Rockwell Automation iTRAK User manual

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

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 this 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.
Labels may also be on or inside the equipment to provide specific precautions.
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.
IMPORTANT Identifies information that is critical for successful application and understanding of the product.
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 safe work practices and for Personal Protective Equipment (PPE).

Rockwell Automation Publication 2198T-UM002C-EN-P - March 2019 3
Table of Contents
Preface
Summary of Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Conventions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Appropriate Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Chapter 1
Start About the iTRAK System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Motor Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Mover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Support Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
iTRAK Bus Conditioner Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Gateway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2198T-G02-xxx-E Gateway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2198T-G03-xxx-E Gateway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Digital USB I/O Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Catalog Number Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Risk Assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
General Assembly Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Machine Guarding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Avoid Accidents, Injury, and Property Damage . . . . . . . . . . . . . . 30
Avoid Electrical Shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Pinch Point Hazard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Protection Against Contact with Hot Parts. . . . . . . . . . . . . . . . . . 31
Protection Against Magnetic and Electromagnetic Fields
During Installation and Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Safe Magnet Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Magnet Plate Keeper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Chapter 2
Track Installation Install the Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Mount an Oval Track. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Install the Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
What You Need . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Mount the Lubricator Pumps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Wiring Lubrication Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Lubrication Pump Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Chapter 3
Connect Your iTRAK System to a
Kinetix 5700 iTRAK Power Supply
Typical iTRAK System with an iTRAK Power Supply . . . . . . . . . . . 45
Wire the iTRAK System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

4Rockwell Automation Publication 2198T-UM002C-EN-P - March 2019
Table of Contents
Using Multiple iTRAK Power Supplies . . . . . . . . . . . . . . . . . . . . . 48
Wire the Digital USB I/O Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Wire the Gateway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Numbering the Motor Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Wire a 2918T-G02-xxx-E Gateway . . . . . . . . . . . . . . . . . . . . . . . . . 54
Wire a 2918T-G03-xxx-E Gateway . . . . . . . . . . . . . . . . . . . . . . . . . 55
Logix Designer Application Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Chapter 4
Power on Your System Before You Power On the Track. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Identify Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Identify Firmware Revision. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Configure and Customize Project File. . . . . . . . . . . . . . . . . . . . . . . 58
Apply Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Commission with Programming Manual . . . . . . . . . . . . . . . . . . . . . . . . 59
Chapter 5
Maintenance Before You Begin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Add or Replace Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Install or Remove a Position Magnet Assembly. . . . . . . . . . . . . . . 62
Magnet Plate Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . 64
Install or Replace a Mover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Replace a Straight Motor Module . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Replace a Curved Motor Module . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Replace Mover Cam-follower Wheels and Flexures . . . . . . . . . . . 80
Install Top and Bottom Straight Rails . . . . . . . . . . . . . . . . . . . . . . . 87
Install Transverse Straight Rails. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Replace or Install Top and Bottom Straight Bearing Rail with
Lubrication Port. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Install Curved Transverse Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Install a Top or Bottom Radial Curved Rail. . . . . . . . . . . . . . . . . . 95
Update Gateway Firmware. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Firmware Update Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 99
Downgrade Firmware. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Update Motor Module Firmware. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Initial Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Normal Operation Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Chapter 6
Troubleshooting Errors Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Rockwell Automation Publication 2198T-UM002C-EN-P - March 2019 5
Table of Contents
Chapter 7
Functional Safety Important Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Category 3 Requirements according to EN ISO 13849-1 . . . . . . . . 111
Stop Category Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Performance Level and Safety Integrity Level (SIL). . . . . . . . . . . . . . 112
Safety Distance Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Functional Safety Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Considerations for Category 1 Stop. . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Overall System Stopping Performance . . . . . . . . . . . . . . . . . . . . . . . . . 113
Schematic and Block Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
iTRAK Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Chapter 8
Compatibility Motor Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Movers and Magnets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Gateways . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Power Supplies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Appendix A
Label Placement Safety Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

6Rockwell Automation Publication 2198T-UM002C-EN-P - March 2019
Table of Contents
Notes:

Rockwell Automation Publication 2198T-UM002C-EN-P - March 2019 7
Preface
This manual provides installation instructions to mount, wire, and
troubleshoot the iTRAK® system with TriMax bearings.
This manual is intended for engineers or technicians that are directly involved
with the design, installation, and wiring of the iTRAK 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 understand the basics of the iTRAK system, contact your
Rockwell Automation sales representative for information on available training
courses.
Summary of Changes This manual contains new and updated information as indicated in the
following table.
Conventions These conventions are used throughout this manual: Bulleted lists provide
information, not procedural steps. Numbered lists provide steps or hierarchical
information.
Appropriate Use Read and understand the safety instructions before using the iTRAK system
and review Safety Labels on page 117.
• Hardware must remain in its original state; never make structural
changes.
• Do not de-compile software or alter source codes.
• Do not use damaged or faulty components.
• Install the system in the manner that is described in this manual.
• Operate the system in the ambient conditions that are described in
iTRAK System Technical Data, publication 2198T-TD001.
Topic Pages
Corrected bolt size in step e 39
Corrected torque value in step f 39
Corrected torque value in step 7 68
Corrected torque value in step 9 69
Corrected torque value in step 21 86
Corrected pinout for Control Power signals 114
ATTENTION: Incorrect use of the products can cause personal injury and
property damage.

8Rockwell Automation Publication 2198T-UM002C-EN-P - March 2019
Preface
Additional Resources These documents contain additional information concerning related products
from Rockwell Automation.
You can view or download publications at
http://www.rockwellautomation.com/global/literature-library/overview.page.
To order paper copies of technical documentation, contact your local Allen-
Bradley® distributor or Rockwell Automation sales representative.
Resource Description
iTRAK SystemTechnical Data, publication 2198T-TD001 Product specifications for Rockwell Automation iTRAK system components, with
performance, environmental, certifications, load force, and dimension drawings.
Kinetix® Servo Drives Specifications Technical Data, publication KNX-TD003 Product specifications for Kinetix Integrated Motion over the EtherNet/IP network, Kinetix 5700 iTRAK Power Supply, Integrated Motion over sercos interface, EtherNet/
IP networking, and component servo drive families.
Kinetix 5700 iTRAK Power Supply and iTRAK Bus Conditioner
Module Supply Installation Instruction, publication 2198T-IN001
Provides information for wiring and connecting the Kinetix 5700 iTRAK power supply
to the iTRAK system.
iTRAK System Programming Manual, publication 2198T-PM001 Provides information on how to commission and program an iTRAK system.
3D CAD Models of iTRAK Components 2198T-3DCAD.zip.
https://motionanalyzer.rockwellautomation.com/Products/iTrak
Provides 2D outline, assembly, and system drawings, STEP files for the movers and
motor modules, and hyper links to complete systems STEP files.
ControlLogix® System User Manual, publication 1756-UM001 Details how to configure, program, and operate a 1756 ControlLogix® system, and
provides technical specifications
System Design for Control of Electrical Noise Reference Manual,
publication GMC-RM001 Information, examples, and techniques that are designed to minimize system electrical noise failures.
Industrial AutomationWiring and Grounding Guidelines, publication 1770-4.1 Provides general guidelines for installing a Rockwell Automation industrial system.
Product Certifications website, rok.auto/certifications Provides declarations of conformity, certificates, and other certification details.

Rockwell Automation Publication 2198T-UM002C-EN-P - March 2019 9
Chapter 1
Start
Use this chapter to become familiar with the design, installation, and safety
requirements for iTRAK® systems.
About the iTRAK System The iTRAK system is composed of motor modules, mounting plates, bearing
rails, and movers. The motor modules are an integrated drive motor system
with feedback. Mounting plates can be attached to the sides of motor modules
and bearing rails can be attached to the mounting plates. Movers have
independent linear motor magnets and cam followers, and multiple movers can
be operated on a motor module at any time. Movers can be synchronized or
independently controlled, however they are programmed.
The motor modules are available with both straight and curved motors, and
more movers can be added as the system grows. The movers can be stopped and
positioned on the curves with high accuracy. When the curves are applied to
create an oval, new machine shapes and dynamic performances are possible.
The iTRAK system can be arranged and mounted in many configurations,
including horizontal carousel, vertical over-under, and stand-up configurations.
The system is modular, scalable, and can be expanded to well over 10 meters.
Even on large systems, each mover still retains independent servo control. The
system can be also built into other geometries such as rectangles.
The iTRAK system can produce high speeds and high forces. The different
combinations of magnet sizes and motor coil sizes produce nine different force
speed options.
Topic Page
About the iTRAK System 9
Motor Module 12
Mover 14
Support Frame 15
Power Supply 16
iTRAK Bus Conditioner Module 16
Gateway 17
Digital USB I/O Module 26
Catalog Number Explanation 27
Safety Information 28

10 Rockwell Automation Publication 2198T-UM002C-EN-P - March 2019
Chapter 1 Start
The gateway facilitates communication between the iTRAK system and
controller and provides abstraction between physical and virtual mover axes.
The iTRAK system requires a specialized power supply that converts three-
phase AC power to the appropriate DC bus voltage. The USB I/O module
provides discrete communications between the power supply and the gateway.
Figure 1 - Exploded View of the Servo and Mechanical Components with TriMax Bearings
1
4
5
67
8
9
10
11
12
3
2
2
2
2
Item Description Item Description
1 Top bearing rail 7 Movers
2 Transverse bearing rail 8 Mover magnets
3 Top frame plate 9 Bottom frame plate
4 Straight motor modules 10 Bottom bearing rail
5 Curved motor modules 11 Spine bars
6 Position magnets 12 Mounting plate