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Rockwell Automation iTRAK User Manual

System with trimax bearings
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User Manual
Original Instructions
iTRAK System with TriMax Bearings
Bulletin 2198T

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Summary of Contents for Rockwell Automation iTRAK

  • Page 1 User Manual Original Instructions iTRAK System with TriMax Bearings Bulletin 2198T...
  • Page 2 If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be impaired. In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment.

  • Page 3: Table Of Contents

    Wire the iTRAK System ........48...
  • Page 4 Table of Contents Using Multiple iTRAK Power Supplies ..... 48 Wire the Digital USB I/O Module ......51 Wire the Gateway .
  • Page 5 Power Supply........114...
  • Page 6 Table of Contents Notes: Rockwell Automation Publication 2198T-UM002C-EN-P - March 2019...

  • Page 7: Preface

    EtherNet/IP™ communication module or controller. If you do not understand the basics of the iTRAK system, contact your Rockwell Automation sales representative for information on available training courses.

  • Page 8: Additional Resources

    Kinetix 5700 iTRAK Power Supply, Integrated Motion over sercos interface, EtherNet/ IP networking, and component servo drive families. Kinetix 5700 iTRAK Power Supply and iTRAK Bus Conditioner Provides information for wiring and connecting the Kinetix 5700 iTRAK power supply to the iTRAK system. Module Supply Installation Instruction, publication...

  • Page 9: Start

    Even on large systems, each mover still retains independent servo control. The system can be also built into other geometries such as rectangles. The iTRAK system can produce high speeds and high forces. The different combinations of magnet sizes and motor coil sizes produce nine different force speed options.
  • Page 10 The gateway facilitates communication between the iTRAK system and controller and provides abstraction between physical and virtual mover axes. The iTRAK system requires a specialized power supply that converts three- phase AC power to the appropriate DC bus voltage. The USB I/O module provides discrete communications between the power supply and the gateway.
  • Page 11 Power circuitry and components The iTRAK power supply connects to the Kinetix 5700 power supply and generates the voltages that are required for the iTRAK system from the full bus voltage. It is used with other Kinetix 5700 components and branch circuit protection.

  • Page 12: Motor Module

    Right Curved Motor Module is shown. Table 3 - Motor Module Component Description Item Description Item Description Position sensing surface Incoming bus connector Motor coil assembly Communication connector Motor module status indicator Vent Outgoing bus connector Drive housing Rockwell Automation Publication 2198T-UM002C-EN-P - March 2019...
  • Page 13 Power Off. Lockout/Tagout B624958 Table 5 - Series B Motor Module Status Indicator Description Item Color Status Control Power Green 24V present. Communication Green Motor module is communicating. Drive Enable Green Motor module is enabled. Rockwell Automation Publication 2198T-UM002C-EN-P - March 2019...

  • Page 14: Mover

    Chapter 1 Start Mover Movers are available in nine sizes, each with their own force-speed curve. See the iTRAK System Technical Data, publication 2198T-TD001 for the force- speed curves. Do not exceed the force-speed parameters when programming your system. Your system only has one size of mover installed.

  • Page 15: Support Frame

    Start Chapter 1 Support Frame The iTRAK system track has a frame to support the motor modules and bearing rails. Figure 7 shows the main components that are used to construct a single-base plate support structure. Figure 7 - Single Base Plate Support Structure...

  • Page 16: Power Supply

    The iTRAK system is powered using a scalable Kinetix 5700 iTRAK power supply as part of a Kinetix 5700 system. Details and installation instructions on for the use of the power supply are covered in Kinetix 5700 iTRAK Power Supply and iTRAK Bus Conditioner Module Installation Instructions, publication 2198T-IN001.

  • Page 17: Gateway

    Machine Ethernet connection (AMT) The gateway computer is dedicated to the control and coordination of the iTRAK motor modules and to provide an interface for them to the Logix system. Therefore, the only connector and ports that you can use on the gateway computer are the power input, one of the USB ports, and the Ethernet port (AMT) marked with an X.
  • Page 18 7 6 5 4 3 2 1 0 Communication Port 8 9 10 11 12 13 14 15 (1) Make only this connection. Do not use any other Ethernet ports for machine Ethernet. Rockwell Automation Publication 2198T-UM002C-EN-P - March 2019...
  • Page 19 - RX Receive Port (-) Data Terminal — — — — The AMT Ethernet port is for connection to the machine Ethernet, it is the only Ethernet port that can be used on gateway. Rockwell Automation Publication 2198T-UM002C-EN-P - March 2019...
  • Page 20 The CFast card in the only media storage device. If you require a replacement CFast card contact Rockwell Automation support. USB Side View CFast Card Slot Rockwell Automation Publication 2198T-UM002C-EN-P - March 2019...
  • Page 21 Solid green Ethernet connection is linked Ethernet active Blinking yellow Transmitting and receiving data CMOS battery has gone below 2.3V — Not used Green Gateway is on Yellow Gateway is in standby mode Rockwell Automation Publication 2198T-UM002C-EN-P - March 2019...

  • Page 22: 2198T-G03-Xxx-E Gateway

    (1) Make only this connection. Do not use any other Ethernet ports for machine Ethernet. The gateway computer is dedicated to the control and coordination of the iTRAK motor modules and to provide an interface for them to the Logix system. Therefore, the only connector and ports that you can use on the gateway computer are the power input, one of the USB ports, and the Ethernet port LAN1.
  • Page 23 Receive Port (-) Data Terminal — — — — The LAN 1 Ethernet port is for connection to the machine Ethernet, it is the only Ethernet port that can be used on gateway. Rockwell Automation Publication 2198T-UM002C-EN-P - March 2019...
  • Page 24 Logix Designer application interface software. The gateway does not have a hard disk drive, The CFast card in the only media storage device. If you require a replacement CFast card contact Rockwell Automation support. CFast Card Slot Rockwell Automation Publication 2198T-UM002C-EN-P - March 2019...
  • Page 25 Ethernet connection is linked Ethernet active Blinking yellow Transmitting and receiving data TX 1/2 Not used RX 1/2 Not used HDD( ) Yellow SATA activity Green Gateway is on Gateway is in standby mode Rockwell Automation Publication 2198T-UM002C-EN-P - March 2019...

  • Page 26: Digital Usb I/O Module

    The digital USB I/O module provides an interface between the power supply that is used by your system and the gateway. This module must be included in your system when using Kinetix 5700 iTRAK power supply. Figure 13 - 2198T-GUSB, Digital USB I/O Module...

  • Page 27: Catalog Number Explanation

    Start Chapter 1 Catalog Number Explanation Use the following key to identify your iTRAK system and its options. 2198T - E XX - X XXX - XXX - X XX XXX X - QXXXX Customized (quote number reference) Power and Control Configuration...

  • Page 28: Safety Information

    • See the iTRAK System Technical Data, publication 2198T-TD001 operational ratings. Do not exceed these ratings. • The iTRAK system must only be used in the environment specified. • See Chapter 2 - Track Installation and Kinetix 5700 iTRAK Power...

  • Page 29: Machine Guarding

    Chapter 7 Functional Safety. Movers can fall when motor power is removed or servo control is disabled on vertical or stand-up iTRAK system installations. • Help prevent the risk of contact with parts that move by the use of guards and protective devices, see Machine Guarding.

  • Page 30: Avoid Accidents, Injury, And Property Damage

    Avoid Electrical Shock ATTENTION: The motor modules, Kinetix 5700 iTRAK power supply, and the bus conditioner require 5 minutes to discharge before you handle wire and cable connections. ATTENTION: Permanent magnets can act as generators when power is removed.

  • Page 31: Protection Against Contact With Hot Parts

    The magnetic field that is generated can disrupt the functionality of automatic-implantable cardioverter defibrillators (AICD). People with cardiac pacemakers must not work near the iTRAK system. Magnetic Field Strength The movers of the iTRAK system contain components with strong magnetic fields.
  • Page 32 175 (6.9) 70 (2.8) 140 (5.5) 105 (4.1) 2198T-VT1515-x 300 (11.8) 210 (8.3) 320 (12.6) 200 (7.9) 250 (9.8) 165 (6.5) 210 (8.3) 170 (6.7) 160 (5.9) 85 (3.3) 140 (5.5) 110 (4.3) Rockwell Automation Publication 2198T-UM002C-EN-P - March 2019...
  • Page 33 0.5 mT H (+/–) H (+/–) H (+/–) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) 2198T-NN-318 135 (5.3) 276 (10.9) 120 (4.7) 221 (8.7) 80 (3.1) 131 (5.2) 2198T-NS-318 Rockwell Automation Publication 2198T-UM002C-EN-P - March 2019...

  • Page 34: Safe Magnet Handling

    Strong magnets can erase magnetic media. Never let credit cards or electronic media contact or come near the mover or iTRAK system. • The track creates strong magnetic fields while energized during operation.

  • Page 35: Track Installation

    Chapter Track Installation Use this chapter to install an iTRAK® system track and lubrication system. Topic Page Install the Track Install the Lubrication System Choose the location for system components following these considerations: • operator and maintenance access to movers and motor modules •...

  • Page 36: Mount An Oval Track

    2. Make sure that the mounting surface supports the track evenly so that it is free of mechanical stress and distortion. If mounting the iTRAK track directly to mounting surface, make sure that the mounting surface has a flatness of 0.05 mm per 300 x 300 mm (0.002 in.
  • Page 37 Mount by using the M16 x 2 threaded holes and the slots in mounting plate. 500.0 (19.7) 450.0 (17.7) 12.7 (0.5) 90.0 (3.5) 45.0 (1.8) 25.0 (1.0) 2X TAP M16 X 2.0 4X 13.5 (0.53) Rockwell Automation Publication 2198T-UM002C-EN-P - March 2019...
  • Page 38 M12 Hold Down Screws (X2) Leveling Feet 6. If your system was shipped multiple segments, do the following, otherwise skip to next step. a. Apply Loctite 243 to all screws used in the following steps. Rockwell Automation Publication 2198T-UM002C-EN-P - March 2019...
  • Page 39 40 N•m (29.5 lb•ft). M5 x 20 SHCS (X22)s M8 x 25 SHCS (X4) Shoulder Screw, M8 x 25 (X4) M8 x 40 SHCS (X4) h. Clean the rail screws and apply Loctite 243. Rockwell Automation Publication 2198T-UM002C-EN-P - March 2019...
  • Page 40 8. Follow the guidelines in System Design for Control of Electrical Noise Reference Manual, publication GMC-RM001, and Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.1 to obtain proper low-impedance grounding for high-frequency electrical noise. Rockwell Automation Publication 2198T-UM002C-EN-P - March 2019...

  • Page 41: Install The Lubrication System

    Track Installation Chapter 2 Install the Lubrication The iTRAK lubrication system, catalog number 2198T-AL-SYS, comes with a coil of tube to connect system fittings to the remotely located pumps and System system fittings. Three pump assemblies are included in the system; one is intended for each bearing rail.

  • Page 42: What You Need

    1. Locate a mounting position for the pumps. The pump must be located within the 10 m (32.8 ft) of tube routing distance to the iTRAK system lubrication connectors and 5.0 m (16.4 ft) of the power cable routing distance to 24V I/O port of your controller.

  • Page 43: Wiring Lubrication Pump

    Lubrication Pump Configuration Table 14 - Recommend Lubrication Pump Setting Feature Setting Mode Impulse Lubrication on page 100 to make tube connections, initial lubrication, and lubrication during normal operation. Rockwell Automation Publication 2198T-UM002C-EN-P - March 2019...
  • Page 44 Chapter 2 Track Installation Notes: Rockwell Automation Publication 2198T-UM002C-EN-P - March 2019...

  • Page 45: Connect Your Itrak System To A Kinetix 5700 Itrak Power Supply

    The iTRAK power supply derives bus power for and distributes control power to the iTRAK system. It is a Kinetix 5700 component, and is designed to work with the 2198-Pxxx Kinetix 5700 power supplies as part of a Kinetix 5700 system.
  • Page 46 Chapter 3 Connect Your iTRAK System to a Kinetix 5700 iTRAK Power Supply Figure 19 is a full view of the system that includes customer supplied components, iTRAK solutions, and wiring. Figure 19 - Typical iTRAK System with an iTRAK Power Supply...
  • Page 47 Connect Your iTRAK System to a Kinetix 5700 iTRAK Power Supply Chapter 3 For detailed information on the installation and how to wire the iTRAK power supply into a Kinetix 5700 system, see the Kinetix 5700 Servo Drives User Manual, publication 2198-UM002. The Kinetix 5700 Servo Drives User...

  • Page 48: Wire The Itrak System

    Chapter 3 Connect Your iTRAK System to a Kinetix 5700 iTRAK Power Supply Wire the iTRAK System An iTRAK power supply can power up to 20 series A or 32 series B motor modules depending on current requirements. See Figure 20 for a typical layout on how to wire a system using one iTRAK power supply.
  • Page 49 In this case iTRAK power supply 1 powers the first group of ten motor modules, while iTRAK power supply 2 provides power to the remaining six motor modules.
  • Page 50 IPS READY IN Ready (IR) Connector (1) Only one connection to 24V Com is required for each iTRAK power supply. Either pin 2 or pin 4 must be connected, it is not necessary to connect both. Rockwell Automation Publication 2198T-UM002C-EN-P - March 2019...

  • Page 51: Wire The Digital Usb I/O Module

    Connect Your iTRAK System to a Kinetix 5700 iTRAK Power Supply Chapter 3 Wire the Digital USB I/O The digital inputs and output from the iTRAK power supply communicate with the gateway through the 2198T-GUSB Digital USB I/O Module. Module To access the connectors, complete these steps.

  • Page 52: Wire The Gateway

    Chapter 3 Connect Your iTRAK System to a Kinetix 5700 iTRAK Power Supply Wire the Gateway This manual covers wiring the 2198T-G02-xxx-E and the 2198T-G03-xxx-E gateway. Wire the gateway with 24V power input, a machine Ethernet connection, the USB cable from the digital USB I/O module and a communication cable from each of the motor modules.

  • Page 53: Numbering The Motor Modules

    Connect Your iTRAK System to a Kinetix 5700 iTRAK Power Supply Chapter 3 Figure 26 - 2198T-G03-xxx-E Gateway USB, LAN, and 24V Power Plug Wiring Ground Terminal For machine Ethernet connection use LAN1 only. Machine Ethernet Connection USB cable connection to Digital USB I/O Module.

  • Page 54: Wire A 2918T-G02-Xxx-E Gateway

    Chapter 3 Connect Your iTRAK System to a Kinetix 5700 iTRAK Power Supply Wire a 2918T-G02-xxx-E Gateway To wire the motor modules to the 2918T-G02-xxx-E gateway, complete the following steps. 1. Remove the loopback connector from the number seven communication port.

  • Page 55: Wire A 2918T-G03-Xxx-E Gateway

    Connect Your iTRAK System to a Kinetix 5700 iTRAK Power Supply Chapter 3 Wire a 2918T-G03-xxx-E Gateway To wire the motor modules to the 2918T-G03-xxx-E gateway, complete the following steps. 1. Remove the loopback connector from the number seven communication port.

  • Page 56: Logix Designer Application Support

    You can obtain the Studio 5000 Logix Designer controller ladder code by going to the Rockwell Automation Knowledgebase article 778917 IMPORTANT Do not add the iTRAK power supply to Logix I/O tree. If you do, unexpected results can occur. Rockwell Automation Publication 2198T-UM002C-EN-P - March 2019...

  • Page 57: Power On Your System

    Integrated Architecture® Builder from Rockwell Automation can help you size the application and estimate which controller is properly suited for you; see Knowledgebase Article 1040301, How to size an iTRAK® in IAB? for more information. Identify Firmware Revision Each firmware revision is designed to operate with a paired version of the iTRAK_IO Add-On Instruction.

  • Page 58: Configure And Customize Project File

    The bus voltage is applied to the system when the appropriate commands are sent from the processor to the gateway. This action triggers the Kinetix 5700 iTRAK power supply via the USB I/O module. See the Motion Commands section of the iTRAK Programming Manual, publication 2198T-PM001, for more information.

  • Page 59: Commission With Programming Manual

    The DC BUS voltage that is displayed can differ depending on your system configuration. 5. To determine if the iTRAK system is ready for application of the bus voltage, monitor the status indicators from the gateway in Studio 5000 Logix Designer application.
  • Page 60 Chapter 4 Power on Your System Notes: Rockwell Automation Publication 2198T-UM002C-EN-P - March 2019...

  • Page 61: Maintenance

    Preventive Maintenance Cleaning To prolong the life of your iTRAK® system, do the following cleaning procedures. The frequency in which to perform them is depended on the machine usage, the environment in which it is used, and the exposure to containments.

  • Page 62: Add Or Replace Components

    Install or Remove a Position Magnet Assembly To install or remove a position magnet assembly, complete these steps. Before You Begin ATTENTION: Before attempting any service to an iTRAK system. See Safety Information on page What You Need • 2.5 mm hex driver •...
  • Page 63 You can check the polarity by examining the color of the magnets or by using a compass. Item Description Shoulder-Socket Head Cap Screws Position Magnet Assembly Mover IMPORTANT If you are using the iTRAK_Control.Data.MoverOffset tag, recalibrate the movers that have new position magnets. Rockwell Automation Publication 2198T-UM002C-EN-P - March 2019...

  • Page 64: Magnet Plate Assembly Installation

    Magnet Plate Assembly Installation Follow this procedure to install or remove a magnet plate assembly. Before You Begin ATTENTION: Before attempting any service to an iTRAK system. See Safety Information on page ATTENTION: If you are using your own design for a mover, make sure of the following.
  • Page 65 9 N•m (6.6 ft•lb) and M6 flat head cap screws to 7 N•m (5.2 ft•lb). Item Description Magnet plate assembly Flat head cap screw Socket-head cap screw Install mover by following the procedure in Install or Replace a Mover on page Rockwell Automation Publication 2198T-UM002C-EN-P - March 2019...

  • Page 66: Install Or Replace A Mover

    Install or Replace a Mover Follow this procedure to install or replace a mover. Before You Begin ATTENTION: Before attempting any service to an iTRAK system. See Safety Information on page Choose an accessible curved section of the track. Position the mover that you want to replace over a straight motor module next to the curved section.
  • Page 67 3. Attach mover installation fixtures to the end of straight bearing rails by using two socket head cap screws from the curved bearing rail. Socket head cap screws from the curved bearing rail. Mover Installation Fixtures Socket head cap screws from the curved bearing rail. Rockwell Automation Publication 2198T-UM002C-EN-P - March 2019...
  • Page 68 7. Install the spacers and the top and bottom curved bearing rails. Torque the middle screws to 9 N•m (6.6 lb•ft) by using 4 mm hex driver; leave the two screws on each end of the curved rail loose. End Screws Rockwell Automation Publication 2198T-UM002C-EN-P - March 2019...
  • Page 69 9. Torque the two screws under the clamp to 9 N•m (6.6 lb•ft) by using 4 mm hex driver. 10. Repeat steps to the bottom rail. 11. Install the position magnet assembly by following the procedure Install or Remove a Position Magnet Assembly on page Rockwell Automation Publication 2198T-UM002C-EN-P - March 2019...

  • Page 70: Replace A Straight Motor Module

    Maintenance Replace a Straight Motor Module Use this procedure to replace a straight motor module. Before You Begin ATTENTION: Before attempting any service to an iTRAK system. See Safety Information on page What You Need • 5 mm and 6 mm hex drivers •...
  • Page 71 5…step 8. Torque shoulder screws to 13 N•m (9.6 lb•ft) and torque socket head cap screws to 22 N•m (16.2 lb•ft). 9. Update motor module firmware, see Update Motor Module Firmware on page Rockwell Automation Publication 2198T-UM002C-EN-P - March 2019...

  • Page 72: Replace A Curved Motor Module

    Maintenance Replace a Curved Motor Module Use this procedure to replace a curved motor module. Before You Begin ATTENTION: Before attempting any service to an iTRAK system. See Safety Information on page What You Need • Left and right straight-to-curved clamps from 2198T-A04 iTRAK alignment tool kit •...
  • Page 73 5. Remove the M5 x 20 socket head cap screws that secure the top and traverse rails to the curved top plate. Curved Top Plate Top Rail Traverse Rail Socket Head Cap Screw, M5 x 20 (X12) Rockwell Automation Publication 2198T-UM002C-EN-P - March 2019...
  • Page 74 Curved Top Plate and Rail Assembly 8. Slide the adjacent straight motor module halfway off the base plate and disconnect the communication and power bus connectors. Power Bus Communication Connector (X2) Connector Adjacent Straight Motor Module Rockwell Automation Publication 2198T-UM002C-EN-P - March 2019...
  • Page 75 29 kg (64 lb). Be sure to use a two man lift when moving the motor module. ATTENTION: You are exposed to pinch points between base plate and motor module when removing and installing the curved motor module. Rockwell Automation Publication 2198T-UM002C-EN-P - March 2019...
  • Page 76 4. Slide straight motor module more than half way into position and connect the communication and power bus connectors, then slide into final position. Power Bus Communication Connector (X2) Connector Adjacent Straight Motor Module Rockwell Automation Publication 2198T-UM002C-EN-P - March 2019...
  • Page 77 6. Connect the curved motor communication and power bus connectors. Shoulder Screws, M8 x 25 (X4) Socket Head Cap Screw, M8 x 25 (X4) Communication Power Bus Connector Connector (X2) 7. Slide into place the top curved plate and rail assembly. Rockwell Automation Publication 2198T-UM002C-EN-P - March 2019...
  • Page 78 9. Slide the shims into place until they are flush with the motor modules. Straight Shim (X2) Curved Shim (X2) 10. Torque shoulder screws to 13 N•m (9.6 lb•ft) and M8 socket head cap screws to 22 N•m (16.2 lb•ft). Rockwell Automation Publication 2198T-UM002C-EN-P - March 2019...
  • Page 79 15. Install three M5 x 20 socket head cap screw at each transition and torque to 9 N•m (6.6 lb•ft). Right transverse straight-to-curved rail transition Transverse Rail M5 x 20 SHCS (X3)s Straight-to-straight Rail Clamp 16. Update motor module firmware, see Update Motor Module Firmware on page Rockwell Automation Publication 2198T-UM002C-EN-P - March 2019...

  • Page 80: Replace Mover Cam-Follower Wheels And Flexures

    Maintenance Replace Mover Cam-follower Wheels and Flexures Use this procedure to replace the cam-follower wheels and flexures on a mover. Before You Begin ATTENTION: Before attempting any service to an iTRAK system. See Safety Information on page What You Need •...
  • Page 81 5. Clamp the top plate to a sturdy surface. 6. To remove the fixed cam follower nuts, use 14 mm socket wrench. To help prevent the cam follower shafts from turning, use a 5 mm hex driver on the opposite side. Rockwell Automation Publication 2198T-UM002C-EN-P - March 2019...
  • Page 82 To help prevent the cam follower shafts from turning, use a 5 mm hex driver on the opposite side. 14 mm Socket Wrench Cam Follower Nut (X2) 5 mm Hex Driver 10. Place the flexure in a vise as shown. Rockwell Automation Publication 2198T-UM002C-EN-P - March 2019...
  • Page 83 12. Position new cam follower stud into bore and engage with the fixed cam-follower bore chamfer. Make sure that stud is not cocked in relation to support surface. Cam Follower Stud Bore Chamfer Top Plate Rockwell Automation Publication 2198T-UM002C-EN-P - March 2019...
  • Page 84 Cam Follower Top Plate Fully Seated Fully Seated 14. Position flexure on arbor press support plate and align to an 11…13.5 mm (0.43…0.53 in.) opening. Cam Follower Shim Flexure 11…13.5 mm (0.43…0.53 in.) opening Rockwell Automation Publication 2198T-UM002C-EN-P - March 2019...
  • Page 85 18. Attach the nuts to the flexure cam followers by using a 14 mm socket head driver and torque to 16 N•m (11.8 lb•ft). Help prevent the cam follower from turning by using a 5 mm hex driver. Rockwell Automation Publication 2198T-UM002C-EN-P - March 2019...
  • Page 86 25. Attach the top plate to the middle plate by using the M6 x 30 socket head cap screws, but do not tighten. 26. Place the top of the top plate on a flat surface and clamp the assemblies together by using a padded bar clamp. Rockwell Automation Publication 2198T-UM002C-EN-P - March 2019...

  • Page 87: Install Top And Bottom Straight Rails

    Install Top and Bottom Straight Rails Use this procedure to install top and bottom straight rails. Before You Begin ATTENTION: Before attempting any service to an iTRAK system. See Safety Information on page The straightening bar can be used with the track motor modules in any of three...
  • Page 88 • 3 mm, 4 mm, and 5 mm hex drivers • Loctite 243 • 2198T-A06 iTRAK TriMax rail straightening tool To install a top or bottom rail complete these steps. 1. Choose the rail configuration that you would like to install from Figure 2.
  • Page 89 6. Mount the straightening bar on the track by using two shoulder screws. Shoulder Screw Shoulder Screw 7. To straighten and locate the rail, evenly tighten all straightening bar set screws, then torque to 13 N•m (9.6 lb-ft). Rockwell Automation Publication 2198T-UM002C-EN-P - March 2019...
  • Page 90 14. Clamp the two adjacent-straight rails using tool straight-to-straight rail alignment clamp, as shown. The clamp aligns bearing surfaces. M5 x 20 LHCS (X2) Straight-to-Straight Rail Alignment Clamp 15. Tighten two M5 x 20 LHCS and torque to 9 N•m (6.6 lb•ft). Rockwell Automation Publication 2198T-UM002C-EN-P - March 2019...

  • Page 91: Install Transverse Straight Rails

    Chapter 5 Install Transverse Straight Rails Use this procedure to install transverse straight rails. Before You Begin ATTENTION: Before attempting any service to an iTRAK system. See Safety Information on page What You Need • M5 x 0.8 x 20 mm low head socket cap screws, as required •...

  • Page 92: Replace Or Install Top And Bottom Straight Bearing Rail With

    Lubrication Port Use this procedure to replace or install top and bottom straight bearing rail with lubrication port. Before You Begin ATTENTION: Before attempting any service to an iTRAK system. See Safety Information on page What You Need • M5 x 0.8 x 20 mm low head socket cap screws, as required •...
  • Page 93 4. Install new rail by following the procedure Install Top and Bottom Straight Rails on page 5. Install lubrication cover with two M4 x 8 mm screws and torque to 4.5 N•m (3.32 lb•ft). Rockwell Automation Publication 2198T-UM002C-EN-P - March 2019...

  • Page 94: Install Curved Transverse Rail

    Install Curved Transverse Rail Use this procedure to install transverse curved rails. Before You Begin Install transverse straight rails before you install the transverse curved rails. ATTENTION: Before attempting any service to an iTRAK system. See Safety Information on page What You Need •...

  • Page 95: Install A Top Or Bottom Radial Curved Rail

    Use this procedure to install a top or bottom radial curved rail. Before You Begin Install top or bottom straight rails before you install the radial curved rails. ATTENTION: Before attempting any service to an iTRAK system. See Safety Information on page What You Need •...
  • Page 96 Start at the apex and work toward the rail ends and alternate sides. 7. Tighten the straight rail M5 x 20 mm low head socket cap screws and torque to 9 N•m (6.6 lb•ft). 8. Release push force and clamp tools. Rockwell Automation Publication 2198T-UM002C-EN-P - March 2019...

  • Page 97: Update Gateway Firmware

    4. From the dialog box, change the base IP address if needed, and click Update Gateway and Section Firmware with iTFlash. The software copies files to the system over the network. It can take up to ten minutes. Rockwell Automation Publication 2198T-UM002C-EN-P - March 2019...
  • Page 98 Gateway Cat. No. No. OS Restarts No. Gateway Restarts Total Restart Time (m) 2198T-Gx1-xxx-E 2198T-Gx2-xxx-E 7. See iTRAK System Programming Manual, publication 2198T-PM001, for detail on Logix Designer application project file changes associated with firmware revisions. Rockwell Automation Publication 2198T-UM002C-EN-P - March 2019...

  • Page 99: Firmware Update Troubleshooting

    5. Plug in the communication cable for the new motor module. 6. Power on the gateway. 7. Toggle Cmd.FlashSectionsxxxmm that correspond to the mover type you have. There are three types of movers: 2198T-VTxx05-x 2198T-VTxx10-x 2198T-VTxx15-x For troubleshooting, see Knowledgebase Article 600812. Rockwell Automation Publication 2198T-UM002C-EN-P - March 2019...

  • Page 100: Lubrication

    Use 68 viscosity mineral oil, such as Kluber 4 UH1-68N, to lubricate the bearing rails. To provide continuous lubrication, we recommend that you use the iTRAK Lubrication System, catalog number 2198T-AL-SYS, installation instructions that start on page 35.

  • Page 101: Initial Lubrication

    It is best to have a higher frequency with lower amounts of oil dispense to allow the oil to coat the rails evenly. Rockwell Automation Publication 2198T-UM002C-EN-P - March 2019...

  • Page 102: Rockwell Automation Publication 2198T-Um002C-En-P - March

    Chapter 5 Maintenance Notes: Rockwell Automation Publication 2198T-UM002C-EN-P - March 2019...

  • Page 103: Troubleshooting

    Topic Page Errors Codes The iTRAK system can generate errors from the gateway or from the motor Errors Codes modules. The error codes are pushed from those devices to tags in the control structure. These error codes are in addition the Logix Designer application generated codes.
  • Page 104 Chapter 6 Troubleshooting Table 23 - iTRAK System Error Codes iTRAK_Control.Status. iTRAK_Control.Status. Displayed Text Description and Solution GatewayFaultCode SectionFaultCode This error indicates that the motor module has lost high voltage on one or both of its buses. The following are possible causes.
  • Page 105 Value 7: 3. Reset the fault by latching iTRAK_Control.Cmd.FaultReset iTRAK could not find all movers at their last If the iTRAK_Control.Status.SectionFaultData tag = 7, then upon reported positions. The movers have been start-up, the movers were not found in the same positions as they automatically renumbered.
  • Page 106 Check track path and cables or reduce motion profile demands. To clear this fault properly, complete these steps. 1. Leave the iTRAK high voltage off for 5 minutes, Do not turn off the control voltage. 2. Check the track path.
  • Page 107 Troubleshooting Chapter 6 Table 23 - iTRAK System Error Codes (Continued) iTRAK_Control.Status. iTRAK_Control.Status. Displayed Text Description and Solution GatewayFaultCode SectionFaultCode This error indicates a communication failure between the gateway and a motor module. The iTRAK_Control.Status.SectionNumberFaulted tag contains the motor module that is reporting this fault.
  • Page 108 Chapter 6 Troubleshooting Table 23 - iTRAK System Error Codes (Continued) iTRAK_Control.Status. iTRAK_Control.Status. Displayed Text Description and Solution GatewayFaultCode SectionFaultCode This error indicates that the motor module has lost high voltage on one or both of its buses. The following are possible causes.
  • Page 109 Otherwise, iTRAK_Control.Status.SectionNumberFaulted tag contains the motor module that has reported this fault. The iTRAK power supply is not in Running mode. Check the iTRAK power supply screen for more information and acknowledge the fault. The gateway failed to acknowledge the fault on the iTRAK power supply.
  • Page 110 Mover size mismatch, size of movers are not There is an inconsistency between the size of the movers on the iTRAK consistent on the track system, and the firmware that is downloaded into one or more of the Check section types and set them to correct motor modules.

  • Page 111: Important Safety Considerations

    Chapter Functional Safety The iTRAK® components do not have Safe Torque Off or any other features that are described in EN 61800-5-2. When combined into a system, implement safety functions to prevent motor actuation. Remove the AC power by using similar methods that are used for variable frequency drives that do not have Safe Torque Off.

  • Page 112: Stop Category Definition

    When the timer expires, power is removed from the safety output contactors that remove power that produces motion from the iTRAK system. If the track is in motion, it coasts to a stop.

  • Page 113: Considerations For Category 1 Stop

    A low can happen when a wire falls off or control power fails before the iTRAK system has a chance to come to a complete stop. Use additional protective measures if this occurrence can introduce unacceptable risks to personnel.

  • Page 114: Schematic And Block Diagrams

    Chapter 7 Functional Safety Schematic and Block These simplified schematic diagrams are intended to inform qualified engineers on how to structure a safety system around the iTRAK system. They Diagrams are not considered complete. iTRAK Power Supply The block diagram that is shown in...

  • Page 115: Motor Modules

    Bulletin 2198T iTRAK motor modules. • If a Bulletin 2198T iTRAK motor module is replacing s a Bulletin IT3 iTRAK motor module, all similar modules that are adjacent must be replaced also.

  • Page 116: Movers And Magnets

    (2) The communication to the gateway must be through 1756-ENxT modules capable of Integrated Motion on EtherNet/IP™. (3) The memory requirements and CPU utilization of typical iTRAK applications can reduce the possible catalog numbers available in these families. Work with Rockwell Automation application engineering to determine suitability.

  • Page 117: Safety Labels

    Page Safety Labels Safety Labels The following safety-identification labels are affixed to the iTRAK® system. To help prevent injury and damage to the system, review the safety labels, their details, and locations before using the system. Figure 31 - Safety Label Placement...
  • Page 118 (AICD). People with cardiac pacemakers Magnetic field locate in this area Can be harmful to pacemakers and must not work near the iTRAK system. The strong magnets of the other sensitive equipment mover can attract metal objects that are in its proximity. When you handle and install maintain distance between the mover and ferrous metal mounting surfaces or structures.

  • Page 119: Index

    12 installation gateway 46 planning 35 mover 14 iTRAK power supply straight motor module 12 multiple 48 connector locations safety circuit 114 digital USB I/O 51 status indicators 58 gateway 52 Rockwell Automation Publication 2198T-UM002C-EN-P - March 2019...
  • Page 120 36 replace 66 wire gateway 52 iTRAK power supply multiple 49 number motor modules 53 single 48 lubrication pump 43 USB I/O 51 position magnet install 62 magnetic field strength 33 remove 62 Rockwell Automation Publication 2198T-UM002C-EN-P - March 2019...
  • Page 121 Index Notes: Rockwell Automation Publication 2198T-UM002C-EN-P - March 2019...
  • Page 122 Index Rockwell Automation Publication 2198T-UM002C-EN-P - March 2019...
  • Page 124 Rockwell Automation maintains current product environmental information on its website at http://www.rockwellautomation.com/rockwellautomation/about-us/sustainability-ethics/product-environmental-compliance.page. Allen-Bradley, CompactLogix, ControlLogix, Integrated Architecture, iTRAK, Kinetix, Rockwell Software, Rockwell Automation, Studio 5000, and Studio 5000 Logix Designer are trademarks of Rockwell Automation, Inc. EtherNet/IP is a trademark of ODVA, Inc.

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