I TRAK

User Manual
Original Instructions
iTRAK System
Bulletin 2198T
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.
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.
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 safe work practices and for Personal Protective Equipment (PPE).
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 Supplies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
iTRAK Bus Conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Gateway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Digital USB I/O Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Catalog Number Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Risk Assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
General Assembly Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Machine Guarding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Avoid Accidents, Injury, and Property Damage . . . . . . . . . . . . . . 21
Avoid Electrical Shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Pinch Point Hazard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Protection Against Contact with Hot Parts. . . . . . . . . . . . . . . . . . 22
Protection Against Magnetic and Electromagnetic
Fields During Installation and Use . . . . . . . . . . . 22
Safe Magnet Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Chapter 2
Track Installation Install the Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Mount an Oval Track. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Install the Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
What You Need . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Mount the Lubricator Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Wiring Lubrication Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Lubrication Pump Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Lubrication Volume Calculation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Rockwell Automation Publication 2198T-UM001D-EN-P - October 2019 3

Table of Contents
Chapter 3
Connect Your iTRAK System to a Typical iTRAK System with an iTRAK Power Supply . . . . . . . . . . . 37
Kinetix 5700 iTRAK Power Design Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Determine the Number iTRAK Power Supplies Required . . . . 40
Supply
Output Bus Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
24V Control Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
iTRAK Power Supply Output Power Connections . . . . . . . . . . . 41
Maximum iTRAK Power Supply to iTRAK Module
Cable Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Choose a 2198-Pxxx Kinetix 5700 Power Supply . . . . . . . . . . . . . 43
Shunting Capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Kinetix 5700 System Design. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Cabinet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Ethernet Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Wire the iTRAK System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Using Multiple iTRAK Power Supplies . . . . . . . . . . . . . . . . . . . . . 45
iTRAK Power Supply Connector Data . . . . . . . . . . . . . . . . . . . . . . . . . 48
Wiring Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Wire the iTRAK Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Wire the Digital Input Connector . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Wire the iTRAK PS Ready (IR) connector . . . . . . . . . . . . . . . . . . 53
Wire the iTRAK Power Supply DC Bus and Control
Power Output Connectors . . . . . . . . . . . . . . . . . . 54
Apply the iTRAK Power Cable Shield Clamp . . . . . . . . . . . . . . . . . . . 55
Wire the Digital USB I/O Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Wire the Gateway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
iTRAK Power Supply Wiring Example . . . . . . . . . . . . . . . . . . . . . . . . . 59
Cable Preparation for iTRAK Power Supply Output
Power Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Logix Designer Application Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Chapter 4
Install Your System with a Typical System Configuration Using a PCM . . . . . . . . . . . . . . . . . . . . 65
Power Control Module About the Power Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
PCM Status Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
PCM Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
PCM Connector Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
About the Gateway. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Plan Your System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Install the Power Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Install the Gateway Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Connect Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
4 Rockwell Automation Publication 2198T-UM001D-EN-P - October 2019

Table of Contents
Chapter 5
Power on Your System Before You Power On the Track. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Identify Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Identify Firmware Revision. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Configure and Customize Project File. . . . . . . . . . . . . . . . . . . . . . . 78
Apply Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Kinetix 5700 iTRAK Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . 78
Power Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Commission with Programming Manual . . . . . . . . . . . . . . . . . . . . . . . . 82
Chapter 6
Maintenance Before You Begin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Add or Replace Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Install or Remove a Position Magnet Assembly. . . . . . . . . . . . . . . 84
Magnet Plate Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . 86
Install or Replace a Mover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Replace a Straight Motor Module . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Replace a Curved Motor Module . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Update Gateway Firmware. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Firmware Update Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . 104
Downgrading Firmware. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Update Motor Module Firmware. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Initial Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Lubrication During Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . 106
Replace Mover Lubrication Wipers . . . . . . . . . . . . . . . . . . . . . . . . 106
Replace Lower Mover Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Circuit Breakers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Chapter 7
Troubleshooting Errors Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Table of Contents
Chapter 8
Functional Safety Important Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Category 3 Requirements according to EN ISO 13849-1 . . . . . . . . 121
Stop Category Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Performance Level and Safety Integrity Level (SIL). . . . . . . . . . . . . . 122
Safety Distance Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Functional Safety Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Considerations for Category 1 Stop. . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Overall System Stopping Performance . . . . . . . . . . . . . . . . . . . . . . . . . 123
Schematic and Block Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
iTRAK Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Power Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Chapter 9
Compatibility Motor Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Movers and Magnets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Gateways . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Power Supplies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Appendix A
Label Placement Safety Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

Preface
This manual provides installation instructions to mount, wire, and

troubleshoot the iTRAK® system.
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.
Topic Pages
Corrected pin numbers in the table entitled IDC and ICP Connector Wiring. 55
Corrected pin numbers in the wiring diagram entitled Connecting an iTRAK Power Supply to a System. 59
Corrected pin numbers in the wiring diagram entitled Kinetix® 5700 iTRAK Power Supply Safety Circuit 124
Block Diagram.
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 Label Placement on page 129.
ATTENTION: Incorrect use of the products can cause personal injury and
property damage.
• 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

Preface
Additional Resources These documents contain additional information concerning related products
from Rockwell Automation.
Resource Description
iTRAK System Technical Data, publication 2198T-TD001 Product specifications for Rockwell Automation iTRAK system components, with
performance, environmental, certifications, load force, and dimension drawings.
Product specifications for Kinetix Integrated Motion over the EtherNet/IP network,
Kinetix® Servo Drives Specifications Technical Data, publication KNX-TD003 Kinetix 5700 iTRAK Power Supply, Integrated Motion over sercos interface, EtherNet/IP
networking, and component servo drive families.
Kinetix 5700 iTRAK Power 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. Provides 2D outline, assembly, and system drawings, STEP files for the movers and motor
https://motionanalyzer.rockwellautomation.com/Products/iTrak 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, Information, examples, and techniques that are designed to minimize system electrical
publication GMC-RM001 noise failures.
Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.1 Provides general guidelines for installing a Rockwell Automation industrial system.
Product Certifications website, http://www.rockwellautomation.com/global/ Provides declarations of conformity, certificates, and other certification details.
certification/overview.page
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.

Chapter 1
Start
Use this chapter to become familiar with the design, installation, and safety
requirements for iTRAK® systems.
Topic Page
About the iTRAK System 9
Motor Module 12
Mover 14
Support Frame 15
Power Supplies 16
iTRAK Bus Conditioner 16
Gateway 17
Digital USB I/O Module 17
Catalog Number Explanation 18
Safety Information 19
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 bearings, 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 also be 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.

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 specialized power supplies that convert three-
phase AC power to the appropriate DC bus voltage. The USB I/O module
provides discrete communications between the power supplies and the
gateway.
An animation of the iTRAK system can be viewed at https://

www.youtube.com/watch?v=1KA0EpQXgx8.
Figure 1 - Exploded View of the Mechanical and Servo Components
3 5 6
7
9 8
10
11
12
Item Description Item Description

1 Top bearing rail 7 Movers
2 Top frame plate 8 Mover Magnets
3 Straight motor modules 9 Bottom frame plate
4 Curved motor modules 10 Lower bearing
5 Lubrication wipers 11 Spine bars
6 Position magnets 12 Mounting plate

Start Chapter 1
Table 1 - Electromechanical Components of an iTRAK System

iTRAK System Component Description
Motor module 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 shapes.
Track frame 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.
Bearing rails The bearing rails attach to the track frame. They provide high precision guidance for the movers.
Mover 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.
Mover magnets (included in mover) Mover magnet plates can be used to build your own movers to optimize weight or bearing solutions. They are
normally included in the mover.
Position magnets Position magnets are used to actuate sensors in the track. These magnets are typically sold separately from the
mover, but are pre-installed on fully assembled systems.
Lubrication wipers Lubrication wipers are used to spread oil around the track. They are typically attached to some movers, but not
all. They are sold separately from the mover, but are pre-installed on fully assembled systems.
Table 2 - Power and Control Components of an iTRAK System

iTRAK System Component Description
Power circuitry and components The Power Control Module (PCM) is a fully wired and assembled cabinet. It accepts main power and provides
bus power for the motor modules and logic power for the gateway and motor modules. It includes disconnects,
fuses, and USB I/O module. It has pre-wired functional safety features such as an E-stop and reset circuit.
The iTRAK power supply connects to the Kinetix® 5700 power supply and generates the voltages that are
required for the iTRAK system from the full bus voltage. It is used with other Kinetix® 5700 components and
branch circuit protection.
Bus conditioner The bus conditioner module is mounted near the iTRAK for each power cable when using the iTRAK power
supply. It incorporates additional filtering and capacitance to improve dynamic servo response and increase
reliability of the system.
Power cables The power bus cables are daisy chained between the motor modules. The number of motor modules on one
daisy chain is system-dependent.
Gateway The Gateway provides communication interface between the Logix controller and all motor modules. It also
provides more motion processing for the motor modules.
USB I/O Executes discrete communication between the Gateway and power components.
Communication cables Each motor module in the system has a communication cable that is connected directly to the Gateway. Use
only the cables that are provided with your system and referenced in this user manual.
Logix controller platform CompactLogix™ controller or ControlLogix® controller with Ethernet connection that supports Integrated
Motion on EtherNet/IP.
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.
You can power your system with a Power Control Module (PCM), which is a
fixed output power supply, or a scalable Kinetix 5700 power supply system.
The typical system configuration for a PCM powered iTRAK system is shown
in Typical System Configuration Using a PCM on page 65. The typical system
configuration for Kinetix 5700 power supply powered iTRAK system is shown
in Typical iTRAK System with an iTRAK Power Supply on page 37.

Chapter 1 Start
Motor Module Your system has two types of motor modules. Figure 2 shows the features of the
straight motor module and Figure 3 shows the features of the curved motor
module.
Figure 2 - 2198T-L16-Txx04-AOON-2E1E-NS, Straight Motor Module
2198T-L16-T0504-AOON-2E1E-NS,
Straight Motor Module is shown. 1
8
3
7
4
6
5
Figure 3 - 2198T-L16-Txx04-B09x-2E1E-NS, Curved Motor Module
2198T-L16-T0504-B09R-2E1E-NS,
Right Curved Motor Module is shown. 3
2
8 1
6 7
Table 3 - Motor Module Component Description

1 Position sensing surface 5 Incoming bus connector
2 Motor coil assembly 6 Communication connector
3 Motor module status indicator 7 Vent
4 Outgoing bus connector 8 Drive housing

Start Chapter 1
Figure 4 - Series A Motor Module Status Indicators
Straight Motor Module Curved Motor Module
Table 4 - Series A Motor Module Status Indicator Description

Item Color Status
Control Power Green 24V present.
Motor Power Yellow Motor module is enabled.
Communication Green Motor module is communicating.
Figure 5 - Series B Motor Module Status Indicators
Straight Motor Module Curved Motor Module
CONTROL POWER Left

COMMUNICATION
DRIVE ENABLED
DANGER
Hazardous Voltage Inside
Power Off. Lockout/Tagout and
wait 5 minutes
WARNING
Magnetic Field
Can be harmful to
pacemaker wearers
CAUTION Right
Metal Surfaces May be Hot
Do not touch
Power Off. Allow to cool down
CAUTION
PINCH POINTS NEARBY
Sudden motion. Stand Clear
Power Off. Lockout/Tagout
B624958
Table 5 - Series B Motor Module Status Indicator Description

Item Color Status
Control Power Green 24V present.
Communication Green Motor module is communicating.
Drive Enable Green Motor module is enabled.

Chapter 1 Start
Mover Movers are available in nine sizes, each with their own force-speed curve. Your
system only has one size of mover installed.
ATTENTION: See Safety Information on page 19 before handling a mover.
Figure 6 - 2198T-VTxxxx-A, Mover

7 6 5
4
3
2
1
Shown here is a 2198T-VT0510-A mover and position magnet assembly. Your mover can look
slightly different, but will have similar components.

1 Lower bearing-rail lubrication wiper (1) 5 Vee-wheel with external bearings (x4)
2 Vee-wheel with integrated bearing (x2) 6 Upper-outer bearing rail lubrication wiper (1)
3 Bumper (x2) for 2198T-VTxx05-A and 2198T-VTxx10-A and (x3) 7 Upper-inner bearing rail lubrication wiper (1) (2)
for 2198T-VTxx15-A movers
4 Magnet assembly 8 Position feedback magnet (sold separately from the mover)
(1) Not every mover has lubrication wipers. Your system specifications determine the number of movers with lubrication wipers.
(2) 2198T-VTxx05-A movers do not have this lubrication wiper.

Start Chapter 1
Support Frame The iTRAK system track has a frame to support the motor modules and
bearing rails. Figure 7 shows the main components that are used to construct a
single-base plate support structure.
Figure 7 - Single Base Plate Support Structure
1
1
2
Item Description
1 Curved top plate
2 Straight top plate
3 Base plate
4 Spine bar
5 Mounting plate
6 Notched mounting plate
Systems that are greater that 2.4 m (8.2 ft) in length use a multi-plate design for
items 2, 3, 4. See https://ramotionanalyzer.blob.core.windows.net/3dmodels/
2198T-3DCAD.zip for more detail.

Chapter 1 Start
Power Supplies The iTRAK system can be powered using a preconfigured Power Control
Module (PCM) with fixed output wattage or with a scalable Kinetix 5700
iTRAK power supply as part of a Kinetix 5700 system. Details and installation
instructions on for the use of the two power supplies are covered in Chapter 3
and Chapter 4.
Figure 8 - Two Types of iTRAK Power Supplies
2198T-W25K-ER, Kinetix 5700

iTRAK power supply is shown.
2198T-WPCM-08
Images not to scale. Power control module (PCM) is shown
iTRAK Bus Conditioner The bus conditioner module is mounted near the iTRAK for each power cable
when using the iTRAK power supply. The packaging for the bus conditioner is
intended to be mounted in the same environments as the iTRAK system. It
incorporates additional filtering and capacitance to improve the dynamic servo
response and increase reliability of the system.
Figure 9 - 2198T-WBCMOD, iTRAK Bus Conditioner
Item Description
1 Cable and connector to track system
2 Vent
3 Module

Start Chapter 1
Gateway The gateway provides centralized motion processing and communication

between the controller and the motor modules.
Figure 10 - 2198T-G02-016-E, Gateway
4
3
1
2 2
Gateway Front View Gateway Back View

1 Gateway computer 4 USB connections
2 Motor module communication connections 5 24V power input
3 Machine Ethernet connection (AMT)
Digital USB I/O Module The digital USB I/O module provides an interface between the power supply
that is used by your system and the gateway. This module is integrated in a
gateway cabinet and must be included in your system when using Kinetix 5700
iTRAK power supply.
Figure 11 - 2198T-GUSB, Digital USB I/O Module
4
1 3

1 Terminal blocks 3 USB connector
2 Removable cover 4 Power status indicator
The status indicator indicates powers and data transmissions. When the status
indicator is in an illuminated steady green state, the module is successfully
connected to the gateway computer and the operating system has detected and
configured it. When the status indicator blinks continuously, there is data
being transmitted over the USB bus.

Chapter 1 Start
Catalog Number Explanation Use the following key to identify your iTRAK system and its options.
2198T - E XX - X XXX - XXX - X XX XXX X - QXXXX

Customized (quote number reference)
Power and Control Configuration
B = 10 kW power and control modules
C = Kinetix 5700 iTRAK power supply components
D = PCM components without a cabinet
Mover Quantity
### = Number of movers
Mover Magnet Stack Length
05 = 5 cm
10 = 10 cm
15 = 15 cm
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 = 10 cm
15 = 15 cm
Module Type
E = Configured system
Bulletin Number
2198T = iTRAK intelligent track

Start Chapter 1
Safety Information Follow all safety information that is presented in this section while working
with or near an iTRAK system.
ATTENTION: Lockout and tagout input power before servicing.
Before working with iTRAK systems or components, review the

EU Declarations of Incorporation, Directive 2006/42/EC that is appropriate
for your installation and the General Assembly Instructions.
• 2198T Kinetix iTRAK System with PCM - CE DoC, publication
2198T-CT003
• 2198T Kinetix iTRAK System without PCM - CE DoC, publication
2198T-CT004
The iTRAK system is partly completed machinery. This machinery must not
be put into service until the final machinery into which it is to be incorporated
has been declared in conformity with relevant provisions of the Machinery
Directive.
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.
General Assembly Instructions

• When integrating the iTRAK system to tools and external machinery,
see https://ramotionanalyzer.blob.core.windows.net/3dmodels/2198T-
3DCAD.zip
for models and outline drawings
• See the iTRAK System Technical Data, publication 2198T-TD001 for
operational ratings. Do not exceed these ratings.
• The iTRAK system must be only used in the environment specified.
• See Chapter 2 -Track Installation and Chapter 3 - Connect Your
iTRAK System to a Kinetix 5700 iTRAK Power Supply or Chapter 4 -
Install Your System with a Power Control Module for system installation
instructions. Larger iTRAK systems are shipped in multiple sections.
Use the special assembly instructions that are provided with these
section shipments.

Chapter 1 Start
• Although system components have IP65 protection, the mover bearings

and rails exposure to water must be minimized, as they can corrode over
time.
• Bearing rails must be lubricated. See Install the Lubrication System.
• If necessary, additional precautions must be taken to help prevent excess
lubrication from product contamination or external machinery.
• Power and data cables must be managed or located to help prevent trip
hazards for machine operators.
• When you install tools on movers, consider that there can be high
accelerations and forces in particular when movers transition between
straight and curve modules.
– Consider mass and center of gravity of tools that are mounted to
movers.
– When you fasten tools, and machinery to movers, use the two dowel
pins, and four 5 mm screws. Be sure that the screws engage is at least
10 mm (0.39 in.) of thread and the screw is locked in place.
– When you load movers with product, take care to be sure that they
are fastened securely for all anticipated forces and accelerations.
• Do not install ferromagnetic material near the movers. Maintain a
minimum distance is 50 mm (2.0 in.) for any installation ferromagnetic
material.
• Control systems must be designed and constructed in such a way as to
help prevent hazardous situations from arising, see Chapter 8 -
Functional Safety.
• Movers can fall when motor power is removed or servo control is
disabled on vertical or standup iTRAK system installations.
• Help prevent the risk of contact with parts that move by the use of
guards and protective devices, see Machine Guarding.
Machine Guarding
The movers can have high acceleration and carry application loads. The movers
experience more acceleration in the curved sections of the track due 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 help protect against tangential projectiles along the system
perimeter.

Start Chapter 1
Avoid Accidents, Injury, and Property Damage

• Mount emergency stop switches in the immediate reach of the operator.
• Keep free and clear of the range of motion of the machine and parts that
move. Help 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 20.
• Light barriers are not recommended without detailed risk assessment,
due to the high kinetic energy of the movers.
• After the drive power is switched off secure vertical axes against falling
by:
– Securing the vertical axes mechanically
– Adding an external braking, arrester, or clamp mechanism
– Having sufficient equilibrium of the vertical axes.
• 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.
Avoid Electrical Shock
ATTENTION: The PCM, motor modules, Kinetix 5700 iTRAK power supply,
and the bus conditioner require 5 minutes to discharge before electrical you
handle wire and cable connections.
ATTENTION: Permanent magnets can act as generators when power is

removed. The voltage that is generated is proportional to the speed of the
movers. The electronics are designed to handle high voltages, however if the
cables are not connected, the terminals can have voltage potential of up to
35 V/m/s.
Pinch Point Hazard
ATTENTION: There is a pinch point hazard while installing a mover. A mover

can have sudden and fast motion due to magnetic attraction. Do not put
fingers between the mover and motor module.

Chapter 1 Start
Protection Against Contact with Hot Parts
BURN HAZARD: Some components of the system have hot surfaces.
See Safety Label Placement on page 129 for location of Hot Surface label.
• Do not touch hot surfaces such as brake resistors, heat sinks, power
supply units, drive controllers, motors, windings, and laminated cores.
• Temperatures of the track motor-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.
• After powering down switching chokes, power supply units, and drive
controllers, let them cool for 15 minutes before touching.
Protection Against Magnetic and Electromagnetic Fields During

Installation and Use
See Safety Label Placement on page 129 for location of series A motor module
labels.
The motor modules, when in use, and permanent motors magnets pose a
danger to persons with heart pacemakers, metal implants, and hearing aids.
ATTENTION: The mover uses strong magnets. There is a risk of health hazard
for persons with heart pacemakers, metal implants, and hearing aids while
in proximity of magnetic and magnetic-field producing components. The
magnetic field that is generated can disrupt the functionality of automatic-
implantable cardioverter defibrillators (AICD). People with cardiac
pacemakers must not work near the iTRAK system.
Magnetic Field Strength
The movers of the iTRAK system contain components with strong magnetic
fields. The motor modules also produce magnetic fields while movers are being
commanded. This section shows the strength of the field for an enabled mover,
uninstalled mover, and an uninstalled position magnet.
When motion is present on the system, the magnetic field does not exceed
0.05 mT at 500 mm (19.7 in.) in any direction from the track. Ferrous metals
can influence the magnetic field direction and strength. For the most accurate
data, measure the magnetic field strength on a track that is installed in its final
configuration.

Start Chapter 1
Figure 12 - Mover Magnetic Field Orientation
To avoid the interaction with magnetic field, Table 6 shows the magnetic field
strength versus distances from the center point of an uninstalled mover.
Table 6 - Magnetic Field Strength of an Uninstalled Mover
Cat. No. Magnetic Strength
0.05 mT 0.1 mT 0.5 mT
L (+/–) W+ W- H (+/–) L (+/–) W+ W- H (+/–) L (+/–) W+ W- H (+/–)
mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.)
2198T-VT0505-A 180 (7.1) 145 (5.7) 310 (12.2) 90 (3.5) 140 (5.5) 120 (4.7) 130 (5.1) 70 (2.8) 90 (3.5) 65 (2.6) 95 (3.7) 55 (2.1)
2198T-VT0510-A 215 (8.5) 175 (6.9) 375 (14.8) 140 (5.5) 180 (7.1) 135 (5.3) 260 (10.2) 120 (4.7) 125 (4.9) 70 (2.8) 140 (5.5) 55 (2.1)
2198T-VT0515-A 220 (8.7) 190 (7.5) 320 (12.6) 140 (5.5) 190 (7.5) 145 (5.7) 190 (7.5) 130 (5.1) 140 (5.5) 70 (2.8) 100 (3.9) 50 (2.0)
2198T-VT1005-A 170 (6.7) 200 (7.9) 230 (9.1) 165 (6.5) 120 (4.7) 150 (5.9) 160 (6.3) 145 (5.7) 70 (2.8) 60 (2.4) 110 (4.3) 75 (3.0)
2198T-VT1010-A 230 (9.1) 200 (7.9) 360 (14.2) 165 (6.5) 200 (7.9) 150 (5.9) 255 (10.0) 150 (5.9) 150 (5.9) 70 (2.8) 135 (5.3) 80 (3.1)
2198T-VT1015-A 260 (10.2) 200 (7.9) 300 (11.8) 170 (6.7) 220 (8.7) 155 (6.1) 200 (10.0) 150 (5.9) 150 (5.9) 85 (3.3) 120 (4.7) 80 (3.1)
2198T-VT1505-A 180 (7.1) 255 (10.0) 310 (12.2) 240 (9.4) 140 (5.5) 180 (7.1) 190 (7.5) 220 (8.7) 90 (3.5) 65 (2.6) 125 (4.9) 95 (3.7)
2198T-VT1510-A 245 (9.6) 225 (8.9) 375 (14.8) 190 (7.5) 220 (8.7) 165 (6.5) 260 (10.2) 180 (7.1) 175 (6.9) 70 (2.8) 140 (5.5) 105 (4.1)
2198T-VT1515-A 300 (11.8) 210 (8.3) 320 (12.6) 200 (7.9) 250 (9.8) 165 (6.5) 210 (8.3) 170 (6.7) 160 (5.9) 85 (3.3) 140 (5.5) 110 (4.3)

Chapter 1 Start
To avoid the interaction with magnetic field, Table 7 shows the magnetic field
strength versus distances from the center point of a mover that is installed on a
track.
Table 7 - Magnetic Field Strength of an Installed Mover, Enabled at Zero Speed
0.05 mT 0.1 mT 0.5 mT
L (+/–) W H (+/–) L (+/–) W H (+/–) L (+/–) W H (+/–)
mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.)
2198T-VT0505-A 220 (8.7) 125 (4.9) 125 (4.9) 195 (7.7) 95 (3.7) 70 (2.8) 75 (3.0) 40 (1.6) 55 (2.2)
2198T-VT0510-A 250 (9.8) 95 (3.7) 130 (5.1) 210 (8.3) 60 (2.4) 120 (4.7) 120 (4.7) 20 (0.8) 55 (2.2)
2198T-VT0515-A 300 (11.8) 150 (5.9) 140 (5.5) 220 (8.7) 100 (3.9) 130 (5.1) 120 (4.7) 30 (1.2) 60 (2.4)
2198T-VT1005-A 330 (13.0) 125 (4.9) 170 (6.7) 175 (6.9) 95 (3.7) 130 (5.1) 75 (3.0) 40 (1.6) 70 (2.8)
2198T-VT1010-A 340 (13.4) 130 (5.1) 165 (6.5) 190 (7.5) 100 (3.9) 125 (4.9) 100 (3.9) 40 (1.6) 65 (2.6)
2198T-VT1015-A 360 (14.2) 130 (5.1) 170 (6.7) 290 (11.4) 105 (4.1) 130 (5.1) 130 (5.1) 40 (1.6) 105 (4.1)
2198T-VT1505-A 440 (17.3) 125 (4.9) 215 (8.5) 195 (7.7) 95 (3.7) 190 (7.5) 75 (3.0) 40 (1.6) 85 (3.3)
2198T-VT1510-A 430 (16.9) 165 (6.5) 200 (7.9) 210 (8.3) 140 (5.5) 130 (5.1) 120 (4.7) 60 (2.4) 70 (2.8)
2198T-VT1515-A 420 (16.5) 150 (5.9) 200 (7.9) 360 (14.2) 110 (4.3) 130 (5.1) 140 (5.5) 50 (2.0) 150 (5.9)
Figure 13 - Position Magnet Magnetic Field Orientation
Table 8 - Magnetic Field Strength of an Uninstalled Position Magnet

0.05 mT 0.1 mT 0.5 mT
R H (+/–) R H (+/–) R H (+/–)
mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.)
2198T-NN-318
135 (5.3) 276 (10.9) 120 (4.7) 221 (8.7) 80 (3.1) 131 (5.2)
2198T-NS-318

Start Chapter 1
Safe Magnet Handling
ATTENTION: 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 clips and 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.
• 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.
Magnet Plate Keeper
Exposed or uninstalled magnet plates, whether they are mounted to a mover or

free-standing, must have a keeper that covers the entire magnet face. The
keeper must consist of 5…10 mm (0.2…0.4 in.) wood or cardboard over the
magnets and a 0.5…1.5 mm (0.02…0.06 in.) thick ferrous sheet metal over the
wood or cardboard.
Figure 14 - Magnet Plate Keeper
Ferrous Sheet Metal
Wood or Cardboard
Magnet Plate
Magnet plates that are covered with a keeper are fairly safe to handle. They
must be kept at least 305 mm (12 in.) away from other magnet plates and other
ferrous metal parts such as hardware and tools.
Magnet plates without keepers must be kept a minimum of 1 m (3.3 ft) away
from other magnet plates and ferrous metal parts.

Chapter 1 Start
Notes:

Chapter 2
Track Installation
Use this chapter to install an iTRAK® system track and lubrication system.
Topic Page
Install the Track 27
Install the Lubrication System 32
Choose the location for system components following these considerations:

• operator and maintenance access to movers and motor modules
• cable lengths
• vibration free surfaces
ATTENTION: Before you start the installation of the system, read the
See Safety Information on page 19 to reduce the risk of injury and property
damage.
WARNING: Improper use of these components, failure to follow the safety

instructions, tampering with the product, or disabling of safety devices could
result in property damage, injury, electric shock, or death.
Install the Track Use the following sections as guide for the installation of your preassembled
track. Your track can be made with more or less motor modules than are shown
in these procedures, but the same principles apply.
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.
• Only qualified persons can work with components of the system or

within their proximity.
• Observe the relevant statutory regulations of accident prevention.
• Use protective equipment such as hard hat, safety goggles, safety shoes,
safety gloves while handling system.

Chapter 2 Track Installation
• Proper transport, storage, mounting and installation, and care in

operation and maintenance are prerequisites for optimal and safe
operation of the system.
– Use suitable equipment for mounting and transport.
– Use proper tools and use special tools if specified.
– Use hoist equipment and tools in the correct manner.
– Avoid jamming and crushing by using safety measures.
– Do not stand under loads.
• Use the components of the system only in the manner that is defined as
appropriate. See Appropriate Use on page 7
• Follow the safety regulations and requirements of the country in which
the system is operated.
• Only operate if the national Electromagnetic Compatibility (EMC)
regulations for the application are met.
• In accordance with EMC requirements, the machine or installation
manufacturer is responsible for compliance with the limit values as
prescribed in the national regulations.
Mount an Oval Track
To mount the oval track or oval track sections, do the following.
1. Calculate the weight of the track or track section.

Frame Size Weight, Approx
50 123 kg/m (83 lb/ft)
100 156 kg/m (105 lb/ft)
150 189 kg/m (127 lb/ft)
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.
If mounting the iTRAK track directly to mounting surface, make sure
that the mounting surface has a flatness of 0.05 mm per 300 x 3 00 mm
(0.002 in. per 11.8 x 11.8 in.). For systems longer than 2400 mm
(94.48 in.), we recommended that you use leveling feet between iTRAK
mounting plates and the mounting surface.
3. Unpack track sections within the crate so that the lifting slots are easily
accessible.

Track Installation Chapter 2
4. Thread lifting straps through lifting slots as necessary for your

installation and secure them to lifting machinery.
Lifting Strap Position for Horizontal Installation
Lifting Slots Lifting Slots Lifting Slots
Lifting Strap Position for Vertical Installation
Lifting Slots
Lifting Slots
Mounting plates are not shown for clarity.

Lifting Slots
5. Lift and transfer track section to its intended location.

Mount by using the M16 x 2 threaded holes and the slots in mounting
plate.
500.0
(19.7)
450.0 12.7
(17.7) (0.5)
90.0
(3.5) 45.0
(1.8)
25.0
(1.0) 4X 13.5 2X TAP M16 X 2.0
(0.53)

Mounting plate installed

on spine bars.
We recommend using leveling feet at each mounting point. For example,

Misumi Adjuster Feet - Resin Rubber Type, Misumi part number
AJPDR16-100E.
Mounting Plate
Mounting Surface
M12 Hold Down Screws (X2)
Leveling Feet
6. If your system was shipped multiple segments, do the following,

otherwise skip to next step.
a. Align track sections by using the shoulder bolt holes of the motor
modules and the track frame.
b. 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.
c. Torque shoulder bolts to 13 N•m (9.6 lb•ft).
d. Insert bearing rail key in the end of a pre-installed bearing rail.
e. 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.

f. Apply Loctite 243 (blue) to threads of M8 x 25 socket head cap

screws, quantity as required, and secure the bearing rail.
g. Torque all bearing rail screws to 22 N•m (16.22 lb•ft).
h. Check rail alignment.
If mis-alignment is less than 0.0254 mm (0.001 in.), then restone. If
greater than 0.0254 mm (0.001 in.) readjust rail alignment.
7. Remove shipping clamps.
8. Follow the guidelines in System Design for Control of Electrical Noise
Reference Manual, publication GMC-RM001, and Industrial
Automation Wiring and Grounding Guidelines, publication 1770-4.1
to obtain proper low-impedance grounding for high-frequency electrical
noise.

Install the Lubrication Catalog number 2198T-AL-SYS iTRAK Lubrication System, comes with a
coil of tubing to connect system fittings to the remotely located pumps and
System system fittings. The assembled pumps have push-to-connect connectors with
plugs. These plugs help prevent oil from leaking during shipment. You remove
these plugs when you are ready to connect the tubing. The pump fittings
contain a check valve to help prevent backflow when a replacement reservoir is
installed.
The lubrication system is assembled with right angle fittings. Additional

straight hex nipple fittings are provided to let you redirect pump tubing. If
your system requires straight exit from the pump, use the supplied straight
fittings to replace the right angle fittings. Use Teflon tape for the tapered NPT
threads.
The reservoir uses a straight 1/4 BSPP thread. A sealing washer is supplied
with the support bracket. Do not use Teflon tape at this joint.
IMPORTANT The lubrication tubes that are provided in your iTRAK system are all of equal
length, the equal length splits the flow evenly and avoids back flow. Do not
modify their length.
For systems installed horizontally, the shared lube ports are for the top rail. For
systems installed vertically or stand up, the shared ports are for the highest
weep holes on the upper and lower rail.
Figure 15 - Lubrication Tubing Configuration
Horizontally installed systems. Vertically or stand up installed systems.

The shared lube points must be
at the same vertical height.
6
3 2
1
2
1
4
5
4
7
3
Use a maximum of 10 m
(32.8 ft) tubing per pump.
5

1 Top inner lubrication tube 5 Straight push-to-connect tube connector
2 Top outer lubrication tube 6 Top rail
3 Bottom outer lubrication tube 7 Bottom rail
4 Y-split push-to-connect tube connector

Figure 16 - Lubrication Pump Description
4 12
11
10
7 8
5 6

1 5 m (16.4 ft) Digital signal cable 7 Brass elbow fitting
2 Digitally activated pump 8 Straight brass fitting (1)
3 Pump status indicators 9 Mounting bracket
4 Lubricant cartridge 10 0.25-20 x 0.5 bolt
5 Plug 11 Beam clamp
6 Check valve 12 0.25-20 x 1.25 bolt
(1) If your installation requires the tubing to exit the pumps vertically, you can replace the brass elbows with the two straight brass nipples
that are supplied with the kit.
What You Need
7/16 in. open-end wrench
Mount the Lubricator Pumps
To mount the lubricator pumps, do the following.
1. Locate a mounting position for the pumps.

The pump must be located within the 10 m (32.8 ft) of tube routing
distance to the iTRAK system lubrication connectors and 5.0 m
(16.4 ft) of the power cable routing distance to 24V I/O port of your
controller. The location must be accessible for maintenance and visible
for monitoring the pumps status indicators. Observe the clearance
requirements that are shown in Figure 17.

2. Adjust the beam clamp to accommodate the attachment surface by using

a 7/16 in. open-end wrench.
The beam clamp can be positioned anywhere on the H pattern of the
mounting clamp.
3. Attach the lubricator pumps to their mounting surface by the beam
clamp by using 7/16 in. open-end wrench.
4. Label, route, and secure the tubing from the pumps to the lubrication
connectors on the iTRAK system.
5. Remove the plug from the lubricator pump connector and immediately
replace with the tubing.
To remove the plug, pull back on the connector face and pull out the
plug.
6. Repeat step 5 for the other pump and at each connector on the iTRAK
system.
Figure 17 - Mounting Dimensions and Clearance

Power Cable Length
5.0 m (16.4 ft)
102
(4.0)
Minimum Clearance Minimum static bend
radius 22 mm (0.87 in.)
Minimum Clearance Minimum Clearance

102 102
(4.0) (4.0)
271.3
(10.7) 6.35
(.3)
232.82
(9.2)
63.5 88.9
(3.0) (3.5)
45.4 95.25
(2.0) (3.75)
127.0
(5.0)
Wiring Lubrication Pump
Connect the power cable the 24V I/O port of your controller.
1 BROWN
4 2 +24V
M8 2 WHITE Not Used
Connector 3 BLUE GND
4 BLACK
3 1 Not Used

An initial coating of oil is required on the entire track before operating the
iTRAK and auto lubrication systems.
IMPORTANT The mover wheels and lubrication wipers help to distribute the oil on the
track. The movers must be in motion when the pump is activated, otherwise
the oil drips away.
Lubrication Pump Configuration

Table 9 - Recommend Lubrication Pump Settings
Feature Setting
Mode Impulse
Top rail 0.8 cc/pulse
Bottom rail 0.4 cc/pulse
Lubrication Volume Calculation
To calculate the volume of oil that is required to coat the running surfaces of
the iTRAK system with 0.025 mm (0.001 in.) thickness of oil.
Volume (cc)= 0.393 + 0.0002445 x l + 0.033 x m
Where,
l = straight length of track in mm

m = the quantity of movers
EXAMPLE For 1200 mm (94.5 in.) track with eight movers.

Volume (cc) = 0.393 +0.0002445 x 1200 + 0.033 x 8
Volume (cc) = 0.9504 cc
See Lubrication Examples on page 106 for more examples.

Notes:

Chapter 3
Connect Your iTRAK System to a Kinetix 5700

iTRAK Power Supply
This chapter contains information for designing a system that uses the iTRAK®
power supply, including connectivity to the motor modules, the USB I/O, and
the gateway.
The iTRAK power supply derives bus power for and distributes control power
to the iTRAK system. It is a Kinetix® 5700 component, and is designed to work
with the 2198-Pxxx Kinetix 5700 power supplies as part of a Kinetix 5700
system.
Topic Page
Typical iTRAK System with an iTRAK Power Supply 37
Design Guidelines 40
iTRAK Power Supply Connector Data 48
Wiring Requirements 51
Wire the iTRAK Power Supply 52
Apply the iTRAK Power Cable Shield Clamp 55
Wire the Digital USB I/O Module 56
Wire the Gateway 57
iTRAK Power Supply Wiring Example 59
Cable Preparation for iTRAK Power Supply Output Power Cables 60
Logix Designer Application Support 63
Typical iTRAK System with an The iTRAK power supply interfaces to the gateway computer via a USB I/O
module. The gateway sends enable and disable signals and clears faults for
iTRAK Power Supply iTRAK power supply. The iTRAK power supply reports its status through a
relay that the USB I/O monitors.
There is sample code for Logix Designer that provides code for the gateway
computer to control the iTRAK power supply and interface to the rest of the
Kinetix 5700 system. See Logix Designer Application Support on page 63 for
more information.
ATTENTION: The correct Logix Designer code must be used as instructed to

control the iTRAK power supply and provide fault support to the Kinetix 5700
system. Failure to use the program can result in equipment damage.

Chapter 3 Connect Your iTRAK System to a Kinetix 5700 iTRAK Power Supply
Figure 18 is a full view of the system that includes customer supplied

components, iTRAK solutions, and wiring.
Figure 18 - Typical iTRAK System with an iTRAK Power Supply

1
24V Control
Power Supply
2 3
4
EtherNet/IP
6 7
LNK1 LNK2 NET OK
5 Branch Protection,
2
Disconnect,
1
8 Line Filter, and 9

1 Functional Safety (1)
6 1
11
10
12
13
6 18
15 16 17
19 24
14
23
20
22
21
(1) See Kinetix 5700 Servo Drives User Manual. publication 2198-UM002, for more information on theses components.

1 24V control power 13 Motor module power bus and control power
(number of cables vary by system)
2 Kinetix 5700 power supply 14 Studio 5000® Programming Interface (not supplied with system)
3 Kinetix 5700 iTRAK power supply 15 Gateway
4 Controller 16 Communication cable to motor module (one cable per motor module)
5 Managed Ethernet Switch 17 Digital USB I/O module
6 Machine Ethernet 18 iTRAK ready connection
7 Contactor enable signal line 19 Bearing rail
8 Mains power (460V nominal) 20 Track frame
9 Kinetix 5700 line voltage 21 Mover
10 Plant Ethernet 22 Straight motor module
11 USB cable 23 Curved motor module
12 iTRAK power supply I/O connections 24 iTRAK bus conditioner (not visible mounted below track frame)

Connect Your iTRAK System to a Kinetix 5700 iTRAK Power Supply Chapter 3
For detailed information on the installation and how to wire the iTRAK power
supply into a Kinetix 5700 system, see the Kinetix 5700 Servo Drives User
Manual, publication 2198-UM002. The Kinetix 5700 Servo Drives User
Manual publication contains the information that is needed for using the other
parts of the Kinetix 5700 system, including:
• 2198-Pxxx Kinetix 5700 power supply
• Other Kinetix 5700 components that can be part of your Kinetix 5700
system
• Branch protection, disconnect, and line filter hardware
• Enclosure requirements
• Requirements for EMC and agency compliance
• Kinetix 5700 hardware mounting
• Bonding, wire routing, EMC considerations
As shown in Figure 18, components of the iTRAK power supply based system
include items that are listed in Table 10.
Table 10 - Components of an iTRAK System Using an iTRAK Power Supply
Item Description
iTRAK track Frame, bearings, motor modules, and movers.
iTRAK power supply, bus conditioner, Creates bus voltages and distributes control power for the iTRAK
and power cables system.
Kinetix 5700 power supply Creates the bus voltage that is used by other Kinetix 5700 modules,
including the iTRAK power supply.
Gateway and communication cables Controls and coordinates iTRAK motor modules, provides an interface
for them to the Logix system. In systems with an iTRAK power supply,
the gateway also enables, disables, and clears the faults for the iTRAK
power supply.
USB I/O module The USB I/O module serves as the physical input and output interface
between the iTRAK power supply and gateway computer.
Other Kinetix 5700 components and Other components that are used in your Kinetix 5700 system and other
related hardware hardware that is used for connecting the Kinetix 5700 system to three-
phase input power, as needed for branch protection, filtering,
contactor, and other functions.

Design Guidelines Use the following guidelines to help design the iTRAK system that includes an
iTRAK power supply.
Determine the Number iTRAK Power Supplies Required
The number of iTRAK power supplies can be scaled to match the power needs
of the iTRAK system closely. Additional iTRAK power supplies can be added
to the system as needed. The following factors impact the number of iTRAK
power supplies required for a system.
• Output Bus current
• 24V Control Current
• Cable length
If needed, See Using Multiple iTRAK Power Supplies for information on how
to connect a system with multiple iTRAK power supplies.
Output Bus Current
Sizing is the process of determining the required size and quantity of power
hardware components and motors modules for an application. Sizing an
iTRAK system involves many variables. Call a Rockwell Automation
application engineer to size your system.
24V Control Power
The following criteria must be met for the operation of the system.
• Sufficient current can be delivered.
• The required voltage is maintained at the input to the iTRAK power
supply.
• Maximum iTRAK power supply input current is never exceeded.
• Maintaining an acceptable voltage drop from the iTRAK power supply
to the iTRAK motor modules, see the Maximum iTRAK Power Supply
to iTRAK Module Cable Length.
The iTRAK power supply uses 24V control power to run all low voltage
circuits and it distributes 24V control power to the iTRAK motor modules
that are connected to it.
24V Current Requirements
Determine the amount of current required; add the current draw of the
iTRAK power supply to the current used by each of the motor modules that
are connected to that iTRAK power supply. Make sure that you include all
iTRAK motor modules that are connected to both the A and B outputs. When
designing the system, be sure to account for the 16 A pass through limit of the

iTRAK power supply to the iTRAK motor modules. See iTRAK System
Technical Data, publication 2198T-TD001 for the amount of current required
for the iTRAK power supply and the iTRAK motor modules.
Input Voltage
See Table 11 for the control-power input-voltage requirements. The table

shows the voltage that is required at the input connector on the iTRAK power
supply. You must take in account for all voltage drops in wiring from the 24V
power supply to the iTRAK power supply and the motor modules.
Table 11 - 24V DC Control Power Input (CP) Specifications

Connector Input Voltage, Input Voltage, iTRAK Power Pass Through Total at Input,
Max Min Supply to Motor Max
Consumption, Modules, Max
Max
24V DC Control 26.4V DC 21.6V DC 1A 16 A 17 A
Power Input (CP)
Table 12 - 24V DC Control Power Output (ICP) Specifications

Connector Pass Through to Motor
Modules, Max (1)
24V DC Control Power 16 A
Output to iTRAK (ICP)
(1) These ratings apply to both the total combined current from
connector A and B, and also applies to the rated output for
connector A or B individually.
iTRAK Power Supply Output Power Connections

The iTRAK power supply has two sets of output power cable connectors,
referenced as A and B; they let you connect two power cables to the iTRAK
system. The two sets of connectors have identical sets of signals, they are
connected internally, and are interchangeable.
By using multiple cables the iTRAK power supply can deliver control power to
more iTRAK motor modules, see Maximum iTRAK Power Supply to iTRAK
Module Cable Length.

Maximum iTRAK Power Supply to iTRAK Module Cable Length
Account for the resistive losses in the 2198T-CHBFLS8-12AAxx power cable

that connects the iTRAK power supply to motor modules. Make sure that
there is sufficient control power voltage at the input to all motor modules. The
amount of current flow and the number of motor modules that are connected
in series limits the length of this cable.
See Table 13 to determine the maximum length of a power cable that is based
on the number of motor modules that are connected to it at the minimum
control power input voltage. This table is for 2198T-CHBFLS8-12AAxx
cables, which are the only cables supported.
Cables between the iTRAK power supply and the iTRAK system are limited
to 30 m (98 ft).
The cable length calculations are made separately for output A and B.
Table 13 - Number of Series A Motor Modules Connected to a Single Input Cable

Cable Length (1) Motor Module Quantity
1 2 3 4 5 6 7 8 9 10 11
3 m (9.8 ft)
6 m (19.7 ft)
9 m (29.5 ft)
12 m (39.4 ft)
15 m (49.2 ft)
30 m (98.4 ft)
(1) The cable lengths that are shown are for the cable from the iTRAK power supply to the first motor module. It
is assumed that the subsequent motor modules are connected using short motor module-to-motor module
cables.
Table 14 - Number of Series B Motor Modules Connected to a Single Input Cable

Cable Length (1) Motor Module Quantity
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
3 m (9.8 ft)
6 m (19.7 ft)
9 m (29.5 ft)
12 m (39.4 ft)
15 m (49.2 ft)
30 m (98.4 ft)
(1) The cable lengths that are shown are for the cable from the iTRAK power supply to the first motor module. It is assumed that the subsequent motor modules are
connected using short motor module-to-motor module cables.

Choose a 2198-Pxxx Kinetix 5700 Power Supply
The iTRAK power supply connects to the Kinetix 5700 DC-bus created by
the 2198-Pxxx, Kinetix 5700 power supply. The Kinetix 5700 power supply
must be sufficiently sized to support the iTRAK power supply load and any
other servo drive load.
Sizing an iTRAK system involves many variables. Call a Rockwell Automation

application engineer to size your system.
The iTRAK power supply creates two power buses that are used by iTRAK
motor modules. The topology of the iTRAK motor modules uses the center
voltage bus as a return, and the upper and lower as sources.
Once the output current requirements of the iTRAK power supplies are
known, the amount of power that is required from the Kinetix 5700 power
supply for the iTRAK power supplies is calculated by using this equation.
P (Watts) = Output Current * (Nominal Bus Voltage 1 + Nominal Bus Voltage 2) + iTRAK Power Supply Losses
See Kinetix Servo Drives Specifications Technical Data, publication

KNX-TD003, for iTRAK power supply losses
Any other Kinetix 5700 components that are connected to the Kinetix 5700
power supply bus must also be added to this number.
Table 15 shows the nominal bus voltages and currents of the iTRAK power
supply.
Table 15 - Bus Output (IDC) Specifications

Connector Continuous Peak Output Nominal H to DC- Nominal L to DC- Bus
Output Current Current Voltage Voltage
Bus Output (IDC) (1) 12.5 A 25.0 A 330V DC 165V DC
(1) These ratings apply to both the total combined current from connector A and B, and also applies to the rated output for
connector A or B individually.
The Kinetix 5700 power supply that is used must be able to deliver the total
power to be consumed. The Kinetix 5700 Servo Drives User Manual,
publication 2198-UM002, has more information.
Kinetix Servo Drives Specifications Technical Data, publication

KNX-TD003, contains the power ratings of the 2198-Pxxx Kinetix 5700
power supplies. Their power ratings are derived assuming 460V AC line input;
scale their power rating based on your line voltage.
Verify that the shunting capacity of the system that the 2198-Pxxx Power
Supply manages is not exceeded. For further details, see Shunting Capacity.

Shunting Capacity
The iTRAK power supply can move regenerative energy from the iTRAK
system back to the Kinetix 5700 DC bus. The Kinetix 5700 power supply
turns on a shunt to limit DC bus voltage if the DC bus voltage gets too high.
The amount of shunting capacity available depends on which 2198-Pxxx
Kinetix 5700 power supply that is used and whether an external shunt is
present. See the Kinetix 5700 Servo Drives User Manual, publication
2198-UM002, for more information on shunting capacity.
Kinetix 5700 System Design

When the number of iTRAK power supplies and type of 2198-Pxxx Kinetix
5700 power supplies are known, the Kinetix 5700 system design can be
determined.
The important items to be determined and designed are listed here.

• Connections of the Kinetix 5700 components including the iTRAK
power supply
• Cabinet selection
• Cabinet layout and wiring
• Other components as required such as contactor and line filter
See the Kinetix 5700 Servo Drives User Manual, publication 2198-UM002,
for information regarding design of these Kinetix 5700 components.
Cabinet
Cabinet selection is important to maintain a proper temperature and EMC

performance. See the Kinetix 5700 Servo Drives User Manual, publication
2198-UM002, for information regarding cabinet selection, parts layout,
wiring, and other information.
Ethernet Connection
Connection to the EtherNet/IP™ network is not required during runtime for
the iTRAK power supply. An Ethernet connection is required when
downloading firmware updates by using ControlFLASH™ software.

Wire the iTRAK System
An iTRAK power supply can power up to 20 Series A or 32 Series B motor

modules depending on current requirements. See Figure 19 for a typical layout
on how to wire a system using one iTRAK power supply. Detailed wiring the
connections to the iTRAK power supply are shown in Figure 30 on page 59.
Figure 19 - Wiring an iTRAK System with an iTRAK Power Supply
2 2 2 2 2 2 2 4
3
2198-Pxxx 2198T-W25K-ER
Kinetix 5700 Kinetix 5700 3
Power Supply iTRAK Power
Supply
Output Output
A B
1 3
4 2 2 2 2 2 2 3
1
Item Description
1 2198T-CHBFLS8-12AAxx, iTRAK power supply to motor module cable
2 2198T-CHBP8S8-12P3, power cable
4 2198T-WBCMOD, iTRAK bus conditioner
Wiring the connections from multiple iTRAK power supplies is shown in

Figure 20 on page 46 and Figure 21 on page 47.
See the Kinetix 5700 Servo Drives User Manual, publication 2198-UM002,
for details on how to wire the rest of the Kinetix 5700 system. Information on
how to wire to the iTRAK power supply is found in Wire the iTRAK Power
Supply on page 52.
Using Multiple iTRAK Power Supplies
Follow these guidelines when using multiple iTRAK power supplies in an

iTRAK system.
When using multiple iTRAK power supplies, the system must be parsed into
separate electrical pieces for each of the iTRAK power supplies.
The iTRAK power supply is not designed to have the output buses of multiple
power supplies connected together to create one bus of higher current capacity.
IMPORTANT In systems that use multiple iTRAK power supplies, make sure that the
output bus of one power supply is never connected to the output bus of
another power supply.

Use the following scenario to understand the use of multiple iTRAK power
supplies for systems that require a higher current draw. In this example, part of
the track has a high-power demand, and the rest of the track has a lower power
demand. In this case iTRAK power supply 1 powers the first group of ten
motor modules, while iTRAK power supply 2 provides power to the remaining
six motor modules. The DC buses of these two groups are electrically isolated
from each other as shown in Figure 20.
Figure 20 - Connecting Multiple iTRAK Power Supplies in a System
3 2 2 2 4 2 3
3
2198T-W25K-ER 2198T-W25K-ER
2198-Pxxx Kinetix 5700 3
Kinetix 5700 Kinetix 5700
iTRAK Power iTRAK Power
Power Supply Supply 1 Supply 2
Output Output Output Output
A B A B
1 1
4 2 2 2 2 4 3
1
Item Description
1 2198T-CHBFLS8-12AAxx, iTRAK power supply to motor module cable
4 2198T-WBCMOD iTRAK bus conditioner
ATTENTION: Power from iTRAK power supply 1 must not be connected to

the power from iTRAK power supply 2.
One gateway can interface to multiple iTRAK power supplies through the
Digital USB I/O Module. When you use this configuration, connect the
Enable and Clear Fault signals in parallel, and connect the IPS Ready signal in
series through all iTRAK power supplies as shown in Figure 21.

Figure 21 - Wiring Multiple iTRAK Power Supplies to the Digital USB I/O Module
2198T-W25K-ER 2198T-GUSB
Kinetix 5700 iTRAK Digital USB I/O
Power Supply 1 Module
1 ENABLE
IN1 OUT 00 NO
2 (1)
COM 24V COM 24V OUT 00 C
Digital Input 3 CLEAR FAULT
(IOD) Connector
IN2 OUT 01 NO
4 (1)
5
SHLD SHIELD
iPS READY
ITRAK Power Supply - 24V COM IN00 A
Ready (IR) Connector + 24V IN00 B USB
Port
2198T-W25K-ER
Kinetix 5700 iTRAK
Power Supply 2
1 ENABLE
IN1
2 (1)
COM 24V COM
Digital Input 3 CLEAR FAULT USB
(IOD) Connector IN2 Port
4 (1)
COM 24V COM 2198T-Gxx-xxx-E
Gateway
SHLD SHIELD
- IPS READY
ITRAK Power Supply
Ready (IR) Connector + IPS READY IN
(1) Only one connection to 24V Com is required for each iTRAK power supply. Either pin 2 or pin 4 must be connected, it is not necessary to
connect both.

iTRAK Power Supply Connector Data

Use this illustration to identify the iTRAK power supply features and
indicators.
Figure 22 - iTRAK Power Supply Features and Indicators (2198T-W25K-ER)
6 6
MOD– 7
NET– 8
5700
9 16
10 17
5 2
4 1 11
12 DC+
18
I/O
1 6
19
1 6
3
2 7
-
13
3 8
4 9
IPS RDY
5
5 10
10
+
14
DC-
15
IN 24V -
IN 24V +
18
20
21
iTRAK Power Supply iTRAK Power Supply

(top view) (bottom view)
iTRAK Power Supply

(front view)
2 2
Item Description Item Description Item Description

1 Power bus cable clamp 8 Network status indicator 15 24V control input power (CP) connector
2 Ground lug 9 LCD display 16 24V control output power (ICP) connector -A
3 Digital inputs (IOD) connector 10 Navigation push buttons 17 DC bus output (IDC) connector - A
4 Ethernet (PORT1) RJ45 connector 11 Link speed status indicators 18 24V control output power (ICP) connector - B
5 Ethernet (PORT2) RJ45 connector 12 Link/Activity status indicators 19 DC bus output (IDC) connector - B
6 Zero-stack mounting tab/cutout 13 iTRAK PS ready (IR) connector 20 Cooling fan
7 Module status indicator 14 DC bus input (DC) connector 21 Fuse holder

Table 16 - iTRAK Power Supply Connectors

Designator Description Connector
DC DC common bus power DC-bus links and end caps
CP 24V control input power 2-position plug, terminal screws
IDC iTRAK DC bus output A and B 4-position plug, terminal screws
ICP iTRAK 24V control output power A and B 2-position plug, terminal screws
IOD Digital inputs 10-position plug, spring terminals
IR iTRAK power supply ready 2-position plug, terminal screws
PORT1, PORT2 Ethernet communication ports RJ45 Ethernet
Table 17 - DC Bus Input Power Connector

DC Pin Description Signal
DC–
Bus bar DC bus connections
DC+
Table 18 - Control Input Power (CP) and Control Output Power A and B (ICP) Connectors Pinout
Pin Description Signal 2
1 Control Input Power (CP) Connector
2 24V common 24V-
1 24V power supply, customer-supplied 24V+
2 1
Control Output Power A and B (ICP) Connectors
Table 19 - iTRAK Power Supply Ready (IR) Connector Pinout

IR Pin Description Signal
2 RDY- -
iTRAK PS ready +
1 RDY+
Table 20 - DC Power Bus Output A and B (IDC) Connectors Pinout

IDC Pin Description Signal
4 Chassis ground GND
H
3 DC high voltage H
L
2 DC low voltage L
DC-
1 DC- bus DC-

Table 21 - Digital Inputs (IOD) Connector Pinout

IOD Pin Description Signal
1 Digital input #1 Enable
2 I/O common for customer-supplied 24V supply COM 1 6
2 7
3 Digital input #2 Fault Clear
3 8
4 I/O common for customer-supplied 24V supply COM
4 9
5 I/O cable shield termination point SHLD
5 10
6 Digital input #3 IN3
8 Digital input #4 IN4
10 I/O cable shield termination point SHLD

Wiring Requirements
The wire must be copper with 75 °C (167 °F) minimum rating. Phasing of the mains AC power
is arbitrary and earth ground connection is required for safe and proper operation.
IMPORTANT The National Electrical Code and local electrical codes take precedence over the values and
methods provided.
Table 22 - iTRAK Power Supply (2198T-W25K-ER) Wiring Requirements

Description Connects to Terminals Wire Size Strip Length Torque Value
mm2 (AWG) mm (in.) N•m (lb•in)
Pin Signal
DC-bus input power Bus bar DC– N/A (2) N/A (2) N/A (2)
DC+
SELV/PELV rated 24V power CP-1 24V+ 1.5…4 (3) 10.0 (0.39) 0.5…0.6
(connector plug) CP-2 24V– (16…12) (4.4…5.3)
6 (3) 10.0 (0.39) 0.7…0.8
(10) (6.1…7.0)
iTRAK power supply ready IR-1 RDY+ 0.05…2.5 7.0 (0.28) 0.4…0.5
IR-2 RDY- (30…12) (3.5…4.4)
24V iTRAK control power (1) ICP-1 24V+ 1.5…6 10.0 (0.39) 0.7…0.8
ICP-2 24V– (16…10) (6.1…7.0)
DC-bus output power A and B (1) IDC-1 DC- 2.5…6.0 10.0 (0.39) 0.7…0.8
IDC-2 L (12…10) (6.1…7.0)
IDC-3 H
IDC-4 GND
Digital inputs IOD-1 Enable 0.20…1.31 10.0 (0.39) N/A (4)
IOD-2 COM (24…16)
IOD-3 Clear Fault
IOD-4 COM
IOD-5 SHLD
IOD-6 IN3
IOD-7 COM
IOD-8 IN4
IOD-9 COM
IOD-10 SHLD
(1) The iTRAK control power (ICP) and iTRAK DC bus output (IDC) connections must be made using catalog number 2198T-CHBFLS8-12AAxx.
(2) Shared DC-bus power connections are always made from power supply to power supply over the bus-bar connection system. These terminals do not receive discrete wires.
(3) Use sufficient wire size to support the complete control power load, including Kinetix 5700 modules and pass-through current for the attached motor modules.
(4) This connector uses spring tension to hold wires in place.
ATTENTION: To avoid personal injury and/or equipment damage, observe

the following:
• Make sure that installation complies with specifications regarding wire
types, conductor sizes, branch circuit protection, and disconnect devices. The
National Electrical Code (NEC) and local codes outline provisions for safely
installing electrical equipment.
• Use motor power connectors only for connection purposes. Do not use them
to turn on or off the unit.
• Ground shielded power cables to help prevent potentially high voltages on
the shield.

Wire the iTRAK Power Supply The following sections cover wiring the iTRAK power supply to an iTRAK
system.
For information on how to wire to the input control power (CP) connector
and connect the DC-power bus links, see the Kinetix 5700 Servo Drives User
Manual, publication 2198-UM002.
Wire the Digital Input Connector
The digital inputs are part of a required I/O interface with the gateway. The
digital inputs are connected to the gateway through the digital USB I/O
module.
Figure 23 - Digital Input Connector Wiring

2198T-W25-ER
iTRAK Power Supply
MOD
(front view)
NET
Digital Input Connector Plug 2
1 6 1
I/O
6
2 7
iPS RDY
3 8 5 10
4 9
5 10
Table 23 - Digital Input Connector Plug Specifications

Description Pin Signal Recommended Strip Length Torque Value
Wire Size mm (in.) N•m (lb•in)
mm2 (AWG)
Digital inputs IOD-1 Enable 0.20…1.31 10.0 (0.39) — (1)
IOD-2 COM (24…16)
IOD-3 Clear Fault
IOD-4 COM
IOD-5 SHLD
See Connecting an iTRAK Power Supply to a System on page 59 for wiring

diagram information.

Wire the iTRAK PS Ready (IR) connector
The iTRAK PS relay output is part of a required I/O interface with the
gateway and is connected to the gateway through the digital USB I/O module.
Figure 24 - iTRAK PS Ready (IR) Connector Wiring - Connector Plug
2198T-W25-ER
iTRAK Power Supply
MOD
NET
(front view)
iTRAK PS Ready (IR) Connector Plug

2
I/O
1 6
- iPS RDY
5 10
Table 24 - iTRAK PS Ready (IR) Connector Plug Specifications

mm2 (AWG)
iTRAK power 2 - 0.14…2.5 0.4…0.5

7.0 (0.28)
supply ready 1 + (26…12) (3.5…4.4)
See Connecting an iTRAK Power Supply to a System on page 59 for wire

diagram information.

Wire the iTRAK Power Supply DC Bus and Control Power Output
Connectors
The iTRAK power supply uses one cable, 2198T-CHBFLS8-12AAxx, to
connect to the iTRAK system. The single cable terminates at two connectors
on the iTRAK power supply: one for iTRAK control power (ICP) and one for
iTRAK DC bus power (IDC). Two sets of these connectors, referenced as A
and B, are provided on the iTRAK power supply to allow using two cables for
larger iTRAK systems.
ATTENTION: Make sure that the iTRAK power connections are correct when
wiring the plugs and that the plug is fully engaged in the module connector.
Incorrect wiring, polarity, or loose wiring can cause an explosion or damage
equipment.
You can create custom cable lengths by cutting a 2198T-CHBFLS8- 12Axx to

length, remove the flying lead end and preparing new leads. See Cable
Preparation for iTRAK Power Supply Output Power Cables on page 60 for
instructions.
Figure 25 - IDC and ICP Connector Wiring
2198T-W25K-ER iTRAK Control Power iTRAK DC Bus

iTRAK Power Supply Output Connector Plugs Output Connector Plugs
(right side view)
(ICP A) (IDC A) (ICP B) (IDC B)
2 1 H L DC- 2 1 H L DC-
2198T-W25K-ER
iTRAK Power Supply
(right side view)
2198T-W25K-ER
iTRAK Power Supply
(bottom view)

Table 25 - IDC and ICP Connector Wiring
Description Connects to Terminals Wire Size Strip Length Torque Value

mm2 (AWG) mm (in.) N•m (lb•in)
Pin Signal Wire Color
24V iTRAK control power (1) ICP-1 24V+ White 1.5…6 10.0 (0.39) 0.7…0.8
ICP-2 24V– Red (16…10) (6.1…7.0)
DC-bus output power A and B (1) IDC-4 GND Green/Yellow 2.5…6.0 10.0 (0.39) 0.7…0.8
IDC-3 H Brown (12…10) (6.1…7.0)
IDC-2 L Black
IDC-1 DC- Blue
(1) The iTRAK control power (ICP) and iTRAK DC bus output (IDC) connections must be made using catalog number 2198T-CHBFLS8-12AAxx.
Apply the iTRAK Power Cable Factory-supplied 2198T-CHBFLS8-12AAxx iTRAK cables are shielded. The
braided cable shield must terminate at the iTRAK power supply when
Shield Clamp installed. A small portion of the cable jacket has been removed to expose the
shield braid. The exposed area must be clamped by using the clamp on the
bottom front of the iTRAK power supply.
This procedure assumes that you have completed wiring your IDC and ICP
connectors and are ready to apply the cable shield clamp.
To apply the iTRAK power-supply cable-shield clamp, do the following.
1. Loosen the clamp knob.

2. Position the exposed portion of each cable braid directly in line with the
clamp.
3. Hand tighten the clamp knob.
Only finger-tight torque on the clamp knob is required. The cable must
not move within the clamp under its own weight or when slight pressure
is applied by hand.

Wire the Digital USB I/O The digital inputs and output from the iTRAK power supply communicate
with the gateway through the 2198T-GUSB Digital USB I/O Module.
Module
To access the connectors, do the following.
1. Remove the four Phillips head screws that secure the cover.
2. Remove the cover.
Figure 26 - 2198T-GUSB, Digital USB I/O Module Connector Wiring
2198T-GUSB Digital
USB I/O Module with
cover removed
(top view).
A B
OUT 01 C
OUT 01 NO
OUT 00 C OUT 00 NO IN00
Digital Outputs
Digital Inputs
Table 26 - Digital USB I/O Module Connector Specifications

mm2 (AWG)
iTRAK power IN00 A - 0.14…2.5 9.0 (0.35) N/A (1)
supply ready IN00 B + (26…12)
Digital inputs OUT 00 NO Enable 0.20…1.31
OUT 00 C COM (24…16)
OUT 01 NO Clear Fault
OUT 01 C COM
Figure 27 - Connect the USB Cable
2198T-GUSB Digital
USB I/O Module.
USB cable connection to gateway.

Wire the Gateway Wire the gateway with 24V power input, a machine Ethernet connection, the
USB cable from the digital USB I/O module and a communication cable from
each of the motor modules.
Figure 28 - Gateway USB, LAN, and 24V Power Plug Wiring
USB Side View Power Connector Side View
2198T-G01-016-E
Gateway is shown.
USB 2.0
24V Power Plug
USB cable connection to The USB cable can be connected to

Digital USB I/O Module. any of the USB Ports on the Machine Ethernet connection
Gateway. Machine Ethernet
Connection as marked on the chassis.(1)
(1) Make only this connection. Do not use any other Ethernet ports for machine Ethernet.
Table 27 - Gateway 24V Power Plug Specifications

mm2 (AWG)
+ 24V
Gateway - 0.82 (18)
24V Comm 7 (0.25) 0.79 (7.0)
24V Power Plug
GND PE 2.08 (14)
Numbering the Motor Modules
Motor module 0 can be any motor module in the system, but they must be
sequentially numbered counterclockwise facing the position sensing surface.
Table 28 - Numbering the Motor Modules - Example
Curved Motor Module
13 12 11 10 9 8 7
14
15
6
0 1 2 3 4 5
Straight Motor Module Position Sensing Surface

Number motor modules sequentially and counterclockwise.

To wire the motor modules to the gateway, do the following.
1. Remove the loopback connector from the number seven

communication port.
If the number of communication ports in your gateway is 16, 32, 48, or
64, and you have an equal number of motor modules in your system, you
can discard the loop back connector. If it is not, save the loop back
connector for use in step 4.
2. Attach the 2198T-CC-xx communication cables, start by connecting
motor module 0 to communication port 0.
3. Continue to make connections for each motor module by matching the
motor module number, as numbered in Numbering the Motor Modules,
to the communication port number, until all motor modules are
connected.
4. If the number of motor modules is not equal to 16, 32, 48, or 64, install
the loop back connector in the next available communication port.
Figure 29 - Gateway to Motor Module Wiring
Connect communication port 0 to motor

Sequentially connect the communication module 0 by using 2198T-CC-xx
ports to motor modules. communication cable.
Remove Loop
Back Connector
7 6 5 4 3 2 1 0
2198T-G01-016-E
Gateway is shown.
8 9 10 11 12 13 14 15

iTRAK Power Supply Wiring Example

Use the following wiring diagram to connect your iTRAK power supply.
Figure 30 - Connecting an iTRAK Power Supply to a System
2198-Pxxx 2198T-W25K-ER
Kinetix 5700 Kinetix 5700 iTRAK
DC-bus Power Supply Power Supply
Cable Shield
Clamp
DC- DC-
DC-
DC+ Shunt Power L L
(RC) Connector L DC Power Bus A to iTRAK
SH H H Motor Modules
DC Power Bus A A H
(IDC) Connector
1 24V +
24V + Control Power A to iTRAK
2 24V - Motor Modules
24V - Do not connect DC Power Bus
A and B in parallel to another
Bonded Cabinet DC Bus Bar iTRAK power supply on the
100 mm link
Ground Bus (1) same daisy chain.
DC+ DC+ DC Bus
DC- DC- (DC) Connectors
DC- DC- DC-
L L DC Power Bus B to iTRAK
Optional L Motor Modules
2198-TCON-24VDCIN36 DC Power Bus B H H
Chassis H
24V Input Power (IDC) Connector B
Wiring Connector
1 24V + Control Power B to iTRAK
Customer Supplied 1 24V + Motor Modules
+24V +24V Control Power 2 24V -
+24V DC 2 24V -
24V_COM 24V_COM (CP) Connectors
Power Supply (1)
Optional
2198T-W25K-P-T
T-connectors and Bus Bars
1
USB I/O
IN1
2 1
COM Digital Input ENABLE OUT 00 NO
3 (IOD) Connector
IN2 2 (2)
4
SHLD
Digital Input 3
(IOD) Connector
CLEAR OUT 01 NO
FAULT
4 (2)
Connect EN–
contactor enable CONT EN– Contactor Enable 5
(1) EN+ (CED) Connector SHLD SHIELD
circuitry CONT EN+
- IN00 A
iTRAK Power Supply RDY- IPS READY 24V COM
Ready (IR) Connector +
Three-phase Input RDY+ IN00 B
(IPD) Connector
For multiple iTRAK power supplies,
PE Ground PE Ground see Wiring Multiple iTRAK Power
L3 L2 L1 Supplies to the Digital USB I/O
Module on page 47
Connect to Bonded Cabinet

three-phase Ground Bus (1)
power input
(1) Customer supplied.

(2) Make only one of these 24V COM connections.

Cable Preparation for iTRAK Follow these instructions to prepare the wires for creating custom length
2198T-CHBFLS8-12Axx cables.
Power Supply Output Power
Cables These instruction steps assume that the cable has already been cut to the
desired length.
1. Mark the cable at 138 mm (5.4 in.) from the end.

2. Carefully cut away the outer jacket at the mark.
Be mindful not to damage the braided shield underneath.
3. Measure 32 mm (1.26 in.) from where the outer jacket ends and cut and
remove the braided metal shield.
Save the braided metal piece that was trimmed for use in step 8.
4. Measure 75 mm (3 in.) from where the outer jacket ends or 43 mm
(1.7 in.) from where the shield ends, and trim the blue filler material.
138 mm (5.43 in.)

Can be longer and trimmed at end
remove outer jacket only.
32 mm 43 mm (1.7 in.)
(1.26 in.) Trim filler material.
5. Pull back the outer braided shield and carefully create an opening in the
braid as close as possible to where the outer jacket ends.
6. Feed the internal shielded twisted pair through the opening in the outer
braided shield, and pull it through tight.
Pull shielded twisted pair free by

forming an opening and threading it
back through the carefully expanded
shield.

The shielded twisted pair is now outside of the main braided shield and
the two shields are in contact.
(Rotated View)
Exposed twisted shielded pair is

stripped to the shield and the two
shields are in contact.
7. To hold the wires together, bundle the group of four wires with the
previously trimmed filler material and slip on a 45 mm (1.8 in.) length
piece of shrink tube.
Bundle wires with the previously

trimmed filler material into a
diameter approximately 8 mm
(0.32 in.) and cover with heat shrink.
75 mm
(3 in.)
8. Slide previously trimmed piece of the outer braided shield over the
entire bundle, butt it up to the cable jacket, pull tight, then trim the
piece so it is approximately 75 mm (2.9 in.) long.
75 mm
(3 in.)
Slide expanded tubular braids over

all conductors butt up to cable jacket
and pull tight.
9. Place a 64 mm (2.5 in.) length of adhesive-lined shrink tube over the

cable located 113 mm (4.4 in.) from the end of the wires.

10. Place a 23 mm (0.9 in.) length piece of adhesive-lined shrink tube over
the cable so that a 35 mm (length of shielded braid is left exposed.
64 mm 138 mm
(2.5 in.) (5.4 in.)
75 mm
(3 in.)
35 mm 23 mm
(1.4 in.) (.09 in.)
Adhesive lined heat shrink two
Jacket
11. Trim the braided shield on the twisted-pair shield back 40 mm (1.6 in.)
from the end of the wires.
12. Place a 20 mm (0.79 in.) length piece of shrink tube over the twisted
pair approximately 30 mm (1.18 in.) from the end of the wires.
13. Strip the individual wires back 9 mm (0.35 in.).
64 mm 138 mm
(2.5 in.) (5.4 in.)
Exposed Ring cut
Shield Heat 9 ± 0.1 mm insulation six
13 mm Shrink (0.5 ± 0.004 in.) places.
(0.5 in.)
Label wires 6
places.
35 mm 23 mm
(1.4 in.) (.09 in.) 9 ± 0.1 mm
30 mm
Heat (1.18 in.) (0.5 ± 0.004 in.)
Jacket
Shrink 20 mm (0.787 in.) long heat
shrink over twisted pair.
Label wire with the signal names as shown in Table 29

Table 29 - Power Supply Wire Labels
Color Gauge Signal
Brown 12 H
Black L
Blue DC-
Green/Yellow PE
Red 14 +24V
White -24V

Logix Designer Application The Studio 5000 Logix Designer® application controller program necessary to
support the iTRAK power supply is provided in the Pxx_IPS_Support
Support program. The code performs the following functions.
• Sends the power supply type for PCM or iTRAK power supply to the
gateway.
• Sends the DC-bus power supply DCBusUPStatus to the gateway. The
bus up status is used by the gateway to gate the iTRAK power supply
Enable signal.
• Monitors DC-bus power supply DCBusUnload in the sample code to
trigger stopping actions.
The code also provides examples for disabling the iTRAK power supply via the
gateway.
Name the DC-bus power supply axis DFE. If you use a name other then DFE,
update the DFE tags to match the name that is given to the DC-bus power
supply.
The Pxx_IPS_Support program version can be checked in Logix under

controller tag FeatureRevision.
IMPORTANT You must import Pxx_IPS_Support program into the same task as the
iTRAK_IO code.
ATTENTION: The Studio 5000 Logix Designer application Pxx_IPS_Support

program must be used as instructed to control the iTRAK power supply
properly and provide required fault support to the Kinetix 5700 system.
Failure to use this program code can result in equipment damage.
You can obtain the Studio 5000 Logix Designer controller ladder code by
going to the Rockwell Automation Knowledgebase article 778917.
IMPORTANT Do not add the iTRAK power supply to Logix I/O tree. If you do, unexpected
results can occur.

Notes:

Chapter 4
Install Your System with a Power Control

Module
The power control module (PCM) is a fully wired and assembled cabinet. It
accepts main power and provides bus power for the motor modules and logic
power for the gateway and motor modules. It includes disconnects, fuses, and
USB I/O module. It has pre-wired functional safety features such as an E-stop
and reset circuit.
Topic Page
Typical System Configuration Using a PCM 65
About the Power Control Module 67
About the Gateway 73
Plan Your System Installation 75
Install the Power Control Module 75
Install the Gateway Enclosure 75
Connect Cables 75
Typical System Configuration Table 30 - System Component Overview Using a PCM

Using a PCM System Component Description
Motor Module 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.
Track Frame 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 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.
Gateway The Gateway provides communication interface between the Logix controller
and all motor modules. It also provides more motion processing for the motor
modules.
Power Control Module (PCM) The PCM accepts mains power and provides bus power for the motor modules
and logic power for the Gateway and the 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.
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.

Chapter 4 Install Your System with a Power Control Module
Figure 31 shows a typical iTRAK® system that uses a PCM. Your system can
vary in the quantity and layout of each component, but all follow the same
concept.
Figure 31 - Typical iTRAK System Configuration Using a PCM
5
14
7
13
9 12
10 11
9
8
15
4
2 3
1
Table 31 - System Component Description

1 Mover 9 EtherNet/IP communication cables
2 Bearing rail 10 Communication cable to motor module (one cable per motor module)
3 Straight motor module 11 PCM to Gateway power and communication
4 Curved motor module 12 Motor module power bus (number of cables vary by system)
5 Power control module (PCM) 13 External monitoring, reset, guard stop, E-stop connections
6 Assembled gateway cabinet 14 Mains power (460V nominal)
7 Controller (sold separately) 15 Track frame
8 Computer (not supplied with system)

Install Your System with a Power Control Module Chapter 4
About the Power Control Figure 32 shows a typical power control module (PCM). Your system can
differ in the layout and the number of connectors, but has the same
Module components.
Figure 32 - Power Control Module
2 5
7
8
9
10 3
12 11
Table 32 - PCM Component Description

Item Description
1 Emergency stop switch
2 Status indicators (x5)
3 Power cable (not included)
4 Main power switch
5 Exhaust vent
6 Power bus connectors are shown with cap (quantity is system-dependent)
7 External emergency stop switch connector
8 External guard-switch connector
9 External reset-switch connector
10 External monitoring connector
11 PCM to Gateway communication connector
12 Intake vent (not shown)

PCM Status Indicators
RESET iTRAK DC-CB AC-CB POWER

“ON” “ON”
Table 33 - 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 button
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, IC1
or IC2 are tripped.
If any of the status indicators do not light when expected, check the associated
circuit breakers. See Circuit Breakers on page 111.
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.

PCM Dimensions
724 Dimensions are in mm (in.)

(28.5)
1181.4
(46.5)
1219
(48.0)
329 762
(13.0) (30.0)
Side View Front View
(4X) Ø 6.35 (0.25)
Rear Mounting Holes

PCM Connector Data
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 33 shows the pinout for the reset connector.
Figure 33 - Reset Connector Pinout (P3)
Figure 34 shows the schematic for the reset circuit.
Figure 34 - Reset Switch Circuit Schematic
S04 Reset
Reset
A A 14 13
B B
C C 14 13
D D
Figure 35 shows the pinout for the E-stop and guard connectors.
Figure 35 - E-Stop and Guard Connector Pinout (P4 and P5)
Figure 36 shows the schematic for the E-stop circuit.

Figure 36 - E-Stop Switch Circuit Schematic (P5)
External
Emergency Stop
A A
B B
104 C C
D D
E E
E and F Dry NC
F F Contact
Figure 37 shows the schematic for the guard switch circuit.
Figure 37 - Guard Switch Circuit Schematic (P4)
S03 Guard Guard

Guard Switch Switch
A A
B B
C C
D D
E E
E and F Dry NC
F F Contact
Figure 38 shows the pinout for the monitor connector.
Figure 38 - Monitor Connector Pinout (P2)
MOA A F
MOB B G E MOE
MOC C D MOD

Figure 39 shows the schematic for the monitor circuit.
Figure 39 - Monitor Circuit
M01
BLU M0A
A 11 14
R2A
BLU M0B
11 14
B R2B
BLU M0C
11 14
C R2C
BLU M0D
11 14
D R2D
BLU M0E
E
Table 34 - Monitor Circuits Descriptions

Monitor Description
(PCM Status Indicator)
A Bus voltage (0, 160V and 320V) is on
B AC circuit breaker tripped
C DC circuit breaker tripped
D PCM main circuit breaker (CB01) is on
Figure 40 - PCM (P7) to Gateway (P6) Cable Connector Pinout

Pin Signal
1 24V (CB 05, Gateway 1)
2 24V (CB 05A, Gateway 2) 1 24
3 24V (CB 06, Ethernet Hub) 2 10 17 25
4 PS02 Undervoltage 3 11 18 26
5 PS02 Option COM 4 12 19 27
6 PS02 Power Fail 5 13 20 28
7 PS02 Logic Return 6 14 21 29
9 PS01 Option COM 8 16 23 31
10 PS01 Power Fail 9 32
11 PS01 Logic Return GND

12 PS01 Logic Inhibit
14 iTRAK Power On/Off
15 24V (TB05, I/O USB)
16 24V Common (TB05C I/O USB)

Figure 41 - Power Bus Connector Pinout (ITP00…ITP007)

Pin Signal ITP00…ITP007
A 320V DC D C
B 160V DC
E 2 B
C 0V DC
3
D — 1
E 24V A
F
F 24V Common
GND
GND PE
About the Gateway Figure 42 shows a typical 16-port gateway. Your system can differ in the layout
and the number of connectors, but has the same components.
Figure 42 - Gateway Enclosure Components
4 5 6
3
2
Item Description
1 Gateway (P6) to PCM (P7) cable connector
2 Ethernet ports
3 Gateway computer
4 Wire terminals
5 USB I/O
7
6 Ethernet hub
7 Wiring glands

Figure 43 - Gateway Dimensions
469.9
(18.50) 228.6 508
4X Ø 0.44 (9.00) (20.00)
Rear Mounting Holes
469.9 508
(18.50) (20.00)
Figure 44 - Gateway (J6) Cable Connector to PCM (J7) Pinout

Pin Signal
1 24V (gateway 1 power input)
2 24V (gateway 2 power input) 1 24
3 24V (Ethernet Hub power input) 2 10 17 25
5 PS02 Option COM 4 12 19 27
6 PS02 Power Fail 5 13 20 28
7 PS02 Logic Return 6 14 21 29
9 PS01 Option COM 8 16 23 31
10 PS01 Power Fail 9 32
11 PS01 Logic Return GND

14 iTRAK Power On/Off
15 24V (TB05, I/O USB)
16 24V Common (TB05C I/O USB)

Plan Your System Installation Choose the location for system components by 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
Install the Power Control

Module IMPORTANT The 10 kW PCM weighs approximately 100 kg (220 lb). Be sure the lifting
machinery that is used can lift the load.
1. Mount PCM to a solid vibration-free vertical surface.

2. Secure by using all mounting holes inside the enclosure. See PCM
Dimensions on page 69.
3. Connect the system ground conductor to the main power supply.
Before switching on the equipment, cables 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 the Gateway

Enclosure IMPORTANT The gateway enclose weighs approximately 27 kg (60 lb) Be sure to
use a two man lift when installing the gateway cabinet.
1. Mount the gateway enclosure to a solid vibration-free surface.

2. Secure by using all four mounting holes in the enclosure. See Gateway
Dimensions on page 74.
3. Connect the 2 m (6.6 ft) Gateway-PCM Interconnect cable from the
gateway to the PCM.
The connectors are keyed and the same on either end. Be sure to secure
with the locking mechanism.
Connect Cables Your system comes with the power bus and communication cables. You are
required to route and connect them to the motor modules, PCM, and gateway.
To connect these cables following the system diagram.
The motor module-to-motor module power-bus jumper cables and the power-
bus terminator are already installed.

To access standard systems diagrams, do the following.
1. Browse to https://motionanalyzer.rockwellautomation.com/Products/
iTrak.
2. Click 3D CAD Models of iTRAK Components.
3. Open 2198T-3DCAD.zip.
4. Double-click 2D Outline and Assembly Drawings.
5. Double-click C806607-3-X_REVA.
6. Click Open.
To connect system cables, do the following.
IMPORTANT Help protect cables from stress and damage during use of the
system.
1. Route and connect the power bus cables from the appropriate motor
module to the PCM.
See your system diagram to determine power bus cable that is required
for each motor module. Power bus cables are labeled on the ends of cable
next to the SpeedTec connector.
2. In the gateway enclosure, remove the loopback connector from the
number seven communication port.
If the number of motor modules in your system is 16, 32, 48, or 64, and
you have an equal number of motor modules, you can discard the loop
back connector. If it is not, save the loop back connector for use in
step 4.
3. Route and connect communication cables from the motor modules to
the gateway.
The communication cables are labeled with the motor module number
0…63 depending on the number of motor modules in your system. Be
sure to pass the cable through the cable gland of the gateway. Each gland
can take up to 10 cables.
4. If the number of motor modules is not equal to 16, 32, 48, or 64, install
the loop back connector in the next available communication port.
5. Secure the communication cables to the cable gland by using the Skintop
cube. See Lapp Kable instructions BS09/3878-3
6. Connect the PCM to mains power line.
Use minimum of 10 mm2(8 AWG) copper for the ground wire.
7. Connect your personal computer and Allen-Bradley® controller to the
gateway Ethernet ports.

Chapter 5
Power on Your System
Use this chapter to power on your system by using a Kinetix® 5700 system or a
PCM.
Topic Page
Before You Power On the Track 77
Apply Power 78
Commission with Programming Manual 82
Before You Power On the There are some items that you can review before the system is powered that can
speed up the time to commission your system.
Track
Identify Controller
The controller that you use determines which type of Starter Project is best suited
for your application. Consider the memory requirements, axis count, and motion
task utilization when choosing the catalog number of controller. Integrated
Architecture® Builder from Rockwell Automation can help you size the
application and estimate which controller is properly suited for you; see
Knowledgebase Article 1040301, How to size an iTRAK® in IAB? for more
information.
Identify Firmware Revision
Each firmware revision is designed to operate with a paired version of the

iTRAK_IO Add-On Instruction. Identify which firmware revision of the
iTRAK system you plan to use before starting your application code
development. We recommend that you use the latest published firmware revision.
Firmware revisions are available from the Rockwell Automation Product
Compatibility and Download Center.
To update your motor module firmware see Update Motor Module Firmware on
page 104
If you plan to do a Factory Acceptance Test with Rockwell Automation, contact

ICTSupport@ra.rockwell.com to determine which firmware revision is planned
for your visit.

Chapter 5 Power on Your System
Configure and Customize Project File
When you download the firmware revision from the Rockwell Automation
Product Compatibility and Download Center, the software files for Studio 5000®
Logix Designer are included. Choose the appropriate project file that is based on
the features and controller for that firmware revision.
The iTRAK System Programming Manual, publication 2198T-PM001, is

available on the Rockwell Automation Literature Library. It includes detailed
descriptions of the Starter Projects and the procedures to develop your own
project file. After you have configured your project file according to the
instructions in the programming manual, proceed with Apply Power.
Apply Power There are different sequences to follow that depend on the type power supply
that you have in your system. For Kinetix 5700 systems, see Kinetix 5700 iTRAK
Power Supply section. For PCM systems, see Power Control Module section.
Kinetix 5700 iTRAK Power Supply
1. Energize your ControlLogix® or CompactLogix™ processor.

2. Download the ACD file to the controller.
3. Start the initialization sequence of the Kinetix 5700 system, motor
modules, and the gateway by applying 24V control power to the gateway
safety circuit, and motor modules, and Kinetix 5700 system.
On initial powerup, the drive performs a self-test. Upon successful
completion, the firmware revision is displayed.
Kinetix 57 until Kinetix 5700 is spelled out… Kinetix 5700
SELF-TEST SELF-TEST
FW REV: x.x.xxxxxxx FW REV: x.x.xxxxxxx
75% until the test is complete… 100%
When the Kinetix 5700 power supply is ready, the contactor enable relay is
closed so that main power can be applied to the Kinetix 5700 system bus.
4. Apply bus voltage.
The bus voltage is applied to the system when the appropriate commands
are sent from the processor to the gateway. This action triggers the
Kinetix 5700 iTRAK power supply via the USB I/O module. See the
Motion Commands section of the iTRAK Programming Manual,
publication 2198T-PM001, for more information.

Power on Your System Chapter 5
When the high-voltage power completes initialization, the displays change

to Running mode.
RUNNING
192.168.1.4
DC BUS: 165.5V
iTRAK Power Supply
The DC BUS voltage that is displayed can differ depending on your

system configuration.
5. To determine if the iTRAK system is ready for application of the bus
voltage, monitor the status indicators from the gateway in Studio 5000
Logix Designer® software.
There are two controller tags that indicate the status of the gateway and
iTRAK power supply.
The iTRAK_Control.Status.GatewayRunning indicates that the iTRAK

system initialization is finished, and the gateway is ready to respond to
requests from the controller.
The iTRAK_Control.Status.DCBusContactor = 1 means the iTRAK
high-voltage bus is closed, and the iTRAK power supply is providing high
voltage to the iTRAK system.
Power Control Module
1. Energize your ControlLogix® or CompactLogix™ processor.

2. Energize the main disconnect switch on the front of the panel of the
PCM.
Main power is applied to the 24V control power supply and the low
voltage components begin to come on line including the gateway, safety
circuit, and motor modules. The amber CONTROL POWER status
indicator illuminates.
3. Check that the red EMO button is pulled out.
The red status indicator stays illuminated.
4. Press and release the RESET push button on the PCM panel.
This action clears the cold start inhibit condition of the safety circuit. The
blue RESET status indicator illuminates and the red EMO status indicator
turns off.
5. Determine if the system is ready for the application of main bus voltage by
monitoring the status indicators from the gateway in Studio 5000 Logix
Designer® Software.

After main bus voltage is applied to the system and the command motor
power is sent from the processor to the gateway, look for following status
indicators.
On the PCM, the white DRIVE ENABLED status indicator is on when

iTRAK_Start command is executing in the Logix Application Designer. It
turns off after the iTRAK_Stop command is executed, E-stop is pressed, or
shutdown operation is performed.
6. Verify power and communication.
For the series A motor modules, all three status indicators are solidly
illuminated. Control Power and Communication status indicator
illuminates green. Motor Power status indicator illuminates amber.
Straight Motor Modules Curved Motor Modules

Status Indicators Status Indicators
For the series B motor modules, all three status indicators are solidly
illuminated green. The series B status indicator uses different
nomenclature. The Drive Enabled status indicator on series B motor
modules replaced Motor Power status indicator on a series A motor
module.
CONTROL POWER
COMMUNICATION
DRIVE ENABLED
DANGER
IMPORTANT Series B motor modules require firmware revision 1.107 or later to

function. The Drive Enabled status indicator is turned on by the
firmware when conditions are met in the gateway and Logix Designer
application. Prior versions of firmware allow the module to operate
however the Drive Enabled status indicator never illuminates.
For the gateway, there are no physical status indicators on the gateway that
would notify that it is ready for motion. The status indicators are displayed
in the Logix Designer application, which is discussed in the next section.
In the Logix Designer application, there are numerous status indicators
that verify the iTRAK is ready for motion.

Power on Your System Chapter 5
In the top left-hand corner of the Logix Designer application, I/O OK

status indicator is solidly green.
If the gateway is not ready, the I/O OK status indicator turns to a flashing
green and say I/O NOT RESPONDING.
Under the Controller Tags, the iTRAK_Control tags are displayed.
Under the iTRAK_Control tag, there are three subsets of tags, .Cmd,
.Status, and .Data are displayed.
Under the iTRAK_Control.Cmd tags are displayed.
Setting Cmd.iTRAKStart to 1 enables the iTRAK and Cmd.ServoOn bit

automatically sets to 1.

Under the iTRAK_Control.Status tags are displayed.
The tags Status.GatewayRunning, Status.DCBusContactor, and

Status.ReadyForMotion all set to 1. These bits are set when the iTRAK is
enabled with Cmd.iTRAKStart.
If any of these tags have values in them, the iTRAK cannot be enabled
because of an existing fault condition:
• iTRAK_Control.Status.Faulted
• iTRAK_Control.Status.FaultMessageLine1
• iTRAK_Control.Status.FaultMessageLine2
See the Motion Commands section of the iTRAK Programming Manual

publication 2198T-PM001, for more information.
Commission with Configure, tune, and program the iTRAK system by following the instructions in
the iTRAK Programming Manual, publication 2198T-PM001.
Programming Manual

Chapter 6
Maintenance
This chapter contains information for on how to care for your system, replace
component, and update firmware.
Topic Page
Before You Begin 83
Preventive Maintenance 83
Add or Replace Components 84
Update Gateway Firmware 102
Update Motor Module Firmware 104
Lubrication 105
Circuit Breakers 111
Before You Begin Before you attempt maintenance on the system, do the following.
• Make sure that the movers are motionless.
• Disconnect electrical power to the system by using the master switch
and lockout.
Preventive Maintenance Cleaning
To prolong the life of your iTRAK® system, do the following cleaning

procedures. The frequency in which to perform them is depended on the
machine usage, the environment in which it is used, and the exposure to
containments. You must determine through best engineering practices how
often to perform the following procedure.
Before You Begin
ATTENTION: Before attempting any service to an iTRAK system See Safety

Information on page 19.

Chapter 6 Maintenance
Bearing Rail
1. Wipe the rails down with a lint free cloth.

If necessary, you can use isopropyl alcohol on the lint free cloth.
2. Apply a thin coat of Kluber oil (Kluber 4-UH1-68N) on all exposed
bearing rail surfaces.
Track Components
Clean the following surfaces with isopropyl alcohol and soft lint free cloth.
• position sensor
• top and bottom plates
• motor module coil
If there is ferrous debris on the magnet plates, remove them with the sticky side
of duct tape or clay.
Add or Replace Components The following procedures show you how to install or replace system
components.
Install or Remove a Position Magnet Assembly
To install or remove a position magnet assembly, do the following.
Before You Begin

What You Need

• 2.5 mm Allen wrench
• Loctite 222
• 2198T-NN-318 or 2198T-NS-318, position magnet assembly
• 2198T-VTxxxx-A, mover
Position magnet assemblies can be replaced while the mover is on the track.
To remove a position magnet assembly, do the following.
Remove the shoulder socket head cap screws that secure the position magnet
assembly to the mover by using a 2.5 mm Allen wrench.

Maintenance Chapter 6
To install a position magnet assembly, do the following.
1. Clean shoulder socket-head cap screws and apply fresh Loctite 222.
2. Install position magnet assembly onto the mover with shoulder socket-
head cap screws by using 2.5 mm Allen wrench, torque to 0.85 N•m
(7.5 lb•in)
3. 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.
Item Description
1 Shoulder Socket-Head Cap Screws
2 Position Magnet Assembly
3 Mover

Magnet Plate Assembly Installation
Follow this procedure to install or remove a magnet plate assembly.
Before You Begin

ATTENTION: If you are using your own design for a mover, make sure of the
following.
• The mounting hardware is not too long that it protrudes past or pops
through the magnet plate.
• Be sure to use all mounting holes. By using all mounting holes, the magnet
maintains correct orientation of north-south magnet polarity.
What You Need

• 6 mm Allen wrench
• Loctite 243
• 2198T-Mxxxx-A000, magnet assembly
• M6 x 25 socket head cap screws and M6 x 30 flat head socket screws as
shown in Table 35.
Table 35 - Screws Required for Mounting Magnet Plates
Cat. No. FHCS M6 X 30 SHCS M6 X 25
Quantity Quantity
2198T-M0505-A000 3 -
2198T-M0510-A000 3 -
2198T-M0515-A000 5 -
2198T-M1005-A000 2 3
2198T-M1010-A000 2 3
2198T-M1015-A000 2 3
2198T-M1505-A000 2 3
2198T-M1510-A000 2 3
2198T-M1515-A000 2 3

To install a magnet plate assembly, do the following.
1. Remove mover by following the procedure in Install or Replace a Mover

on page 88.
2. Clean all screws and apply Loctite 243.
3. Install magnet plate assembly and torque M6 Socket head cap screws to
9 N•m (6.6 ft•lb) and M6 flat head cap screws to 7 N•m (5.2 ft•lb).
Item Description
1 Magnet plate assembly
2 Flat head cap screw
3 Socket head cap screw
Install mover by following the procedure in Install or Replace a Mover on

page 88.

Install or Replace a Mover
Follow this procedure to install or replace a mover.
Before You Begin

Choose an accessible curved section of the track, Position the mover that you
want to replace over a straight motor module next to the curved section. Move
all other movers off the curved end of the track.
What You Need

• 2.5 mm and 5 mm Allen wrenches
• Loctite 243
• 2198T-A01, Pair of mover installation fixtures
• 2198T-VTxxxx-A, mover assembly
To remove a mover, do the following.
1. Remove the position magnet assembly by following the procedure

Install or Remove a Position Magnet Assembly on page 84.
2. Remove the socket head cap screws from the curved top bearing rails by
using a 5 mm Allen wrench.
Top Curved Bearing Rail
Bottom curved
bearing rail is not
shown.

3. Remove the curved bearing rails by pulling parallel to the track away
from the straight bearing rails.
ATTENTION: Avoid bending the bearing-rail key. Do not lift the curve
bearing rail up until the bearing-rail keys have cleared the straight
bearing-rail key slot.
Bearing Rail Key Bearing Rail Key Slot
Bearing Rail Key - Short Bearing Rail Key Slot
4. Repeat step 1 through step 3 for the bottom bearing rail.

5. Attach mover installation fixtures to the end of straight bearing rails by

using two socket head cap screws from the curved bearing rail.
Socket head cap screws from the

curved bearing rail.
Mover Installation Fixtures
Socket head cap screws from the

curved bearing rail.
6. Install or replace your mover.
ATTENTION: When removing or installing the mover, keep the mover square
to the fixtures and take care not to damage the felt surfaces of the
lubrication wiper assemblies.
7. Remove the mover installation fixtures.

8. Clean all bearing rail screws and apply fresh Loctite 243.

9. Install the curved bearing rails by holding them parallel to the track and
aligning the bearing rail keys with the bearing-rail key slots on the
straight bearing rails. Slide the bearing rails keys into straight bearing-
rail key slots.
10. Torque the middle screws to 22 N•m (16.2 lb•ft) by using 5 mm Allen
wrench; leave the two screws on each end of the curved rail loose.
11. If necessary, align the straight and curve rails by adjusting the set screws
on the ends of the curved rails to within 0.0127 mm (0.0005 in.) by
using 2.5 mm Allen wrench.
12. Torque the remaining screws to 22 N•m (16.2 lb•ft) by using 5 mm
Allen wrench.
End Screws
Set Screws (x4)
13. Install the position magnet assembly by following the procedure Install
or Remove a Position Magnet Assembly on page 84.

Replace a Straight Motor Module
To replace a straight motor module, do the following.
Before You Begin

What You Need

• 5 mm and 6 mm Allen wrenches
• Loctite 243
• 2198T-L16-Txxxx-A00N-2E1E-NS, straight motor module
To remove the straight motor module, do the following.
1. Remove the socket head cap screws M6 x 20 that secure the rails above
and below the module you are replacing.
3
4
Item Description
1 Upper rail
2 Module to be replaced
3 Lower rail
4 Socket head cap screws M6 x 20
2. Fully support the motor module.

ATTENTION: You must support the motor module while performing

the next step. If the motor module is not supported before you
remove the screws the motor module drops.
ATTENTION: The straight motor modules can weigh up to

approximately 25 kg (54 lb) Be sure to use a two man lift when
moving the straight motor module.
3. Remove the socket head cap screws M8 x 25 and shoulder bolts,

shoulder Ø 20 x10, thread M8 x 25 that secures the motor module to
the top and bottom frames.
2
3
Item Description
1 Motor module
2 Motor module shim
3 Shoulder bolts, shoulder Ø 20 x 10, thread M8 x 25 (x4)
4 Socket head cap screw M8 x 25 (x4)
4. Remove motor module shim.

5. Slide motor module from frame and disconnect the communication and
Motor-power bus cables.
6. Clean all screws and bolts and apply Loctite 243.
7. Install new module by reversing step 5 through step 2.
8. Torque shoulder bolts to 13 N•m (9.6 lb•ft) and torque socket head cap
screws to 22 N•m (16.2 lb•ft).

9. Loosely secure the top and bottom straight rails in position by using all
socket head cap screws M6 x 20.
Be sure to minimize gap between rails.
10. Torque screws to 16 N•m (11.8 lb•ft) by using 5 mm Allen wrench.
11. Update motor module firmware, see Update Motor Module Firmware
on page 104.
Replace a Curved Motor Module
To replace a curved motor module, do the following.
Before You Begin

What You Need

• 2.5 mm, 5 mm, and 6 mm Allen wrenches
• Loctite 243
• 2198T-L16-Txxxx-B09x-2E1E-NS, curved motor module
To remove the curved module, do the following.
1. Move movers away from the area where the curved module is to be
replaced.
If you have to remove the movers follow steps in Install or Replace a
Mover on page 88.

2. Remove all M6 x 20 socket head cap screws from the curved bearing rails
on the top and bottom of the track by using a 5 mm Allen wrench..
1
Item Description
1 Socket head cap screws M6 x 20
2 Curved motor module to be replaced
3. Remove the top and bottom curved bearing rail by pulling parallel to the
track away from the straight bearing rails.
ATTENTION: Avoid bending the bearing key. Do not lift the curve
bearing rail up until the bearing keys have cleared the straight
bearing rail key slot.

3
2
Item Description
1 Top curved rail
2 Bottom curved rail
3 Bearing rail key (X4)
4. Remove the socket head cap screws M6 x 20 that secure the straight rails
to the curved top plate and the bottom straight rail that is located below
the adjacent straight motor module by using a 5 mm Allen wrench and
remove the straight rails.
1
2
4
3

1 Upper straight rails 3 Bottom straight rail
2 Curved motor module to be replaced 4 Adjacent straight motor module

Before removing the curved motor module, the straight motor module
located next to it must be removed to clear the removal of the curved
motor module.
5. Remove the adjacent straight motor module by following the procedure
to Replace a Straight Motor Module on page 92.
2 4
3
6.

1 Socket head cap screws 3 Shoulder bolts
2 Curved motor module to be replaced 4 Adjacent straight motor module
7. Remove the socket head cap screws and shoulder bolts that secure the
top curved plate to the curved modules by using a 6 mm Allen wrench
and remove the top curved plate.
1 2
5
3
4

1 Shoulder bolts 4 Shim
2 Socket head cap screws 5 Top curved plate
3 Curved motor module to be replaced

8. Remove the bottom socket-head cap screws and shoulder bolts that
secure the curved module to the base plate by using 6 mm Allen wrench.
9. Remove motor module shim.
10. Move the curved motor module towards the end of the iTRAK system
about 25.4 mm (1 in.) and disconnect the cables.
11. Lift the curved module straight up and out.
ATTENTION: The curved motor modules can weigh up to

approximately 29 kg (64 lb). Be sure to use a two man lift when
moving the curved motor module.
ATTENTION: You are exposed to pinch points between base plate

and motor module when removing and installing the curved motor
module.
3
2

1 Curved motor module to be replaced 3 Socket head cap screws
2 Shoulder bolts 4 Base plate

To install replacement curved module, do the following.
1. Clean base and curved top plates.

2. Clean all screws and bolts and apply Loctite 243.
3. Place the replacement curved motor module about 25.4 mm (1 in.) from
its final position and reconnect the cables.
Place within 25 mm
(1 in.) of final position
4
3

1 Shim 4 Socket head cap screws
2 Curved motor module to be replaced. 5 Base plate
3 Shoulder bolts
4. Move the replacement curved motor module into its final position.
5. Bolt the curved motor module to the base plate from the bottom.
Torque shoulder bolt screws to 13 N•m (9.6 lb•ft) and torque M8
socket head cap screws to 22 N•m (16.2 lb•ft).
6. Place shim on top as shown
7. Reinstall the top curved plate by loosely attaching all bolts.

8. Install the adjacent straight motor module.
For the straight module installation, follow the procedure to Replace a
Straight Motor Module on page 92.

9. Torque shoulder bolt screws to 13 N•m (9.6 lb•ft) and torque M8

socket head cap screws to 22 N•m (16.2 lb•ft).
1 2
Item Description
1 Shoulder Bolts
2 Socket Head Cap Screws
3 Top Curved Plate
10. Loosely secure the top and bottom straight rails in position by using all
screws.
Be sure to minimize gap between rails.
11. Torque screws to 16 N•m (11.8 lb•ft) by using 5 mm Allen wrench.
Upper Straight Rails
Bottom Straight Rail

1 Upper straight rails 2 Bottom straight rail

12. Place the curved top and bottom rails in position by sliding them into
the bearing key slots and loosely attach by using all screws.
13. Torque the middle screws to 16 N•m (11.8 lb•ft) by using 5 mm Allen
wrench leave the two screws on each end of the curved rail loose.
14. Align the straight and curve rails by adjusting the set screws on the ends
of the curved rails to within 0.0127 mm (0.0005 in.) by using 2.5 mm
Allen wrench.
15. Torque the remaining screws to 16 N•m (11.8 lb•ft) by using 5 mm
Allen wrench.
1
Item Description
1 End bolts
2 Socket head cap screws
3 Set screws (X4)
16. Update motor module firmware, see Update Motor Module Firmware
on page 104.

Update Gateway Firmware To update the firmware using iTFlash, do the following.
1. Download the appropriate revisions of iTFlash from the Rockwell

Automation Product Compatibility and Download Center
2. Make sure that your computer is connected to the gateway computer
with an Ethernet cable.
The Ethernet port is marked AMT on the gateway computer. If you
have a gateway in an enclosure, make a connection to either enclosure
Ethernet port.
Gateway Computer Gateway Enclosure
Ethernet Ports
TIP You can validate that communications are properly established by

pinging the gateway at its base IP address, typically 192.168.1.249.
3. Run iTFlash.exe on the computer.

TIP You can see a limited number of command prompt windows display
briefly, then disappear. If a command prompt window asks for a
Host Key stays displayed, answer y or yes to any security questions.
4. From the dialog box, change the base IP address if needed, and click the
Update Gateway and Section Firmware with iTFlash button.
The software copies files to the system over the network. It can take up
to ten minutes.
TIP If the dialog box has not appeared within 5 minutes of running
iTFlash.exe, see the Firmware Update Troubleshooting section.

ATTENTION: Do not remove power during the process. If you remove

power you risk permanently damaging the motor module.
5. If you are changing to revision 1.099 or earlier, when the iTFlash Success
dialog box is displayed, wait at least 1 minute, and cycle power on the
gateway to restart it.
In revisions greater than 1.099, the gateway automatically restarts itself.
TIP If the iTFlash failed dialog box comes up, see the
Firmware Update Troubleshooting section.
6. Wait the operating system (OS) and gateway to restart.

Gateway Cat. No. No. OS Restarts No. Gateway Restarts Total Restart Time (m)
2198T-Gx1-xxx-E 2 1 15
2198T-Gx2-xxx-E 2 1 10
7. See iTRAK System Programming Manual, publication

2198T-PM001, for details on Logix Designer application project file
changes associated with firmware revisions.

Firmware Update Troubleshooting
In some rare cases when iTFlash has been previously executed, extra steps can
be required to complete the installation. Follow this procedure if the operation
failed.
1. Execute the iTFlash.exe file from a Command Prompt window.

2. Note the names of the files that the Command Prompt window
indicates that they exist.
3. Find the location of the listed files on your system, and navigate to the
enclosing directory.
4. Delete the enclosing directory and all of its contents.
5. Rerun the iTFlash.exe file. If a problem persists, contact Rockwell
Automation Technical support at ICTSupport@ra.rockwell.com.
Downgrading Firmware
If the currently installed firmware revision is revision 1.101, contact Rockwell

Automation Technical support at ICTSupport@ra.rockwell.com. All other
firmware revisions use the standard updating process for downgrading
firmware.
Update Motor Module To update the firmware of a newly installed motor module, do the following.
Firmware 1. Disconnect the communication cable to the new motor module.
2. Power on the gateway.
3. To update all existing motor modules to 2198T-VTxx05-A firmware,
toggle Cmd.FlashSections50mm.
4. Power down the gateway.
5. Plug in the communication cable for the new motor module.
6. Power on the gateway.
7. Toggle Cmd.FlashSectionsxxxmm that corresponds to the mover type
you have. There are three types of movers:
2198T-VTxx05-A
2198T-VTxx10-A
2198T-VTxx15-A.
For troubleshooting, see Knowledgebase Article 600812.

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 UH1-68N, to lubricate the bearing rails.
To provide continuous lubrication, we recommend that you use the iTRAK

Lubrication System, catalog number 2198T-AL-SYS, installation instructions
start on page 111. If you design and supply your own oil bleed system, you can
use these installation instructions for guidance. The iTRAK system comes
equipped tubing that is connected to the bleed points on the bearing rail.
3 6
Items Description
1 Spine bar
2 Top inner lubrication tube
3 Top outer lubrication tube
4 Bottom outer lubrication tube
5 Y-split push-to-connect tube connector
6 Plug
7 Straight push-to-connect tube connector

Initial Lubrication During first-time start or when rails have been completely cleaned do the
following.
1. Run system at 0.5 m/s mover velocity.

2. Pump at 0.7 cc (0.024 oz) increments every 10 minutes until the furthest
rail section from the pump has become lubricated.
TIP The film of oil is thin and can be hard to see. Wipe the rail section
that contacts the mover roller with a finger you want to see a small
amount of lubricant.
It is normal for some of the oil to become black, but you must not see
signs of rusting or burnt grease, which is a sign of missing lubrication.
Lubrication During Normal Lubrication amounts and frequency during normal operation depend on many
factors including length of track, number of movers, application motion
Operation profile, cleanliness of the operating environment and other factors. Table 36 is
a rough guideline that must be adjusted for each application strike a balance
between keep a thin film of oil on the rail contact surfaces and over lubrication
that causes excess oil splatter.
Table 36 - Lubrication Examples
System Length Amount of Movers Pump Volume Time Interval
mm (ft) cc (oz) in Hours
800…2400 (2.6…7.9) 1…12 0.7 (0.002)
2400…4800 (7.9…15.7) 1…12 1.4 (0.047) 2
5200…10000 (17.1…32.8) 24…36 2.8 (0.095)
The values in Table 36 are guidelines only; monitor the rails every few hours
until a quantity and frequency can be established for the current application. It
is best to have a higher frequency with lower amounts of oil dispense to allow
the oil to coat the rails evenly.
For systems with large number of movers, increase the pump volume by 1…2 cc
(0.034…0.068 oz).
Replace Mover Lubrication Wipers
Before You Begin


What You Need

• 2.5 mm Allen wrench
• Loctite 243
• The quantity of replacement lubrication wipers as shown inTable 37.
Table 37 - Number of Lubrication Wipers on a Mover
Cat. No. Replacement Part Lubrication Location
Number Wiper Quantity
2198T-VTxx05-A 2198T-AL-PAD-V-50 2 One upper and one lower.
2198T-VTxx10-A 2198T-AL-PAD-V
3 Two upper and one lower.
2198T-VTxx15-A 2198T-AL-PAD-V
1. Remove mover by following steps in Install or Replace a Mover on

page 88.
2. Remove lubrication wipers by using a 2.5 mm Allen wrench.
2
3
Item Description
1 Inner Track Lubrication Wiper Assembly
2 Socket Head Cap Screw (x3)
3 Outer Track Lubrication Wiper Assembly (x2)
3. Clean all screws and apply Loctite 243.

4. Install new lubrication wipers and hand tighten.
5. Reinstall mover by following steps in Install or Replace a Mover on
page 88.
ATTENTION: Use caution when installing mover to help prevent

damage to the felt on the lubrication wipers.

Replace Lower Mover Bearing
The top four bearings are not field replaceable. For further information contact
a Rockwell Automation sales representative. There are two procedures for
replacing the lower bearings. The first one is for 2198T-VTxx05-A movers and
the second is for 2198T-VTxx10-A and 2198T-VTxx15-A wide movers.
Use the following procedure for movers with these catalog numbers.
• 2198T-VT0505-A
• 2198T-VT1005-A
• 2198T-VT1505-A
Before You Begin

What You Need

• 17 mm socket wrench
• Loctite 243
1. Remove mover by using the procedure found in Install or Replace a

Mover on page 88.
2. Remove the two bottom bearings by using a 17 mm socket wrench.
Item Description
1 Vee-wheel with integrated bearing
2 Lock nut

3. Clean all bolts and apply Loctite 243.

4. Attach new bearings to the mover.
5. Torque all bolts to 18 N•m (13.3 lb•ft).
6. Follow steps in Install or Replace a Mover on page 88 to reinstall mover.
Use the following procedure for movers with these catalog numbers.
• 2198T-VT0510-A
• 2198T-VT0515-A
• 2198T-VT1010-A
• 2198T-VT1015-A
• 2198T-VT1510-A
• 2198T-VT1515-A
Before You Begin

What You Need

• 17 mm socket wrench
• Loctite 243
• 0.8 mm (0.03 in.) shim
1. Remove mover by using the procedure found in Install or Replace a

Mover on page 88.
2. Remove three M6 x 30 screws to separate bottom plate from mover.
Bottom Plate
M6 x 30 Screws

3. Remove the two bottom bearings by using a 17 mm socket wrench.
4. Clean all bolts and apply Loctite 243.

5. Attach new bearings to the bottom plate.
6. Torque all bolts to 18 N•m (13.3 lb•ft).
7. Lay the mover and bottom plate on a flat surface.
8. Assemble bottom plate to mover put a 0.8 mm (0.03 in.) shim
underneath the mover plate.
Shim
9. Clean the three M6 x 30 screws and apply Loctite 243.

10. Insert and tighten three M6 x 30 screws to 17 N•m (12.5 lb•ft).

Circuit Breakers Use Figure 45 to locate circuit breakers in the PCM. Before accessing the
PCM, read the following.
BURN HAZARD: Some components of the system have hot surfaces.
• Do not touch hot surfaces such as brake resistors, heat sinks, power
supply units, drive controllers.
• 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

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 131.
Measure the voltage before working on components to make sure that they are
safe to touch.
• Do not connect, disconnect, or touch electrical connections or

components when power is applied.
• Only take measurements or test the operation of the system if a ground
conductor is properly connected.

Figure 45 - PCM Circuit Breakers
112
Chapter 6
14
1
INPUT
A2
12
41
8
11
4
44
31
42
7
34
3
32
10
21
13
Maintenance
INPUT
6
11
9
2
24
A1
22
14
1
12
2
3
4
5



6
shock.
High voltage may
DANGER
Risk of electrical
exist up to 5 minutes
after removing power.
7
Rockwell Automation Publication 2198T-UM001D-EN-P - October 2019

8
Item Description Item Description Item Description

1 CB04 AC Input to 24V Supply 4 CB06 24V Ethernet Switch 7 CB01 AC Main Disconnect (1)
2 CB05 24V Gateway 1 5 CB07 Fan 8 CB02, CB03 High-Voltage Supply Lines
3 CB05A 24V Gateway 2 6 CB08…CB12 24V to Track Motor Modules
(1) Location is dependent on the presence of a panel disconnect interlock.
Chapter 7
Troubleshooting
Use the system reported errors in this section to diagnose iTRAK® system
problems.
Topic Page
Errors Codes 113
Errors Codes The iTRAK 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 38 - Error Code Tags
Tag Description
iTRAK_Control.Status.GatewayFaultCode This tag contains the error codes from the Gateway. In Table 39 it
is referred to as the Gateway Code.
iTRAK_Control.Status.SectionFaultCode This tag contains the error codes from the motor module. In
Table 39 it is referred to as the Device Code.
iTRAK_Control.Status.FaultMessageLine1 This tag contains the first line of displayed text in the error code
description.
iTRAK_Control.Status.FaultMessageLine2 This 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 - position-related
1 - power-related
iTRAK_Control.Status.SectionFaultData Helpful data to troubleshoot the error.
The error codes are described in Table 39.

Chapter 7 Troubleshooting
Table 39 - iTRAK System Error Codes

iTRAK_Control.Status. iTRAK_Control.Status. Displayed Text Description and Solution
GatewayFaultCode SectionFaultCode
This error indicates that the motor module has lost high voltage on
one or both of its buses. The following are possible causes.
• Loose cables
• Module incorrectly wired
• Power supply has faulted
The iTRAK_Control.Status.SectionNumberFaulted tag contains the
motor module that is reporting this fault.
ERR_VOLTS_LO: Section voltage is too low or The iTRAK_Control.Status.SectionFaultData tag indicates the bus that
off. Check Power Supply, Power Cables, Power has failed.
20 Supply IO, etc. IF problem persists, Call FOR If the iTRAK_Control.Status.SectionFaultData tag =
Service. 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 ¼ of the high-
voltage rail.
Other values, then the PWM board in this motor module has no
current, call for service.
3
Check power supply and power cables. Reset power supply.
Check status indicator on the power supply and power cables. Reset
power supply.
There can be an issue with the power supply that is being reported by
a motor module.
ERR_VOLTS_HI: Section voltage is too high. motor module that is reporting this fault.
Emergency shunting has been activated. Check If the iTRAK_Control.Status.SectionFaultData tag =
21 Power Supply AND Shunt Regulator. Call FOR 0, then the high-voltage rail is higher than 509V.
service 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.
This error indicates the EtherNet/IP™ connection between the

controller and the gateway has dropped. The following are possible
causes.
• The time Sync of the Ethernet module 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 can need to be manually
reset.
a. Unplug the Ethernet cable from the gateway.
Fault_FieldBusSys - Sign of Life between b. Cycle the power on the gateway, wait 3…4 minutes until the
9 0 controller and gateway has been lost. Increase gateway powers up.
sync period AND check cables. c. Reconnect the Ethernet cable.
• Unshielded cables.
• Bad switch.
• Faulty hardware.
• Overuse of Logix Designer application trending.
Turn off application trending. Check cabling.
The iTRAK_Control.Status.SectionNumberFaulted tag is not
applicable for diagnostics. When this fault occurs, record the
information and be prepared to provide it to Customer Support if
requested.

Troubleshooting Chapter 7
Table 39 - iTRAK System Error Codes (Continued)

This error indicates that at the end of the next Coarse Update Period
two movers can crash into each other. The following are possible
causes.
• Two motion commands are not synchronized to run in the same
Coarse Update Period.
• A mover was applied over another mover.
• Tasks have overlapped and cannot finish in allocated time.
Headway Fault. Two movers cmd or actual pos The iTRAK_Control.Status.SectionNumberFaulted tag contains the
10 0 is under headway setting. Increase amt 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 neighbor movers did not trigger the fault.
Check for task overlaps. Verify proper motion instruction execution
order.
This error indicates the following.
• The number of movers exceeds the maximum number that is
specified in the iTRAK_Control.Data.ActiveMovers tag.
• A mover was lost in the middle of the track.
Displayed Text varies according to the value of • Movers have been moved when the gateway is off.
iTRAK_Control.Status.SectionNumberFaulted: If the iTRAK_Control.Status.SectionFaultData tag = 0, then the
Value 0: number of movers that are specified in the Logix Designer application
Wrong Number of movers reported. A mover doesn't match the number of movers actually found.
has been lost on the system or the wrong To reset this fault, do the following.
11 0 or 7 number specified in the active axis tag. Check 1. Correct the value in the iTRAK_Control.Data.ActiveMovers tag.
magnets or re-number with HMI tag. 2. Renumber the movers by latching
Value 7: iTRAK_Control.Cmd.RenumberMovers.
iTRAK could not find all movers at their last 3. Reset the fault by latching iTRAK_Control.Cmd.FaultReset
reported positions. The movers have been If the iTRAK_Control.Status.SectionFaultData tag = 7, then upon
automatically renumbered. start-up, the movers were not found in the same positions as they
were when the track was shut down. The movers on the track have
been automatically renumbered.
Check position magnets. Check specified movers and licenses. Check
track for debris.
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
• Electrical noise
Fault_InternalComm - Data could not be
0 If the iTRAK_Control.Status.SectionFaultData tag =
written to sections.
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
12 command was not received.
This fault can cause the gateway to lose movers; therefore, the movers
must be renumbered before clearing this fault.
Check power connections. Cycle power.
This error indicates that the current in the motor module has risen to
an unacceptable level.
ERR_OVERCURRENT_FAULT: Section has an
2 The iTRAK_Control.Status.SectionDeviceFaulted tag is the PWM board
overcurrent fault. Reset system. 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.
ERR_WAYWARD_ISR: Section is reporting an The iTRAK_Control.Status.SectionNumberFaulted tag contains the
6 Wayward ISR fault. Call FOR service. motor module that is reporting this fault.
Replace the failed module.
This error indicates a failure in the position sensing hardware.
ERR_SENSOR_TIMEOUT: Section is reporting a The iTRAK_Control.Status.SectionNumberFaulted tag contains the
7 sensor hardware fault. Call for service. motor module that is reporting this fault.
Replace the failed module.
This error indicates a failure in communication from the gateway to
the motor module.
ERR_INVALID_PKT: Section received an invalid
8 If the iTRAK_Control.Status.SectionFaultData tag < 12, then the
packet. Reset system. iTRAK_Control.Status.SectionFaultData tag has a gain that is 0.
If the iTRAK_Control.Status.SectionFaultData tag ≥12, the section is
not calibrated properly.
Check the cable and reset the system.
This error indicates communication failure between the gateway and
a motor module.
ERR_COMMUTATOR_TIMEOUT: Commutator motor module that is reporting this fault.
12 12 could not finish in allocated time. Call FOR
Software update. The iTRAK_Control.Status.SectionDeviceFaulted tag = The PWM
board number.
Check the cable. Reset the system. Contact Rockwell Automation
Technical Support for service.
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
• A motor module is loosely mounted
• General over all performance is low
If the iTRAK_Control.Status.SectionFaultData tag < 12, then the coil
I2T Error: A coil or all coils have been on for too with number equal to iTRAK_Control.Status.SectionFaultData is
14 overheated, stop the system.
long for heat. ExtraData=Coil
If iTRAK_Control.Status.SectionFaultData tag = 12, then overcurrent
has run for too long.
Check track path and cables or reduce motion profile demands.
To clear this fault properly, do the following.
1. Leave the iTRAK high voltage off for 5 minutes, Do not turn off the
control voltage.
2. Check the track path.
3. Clear the fault and start the track
4. If the fault is reproduced, reduce motion profile demand.


This error indicates a communication failure between the gateway
and a motor module.
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.
ERR_CHECKSUM: Section communication error. 3, then the packet is not from the gateway.
15 Check comm. cable. Reset system.
5, then the packet that was received is not for this motor module.
13, then the packet that was received is not good.
14, then the size of the packets exceeds maximum size.
100, then there were ten communication errors in a row.
109…112, then check the communication cable shield and ground
and all other potential interference on serial communication, Move
noise producing devices such as transformers and AC drives away from
the gateway. If the fault is reproduced, replace the motor module.
Check the communication cable and reset the system.
This error indicates a failed position sensor.
ERR_POS_RANGE: Position Sensor error. motor module that is reporting this fault.
16 Indicates electrical fault. Extra Data indicates
which sensor. Call FOR service. The iTRAK_Control.Status.SectionFaultData tag is the number of the
12 sensor whose analog-to-digital converter is out of range.
Replace the failed motor module.
This error indicates a failed current sensor.
The iTRAK_Control.Status.SectionFaultData tag contains the failed
sensor.
ERR_CUR_RANGE: Current Sensor error. If iTRAK_Control.Status.SectionFaultData < 20, then
17 iTRAK_Control.Status.SectionFaultData is the number of the coil that
Indicates electrical fault.
has a failed sensor. This fault happens during run time.
If iTRAK_Control.Status.SectionFaultData ≥ 20, then
(iTRAK_Control.Status.SectionFaultData - 20) is the number of the
coil that has a failed sensor. This fault happens during the power on
self test.
Replace the failed motor module.
This error indicates that the electrical boards are warm. This error is
usually the result of failed mechanical part that caused the motor to
ERR_PCB_TEMP: Drive overtemperature fault. over work and transfer heat.
Check mover bearings, venting, reduce motion The iTRAK_Control.Status.SectionNumberFaulted tag contains the
18 motor module that is reporting this fault.
profile demands. IF problem persists, call FOR
service. The iTRAK_Control.Status.SectionFaultData tag is the temperature of
the device.
Check mover bearings, vents, or reduce motion profile demands.


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
ERR_VOLTS_LO: Section voltage is too low or The iTRAK_Control.Status.SectionFaultData tag indicates the bus that
off. Check Power Supply, Power Cables, Power has failed.
20 Supply IO, etc. IF problem persists, Call FOR If the iTRAK_Control.Status.SectionFaultData tag =
Service. 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 ¼ of the high-
voltage rail.
Other values, then the PWM board in this motor module has no
current, call for service.
This error indicates that the motor module voltage is too high.
ERR_VOLTS_HI: Section voltage is too high. 0, then the high-voltage rail is higher than 509V.
Emergency shunting has been activated. Check
21 1, then the common rail is higher than 254V.
Power Supply AND Shunt Regulator. Call FOR
service 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.
12 Power stage is overtemperature.
ERR_PWRSTAGE_TEMP: Power stage is motor module that is reporting this fault.
overtemperature. Check mover bearings,
22 The iTRAK_Control.Status.SectionFaultData tag is the amplifier
venting, reduce demands. IF problem persists,
call FOR service. module has reported this fault.
Check mover bearings, how the machine is vented, or reduce
demands.
There is a bad coil.
ERR_ONE_BAD_COIL: Power on Self Test The iTRAK_Control.Status.SectionNumberFaulted tag contains the
indicates at least one coil is bad. Extra data
23 motor module that is reporting this fault.
indicates Coil. System may still run. Call FOR
service The iTRAK_Control.Status.SectionFaultData tag contains the number
of the bad coil.
There are too many bad coils.
ERR_TOO_MANY_BAD_COILS: Power on Self The iTRAK_Control.Status.SectionNumberFaulted tag contains the
24 Test indicates at multiple coils are bad. System motor module that is reporting this fault.
will NOT run. Call FOR Service The iTRAK_Control.Status.SectionFaultData tag contains the number
of the first bad coil. Call service to replace the module.
Nonvolatile memory operations failed.
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.
Any other value. Any other value. Contact ICTSupport@ra.rockwell.com.


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 following are possible causes.
• Mechanical failure
Position Window Err: a mover is outside its • Over-aggressive programming
17 0 position window. Check or increase win • The following error set too low in the HMI.
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. The following are possible causes.
• The control tags are set incorrectly.
• The motor modules are improperly cabled.
• Foreign magnetic material on the track is adding an extra mover.
Sections are not connected correctly or too • If there is a newly installed motor module on the track, this error
18 0 many movers reported or NOT communicating can indicate that the firmware in the newly installed motor
or wrong track length 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 that is specified in iTRAK_Control.Data.TrackLength
doesn't match the track length the gateway calculated.
Otherwise, iTRAK_Control.Status.SectionNumberFaulted tag contains
the motor module that has reported this fault.
The iTRAK power supply is not in Running mode. Check the iTRAK
30 power supply screen for more information and acknowledge the fault.
The gateway failed to acknowledge the fault on the iTRAK power
31 The iTRAK power supply has a fault. Check the supply. Check the iTRAK power supply wiring and acknowledge the
20 iTRAK power supply screen and gateway fault.
terminal for details. The gateway failed to enable the iTRAK power supply. Check the
32 iTRAK power supply wiring and acknowledge the fault.
The wiring of the iTRAK power supply is incorrect. Check the wiring
34 and reboot the gateway to clear the fault.
During the download of the user-specified External Force
Compensation table, two adjacent entries were found to have the
N/A N/A same position value, which is not permitted. You must change at least
23 one of the position values, and re-trying the download of the External
Force Compensation table.
The External Force Compensation table contains more than six entries.
1 N/A Six entries is the maximum.
During the download of the user-specified External Current Limit
table, two adjacent entries were found to have the same position
N/A N/A value, which is not permitted. You must change at least one of the
24 position values, and re-trying the download of the External Current
Limit table.
The External Current Limit table contains more than six entries.Six
1 N/A entries is the maximum.


1 N/A Sub code 1. The velocity bandwidth is out of the range of 1…1000
2 N/A Sub code 2. The velocity integrator is out of the range of 1…2000.
Sub code 3. The gain values are attempting to be applied to a motor
3 N/A module number that is not in the range of 0 …(Number of motor
25 modules on the track - 1).
Sub code 4. The gain values are attempting to be applied to a mover
number that is not in the range of 0…15.
4 N/A Per-mover gains may be specified only for the first 16 movers on an
iTRAK system.
Mover size mismatch, size of movers are not There is an inconsistency between the size of the movers on the iTRAK
consistent on the track system, and the firmware that is downloaded into one or more of the
26 0 Check section types and set them to correct motor modules. Fix the error by toggling the appropriate
types, Call service for more details iTRAK_Control.Cmd.FlashSections<x>mm controller tag.

Chapter 8
Functional Safety
The iTRAK® components do not have Safe Torque Off or any other features
that are described in EN 61800-5-2. When combined into a system,
implement safety functions to prevent motor actuation. Remove the AC power
by using similar methods that are used for variable frequency drives that do not
have Safe Torque Off. The safety function subsystem that is described here
explains how to wire contactors for the successful removal of power to the
iTRAK system.
Topic Page
Important Safety Considerations 121
Category 3 Requirements according to EN ISO 13849-1 121
Stop Category Definition 122
Performance Level and Safety Integrity Level (SIL) 122
Safety Distance Calculations 122
Functional Safety Description 122
Considerations for Category 1 Stop 123
Overall System Stopping Performance 123
Schematic and Block Diagrams 124
Important Safety You are responsible for the following.

Considerations • Validation of any sensors or actuators that are connected to the system.
• Completing a machine-level risk assessment.
• Certification of the machine to the desired EN ISO 13849 performance
level or IEC 62061 SIL level.
• Project management and proof tests in accordance with EN ISO 13849
or IEC 62061.
Category 3 Requirements Safety-related parts are designed with these attributes.

according to EN ISO 13849-1 • One fault in any of these parts of the control system does not lead to the
loss of the safety function.
• One fault is detected whenever reasonably practicable.
• Accumulation of undetected faults can lead to the loss of the safety
function and a failure to remove power that produces motion from the
motor.

Chapter 8 Functional Safety
Stop Category Definition Stop Category 0 as defined in IEC 60204 is achieved with immediate removal
of power that produces actuator motion.
Stop Category 1 as defined in IEC 60204 is achieved with the delayed removal
of power that produces actuator motion, to facilitate the controlled stoppage of
elements that move.
Performance Level and For safety-related control systems, Performance Level (PL), according to
EN ISO 13849-1, and SIL levels, according to IEC 61508 and IEC 62061.
Safety Integrity Level (SIL) Include a rating of the ability of the system to perform its safety functions. All
safety-related components of the control system must be included in both a
risk assessment and the determination of the achieved levels.
See the EN ISO 13849-1, IEC 61508, and IEC 62061 standards for complete
information on requirements for PL and SIL determination.
Safety Distance Calculations Detailed calculation of a proper safety distance is beyond the scope of this
document, but here are some considerations to follow.
System safeguards must be in place such that a person cannot reach a hazardous
motion before the safeguarding system has brought that hazardous motion to a
halt. These issues are addressed in safety standards relevant to this application
that are listed here.
• IS0 14119 Safety of machinery - Interlocking devices that are associated
with guards - Principles for design and selection.
• ISO 13855 Safety of machinery - Positioning of safeguards regarding the
approach speeds of parts of the human body.
• ANSI B11.19 Performance Criteria for Safeguarding.
Functional Safety The safety logic device, such as a configurable safety relay or programmable
safety automation controller, monitors the safety input device, such as a door
Description switch or emergency stop button, for commands, proper operation, and safety
demands. The safety logic device must monitor itself for any internal faults.
When actuated, the safety logic device sends a safety stop command to the
motion control device and start the configurable timer. During this time, the
iTRAK system must decelerate to zero speed.
When the timer expires, power is removed from the safety output contactors
that remove power that produces motion from the iTRAK system. If the track
is in motion, it coasts to a stop.
The safety logic device must monitor the contactors for welded contacts via
feedback from two normally closed contacts in a series, one from each
contactor, in the reset circuit. If a contact is welded, the normally closed

Functional Safety Chapter 8
contact is held open, which breaks the reset circuit. The system must not be
restarted until appropriate measures have been taken.
Considerations for Category 1 If there is a malfunction, it is possible that stop category 0 can occur. When
designing the machine application, timing and distance must be considered for
Stop a coast to stop and the possibility of the loss of control of a vertical load. The
malfunction that causes this condition maybe when a signal to the output
contactor coil were to go low. A low can happen when a wire falls off or control
power fails before the iTRAK system has a chance to come to a complete stop.
Use additional protective measures if this occurrence can introduce
unacceptable risks to personnel.
Overall System Stopping ISO 14119 6.2.1 stipulates that the overall system stopping time for a
hazardous machine that is safeguarded by an interlock must be less than the
Performance access time. If the overall system stopping performance is equal to or greater
than the access time, an interlock with guard locking must be used, the distance
from the safeguard to the hazard must be increased, or another, more suitable
method must be used to safeguard the hazard.
The overall stopping performance of these applications is the sum of the

following.
• Response time of the safety input device.
• Safety logic devices.
• Any delay that is configured in the safety logic devices.
• The safety reaction time of the output contactors used.
• The coast-to-stop time of the hazardous motion.
The response and reaction times can be taken from the product support
literature.
IMPORTANT Determine the overall system stopping performance of a safeguarding

system by actual system testing and measurement. The worst-case, overall
system stopping performance from these tests and measurements must be
used to evaluate the safety distance requirements.
The sum response and reaction time of the safety logic devices, output
contactors, and worst-case, coast-to-stop portion of the overall system-
stopping performance is the same regardless of the input device used.
It is useful to estimate how fast the hazardous motion must coast to a stop
before the safeguarded system is available for testing.

Schematic and Block These simplified schematic diagrams are intended to inform qualified
engineers on how to structure a safety system around the iTRAK system. They
Diagrams are not considered complete.
iTRAK Power Supply
The block diagram that is shown in Figure 46 is an outline schematic for the
safety circuit to use with a system that uses an iTRAK power supply.
Figure 46 - Kinetix® 5700 iTRAK Power Supply Safety Circuit Block Diagram
2198-P070 2198T-W25K-ER
Kinetix 5700 Kinetix 5700
Bonded Cabinet DC-bus Power Supply iTRAK Power Supply
Ground Bus *
Cable Shield
Clamp
DC-
DC-
Chassis DC+ Shunt Power L
(RC) Connector DC-bus Power Output A L
SH H
(IDC) Connector H
Customer Supplied and Control Power Output A
+24V DC (ICP) Connector 1 24V +
Power Supply * 24V +
2 24V -
24V -
DC+ DC+ DC Bus

DC- DC- (DC) Connectors
DC- DC-
24V AC/DC CR1 * START * DC-bus Power Output B L L
or 120/240V AC CR1 * H
2198-TCON-24VDCIN36 (IDC) Connector H
50/60 Hz M1 * 24V Input Power and Control Power Output B
STOP * Wiring Connector (ICP) Connector
1 24V +
CR1 * 1 24V +
+24V +24V Control Power 2 24V -
2 24V -
24V_COM 24V_COM (CP) Connectors
2198-xxxx-P-T
T-connectors and Bus Bars 1
324…528V AC rms ENABLE
Safety Logic 1 2 (2)
Three-phase Input IN1 COM 24V COM
Devices 2
COM Digital Input Digital Input CLEAR 3
3 (IOD) Connector FAULT
IN2 Connections
+24 V 4 4 (2)
SHLD COM 24V COM
SAFE OUT 1 5
SHLD SHIELD
COM Safety Output EN–
CONT EN– Contactor Enable
SAFE OUT 2 Contactors EN+
CONT EN+ (CED) Connector
-
COM iTRAK Power Supply RDY- IPS READY
+
REST IN Ready (IR) Connector RDY+
Three-phase Input PE Ground PE Ground

(IPD) Connector L3 L2 L1
Circuit
Safety Protection*
Inputs
Bonded Cabinet
2198-DBxx-F Ground Bus *
Three-phase
AC Line Filter
M1 * Indicates User Supplied Component

Contactor*

Functional Safety Chapter 8
Power Control Module
When the iTRAK system is used with a pre-assembled power control module,
the safety logic devices and safety output contactors are pre-wired in the
cabinet. You are responsible for wiring safety input devices to the appropriate
connectors on the cabinet. The safety circuit wiring schematic included in a
pre-assembled cabinet is shown in Figure 47.
Figure 47 - Power Control Module Safety Circuit
2198T-WPCM-08 Power Control Module

CES01
A2 S11 A1 CRST01
COM S33 24V
A 6 5 Emergency
External B 14 S12 Stop Relay 13 PB01 A
S34 24V
E-stop C
k2 k1
B
C
(P5) D 24 S21 14 13
41
23 6 5
E 2 1 24 23 D
34 33
E and F DRY F
NC 34 S22 42 41 42 33
CONTACT External
Reset
(P3)
CGS01 S11
A2 S33 A1
COM 24V
Guard Stop 1 2
A
External B 14 S12 Relay S34 13
CGS02 C
Guard Stop D
k2 k1
S21 14 13 23
(P4) E
24
24 23 41
34 33
E and F DRY F
NC 34 S22 42 41 42 33
CONTACT
Circuit
Protection
L3 3
28 320V
PS01 L2 2
29 0V L1 1
324…528V AC rms
Three-phase Input
A
L3 3
B 28 160V
ITP00…ITP07 29 0V
PS02 L2 2 Safety
C L1
To Motor Module D
1 Contactors
E
Circuit
F Protection

Notes:

Chapter 9
Compatibility
Use this chapter to determine compatibility between newer and older

components of your iTRAK® system.
Topic Page
Motor Modules 127
Movers and Magnets 128
Gateways 128
Power Supplies 128
Controllers 128
Motor Modules Bulletin 2198T iTRAK motor modules are compatible and can be mixed
mechanically, regardless of the series.
• If you have any series B modules in your system, the minimum firmware
revision for the entire system is 1.107.
• There are minor differences in labeling and appearance but the modules
are functionally the same.
Bulletin IT3 iTRAK motor modules have limited compatibility with the
Bulletin 2198T iTRAK motor modules.
• Bulletin IT3 iTRAK motor modules have higher cogging force in the
motors and can require modifications to the tuning when replacing with
Bulletin 2198T iTRAK motor modules.
• If a Bulletin 2198T iTRAK motor module is replacing s a Bulletin IT3
iTRAK motor module, all similar modules that are adjacent must be
replaced also.
– If replacing one curve module, the adjacent curve module must be
replaced also. The straights and opposite curve can stay.
– If replacing a straight module, all of straight modules between the
nearest curve modules must also be replaced. The opposite straights
and curves can stay in the system.
• All modules must be updated to the same firmware revision that the
newest module requires.
• Contact ICTSupport@ra.rockwell.com before making any Bulletin IT3
to Bulletin 2198T migrations for additional support.

Chapter 9 Compatibility
Movers and Magnets Mover magnets on a track must all be the same size and geometry. All mover
magnets are compatible with all motor modules of the same frame size.
Gateways Two styles of gateways are supported for the iTRAK system.
Generation one gateways are compatible with all motor module types and
firmware revisions.
Generation two gateways are compatible with all motor module types, from
firmware revision 1.100 and later for tracks smaller than 16 motor modules and
firmware revision 1.108 for larger tracks.
Power Supplies Two styles of power supplies are supported for the iTRAK system. They must
not be used on the same system.
The assembled Power Control Module (PCM), or components of the PCM

assembled by the customer, is designed to work with all types of iTRAK motor
modules.
If you are using the Kinetix® 5700 iTRAK power supply, you must use firmware
revision 1.110 or later and the associated ladder logic that is referenced in
Knowledgebase Article 778917. If using a Kinetix 5700 iTRAK Power Supply at
lower firmware revisions, contact ICTSupport@ra.rockwell.com for assistance
and sizing.
Controllers The iTRAK system is designed to work with the controllers that are shown in
Table 40.
Table 40 - Compatible Controllers
Platform Controller
ControlLogix® 5580 (1)
5570 (2)
CompactLogix™ 5380 (1) (3)
5370 (3)
5480 (1)
(1) The minimum firmware revision to use these processors is 1.103.
(2) The communication to the gateway must be through 1756-ENxT modules capable of Integrated
Motion on EtherNet/IP™.
(3) The memory requirements and CPU utilization of typical iTRAK applications can reduce the possible
catalog numbers available in these families. Work with Rockwell Automation application
engineering to determine suitability.

Appendix A
Label Placement
Use this chapter to understand the safety labels and what is on a safety label if it
is unlegible.
Topic Page
Safety Labels 129
Safety Labels The following safety-identification labels are affixed to the iTRAK® system. To
help prevent injury and damage to the system, review the safety labels, their
details, and locations before using the system.
Figure 48 - Safety Label Placement

Series A Safety Labeling Series B Safety Labeling
B
CAUTION
Heavy Obje
H CONTRO
COMMU
NICATIO
DRIVE ENABLE
L POWER
Two perso ct D
C
n
required. lift WARNIN DANGER
Hazardous
Power Off. Voltage Inside
G Lockout/Ta
wait 5 minutes gout and
Hazardou WARNING
other sensitive equipment

Can be harmful to pacemakers and
Magnetic field locate in this area
Moving parts Lockout/Tagout
PINCH POINTS
inside. s voltage Magnetic
pacemaker
Field
Can be harmful
to
WARNING
wearers
E
Disconnect
A
CAUTION
before openpower Metal Surfaces
Do not touch May be Hot
CAUTION ing Power Off.
Allow to
cool down
CAUTION
Hot Surfa PINCH POINTS
NEARBY
ce. B624958
Sudden
motion.
Power Off. Stand
Lockout/Ta Clear
Do not touc gout
h.
CAUTION
Sudden machin
injury. e motion
can cause
Stand clear
Pinch Point.
Keep clear
when machin
during operatio
e is in motion
n.
.
D 3
1 1
C WARNING
HAZARDOUS
VOLTAGE.
F
Disconnect power
before opening.
GER
DAN
Do not touch.
TAGE
HIGH VOL
Hot Surface.
CAUTION
req per Ob
Twoavy
He
uire son jec
CA
d. lift t
UT
A
IO
N
H
t and
ER
befoonn
Discde. ous
ING
insi ard
ER
e
agou
Haz
ATION
n
wait r Off. Lock ge Insid
dow
be Hot
N
L POW
DANG
agou r
5 minu out/T
re ect
BLED
out/T Clea
ION
t
IO
WA
to cool
WARN
Keep Point. when
ope pow
Pinch clear
Stand
ers
r Off. on. StanBY

injury. n machin
Powerdous Volta
Sudde
MUNIC
Lock d
make ful to
Powe touc May

CAUT
Powe en motiTS NEAR

tes
r wear
TRO
ENA
clear
Can netic Field

RN
CAUT
ning er
Allow
Do notl Surfaces
pacebe harm
volt
during
CA
r Off. h
CON
ING
DRIVE
COM
SuddH POIN
Haza
age
e motion
UT
operat
Mag
machin
Meta
PINC
ion.
ION
e is
can
in motion
cause
958
.
B624
2 4
2
DANGER
Risk of electrical
shock.
High voltage may
G
Table 41 - System Components with Safety Labels

Item Component Item Component
1 Straight Motor Module 3 Mover
2 Curved Motor Module (left and right 4 Power Control Module
modules are labeled the same)

Appendix A Label Placement
Table 42 - Safety Labels

Title Component Label Details
Location
Hot Surface Series A Motor A Indicates that the surface can be hot enough to burn if touched.
Module CAUTION
Hot Surface.
Do not touch.
Heavy Object Series A and B B Components with this label are 22.7 kg (50.0 lb) or more and
Motor Modules CAUTION require two people to lift.
Heavy Object
Two person lift
required.
Hazardous Voltage Series A Motor C Do not open PCM, motor module, or right angle connectors while
Module and PCM WARNING the cables are connected. Lockout/tagout if access to the motor
Hazardous voltage
inside.
module is required during maintenance.
Disconnect power
before opening.
Automated Machinery Series A Motor D Movers can make as sudden and unexpected movements while
and Pinch Points Module CAUTION the system is powered. Lock-out/tag out before servicing.
Sudden machine motion can cause
injury.
Stand clear when machine is in motion.
Pinch Point.
Keep clear during operation.
Magnet and Pinch Points Mover E The mover uses strong magnets. The magnetic field that is
WARNING
PINCH POINTS
Moving parts Lockout/Tagout
generated can disrupt the functionality of automatic- implantable
Magnetic field locate in this area cardioverter defibrillators (AICD). People with cardiac pacemakers
Can be harmful to pacemakers and
other sensitive equipment 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 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.
Pinch points exist between adjacent movers and motor modules
and movers. Keep your hands clear of a system under power.
High Voltage PCM F The power control module can have voltages greater than 240V
present inside the cabinet and at the connectors.
DANGER
HIGH VOLTAGE

Label Placement Appendix A
Table 42 - Safety Labels (Continued)

Title Component Label Details
Location
High Voltage PCM G The capacitors inside the PCM can have high voltage present for 5
(capacitors) DANGER minutes. Do not attempt to service the PCM until 5 minutes after
Risk of electrical
power has been removed.
shock.
High voltage may
Unified Safety Label Series B Motor H See Safety Information on page 19 for details on danger,
Module warnings, and cautions on this label.
CONTROL POWER
COMMUNICATION
DRIVE ENABLED
DANGER
Power Off. Lockout/Tagout and
wait 5 minutes
WARNING
Magnetic Field
Can be harmful to
pacemaker wearers
CAUTION
Metal Surfaces May be Hot
Do not touch
Power Off. Allow to cool down
CAUTION
PINCH POINTS NEARBY
Sudden motion. Stand Clear
Power Off. Lockout/Tagout
B624958

Appendix A Label Placement
Notes:

Index
Numerics C
2198T-A01 88 cable
2198T-AL-SYS 105 installation 75
configuration 35 cable gland
installation 32 installation 76
2198T-CHBFLS8-12AAxx 42, 45, 46 cable installation 75
2198T-CHBFLS8-12Axx circuit breaker
installation 54 10 kW power control module type 2 112
2198T-CHBP8S8-12P3 45, 46 cleaning 83
2198T-CHBP8S8-12P6 45, 46 commission 82
2198T-G02-016-E 17 compatibility
2198T-GUSB 17, 47, 56 controller 128
2198T-Gxx-xxx-E 47 gateway 128
2198T-L16-Txx04-AOON-2E1E-NS 12 motor module 127
mover 128
2198T-L16-Txx04-B09x-2E1E-NS, 12 power supply 128
2198T-L16-Txxxx-A00N-2E1E-NS 92 component description
2198T-L16-Txxxx-B09x-2E1E-NS 94 curved motor module 12, 38, 66
2198T-M0505-A000 86 gateway 38, 65, 66
2198T-NN-318 84 gateway enclosure 74
2198T-NS-318 84 mover 14, 38, 66
power control module 65, 66, 67
2198T-VT0505-A 108 straight motor module 12, 38, 65, 66
2198T-VT0515-A 109 connector locations
2198T-VT1005-A 108 digital USB I/O 56
2198T-VT1010-A 109 gateway 57
2198T-VT1015-A 109 iTRAK power supply 48
2198T-VT1505-A 108 contoller
2198T-VT1510-A 109 compatability 128
2198T-VT1515-A 109
2198T-VTxxxx- 88 D
2198T-VTxxxx-A 14, 84 description
2198T-W25K-ER 16, 47, 48
2198T-WBCMOD 16, 46 iTRAK power supply 48
2198T-WPCM-08 16 dimensions
gateway enclosure 74
PCM 69
A
automatic implantable cardioverter
defibrillator (AICD) 130
E
enclosure
Ethernet ports 102
B error codes 113
bearing e-stop
installation 108 circuit schematic 71
block diagram pinout 70
Ethernet
iTRAK power supply 38
iTRAK power supply safety 124 ports 102
bus cable
preparation 60 F
resisitve loss 42
bus conditioner 38 firmware
description 16 downgrade 104
installation 45, 46 update gateway 102
bus reset 68 update motor module 104
update troubleshooting 104

Index
G lubrication
gateway 75 first time 106
frequency 106
compatability 128 Kluber 4-UH1-68N 84
installation 75 straight nipple fittings 32
weight 75 weep holes 32
wire 57 lubrication pump
gateway enclosure
configuration 35
description 74 description 33
dimension 74 installation 33
guard mounting dimensions 34
circuit schematic 71 volume calculation 35, 106
pinout 70 wire 34
lubrication system
installation
I horizontal 32
installation vertical 32
bus conditioner 45
lubricaiton system horizontal 32
lubricaiton system vertical 32 M
multiple iTRAK power supplies 45 magnet plate
multiple segments 30 handeling 25
track 27 install 86
installation bus conditioner 46 magnetic field strength 22, 25
instructions magnetic plate
bus cable preparation 60 screws 86
installation 27, 75 mechanical and servo components 10
bearings 108 monitor
cable gland 76
cables 75 circuit schematic 72
pinout 70
curved motor module 94
motor module
gateway 75
lubrication wiper 106 compatability 127
magnet plate 86 firmware update 104
mover 88 installation
planning 27, 75 curved 94
position magnet 84 straight 92
power control module 75 numbering 57
straight motor module 92 mount 75
iTRAK power supply gateway 75
block diagram 38 PCM 75
connectors 48 track 27
description 48 mounting holes 29
multiple 45 mover
safey circuit 124 compatability 128
status indicators 78, 79 description 14
wire 59 installation 88
wirirng requirements 51 magnetic field strength 22
replace 88
L
label N
series B motor module 13 number motor modules 57
labels
automated machinery 130
high voltage 130 P
hot surface 130 PCM
series A motor module 13
strong magnets 22 mount 75
leveling feet 30 safety circuit 125
status indicators 68
lifting slots 29 weight 75
loop back connector 58 PCM dimensions 69

Index
pinout U
e-stop 70 USB I/O
gateway to PCM cable 74
guard 70 description 17
monitor 70 wire 56
reset 70
position magnet
magnetic field strength 24
W
power control module warning
circuit breaker automatic implantable cardioverter
10 kW type 2 112 defibrillator (AICD) 130
description 67 powerful forces 130
installation 75 weight
power supply gateway 75
compatability 128 PCM 75
track 28
wire
R gateway 57
replace iTRAK power supply 59
multiple 46
curved motor module 94 single 45
mover 88
lubrication pump 34
position magnet 84
USB I/O 56
reset
bus 68
circuit schematic 70
pinout 70
S
safety
automated machinery 130
handling 27
heat 130
high voltage 130
machine guarding 19
risk assessment 19
strong magnets 22
schematic
e-stop circuit 71
guard circuit 71
monitor circuit 72
power control module safety 125
reset circuit 70
series A
labels 13
series B
label 13
status indicators
iTRAK power supply 78, 79
PCM 68
series A motor module 13
series B motor module 13
T
tags
controller 81
track
installation 27
weight 28

Index
Notes:

.
Rockwell Automation Support

Use the following resources to access support information.
Technical Support Center Knowledgebase Articles, How-to Videos, FAQs, Chat, User https://rockwellautomation.custhelp.com/
Forums, and Product Notification Updates.
Local Technical Support Phone Numbers Locate the phone number for your country. http://www.rockwellautomation.com/global/support/get-support-now.page
Find the Direct Dial Code for your product. Use the code to
Direct Dial Codes route your call directly to a technical support engineer. http://www.rockwellautomation.com/global/support/direct-dial.page
Installation Instructions, Manuals, Brochures, and

Literature Library http://www.rockwellautomation.com/global/literature-library/overview.page
Technical Data.
Product Compatibility and Download Get help determining how products interact, check
http://www.rockwellautomation.com/global/support/pcdc.page
Center (PCDC) features and capabilities, and find associated firmware.
Documentation Feedback
Your comments will help us serve your documentation needs better. If you have any suggestions on how to improve this document, complete the
How Are We Doing? form at http://literature.rockwellautomation.com/idc/groups/literature/documents/du/ra-du002_-en-e.pdf.
Rockwell Automation maintains current product environmental information on its website at http://www.rockwellautomation.com/rockwellautomation/about-us/sustainability-ethics/product-environmental-compliance.page.
Allen-Bradley, CompactLogix ,ControlFLASH, ControlLogix, Integrated Architecture, iTRAK, Kinetix, Rockwell Software, Rockwell Automation, Studio 5000, and Studio 5000 Logix Designer are trademarks of Rockwell Automation, Inc.
EtherNet/IP is a trademark of ODVA, Inc.
Trademarks not belonging to Rockwell Automation are property of their respective companies.
Rockwell Otomasyon Ticaret A.Ş., Kar Plaza İş Merkezi E Blok Kat:6 34752 İçerenköy, İstanbul, Tel: +90 (216) 5698400
Publication 2198T-UM001D-EN-P - October 2019

Supersedes Publication 2198T-UM001B-EN-P - June 2017 Copyright © 2019 Rockwell Automation, Inc. All rights reserved. Printed in the U.S.A.

I TRAK

Uploaded by

Copyright:

Available Formats

I TRAK

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

I TRAK

Uploaded by

Copyright:

Available Formats

User Manual

Labels may also be on or inside the equipment to provide specific precautions.

Rockwell Automation Publication 2198T-UM001D-EN-P - October 2019 3

4 Rockwell Automation Publication 2198T-UM001D-EN-P - October 2019

Rockwell Automation Publication 2198T-UM001D-EN-P - October 2019 5

6 Rockwell Automation Publication 2198T-UM001D-EN-P - October 2019

This manual provides installation instructions to mount, wire, and

• Hardware must remain in its original state; never make structural

Rockwell Automation Publication 2198T-UM001D-EN-P - October 2019 7

You can view or download publications at

8 Rockwell Automation Publication 2198T-UM001D-EN-P - October 2019

Rockwell Automation Publication 2198T-UM001D-EN-P - October 2019 9

The gateway facilitates communication between the iTRAK system and

An animation of the iTRAK system can be viewed at https://

Figure 1 - Exploded View of the Mechanical and Servo Components

Item Description Item Description

10 Rockwell Automation Publication 2198T-UM001D-EN-P - October 2019

Table 1 - Electromechanical Components of an iTRAK System

Table 2 - Power and Control Components of an iTRAK System

Rockwell Automation Publication 2198T-UM001D-EN-P - October 2019 11

Figure 2 - 2198T-L16-Txx04-AOON-2E1E-NS, Straight Motor Module

Figure 3 - 2198T-L16-Txx04-B09x-2E1E-NS, Curved Motor Module

Table 3 - Motor Module Component Description

12 Rockwell Automation Publication 2198T-UM001D-EN-P - October 2019

Figure 4 - Series A Motor Module Status Indicators

Straight Motor Module Curved Motor Module

Table 4 - Series A Motor Module Status Indicator Description

Figure 5 - Series B Motor Module Status Indicators

Straight Motor Module Curved Motor Module

CONTROL POWER Left

Table 5 - Series B Motor Module Status Indicator Description

Rockwell Automation Publication 2198T-UM001D-EN-P - October 2019 13

ATTENTION: See Safety Information on page 19 before handling a mover.

Figure 6 - 2198T-VTxxxx-A, Mover

Item Description Item Description

14 Rockwell Automation Publication 2198T-UM001D-EN-P - October 2019

Figure 7 - Single Base Plate Support Structure

Rockwell Automation Publication 2198T-UM001D-EN-P - October 2019 15

Figure 8 - Two Types of iTRAK Power Supplies

2198T-W25K-ER, Kinetix 5700

Figure 9 - 2198T-WBCMOD, iTRAK Bus Conditioner

16 Rockwell Automation Publication 2198T-UM001D-EN-P - October 2019

Gateway The gateway provides centralized motion processing and communication

Figure 10 - 2198T-G02-016-E, Gateway

Gateway Front View Gateway Back View

Item Description Item Description

Figure 11 - 2198T-GUSB, Digital USB I/O Module

Item Description Item Description

Rockwell Automation Publication 2198T-UM001D-EN-P - October 2019 17

2198T - E XX - X XXX - XXX - X XX XXX X - QXXXX

18 Rockwell Automation Publication 2198T-UM001D-EN-P - October 2019

ATTENTION: Lockout and tagout input power before servicing.

Before working with iTRAK systems or components, review the

General Assembly Instructions

Rockwell Automation Publication 2198T-UM001D-EN-P - October 2019 19

• Although system components have IP65 protection, the mover bearings

20 Rockwell Automation Publication 2198T-UM001D-EN-P - October 2019

Avoid Accidents, Injury, and Property Damage

Avoid Electrical Shock