 Sync Zone 2

Sync Motor 1 Std Motor Sync Motor 2Sync Zone Position

Path Position1m3m

1m5m

0m2m

0m4m

1m 0m3m



In the second example, each sync motor is treated as a unique Sync Zone with a non-sync area between them. This requires sync control of the vehicle to be started each time the vehicle moves to a new Sync Zone and stopped each time it leaves that motor. When the vehicle moves from the Sync Zone to the non-sync area it must exit the Sync Zone it is in returning control of the vehicle to the Node Controller and then once the vehicle enters the next Sync Zone sync control must be started for that Sync Zone.

Note that the Sync Motor Offsets shown in Figure 6-6 are ‘0’ for the first two motors as each motor is a new Sync Zone and that no offset is shown for motor 3 as it is not being used.

UDT Memory Offset

Value

Sync Motor Offset

2 Motor 1 MSW 0

3 Motor 1 LSW 0

4 Motor 2 MSW 0

5 Motor 2 LSW 0

6 Motor 3 MSW –

7 Motor 3 LSW –

Figure 6-6: Motor Command - Multiple Motors with Multiple Sync Zones (Example 2)



Single-motor Multi-zone Configuration

One sync-enabled motor is treated as multiple zones, refer to Figure 6-7. Typical Sync Motor Offsets are shown in Figure 6-8.

Figure 6-7: Single Motor with Multiple Sync Zones

In this example, the sync motor is treated as two Sync Zones. However, since they are both on the same motor the vehicle can be moved from Zone 1A to Zone 1B by the PLC under sync control. If required, sync control can be stopped after Sync Zone 1A and then restarted for Sync Zone 1B.

Note that the Sync Motor Offsets shown in Figure 6-8 are ‘0’ for the first motor as it is the only motor being used and that no offset is shown for motor 2 or motor 3 as they are not being used.

UDT Memory Offset

Value

Sync Motor Offset

2 Motor 1 MSW 0

3 Motor 1 LSW 0

4 Motor 2 MSW –

5 Motor 2 LSW –

6 Motor 3 MSW –

7 Motor 3 LSW –

Figure 6-8: Motor Command - Single Motor with Multiple Sync Zones

Sync Zone PositionPath Position

1m3m

0m2m

Sync Zone 1A Sync Zone 1B

Sync Motor 1 Std Motor0.3m2.3m

0.6m2.6m 4m

Application NotesUsing the SYNC IT™ Motor Offset Worksheet


Using the SYNC IT™ Motor Offset Worksheet

The SYNC IT™ Motor Offset Worksheet provides an easy method to determine the Sync Motor Offset. This offset is used by the SYNC IT controller to locate the beginning of the motor in relation to the beginning of the first motor in the Sync Zone. The worksheet supports multiple Sync Zones and multiple motors per Sync Zone. The worksheet also provides all conversions to support the use of signed integers in the PLC.

For additional information related to using this worksheet refer to the SYNC IT™ Motor Offset Worksheet Guide.

Figure 6-9: SYNC IT™ Motor Offset Worksheet

1. Open the SYNC IT™ Motor Offset Worksheet in Excel.

2. Select the motor family by clicking on the orange field below Select Motor Family and picking from the drop-down list.

3. In the orange field below SYNC IT Zone # in the first row enter the number of the zone.

4. Select the motor type of the first motor in the Sync Zone by clicking on the orange field below Motor Type in the first row and picking from the drop-down list.

The spreadsheet displays the motor length and calculates the motor offsets.

5. In the orange field below Motor Gap in the first row enter the gap between motors.

• For a standard MagneMover LITE configuration this can be left empty.

• For a QuickStick 100 configuration this is the physical gap between motors.

The spreadsheet updates the motor offsets.

6. Repeat Step 3 through Step 5 for each additional motor in the Sync Zone (to a maxi-mum of three motors per Sync Zone).

7. Repeat Step 3 through Step 5 for the motors in each additional Sync Zone.

Application NotesUsing the SYNC IT™ Motor Offset Worksheet


8. Enter the motor offsets into the Sync Motor Offsets in the Motor Command Memory Interface for each Sync Zone. Ensure that the proper MSW and PLC Adjusted LSW is used for each offset.

NOTE: The Sync Zones do not need to be contiguous, but can be if required.

Examples

The following examples show the SYNC IT™ Motor Offset Worksheet used for calculating the Sync Motor Offsets for both MagneMover LITE and QuickStick 100 systems. In each example there are two Sync Zones. The first Sync Zone has three motors in it, which requires one SYNC IT controller. The second Sync Zone has two motors in it, which requires one additional SYNC IT controller.

MagneMover LITE

Figure 6-10: SYNC IT™ Motor Offset Worksheet – MML Example

QuickStick 100

Figure 6-11: SYNC IT™ Motor Offset Worksheet – QS 100 Example

Application NotesCalculating Sync Motor Offsets


Calculating Sync Motor Offsets

The Sync Motor Offset must be provided when there is more than one sync-enabled motor in a Sync Zone. This offset is used by the SYNC IT controller to locate the beginning of the motor in relation to the beginning of the first motor in the Sync Zone. The formulas for calcu-lating both the MSW and the LSW of the Sync Offset are provided in Figure 6-12. It is critical that these values match the values used by the motor. If not, a move across multiple motors will cause accumulated position errors, which will negatively impact repeatability.

NOTE: The SYNC IT™ Motor Offset Worksheet (page 6-10) can be used to calculate the off-set values needed for the Host Controller software.

Figure 6-12: Motor Offset Calculations

NOTE: Since PLCs typically represent all 16 bit integers as signed, if the value of the Frac-tional Cycles portion is greater than 32767, the negative integer equivalent must be used in the PLC (the SYNC IT controller treats the number as unsigned).

The offset is accurate to 0.7 microns.

Table 6-1: MagneMotion Motor Lengths and Offsets

Motor Length Motor GapLength in Cycles*

* One MML whole cycle = 0.0494 m, one fractional cycle = 0.0494 m/65536.One QS 100 whole cycle = 0.0480 m, one fractional cycle = 0.0480 m/65536.

Motor Offset MSW(whole cycles)

Motor Offset LSW(fractional cycles)

MML straight 250 mm 249.0 mm 1.088 mm†

† The gap (1.088 mm) between motors on a 1 m pitch, the length of the motor includes the internal gap (2 mm).

5.06 5 4086

MML straight 1000 mm

999.26 mm 1.088 mm† 20.25 20 16384

MML curve 199.6 mm 1.088 mm† 4.06 4 4086

QS 100 1/2 m 498 mm 2 mm‡

‡ The gap (2 mm) between motors on a 1 m pitch, the length of the motor includes the internal gap (18 mm).

10.42 10 27307

QS 100 1 m 978 mm 22 mm§

§ The gap (22 mm) between motors on a 1 m pitch, the length of the motor includes the internal gap (18 mm).

20.83 20 54613

TotalLength MotorLength MotorGap+=

FractionalCycles RoundTotalLength WholeCycles CycleLength×( )–( ) 65536×

CycleLength---------------------------------------------------------------------------------------------------------------------------------------------------=

WholeCycles IntTotalLengthCycleLength---------------------------------- =

PLCCorrected FractionalCycle 32767>( ) 65536–=



MagneMover LITE

For MagneMover® LITE motors (MML™), where there is no additional gap (other than the designed-in gap) between the motors, the motor offset calculation to locate a motor after a 250 mm motor is shown in Figure 6-13 with a description of the steps following the figure.

Figure 6-13: Motor Offset Calculations, MML Example

To determine Total Length:

1. Add Motor Length and Motor Gap: 249.0 + 1.088 = 250.080.

2. Convert to meters = 0.25008.

To determine Whole Cycles:

1. Divide the Total Length by the Cycle Length: 0.25008 / 0.0494 = 5.0623.

2. The integer portion of the result = 5.

To determine Fractional Cycles:

1. Multiply the whole cycles from the previous calculation by the cycle length to deter-mine the whole cycle length in meters: 5 * 0.0494 = 0.247.

2. Subtract the result from the total length to determine the fractional portion in meters: 0.25008 - 0.247 = 0.00308.

3. Convert to fractions of a cycle: 0.00308 * 65536 / 0.0494 = 4086.05.

4. Round the result = 4086.

Since the number for the fraction portion is less than 32767 no additional calculation is required.

4086 Round0.250080 5 0.0494×( )–( ) 65536×

0.0494-------------------------------------------------------------------------------------=

5 Int0.250080.0494------------------- =

0m 0.25m250mm 1000mm

250.080 249.0 1.088+=



QuickStick 100

For QuickStick® 100 motors (QS 100), on a 1 m spacing, the motor offset calculation to locate a motor after a 500 mm motor is shown in Figure 6-14.

Figure 6-14: Motor Offset Calculations, QS 100 Example 1





1. Divide the total length by the cycle length: 0.500 / 0.0480 = 10.41666666.







Since the number for the fraction portion is less than 32767 no additional calculation is required.

27307 Round0.500 10 0.0480×( )–( ) 65536×

0.0480-------------------------------------------------------------------------------=

10 Int0.5000.0480---------------- =

0m 0.5m500mm 1000mm

500.0 498.0 2.00+=



For QuickStick 100, where there is a 55 mm gap between the motors the motor offset calcula-tion to locate a motor after a 500 mm motor is shown in Figure 6-15.

Figure 6-15: Motor Offset Calculations, QS 100 Example 2





1. Divide the total length by the cycle length: 0.555 / 0.0480 = 11.5208.







5. Since the number for the fraction portion is greater than 32767, subtract 65536 from it: 34133 - 65536 = -31403.

34133 Round0.553 11 0.0480×( )–( ) 65536×

0.0480-------------------------------------------------------------------------------=

11 Int0.5530.0480---------------- =

31403– 34133 65536–=

0m 0.555m500mm 1000mm

553.0 498.0 55.0+=

Application NotesCommunication


Communication

Timing diagram for communications with a Sync Zone.

Figure 6-16: Sync Zone Communications Timing Diagram

1. Data received by the SYNC IT controller from the PLC.

2. As soon as data comes in from the PLC the last data for the motors is sent to the PLC.

3. SYNC IT controller and sync motor have a fixed 2 ms update rate.

4. The PLC timestamps the profile data.

5. The SYNC IT controller timestamps both the incoming PLC data and the Sync motor data. The SYNC IT controller uses these timestamps to adjust for communication delays of the data. Data is adjusted based on the time stamp as it leaves the SYNC IT controller to either the PLC or the sync motors.

6. The sync motor interpolates the profile data once per millisecond.

PLC

SYNC IT Controller

Sync Motor

0 2 4 6 8 10 12

21

3 3 3

5

5

4

Application NotesVehicle Movement in Sync Zones


Vehicle Movement in Sync Zones

Vehicle Introduction into Sync Zones

Vehicle control can be transferred from the HLC to the user’s Host Controller while the vehi-cle is in a Sync Zone. This process assumes that control of the vehicle will be transferred from the HLC to the user’s PLC while the vehicle is moving.

1. The Host Controller (PLC) generates a movement order to move a vehicle through the specific Sync Zone with the vehicle’s destination past the end of the Sync Zone and sends it to the High Level Controller.

NOTE: Once the vehicle is released from sync control it will continue moving based on its original movement order from the HLC. If that order set the vehicle’s destination within the Sync Zone the vehicle will move (forward or back-ward) to that position, which could cause a collision with a sync controlled vehicle. Therefore, the movement order should always send the vehicle to a position outside the Sync Zone.

2. The Host Controller initiates a virtual axis.

NOTE: If control is being taken of a moving vehicle, this axis should be set to Jog before the vehicle arrives, to ensure a smooth transition.

MagneMotion recommends using a rotary axis so it can jog and unwind until it is matched to a vehicle upon sync-up. The rotary axis should be configured with the Conversion Constant set to 1000000 (one million) and the Position Unwind set to the Length_of_Zone * 1000000.

3. The Host Controller monitors the Sync Zone to detect the arrival of the vehicle in the Sync Zone. This can be accomplished by monitoring the Vehicle ID field.

A. Wait for the Vehicle ID in the Motor Status Memory Interface to be non-zero, the Motor’s Vehicle Master flag is high, and the Good Signal flag is high.

B. Depending on the zone setup, examine the Sync Zone bits in the Motor Status Memory Interface to ensure the vehicle is in the correct Sync Zone.

C. Examine the vehicles’ position in the zone, so that control is not accidently taken again when the vehicle is released at the end of the zone.

Figure 6-17 shows the changes to the Motor Status Memory Interface from when no vehicle has been detected to once a vehicle has been detected. Note that the first avail-able axis in the status memory will be populated with the vehicle data.

NOTE: The axes data may not be either contiguous or sequential with respect to Axis ID or Vehicle ID. However, once an axis is used to communicate data for a specific vehicle it will continue to be used for that vehicle until the vehicle exits the Sync Zone.



4. The Host Controller generates a movement profile (shown in Figure 6-18) for the vehicle matching the Velocity and Acceleration of the original move profile (the initial Jog), calculating the appropriate Position, sets the flag to take control of the vehicle, and writes the profile to the Motor Command Memory Interface.

The profile is written by issuing an MRP (Motion Redefine Position) command on the axis to the position of the slot. This ensures that the virtual axis and the physical vehi-cle are in the same place. Once this is finished, the vehicle ID is moved to the correct output slot, then latched using the Use Host Profile flag.

NOTE: It is important that the Vehicle ID field be set to the right value in the Motor Command Memory Interface (4 in this case) before the flag is set to ‘take control of the vehicle’.

UDT Memory Offset

No Vehicle Vehicle Detected

0 Global Flags 0 0

1 Heartbeat 3528 3529

Axis 1

2 Vehicle Flags 0 0010 0000 1001 0101(8341)*

* The Vehicle Flags indicate the vehicle is unloaded and moving downstream, the motor is the master,the vehicle signal is OK, the motor is not under sync control, and the vehicle is on the motor.

3 Vehicle ID 0 4

4 Actual Position MSW 0 0

5 Actual Position LSW 0 -1017

6 Position Error 0 -16235

7 Actual Velocity 0 2844

Figure 6-17: Motor Status - Vehicle Entering Sync Zone (SyncIT:I.Data)



5. The Host Controller starts streaming updated movement profiles for the vehicle every 2 ms. These profiles include an updated Position and may include changes to the vehi-cle velocity and acceleration.

UDT Memory Offset

Asynchronous Control(Sync Control Off)

Synchronous Control

0 Global Flags 0 0

1 Heartbeat 17012 17013

Sync Motor Offset

2 Motor 1 MSW 0 0

3 Motor 1 LSW 0 0

4 Motor 2 MSW 20 20

5 Motor 2 LSW 16384 16384

6 Motor 3 MSW 40 40

7 Motor 3 LSW -32768 -32768

Axis 1

8 Pset MSW 0 0

9 Pset LSW 183 185

10 Vset 2844 2844

11 Aset 2844 2844

12 Vehicle ID 4 4

13 Vehicle Flags 0010 0000 0000 0000(8192)

0010 0000 0000 0001

(8193)

Figure 6-18: Motor Command - Vehicle Entering Sync Zone (SyncIT:O.Data)



Vehicle Movement in Sync Zones

While the Host Controller is streaming updated movement profiles for the vehicle in the Sync Zone every 2 ms, the Host Controller synchronizes the movement of the vehicle to an external mechanism by adjusting the position, velocity, and acceleration of the vehicle as required.

Synchronization of the movement profile of the vehicle to the movement profile of an external device can be accomplished in several ways on a PLC.

Gearing

Gearing provides electronic gearing between any two axes in a specified direction and at a specified ratio. This allows the PLC to calculate the position for one device and have the sec-ond device automatically follow it.

Camming

Camming provides electronic camming between any two axes in a specified direction using a cam profile based on an array of cam points. This allows the PLC to calculate the position for one device and have the second device automatically follow a complex profile based on the first device.

Synchronized Movement

Synchronizing the movement without a direct connection can be accomplished by sending both devices (the vehicle and the external mechanism) movement commands at the same time. In this case the PLC must continuously calculate the appropriate position for each device.

The motion planner in the PLC runs for all axes all the time and the ProfileTask sends profile updates to the SYNC IT controller every 2 ms whether or not any vehicles are currently under Sync control. Motion instructions do not need to be started at the same time in the PLC to get sync without camming or gearing. Instead execute instructions that do incremental moves while in motion to match speed or both speed and position (the motion planner runs for all axes every 2 ms so once two axes match speed/position even if not geared or cammed, they will stay together).

NOTE: This is true for commanded position in the PLC, but when the external device is more than just another virtual axis (like an actual motor or robot), the actual position might drift from commanded and it’s best to gear the actual axis to the vehicle’s vir-tual axis to ensure they stay together. It’s best to rely on the motion planner updating all axes at once when doing something like having multiple vehicles match each other.

Example

The vehicle master (motor) streams vehicle status information to the SYNC IT controller, which updates the Motor Status memory whenever it detects a change in the status from the



motor. The Host Controller monitors the Motor Status memory to verify the position of the vehicle. Figure 6-19 shows the Motor Status as the vehicle moves through the Sync Zone (the Flags = unloaded, moving downstream, the Vehicle ID = 4).

UDT Memory Offset

t=0 t=0+1 t=0+2

0 Global Flags 0 0 0

1 Heartbeat 3529 3560 3561

Axis 1

2 Vehicle Flags 8341 8341 8341

3 Vehicle ID 4 4 4

4 Actual Position MSW 8 8 8

5 Actual Position LSW 17682 17683 17684

6 Position Error 1326 1326 1326

7 Actual Velocity 2877 2877 2877

Figure 6-19: Motor Status – Vehicle Under Control in Sync Zone (SyncIT:I.Data)



Vehicle Exit from Sync Zones

1. Once the Host Controller completes the actions that require synchronization between the vehicle and the external device it releases control of the vehicle as shown in Fig-ure 6-20.

A. The Host Controller sets the Velocity of the current move profile to match the Velocity of the original move profile to eliminate any unexpected acceleration or deceleration.

B. The Use Host Profile flag for the vehicle (Bit 0 of the Axis n Vehicle Flags in the Command Memory Interface) is set low.

C. If the Lead Vehicle flag for the vehicle (Bit 1 of the Axis n Vehicle Flags in the Command Memory Interface) was set, it should be set low.

D. Once the Under Sync Control flag for the vehicle (Bit 8 of the Axis n Vehicle Flags in the Status Memory Interface) is cleared, clear the Vehicle ID of the output slot that was previously in use.

E. Once the Vehicle ID on the input side shows zero, the slot can be re-used.

2. The vehicle will then continue motion under its previous asynchronous movement order.

UDTOffset

Synchronous ControlAsynchronous Control

(Sync Control Off)

0 Global Flags 0 0


Sync Motor Offset

2 Motor 1 MSW 0 0

3 Motor 1 LSW 0 0

4 Motor 2 MSW 20 20

5 Motor 2 LSW 16384 16384

6 Motor 3 MSW 40 40

7 Motor 3 LSW -32768 -32768

Axis 1

8 Pset MSW 10 10

9 Pset LSW 7959 7960

10 Vset 2844 2844

11 Aset 2844 2844

12 Vehicle ID 4 4

13 Vehicle Flags 0010 0000 0000 0011(8195)

0010 0000 0000 0000(8192)

Figure 6-20: Motor Command - Vehicle Exiting Sync Zone (SyncIT:I.Data)



3. The vehicle master (motor) updates the vehicle status information. Figure 6-21 shows the Motor Status with the vehicle no longer under sync control.

4. Once the vehicle moves off of the Sync Zone, the vehicle master (motor) updates the vehicle status information. Figure 6-22 shows the Motor Status with the vehicle no longer in the Sync Zone.

• When the PLC does not receive data for a Vehicle ID, the vehicle has been deleted from the sync box (Vehicle ID will be zeroed).

UDTOffset

Synchronous ControlAsynchronous Control

(Sync Control Off)

0 Global Flags 0 0


Axis 1

2 Vehicle Flags 0010 0011 0001 0101(8981)

0010 0000 0001 0101(8213)

3 Vehicle ID 4 4


5 Actual Position LSW 17682 17683

6 Position Error -16252 -16252


Figure 6-21: Motor Status – Vehicle Leaving Sync Control (SyncIT:I.Data)

UDTOffset

Vehicle Detected No Vehicle Detected

0 Global Flags 0 0


Axis 1

2 Vehicle Flags 0010 0000 0001 0101(8213)

0

3 Vehicle ID 4 0


5 Actual Position LSW -1017 0

6 Position Error -16235 0


Figure 6-22: Motor Status – Vehicle Exiting Sync Zone (SyncIT:I.Data)

Application NotesMMI PLC Tools


MMI PLC Tools

The Tool Kit provided by MagneMotion with the Synchronization Option provides prebuilt routines and add-on instructions for Allen Bradley ControlLogix® PLCs running RSLogix 5000 Version 19 or later firmware. These tools are provided to simplify the creation of logic for controlling vehicles in a Sync Zone.

The PLC logic provided by MagneMotion runs in a task on the PLC that is scheduled upon the event of the motion group execution completing its coarse update. This task runs at the highest priority in the PLC and interrupts all other activity to take any axes being used and extract their profile data (commanded position, commanded velocity, commanded acceleration, and time stamp) and convert the data to fixed point representation compatible with the SYNC IT controller and populates the SYNC IT controller’s memory with the values calculated by the PLC motion planner as well as the current PLC timestamp. The recommended coarse update rate for the motion group is 2 milliseconds as the event driven logic to copy the axis data to the memory can take between 0.75 and 1.25 milliseconds to run depending on how many axes are being populated into the memory. The I/O implementation then shuttles the data using Class 1 EtherNet/IP at an RPI (Requested Packet Interval) of 1 ms over to the SYNC IT con-troller for direct application of the profile data to the vehicles specified in the axis slots by the Vehicle ID within the slot.

Main Task Routines

cold_start_service

This routine sets all of the basic variables including the Sync Motor Offsets (enter the calcu-lated values for the motor offsets in this routine).

sync_take_control_of_puck

This routine synchronizes with a vehicle moving through a Sync Zone under asynchronous command from the Host Controller, takes control of the vehicle when it reaches a user-defined position in the Sync Zone, then stops the vehicle (puck) while under synchronous control so the user can then experiment with synchronized movement by doing manual motion direct commands to move the vehicle around.

utilities

This routine takes the data converted by MMI_CIP_sync_conv_feedback and makes it avail-able for display.

Application NotesMMI PLC Tools


Profile Task Routines

Profiles_to_motor

This routine updates the heartbeat and writes the vehicle profile data supplied by MMI_sync_motion_IO and the current time stamp to the SYNC IT controller’s memory. For each axis being used there should be an instance of MMI_sync_motion_IO running on this ladder that is affiliated with a particular ‘slot’ in the output memory to the SYNC IT controller. The out_slot_base field is what determines which memory location is the ‘base’ one for the particular slot.

Add-On Instructions

MMI_CIP_sync_conv_feedback

This Add-On instruction for the PLC reads the Motor Status Memory Interface for an axis (vehicle) and converts the data to usable formats. This routine also corrects the vehicle's posi-tion based on the time delay from the SYNC IT controller to the PLC to ensure the most accu-rate position is provided.

MMI_sync_motion_IO

This Add-On instruction for the PLC converts the axis (vehicle) data (Pset, Vset, and Aset) to the required formats for the Motor Command Memory Interface. Logic is included to set the Axis n Flags based on the current position of the axis the vehicle is using. When near a transi-tion from one motor to another within a Sync Zone (100 mm around the joint), the profile data will be directed to both motors involved in the joint (e.g., when moving from motor 1 to motor 2 both bits 13 and 14 will be set).

NOTE: Change the position offset values in rungs 0, 1, and 2 to set the appropriate Sync Zone.

Application Notes




Interface Reference 7

Overview

This chapter provides an overview of the memory interface used by the SYNC IT™ controller for the LSM Synchronization option and provides details of the interface. The interface pro-vides a broad range of command options for direct control of specific motors in a MagneMo-tion transport system. The interface also provides the user’s Host Controller (PLC) with constant status updates from those motors. This interface reference reflects the version of the SYNC IT controller software indicated in Changes at the front of the manual.


• Description of the Motor Command Memory Interface.

• Description of the Motor Status Memory Interface.

NOTE: Specific builds of MagneMotion’s software may not implement all of the features described in this manual. Refer to the Release Notes for more information.

Interface ReferenceCommunications Protocol


Communications Protocol

Introduction

All MagneMotion transport systems support the standard communication protocol described in the Host Controller TCP/IP Communication Protocol User’s Manual or the Host Controller EtherNet/IP Communication Protocol User’s Manual. Additionally, the sync-enabled motors in the Sync Zones of a transport system support high speed direct motion control and position sense feedback when the optional SYNC IT controller is used with a PLC.

The SYNC IT controller supports a Class 1 EtherNet/IP memory based interface and is con-figured as I/O off of an EtherNet/IP interface in the PLC. This allows the PLC to read and write the SYNC IT controller’s memory. The memory is setup as 132 x 16 bit words that are sent from the PLC to the SYNC IT controller and from the SYNC IT controller to the PLC at the I/O requested packet interval (RPI) specified when setting up the I/O in the PLC.

This chapter provides detailed information on the memory structure, including the format and contents of the memory words, used for communications between the Host Controller (PLC) and the SYNC IT controller in both directions.

Table 7-1: SYNC IT Controller Memory Structure

Description Type Page

Motor Command Memory Interface Host Controller (PLC) SYNC IT 7-3

Motor Status Memory Interface Host Controller (PLC) SYNC IT 7-7



Motor Command Memory Interface

Type

Host Controller (PLC) SYNC IT

Purpose

This memory interface is populated by the PLC with the generated profile set points (Pset, Vset, Aset) based on the Vehicle ID. The PLC must update this custom data structure in the SYNC IT controller at a specified update rate; typically 2 - 5 ms.

NOTE: Command is 132 x 16 bit words configured as memory out (SyncIT:O.Data).

One instance of this memory interface must be implemented for each SYNC IT con-troller connected to the PLC.

One set of axis data must be provided for each vehicle in the Sync Zone. The sets of data for each axis do not need to be either contiguous or sequential.

Format

Offset Name Units* Description

0 Global Flags to Motor 16 bits of flags Flags from Host to motor

1 Heartbeat Integer Incrementing counter

2 Sync Motor 1 Offset MSW 16 bit Motor 1 offset, whole cycles

3 Sync Motor 1 Offset LSW 16 bit Motor 1 offset, fractional cycles





8 Axis 1 Pset MSW 16 bit Position set point, whole cycles

9 Axis 1 Pset LSW 16 bit Position set point, fractional cycles

10 Axis 1 Vset 8.8 8.8 Velocity set point

11 Axis 1 Aset 10.6 10.6 Acceleration set point

12 Axis 1 Vehicle ID Integer ID of vehicle using Axis

13 Axis 1 Vehicle Flags 16 bit Vehicle status flags

The axis data repeats for a total of 20 axes (vehicles)

122 Axis 20 Pset MSW 16 bit Position set point, whole cycles



Arguments

Global Flags to Motor – Flags from the Host to the motor - none allocated yet.

Heartbeat – Provides notification to the SYNC IT controller that the connection to the Host Controller is active. The heartbeat should change every Axis course update (2 ms).

Sync Motor 1 Offset MSW – The whole cycles portion of the offset of the first motor in the Sync Zone (connected to SP1 on the SYNC IT controller).

• One MML whole cycle = 0.0494 m

• One QS 100 whole cycle = 0.0480 m

Sync Motor 1 Offset LSW – The fractional cycles portion of the offset of the first motor in the Sync Zone.

• One MML fractional cycle = 0.0494 m/65536

• One QS 100 fractional cycle = 0.0480 m/65536

Sync Motor 2 Offset MSW – The whole cycles portion of the offset of the second motor in the Sync Zone (connected to SP2 on the SYNC IT controller). This is only used when two or more motors are combined to create one Sync Zone.

Sync Motor 2 Offset LSW – The fractional cycles portion of the offset of the second motor in the Sync Zone. This is only used when two or more motors are combined to create one Sync Zone.

Sync Motor 3 Offset MSW – The whole cycles portion of the offset of the third motor in the Sync Zone (connected to SP3 on the SYNC IT controller). This is only used when three motors are combined to create one Sync Zone.

123 Axis 20 Pset LSW 16 bit Position set point, fractional cycles

124 Axis 20 Vset 8.8 8.8 Velocity set point

125 Axis 20 Aset 10.6 10.6 Acceleration et point


127 Axis 20 Vehicle Flags 16 bit Vehicle status flags

128 PLC Timestamp Microseconds The 64-bit time stamp of the profile data from the PLC

129 PLC Timestamp Microseconds



* Unless otherwise specified all units are unsigned. However, the display format of many PLCs assumes signeddata and will display some values as negative numbers.




Sync Motor 3 Offset LSW – The fractional cycles portion of the offset of the third motor in the Sync Zone. This is only used when three motors are combined to create one Sync Zone.

Axis n Pset MSW – The whole cycles portion of the position set point for the vehicle.

Axis n Pset LSW – The fractional cycles portion of the position set point for the vehicle.

Axis n Vset 8.8 – The velocity set point for the vehicle in cycles/s, where the first 8 bits are whole cycles and the last 8 bits are fractional cycles.

Axis n Aset 10.6 – The acceleration set point for the vehicle in cycles/s2, where the first 10 bits are whole cycles and the last 6 bits are fractional cycles.

Axis n Vehicle ID – The ID of the vehicle being controlled. Set to ‘0’ for no vehicle.

Axis n Vehicle Flags – The vehicle flag bits are used to set vehicle attributes.

Bit Flag

0 Use Host Profile

0 – Asynchronous control.

1 – Host controlled Sync operation.

1 Lead Vehicle – When this bit is set, the vehicle acquires motor block permissions to ensure that it will have enough blocks of headway in front of it so that when sync con-trol is relinquished the vehicle doesn’t slow down or hesitate. This is used to prepare for switching back to the internal profile from the last vehicle order the motors received for this vehicle through the asynchronous Host Controller interface.

0 – The vehicle is following another vehicle.

1 – The vehicle is the next vehicle to exit the Sync Zone (single vehicle or vehicle ‘lead-ing’ other vehicles).

2 - 12 Reserved

13 Send to Sync Motor 1 – When near the joint to sync motor 2 (100mm around the joint) both bits 13 and 14 should be set to send the profile data to both motors involved in the joint.

0 – Do not send profile data.

1 – Send profile data to sync motor 1.

14 Send to Sync Motor 2 – When near the joint to sync motor 3 (100mm around the joint) both bits 14 and 15 should be set to send the profile data to both motors involved in the joint.



15 Send to Sync Motor 3





PLC Timestamp – This is the current timestamp from the PLC in microseconds. The SYNC IT controller uses this timestamp to correct the commanded position for communication delay from the PLC to the controller.

Response

The SYNC IT controller does not provide any response to the Host Controller on receipt of a memory update. However, the SYNC IT controller has feedback bits that will be set to pro-vide confirmation of certain actions. Once the memory update is received the controller parses it and forwards it to the appropriate motor.



Motor Status Memory Interface

Type

Host Controller (PLC) SYNC IT

Purpose

This memory interface provides the PLC with the actual position and velocity feedback based on Vehicle ID with the data placed in the next available slot in the memory interface. The same slot will be used for the life of the particular vehicle being in the Sync Zone. The SYNC IT controller will update this memory at the same update rate as the PLC sends data to the controller; typically 2 - 5 ms.

NOTE: Command is 132 x 16 bit words configured as memory in (SyncIT:I.Data).

One instance of this memory interface must be implemented for each SYNC IT con-troller connected to the PLC.

One set of axis data is provided for each vehicle in the Sync Zone. The axes data may not be either contiguous or sequential with respect to Axis ID or Vehicle ID. However, once an axis is used to communicate data for a specific vehicle it will con-tinue to be used for that vehicle until the vehicle exits the Sync Zone.

Format


0 Global Flags to PLC 16 Bits Flags from motor to Host

1 Heartbeat Integer Incrementing counter

2 Axis 1 Vehicle Flags 16 Bits Vehicle status flags


4 Axis 1 Actual Position MSW 16 Bit Vehicle position, whole cycles

5 Axis 1 Actual Position LSW 16 Bit Vehicle position, fractional cycles

6 Axis 1 Position Error 16 Bit signed Vehicle position error

7 Axis 1 Actual Velocity 8.8 Vehicle velocity

The axis data repeats for a total of 20 axes (vehicles)

116 Axis 20 Vehicle Flags 16 Bits Vehicle status flags


118 Axis 20 Actual Position MSW 16 Bit Vehicle position, whole cycles

119 Axis 20 Actual Position LSW 16 Bit Vehicle position, fractional cycles

120 Axis 20 Position Error 16 Bit signed Vehicle position error



Arguments

Global Flags to PLC – Flags from the Motor to the Host Controller.

Heartbeat – Provides notification to the Host that the connection to the SYNC IT controller is active. The heartbeat should change at least every 100 milliseconds.

121 Axis 20 Actual Velocity 8.8 Vehicle velocity

122 Reserved — For MMI use






128 SYNC IT Timestamp Microseconds The 64-bit time stamp from the SYNC IT controller to the PLC for the data in the message.129 SYNC IT Timestamp Microseconds

130 SYNC IT Timestamp Microseconds

131 SYNC IT Timestamp Microseconds

* Unless otherwise specified all units are unsigned. However, the display format of many PLCs assumes signeddata and will display some values as negative numbers.

Bit Flag

0 SPI Comm 1 Status

0 – Fault

1 – OK

1 SPI Comm 2 Status

0 – Fault

1 – OK

2 SPI Comm 3 Status

0 – Fault

1 – OK

3 Sync Status

0 – No time sync established with PLC.

1 – Time sync established with PLC.

4 - 15 Reserved




Axis n Vehicle Flags – The vehicle flag bits are used to indicate vehicle attributes.

Bit Flag

0 Last Commanded Direction – Last direction the vehicle was commanded to move.

0 – Moving upstream (backward).

1 – Moving downstream (forward).

1 Load Status – Identifies the current load state of the vehicle.

0 – The vehicle is unloaded.

1 – The vehicle is loaded.

2 Vehicle Master – Indicates when the motor indicated in bits 13 - 15 is the vehicle mas-ter.

0 – The motor is not the master.

1 – The motor is the master.

3 Reserved

4 Signal – Identifies the vehicle presence status for the motor indicated in bits 13 - 15.

0 – The vehicle signal is missing.

1 – The vehicle signal is OK.

5 - 7 Reserved

8 Under Sync Control – Indicates when the motor indicated in bits 13 - 15 is under sync control for the vehicle.

0 – The motor is not under sync control.

1 – The motor is under sync control.

9 Vehicle Position Error – Indicates when the current vehicle position is within toler-ance of its commanded position.

0 – The current position is out of tolerance.

1 – The current position is within tolerance.

10 - 12 Reserved

13 Sync Motor 1

0 – The vehicle is not on the motor.

1 – The vehicle is on the motor.

14 Sync Motor 2



15 Sync Motor 3





Axis n Vehicle ID – The ID of the vehicle having data reported. Set to ‘0’ for no vehicle.

Axis n Actual Position MSW – The whole cycles portion of the vehicle’s actual position in the Sync Zone.

• One MML whole cycle = 0.0494 m

• One QS 100 whole cycle = 0.0480 m

Axis n Actual Position LSW – The fractional cycles portion of the vehicle’s actual position in the Sync Zone.



Axis n Position Error – The position error for the vehicle (actual vs. commanded) as a signed value up to ±1/2 cycle.



Axis n Actual Velocity – The actual velocity of the vehicle in cycles (8 bits) and fractional cycles (8 bits).

SYNC IT Timestamp – The current timestamp from the SYNC IT controller in microsec-onds. The PLC uses this timestamp to correct the commanded position for communication delay from the SYNC IT controller to the PLC.


Maintenance 8

Overview

This chapter provides complete maintenance schedules and procedures for the MagneMotion LSM Synchronization option. Only trained, qualified personnel should attempt to perform maintenance or troubleshooting on the SYNC IT™ controller. MagneMotion provides train-ing in the troubleshooting of the LSM Synchronization (Sync) option.


• Preventive Maintenance.

• Troubleshooting.

• Contacting MagneMotion Customer Support.

• Repair.

• Shipping.

MaintenancePreventive Maintenance


Preventive Maintenance

The SYNC IT controller and the sync enabled motors that make up the Sync option transport system are self contained components designed for use in a clean, inert environment and require no maintenance other than that described here. Any deviation from this basic environ-ment may affect the maintenance requirements, contact MagneMotion Customer Support for additional information. Refer to Troubleshooting on page 8-4 if any problems are detected.

Table 8-1: Preventive Maintenance Schedule

Component Maintenance Action Frequency*

* The specified frequency is based on a certified clean, inert environment. The user should adjust their Preven-tative Maintenance Schedule to account for any deviations from this environment.

Page #

Synchronization option Cleaning 3 months or as required

8-3

Cable Connection Inspection 3 months or as required

8-3

MaintenancePreventive Maintenance


Cleaning

Refer to the transport system’s User’s Manual for detailed cleaning information.

Cable Connection Inspection

1. Turn off all transport system components with accessible power controls.

2. Ensure the power connections to the motor power supplies are fully seated and secure.

3. Ensure all communications connections are fully seated and secure.

4. Return the transport system to normal operation.

MaintenanceTroubleshooting


Troubleshooting

This section describes the common difficulties that may be encountered when using the Sync option with either a MagneMover® LITE or QuickStick® 100 transport system and software components.

For assistance, contact MagneMotion Customer Support at +1 978-757-9102 or [email protected].

Initial Troubleshooting

This section covers the initial determination of the problem area within the transport system and provides direction to the second step of the troubleshooting process. If a specific problem is suspected, refer to that problem in Table 8-2. If the problem has not been identified, review each of the symptoms identified in Table 8-2 to help determine the problem area.

Table 8-2: Initial Troubleshooting

Symptom Possible Problem Area

Power lights do not turn on. See Power Related Troubleshooting on page 8-5.

The lights on the SYNC IT controller are not green.

See SYNC IT Controller Troubleshooting on page 8-6.

The transport system does not respond to the Host Controller.

See Communications Troubleshooting on page 8-7.

Vehicle motion is not as expected. See Motion Control Troubleshooting on page 8-8.

Vehicles do not seem to move as fast as when the transport system was initially installed.



Power Related Troubleshooting

This section covers the determination of power related problems within the transport system.

Table 8-3: Power Related Troubleshooting

Problem Description Possible Causes

Lights on power supplies do not turn on. • Verify the Power Cable from the facility’s power is fully seated and secured.

• Check the facility’s power to the transport sys-tem. Verify correct power rating.

• Verify power supply main fuses are not blown. Replace if necessary.

Lights on SYNC IT controller do not turn on. MagneMover LITE• Verify the cable from the SYNC IT controller

to the motor is fully seated and secure.• Check the power to the motor. Verify correct

power rating.

QuickStick• Verify the power cable from the SYNC IT

controller to the remote power supply is fully seated and secure.



SYNC IT Controller Troubleshooting

This section covers the determination of problems within the SYNC IT controller.

Table 8-4: Controller Related Troubleshooting


NS light status: Flashing green No established connection.

Solid red Duplicate IP address*.

* Use the SYNC IT controller configuration tool to verify the IP address is set correctly (refer to Configure IPAddress on page 5-4).

Flashing red Connection time-out.

MS light status: Flashing green Not configured.

Solid red Major fault.

Flashing red Minor fault.

SYS light status: Flashing green/yellow Firmware not loaded.

Flashing yellow Software not loaded.



Communications Troubleshooting

This section covers the determination of communications related problems within the trans-port system.

Table 8-5: Communications Troubleshooting


The transport system is powered but there is no response to the Host Controller.

• Check proper connection and continuity.• Verify all communications cables are fully

seated and secure.• Check communication to Host Controller.• Verify Host Controller is correctly configured

and connected to the network.• Verify software is correctly written.

Intermittent Communication with the Host Controller.

• Ensure all network cables are properly seated.• Ensure there are no IP address collisions.

The transport system responds to the Host Controller but motors do not operate.

• Ensure power cables to all motors are properly seated.

• Ensure communications cables to all motors are properly seated.



Motion Control Troubleshooting

This section covers the determination of motion related problems within the transport system.

Table 8-6: Motion Control Troubleshooting


Material slipping on vehicles. • Ensure vehicle speed is correct during handoff from asynchronous to synchronous control and back.

Vehicles not moving smoothly. • Ensure vehicle speed and position is correct during handoff from asynchronous to synchro-nous control and back.

• Ensure coarse update rate is less than 20 ms (refer to Step 5 on page 5-12).

SYNC IT controller not responding. • Ensure the controller is receiving power.• Ensure the IP address of the controller is cor-

rectly referenced by the PLC.

Vehicles not moving smoothly in Sync area when under Sync control, but do move smoothly when under normal (asynchronous) control.

• Ensure coarse update rate is around 2 - 4 ms (refer to Step 5 on page 5-12).

Two motors are configured for sync operation, but vehicle does not enter second motor.

• Verify the offsets are correct for the motors (refer to Sync Zone Offsets on page 6-4).

• Verify that the PLC logic is setting the correct motor enable bits based on the vehicle’s posi-tion (refer to Motor Command Memory Inter-face on page 7-3).

• Verify that the Sync enabled motors are con-nected to the correct zones on the SYNC IT controller.

Sync motors not moving vehicles at full speed.

• Verify the commands being sent to the motors are setting the correct velocity, and accelera-tion.

One or more sync motors do not operate. • Verify the commands being sent to the motors are identifying the correct motors.

Reported vehicle position is incorrect. • Verify motor cables are plugged into correct SYNC IT controller ports.

• Verify Add-On instruction is functioning cor-rectly.

• Verify that the correct Axis slot is being exam-ined.



Vehicles are not going under sync control as expected.

Check that the input vehicle ID slot indicates the vehicle is under sync control.• If it does not, check:

Is the output ID valid?

Is the output ID in the correct slot?

Is the “Use Sync Control” bit set for the cor-rect slot?

Did the vehicle reach all of the initial condi-tions?

• If it does, check:

Is the motion commanded operating without error?

Are the zones set up correctly?

Does the reported position seem valid?

Vehicle doesn’t move through entire Sync Zone.

If the vehicle stops or backs up within a motor:• Check the position unwind for the axis.• Check the conversion constant for the axis.

If the vehicle stops at a motor joint:• Check in Sync_motion_IO that the profile.

information is being sent to the correct motors.

• Check that all motors are plugged into the SYNC IT box.

• Check for correct SYNC IT offsets.

Table 8-6: Motion Control Troubleshooting


MaintenanceContact MagneMotion Customer Support


Contact MagneMotion Customer Support

To help you receive the most value from the MagneMotion Support Specialists, have the fol-lowing information ready before contacting MagneMotion Customer Support.

1. Download and save the Node Controller and High Level Controller logs.

2. Record the serial numbers from the motors and Node Controllers.

3. Record the serial numbers and MAC IDs from the SYNC IT controllers.

4. Provide the location of the transport system.

5. Provide the name of the person to contact, e-mail address, and telephone number.

6. List any error codes received during the failure.

7. Prepare a detailed description of the events leading up to the error.

• How long has the equipment been in operation?

• Was any work done on the equipment prior to the error?

• What command was the equipment performing when the error occurred?

• List all actions taken after the error was performed. What were the results of those actions?

• Is there any other information that may assist our Specialist?

8. Contact MagneMotion Customer Support:

Main Office Customer Support

MagneMotion, Inc.139 Barnum RoadDevens, MA 01434USAPhone: +1 978-757-9100Fax: +1 978-757-9200

+1 [email protected]

MaintenanceRepair


Repair

If the SYNC IT controller malfunctions, refer to Troubleshooting on page 8-4 in this manual for diagnostic procedures. If these procedures are not adequate to determine the source of the problem, refer to Contact MagneMotion Customer Support on page 8-10. Once the failure has been identified, a replacement SYNC IT controller can be ordered if needed and installed as directed in Installation on page 4-1.

NOTE: The SYNC IT controller does not contain any user serviceable parts.

NOTICE

Only a qualified service representative can service the components of thetransport system. Any attempt to open the transport system modules by any-one other than a qualified MagneMotion service representative will void thewarranty.

MaintenanceShipping


Shipping

If the controller will be shipped, either for return to MagneMotion for service or to another location, it must be properly packaged to ensure it arrives undamaged. The following proce-dure provides the correct method of handling and packaging the SYNC IT controller for ship-ment.

Packing Procedure

NOTE: The original shipping packaging must be used when shipping the SYNC IT control-ler. If the original packaging has become lost or damaged, contact MagneMotion for replacements.

1. Turn off and disconnect all power and communications connections as detailed in Safe Shut-down on page 5-16.

2. Ensure the SYNC IT controller has been properly decontaminated following the facil-ities decontamination procedures. Follow all Federal, State, Local, and Facility proce-dures for the disposal of any hazardous materials.

3. The SYNC IT controller should be wrapped, bagged, and packed following standard packing procedures.

4. Using the container the SYNC IT controller was originally shipped in, set the control-ler into the container and secure it using the supplied packing material.

5. Close the shipping container and secure with tape.

6. Ensure the container is properly labeled and all shipping documents are attached to the outside of the container.

7. When shipping to MagneMotion, ensure the RMA number is clearly visible on the outside of the box.

CAUTION

Electrical Hazard

Before beginning this procedure the SYNC IT controllermust be shut down following the procedure provided in SafeShut-down on page 5-16.

LSM Synchronization Option User’s Manual A-1

Appendix

Overview

The following appendices are included to provide the user with a single location for additional information related to Host Controller communication.


• Communications protocol.

• File maintenance.

• Additional documentation.

• Transport system configuration limits.

AppendixCommunications Protocol

MagneMotion, Inc.A-2 990000447 Rev. C

Communications Protocol

Communications Format

The SYNC IT™ controller supports communication with the Host Controller via EtherNet/IP as defined in the Open DeviceNet Vendor Association (ODVA) specification ‘EtherNet/IP Adaptation of CIP Specification’ Volume 1 and Volume 2. EtherNet/IP is an application that runs directly over the TCP and UDP layer 5 transport layers in the OSI model. The SYNC IT controller uses the implementation supplied by Hilscher.

EtherNet/IP

The SYNC IT controller application runs on top of the TCP transport layer. The standard 10/100 Base-TX, half or full duplex twisted pair Ethernet with RJ-45 connector is used for all network communications as defined in the Interface Reference on page 7-1.

AppendixFile Maintenance


File Maintenance

Backup Files

MagneMotion recommends regular backups of all files that may have been changed. Copies of all original and backup files should be kept at a remote location for safety.

Creating Backup Files

Backup files are not created automatically. It is the user’s responsibility to create backups of all files by copying them to a safe location and naming them appropriately.

Restoring from Backup Files

Damaged files can be restored by copying the backup files into the appropriate locations and renaming them to their original name.

AppendixAdditional Documentation


Additional Documentation

Release Notes

The Release Notes for MagneMotion software include special instructions, identification of software versions, identification of new features and enhancements, and a list of known issues. The Release Notes are supplied on the CD with the software. MagneMotion recom-mends that this file be read before using the software.

Upgrade Procedure

The Upgrade Procedure provides the instructions for upgrading from one version of MagneMotion software to another. It also includes the procedures for upgrading files and drivers associated with the software. The Upgrade Procedure is supplied on the CD with the software.

AppendixTransport System Limits


Transport System Limits

Table A-1: MagneMotion Transport System Limits

Path Node Controller System

Motors 20 240*

* Limited by the number of RS-422 connections on the Node Controller (NC LITE – 4, NC-12 – 12).

1,280

Node Controllers – – 64

Nodes 2 –* 128

Paths – –* 64

Stations – – 255

Vehicles – 384 2,560

Table A-2: MagneMotion Transport System Motion Limits

Acceleration Velocity Thrust*

* Thrust at 25% duty cycle.Nominal Vehicle Gap for MM LITE is 1 mm for G3 and 1.5 mm for G4.2.Nominal Vehicle Gap for QS 100 using a standard magnet array is 3 mm.Nominal Vehicle Gap for QSHT using a high flux magnet array is 12 mm.

Payload

MagneMover® LITE 2.0 m/s2 (0.2 G) 2.0 m/s [4.5 mph] 6 N/cycle 2 kg [4.4 lb]†

† Single puck maximum payload is 1 kg, tandem puck maximum payload is 2 kg.

QuickStick® 100 9.8 m/s2 (1.0 G) 2.5 m/s [5.6 mph] 20 N/cycle 100 kg [220 lb]

QuickStick® HT 60 m/s2 (6.1 G) 2.5 m/s [5.6 mph] 279 N/cycle 4500 kg [9900 lb]

Appendix



LSM Synchronization Option User’s Manual G-1

Glossary

Block: See Motor Block.

Bogie: A structure underneath a vehicle to which a magnet array is attached. The structure is then attached to the vehicle. For vehicles traveling over curves the attachment is through a bearing allowing independent rotation.

Brick-wall Headway: Space maintained between vehicles to ensure that a trailing vehicle is able to stop safely if the leading vehicle stops suddenly (‘hits a brick wall’).

Byte: A single octet of data (8 bits).

Component: The main parts that form a MagneMotion transport system. Also called system components, these include Motors and Controllers.

Configurator: The application used to define and edit the basic operating parameters of the transport system stored in the Node Controller Configuration File.

Controller: A device that monitors and controls the operating conditions of the equipment being monitored. In a MagneMotion transport system these include the High Level Controller, Motor Controller, Node Controller, and Host Controller.

Cycle Length: Cycle Length is the distance between the centerlines of two like poles on the magnet array.

Demonstration Script: A text file used with the NCHost TCP Interface Utility for test or demon-stration purposes to move vehicles on the transport system. Also called a Demo Script.

Design Specifications: The unique parameters for a specific MagneMotion transport system.

Downstream: The end of a motor or Path where a vehicle exits if it is travelling in the default forward direction. The vehicle typically enters the motor or Path on the Upstream end.

Downstream Gap: The physical distance from the end of the stator in one motor to the beginning of the stator in the next motor downstream on the same Path. This includes the Motor Gap.

E-Stop: See Emergency Stop.

Emergency Off: A user-supplied device that disconnects AC power to the transport system.

GlossaryEmergency Stop

MagneMotion, Inc.G-2 990000447 Rev. C

Emergency Stop: A user-supplied circuit with a locking button that anyone can press to stop motion in the transport system. It may be wired through the Digital I/O ports on the NC-12 Node Controller.

EMO: See Emergency Off.

Forward Direction: The default direction of movement, from Upstream to Downstream, on a MagneMotion transport system.

Global Directives: The Demonstration Script commands that define the general operating charac-teristics for all vehicles specified. See also Vehicle Directives.

Guideway: A component of the Track System that consists of rails or other devices in con-tact with the Vehicle, either through wheels or low friction runners on the vehi-cle, to ensure the vehicles are maintained in the proper relationship to the motors. In the MagneMover LITE system this is the integral rails mounted on the motors.

High Level Controller: The application in a Node Controller that communicates with the Host Con-troller. In a transport system with only one Node Controller, it runs both the Node Controller and High Level Controller applications.

HLC: See High Level Controller.

HLC Control Group: The portion of a multi-HLC LSM transport system under control of a specific HLC.

Host Application: The user’s software, running on the Host Controller, that provides monitoring and control of the transport system.

Host Controller: The user supplied controller for the operation of the transport system. The con-troller may be either a PC-Based Controller or a Programmable Logic Con-troller.

Host Control Session: A user session between an application running on the Host Controller (such as the NCHost TCP Interface Utility) and a High Level Controller that allows the user to issue commands to control all aspects of Transport System opera-tion as well as to actively monitor Transport System status.

Host Status Session: A user session between an application running on the Host Controller (such as the NCHost TCP Interface Utility) and a High Level Controller that only allows the user to actively monitor Transport System status.

ID: The software labels used to uniquely identify various components of the trans-port system to ensure proper execution of commands involving vehicle posi-tion, vehicle destination, and transport system configuration. ID types include vehicle and Path.

Interlock: A user-supplied circuit used to stop motion in the transport system. It is wired through the Digital I/O ports on the NC-12 Node Controller.

Keepout Area: An area of a Path where the motors will not allow a vehicle to enter unless it has permission from the motors to move past the area.

Logic Power: The power used for the controllers and signals. See also, Propulsion Power.

GlossaryPath


LSM: Linear Synchronous Motor. See MagneMover® LITE and QuickStick®.

MagneMover® LITE: A MagneMotion linear synchronous motor with integrated guideways and vehicles (pucks) that enables quick, efficient conveyance of loads up to 1 kg on a single vehicle (2 kg on a tandem puck).

Magnet Array: The magnets attached to the Vehicle. It is the motor secondary, moved by the primary in the motor.

MM LITE: See MagneMover® LITE.

Motor: See LSM.

Motor Block: A discrete motor primary section (coil or set of coils) within a motor that can be energized independently. This section can contain only one vehicle during transport system operation.

Motor Controller: The controller for each motor that communicates vehicle positions and other information to the Node Controller. It is internal to the motor on MagneMover LITE and QuickStick 100 motors and external on QuickStick HT motors.

Motor Gap: The physical distance between two motors mounted end to end. This does not include the distance from the end of the stator to the end of the motor housing.

NC: See Node Controller.

Node: A junction defined as the beginning, end, or intersection of Paths. The differ-ent Node types are defined by their use: Simple, Relay, Terminus, Merge, Diverge, etc.

Node Controller Configuration File: The XML file unique to the transport system containing the basic operating parameters of the transport system. A copy of the Configura-tion File is uploaded to each Node Controller in the transport system.

Node Controller: The controller that coordinates vehicle movements along a Path or Paths of motors. The Node Controller is responsible for the motors on all Paths origi-nating from Nodes that the Node Controller is responsible for.

There can be multiple Node Controllers in a transport system each responsible for a subset of the Nodes within the transport system.

NRTL/ATL: Nationally Recognized Test Lab/Accredited Test Lab.

NRTL organizations have been recognized by OSHA in accordance with 29 CFR 1910.7 to test and certify equipment or materials (products).

ATL organizations have been evaluated by Accreditation bodies to ISO/IEC 17025 for testing and calibration laboratories.

Path: A designation for one or more motors placed end to end, which defines a linear route for vehicle travel. A Path begins at the Upstream end of the first motor in the series and ends at the Downstream end of the last motor in the series. All Paths must begin at a Node and the beginning of a Path is always the zero posi-tion for determining vehicle positions along that Path.

GlossaryPC-Based Controller


PC-Based Controller: The user supplied computer that provides control and sequencing for the operation of the transport system.

PLC: See Programmable Logic Controller.

Position: A specific location on a Path, measured from the beginning of that Path, used as a vehicle destination. Position zero on any Path is defined as the leading edge of the first LSM in the Path.

A vehicle at a specific position has its midpoint over that location on the Path.

Power Supply: The equipment used to convert facility AC power to the correct voltages for the transport system.

Programmable Logic Controller: The user supplied dedicated controller consisting of Processor and I/O modules that provides control, sequencing, and safety interlock logic for the operation of the transport system.

Propulsion Power: The power used for vehicle movement. See also, Logic Power.

Puck: A pre-configured vehicle for use on MagneMover LITE transport systems. See also, Vehicle.

QS: See QuickStick®.

QuickStick®: A MagneMotion linear synchronous motor that enables quick, efficient con-veyance of large loads using user designed guideways and vehicles. Quick-Stick 100 (QS 100) motors move loads up to 100 kg [220 lb] per vehicle and QuickStick High Thrust (QSHT) motors move loads up to 4,500 kg [9,900 lb] per vehicle.

QuickStick® System: A group of specific components that contribute to a Transport System. These components include QuickStick® motors, Node Controllers, Motor Controllers (if applicable), Magnet Arrays, and other parts available from MagneMotion.

Single Vehicle Area: An area of a Path where only one vehicle may move at any time. Other vehi-cles on the Path must form a queue and wait before entering this area until the previous vehicle leaves the area. This option allows one vehicle to move back-ward and forward along a portion of a Path without interfering with any other vehicles.

Station: A specific location on a Path, measured from the beginning of that Path and identified with a unique ID, used as a vehicle destination.

Stator: The stationary part of the motor over which the magnet array is moved.

Switch: The mechanical guide for positioning a vehicle through merging or diverging guideway sections.

Sync Zone: An area where vehicle motion may be synchronized with other moving sys-tems through direct control of the motor by the Host Controller.

System Component: The main parts that form a Transport System. Also called components, these include Motors and Controllers.

GlossaryZero Point


Tandem Vehicle: A vehicle designed to carry larger loads that uses dual bogies (two magnet arrays on pivoting carriers linked to the vehicle) to provide enough thrust.

Track System: The components that physically support and move vehicles. For a QuickStick transport system, this includes a Guideway, one or more QuickStick® motors, and mounting hardware. For a MagneMover LITE transport system this includes the MagneMover® LITE components and stands.

Transport System: The components that collectively move user material. This includes the Motors, external Motor Controllers (if applicable), Track System, Node Con-trollers, Vehicles, cables, and hardware.

Upstream: The end of a motor or Path where a vehicle enters if it is travelling in the default forward direction. The upstream end of all Paths are connected to Node Controllers. The vehicle typically exits the motor or Path on the Downstream end.

V-Brace: The mechanical fixture used to align and secure MagneMover LITE guide rail sections.

Vehicle: The independently controlled moving element in a MagneMotion transport system. The vehicle consists of a platform that carries the payload and a pas-sive magnet array to provide the necessary propulsion and position sensing. All vehicles on Paths connected through Nodes must be of the same length.

The transport system constantly monitors and controls vehicle position and velocity for the entire time the vehicle is on the transport system. All vehicles are assigned a unique ID at startup and retain that ID until the transport system is restarted or the vehicle is removed or deleted.

Vehicle Directives: The Demonstration Script commands that define the individual movement characteristics for a specific vehicle. See also Global Directives.

Vehicle Gap: The distance between the bottom of the magnet array attached to a vehicle and the top surface of a motor.

Vehicle Signal: A motor software flag for each vehicle used to indicate if the vehicle is cur-rently detected on the transport system.

Vehicle Spacing: The distance between two vehicles on the same Path.

Zero Point: The position on the Upstream end of a Path that denotes the first part on which a Vehicle travels.

Glossary



LSM Synchronization Option User’s Manual I-1

Index

AAxis

data, 7-3, 7-7virtual, 5-12, 6-17

BBackup, A-3Brick-wall Headway, 6-2

CCables

Ethernet, 3-6MML Sync, 3-8QS 100 Sync, 3-8USB, 3-7

Cleaning, 8-3cold_start_service, 6-24Communications Timing Diagram, 6-16Computer Requirements, 1-6Configuration File, see Node Controller Config-uration FileConfigurator, see MagneMotion ConfiguratorConnections

Ethernet, 4-7power, 4-6Sync, 4-7

Contact MagneMotion, xviii, 8-4, 8-10ControlLogix

minimum requirements, 6-24MMI supplied routines, 6-24prerequisite, xiii

Cycle Length, 6-12

DDemonstration Script, for testing, 4-11

EEquipment Safety, 2-5Ethernet

cable, 3-6connection, 3-5

EtherNet/IPconfiguration, 4-8, 5-8connections, 4-7description, 3-7

FFlags

global, 7-4, 7-8vehicle command, 7-5vehicle status, 7-9

GGetting Started, 1-6

HHazards, mechanical, 2-9Heartbeat, 7-4, 7-8High Level Controller, 1-3Host Controller, 1-3

IImage Files

motor, 1-5Node Controller, 1-5

Inspectioncables, 8-3connections, 8-3

IP Addressduplicate, 8-6set, 5-4

MagneMotion, Inc.I-2 990000447 Rev. C

IndexJ

JJam Bit, 4-12

LLabels, SYNC IT Controller, 2-8LSM Synchronization Option

configuration, 5-4getting started, 1-6installation, 4-4MML motors, 4-6overview, 1-2PLC memory based interface, 7-2QS 100 motors, 4-7testing, 4-11

MMagneMotion

contact, xviii, 8-10support, 8-4

MagneMotion Configurator, description, 1-4MagneMover LITE

motor connection, 4-6SYNC IT power connection, 3-8sync motor offset, 6-13SYNC IT controller installation, 4-4

Magnet Array, 1-3Maintenance

cables, 8-3cleaning, 8-3transport system, 8-2

Manualchapter descriptions, xviconventions, xivprerequisites, xiiirelated documents, xvii

MMConfigTool.exe, see MagneMotion ConfiguratorMMI_CIP_sync_conv_feedback, 6-25MMI_sync_example_logic.ACD, 5-12MMI_sync_motion_IO, 6-25Motor Command Memory Interface, 7-3Motor Status Memory Interface, 7-7Motors

identification, 1-3limits, A-5MML connections, 4-6QS 100 connections, 4-7sync motor offset, 6-12

Movement Orderasynchronous, 6-2synchronous, 6-3

NNCHost TCP Interface Utility, description, 1-4NCHost.exe, see NCHost TCP Interface UtilityNetwork

connection, 4-6description, 1-3wiring diagram, 4-8

Node Controllerlimits, A-5NC LITE, 1-3NC-12, 1-3Web Interface description, 1-4

Node Controller Configuration Filedefinition, 4-11description, 1-5

node_configuration.xml, see Node ControllerConfiguration FileNodes, limits, A-5

OOperation

shut down, 5-16start up, 5-15

PPaths, limits, A-5Personnel Safety, 2-4PLC

configuration, 5-10firmware version, 1-2type supported, 1-2

Power Supplyidentification, 1-3MML systems, 3-6QS 100 systems, 3-6

Power, Connecting, 4-6Profiles_to_motor, 6-25

QQuickStick 100

motor connection, 4-7SYNC IT power connection, 3-8

LSM Synchronization Option User’s Manual I-3

IndexX

QuickStick 100 (Continued)sync motor offset, 6-14SYNC IT controller installation, 4-4

RRecycling, 2-11Regulatory Guidelines, 2-2Repair, 8-11Replacement, 8-11

SSafety

alert types, xvequipment, 2-5personnel, 2-4symbols, 2-7

Shipping, 8-12Shut Down, 5-16Software Types, 1-4Start Up, 5-15Stations, limits, A-5SYCON.net, 5-4Sync Cable

MML systems, 3-8QS 100 systems, 3-8

Sync Motor Offset, 6-5, 6-12Sync Zone

description, 6-4multiple motors, 6-5single motor, 6-7standard configuration, 6-5

SYNC IT Controllercommands, 7-3configuration, 5-4connections, 3-5, 4-6dimensions, 3-3identification, 1-3installation, 4-4interface, 7-2responses, 7-7

Sync, see LSM Synchronization Optionsync_take_control_of_puck, 6-24

TText Files

Demo Script, 1-5Track File, 1-5

Track File, description, 1-5Track Layout File, description, 1-5track_file.mmtrk, see Track Filetrack_layout.ndx, see Track Layout FileTransport System

components, 1-3layout, 3-2software, 1-4

Troubleshootingcommunications, 8-7motion, 8-8power, 8-5SYNC IT controller, 8-6

Type Filesmagnet array, 1-5motor, 1-5

UUnpacking, 4-2Update Rate, 5-2, 5-12, 6-16USB

cable, 3-7connecting, 5-4connection, 3-5

utilities, 6-24

VVehicle

command flags, 7-5limits, A-5status, 4-12status flags, 7-9

Virtual Axis, 5-12, 6-17

XXML Files

magnet array type file, 1-5motor type file, 1-5Node Controller Configuration File, 1-5Track Layout File, 1-5

Index

MagneMotion, Inc.I-4 990000447 Rev. C


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