Rockwell Automation iTRAK User Manual
Release Notes
iTRAK System, Firmware Revision 3.003
Bulletin 2198T
This publication contains release notes for the iTRAK® system, firmware revision 3.003, when used with the Studio
5000 Logix Designer® application.
Topic Page
Considerations 1
Restrictions 2
Enhancements 3
Corrected Anomalies 14
Known Anomalies 14
Additional Resources 15
Considerations
When using this firmware, consider the following.
• The example Logix program file is being deprecated and may be eliminated in a future release of the firmware.
You are encouraged to use the ICT Libraries to write your Logix programs for your iTRAK systems.
• When upgrading from a previous revision of firmware, and your Logix program is based on the example Logix
program, the following items must be imported or copy/pasted:
- P01_iTRAK_Communications
-P01_Main_Program
- P00_Faults_Version_and_CIP_Messaging
-UDT_iT_Faults
- UDT_iT_Fault_Array
- UDT_iT_Fault_Strings
- Controller Tag iTRAK_Faults (Copy/Paste)
- Controller Tag iTRAK_Fault_Strings (Copy/Paste)
• To make the EtherNet/IP™ connection and complete initialization, the following conditions are required:
- The controller must be on.
- The Logix program must be running.
- If iTRAK Power Supplies (iPS) are being used, the associated Diode Front End (DFE) must be ready and
communicating.
• Headway checking is done only in the gateway. The Logix program no longer performs this task.
• Changes to the track configuration that are made while the track is enabled do not take effect until the track is
disabled and reenabled. If configuration changes do not match the actual track configuration, faults are
generated when the track is reenabled.
• The default timing model is for the ControlLogix® 5580 controller.
iTRAK System, Firmware Revision 3.003 Release Notes
• The 400-byte configuration packet is required for both ControlLogix 5570 and 5580 controllers. The first byte
represents the timing model of the controller. The default is 2, to represent 2-cycle timing in the program.
- For the ControlLogix 5570 controller, which is not supported, the controller tag
Gateway_Movers0to15:C.Data [0] must be changed to 1, to represent 1-cycle timing.
- For the ControlLogix 5580 controller, the controller tag
Gateway_Movers0to15:C.Data [0] is set to 2
(default), to represent 2-cycle timing.
• Unicast Ethernet Communication is the only communications method that works with networks other than
192.168.x.y.
• Multicast Ethernet Communication is required for the second and succeeding I/O modules (more than 16
movers).
• The only support for more than 16 movers is a 192.168.x.y network.
• The mover torque percentage range is 0…125%.
Restrictions
Unless updated in a section for a later revision, these restrictions apply from their revision of introduction.
• In order for the iTRAK system to function properly, a USB-IIRO-4 device from Access IO Products, Inc, must be
connected to the gateway via a USB connection, regardless of the Power Supply Mode (PCM or iPS) that is
specified. This hardware does not have to be used in any other way. However, failure to connect this hardware
to the gateway prevents the gateway from fully initializing and running.
• This firmware release supports the third-generation gateway hardware. Only V3.xxx versions of firmware will
run on the third-generation gateway.
• The Position Loop and Velocity Loops are synchronized and run in the same period.
• When more than five movers are present on or seen by a single motor module, the minimum time that the
motor module requires to process the movers is 1000 microseconds. This forces the minimum Position Loop
Period to be 2 milliseconds. If your application can guarantee that no more than five movers can be seen at any
one time on any given motor module, the iT_MPM AOI can be used to set the maximum number of movers-permotor module that is used by the motion profile, and ease the 2 millisecond restriction.
• When a program is downloaded, the time or master time is changed, or the EtherNet/IP™ connection is broken
and restored, the following can occur:
-The
iTRAK_Control.StatusGatewayRunning tag is set to 0 for several seconds. If there are more than 16
movers on the system, the time that
The system auto-restarts the gateway to make sure that there is communication between the controller and
gateway.
- If the iTRAK system was enabled, a FaultCode 9 is generated and displayed when the
iTRAK_Control.Status.GatewayRunning tag returns to a value of 1.
- If motion was being performed, the motion stops, and faults are generated depending on the stopped
position of the movers.
- If there was a program download and an iTRAK power supply was in use, the power supply must be reset and
the FaultCode 30 cleared.
iTRAK_Control.StatusGatewayRunning tag dwells at 0 can be longer.
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iTRAK System, Firmware Revision 3.003 Release Notes
Enhancements
These enhancements correspond to the iTRAK system firmware revision when used with the Logix Designer
application.
Table 1 - Enhancements with Revision 3.003
Enhancement Description
Support for Additional Movers The iTRAK firmware and associated example Logix file have been modified and tested to allow up to 104 movers on a track,
with a potential of up to 250 movers in the future.
New Fault Codes and New Fault Code Structure The complicated set of gateway fault codes and section fault codes has been replaced with a simplified single fault code and
Ability to View Multiple Generated Faults Frequently on the iTRAK system, several faults are generated when fault conditions occur. However, only information about
extended information. Please see Tab le 2
To accommodate the new set of faults, members of UDT_iTRAK_Status have been changed.
The following members have been removed:
• GatewayFaultCode
• SectionFaultCode
• SectionNumberFaulted
• SectionDeviceFaulted
• SectionFaultData
• FaultMessageLine1
• FaultMessageLine2
The following new members have been added:
•ERR DINT New fault code
• EXERR DINT New extended numeric fault information
• FaultDescription STRING New fault description
As before, the new fault-related fields in the controller tag iTRAK_Control.Status will contain information on
the first fault that is generated when fault conditions occur.
The fault information is not persistent. When the controller tag iTRAK_Control.Cmd.FaultReset is
latched, all fault information is cleared.
the first generated fault would be sent to the Logix controller. Often this meant that the most relevant fault would not be
displayed.
To address this issue, the User-defined type UDT_iT_Faults and the associated controller tag iTRAK_Faults have
been added. This array of 64 elements of type UDT_iT_Faults supplies information about the first 64 faults that occur on the
iTRAK system whenever fault conditions happen. The following members belong to UDT_iT_Faults:
• TimeStamp DINT Relative timestamp in nanoseconds from the first reported fault
• ERR DINT New fault code
• EXERR DINT New extended numeric fault information
• FaultName STRING New fault name
• FaultDescription STRING New fault description
for details about the new set of fault information.
This array of faults is neither cumulative nor persistent. When the controller tag
iTRAK_Control.Cmd.FaultReset is latched, all fault information is cleared, and the information is stored in
the persistent, cumulative fault log file that is maintained internally on the gateway.
Persistent Fault Log The iTRAK system now maintains a persistent, cumulative fault log file that is stored internally on the gateway. This comma-
separated value (.csv) file contains the following information about each of the faults:
• Timestamp Absolute Eastern Daylight system date and time (in year, month, day, hour, minute, second, and
nanosecond) when the fault was generated.
•ERR New fault code
• FaultName New fault name
• FaultDescription New fault description
• EXERR New extended numeric fault information
Whenever the controller tag iTRAK_Control.Cmd.FaultReset is latched or the gateway is reset, any
faults that currently exist are added to the fault log file.
The fault log file is limited to a maximum size of 100 megabytes. If an attempt to save additional faults would exceed this limit,
the faults are temporarily saved and a fault 249 (‘Fault Log File too Large to Add Faults’) is generated. This gives the user one
last opportunity to retrieve the fault log from the iTRAK system before resetting the faults once again. On the fault reset
immediately following the fault 249, the fault log file is removed, and the faults generated prior to and including the fault 249
are stored in the newly emptied fault log file.
The fault log file can be retrieved using the V3.003 version of the iTRAK Log Retrieval Tool.
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iTRAK System, Firmware Revision 3.003 Release Notes
Table 1 - Enhancements with Revision 3.003 (Continued)
Customer Log File Simplification As fault reporting on the iTRAK system has been significantly improved, the amount and kind of data that is supplied in the
Addition of Developer Log Files The iTRAK system now generates very detailed log files for use by Customer Support Engineers, Motion Solution Consultants,
Improved Initial Connectivity between the Logix
Controller and the iTRAK System
Addition of Clean Startup Capability to Simplify
Commissioning, Static Addition and Removal of
Movers, and Motor Module Replacement
standard iTRAK log files has been greatly reduced and simplified. The resulting log files are much easier to read and
understand.
These log files can be retrieved using the iTRAK Log Retrieval Tool.
GOTCs, Firmware Developers, and other Rockwell Automation employees. These encoded log files can be retrieved using the
V3.003 version of the iTRAK Log Retrieval Tool and sent to the appropriate Rockwell Automation employees whenever
additional assistance is required.
With the introduction of the third-generation gateway hardware, the gateway often had to be restarted automatically to
establish solid and robust Ethernet/IP communications between the Logix Controller and the iTRAK system. Firmware
modifications and improvements have been made such that the automatic restart is no longer required.
The iTRAK system maintains information about the last position and status of all movers when the system was shut down. In
certain instances (for example, when initially commissioning a track, when replacing motor modules, and when adding or
removing movers), this mover position and status information may be invalid, and must be regenerated from information
obtained from the track.
To assist in this “scratch build” of mover position and status information, a Clean Startup capability has been created, and the
member “CleanAndResetGateway” has been added to the user-defined type UDT_iTRAK_Cmd.
When the controller tag iTRAK_Control.Cmd.CleanAndResetGateway is latched, the stored mover
position and status information are removed, and the gateway is reset. This causes the gateway to rebuild the stored mover
position and status information from new information obtained from the track.
To ensure that the stored mover information gets reconstructed cleanly and accurately, it is best to adhere to the following
rules regarding mover positioning during a Clean Startup:
1. No Movers on Curves
2. For tracks with more than 8 motor modules, no movers next to curves.
3. No more than five 50 mm movers, three 100 mm movers, and two 150 mm movers on a single motor module.
4. No movers on or within +/- 3 mm of motor module transitions.
To assist in following these rules, faults are generated for any violations. However, the new stored mover information is
still generated, and may be valid, despite any faults.
The usual procedure for a Clean Startup is as follows:
1. Shut down the track.
2. Make all the mover adjustments, additions, removals, and motor module replacement.
3. Restart the track.
4. When the track comes up, if the correct number and position of all movers is displayed in the controller tag
iTRAK_Control.Status.ActualPosition, the process is complete, and any faults that may have
occurred can be ignored and reset.
5. Otherwise, issue the iTRAK_Control.Cmd.CleanAndResetGateway command.
6. After the system comes up completely, if the correct number and position of all movers is displayed in the controller tag
iTRAK_Control.Status.ActualPosition, the process is complete and any faults that may have
occurred can be ignored and reset.
7. Otherwise, make appropriate mover position adjustments as any faults may recommend, and repeat steps 5 and 6 until
iTRAK_Control.Status.ActualPosition accurately reflects the state of the track.
4 Rockwell Automation Publication 2198-RN001P-EN-P - February 2021
Table 1 - Enhancements with Revision 3.003 (Continued)
iTRAK System, Firmware Revision 3.003 Release Notes
Relaxed Restrictions on Motion Polarity and
Numbering Order Tags
Power on self-test (POST) on Demand The power on self-test (POST) no longer runs as part of the initialization sequence at power-up or gateway reset. Instead, the
ECO Current Mode Eco Current Mode decreases the amount of current used by the iTRAK system as the movers cross transition between motor
The controller tags iTRAK_Control.Data.MotionPolarity,
iTRAK_Control.Data.ReverseMoverNumbering, and
iTRAK_Control.Data.MoverNumberingOffset no longer require a First Scan condition to take
effect. However, the track must be de-energized for these tags and the
iTRAK_Control.Data.PositionOffset tag to take effect.
Controller tag iTRAK_Control.Cmd.RunPOST has been added to allow you to choose when the POST is to be run.
The POST can only be run when the track is not energized. When the POST completes, the Controller Tag
iTRAK_IPSSupport.POSTDone is set to ‘1’. This tag is used for both PCM and iPS power supply modes. If the
POST fails while it is running, the appropriate faults indicating the problem are generated.
It is recommended that the POST be run during the application's power-up sequence, as soon as high-voltage power is
available. Otherwise, motor module problems that could cause damage to the track and/or tooling, such as a bad motor coil
or driver chip, go undetected until the damage occurs.
modules. However, Eco Current Mode also has the side effect of significantly decreasing performance across the track.
Eco Current mode is OFF by default. It can be turned off or on using the Controller Tag
iTrak_Control.Cmd.ToggleEcoCurrentMode.
Toggling this tag causes the Gateway to reset.
Table 2 - Fault Code and Fault Code Structure
ERR – Fault Name Fault Description EXERR Details
1 – Internal Error Internal gateway error during initialization. The gateway failed during initialization due to an internal error. Check all
2 – iMF Initialization Failure Track initialization failure. Initialization of the gateway failed. Check all power and communications
power and communications cables and connections. Then, power-cycle
the system. If the problem persists, contact ICTSupport@ra.rockwell.com
for assistance.
cables and connections. Then, power-cycle the system. If the problem
persists, contact ICTSupport@ra.rockwell.com for assistance.
3 – Internal Motor Module Failure Internal error in motor module EXERR. Motor
4 – Power-on Self-test Internal
Error
5 – Bad Motor Module Coils Bad coils on motor module EXERR during POST. Motor
6 – Motor Module Coil Overheat Coils overheated in motor module EXERR. Motor
7 – IRAM Error Threshold Exceeded Recoverable IRAM errors on motor module EXERR
iPS fault-clearing failure caused POST failure. The Power-On Self-Test failed due to the inability to clear an iPS fault. Make
exceeded threshold.
Module
Number
Module
Number
Module
Number
Motor
Module
Number
The motor module specified in EXERR had an internal error. Check all
power and communications cables and connections. Then, power-cycle
the system. If the problem persists, contact ICTSupport@ra.rockwell.com
for assistance.
sure that all the DFE and iPS modules are functioning correctly. Then,
power-cycle the system. If the problem persists, contact
ICTSupport@ra.rockwell.com for assistance.
One or more bad coils on the motor module specified in EXERR were found
during the Power-On Self-Test. If power-cycling and a subsequent rerun of
the POST does not eliminate the problem, the motor module should be
replaced.
One or more coils has overheated in the motor module specified in EXERR.
Shut down the system, allow it to cool down for 10…15 minutes, and then
restart it. If the problem persists, contact ICTSupport@ra.rockwell.com for
assistance.
Recoverable errors on the IRAM board of the motor module specified in
EXERR have exceeded the allowable threshold. If power-cycling and a
subsequent rerun of the POST does not eliminate the problem, the motor
module should be replaced.
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