Rockwell Automation ITRAK Bedienungsanleitung

Dieses Handbuch passt für folgende Modelle

12

Inhaltsverzeichnis

Andere Rockwell Automation Industrieanlagen Handbücher

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Beliebte Industrieanlagen Handbücher anderer Marken

ABB

ABB Unifix AD Handbuch

Mark 7

Mark 7 Evolution Bedienungsanleitung

Husky

Husky HyPET Bedienungsanleitung

bora

bora PM-1800 Bedienungsanleitung

Grizzly

Grizzly T32428 Bedienungsanleitung

Siemens

Siemens 8MF1 Series Bedienungsanleitung

ABB

ABB HT610965 Bedienungsanleitung

ABB

ABB SafeLink Bedienungsanleitung

Phoenix

Phoenix PHX-150 Bedienungsanleitung

ABB

ABB A165-L32 Bedienungsanleitung

ABB

ABB HT842936 Bedienungsanleitung

Hermetica

Hermetica 10 Series Bedienungsanleitung

HORNER

HORNER OEE Solution Bedienungsanleitung

Hammerhead

Hammerhead HG375 Bedienungsanleitung

SCHUNK

SCHUNK VERO-S NSE-A3 138 Gebrauchsanweisung

ABB

ABB HT566657 Bedienungsanleitung

Webasto

Webasto GSE CAN Bedienungsanleitung

ABB

ABB HT614003 Bedienungsanleitung

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