Rockwell Automation Allen-Bradley iTRAK Troubleshooting Manual
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Rockwell Automation Allen-Bradley iTRAK Troubleshooting Manual

Rockwell Automation Allen-Bradley iTRAK Troubleshooting Manual

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iTRAK System
Bulletin Number 2198T-L16
Troubleshooting Guide
Original Instructions

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Summary of Contents for Rockwell Automation Allen-Bradley iTRAK

  • Page 1 iTRAK System Bulletin Number 2198T-L16 Troubleshooting Guide Original Instructions...
  • 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

    Index ............49 Rockwell Automation Publication 2198T-TG001A-EN-P - October 2020...
  • Page 4 Table of Contents Notes: Rockwell Automation Publication 2198T-TG001A-EN-P - October 2020...

  • Page 5: 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. Conventions These conventions are used throughout this manual: •...

  • Page 6: Additional Resources

    Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.1 Provides general guidelines for installing a Rockwell Automation® industrial system. Product Certifications website, rok.auto/certifications. Provides declarations of conformity, certificates, and other certification details. You can view or download publications at rok.auto/literature.
  • Page 7 System with TriMax Bearings User Manual, publication 2198T-UM002. This document focuses on basic troubleshooting steps to get your iTRAK system running for the first time, or after a fault has occurred. Rockwell Automation Publication 2198T-TG001A-EN-P - October 2020...

  • Page 8: Mechanical Itrak Components

    Gateway The gateway provides centralized motion processing and communication between the controller and the motor modules. There are three generations of gateways, which all provide the same function, however, there are some differences: Rockwell Automation Publication 2198T-TG001A-EN-P - October 2020...

  • Page 9: Digital Usb I/O

    Kinetix 5700 iTRAK power supply. For more information about the digital USB I/O module, see the iTRAK System with TriMax Bearings User Manual, publication 2198T-UM002. Rockwell Automation Publication 2198T-TG001A-EN-P - October 2020...
  • Page 10 Chapter 1 iTRAK System Hardware Notes: Rockwell Automation Publication 2198T-TG001A-EN-P - October 2020...

  • Page 11: Turn Main Power On

    When you use a Kinetix® 5700 iTRAK Power Supply (iPS), the cabinet has been designed and built by the original equipment manufacturer (OEM). In the past, Rockwell Automation provided a single cabinet with the electronic components known as a Power Control Module (PCM), which provided DC power to the iTRAK motors and gateway.

  • Page 12: Control Power Or Communication Led Off

    After you verify that the cables are connected properly, and you still see the communication issue, two scenarios are possible. • There is a bad port on the gateway. Connect one section at a time to the gateway until the bad port is found. Rockwell Automation Publication 2198T-TG001A-EN-P - October 2020...
  • Page 13 00 of the gateway (make sure to move the loopback to port 01 if you use a Gen 1 or Gen 2 gateway), and then reboot. If the problem persists, the module needs to be replaced. Rockwell Automation Publication 2198T-TG001A-EN-P - October 2020...
  • Page 14 Chapter 2 Power Up the System Notes: Rockwell Automation Publication 2198T-TG001A-EN-P - October 2020...
  • Page 15 2. If the monitor has a VGA connector, use an adapter VGA to DVI in order to connect to the gateway. 3. Connect the DVI-A male end from your computer monitor into the DVI plug on the gateway. Rockwell Automation Publication 2198T-TG001A-EN-P - October 2020...
  • Page 16 4. Connect a keyboard to any one of the free USB ports in the gateway. 5. Once the gateway has booted up, it asks for a log in. Press Alt + F2. 6. The screen display a screen similar to the one shown. Rockwell Automation Publication 2198T-TG001A-EN-P - October 2020...

  • Page 17: Check Firmware Revision And Section Type

    If, in the previous procedure, you find that your section types do not match, follow these instructions to change the firmware from Bitvise or from the Type using Bitvise or terminal screen: Terminal Monitor 1. Press x. Rockwell Automation Publication 2198T-TG001A-EN-P - October 2020...
  • Page 18 50 mm optimal force, while the rest of the track is 100 mm optimal current. 2. Press Shift + U at the same time. The system prompts you to enter the number of the section you want to change. In this example we are changing 0. Rockwell Automation Publication 2198T-TG001A-EN-P - October 2020...
  • Page 19 The prompt asks: Do you want to download the PWM FW to the section as well? (y/n). 4. Type y. The system asks you to confirm the change: You want to change section number x to type y? (y/n). Rockwell Automation Publication 2198T-TG001A-EN-P - October 2020...
  • Page 20 Connect a Monitor and Key Board to the Gateway 5. Type y. The gateway immediately goes down for a reboot. After the reboot, the gateway downloads the firmware and begins to burn the section. After completion, the gateway reboots again. Rockwell Automation Publication 2198T-TG001A-EN-P - October 2020...
  • Page 21 6. When the second reboot is finished, press x again and verify that your section type is now correct. Section 0 now has the correct section type. 7. Repeat steps 1…6 as many times as needed for all sections with incorrect section types. Rockwell Automation Publication 2198T-TG001A-EN-P - October 2020...
  • Page 22 Chapter 3 Connect a Monitor and Key Board to the Gateway Notes: Rockwell Automation Publication 2198T-TG001A-EN-P - October 2020...

  • Page 23: Sections Are Not Displayed On The Monitor

    • Remove the white position board cover from the module. • Unplug the 4 connectors J1, J2, J3, and J4 from the power board. Rockwell Automation Publication 2198T-TG001A-EN-P - October 2020...
  • Page 24 Resistance should measure 1.9 Ω or very close to it. Check all six wires on both sets. All readings should be the same. 5. If confirmed short, the motor module needs to be replaced. Rockwell Automation Publication 2198T-TG001A-EN-P - October 2020...

  • Page 25: Log File Retrieval Tool

    4. To use the tool, complete the following steps: a. Type the IP address of the iTRAK gateway. b. Click Retrieve Logs. c. Click Save As to name the log file and place it in your desired location. Rockwell Automation Publication 2198T-TG001A-EN-P - October 2020...

  • Page 26: Gen 1 And Gen 2 Gateway Bitvise

    2. In the remote files screen on the right hand side, begin by typing / into the address bar of the Remote Files, and navigate through the following folders: a. Usr b. Src c. Rtai-extra d. Jacobs_Automation e. PackTrak-devel Rockwell Automation Publication 2198T-TG001A-EN-P - October 2020...
  • Page 27 Chapter 5 Retrieve a Log File The following screen shots show what these screens look like. Rtai-extra Rockwell Automation Publication 2198T-TG001A-EN-P - October 2020...
  • Page 28 3. In the PackTrak-devel folder, there can be up to five log files. iT_GW_00.log is the latest file. You can use Note Pad or Note Pad ++ to open this file. 4. If requested, send this log file to ictsupport@ra.rockwell.com. Rockwell Automation Publication 2198T-TG001A-EN-P - October 2020...

  • Page 29: Gen 3 Bitvise

    2. In the remote files screen on the right hand side, begin by typing / into the address bar of the Remote Files and navigate through the following folders: a. Mnt b. Cf c. GW_logfiles The following screen shots show what these screens look like. Rockwell Automation Publication 2198T-TG001A-EN-P - October 2020...
  • Page 30 3. In the GW_logfiles folder, there can be up to 5 log files. iT_GW_00.log is the latest file. You can use Note Pad or Note Pad ++ to open this file. If requested, send this log file to ictsupport@ra.rockwell.com. Rockwell Automation Publication 2198T-TG001A-EN-P - October 2020...

  • Page 31: Loop Update Rates

    The value for the PLUP is displayed under iTRAK_Control.Status.PositionLoopPeriod in μS. In the example below, 1000 μs is 1 ms. 4. Based on this value, set the RPI to 2 ms and set the CUR to 4 ms. Rockwell Automation Publication 2198T-TG001A-EN-P - October 2020...
  • Page 32 2. To view or set the RPI, right click on each of the modules you are using and select properties. 3. Click the connection tab and set the RPI to the appropriate number based on the PLUP, and click Apply. Rockwell Automation Publication 2198T-TG001A-EN-P - October 2020...
  • Page 33 1. Locate your Motion Group, right click on Axes, and select properties. 2. On the Attribute tab, set the Base Update Period to the appropriate value based on the RPI, and click Apply. Rockwell Automation Publication 2198T-TG001A-EN-P - October 2020...
  • Page 34 2. Set the correct number of movers in the motion group and set your course update. For guidance on what to set the course update rate to, see Position Loop Update Period on page 3. Expand I/O Configuration, right click the DFE line, and select properties. Rockwell Automation Publication 2198T-TG001A-EN-P - October 2020...
  • Page 35 6. On the Power tab, verify that the following parameters are set: • Primary Bus Sharing Group is set to Group 1. • Bus Regulator Action is set to Disabled. Rockwell Automation Publication 2198T-TG001A-EN-P - October 2020...
  • Page 36 8. In the Advanced User Limits dialog box, verify that Demonstration Mode is set to Inactive. 9. On the Digital Input tab, verify that Digital Input 1 and Digital Input2 are both set to Unassigned, and click Apply. Rockwell Automation Publication 2198T-TG001A-EN-P - October 2020...
  • Page 37 Depending on the number of movers on your system, inhibit those modules not being used. For guidance on what to set the RPI to, see the section entitled Loop Update Rates on page 11. In the controller tags, find iTRAK_Control.Data Rockwell Automation Publication 2198T-TG001A-EN-P - October 2020...
  • Page 38 13. Set the number of zones to 1 and enter the value 0 in the [0] array for each of the following tags: a. Zone Start Position [0] b. Zone Begin Report Offset [0] c. Zone Begin Command Offset [0] d. Zone Begin Hold Offset [0] Rockwell Automation Publication 2198T-TG001A-EN-P - October 2020...

  • Page 39: Configuring With Libraries

    Configuring Template Code on page 34, for steps on how to configure the CUR, RPI, and DFE. These steps are the same whether working with template code or libraries. Rockwell Automation Publication 2198T-TG001A-EN-P - October 2020...
  • Page 40 4. Find the iTRAK_StartupSequence. 5. In rung 2, there is a Configure iTRAK command. Set the number of movers on your system and type the number of motor sections. 6. Download your code to the PLC. Rockwell Automation Publication 2198T-TG001A-EN-P - October 2020...

  • Page 41: Intermittent Low Voltage Errors

    USB IO outputs are connected per the schematic. OUT0/NC Not connected OUT0/NO PCM 61AG27:P15, Logic Return in PCM PCM 61AG27:P12 (COM), PCM 61GB28:P12 (COM), Common rail OUT1/COM PCM 61AG27:P12 (COM), PCM 61GB28:P12 (COM), Common rail Rockwell Automation Publication 2198T-TG001A-EN-P - October 2020...

  • Page 42: Mover Oscillations, Missing Movers, Error 12

    Switch? Managed? Rails? Libraries? 50W x 100L Gen 3 Libraries V3.002.231 Track Logix Other Other Comments/Configuration Orientation Vertical — Multi-gateway, multi-track system. Troubleshooting the Problem Completed the following steps to troubleshoot the problem: Rockwell Automation Publication 2198T-TG001A-EN-P - October 2020...

  • Page 43: Rough And Choppy Mover Motion In Straights And Curves

    With all three firmware revisions, no change was seen. 4. Loop Update rates With each version of firmware, the position loop update rate (PLUP), RPI and CUR were adjusted. Regardless of the rates, there was no improvement. Rockwell Automation Publication 2198T-TG001A-EN-P - October 2020...
  • Page 44 This test was to confirm that there was no power issue or undersized the power supplies causing erratic motion. 12. Completed an additional set of tests by using a visual of the track to understand the testing. Rockwell Automation Publication 2198T-TG001A-EN-P - October 2020...
  • Page 45 15. Connected straight sections 24…26 to the Gen 2 gateway and had 1 mover jog back and forth at 600 mm (23.62 in.)/s. Sections 24 and 25 behaved poorly with rough motion with servo oscillation. Section 26 performed as expected Rockwell Automation Publication 2198T-TG001A-EN-P - October 2020...

  • Page 46: Intermittent Error Code 9

    IPS or Stratix Switch TriMax Size Mover Code or Movers Sections Version Version PCM? Switch? Managed? Rails? Libraries? 100x50 Gen 2 Template V1.111 Track Logix Other Other Comments/Configuration Orientation Vertical — Multi-gateway, multi-track system. Rockwell Automation Publication 2198T-TG001A-EN-P - October 2020...

  • Page 47: Error Code 28 After Power Cycle

    This is due to the Stratix switch booting up much slower than the PLC and gateway. 2. The gateway requests a power supply configuration once and if it does not receive it generates an error code 28. Rockwell Automation Publication 2198T-TG001A-EN-P - October 2020...
  • Page 48 The solution to error code 28 is to have the proper topology for ethernet communications. The iPS and gateway need to be talking to each other past the switch. Alternatively, firmware 1.112 eliminates error code 28 with the POST on demand feature. Rockwell Automation Publication 2198T-TG001A-EN-P - October 2020...

  • Page 49: Index

    Straights and Curves 43 Error Code 28 after Power Cycle 47 Mechanical iTRAK system component 8 Mnt folder 29 Firmware Monitor Check revision 17 Connect to gateway 15 Download 5 Monitor problem Correct 23 Rockwell Automation Publication 2198T-TG001A-EN-P - October 2020...
  • Page 50 Log file 25 RIP 32 Rough and Choppy Mover, Motion in Straights and Curves 43 Rtai-extra folder 26 Section type Check 17 Src folder 26 Template code Configure 34 Guidelines 5 Usr folder 26 Rockwell Automation Publication 2198T-TG001A-EN-P - October 2020...
  • Page 51 System Troubleshooting Guide Rockwell Automation Publication 2198T-TG001A-EN-P - October 2020...
  • Page 52 At the end of life, this equipment should be collected separately from any unsorted municipal waste. Rockwell Automation maintains current product environmental compliance information on its website at rok.auto/pec. Allen-Bradley, ControlLogix, expanding human possibility, iTRAK, Kinetix, Rockwell Automation, and Stratix are trademarks of Rockwell Automation, Inc. EtherNet/IP is a trademark of ODVA, Inc.

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