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iTRAK System User Manual

1. Nm ti o CB04 PSI 2 v LI zi gelele EMI H E H R Mean Vell 6 in i nel POWER vcl amp I2 Ell Hp i S 1 S S l e Z H se ele Ss es 2 z a a Er s Sim P E glide Slala 1 3 83 a Iu w E o lr es CB05 CBOSA CBR CB07 CBOB CB09 CBIO CBII CBI2 C813 CBI4 CBI5 RIA RIB RIC l L RIA ROB ROC R2D TB06 1B07 B elfele elelelelele e e Ero Pe oo for Jo m SS H EH f mu AMU ARA AAR EN AEU ANNEN AN i H E R fel a E a SIERPI S egsjesesi E o lo io oco x Ge Exec 9 e 9 d 9 e e e FAC MOM E c lt x E S z Nn e T S sii c e 5 e CBO2 CBOS C C2 zii gt B l Ser Sls ns e e eiele e Ld PSO1 PS02 SSCS ETS R7 R8 sigisis H MSS ajojo o HI HI ul Pi EL OH elalsjeajisisia ig LE SIS SIS a gg y Y E E B feta d l wd ad S ye va a gt 2 g a e e g SI ca a miS pm SR01 oelS z 2 2 2 S o S 1515 a D w o S lel le ie gt S a 2 N BROI BRO2 Sla a 0 Risk of electrical a s ea e d shock gs g Pa High voltage may exist up to 5 minutes v after removing power E z e S o E Slolnin ra co wow 1808 SS El oj O Sa oj O N TBO TBO2 TBO3 TB04 e o tee ke je i i Ojojoo opel G G aie owe RS E 48
2. Mover A B C D SOW x 0501 20506 mun ora 17400 03 RE 100W x 050L 279 5 11 0 150 5 9 75 3 0 2144 8 4 150W x 050L 329 5 13 0 180 7 1 90 3 5 2644 10 4 i Ref dimensions are approximate 160 2 6 3 REF i j Track shown i for reference 50 Length T _ Magnet L 02 REF M 38 73 2 7 1 5 soe I el Minimum pitch straight track 2X 05 H7 Thru All q i 4X M5X0 8 333 Thru All 1 31 RE ce i i i T T C i le D j Track REF 257 1 01 14 50 40 N Lo q N Fap Minimum pitch curved track Rockwell Automation Publication 2198T UM001A EN P March 2015 Appendix A Specifications and Dimensions Figure 30 100 Length Mover Dimensions w 3 ZT 1t T 3 eane 50W x 100L 248 5 9 8 120 47 60 24 177 401 1008 x 100 2855012 15059 560 2144 84 2350 03 REF Ref dimensions are approximate 62 150W x 100L 335 5 13 2 180 7 1 90 3 5 264 4 10 4 1602 63 REF Track shown for reference 100 Length Magnet 43 Minimum pitch straight track 393 15 REF 2X OSH q Thru AIl AX MS X08 Thru All k L 9600 pod i q Tak REF 25 7 10 80 80 1 0 4 1 6 247 Minimum pitc
3. Tag Conversion Constant 1000 0 Feedback Counts 1 0 mm Feedback Counts Unwind 7 Type 1000 in Conversion Constant field This sets an effective command resolution of 1 wm 8 Type the value for Position Unwind The Position Unwind is the track length in microns 9 Repeat steps 5 and 8 for all axes in the Motion Groups Other non iTRAK system axes can be added to this Motion Group such as the master axis used for camming The sample starter project is configured in this way Ethernet Communication Each generic Ethernet module connection type can accommodate up to 16 movers Do the following steps to configure the number of Ethernet modules that are required for your system 1 From the Controller Organizer expand I O configuration then expand Ethernet VO Configuration 5 8 1756 Backplane 1756 A17 ffa 0 1756 L75 TRAK ci 3 1756 EN3TR Enet Ges Ethernet fj 1756 EN3TR Enet 4 ETHERNET MODULE Gateway_Movers80to95 fi ETHERNET MODULE Gateway_Movers64to79 fi ETHERNET MODULE Gateway_Movers48to63 fi ETHERNET MODULE Gateway_Movers32to47 ff ETHERNET MODULE Gateway Moversl to31 8 ETHERNET MODULE Gateway _Movers0tol5 2 Double click ETHERNET MODULE Gateway MoversOtol5 30 Rockwell Automation Publication 2198T UM001A EN P March 2015 Commission Chapter 4 3 Type Connection Parameters as follows
4. 30 GainsAllVelocityBandwidth This gain is a multiple of the velocity error The normal values are 5 15 3 20 GainsCurvesPositionDerivative This gain is a constant multiple of the position error The normal value is 5 0 8 GainsCurvesPositionBandwidth This gain is a constant gain multiple of the position error The normal values are 50 275 75 125 GainsCurvesVelocityIntegratorBandwidth This gain is a percentage of the velocity error twice the Velocity Bandwidth The normal 3 40 values are 10 30 GainsCurvesVelocityBandwidth This gain as a multiple of the velocity error The normal values are 5 15 3 20 GainsCurvesGravityKg For vertical tracks specify the weight of the mover the tooling and the payload here If the zero position of the track is on the bottom this value can be negative If the zero position of the track is on the top this value can be positive On a flat or horizontal track enter zero for this value This value is used to offset the effect of gravity GainsSectionPositionBandwidth This gain is constant gain multiple of the position error The normal values are 75 125 GainsSectionVelocityIntegratorBandwidth This gain is a percentage ofthe velocity error usually twice the Velocity Bandwidth The normal values are 10 30 GainsSectionVelocityBandwidth This gain as a multiple ofthe velocity error The normal values are 5 15 Table 20 iTRAK Control Status
5. Name Assembly Instance Size IP Address Input Output Configuration Input Output Configuration Gateway_Movers0to15 769 770 771 44 44 0 192 168 1 249 Gateway_Movers16to31 779 780 781 44 44 0 192 168 1 248 Gateway_Movers32to47 789 790 791 44 44 0 192 168 1 247 Gateway Movers48to63 799 800 801 44 44 0 192 168 1 246 Gateway Movers64to79 809 810 811 44 44 0 192 168 1 245 Gateway Movers80to95 819 820 821 44 44 0 192 168 1 244 E Module Properties Report Enet ETHERNET MODULE 1 1 Ea General Connection Mode ii Type ETHERNET MODULE Generic Ethernet Module Vendor Allen Bradley Parent Enet s Name Gateway Movers toT5 Connection Parameters Assembly Description Instance Size Input 769 44 32 bit Output 770 44 32 bit Comm Format Data DINT TZ 0 Rb Address Host Name IP Address 192 168 1 249 Host Name Status Offline Cancel Apply Help 5 6 From the Comm Format pull down menu select Data DINT Click the Connection tab From the Requested Packet Interval RPI pull down menu select interval that is the same time as you are using for the coarse update rate for the iTRAK axes in the motion group i Module Properties Report Enet ETHERNET MODULE 1 1 General Connection Module Info Requested Packet Interval RPI 4 0 ms 1 0 3200 0 ms F Inhibit Module Major Fault On Controller If Connection Fails While in Run Mode Use Unicast Co
6. 11 PCM to Gateway power and communication 12 Motor module power bus number of cables vary by system 13 External monitoring reset guard stop E stop connections 14 Mains power 460V nominal 15 Track frame 8 Rockwell Automation Publication 2198T UM001A EN P March 2015 Start Chapter 1 Power Control Module Figure 2 shows a typical power control module PCM Your system can differ in Description Figure 2 Power Control Module 2 BET F Table 3 PCM Component Description Item 1 Description Emergency stop switch Status indicators x5 Power cable in BI wj N Main power switch un Exhaust vent Power bus connectors quantity is system dependent External emergency stop switch connector External guard switch connector External reset switch connector External monitoring connector PCM to Gateway communication connector Intake vent not shown Rockwell Automation Publication 2198T UM001A EN P March 2015 the layout and the number of connectors but has the same components Chapter1 Start Figure 3 PCM Status Indicators iTRAK E POWER S l Table 4 PCM Status Indicator Description Status Indicator Description RESET This blue status indicator is off when bus power is unavailable or when the E stop button is pressed or Shutdown routine is performed After an E stop condition reset the E stop b
7. 3 Shoulder socket head cap screws x4 4 Socket head cap screws x4 3 Remove motor module shim 4 Slide motor module from frame and disconnect the communication and motor power bus cables 5 Clean all screws and apply Loctite 243 6 Install new module by reversing these steps 7 Torque shoulder bolt screws to 13 Nem 9 6 Ibeft and torque M8 socket head cap screws to 22 Nem 16 2 lbeft Rockwell Automation Publication 2198T UM001A EN P March 2015 43 Chapter5 Maintenance Replace Mover Lubricators Before You Begin AN ATTENTION Lockout and tagout input power before servicing ATTENTION The mover uses strong magnets The magnetic field that is N generated can disrupt the functionality of automatic implantable cardioverter defibrillators AICD People with cardiac pacemakers must not work near the iTRAK system The strong magnets of the 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 Maintenance personnel must avoid the use of metallic tools and secure items such as badge dips other personnel effect that could be attracted to the strong magnetic field Strong magnets can erase magnetic media Never let credit cards or electronic media contact or come near the mover or iTRAK system What You Need e 2 5 mm Allen key e Loctite 243 s A set of replacement lubricators Lubricators are
8. ControlLogix TimeSynchronization or CIP Sync The controller also participates in the election in the Logix5000 system for the best Grandmaster clock Rockwell Automation Publication 2198T UM001A EN P March 2015 27 Chapter 4 28 Commission Click OK File l Redundancy 1 Nenvolatie Memory Memory Security General Naer Faults _ Minor Faults Date Time Advanced D The Date and Time displayed here is Controller local time not workstation local time Use these fields to configure Time attributes of the Controller IMPORTANT Set Date Time and Zone from Workstation Date and Time d Time Time Zone e Adjust for Daylight Saving 00 00 Time Synchronize DANGER ff time synchronization is V Enable Time Synchronization disabled online active axes in any controller in this chassis or any other C synchronized device may experience a isthe ayatam time master unexpected motion Safety controllers may Q ls a synchronized time slave fault f no other time master exists in the Duplicate CST master detected peni caia CST Mastership disabled No CST master Co Les Het Motion Group The movers are virtual axes in the Logix Designer application software It is important that the number of axes in the Motion Group Axes match the number of axes set in TRAK_Control Data ActiveMovers tag in the Controllers Tags from the Ungrouped
9. 22 guard 21 22 monitor 21 22 reset 21 22 71 power control module 10 kVA horizontal dimensions 57 vertical dimensions 57 7 5 kVA dimensions 57 circuit breaker 10 kVA type 2 48 description 9 installation 19 weight 56 programming Ethernet communication 30 general 27 main task 35 motion event 32 motion group 32 reguirements enviroment 55 reset bus 10 circuit schematic 21 pinout 21 22 S safety automated machinery 26 70 handling 17 heat 70 high voltage 70 machine guarding 17 pacemaker 13 16 26 strong magnets 16 26 schematic e stop circuit 22 guard circuit 22 monitor circuit 23 reset circuit 21 step down transformer dimensions 57 T tags contoller 34 track installation 18 weight 56 trending 36 V virtual axes 28 Rockwell Automation Publication 2198T UM001A EN P March 2015 W warning automatic implantable cardioverter defibrillator AICD 70 powerful forces 70 Index Notes Rockwell Automation Publication 2198T UM001A EN P March 2015 73 Rockwell Automation Support Rockwell Automation provides technical information on the Web to assist you in using its products At http www rockwellautomation com support you can find technical and application notes sample code and links to software service packs You can also visit our Support Center at https rockwellautomation custhelp com for software updates support chats and forums technical information FAQs and to sign up fo
10. 24V TB05 1 0 USB 16 24V Common TBO5C 1 0 USB Rockwell Automation Publication 2198T UM001A EN P March 2015 23 Chapter3 Connector Data Figure 15 Power Bus Connector Pinout IPxx Pin Signal A 320V DC B 160V DC L 0V DC D E 2A F 24V Common GND PE 24 Rockwell Automation Publication 2198T UM001A EN P March 2015 Introduction Before You Begin Chapter 4 Commission Topic Page Introduction 25 Configuration 27 Understanding the iTRAK Sample Starter Project 32 Your iTRAK system Logix Designer application software includes a sample starter project that is called TRAK Start xxxxx for controller integration This sample project was developed using the Studio 5000 environment Logix Designer application version 21 The iTRAK system is compatible with Allen Bradley controllers with built in Ethernet or an Ethernet card that supports time synchronization or Integrated Motion on the EtherNet IP network such as Bulletin numbers EN2T EN2TR EN3TR The controller implementation was designed for easy use by a Logix Designer application programmer Each mover operates as one virtual axis within the system One track loop is one revolution of a rotary axis and the coordinate system is mapped to millimeters The mapping lets you use Logix Designer motion moves jog or stop commands which normally control a rotary axis to control the movers ATTENTION Be
11. Label Placement Safety Labels The following safety identification labels are affixed to the TRAK system To prevent injury and damage to the system review the safety labels their details and locations before using the system Figure 32 Safety Label Placement Table 21 System Components with Safety Labels Item Component Name 1 Straight Motor Module 2 Curved Motor Module left and right modules are labeled the same 3 Mover 4 Power Control Module Rockwell Automation Publication 2198T UM001A EN P March 2015 69 AppendixC Label Placement Table 22 Safety Labels Title s Label Details 3 Hazardous Voltage A Do not open motor module covers or right angle connectors while the cables are connected Lock out tag out if access to the motor module is required during maintenance while the connectors are installed HAZARDOUS VOLTAGE Disconnect power before opening The mover uses strong magnets 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 The strong magnets of the 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 Maintenance personnel must avoid the use of metallic
12. MainTask Normally the headway checks are done in the Gateway to save processor time The headway error is the difference between two axes command positions You can do the same check within the controller by going to routine RO2_Headway Task Properties and setting Priority to 1 The check executes in this routine Logging can be added to help debug the end user program Doing the check in the controller requires a much higher coarse update rate otherwise overlaps occur This routine also checks for overlaps Rockwell Automation Publication 2198T UM001A EN P March 2015 Commission Chapter 4 Figure 17 HighSpeedTask Task Properties General Configuration Program Phase Schedule Monitor Type Event Trigger l Motion Group Execution M Tag Axes X E Execute Task If No Event Occurs Within 6 000 ms Priority 1 Lower Number Yields Higher Priority Watchdog 500 000 ms V Disable Automatic Output Processing To Reduce Task Overhead Inhibit Task Controller Organizer IX amp x Controller TRAK Controller Tags Controller Fault Handler Power Up Handler DATA EXCHANGE WITH TRAK GATEWAY Process Movers in groups or 16 This enables small Ethernet packets which improves reliablity J Tasks iTrack Read Act Pos odi Send Pos Cmd aes HighSpeedTask Status Error E eg P0
13. MainTask is where most of the motion programming occurs The sample project contains routines under the MainTask task that are required to manage certain aspects of the TR AK system The following is a description of each routine and the routine function Figure 20 Main Routine 2X a amp Controller TRAK Controller Tags amp Tasks Y HighSpeedTask Bg e MainTask Ib CX B R03 Start B R04 Stop 5 Motion Groups 0 54 Axes Ungrouped Axes 0 9 Add On Instructions fe iTRAK IO amp LINTSUB 5 6 Data Types c Ej User Defined Y R Strings Y R Add On Defined Y R Predefined Controller Fault Handler E Power Up Handler B ca P01 MainProgram A Program Tags B R01 PowerUP B R02 Monitor B R05 Parametertxchang Unscheduled Programs Phase s Soa 0 lt ab gt FIRST SCAN SPS MOV TOF Timer Off Delay Timer PowerUP Timer Preset 2000 2001 Source 2000 m Dest PowerUP_Timer PRE Accum 2000 POWER UP Executes only on First Scan Temporary End TND prevents all other routines from executing PowerUP_Timer DN JSR JE Jump To Subroutine Routine Name R01 PowerUP lt TND gt JSR Jump To Subroutine Routine Name R02_Monitor iTRAK START JSR m Jump To Subroutine Routine Name R03 Start Table 9 Routine Description Routine ROO Main R01 PowerUP Description This routine is the jump point t
14. only when the installation complies with the national regulations safety specifications and standards of the application Only operate if the national Electromagnetic Compatibility EMC regulations for the application are met Rockwell Automation Publication 2198T UM001A EN P March 2015 15 Chapter2 Installation e In accordance with EMC requirements the machine or installation manufacturer is responsible for compliance with the limit values as prescribed in the national regulations Protection Against Magnetic and Electromagnetic Fields During Mounting See Safety Label Placement on page 69 for location of Strong Magnets label The motor modules when in use and permanent motors magnets pose a danger to persons with heart pacemakers metal implants and hearing aids metal implants and hearing aids while in proximity of magnetic and magnetic ATTENTION There is a risk of health hazard for persons with heart pacemakers field producing components The movers have strong magnets The track creates strong magnetic fields while energized during operation Persons with heart pacemakers metal implants or hearing aids must not enter the following areas Where components of the drive and control systems are mounted commissioned and operated Where parts of motors with permanent magnets are stored repaired or mounted Avoid Accidents Injury and Property Damage Mount emergency stop switches in the imme
15. removed A application mounting 61 62 63 automaticimplantable cardioverter defibrillator AICD 70 bearing installation 45 bus reset 10 C cable installation 20 circuit breaker 10 kVA power control module type 2 48 coarse update 32 component description curved motor module 8 11 gateway 7 8 mover 8 13 power control module 7 8 9 straight motor module 7 8 11 configuration Ethernet connection 27 motion group 28 contoller tags 34 D dimensions gateway 24x24 58 motor module straight 59 mover 61 62 63 power control module 10 kVA horizontal 57 10 kVA vertical 57 7 5 KVA 57 step down transformer 57 error codes 49 e stop circuit schematic 22 pinout 21 22 Ethernet communication setup 30 Rockwell Automation Publication 2198T UM001A EN P March 2015 Index G gateway 24 x 24 dimensions 58 installation 20 weights 56 guard circuit schematic 22 pinout 21 22 instructions installation 15 bearings 45 cables 20 gateway 20 lubricators 44 motor module 41 mover 38 planning 15 power control module 19 track 18 labels automated machinery 26 70 high voltage 70 hot surface 70 Strong magnets 16 26 M monitor circuit schematic 23 pinout 21 22 motor module curved motor module dimensions 59 curved section weight 55 replacement 41 straight section dimensions 60 weight 55 mounting 17 mover description 13 dimensions 61 62 63 installation 38 P pinout e stop 21
16. the cube modules Connect the PCM to mains power line Use minimum of 10 mm 8 AWG copper for the ground wire Connect your personal computer and your Allen Bradley controller to the Gateway 20 Rockwell Automation Publication 2198T UM001A EN P March 2015 PCM Connectors Chapter 3 Connector Data Topic Page PCM Connectors 21 The PCM has external connections to the E stop guard reset switches and monitoring capabilities This section shows the wiring information that you can use to add more safety switches and monitoring capability The PCM connectors for external E stop switch P5 guard switch P4 reset switch P3 and monitor P2 use the connectors that are supplied with the system Figure 7 shows the pinouts for the reset connector Figure 7 Reset Connector Pinout P3 Figure 8 shows the schematic for the reset circuit Figure 8 Reset Switch Circuit Schematic Reset 1 l Rockwell Automation Publication 2198T UM001A EN P March 2015 21 Chapter3 Connector Data Figure 9 shows the pinout for the E stop and guard connectors Figure 9 E Stop and Guard Connector Pinout P4 and P5 Figure 10 shows the schematic for the E stop circuit Figure 10 E Stop Switch Circuit Schematic P5 E s02 A ey C D E F E STOP AY B cY BT EY FY t t l T Customer d d l E amp F Dry NC meaa UN S Contact OJ TN ION I L_4J Lid Figure 11 shows th
17. 1 iTRAK Communications iTRAK IO A Program Tags 2 iTrack Read Act Pos Send Pos Cmd Status Error L BN R00 iTRAK 10 iTRAK IO TRAK IO AOI 0 EJ 3 T t TRAK Control iTRAK Control Base Mover Num 0 B fa MainTask Y R POL MainProgram Axis_A Mover_00 EJ Unscheduled Programs Phases aoe Mur 6 6 Motion Groups Axis D Mover 03 g Axes Axis_E Mover 04 H E Ungrouped Axes i 95 L All settings that control the TR AK system are specified in the iTRAK Control Data tag which is automatically imported with the iTRAK IO Add On Instruction These settings include important configuration data sent to the Gateway such as the track length the number of movers coarse update rate and parameter in out buffers Status information is in the TR AK Control Status tag such as the actual positions and position errors of the movers More status data can be configured via the TraceData tag including torque and velocity Rockwell Automation Publication 2198T UM001A EN P March 2015 33 Chapter4 Commission Figure 19 Controller Tags Scope ffqiTRAK Show All Tags Nam Rl Value T Force Mask Cl Style 4800000 4800000 7 H TTT i n i 3 H in F inp m E E s m S i i a 3 imi E S S E S a a im E a m s El Eg Ej S 3 a El m m 34 Rockwell Automation Publication 2198T UM001A EN P March 2015 Main Task Commission Chapter 4 The
18. Axes into your motion group 1 From the Motion Group category drag the number of axes that are needed In this Figure 10 axes were moved to the Motion Group Axes amp 3 Motion Group Sg Axes m J Ungrouped Axes X Mover 10 Rockwell Automation Publication 2198T UM001A EN P March 2015 Commission Chapter 4 2 Double click Axes Groups X9 Axis Master i X Mover 00 X Mover 01 Xi Mover 02 X Mover 03 RD Mover 04 X Mover 05 gt Mover 06 AQ Mover 07 X Mover 08 I gt Maver 09 The Motion Group Properties Axes dialog box is displayed 3 Click the Attribute tab Axis Assignment Attribute Tag Coarse Update Period 12 0 E ms in 0 5 increments hao Tog nte General Fault Type Non Major Faut v Scan Times elapsed time Max us Reset Max Last us From the Coarse Update Period selector choose a coarse update rate for the motion group The sample application uses a 12 ms Coarse Update Period but your application can have much higher rates The maximum estimated time of the Coarse Update Period is 24 ms because of reduced control capability 5 Double click Mover 00 J Motion Groups eg Axes m Axis Master gt TE gt Mover 01 m Mover 02 L S Mover 03 E i ip Mover_04 X Mover 05 Rockwell Automation Publication 2198T UM001A EN P March 2015 29 Chapter4 Commission 6 Click the Conversion tab
19. D Some components of the system have hot surfaces See Safety Label Placement on page 69 for location of Hot Surface label e Do not touch hot surfaces such as brake resistors heat sinks power supply units drive controllers motors windings and laminated cores e Temperatures of the track motor stator covers can be higher than 60 C 140 F during or after operation e After powering down the motor modules let them cool before touching Motor modules can require 140 minutes to cool e After powering down switching chokes power supply units and drive controllers let them cool for 15 minutes before touching Rockwell Automation Publication 2198T UM001A EN P March 2015 37 Chapter5 Maintenance Add or Replace Com pon ents The following procedures show you how to install or replace system components Install or Remove a Mover Follow this procedure to install or remove a mover Before You Begin ATTENTION Lockout and tagout input power before servicing generated can disrupt the functionality of automatic implantable cardioverter defibrillators AICD People with cardiac pacemakers must not work near the iTRAK system The strong magnets of the 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 ATTENTION The mover uses strong magnets The magnetic field that is Maintenance personne
20. Rockwell Automation Publication 2198T UM001A EN P March 2015 Location is dependent on the presence of a panel disconnect interlock 1 Errors Chapter 6 Troubleshooting Errors Use the system reported errors in this section to diagnose iTRAK system problems The TR AK system can generate errors from the Gateway or from the motor 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 Error codes from the motor module are displayed in iTRAK_Control Status tag The codes are created from the following tags Table 11 Error Code Tags Tag Description iTRAK_Control Status GatewayFaultCode his tag contains the error codes from the Gateway In Table 12 it is referred to as the Gateway Code iTRAK_Control Status SectionFaultCode his tag contains the error codes from the motor module In Table 12 it is referred to as the Device Code iTRAK Control Status FaultMessageLine1 his tag contains the first line of displayed text in the error code description iTRAK_Control Status FaultMessageLine2 his tag contains the second line of displayed text in the error code description iTRAK_Control Status SectionNumberFaulted This tag indicates the motor module that failed iTRAK_Control Status SectionDeviceFaulted This tag indicates if a motor module error is power related or position related 0 pos
21. Start Chapter 1 Motor Module Description Your system has two types of motor modules Figure 4 shows the features of the straight and curved motor module Figure 4 Straight and Curved Motor Modules Table 5 Motor Module Component Description Item Description 1 Straight motor module 2 Curved motor module 3 Position sensing surface similar on curved motor module not shown 4 Motor module status indicator similar on curved motor module not shown 5 Vent 6 Communication connector 7 Incoming bus connector 8 Outgoing bus connector 9 Drive and position sensor housing 10 Motor coil assembly Rockwell Automation Publication 2198T UM001A EN P March 2015 11 Chapter1 Start Figure 5 Motor Module Status Indicators A BC A BC Straight Motor Module Curved Motor Module Table 6 Motor Module Status Indicator Description Item Status A 24V present B Blinking green Module communicating L Orange Voltage greater than 48V present 12 Rockwell Automation Publication 2198T UM001A EN P March 2015 Mover Description Start Chapter 1 Figure 6 Mover Shown here is a one style of 50W x 100L mover Your mover may look slightly different Table 7 Mover Component Description Item Description 1 Lower bearing rail lubricator 2 Bearing x6 3 Magnet assembly 4 Bumper x3 5 Upper outer bearing rail lubricato
22. Tags Tag Name Description CoarseUpdatePeriod Motion Group coarse update period in us Set to the same as in the Motion Group properties dialog GatewayFaultCode Gateway fault code SectionNumberFaulted Motor module that has a fault SectionFaultCode Motor module fault code SectionDeviceFaulted Motor module fault pointer Values are 0 position related 1 power related SectionFaultData Motor module additional fault data FaultMessageLine1 Fault message line 1 FaultMessageLine2 Fault message line 2 if necessary CSTTimeActualPositionRecorded This tag is a CST time that the Actual Position data was captured in the groups of 16 movers Use this time to synchronize with other EtherNet IP time based devices ActualPosition This tag is the Actual Position that was last reported to the Add On Instruction in the Ethernet buffer PositionError TraceData Difference between Command Position and Actual Position Trace data data is not synchronized GatewayRunning Gateway running and communicating Rockwell Automation Publication 2198T UM001A EN P March 2015 67 AppendixB Tags Table 20 iTRAK_Control Status Tags Tag Name Description Faulted Track has a fault ReadyForMotion Track is ready for motion commands DCBusContactor Command status of DC bus contactor 68 Rockwell Automation Publication 2198T UM001A EN P March 2015 Safety Labels Appendix C
23. User Manual ITRAK System Bulletin Number 2198T Allen Bradley Rockwell Software Automation Important User Information Read this document and the documents listed in the additional resources section about installation configuration and operation of this equipment before you install configure operate or maintain this product Users are required to familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes laws and standards Activities including installation adjustments putting into service use assembly disassembly and maintenance are required to be carried out by suitably trained personnel in accordance with applicable code of practice 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 The examples and diagrams in this manual are included solely for illustrative purposes Because of the many variables and requirements associated with any particular installation Rockwell Automation Inc cannot assume responsibility or liability for actual use based on the examples and diagrams No patent liability is assumed by Rockwell Automation Inc with respect to use of information circuits equipment or software described in thi
24. a UE Ge ctotua deat apa 18 Install Power Control Module cc cece e eee c cence 19 Install Gateway a bed nodes Eu m o re do erbe vous T ER Reus 20 Cohnscbtables sinas assu nus ea Lin mde M AS S V EC 20 Chapter 3 PCM Gonfiectors i cus era Soe hee eS hw ge den d LORS 21 Chapter 4 Introduction nera ee ez s a UE te testetlen kel 25 Before You Begin y ror R EEE AET S RENE E NEUNA bas E EE 25 Protection Against Magnetic and Electromagnetic Fields During Operation uer unb ceme eeo mede 26 Gonfig raon seo mirus beket uiris detto ence Re ei estia iei 27 Genepilo dist temen Ld cud ILE aS LR Under 27 Motion Popup Pret tuor tastes a RE pt ex a UE D Salire 28 Ethernet Communication aad st eos voe se okt ek oie ll ot 30 Understanding the TR AK Sample Starter Project ss 32 TRAK Motion Task sos un a ToS ER Du acu GR ES RU TNR Pa 32 Rockwell Automation Publication 2198T UM001A EN P March 2015 3 Table of Contents Maintenance Troubleshooting Specifications and Dimensions Tags Label Placement Index Main Task es rinde bene ezzel ERG 35 RED Ac 36 Chapter 5 Before You Begin iss eee UH ERE REV Asses 37 Protection Against Contact with Hot Parts 37 Add or Replace Components ird Ret oor eeu E 38 Install or Remove a Movers 38 Replace a Motor Module 41 Replace Mover Lubricators eecos oenenc Modan dI ete sss 44 Replace Mover Bearings cite c mr vue du eei cee etd vid 45 Lubtcat
25. ation we recommend that you design and supply an oil bleed system The bearing rails come equipped with fittings for you to attach 4 0 mm O D x 2 5 mm I D tubing Figure 22 shows the location of features that are provided for you to install your oil bleed lubrication system Figure 22 Top Track Oil Bleed Fittings and Access Table 10 Oil Weep System Features Kem Description Item Description 2 Access to bleed fitting 5 Top frame 3 Bearing rail 6 Bottom frame 46 Rockwell Automation Publication 2198T UM001A EN P March 2015 Maintenance Chapter 5 Circuit Brea kers Use Figure 24 to locate circuit breakers in the PCM Before accessing the PCM read the following A BURN HAZARD Some components of the system have hot surfaces e Do not touch hot surfaces such as brake resistors heat sinks power supply units drive controllers s After powering down switching chokes power supply units and drive controllers let them cool for 15 minutes before touching SHOCK HAZARD Before accessing electrical components with voltage A potentials higher than 50V disconnect them from the mains or power supply Wait 5 minutes after switching off power to let capacitors discharge See High Voltage capacitors on page 70 Measure the voltage before working on components to make sure that they are safe to touch e Do not connect disconnect or touch e
26. ble servo Power up the track and hold mover position ServoOff Disable servo Power down the track and remove mover control This tag is not a controlled stop If controlled stop is desired use motion group stop instructions ReportPositionOutsideZone This tag is used for hybrid tracks It tells the Gateway to report back to the Virtual Axis position if it is outside a zone It lets you track positioning all round the track by gearing movers to other axes in simple areas of the track FeedbackUpdateOff This tag tells the Add On Instruction to report only the Actual Position to the Control Tags By not updating other feedback tags the Add On Instruction scan time is greatly reduced FaultReset Reset active fault RunMoverRegistration Run mover registration Future TraceSelect Select trace data iTRAK Stop Initiate shutdown tasks and disable track TRAK Start Start initialization tasks and enable track ResetGateway Initiate a Gateway reset and the power on self test It can take several minutes for the Gateway to reset RenumberMovers Initiate a renumbering of the track movers Perform after homing if you need to start with a particular mover number if there are odd and even movers or if multiple zones exist and they cleared all simple areas except the first movers Only the first simple area after the first smart zone can have movers on it at startup FlashSections5Omm Update track motor mo
27. bles with a ground conductor must be permanently connected to all electric components in accordance with the connection diagram Do not use residual current operated circuit breakers for drives Install Gateway IMPORTANT The gateway cabinet weighs approximately 27 kg 60 Ib Be sure to use atwo man lift when installing the gateway cabinet Mount the gateway cabinet to a solid vibration free surface Secure by using all four mounting hole in the enclosure See Dimensions on page 57 Connect Cables Your system comes with the power bus and communication cabling that is already connected to the motor modules You make the final connections to the PCM and Gateway by using the system diagram that was delivered with your system 1 Route power bus cables to the PCM Use best practices to help protect cables from stress and damage during use of the system Connect power bus cables to the PCM Power bus cables are labeled with the PCM connector identifier on the end of each cable next to the Speed Tec connector Cap unterminated output power bus connectors Route communication cables to the gateway Use best practices to help protect cables from stress and damage during use of the system Connect the communication cables to the gateway The communication cables are labeled with the gateway connector identifier on the end of each cable next to the RJ45 connector Secure the communication cables to the cable gland by using
28. ckets exceeds maximum size 100 then there were ten communication errors in a row 109 112 then replace motor module Check the communication cable and reset the system ERR POS RANGE Position Sensor error Indicates electrical fault Extra Data indicates which sensor Call FOR service This error indicates a failed position sensor The iTRAK_Control Status SectionNumberFaulted tag contains the motor module that is reporting this fault The iTRAK_Control Status SectionFaultData tag is the number of the sensor whose analog to digital converter is out of range Replace the failed motor module ERR_CUR_RANGE Current Sensor error Indicates electrical fault This error indicates a failed current sensor The iTRAK_Control Status SectionNumberFaulted tag contains the motor module that is reporting this fault The iTRAK_Control Status SectionFaultData tag contains the failed sensor IfiTRAK_Control Status SectionFaultData lt 20 then iTRAK_Control Status SectionFaultData is the number of the coil that has a failed sensor IfiTRAK_Control Status SectionFaultData gt 20 then iTRAK Control Status SectionFaultData 20 is the number of the coil that has a failed sensor Replace the failed motor module ERR PCB TEMP Drive overtemperature fault Check mover bearings venting reduce motion profile demands IF problem persists call FOR service This error indicates that the electrical boards are warm This error i
29. data return code ParameterSizeReturn Parameter data return size ParameterDataReturn Parameter data return MoverOffset Mover offset of magnet sensor relative to motor magnet stack HeadwayTolerance Mover to mover tolerance in mm If movers are commanded less than this value an error Occurs RenumberMoversAtStart Renumber movers at start SetGainsSectionNumber Individual motor module number to set gains StandstillWindow Standstill window setting in um The difference that is acceptable to begin reducing the gains until the power driving the mover shuts off Rockwell Automation Publication 2198T UM001A EN P March 2015 Table 19 TRAK_Control Data Tags continued Tag Name PositionErrorTolerance Description Position error tolerance setting in mm The difference between command position and actual position Tags Appendix B Range GainsAllAccelerationFeedForward This gain is a multiple of the difference between two velocity commands The normal 3 90 value is 50 GainsAllPositionDerivative This gain is a constant multiple of the position error The normal value is 5 0 8 GainsAllPositionBandwidth This gain is a constant gain multiple of the position error The normal values are 50 275 75 125 GainsAllVelocityIntegratorBandwidth This gain is a percentage ofthe velocity error usually twice the Velocity Bandwidth The 3 40 normal values are 10
30. diate reach of the operator Keep free and clear of the range of motion of the machine and parts that move Prevent personnel from accidentally entering the range of motion by using Safety fences Protective coverings Safety guards Safety fences and protective coverings must be strong enough to resist maximum kinetic energy of the system See Machine Guarding on page 17 and Safety Label Placement on page 69 for location of Automated Machinery labels Light barriers are not recommended without detailed risk assessment due to the high kinetic energy of the movers Secure vertical axes against falling after switching off the drive power by Mechanically securing the vertical axes Adding an external braking arrester or clamp mechanism Having sufficient equilibrium of the vertical axes 16 Rockwell Automation Publication 2198T UM001A EN P March 2015 Install Your iTRAK System Installation Chapter 2 e Avoid the operation of high frequency remote control and radio equipment near system electronics and their power supply leads If the use of these devices is necessary check that they do not interfere or cause malfunctions in the machine operation We recommend performing an electromagnetic compatibility test before putting the system into service Machine Guarding The movers can have high acceleration and carry application loads The movers experience more acceleration in the curved sections of the track du
31. dicates that the motor module voltage is too high The iTRAK_Control Status SectionNumberFaulted tag contains the motor module that is reporting this fault If the iTRAK Control Status SectionFaultData tag 0 then the high voltage rail is higher than 509V 1 then the common rail is higher than 254V 2 then the voltage of the common rail is greater than 9 10 of the high voltage rail Other values then the voltage of motor module exceeds the safety range Check power supply and power cables Reset power supply Fault_FieldBusSys Sign of Life between controller and gateway has been lost Increase sync period AND check cables This error indicates the EtherNet IP connection between the controller and the Gateway has dropped The following are possible causes The Ethernet module s time Sync is not configured for Time and Motion in the acd file The controller is not configured for Time Synchronization in the acd file The Ethernet connection to the gateway may need to be manually reset a Unplug the Ethernet cable from the gateway b Cycle the power on the gateway wait 3 4 minutes until the gateway powers up c Reconnect the Ethernet cable Unshielded cables Bad switch Faulty hardware e Overuse of Logix Designer application trending Turn off application trending Check cabling Headway Fault Two movers cmd or actual pos is under headway setting Increase amt This error indicates that at the end of t
32. dules with 50 mm firmware FlashSections100mm Update track motor modules with 100 mm firmware FlashSections150mm Update track motor modules with 150 mm firmware SetGainsAll Initiate download of tuning values to all straight and curved motor modules SetGainsCurves SetGainsSections Initiate download of tuning values to all curved motor modules Initiate download of tuning values to an individual motor module GetGainsAll Read gain values Rockwell Automation Publication 2198T UM001A EN P March 2015 65 Appendix B Tags Table 19 TRAK_Control Data Tags 66 Tag Name Description Range TrackLength Total track length in ym AxisUnwind Axes unwind length in um Set to same value as axis unwind in the axis properties dialog ActiveMovers Total number of active movers on the track 1 96 MotionPolarity This tag controls the direction of motion for the track 0 forward motion 1 reverse motion ReverseMoverNumbering This tag controls the numbering order of the movers on the track 0 The mover with the greatest initial position on the track is labeled as Mover 0 the Second greatest as Mover 1 movers are labeled consecutively with mover numbers continuing in this manner until all movers are numbered 1 The mover with the smallest initial position on the track is labeled as Mover 0 the second smallest as Mover 1 movers are labeled consecutively with mover numbers cont
33. e correct manner e Avoid jamming and crushing by using safety measures e Do not stand under loads Rockwell Automation Publication 2198T UM001A EN P March 2015 7 Chapter2 Installation Install Track Do the follow to install the track or track sections 1 Calculate the weight of the track or track section See Weights on page 55 IMPORTANT Be sure that the lifting machinery can lift the load 2 Make sure that the mounting surface supports the track evenly so that it is free of mechanical stress and distortion Evenness of the mounting surface must be within 0 0508 mm 0 002 in 3 Unpack track sections within the crate so that the lifting slots are easily accessible Thread lifting straps through lifting slots as necessary for your installation and secure them to lifting machinery Lifting Strap Position for Horizontal Installation Hb E o B TA Lifting Slots Lifting Slots Lifting Strap Position for Vertical Installation 5 Lift and transfer track section to its intended location 6 Mount by using the M14 x 2 threaded holes or the slots in mounting plate 18 Rockwell Automation Publication 2198T UM001A EN P March 2015 Installation Chapter 2 We recommend using leveling feet at each mounting point For example Misumi Adjuster Feet Resin Rubber Ty
34. e schematic for the reset circuit Figure 11 Guard Switch Circuit Schematic P4 go T NA eo sos AY B GUARD AY Le a PIER JEM TK E amp F Dry NC Guard Contact Switch Guard Switch Pee Figure 12 shows the pinout for the monitor connector Figure 12 Monitor Connector Pinout P2 22 Rockwell Automation Publication 2198T UM001A EN P March 2015 Connector Data Chapter 3 Figure 13 shows the schematic for the monitor circuit Figure 13 Monitor Circuit gt voi A a RB AC MOA BLU MOB BLU MOC BLU MOE BLU IV I za ge gt zo S e zo s ti e e E MOD BLU o Table 8 Monitor Circuits Descriptions Monitor Description PCM status indicator A Bus voltage 0 160V and 320V ison AC circuit breaker tripped L DC circuit breaker tripped D PCM main circuit breaker CB01 is on Figure 14 PCM P7 to Gateway P6 Cable Connector Pinout Pin Signal 24V CB 05 Gateway 1 24V CB 05A Gateway 2 24V CB 06 Ethernet Hub j O PS02 Undervoltage PS02 Option COM PS02 Power Fail 7 PS02 Logic Return 8 PS01 Undervoltage 9 PS01 Option COM 10 P501 Power Fail GN l Mn l t N 00000000 000000 i amp 900 0023Q S S 6 6 R S O 11 PS01 Logic Return GND 12 PS01 Logic Inhibit 13 PS02 Logic Inhibit 14 iTRAK Power On Off 15
35. e to vector directional changes Machine guards and safety enclosures must be implemented to offer protection to personnel The shielding and enclosure must be designed to protect against tangential projectiles along the system perimeter Risk Assessment A risk assessment must be prepared for the installation of the machine within its application conditions and with the system components installed As a result of the risk assessment you must provide for monitoring functions and higher level measurement for personal safety The safety regulations applicable to the installation of the machine must be considered Unintended machine movements or other malfunctions are possible if safety devices are disabled bypassed or not activated Use the following sections as guide for the installation Your system can contain combinations of the panel cabinets that are shown in these procedures See the system diagram that shipped with your equipment for details Before You Begin ATTENTION There is a risk of injury by improper handling Injury by crushing shearing cutting hitting can occur while handling system components e Observe the relevant statutory regulations of accident prevention e Use protective equipment such as hard hat safety goggles safety shoes safety gloves while handling system e Use suitable equipment for mounting and transport e Use proper tools and use special tools if specified s Use hoist equipment and tools in th
36. fe work practices and for Personal Protective Equipment PPE gt gt gt Allen Bradley CompactLogix ControlLogix TRAK Logix 5000 Rockwell Software Rockwell Automation RSLogix and Studio 5000 are trademarks of Rockwell Automation Inc Trademarks not belonging to Rockwell Automation are property of their respective companies Start Installation Connector Data Commission Table of Contents Preface About This Publi tlolc dud wee beu eto vers esa ciate PARE ede i 5 POTN CINGE Gc cre strana ec ee ma prae oda e RIP Uere pe 5 Conventions Used in This Manual esee 5 Studio 5000 Environment e e e e e e e e eR ee Ee DEP EAR 5 ADprapdte Let szegte ez ae HR R brea sell k KE epi d e qi 6 For More Lntarmanion sss s dert tiex E Rats 6 Chapter 1 About the TRAK System ss 7 Typical Hardware Configuration y 555 ses se e 8 Power Control Module Description sse ee ten PER T 9 Motor Module Description iy sese 11 Moyer R TTT 13 Catalog Number Explanation aues dod ona e 14 Chapter 2 Plan Your System Installation c n Rr x 15 Before You Besin esr t A on TOR lE kget azek Taa 15 Protection Against Magnetic and Electromagnetic Fields During Mountitig 55 rer ee oko eth coe RE 16 Avoid Accidents Injury and Property Damage 16 Risk Assessment eorpore diede o get ue b 17 Install Your TRAK Sastre 17 Before You Begin us exu e eh mee EY e oho Neuen E HE ed 17 Tistall Frack idees Suc gare aa
37. fore commissioning verify that the emergency stop equipment works Do not operate the machine if the emergency stop switch is not working Dangerous movements can occur immediately after power is applied or after an unspecified time of operation The monitoring functions of the system are normally sufficient to avoid malfunction of the drives Safety devices for the protection of personnel from injury and property damage cannot be relied upon until the integrated monitoring functions are made effective Until integration is complete you must assume that faulty drive movements can occur at anytime ATTENTION The iTRAK system can produce dangerous movements There is a danger to life and risk of serious injury while integrating the system Rockwell Automation Publication 2198T UM001A EN P March 2015 25 Chapter 4 26 Commission See Safety Label Placement on page 69 for location of Automated Machinery label Faulty control of motors can cause dangerous movements Common examples are e Improper or wrong wiring or cable connection e Operator errors e Wrong input of parameters e Malfunction of sensors and encoders e Defective components Software Or firmware Crrors Protection Against Magnetic and Electromagnetic Fields During Operation See Safety Label Placement on page 69 for location of Strong Magnets label The motor modules when in use and permanent motors magnets pose a danger to persons with heart pace
38. h curved track Rockwell Automation Publication 2198T UM001A EN P March 2015 Figure 31 150 Length Mover Dimensions Mover A B D 50W x 150L 2495 9 8 120 47 60 24 1714 7 100W x 150L 286 5 11 3 150 5 9 758 2144 8 4 150Wx 150L 336 5 13 2 180 7 1 90 3 5 2644 10 4 Ref dimensions are approximate Go Pe 189 Specifications and Dimensions Dimension are in mm in 2330 09 Appendix A S T 0 Track shown q G for reference es T 150 Length Magnet m 162 64 168 6 6 Minimum pitch straight track 160 20 63 REF 15 36 507 Minimum pitch curved track Rockwell Automation Publication 2198T UM001A EN P March 2015 430 ar q Ri REF Track 120 D5 47 1 63 AppendixA Specifications and Dimensions Notes 64 Rockwell Automation Publication 2198T UM001A EN P March 2015 Control Command Tags Tags Control Command Tags Appendix B The following tags are in the TR AK Control Cmd structure they describe the tracks configuration and operation Table 18 iTRAK_Control Cmd Tags Tag Name Description TrackStart No longer used legacy TrackStop No longer used legacy ServoOn Ena
39. he motor modules It has E stop guard reset monitoring functions The PCM also has external connectors for connecting to a remote E stop and monitoring station Studio 5000 Environment Studio 5000 Logix Designer application version 21 or later provides support to program commission and maintain the CompactLogix and ControlLogix controller families that you use with iTRAK system Cables Each motor module in the system has a communication cable that is connected directly to the Gateway The power bus cables are daisy chained between the motor modules The number of motor modules on one daisy chain is system dependent Use only the cables that are provided with your system and referenced in this user manual Rockwell Automation Publication 2198T UM001A EN P March 2015 Chapter1 Start Typical Hardware Figure 1 shows a typical TR AK system Your system can vary in the quantity and Confi gur ation layout of each component but all follow the same concept Figure 1 Typical iTRAK System Configuration Aza D s BS NI 14 Table 2 System Component Description Item Description 1 Mover 2 Bearing rail 3 Straight motor module 4 Curved motor module 5 Power control module PCM 6 Gateway 7 Controller sold separately 8 Computer not supplied with system 9 EtherNet IP communication cables 10 Communication cable to motor module one cable per motor module
40. he next Coarse Update Period two movers can crash into each other The follow are possible causes Two motion commands are not synchronized to run in the same Coarse Update Period A mover was applied over another mover e Tasks have overlapped and cannot finish in allocated time The iTRAK_Control Status SectionNumberFaulted tag contains the motor module that is reporting this fault If the iTRAK Control Status SectionFaultData tag 0 then the headway fault happened between mover 0 and the mover with the largest mover number 7 then the fault is not triggered by neighbor movers Check for task overlaps Verify proper motion instruction execution order 50 Wrong Number of movers reported A mover has been lost on the system or the wrong number specified in the active axis tag Check magnets or re number with HMI tag This error indicates the following The number of movers exceeds the maximum number that is specified in the iTRAK_Control Data ActiveMovers tag Amover was lost in the middle of the track If the iTRAK Control Status SectionFaultData tag 0 then the number of movers specified in the Logix Designer application doesn t match the number of movers actually found 7 then upon start up the movers were not found in the same positions as they were when the track was shut down Renumber the movers Check position magnets Check specified movers and licenses Check track for debris Rockwell Au
41. imension are in mm in E Standard Length Assembled 300 0 Width 2g pst FTT Motor Width pe 623 B 04 2XM8X1 25 V 22 0 __ Q100H7 90 10 02 2XM8X125 xy 220 Communications Connection Power Out Power In Motor Width Assembled Width mm in Common 50mm 1143 5 0 Mounting Pattern 100 mm 151 3 6 0 150 mm 201 3 7 9 Rockwell Automation Publication 2198T UM001A EN P March 2015 59 AppendixA Specifications and Dimensions Figure 28 Curved Motor Module Dimensions Dimension are in mm in id 167 9 6 61 La 7 ee Assembled 21 13 AR Motor Width Widt Common Communications 95 0 Mounting Connection Ns Pattern R2553 a Power Out 5 B q 3 7 Power In o 2X M8X1 25 ij 22 0 2X M8X1 25 i 22 0 L 100H 90 Motor Width Assembled Width mm in 50mm 114 3 5 0 100 mm 151 3 6 0 150mm 201 3 7 9 60 Rockwell Automation Publication 2198T UM001A EN P March 2015 Specifications and Dimensions Appendix A Figure 29 50 Length Mover Dimensions Dimension are in mm in
42. in the TR AK Control tag for actual values Figure 21 Trending Screen M Logging Stopped Periodic 6 ms Capture 0 of 0 me Du 4 800 00 Mover 0 Following Error Tuesday September 16 2014 200 00 800 00 E 1 Mover_00 CommandVelocity 1 900 00 ie 100 00 ITRAK Control Status ActualPosition 0 4 800 00 200 00 E TRAK ControlStatus PositionError 0 500012500 00 50 00 TRAK_Control Status TraceData 0 1 900 00 100 00 2 800 00 1 800 00 800 00 200 00 3 37 46 636 PM 3 37 48 636 PM 14 ETI a na gt pp pa IMPORTANT The Logix Designer application is a motion planner The values from the axis tags are in future time Feedback tags from the Gateway are actual values and are timed in the past This scenario can create a lag between the two that appears in the trend To synchronize them use time interpolations and trend user tags Rockwell Automation Publication 2198T UM001A EN P March 2015 Maintenance Chapter 5 Topic Page Before You Begin 37 Add or Replace Components 38 Lubrication 46 Circuit Breakers 47 Before You Begin Before you attempt maintenance on the system do the following e Make sure that the movers are motionless e Disconnect electrical power to the system by using the master switch and lockout Protection Against Contact with Hot Parts A BURN HAZAR
43. in the HMI The iTRAK_Control Status SectionNumberFaulted tag contains the mover that is reporting this fault Check or increase the position window This error indicates that there is a difference in track length or number of active axes as downloaded from the control structure than what the Gateway is reporting It could be caused by any of the following conditions The control tags are set incorrectly The motor modules are improperly cabled Sections are not connected correctly or too Foreign magnetic material on the track is adding an extra mover 18 0 many movers reported or NOT communicating or wrong track length e If there is a newly installed motor module on the track this error can indicate the firmware in the newly installed motor module does not match the firmware for the mover type that is specified for that track If the iTRAK Control Status SectionNumberFaulted tag 0 then the track length specified in iTRAK_Control Data TrackLength doesn t match the track length calculated by the gateway Otherwise iTRAK Control Status SectionNumberFaulted tag contains the motor module reporting this fault 1 Error codes from the Gateway are displayed in iTRAK Control Status GatewayFaultCode 2 Error codes from the motor module are displayed in iTRAK_Control Status SectionFaultCode 3 Displayed text is from iTRAK Control Status FaultMessageLine and iTRAK_Control Status FaultMessageLine2 Rockwell Automation Publicati
44. inuing in this manner until all movers are numbered PositionOffset This tag is used to change the zero position of the track This tag value in um is added TrackLength the mover positions TrackLength MoverNumberingOffset This tag can be used to change the mover numbering This tag value is added to each of ActiveMovers the mover numbers 2 ActiveMovers NumberOfZones This tag tells the number of zones in the track For all intelligent tracks there is only one zone The limited is two zones ZoneStartPosition Start position of zone in um ZoneBeginReportOffset Position movers are reported in zone in um In most cases this value is zero ZoneBeginCommandOffset Position movers start to accept commands in zone in um ZoneBeginHoldOffset The position that movers start to hold position in zone in um ZoneEndHoldOffset The position that a mover no longer hold position in zone in um ZoneEndCommandOffset The position that a mover no longer accept commands in zone in pm ZoneEndReportOffset The position that a mover no longer be reported in zone in um ZoneLength Zone length in um ParameterStatus Parameter data ready for downloaded to Gateway ParameterCode Parameter data code ParameterSize Parameter data size ParameterData Parameter data ParameterStatusReturn Parameter data ready for upload from Gateway ParameterCodeReturn Parameter
45. ion 11 Mover Description 13 Catalog Number Explanation 14 About the iTRAK System The iT RAK system is designed to provide an integrated Rockwell Automation motion solution It combines the drive and motor actuator into one component to simplify integration into your application Table 1 System Component Overview iTRAK System Component Motor Module Track Frame Description The motor module is an integrated drive and motor coil unit it is referred to as a section in the firmware Motor modules are available in straight and curved orientations The track frame is designed for your specific application The track frame in combination with straight and curved modules and bearing rails creates the track Mover Gateway The movers are passive magnetic components They move along the track in response to the magnetic fields generated by the motor modules You attach your application end effector to the mover The Gateway provides communication interface between the Logix controller and all motor modules It also provides more motion processing for the motor modules Logix5000 Controller Platform CompactLogix 5370 controllers with Integrated Motion on the EtherNet IP network catalog numbers 1769 L3xERM ControlLogix controllers catalog number 1756 L7X with an Ethernet card Power Control Module PCM The PCM accepts mains power and provides bus power for the motor modules and logic power for the Gateway and t
46. ionoa e cde codec oie aC RD VESTIBUS 46 Circuit BREA CLG dovere gites e da uM NUS UE D UEM Nara 47 Chapter 6 BOR o tiene HS XXV MUR EE d NER EE T YR 49 Appendix A Environmental Specifications ois e Seed LEURS cH uH tuo educa 55 Weights ees aoc ad edi aep e aS te uua esu e bee dtes 55 Dimensi ns z s e ahve wines vette vatur bei eszlek Cuv a pas 57 Appendix B Control Command Tags ocv e RR EU e e SE 65 Appendix C Safety babel 62a oi otek es Oo E ee eee Aree tamara e A 69 rN RRR Wee TA ROT e HRS dee Sew eos RE RRR LINE E EE 71 Rockwell Automation Publication 2198T UM001A EN P March 2015 About This Publication Audience Conventions Used in This Manual Studio 5000 Environment Preface This manual provides installation instructions for mounting wiring integration with a Logix5000 controller and troubleshooting for the TR AK system This manual is intended for engineers or technicians that are directly involved in the installation and wiring of the TR AK system and programmers who are directly involved in the operation field maintenance and integration of this system with the EtherNet IP communication module or controller If you do not understanding the basics of the TR AK system contact your local Rockwell Automation sales representative for information on available training courses These conventions are used throughout this manual Bulleted lists provide information not procedural steps Numbered lists provide
47. ions on how to improve this document complete this form publication RA DU002 available at http www rockwellautomation com literature Rockwell Automation maintains current product environmental information on its website at http www rockwellautomation com rockwellautomation about us sustainability ethics product environmental compliance page Rockwell Otomasyon Ticaret A S Kar Plaza Is Merkezi E Blok Kat 6 34752 erenk y stanbul Tel 90 216 5698400 www rockwellautomation com Power Control and Information Solutions Headquarters Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 2496 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Europe Middle East Africa Rockwell Automation NV Pegasus Park De Kleetlaan 12a 1831 Diegem Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Publication 2198T UM001A EN P March 2015 Supersedes Publication IT3 UM001A EN P May 2014 Copyright 2015 Rockwell Automation Inc All rights reserved Printed in the U S A
48. ition related 1 power related iTRAK_Control Status SectionFaultData Helpful data to troubleshoot the error The error codes are described in Table 12 Rockwell Automation Publication 2198T UM001A EN P March 2015 49 Chapter 6 Troubleshooting Table 12 iTRAK System Error Codes Gateway Code Device Code 2 20 Displayed Text ERR VOLTS LO Section voltage is too low or off Check Power Supply Power Cables Power Supply IO etc IF problem persists Call FOR Service Description and Solution This error indicates that the motor module has lost high voltage on one or both of its buses The following are possible causes Loose cables Module incorrectly wired Power supply has faulted The iTRAK_Control Status SectionNumberFaulted tag contains the motor module that is reporting this fault The iTRAK_Control Status SectionFaultData tag indicates the bus that has failed If the iTRAK_Control Status SectionFaultData tag 0 then the high voltage rail is lower than 35V 1 then the common rail is lower than 17V 3 then the voltage of the common rail is less than 4 of the high voltage rail Other values then the PWM board in this motor module has no current call for service Check power supply and power cables Reset power supply 21 ERR_VOLTS_HI Section voltage is too high Emergency shunting has been activated Check Power Supply AND Shunt Regulator Call FOR service This error in
49. kg 220 Ib Gateway 27 kg 60 Ib Rockwell Automation Publication 2198T UM001A EN P March 2015 Specifications and Dimensions Appendix A Dimensions Figure 25 Power Control Module Dimensions Dimension are in mm in A Tope E i i rns o K foltage RESET iTRAK ON DCB AC CB POWER ON PBO1 h 1219 48 4 48 Ha 1181 4 I 6 45 5 O Bi d D B J F L I Y LS Y 7 a sj E a 10 a 762 gt 30 Side View 4 Holes Front View Diameter 6 35 0 25 Rear Mounting Holes Rockwell Automation Publication 2198T UM001A EN P March 2015 57 Appendix A 58 Specifications and Dimensions To 28125 11 07 Side View Figure 26 Gateway Dimensions Dimension are in mm in B d i 011 11 1905 0 44 i A 3 a Ian 9 609 6 24 0 5715 22 5 Y o Q y L 609 6 gt 24 0 Front View Rockwell Automation Publication 2198T UM001A EN P March 2015 Specifications and Dimensions Appendix A Figure 27 Straight Motor Module Dimensions D
50. l must avoid the use of metallic tools and secure items such as badge clips other personnel effect that could be attracted to the strong magnetic field Strong magnets can erase magnetic media Never let credit cards or electronic media contact or come near the mover or iTRAK system can have sudden and fast motion due to magnetic attraction Do not put fingers ATTENTION There is a pinch point hazard while installing a mover A mover between the mover and motor module What You Need e 2 5 and 5 mm Allen keys and Phillips screwdriver e Loctite 243 e Two mover installation fixtures e A mover Do the following to install a mover 1 Prepare the mover for installation by doing the following a Remove the position indicator magnet holder by using 2 5 mm Allen key 38 Rockwell Automation Publication 2198T UM001A EN P March 2015 Maintenance Chapter 5 b Remove the felt lubricators by using 2 5 mm and Phillips screwdriver Felt Lubricators Position Indicator Magnet Holder 2 From one end of the track Remove all socket head cap screw from the curved bearing rails on both sides of the track by using a 5 mm Allen key ii i Set Screws do not 1 loosen Top Curved Bearing Rail i Mee RE i L B I l eb Bottom curved bearing rail not shown IMPORTANT Donotloosen the four set screws at the ends of the curved bearing rail that hold the bearing rail keys in place Rockwell Au
51. lectrical connections or components when power is applied e Only take measurements or test the operation of the system if a ground conductor is properly connected Rockwell Automation Publication 2198T UM001A EN P March 2015 47 Chapter5 Maintenance
52. letin Number 2198T iTRAK intelligent track Rockwell Automation Publication 2198T UM001A EN P March 2015 Chapter 2 Installation Topic Page Plan Your System Installation 15 Before You Begin 15 Install Your iTRAK System 17 Plan Your System Installation Choose the location for system components following these considerations operator access to emergency stop switch on the power control module PCM operator and maintenance access to movers motor modules power control module and gateway cable lengths vibration free surfaces Before You Begin Before you start the installation of the system read the following to reduce the risk of injury and property damage instructions tampering with the product or disabling of safety devices could WARNING Improper use of these components failure to follow the safety result in property damage injury electric shock or death Proper transport storage mounting and installation and care in operation and maintenance are prerequisites for optimal and safe operation of the system Only qualified persons can work with components of the system or within their proximity Use only Rockwell Automation approved accessories and spare parts Use the components of the system only in the manner that is defined as appropriate See Appropriate Use on page 6 Follow the safety regulations and requirements of the country in which the system is operated Commission the system
53. makers metal implants and hearing aids metal implants and hearing aids while in proximity of magnetic and magnetic f ATTENTION There is a risk of health hazard for persons with heart pacemakers field producing components e The movers have strong magnets e The track creates strong magnetic fields while energized during operation e Persons with heart pacemakers metal implants or hearing aids must not enter areas where components of the drive and control systems are mounted commissioned and operated Rockwell Automation Publication 2198T UM001A EN P March 2015 Configuration Commission Chapter 4 This section explains the steps required for integrating the II RAK system into P ps reg RAUDE y your control system If you are using the sample starter project these steps have already been completed and are shown for your information The communication between the controller and the Gateway is made via an Ethernet connection by using EtherNet IP protocol General 1 Start the Logix Designer application 2 From the Controller Organizer double click Controller TRAK A Controller Tags 73 Controller Fault Handler EH Power Up Handler 2 29 Tasks 7 99 HighSpeedTask 3 a POL TRAK Communications Program Tags EH R00 iTRAK IO RO1 Headway 7 589 MainTask eg POL MainProgram 3 Click the Date Time tab 4 Check Enable Time Synchronization Checking Time Synchronization lets the controller participate in the
54. n 0 0127 mm 0 0005 in Replace a Motor Module Follow this procedure to replace a motor module Before You Begin N ATTENTION Lockout and tagout input power before servicing BURN HAZARD Do not touch hot surfaces such as motors windings and laminated cores Temperatures ofthe track motor module stator covers can be higher than 60 C 140 F during or after operation After powering down the motor modules let them cool before touching Motor modules can require 140 minutes to cool Rockwell Automation Publication 2198T UM001A EN P March 2015 41 42 Chapter5 Maintenance See Safety Label Placement on page 69 for location of Hot Surface label What You Need s 6mm Allen key e Loctite 243 e A replacement motor module Do the following to replace a motor module 1 Remove the socket head cap screw that secure rails above and below the module you are replacing Description Description Upper rail 3 Lower rail 2 Module to be replaced 4 Socket head cap screws 2 Remove the socket head cap screws that secures the motor module to the top and bottom frames Rockwell Automation Publication 2198T UM001A EN P March 2015 Maintenance Chapter 5 Support motor module while performing this step Item Description 1 Motor module 2 Motor module shim
55. nFaultData tag contains the number of the first bad coil Call service to replace the module Rockwell Automation Publication 2198T UM001A EN P March 2015 Troubleshooting Chapter 6 Table 12 iTRAK System Error Codes Gateway Device Displayed Text Description and Solution Code Code 2 Nonvolatile memory operations failed The iTRAK_Control Status SectionNumberFaulted tag contains the motor module that is reporting this fault If the iTRAK Control Status SectionFaultData tag 12 25 N A 30 then the erase Hold Buffer failed 31 then the received data is too small missed block changed in the number of blocks wrong block size or wrong byte size 32 then the burn Hold Buffer failed 33 then the received data did not match The gateway EIP connection was The gateway has been restarted either internally or by your request via the 16 0 interrupted If persists repower gateway iTRAK_Control Cmd ResetGateway tag If the gateway continues to reset itself after the first time cycle the power If the problem persists after a power cycle call for service This error indicates that a mover is no longer within the window between the command and actual position as specified by the position window tag in the HMI The causes can be the following od ras Mechanical failure 7 0 Position Window Err a mover is outside its Over aggressive programming position window Check or increase win The following error set too low
56. nnection over EtherNet IP Module Fault Status Offline Help Rockwell Automation Publication 2198T UM001A EN P March 2015 31 Chapter4 Commission Understanding the iTRAK Sample Starter Project 32 7 Repeat steps 1 through 6 for ETHERNET MODULE Gateway Movers16to31 and the other ETHERNET MODULES until you assign enough connections to accommodate the number of movers in the system This section describes the TR AK sample starter project iTRAK Motion Task An Add On Instruction that is named TRAK IO controls the TR AK program communication to the Gateway The TR AK IO Add On Instruction is called by the HighSpeed Task task within the ROO TRAK IO routine The parameters for this Add On Instruction include the TRAK Control tag structure all 16 axes the Motion Group and the input output buffers of the Ethernet layer This event is called every Coarse Update Period IMPORTANT Setthe Coarse Update Period time high enough so the event calls do not overflow Putting other programs in this event can cause the task to overflow and can cause errors such as 10 Headway Faults We recommended that you place other user routines in another task with lower priority Figure 16 HighSpeedTask Controller Organizer B N Controller iTRAK A Controller Tags Controller Fault Handler 53 Power Up Handler 5 Tasks 5 SMEM m c amp P01 iTRAK Communications A Program Tags BN R00 TRAK IO B R01 Headway
57. nts s Install the system in the manner that is described in this manual e Operate the system in the ambient conditions that are described in Environmental Specifications on page 55 For More Information These resources contain information about related products from Rockwell Automation Resource Description 1769 CompactLogix Controllers User Manual publication 1769 UM011 Details how to configure program and operate a 1769 CompactLogix system and provides technical specifications ControlLogix System User Manual publication 1756 UM001 Details how to configure program and operate a 1756 ControlLogix system and provides technical specifications Industrial Automation Wiring and Grounding Guidelines publication 1770 4 1 Product Certifications website http www ab com You can view or download publications at Provides general guidelines for installing a Rockwell Automation industrial system Provides declarations of conformity certificates and other certification details http www rockwellautomation com literature To order paper copies of technical documentation contact your local Allen Bradley distributor or Rockwell Automation sales representative 6 Rockwell Automation Publication 2198T UM001A EN P March 2015 Start Chapter 1 Topic Page About the iTRAK System 7 Typical Hardware Configuration 8 Power Control Module Description 9 Motor Module Descript
58. o the other routines in the program This routine runs on first program scan and sets default conditions and parameters R02 Monitor This routine monitors status of the track such as system faults and system readiness and can initiate actions as required R03 Start This routine performs initialization tasks that are related to the start of the iTRAK system It writes the gain values renumbers the movers sets the trace data and more On completion of the routine the servo loops enables DC Bus power is supplied to the track motor modules and the system is readied for motion R04 Stop This routine initiates ServoOff and shutdown tasks that are related to the stop of the iTRAK system such as performing a controlled Group Stop of all axes R05 ParameterExchange This routine configures data for writing down to the Gateway via the iTRAK 10 Add On Instruction in the HighSpeedTask Task Rockwell Automation Publication 2198T UM001A EN P March 2015 35 Chapter4 Commission 36 Controller Organizer vax 1 amp Controller iTRAK A Controller Tags CH Controller Fault Handler Power Up Handler GB Tasks Motion Groups E Add On Instructions Data Types amp Trends RQ Mover_0_Following_Error VO Configuration Trending The Logix Designer application Trending feature is used with the iTRAK system When using the Trending feature it is important that you trend the feedback members
59. on 2198T UM001A EN P March 2015 53 Chapter6 Troubleshooting Notes 54 Rockwell Automation Publication 2198T UM001A EN P March 2015 Appendix A Specifications and Dimensions Topic Page Environmental Specifications 55 Weights 55 Dimensions 57 Environmental Specifications Table 13 Environmental Specifications for Straight and Curve Modules Weights Attribute Value Ambient temperature 0 40 C 32 104 F Storage temperature 30 70 C 22 158 F Relative humidity 5 95 non condensing Shock 15 g peak 11 ms duration Vibration 2gsine peak Hz 5 500Hz 1 Tested to operate with 3 pulses in the positive direction 3 pulses in the negative direction along the X Y and Z axes 2 Tested to operate for 2 hours along the X Y and Z axes Table 14 Straight Modules Weights Approx Frame Size Weight approx 50 15 kg 33 Ib 100 20 kg 43 Ib 150 25 kg 54 Ib Table 15 Curve Modules Weights Approx Frame Size Weight approx 50 17 kg 38 Ib 100 23 kg 51 Ib 150 29 kg 64 Ib Rockwell Automation Publication 2198T UM001A EN P March 2015 55 56 AppendixA Specifications and Dimensions Table 16 Track Weights Approx Frame Size 50 Weight approx 123 kg m 83 lb ft 100 156 kg m 105 Ib ft 150 189 kg m 127 lb ft Table 17 Other Component Weights Approx Component Weight approx Power Control Module 100
60. pe Misumi part number AJPDRI6 100E M 16X2 Threaded Holes Mounting Plate 7 Ifyour system was shipped multiple segments do the following otherwise skip to next step a ao g Align track sections by using the shoulder bolt holes of the motor modules and the track frame Apply Loctite 243 blue to threads of M10 x 8 socket head cap screw shoulder bolts and secure the motor module to the adjacent track section Torque shoulder bolts to 13 Nem 9 6 lbeft Insert bearing rail key in the end of a pre installed bearing rail Place bearing rail on locator pins Bearing rails are scribed with the location identifiers See mechanical installation drawing that is shipped with your system for placement Apply Loctite 243 blue to threads of M8 x 25 socket head cap screws quantity as required and secure the bearing rail Torque all bearing rail screws to 22 Nem 11 8 Ibeft 8 Remove shipping clamps Install Power Control Module IMPORTANT The 10kVA PCM weighs approximately 100 kg 220 Ib Be sure the lifting machinery that is used can lift the load e Mount PCM to a solid vibration free vertical surface e Secure by using all mounting holes inside the enclosure See Dimensions on page 57 e Connect the system ground conductor to the main power supply Rockwell Automation Publication 2198T UM001A EN P March 2015 19 Chapter2 Installation Before switching on the equipment ca
61. r 0 Upper inner bearing rail lubricator m 7 Position feedback magnet 1 Your system specifications determine the number of movers with lubricators A A ATTENTION Health hazard for persons with heart pacemakers metal implants and hearing aids in proximity to magnetic components ATTENTION There is a pinch point hazard while handling a mover A mover can have sudden and fast movement due to magnetic attraction Do not put fingers between the mover the motor module or other ferrous surfaces Rockwell Automation Publication 2198T UM001A EN P March 2015 13 Chapter 1 Start Catalog Number Expla nation Usethe following key to identify your IT RAK system and its options 14 2198T E XX X XXX XXX X XX XXX X QXXXX ps Customized quote number reference Power and Control Configuration B 10 kW power and control modules Mover Quantity tttHt Number of movers Mover Magnet Stack Length 05 5 cm 10 10cm 15 15cm Mechanical Solution Style B Steel vee wheel Short Dimension width Curve center point width in decimeters 000 Oval 00A Linear Long Dimension length Curve center point width in decimeters Orientation H Horizontal both dimensions horizontal V Vertical short dimension vertical only S Stand Up long dimension vertical only Motor Coil Width 05 5 cm 10 10cm 15 15cm Module Type E Configured system Bul
62. r product notification updates In addition we offer multiple support programs for installation configuration and troubleshooting For more information contact your local distributor or Rockwell Automation representative or visit http www rockwellautomation com services online phone Installation Assistance If you experience a problem within the first 24 hours of installation review the information that is contained in this manual You can contact Customer Support for initial help in getting your product up and running United States or Canada 1 440 646 3434 Outside United States or Canada Use the Worldwide Locator at http www rockwellautomation com rockwellautomation support overview page or contact your local Rockwell Automation representative New Product Satisfaction Return Rockwell Automation tests all of its products to help ensure that they are fully operational when shipped from the manufacturing facility However if your product is not functioning and needs to be returned follow these procedures United States Contact your distributor You must provide a Customer Support case number call the phone number above to obtain one to your distributor to complete the return process Outside United States Please contact your local Rockwell Automation representative for the return procedure Documentation Feedback Your comments will help us serve your documentation needs better If you have any suggest
63. replaced or added while the mover is on the track Do the following to replace the lubricators 1 Remove all three lubricators by using a 2 5 mm Allen key Install lubricators while mover is on the track track not shown here for clarity b a 11 c f 44 Rockwell Automation Publication 2198T UM001A EN P March 2015 Maintenance Chapter 5 2 Clean all screws and apply Loctite 243 3 Install new lubricators Replace Mover Bearing 1 Remove mover by using Install or Remove a Mover on page 38 as a guide 2 Remove bearings by using a 17 mm socket wrench Clean all bolts and apply Loctite 243 Attach new bearings to the mover Torque all bolts to 33 Nem 24 lbeft ON A RR O Follow steps in Install or Remove a Mover on page 38 to reinstall mover Rockwell Automation Publication 2198T UM001A EN P March 2015 45 Chapter5 Maintenance Lubrication The bearings are an open system that requires continuous lubrication To avoid breakdown of the lubrication the bearings must have a film of oil on them Typically indications of breakdown are discoloration and excessive wear on the inner and outer bearing surfaces The interval to resupply the lubrication depends on the length of stroke duty cycle and environmental factors Use 68 viscosity mineral oil such as Kluber 4 UH 1 68N to lubricate the bearing rails To provide continuous lubric
64. rror A coil or all coils have been on for General over all performance is low too long for heat ExtraData Coil The iTRAK_Control Status SectionNumberFaulted tag contains the motor module that is reporting this fault If the iTRAK Control Status SectionFaultData tag lt 12 then the coil with number equal to iTRAK Control Status SectionFaultData is overheated stop the system IfiTRAK Control Status SectionFaultData tag 12 then overcurrent has run for too long Check track path and cables or reduce motion profile demands Rockwell Automation Publication 2198T UM001A EN P March 2015 51 Chapter 6 Troubleshooting Table 12 iTRAK System Error Codes Device Code 2 Gateway Code Displayed Text ERR CHECKSUM Section communication error Check comm cable Reset system Description and Solution 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 If the iTRAK Control Status SectionFaultData tag 2 4 6 7 8 9 10 or 11 then iTRAK_Control Status SectionFaultData is the communications packet ID number on which the checksum error occurred If the iTRAK Control Status SectionFaultData tag 3 then the packet is not from the gateway 5 then the packet received is not for this motor module 13 then the packet received is not good 14 then the size of the pa
65. rting The iTRAK_Control Status SectionNumberFaulted tag contains the motor module that is an Wayward ISR fault Call FOR service reporting this fault Replace the failed module TM This error indicates a failure in the position sensing hardware 7 ES T EMEN f r The iTRAK_Control Status SectionNumberFaulted tag contains the motor module that is shied reporting this fault Replace the failed module This error indicates a failure in communication from the Gateway to the motor module The iTRAK_Control Status SectionNumberFaulted tag contains the motor module that is mts l reporting this fault 8 SS ete MUT an If the iTRAK Control Status SectionFaultData tag 12 then the iTRAK_Control Status SectionFaultData tag has a gain which is 0 If the iTRAK Control Status SectionFaultData tag 2 12 then the default gains are being used Check the cable and reset the system This error indicates communication failure between the Gateway and a motor module ERR_UART_BREAK Section The iTRAK_Control Status SectionNumberFaulted tag contains the motor module that is 12 communication error Check cable Reset reporting this fault system The iTRAK_Control Status SectionDeviceFaulted tag The PWM board number Check the cable Reset the system This error indicates that there is something physically wrong with the track The following are possible causes The movers path is physically impeded Bearings are binding Amotor module is loosely mounted 14 12T E
66. s manual Reproduction of the contents of this manual in whole or in part without written permission of Rockwell Automation Inc is prohibited Throughout this manual when necessary we use notes to make you aware of safety considerations WARNING Identifies information about practices or circumstances that can cause an explosion in a hazardous environment which may lead to personal injury or death property damage or economic loss ATTENTION Identifies information about practices or circumstances that can lead to personal injury or death property damage or economic loss Attentions help you identify a hazard avoid a hazard and recognize the consequence gt gt IMPORTANT Identifies information that is critical for successful application and understanding of the product Labels may also be on or inside the equipment to provide specific precautions SHOCK HAZARD Labels may be on or inside the equipment for example a drive or motor to alert people that dangerous voltage may be present BURN HAZARD Labels may be on or inside the equipment for example a drive or motor to alert people that surfaces may reach dangerous temperatures ARC FLASH HAZARD Labels may be on or inside the equipment for example a motor control center to alert people to potential Arc Flash Arc Flash will cause severe injury or death Wear proper Personal Protective Equipment PPE Follow ALL Regulatory requirements for sa
67. s usually the result of failed mechanical part that caused the motor to over work and transfer heat TheiTRAK Control Status SectionNumberFaulted tag contains the motor module that is reporting this fault TheiTRAK Control Status SectionFaultData tag is the temperature of the device Check mover bearings vents or reduce motion profile demands 22 ERR PWRSTAGE TEMP Power stage is overtemperature Check mover bearings venting reduce demands IF problem persists call FOR service Power stage is overtemperature The iTRAK_Control Status SectionNumberFaulted tag contains the motor module that is reporting this fault TheiTRAK Control Status SectionFaultData tag is the amplifier module reporting this fault Check mover bearings venting or reduce demands 23 ERR ONE BAD COIL Power on Self Test indicates at least one coil is bad Extra daa indicates Coil System may still run Call FOR servicet There is a bad coil The iTRAK_Control Status SectionNumberFaulted tag contains the motor module that is reporting this fault The iTRAK_Control Status SectionFaultData tag contains the number of the bad coil 24 52 ERR TOO MANY BAD COILS Power on Self Test indicates at multiple coils are bad System will NOT run Call FOR Service There are too many bad coils The iTRAK_Control Status SectionNumberFaulted tag contains the motor module that is reporting this fault The iTRAK_Control Status Sectio
68. steps or hierarchical information The Studio 5000 Automation Engineering amp Design Environment combines engineering and design elements into a common environment The first element is the Studio 5000 Logix Designer application The Logix Designer application is the rebranding of RSLogix 5000 software and will continue to be the product to program Logix5000 controllers for discrete process batch motion safety and drive based solutions f Rock well Software Studio 5000 Create A Explore New Project Existing Project Help From Import Sample Project Release Notes From Sample Project From Upload About Recent Projects d Sept Test integrated Motion Co d August 2012 The Studio 5000 environment is the foundation for the future of Rockwell Automation engineering design tools and capabilities The Studio 5000 environment is the one place for design engineers to develop all of the elements of their control system Rockwell Automation Publication 2198T UM001A EN P March 2015 5 Preface Appropriate Use ATTENTION Incorrect use of the products can cause personal injury and property damage e Read and understand the safety instructions before using the TR AK system and review Label Placement on page 69 e Hardware must remain in its original state never make structural changes e Do not de compile software or alter source codes e Do not use damaged or faulty compone
69. tomation Publication 2198T UM001A EN P March 2015 39 40 Chapter5 Maintenance 3 Remove the curved bearing rails by pulling parallel to the track away from the straight bearing rails bearing rail up until the bearing keys have cleared the ends ofthe i ATTENTION Avoid bending the bearing key Do not lift the curve straight bearing rail Bearing Rail Key Slot Bearing Rail Key Slot 4 Attach mover installation fixtures At the end of straight bearing rails attach mover installation fixtures to the track frame by using two socket head cap screws from the curved bearing rail Mover Installation Fixtures Rockwell Automation Publication 2198T UM001A EN P March 2015 Maintenance Chapter 5 5 Install mover Align the mover with the mover installation fixture and slide the mover on to the track 6 Reinstall the position indicator magnet holder Check that the polarity of position magnets alternate between north and south on adjacent movers You can check the polarity by examining the color of the magnets 7 Reinstall the felt lubricators 8 Remove the mover installation fixtures 9 Clean all bearing rail screws and apply fresh Loctite 243 10 Reinstall the curved bearing rail 11 Torque all bearing rail screws to 22 Nem 11 8 Ibeft 12 Align the straight and curve bearing rails by using the set screws on the ends ofthe curve bearing rail to withi
70. tomation Publication 2198T UM001A EN P March 2015 Table 12 iTRAK System Error Codes Gateway Code Troubleshooting Chapter 6 Device Displayed Text Description and Solution Code 2 This error indicates that a motor module is not responding to commands The following are possible causes Low voltage power loss Communication cables are not connected Communication cables are loose i Fault_InternalComm Data could not be The iTRAK_Control Status SectionNumberFaulted tag contains the motor module that is written to sections reporting this fault If the iTRAK_Control Status SectionFaultData tag 0 then writing data to a motor module failed 1 then the motor module received too many communication errors 2 then the force command was not received or the neighborhood command was not received Check power connections Cycle power This error indicates that the current in the motor module has risen to an unacceptable level The iTRAK_Control Status SectionNumberFaulted tag contains the motor module that is 2 ERR_OVERCURRENT_FAULT Sectionhas reporting this fault an overcurrent fault Reset system The iTRAK_Control Status SectionDeviceFaulted tag is the PWM board number The iTRAK_Control Status SectionFaultData tag is the bad coil Verify that the sizing of system is correct Reduce the acceleration and deceleration This error indicates an electronics failure in a motor module 6 ERR_WAYWARD_ISR Section is repo
71. tools and secure items such as badge clips other personnel effect that could be attracted to the strong magnetic field Strong magnets can erase magnetic media Never let credit cards or electronic media contact or come near the mover or iTRAK system Strong Magnets B High magnetic field exerts strong forces Pacemaker and ICD wearers maintain minimum of 300 mm distance Tools metal objects and surfaces can be attracted and cut pinch or entrap hands and fingers field exerts strong aker and ICD wearers maintain ium of 300 mm distance Hot Surface L Indicates that the surface can be hot enough to burn if touched Hot surface Do not touch Automated D Movers and make as sudden and unexpected Machinery movements while the system is powered Lock out tag out before servicing Automated machinery This unit may start at any time Stay clear Lock out tagout before servicing High Voltage E The power control module can have voltages greater than 240V present inside the cabinet and at the connectors HIGH VOLTAGE High Voltage F The capacitors inside the PCM can have high 70 capacitors DANGER Risk of electrical shock High voltage may exist up to 5 minutes after removing power Rockwell Automation Publication 2198T UM001A EN P March 2015 voltage present for 5 minutes Do not attempt to service the PCM until 5 minutes after power has been
72. utton and press the Reset button to enable restoration of the bus power iTRAK ON This yellow status indicator is on when iTRAK_Start command is executing in Logix Application Designer It turns off after the iTRAK Stop command is executed E stop is pressed or shutdown operation is performed DC CB This blue status indicator lights when DC Line is high or when iTRAK system has 24V DC It turns off when relays R1C and R2C are open or when circuit breakers CB02 CB03 or CB04 are tripped AC CB This blue status indicator lights when the AC Line is high It turns off when relays R1B and R2B are open or when circuit breakers CB05 CB05A CB06 or CB07 are tripped POWER ON This white status indicator lights when the AC input line is high It turns off when ESR GSR ICT or IC are tripped If any of the status indicators do not light when expected check the associated circuit breakers See PCM Circuit Breakers on page 48 ATTENTION The DC power bus capacitors have residual voltage for 5 minutes Wait 5 minutes before attempting to service the PCM or the bus power cables ATTENTION If the ESR and GSR safety relays appear to be faulty contact Rockwell Automation for service Do not attempt to service or repair ESR and GSR safety relays ATTENTION If the braking resistors or the power supplies overheat contact Rockwell Automation for service gt 10 Rockwell Automation Publication 2198T UM001A EN P March 2015

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