ATS SuperTrak GEN3 Operation And Maintenance Manual
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ATS SuperTrak GEN3 Operation And Maintenance Manual

Conveyance platform modular conveyor
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Rev. 9, December 2021

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Summary of Contents for ATS SuperTrak GEN3

  • Page 1 Rev. 9, December 2021...
  • Page 3 Operation and Maintenance Manual SuperTrak™ GEN3 Conveyance Platform Modular Conveyor...
  • Page 4 WARRANTY AND LIABILITY Your warranty and issues related to liability are covered by your contract with ATS or its affiliate. Reference your contract or contact our service department if you have specific questions about your warranty. No additional or other warranties are provided in this document and all warranties and conditions, including, without limitation, implied warranties or conditions of merchantability, or fitness for a particular purpose, or non-infringement, are disclaimed.
  • Page 5 Functional Safety requirements are the responsibility of the end user/integrator of this component. SuperTrak GEN3 Conveyor Control Panel a. SuperTrak GEN3 conveyor control panel is evaluated as, and is intended only to be used as, an integrated component of the SuperTrak GEN3 conveyor.

  • Page 7: Table Of Contents

    Table of Contents Preface ............1 Documentation Package .
  • Page 8 Install the SuperTrak Conveyance Platform ....48 Install the SuperTrak Conveyance Platform on a SuperTrak GEN3 Frame ..49 Install the Sections with Custom Stands on a Custom Frame .
  • Page 9 Technician Procedures ......... 143 Electrical Procedures .
  • Page 10 Request Service from ATS ........283...
  • Page 11 SuperTrak GEN3 Frames ........344...
  • Page 12 This page is intentionally blank.

  • Page 13: Preface

    • Special Notations on page 2 • Referenced Terms on page 4 Documentation Package ATS supplies the following documentation and software for the SuperTrak conveyance platform: • SuperTrak™ GEN3 Operation and Maintenance Manual • TrakMaster™ software (with built-in help) •...

  • Page 14: Style Conventions

    Preface Style Conventions This document uses the following styles to indicate different types of information: • Italic text indicates a document title. • Italic text with color indicates hypertext reference information. For example, a web site link or a link to content within the current document. •...

  • Page 15: Frame Of Reference

    Preface Frame of Reference • The SuperTrak conveyance platform image is for representational purposes only. It may not reflect the system you have installed. • The direction of travel on each axis (positive or negative) varies based on configuration. This document describes tooling movement using the following frame of reference: SuperTrak™...

  • Page 16: Referenced Terms

    Preface Referenced Terms This section defines terms that are used throughout this document. Term Description SuperTrak conveyance Represents the SuperTrak™ GEN3. platform TrakMaster Represents the TrakMaster™ software. Power supply Represents the SuperTrak conveyance platform power supply. Control panel Represents the SuperTrak conveyance platform control panel. Pallet Represents the SuperTrak conveyance platform pallet.

  • Page 17: Safety Information

    Read this information thoroughly and completely before operating, or maintaining the SuperTrak conveyance platform. Training SuperTrak conveyance platform training packages are available on request. Contact the ATS Technical Services Department for additional information. SuperTrak™ GEN3 System Operation and Maintenance Manual Rev. 9 (12-2021)

  • Page 18: General Safety Rules

    Safety Information General Safety Rules Everyone: • Learn how automated equipment works. • Understand the potential dangers of automated equipment before operating it. • Energy sources must be shutdown, locked out, and tagged out before preventive maintenance, adjustment, or service. •...

  • Page 19: Personal Protective Equipment

    Safety Information • Do not install substitute parts or make any product modifications that are not authorized by ATS because this may introduce new hazards. • Use insulated tools when working with electrical equipment. Make sure qualified electrical technicians wear appropriate PPE when completing live electrical work according to the hazard assessment.

  • Page 20: Hazardous Energy

    Safety Information Hazardous Energy Any energy source that presents a risk of injury to a person working on equipment is considered a hazardous energy source. The SuperTrak conveyance platform contains the following hazardous energy sources: • Electrical on page 8 •...

  • Page 21: Mechanical

    Safety Information Mechanical Servicing mechanical components or devices while still connected to energy sources may cause injury. As required for access and service of the mechanical component, open the safety circuit or turn the main power disconnect switch to the OFF position and lock out and tag out the main power disconnect switch.

  • Page 22: Thermal Hazards

    Safety Information Thermal Hazards Allow adequate time for hot surfaces to cool before commencing work. Wear the appropriate PPE when working on or near the thermal hazard. Use a non-contact thermometer to verify the temperature. The lifespan of some SuperTrak components may be compromised when temperature-related TrakMaster configuration parameters are adjusted from the default value.

  • Page 23: Lockout And Tagout

    Safety Information Lockout and Tagout Understand and be aware of stored energy sources (for example; uninterrupted power supply (UPS) energy, or magnetism) that exist in the SuperTrak conveyance platform after lockout and tagout. Hazardous Energy on page 8. This lockout and tagout information is provided for reference only. Follow the lockout and tagout procedures listed below or use an applicable lockout tagout procedure that complies with local requirements.

  • Page 24: Lockout And Tagout Locations

    Safety Information Lockout and Tagout Locations The control panel is designed to be integrated with a main electrical panel that includes a main power disconnect switch. To lock out SuperTrak conveyance platform hazardous energy, complete one (1) of the following: •...

  • Page 25: Label Descriptions

    Safety Information Label Descriptions Labels are applied throughout the SuperTrak conveyance platform to warn users of possible or certain hazards. Read this section carefully and comply with the required actions, warnings, or prohibitions. Identification Label An electrical nameplate is located on the door of the control panel. It specifies the SuperTrak conveyance platform power requirements and provides the electrical drawing reference number (25202161).

  • Page 26: Other Labels

    Safety Information Other Labels Label Label Description Name Danger - This label warns users of arc flash and Arc Flash shock hazard. Follow ALL requirements and Shock in NFPA 70E for safe work practices and for Personal Protective Equipment. Label number: C459-53. Warning - This label warns users that UPS voltage UPS Voltage...
  • Page 27 Safety Information Label Label Description Name Warning - This label warns users of electrical Hazardous energy. Only qualified electrical Voltage technicians should complete work in these areas. Disconnect power before opening the electrical cabinet working within. Close the electrical cabinet before turning the power ON.

  • Page 28: Label Locations

    Safety Information Label Locations This section describes the location of the safety labels on the SuperTrak conveyance platform. Pallet Label The pallet has the following label: Label Location Caution - Strong Magnetic Field Side of each pallet. Label number: 125309778. Other Labels on page 14.
  • Page 29 Safety Information Control Panel Labels Label Location Mandatory Lockout and Tagout Outside door of the control panel. Label number: 6013X-ISO. Mandatory Action Labels on page 13. Read and Understand the Manual Label number: 6017X-ISO. Mandatory Action Labels on page 13. Danger - Arc Flash and Shock Hazard Label number: C459-53.
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  • Page 31: Supertrak Conveyance Platform Overview

    • Low maintenance: has few moving parts System Specifications on page 271 for a complete list of SuperTrak conveyance platform specifications. 1.Higher payloads are possible. Contact ATS with application details. SuperTrak™ GEN3 System Operation and Maintenance Manual Rev. 9 (12-2021)

  • Page 32: Supertrak Conveyance Platform Configurations

    SuperTrak Conveyance Platform Overview SuperTrak Conveyance Platform Configurations The standard SuperTrak conveyance platform is available in modular sections, to allow for various SuperTrak conveyance platform configurations. Appendix C: Component Data Sheets on page 299 for additional information about the modular SuperTrak conveyance platform components. SuperTrak™...
  • Page 33 SuperTrak Conveyance Platform Overview The SuperTrak conveyance platform can be configured of sections with low-profile stands in a horizontal or vertical (also known as over/under) configuration. For this method, the SuperTrak conveyance platform is mounted on a plate. Straight Section with RME Data Sheet on page 317, and 180 Deg.

  • Page 34: Supertrak Conveyance Platform Components

    SuperTrak conveyance platform includes. Control panel Pallet setup adjustable chip finder Encoder Assemblies on page 38. SuperTrak GEN3 frame Pallet (may also be referred to as a “shuttle”) Pallet on page 23. Curved section (180 deg. 500 mm in...

  • Page 35: Pallet

    SuperTrak Conveyance Platform Overview Pallet The pallet provides a transport platform for carrying production parts along a SuperTrak conveyance platform. The pallet shelf (not included) is customized for the customer product. A pallet may also be referred to as a “shuttle.” Pallet Data Sheet on page 302 for additional information.
  • Page 36 SuperTrak Conveyance Platform Overview Pallet - Back View Component Name Description Pallet encoder strip assembly Contains the encoder strip. V-wheel (1 of 2) Travels on the upper v-rail of the section. Anti-static brush (1 of 2) Dissipates static that is created during pallet motion. 2-Magnet assembly Supports the pallet against the upper v-rail, and generates the forces needed to control pallet motion.

  • Page 37: Straight Section

    SuperTrak Conveyance Platform Overview Straight Section Straight sections are connected in series to create a path for pallets to travel on. Straight Section Power Options If a pallet moving at high speed transfers from a standard straight section to a low power straight section, the electro-magnetic field aggressively stops the pallet, even when there is no power.
  • Page 38 SuperTrak Conveyance Platform Overview Straight Section - Electrical Door Closed Component Name Description Electrical door (closed) Encloses the electrical components. Straight sections are available with front mounted electronics (FME) as shown, or rear mounted electronics (RME). Linear motor Produces the electromagnetic force that propels the pallets. The linear motor includes: •...
  • Page 39 SuperTrak Conveyance Platform Overview Straight Section - Electrical Door Open • The coil driver boards in the low power straight section are visually identical to the coil driver boards in the high power straight section, but they are different. • The left coil driver board and the right coil driver board are the same. The connections to the gateway boards are different, so they are referenced as the “left”...
  • Page 40 SuperTrak Conveyance Platform Overview Straight Section - Left Coil Driver Board If the SuperTrak conveyance platform is programmed with more than one safety circuit (different guard zones), remove the 28VDC motor power connection from the zone boundaries. See the SuperTrak Conveyance Platform Electrical Drawings for additional information.
  • Page 41 SuperTrak Conveyance Platform Overview Left Coil Driver Board with a Power Supply Connected If the SuperTrak conveyance platform is programmed with more than one safety circuit (different guard zones), remove the 28VDC motor power connection from the zone boundaries. See the SuperTrak Conveyance Platform Electrical Drawings for additional information.
  • Page 42 SuperTrak Conveyance Platform Overview Gateway Board Left encoder cable port 24V digital power connection Right encoder cable port Gateway network port Ribbon cable connection - connects to 24V digital power connection the top-right of the coil driver board IR reader connection (optional) Gateway network port Ribbon cable connection - connects to Ribbon cable connection - connects to...
  • Page 43 SuperTrak Conveyance Platform Overview Right Coil Driver Board The left coil driver board and the right coil driver board are the same. The connections to the gateway boards are different, so they are referenced as the “left” or “right” coil driver board. Right encoder cable Ribbon cable connection - connects to the bottom-right of the coil driver board...

  • Page 44: Curved Sections

    SuperTrak Conveyance Platform Overview Curved Sections A curved section provides a 180° or 90° turning path for the pallets to travel on between straight sections. 180 Deg. Section (500 mm) with Standard-Height Stands Data Sheet on page 320, 180 Deg. Section (500 mm) with Low-Profile Stands Data Sheet on page 323, 180 Deg.
  • Page 45 SuperTrak Conveyance Platform Overview Component Name Description Motor Produces the electromagnetic force that propels the pallets. The motor includes: • Potted coils • Iron core lamination assembly Coils on page 39 for information about coil numbering. Stand (1 of 3) Mounts the section to the SuperTrak conveyance platform frame.
  • Page 46 SuperTrak Conveyance Platform Overview 180 Deg. Section (800 mm) Component Name Description Upper v-rail Provides a track for the pallet v-wheels to travel on. The upper v-rail of the 180 deg. section is 1518.7 mm (59.79 in.) in length Motor Produces the electromagnetic force that propels the pallets.
  • Page 47 SuperTrak Conveyance Platform Overview Component Name Description Ground wire Provides the single point earth ground for the SuperTrak conveyance platform. Although each SuperTrak conveyance platform has two (2) 180 deg. sections, only one (1) 180 deg. section contains a single point earth ground wire. The single point earth ground wire is connected from the bottom plate of the 180 deg.
  • Page 48 SuperTrak Conveyance Platform Overview 90 Deg. Section Component Name Description Motor Produces the electromagnetic force that propels the pallets. The motor includes: • Potted coils • Iron core lamination assembly Coils on page 39 for information about coil numbering. Upper v-rail Provides a track on which the the pallet v-wheels can travel .
  • Page 49 SuperTrak Conveyance Platform Overview Component Name Description Ground wire Provides the single point earth ground for the SuperTrak conveyance platform. Although each SuperTrak conveyance platform has four (4) 90 deg. sections, only one (1) 90 deg. section contains a single point earth ground wire. The single point earth ground wire is connected from the bottom plate of the 90 deg.
  • Page 50 SuperTrak Conveyance Platform Overview Encoder Assemblies Each straight section, 180 deg. section (500 mm), and 90 deg. section has two (2) encoder assemblies: a left encoder assembly and a right encoder assembly. Every encoder assembly has eight (8) encoder read heads, which look like black squares on the top of the encoder assembly.
  • Page 51 SuperTrak Conveyance Platform Overview Coils Each straight section, 180 deg. section (500 mm), and 90 deg. section has twenty (20) coils. A coil pair is connected to each of the five (5) coil connections on the left coil driver board, and a coil pair is connected to each of the five (5) coil connections on the right coil driver board.

  • Page 52: Control Panel

    8 and Lockout and Tagout on page 11. If an ATS control panel is not used, a line filter is required (for example, a Schaffner “FN 3256H-XX”). The control panel provides power to the SuperTrak conveyance platform only. It is designed to be integrated with a main electrical panel, and requires a protective earth connection from the main electrical enclosure.
  • Page 53 SuperTrak Conveyance Platform Overview PLC connection (EtherNet/IP, UPS disconnect EtherCAT, or PROFINET) Bus controller (POWERLINK) SuperTrak conveyance platform power disconnect switch (3 phase) Power supply module Single point ground connection Breaker - enclosure fan Terminals 13A breaker - All SuperTrak Power supply breakers (space for 6 or conveyance platform digital power 12 breakers)

  • Page 54: Power Supply

    This label verifies that the power supply was inspected and tested. If this label does not exist or an unauthorized replacement power supply is used, contact ATS for the correct power supply replacement. Power supply cabinet...

  • Page 55: Ir Reader Assembly (Optional)

    SuperTrak Conveyance Platform Overview IR Reader Assembly (Optional) The IR reader assembly contains an infrared emitting diode (IR LED) that is classified as eye safe. The following standards and classifications apply: • IEC/EN 60825-1 (2007-03), DIN EN 60825-1 (2008-05) “SAFETY OF LASER PRODUCTS - Part 1: equipment classification and requirements”, simplified method.

  • Page 56: Ir Reader Mount Assembly (Optional)

    SuperTrak Conveyance Platform Overview IR Reader Mount Assembly (Optional) The infrared (IR) reader mount assembly is an optional assembly for mounting the IR reader assembly. IR reader mount assembly IR reader installation location IR Reader Components (Optional) Data Sheet on page 339, and Install an IR Reader Mount Assembly on page 110 for additional information.

  • Page 57: Pallet Setup Tools (Optional)

    SuperTrak Conveyance Platform Overview Pallet Setup Tools (Optional) The pallet setup tools are optional SuperTrak conveyance platform tools that allow you to align and calibrate SuperTrak pallet encoder strip assemblies. Pallet setup adjustable chip finder Pallet setup removable locate Pallet setup stationary mount Pallet Setup Tools (Optional) Data Sheet on page 341 for additional information.
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  • Page 59: Installation

    Installation This section describes how to install the SuperTrak conveyance platform. Prerequisites The following services and components are required to successfully install the SuperTrak conveyance platform: • A non-compressing installation surface (for example; a concrete floor) • Electrical connections to the SuperTrak conveyance platform control panel: •...

  • Page 60: Install The Supertrak Conveyance Platform

    2. Complete one (1) of the following, depending on the type of frame that is used: • Install the SuperTrak conveyance platform on a SuperTrak GEN3 frame. Install the SuperTrak Conveyance Platform on a SuperTrak GEN3 Frame on page 49.

  • Page 61: Install The Supertrak Conveyance Platform On A Supertrak Gen3 Frame

    Installation Install the SuperTrak Conveyance Platform on a SuperTrak GEN3 Frame 1. Install the first SuperTrak conveyance platform section. Install the First SuperTrak Conveyance Platform Section on page 92. 2. Install the next SuperTrak conveyance platform section. Connect Two SuperTrak Conveyance Platform Sections Together on page 3.

  • Page 62: Install The Sections With Custom Stands On A Custom Frame

    This section describes how to install SuperTrak conveyance platform sections on custom stands and a custom frame in cases where the SuperTrak system is not provided assembled and configured with stands. ATS stands and an ATS frame are shown for reference.
  • Page 63 Installation 4. Position all straight sections on the frame, with the electrical box facing out. 5. Push each straight section toward the center of the frame, so it is tight against the dowel pins in the frame. SuperTrak™ GEN3 System Operation and Maintenance Manual Rev.
  • Page 64 Installation 6. Loosely install four (4) screws into each stand base. It is very important that the screws are centered in the screw holes as much as possible. This allows for adjustment when sections are connected together later. SuperTrak™ GEN3 System Operation and Maintenance Manual Rev.
  • Page 65 Installation 7. Adjust the position of the straight sections until: • Use shims to verify that a 0.5 mm (0.02 in.) gap exists between all straight sections (between the track structure [or aluminum extrusion], not between the linear motors [or motor laminations]). •...
  • Page 66 Installation 8. Verify that the following are aligned: • Upper v-rails and flat wear strip pockets. • Back of the laminations at all joints. Fix any major misalignment before proceeding with fine alignment. SuperTrak™ GEN3 System Operation and Maintenance Manual Rev.
  • Page 67 Installation 9. Level the first straight section. Place the precision level on the t-slot behind the encoder assembly of the straight section when leveling. SuperTrak™ GEN3 System Operation and Maintenance Manual Rev. 9 (12-2021)
  • Page 68 Installation 10. Level the second straight section, and then adjust it vertically to align the upper v-rails with the first straight section while keeping the section level. Align the SuperTrak Conveyance Platform Section Joints on page 98, and Align the SuperTrak Conveyance Platform Section Heights on page 99 for additional information.
  • Page 69 Installation 12. Adjust the wedge IN or OUT to align the upper v-rails. Only adjust when the wedge adjust screws are loose, and measure when the wedge adjust screws are tight. Fine-Adjust the Upper V-Rail on page 103. 13. Repeat steps 10 to 12 for the remaining sections on the same side of the SuperTrak conveyance platform.
  • Page 70 Installation 14. Return to the first straight section and lay a flat bar across it and the opposing straight section. Make sure the flat bar rests on the t-slot and not the encoder assemblies. Level the opposing section with the first section. 15.
  • Page 71 Installation 16. Install the first curved section. 17. For 180 deg. sections, use shims to verify that a 0.5 mm (0.02 in.) gap exists between the 180 deg. section and each of the two (2) abutting straight sections (between the track structure [or aluminum extrusion], not between the linear motors [or motor laminations]).
  • Page 72 Installation 18. Adjust the vertical, horizontal, and side-to-side positions until the upper v-rails align with the straight sections, and the curved section is centered between the straight sections. SuperTrak™ GEN3 System Operation and Maintenance Manual Rev. 9 (12-2021)
  • Page 73 Installation For 180 deg. (500 mm) sections: Remove the top cover form the 180 deg. section, remove the covers from the 180 deg. section stands, and then level the 180 deg. section. For 180 deg. (800 mm) and 90 deg. curved sections: Level the curved section: a.
  • Page 74 Installation b. Loosen the four (4) screws on each stand. c. Loosen the upper lock nut. d. Turn the leveling screw as required, to raise or lower the side of the wide 180 deg. section. e. Use a level to verify that the curved section is level. If the curved section is not level, repeat steps 4c &...
  • Page 75 Installation 22. Align the lower flat rails with the adjustment features mounted below the E- Turn plate. Align a Flat Wear Strip on page 241. 23. Repeat steps 16 to 22 for the second curved section. 24. Tighten the four (4) screws at the base of each straight section stand. 25.

  • Page 76: Install The Supertrak Conveyance Platform In An Over/Under Configuration

    Lift a SuperTrak Conveyance Platform Section on page 74. ATS recommends that you obtain relevant information from your national Health and Safety Authority. Make sure the frame is designed to hold the weight and force of the SuperTrak conveyance platform sections.
  • Page 77 Installation 3. Install the two (2) 180 deg. sections: a. If not already attached, install three (3) mounting plates on the bottom of the 180 deg. sections with two (2) screws each. b. Align the 180 deg. section with the base plate, and then secure with twelve (12) screws.
  • Page 78 Installation 4. Mount the straight sections with their electrical boxes facing inwards, starting with the sections closest to the 180 deg. sections. 5. Loosely install four (4) screws into each straight section stand base. It is very important that the screws are centered in the screw holes as much as possible.
  • Page 79 Installation 6. Verify that the following are aligned: • Upper v-rails and flat wear strip pockets. • Back of the laminations at all joints. Fix any major misalignment before proceeding with fine alignment. SuperTrak™ GEN3 System Operation and Maintenance Manual Rev.
  • Page 80 Installation 7. Adjust the position of all sections until a 0.5 mm (0.02 in.) gap exists between all sections (between the track structure [or aluminum extrusion], not between the linear motors [or motor laminations]). 8. Install the wedge adjust for the 180 deg. sections. Place the precision level on the t-slot behind the encoder assembly of the straight section when leveling.
  • Page 81 Installation 9. Level the straight sections next to the 180 deg. sections. Place the precision level on the t-slot behind the encoder assembly of the straight section when leveling. SuperTrak™ GEN3 System Operation and Maintenance Manual Rev. 9 (12-2021)
  • Page 82 Installation 10. Level the straight sections in the middle of the track, and adjust them vertically to align the upper v-rails with the other straight sections. Align the SuperTrak Conveyance Platform Section Joints on page 98, and Align the SuperTrak Conveyance Platform Section Heights on page 99 for additional information.
  • Page 83 Installation 12. Adjust the wedges IN or OUT to align the upper v-rails. Only adjust when the wedge adjust screws are loose, and measure when the wedge adjust screws are tight. 13. Align the upper v-rails by adjusting the wedge or adjusting the screws on the inside of the 180 deg.
  • Page 84 Installation 15. Tighten the four (4) screws in each straight section stand base. 16. Add wear strip locators to straight sections with the tabs directed towards the center of the each section. 17. Install the wear strips to the straight sections. Replace a Flat Wear Strip on page 189.
  • Page 85 Installation 18. Add four (4) bolts to the bottom of each electrical box, making sure the grounding cables are secured to locations indicated by grounding symbol stickers. 19. Lift the SuperTrak conveyance platform into position. Use correct lifting techniques with straps and a forklift. 20.

  • Page 86: Lift A Supertrak Conveyance Platform Section

    Always use appropriate lifting devices (for example, a forklift or crane) and use safe lifting practices and procedures when lifting a straight or curved section. ATS recommends that you obtain relevant information from your national Health and Safety Authority. This section describes the correct lifting techniques for the following: •...
  • Page 87 Installation Lift a Straight Section Assembly 1. Thread an M8 rotating eye bolt into the inner-most hole of each of the two (2) stands. 2. Attach each end of one (1) lifting strap to an eye bolt. 3. Use an appropriate lifting device, such as a forklift, to lift the straight section by the middle of the lifting strap.
  • Page 88 Installation Lift a 180 Deg. Section (500 mm) 1. Wrap one (1) strap around each of the three (3) stands. 2. Use an appropriate lifting device, such as a forklift, to lift the 180 deg. section up by the ends of the lifting straps. 3.
  • Page 89 Installation Lift a 180 Deg. Section (800 mm) 1. Thread one (1) M8 rotating eye bolt into the top of each of the three (3) stands. 2. Attach one (1) strap to each of the three (3) M8 rotating eye bolts. 3.
  • Page 90 Installation Lifting Segments in an Over-Under Configuration Optional lifting brackets may be used for conveyors up to 4m long or for sections up to 5m with one e-turn. The brackets must be positioned to balance the load on each side of the brackets, and a spreader bar must be used so that the lifting force on the brackets is vertical.
  • Page 91 Installation 2. If required, reposition lifting brackets so that the mounting holes needed to attach the conveyor to the frame are accessible. Move shackle to the upper of the lifting holes on one side only. 3. Lift so that the lower lifting hole is accessible.
  • Page 92 Installation 5. Lift into vertical position. As mentioned previously, use of a spreader bar is required. 6. Once this change in orientation is complete, mount to frame and then remove lifting bracket (or store in the vertical orientation). SuperTrak™ GEN3 System Operation and Maintenance Manual Rev.

  • Page 93: Install A Supertrak Conveyance Platform Section On A Supertrak Gen3 Frame

    74. ATS recommends that you obtain relevant information from your national Health and Safety Authority. This section describes how to install a straight or curved on a SuperTrak GEN3 frame. Install a Straight Section on a SuperTrak GEN3 Frame 1.
  • Page 94 Installation d. Repeat step a to c for the second cross-brace. e. Secure the cross-brace in position with four (4) screws. Tap two (2) dowels halfway into the cross-brace. Make sure the dowel remains above the cross- brace surface. g. Repeat steps a to f for the second cross-brace. 2.
  • Page 95 Installation b. Loosely install eight (8) screws into the stand bases. c. Position a dowel pin between each straight section stand and the cross-brace dowel pins. d. Push the straight section toward the center of the frame, so it is tight against the dowel pins.
  • Page 96 Installation 5. If the two (2) straight sections were not aligned in step 4, gently tap the straight section left or right (as required) until they are aligned. 6. Tighten the four (4) screws at the base of each straight section stand. It is very important that the screws are centered in the screw holes as much as possible.
  • Page 97 Installation Install a 180 Deg. Section (500 mm) on a SuperTrak GEN3 Frame 1. Install the 180 deg. plate on the frame: a. Align the 180 deg. plate with the frame holes. b. Install six (6) screws to secure the 180 deg.
  • Page 98 Installation 4. Level the 180 deg. section: a. Place a precision spirit level across the frame in the directions illustrated, to determine the leveling foot (or feet) that requires adjustment. For more precise measurements, remove the top cover from the 180 deg.
  • Page 99 Installation Install a 180 Deg. Section (800 mm) on a SuperTrak GEN3 Frame 1. Install the 180 deg. (800 mm) plate on the frame: a. Align the 180 deg. plate with the frame holes. b. Install four (4) screws to secure the 180 deg.
  • Page 100 Installation 4. Level the 180 deg. section: a. Place a precision spirit level across the frame in the directions illustrated, to determine the leveling foot (or feet) that requires adjustment. b. Loosen the four (4) screws on each of the three stands. c.
  • Page 101 Installation Install a 90 Deg. Section on a SuperTrak GEN3 Frame 1. Install the 90 deg. plate on the frame: a. Align the 90 deg. plate with the frame holes. NOTE: When the overall conveyor arrangement is longer than it is wide,...
  • Page 102 Installation 2. Lift and position a 90 deg. section on the 90 deg. plate. 3. Loosely install two (2) lock washers, and two (2) screws in each of the three (3) stand bases. 4. Level the 90 deg. section: a. Place a precision spirit level across the frame in the directions illustrated, to determine the leveling foot (or...
  • Page 103 Installation b. Loosen the four (4) screws on each of the three stands. c. Loosen the upper lock nut. d. Turn the leveling screw as required, to raise or lower the side of the 90 deg. section. e. Use a level to verify that the 90 deg. section is level. If the 90 deg.

  • Page 104: Install The First Supertrak Conveyance Platform Section

    Lift a SuperTrak Conveyance Platform Section on page 74. ATS recommends that you obtain relevant information from your national Health and Safety Authority. To prevent system damage, keep the system sections upright at all times. During installation, consider the size of the system. For large systems (>7 sections) install the middle straight section first and work your way...
  • Page 105 Installation If the section is not level, adjust the required leveling screw. 4. Install two (2) dowels through the outer holes of top connection plate, to position the top connection plate on the frame. The top connection plate for the 180 deg. section is notched; the straight section connection plate is not notched.
  • Page 106 Installation NOTE: If you are using compact frames to support 180 deg sections, use the sup- plied stepped dowels to attach the connector kit to the join between the compact frame and the one-meter section frame, as pic- tured. 5. Install four (4) screws in the top connection plate to secure it in position. SuperTrak™...

  • Page 107: Level The Frame

    Installation Level the Frame To accommodate varying floor heights, the leveling feet of the SuperTrak conveyance platform frame allow for individual height adjustment. 1. Place a precision spirit level across the frame in the directions illustrated, to determine the leveling foot (or feet) that requires adjustment. 2.

  • Page 108: Connect Two Supertrak Conveyance Platform Sections Together

    Lift a SuperTrak Conveyance Platform Section on page 74. ATS recommends that you obtain relevant information from your national Health and Safety Authority. • To prevent system damage, always keep the system sections upright. • When two (2) large SuperTrak conveyance platform sections are joined together, remove the upper v-rail from the connecting straight sections.
  • Page 109 Installation 6. Loosely connect the sides of the frames together. Install a side connection plate on each side of the frame with twelve (12) screws in each. 7. Use a 0.5 mm (0.02 in.) shim to verify that a 0.5 mm (0.02 in.) space exists between the aluminum surfaces of section A and section B.

  • Page 110: Align The Supertrak Conveyance Platform Section Joints

    Installation Align the SuperTrak Conveyance Platform Section Joints 1. In the recess where the motor laminations meet, verify that the laminations align. The image below provides a top view of two straight sections that are not aligned. 2. If the joints are not aligned: a.

  • Page 111: Align The Supertrak Conveyance Platform Section Heights

    Installation Align the SuperTrak Conveyance Platform Section Heights 1. At the upper v-rail joint, measure the offset between the two (2) upper v-rails. If the offset exceeds ±0.07 mm (0.0027 in.), the SuperTrak conveyance platform sections are not aligned. The image below illustrates a possible validation process, where two (2) indicators are mounted to a pallet to measure the offset between the two (2) upper v-rails.

  • Page 112: Install A Wedge Adjust

    Installation Install a Wedge Adjust The wedge adjust compensates for excess tolerance between SuperTrak conveyance platform sections. Install a Wedge Adjust - Straight Section 1. Verify that the edge of the wedge adjust plate aligns with the center notch on the side of the wedge adjust.
  • Page 113 Installation Install a Wedge Adjust - 180 Deg. (500 mm) Section 1. Verify that the edge of the wedge adjust plate aligns with the center notch on the side of the wedge adjust. If required, turn the adjustment knob to obtain the correct position.
  • Page 114 Installation 4. Loosely install four (4) washers and four (4) screws on the straight section side, and then install and tighten two (2) washers and two (2) screws on the side of the 180 deg. section. Note that the screws installed on the 180 deg.

  • Page 115: Fine-Adjust The Upper V-Rail

    Installation Fine-Adjust the Upper V-Rail The maximum vertical tolerance at the upper v-rail joint is 70 µm. Upper v-rail alignment is an iterative process. Alternate between height and wedge adjustments until the upper v-rail is flush and the sound is consistent when a pallet is pushed past the upper v-rail join.
  • Page 116 Installation Adjust the Upper V-Rail ±0.05 mm (±0.002 in.) - Straight Section to Straight Section 1. If vertical upper v-rail adjustment is required, complete the following steps on the side that requires adjustment: a. Loosen the four (4) screws at the top of the stand. b.
  • Page 117 Installation 2. If horizontal (IN or OUT) upper v-rail adjustment is required, complete the following steps on the side that requires adjustment: a. Loosen the four (4) screws at the bottom of the stand. b. Loosen the four (4) wedge screws. c.
  • Page 118 Installation Adjust the Upper V-Rail ±0.05 mm (±0.002 in.) - Straight Section to 180 Deg. Section 1. If vertical upper v-rail adjustment is required, complete the following steps on the side that requires adjustment: a. Loosen the four (4) screws at the bottom of the stand. b.
  • Page 119 Installation 2. If horizontal (in or out) upper v-rail adjustment is required, complete the following steps on the side that requires adjustment: a. Loosen the four (4) stand screws. This allows the stand to shift rather than flex against the rigid stand. b.
  • Page 120 Installation Specialized Upper V-Rail Adjustment - Straight Section to Straight Section This is a specialized procedure that is not generally required. The most important alignment for pallets to travel smoothly is the upper v-rail alignment. The second most important alignment is the lower flat rail alignment.
  • Page 121 Installation Specialized Upper V-Rail Adjustment - Straight Section to 180 Deg. Section This is a specialized procedure that is not generally required. The most important alignment for pallets to travel smoothly is the upper v-rail alignment. The second most important alignment is the lower flat rail alignment.

  • Page 122: Install An Ir Reader Mount Assembly

    Installation Install an IR Reader Mount Assembly During this procedure, make sure the clamp plate (see “G” in the diagram below) is positioned between the clamp bolts and the joint plate when you slide the long side of the IR reader mount assembly under the joint of the two (2) adjacent straight sections.
  • Page 123 Installation 1. Secure the IR reader to the IR reader mount assembly with two (2) screws. 2. Route the IR reader cable through the IR reader mount assembly cable opening. 3. Slide the long side of the IR reader mount assembly under the joint of two (2) adjacent straight sections.
  • Page 124 Installation 5. Route the IR reader cable into the back of the straight section electrical box, using the supplied knock-out reducer and strain relief connector. 6. Plug the IR reader cable into the IR reader connection on the gateway board. It must be connected to the gateway board of the SuperTrak conveyance platform section that the IR reader is mounted on.

  • Page 125: Controls And Connections

    Controls and Connections This section provides the following information about SuperTrak conveyance platform controls, and connections: • TrakMaster Software on page 113 • Guarding on page 114 • Energy Controls on page 115 • Connections on page 116 TrakMaster Software The lifespan of some SuperTrak components may be compromised when temperature-related TrakMaster configuration parameters are adjusted from the default value.

  • Page 126: Guarding

    Controls and Connections Guarding Unguarded devices may cause injury or death. Do not start or operate the equipment with guard doors open. Lockout and tagout all energy sources before entering the guarding. Make sure that all guard panels are in place and guard doors are closed before operating the equipment.

  • Page 127: Energy Controls

    Controls and Connections Energy Controls This section describes the energy controls on the SuperTrak conveyance platform. SuperTrak Conveyance Platform Power Disconnect Switch Servicing an electrical panel that is still connected to its power source may cause injury or death. Unless directed otherwise, turn the main power disconnect switch to the OFF position.

  • Page 128: Connections

    Connections Connection information provided in this section is based on the use of the ATS SuperTrak control panel. The control panel meets UL certification and product testing. If an alternate electrical panel is used, it must meet the guidelines defined in the SuperTrak GEN3 Design Considerations document.

  • Page 129: Ethernet Port Connection

    Controls and Connections Ethernet Port Connection The Ethernet port (ETH1) connection, located inside the control panel, provides TrakMaster software communication. Any computer (for example; a laptop or HMI) can connect to ETH1 with an Ethernet cable. After Before Connection Connection Description Number Type...

  • Page 130: Main Power Connection

    Controls and Connections Main Power Connection For the power drop connection, phase orientation does not matter. The main power cable (incoming) is wired through the back of the panel and into the main AC power disconnect connection, as illustrated: Before After Connection Connection...

  • Page 131: Safety Circuit Connection

    Controls and Connections Safety Circuit Connection The SuperTrak conveyance platform is integrated with a system safety circuit in the control panel. Wire the safety circuit as illustrated: SuperTrak™ GEN3 System Operation and Maintenance Manual Rev. 9 (12-2021)

  • Page 132: Plc Connection

    Controls and Connections PLC Connection The programmable logic controller (PLC) connection is inside the control panel. An Ethernet cable is wired through the back of the panel and into the 14K1 PLC connection, as illustrated: Connection Connection Description Number Type Safety circuit connection location.

  • Page 133: Ethernet Powerlink Connection

    Controls and Connections Ethernet POWERLINK Connection The Ethernet POWERLINK connection exists in the control panel when it is shipped. One end of an Ethernet cable is plugged into the front port of Slot 2 on the controller, and the other end of the cable is plugged into IF1 of the bus controller, as illustrated: Connection Connection Type Description...

  • Page 134: Gateway Network Connections

    Controls and Connections Gateway Network Connections Turn OFF the 24 V gateway power, and turn OFF the controller before connecting the gateway network. Although the gateway network connections are implemented using standard Ethernet cables, it is not an Ethernet network and should not be connected to Ethernet devices.
  • Page 135 Controls and Connections Gateway Board Connections Gateway network cables should never cross one another. As illustrated below, the left gateway connections connect to the controller upstream using the right network ports, and connect from the controller downstream using the left network ports. The right gateway connections are opposite;...
  • Page 136 Controls and Connections Straight Sections with 180 Deg (500 mm) Sections Connection Type Description Ethernet cable - not connected RJ45 Right network port (not connected) RJ45 Left network port (connected) RJ45 Left network port (not connected) RJ45 Right network port (connected) Right head section Ferrite (1 of 6) RJ45...
  • Page 137 Controls and Connections Sample Gateway Network Connections in a 180 Deg (500 mm) Section The following image illustrates some of the gateway network connections. The black line through the center of the image joins two (2) images together. Control panel electrical interconnect Ethernet cable - left network cable from controller (connected) Left network patch cable...
  • Page 138 Controls and Connections Straight Sections with 180 Deg (800 mm) Sections Connection Type Description RJ45 Left network port (connected) RJ45 Right network port (not connected) Ethernet cable - not connected RJ45 Left network port (not connected) RJ45 Right network port (connected) Right head section Left head section Left network patch cable...
  • Page 139 Controls and Connections Straight Sections with 90 Deg Sections Connection Type Description RJ45 Left network port (connected) RJ45 Right network port (not connected) SuperTrak™ GEN3 System Operation and Maintenance Manual Rev. 9 (12-2021)
  • Page 140 Controls and Connections Connection Type Description Ethernet cable - not connected RJ45 Left network port (not connected) RJ45 Right network port (connected) Right head section Left head section Left network patch cable Ferrite (1 of 6) RJ45 F-F coupler RJ45 Ethernet cable - left network cable from controller (connected) RJ45 Ethernet cable - right network cable from controller (connected)

  • Page 141: Operating Procedures

    Operating Procedures This section provides the following SuperTrak conveyance platform operating procedures: • Pre-Start Inspection on page 130 • Pre-Power ON Checks on page 132 • SuperTrak Conveyance Platform Power ON Behavior on page 137 • SuperTrak Conveyance Platform Power OFF Behavior on page 139 •...

  • Page 142: Pre-Start Inspection

    Operating Procedures Pre-Start Inspection Before the SuperTrak conveyance platform power is turned ON for the first time, complete the pre-power ON checks. Pre-Power ON Checks on page 132. In addition, complete one (1) or more of the following to make sure the upper v-rail is adequately lubricated: •...
  • Page 143 Operating Procedures Task Complete Disconnect the black section-to-section Ethernet cable at the end of the right network going into the left network to avoid any errors during start- ups. Gateway Network Connections on page 122. 10. Confirm that the ETH1 port is used for TrakMaster to communicate with SuperTrak.

  • Page 144: Pre-Power On Checks

    Operating Procedures Pre-Power ON Checks • Before the SuperTrak conveyance platform power is turned ON for the first time, complete the pre-power ON checks. • If any straight or curved section is added or removed, complete the pre-power ON checks. •...
  • Page 145 Operating Procedures Measure the Resistance Between the Motor Power Connection and the Common Connection 1. Test the resistance as shown below: 2. Look at the value displayed on the multimeter screen and determine if the resistance is acceptable: • Pass - The value is initially <10Ω and then slowly rises to >10Ω. This occurs because the capacitors are charging.
  • Page 146 Operating Procedures Measure the Resistance Between the Ground (Frame) and the Common Connection 1. Test the resistance as shown below: 2. Look at the value displayed on the multimeter screen and determine if the resistance is acceptable: • Pass - The value is <1Ω. •...
  • Page 147 Operating Procedures Measure the Resistance Between the Common Connection and the 24V Digital Power Connection 1. Test the resistance as shown below: 2. Look at the value displayed on the multimeter screen and determine if the resistance is acceptable: • Pass - The value is initially <500Ω...
  • Page 148 Operating Procedures Measure the Resistance Between the Motor Power Connection and the 24V Digital Power Connection 1. Test the resistance as shown below: 2. Look at the value displayed on the multimeter screen and determine if the resistance is acceptable: •...

  • Page 149: Supertrak Behavior

    Operating Procedures SuperTrak Behavior The SuperTrak conveyance platform is typically integrated with a larger automation system. This section describes the SuperTrak conveyance platform power ON procedure and does not include any steps for the larger system. Each section has two (2) power connections: •...

  • Page 150: Supertrak Conveyance Platform Power Off Behavior

    Operating Procedures • If digital power is not lost, all pallet locations and data are maintained. The system continues to work from where it left off. • If digital (UPS) power is lost and a cold start occurs, the pallets travel to the default target locations and the PLC decides what to do next for startup.
  • Page 151 Operating Procedures SuperTrak Conveyance Platform Power OFF Behavior To stop the system, the PLC disables the SuperTrak conveyance platform over the network at the appropriate time. This is typically triggered by a system cycle stop or cycle end button on the PLC-controlled operator interface. For example: •...

  • Page 152: Trakmaster Procedures

    Operating Procedures TrakMaster Procedures TrakMaster is not required to operate the SuperTrak conveyance platform; however, it is useful for troubleshooting and configuring the SuperTrak conveyance platform. TrakMaster is a Windows-based application that monitors, configures, and is used to troubleshoot the SuperTrak conveyance platform. Download TrakMaster 1.

  • Page 153: Login To Trakmaster

    Operating Procedures Login to TrakMaster 1. Open TrakMaster. 2. Click File > Login. 3. Enter your User Name and Password. User accounts and the associated permissions are configurable. The software includes the following initial accounts: Administrator, Programmer, Maintenance, and Operator. All passwords are initially password. 4.

  • Page 154: Monitor The Supertrak Conveyance Platform

    Operating Procedures Monitor the SuperTrak Conveyance Platform It is important to be aware of the state of SuperTrak conveyance platform during operation. When you are aware of how the SuperTrak conveyance platform correctly works, it is easier to notice when a change occurs. Some things to notice include: •...

  • Page 155: Technician Procedures

    Technician Procedures This section provides the following technician procedures: • Electrical Procedures on page 144 • Install a Power Supply on page 145 • Install a Power Supply on page 145 • Replace an Electrical Interconnect on page 176 • Replace a Coil Driver Board on page 150 •...

  • Page 156: Electrical Procedures

    Technician Procedures Electrical Procedures Completing any maintenance procedures with the SuperTrak conveyance platform electrically powered may result in serious injury or death. Lock out and tag out all electrical energy sources before part service or replacement. Hazardous Energy on page 8, and Lockout and Tagout on page 11.

  • Page 157: Install A Power Supply

    Technician Procedures Install a Power Supply • Make sure the power supply is wired correctly during installation. Incorrect wiring causes component damage. • The length of the 28VDC power cable (between the power supply and track section) must be the same for all power supplies on the same system to obtain the correct voltage and power balancing.
  • Page 158 Technician Procedures Replace or Install a New Power Supply 1. Turn the SuperTrak conveyance platform power disconnect switch to the OFF position. 2. Lock out and tag hazardous energy. Lockout and Tagout Locations on page 12. 3. If you are installing a new power supply, complete the following steps: a.
  • Page 159 Technician Procedures • For 180 deg (500 mm) sections: Remove the top cover from the 180 deg. (500 mm) section. It may also be helpful to remove the panel on the back of the section. 7. Feed the 28 VDC power output cable through the plug opening (step 3d) and then tighten the connection.
  • Page 160 Technician Procedures d. Align the negative (-) common wire from the left electrical interconnect, and the negative (-) common wire of the power supply with the common connection. These two (2) wires both have a white stripe on them. e. Repeat step 8c. Verify that the wiring is the same as the Left Coil Driver Board with a Power Supply Connected...
  • Page 161 Technician Procedures 10. Connect the AC power input plug to the terminal strip (-X1) in the control panel. The control panel can have six (6) or twelve (12) breakers. The base control panel includes six (6), with an option to increase to twelve (12).

  • Page 162: Replace A Coil Driver Board

    Technician Procedures Replace a Coil Driver Board This section describes how to replace a coil driver board in a straight section or in a 180 deg. section. Remove a Coil Driver Board - Straight Section To prevent electrical board damage from electrostatic discharge (ESD), use an ESD wrist strap when working with the coil driver board.
  • Page 163 Technician Procedures 6. Remove the fourteen (14) screws that secure the coil driver board to the bus bar. Note that one (1) screw is nylon. This screw is located in the upper-left corner of the coil driver board. 7. Pull the coil driver board straight down and out, and then disconnect the five (5) thermistor connections.
  • Page 164 Technician Procedures Remove a Coil Driver Board - 180 Deg. Section (500 mm) To prevent electrical board damage from electrostatic discharge (ESD), use an ESD wrist strap when working with the coil driver board. An ESD wrist strap prevents the buildup of static electricity. 1.
  • Page 165 Technician Procedures 6. Remove the fourteen (14) screws that secure the board to the bus bar. 7. Disconnect the three (3) thermistor connections. Squeeze the tabs for each thermistor connector plug and then pull straight out. 8. Lean the coil driver board forward and lift straight up. Remove a Coil Driver Board - 180 Deg.
  • Page 166 Technician Procedures Install a Coil Driver Board - Straight Section, 180 Deg. Section (800 mm), or 90 Deg. Section • To prevent electrical board damage from electrostatic discharge (ESD), use an ESD wrist strap when working with the coil driver board.
  • Page 167 Technician Procedures 5. Secure the coil driver board in position with fourteen (14) screws. Make sure that the screw in the upper-left corner of the coil driver board is nylon, and that the coil driver board wires are clear of the screws.
  • Page 168 Technician Procedures Install a Coil Driver Board - 180 Deg. Section (500 mm) • To prevent electrical board damage from electrostatic discharge (ESD), use an ESD wrist strap when working with the coil driver board. An ESD wrist strap prevents the buildup of static electricity. •...

  • Page 169: Replace A Gateway Board

    Technician Procedures Replace a Gateway Board This section describes how to replace a gateway board in a straight section, 90 deg. section, or in a 180 deg. section Remove a Gateway Board - Straight Section, 90 Deg. Section, or 180 Deg. (800 mm) Section To prevent electrical board damage from electrostatic discharge (ESD), use an ESD wrist strap when working with the gateway board.
  • Page 170 Technician Procedures 5. As required, unplug one (1) or two (2) motor network connection cables. 6. Unplug the four (4) ribbon cables. 7. Disconnect the two (2) encoder cables (right and left). 8. Loosen, do not remove, all four (4) connection screws.
  • Page 171 Technician Procedures 9. Remove the gateway board. As illustrated, verify that three (3) white plastic spacers are connected to each screw. 10. If the gateway board is being returned for repair, remove the hardware (screws, washers, and spacers), and make sure the gateway board is packaged in an ESD safe bag.
  • Page 172 Technician Procedures Remove a Gateway Board - 180 Deg. Section (500 mm) To prevent electrical board damage from electrostatic discharge (ESD), use an ESD wrist strap when working with the gateway board. An ESD wrist strap prevents the buildup of static electricity. 1.
  • Page 173 Technician Procedures 6. Unplug the two (2) encoder cables (right and left). 7. As required, unplug one (1) or two (2) motor network connection cables. 8. Disconnect the ground wire. 9. Remove the four (4) connection screws. 10. Remove the gateway board. 11.
  • Page 174 Technician Procedures Install a Gateway Board - Straight Section, 90 Deg. Section, or 180 Deg. (800 mm) Section To prevent electrical board damage from electrostatic discharge (ESD), use an ESD wrist strap when working with the gateway board. An ESD wrist strap prevents the buildup of static electricity.
  • Page 175 Technician Procedures 4. On each of the four (4) corners of the gateway board, verify that the gateway board sits flat on the white plastic spacers. 5. Secure the gateway board in position with four (4) screws. To prevent distortion of the gateway board, tighten one (1) screw at a time, working around the board in a clockwise direction.
  • Page 176 Technician Procedures Install a Gateway Board - 180 Deg. Section (500 mm) To prevent electrical board damage from electrostatic discharge (ESD), use an ESD wrist strap when working with the gateway board. An ESD wrist strap prevents the buildup of static electricity. If required, reference Gateway Board on page 30 during this procedure.

  • Page 177: Replace An Encoder Assembly

    Technician Procedures Replace an Encoder Assembly A 180 deg. (800 mm) section has four (4) encoder assemblies, while all other curved and straight sections have two (2) encoder assemblies. Replace the encoder assembly if a SuperTrak conveyance platform fault indicates that replacement is required.
  • Page 178 Technician Procedures Remove an Encoder Assembly - Curved Sections 1. Turn the SuperTrak conveyance platform power disconnect switch to the OFF position. 2. Lock out and tag hazardous energy. Lockout and Tagout Locations on page 12. 3. Remove the five (5) encoder assembly screw caps. Note: The images in these instructions show the 180 deg.
  • Page 179 Technician Procedures Install an Encoder Assembly - Straight and Curved Sections Power to the controller and gateways should OFF while installing encoders, and then turned ON before calibration. 1. If required, remove the old encoder assembly. Remove an Encoder Assembly - Straight Section on page 165.

  • Page 180: Replace A Motor Thermistor

    Technician Procedures Replace a Motor Thermistor A thermistor replacement fault can be set to be ignored in the TrakMaster software. This allows the SuperTrak conveyance platform to continue to run until the thermistor can be replaced at a convenient time. See the TrakMaster built-in help for additional information.
  • Page 181 Technician Procedures 6. Pull the old thermistor wire straight out from the thermistor hole. 7. Slide the end of the new thermistor wire into the thermistor hole until you feel resistance. The thermistor tapers. During installation, the thick ridge creates a friction fit against the sides of the thermistor hole.
  • Page 182 Technician Procedures 3. Open the straight section electrical door. Access to the motor thermistor, which is located through the small hole in the cabinet (A), is blocked by the electrical interconnect (B). Remove the electrical interconnect. Replace an Electrical Interconnect on page 176.
  • Page 183 Technician Procedures 5. Replace the thermistor at the end of the wire. 6. Thread the wire with the new thermistor back through the hole in the cabinet. 7. Reinstall the electrical interconnect. SuperTrak™ GEN3 System Operation and Maintenance Manual Rev. 9 (12-2021)
  • Page 184 Technician Procedures Replace a Thermistor - 180 Deg. Section (500 mm) There are six (6) thermistors in each 180 deg. section. 1. Turn the SuperTrak conveyance platform power disconnect switch to the OFF position. 2. Lock out and tag hazardous energy. Lockout and Tagout Locations on page 12.

  • Page 185: Replace The Main Motor Fuse

    Technician Procedures Replace the Main Motor Fuse A 50A fuse is installed on the left coil driver board when a power supply is installed for the motor. The 50A fuse bridges the two (2) 28VDC motor power connections. Fuse replacement may be required if a low motor voltage fault displays. 1.

  • Page 186: Replace A Coil Fuse

    Technician Procedures Replace a Coil Fuse It is possible for the SuperTrak conveyance platform to operate when a coil fuse is blown; however, the pallet stop control is affected. Each coil driver board has ten (10) 15A fuses; there is a dedicated fuse for each coil.
  • Page 187 Technician Procedures 5. Pull the 15A fuse straight out from the slot. 6. Install a new 15A fuse straight into the fuse slot. Make sure the fuse is centered and seated correctly during installation. 7. If required, connect any coil connections that were disconnected in step 4. Replace a Coil Fuse - 180 Deg.

  • Page 188: Replace An Electrical Interconnect

    Technician Procedures Replace an Electrical Interconnect For a wiring overview, see the wiring pin-out overview label located on the electrical door of each straight section and curved section during this procedure. Replace a Section-to-Section Electrical Interconnect--Rigid Connection Remove the existing rigid conduit 1.
  • Page 189 Technician Procedures 3. With the metal conduit flush with the strain relief connectors, tighten the two (2) strain relief connectors. 4. Feed the required wiring through the metal conduit and connect as required, then close the sections’ electrical doors. Straight Section - Left Coil Driver Board on page 28 and Right Coil Driver Board...
  • Page 190 Technician Procedures 3. Tighten the two (2) strain relief connectors. 4. Feed the required wiring through the metal conduit and connect as required, then replace the sections’ electrical doors and/or top covers. Straight Section - Left Coil Driver Board on page 28, Right Coil Driver Board on page 31,...

  • Page 191: Install An Electrical Interconnect Between A Curved Section And A Supertrak Control Panel

    Technician Procedures Install an Electrical Interconnect Between a Curved Section and a SuperTrak Control Panel Use only ATS approved network cables for connecting the SuperTrak G3 Controller to the first section; otherwise, the system may operate incorrectly. The electrical interconnect has four (4) wires on one end and five (5) wires on the other, it also includes a left network patch cable (not shown), an F-F coupler, and three (3) ferrites.
  • Page 192 Technician Procedures The procedure begins with connecting the end with four (4) wires to the curved section. 1. Install the F-F coupler: a. As applicable, align the coupler with the mounting screw hole. Carefully lift the wires, so the F-F coupler fits below them: •...
  • Page 193 Technician Procedures b. As applicable, secure the F-F coupler in position using a screw: • For the 500 mm section, the F-F coupler installation is as shown at right. • For 180 deg. (800 mm) sections, the F-F coupler installation is as shown at right.
  • Page 194 Technician Procedures 2. As applicable, remove the black wire plug from the curved section: • For the 180 deg. (500 mm) section, the wire plug is located at the bottom. • For the 180 deg. (800 mm) section, the wire plug is located on the back (inside).
  • Page 195 Technician Procedures 5. As applicable, connect the common connection wire (COM) to the curved section. Remove the mounting screw, align the common connection wire with the screw hole, and then reinstall the mounting screw: • For the 180 deg. (500 mm) section, the connection is located near the bottom-right corner of the right coil driver board.
  • Page 196 Technician Procedures • For the 90 deg.section, the connection is located on the right side of the right coil driver board that is in the left electrical panel. 6. As applicable, connect the 24 VDC digital power wire (DIG+) to the J17 connector on the gateway board of the curved section: •...
  • Page 197 Technician Procedures • For the 180 deg. (800 mm) section, the connection is located on the gateway board in the left electrical panel. • For the 90 deg. section, the connection is located on the gateway board in the left electrical panel.
  • Page 198 Technician Procedures 7. As applicable, connect the two (2) Ethernet cables (left and right network cables) to the F-F coupler: • For the 180 deg. (500 mm) section, connect the cables on the right side (as indicated) of the F-F coupler.
  • Page 199 Technician Procedures 9. As applicable, connect the left network patch cable to the F-F coupler: • For the 180 deg. (500 mm) section, connect the cable opposite from the left network cable. • For the 180 deg. (800 mm) section, connect the cable opposite from the left network cable.
  • Page 200 Technician Procedures 11. As applicable, connect the gateway network cable from the adjoining straight section on the right to the F-F coupler: • For the 180 deg. (500 mm) section, connect the cable opposite from the right network cable. • For the 180 deg.
  • Page 201 Technician Procedures • For the 180 deg. (800 mm) section, connect the cable to the gateway board in the right electrical enclosure within the 180 deg. section. • For the 90 deg. section, connect the cable to the gateway board in the left electrical enclosure within the 90 deg.
  • Page 202 Technician Procedures 18. Connect the 24VDC digital power wire (DIG+) to -X2:111 in the SuperTrak control panel. This is a red wire or blue wire, depending on the system version. 19. Connect the digital shield wire (GND) to -X1:112 in the SuperTrak control panel. This is a black wire.

  • Page 203: Mechanical Procedures

    Hazardous Energy on page 8. Some equipment requires periodic adjustment to re-establish the accuracy and desired output of the SuperTrak conveyance platform. ATS recommends replacing defective devices rather than repairing them. Only qualified technicians should perform maintenance tasks. Install a Pallet •...
  • Page 204 Technician Procedures 3. Install the pallet removal tool on the pallet: a. Align the pallet removal tool holes with the pallet shoulder screws and then position the tool against the front of the pallet. b. Slide the pallet removal tool to the left, to locate the shaft of the two (2) shoulder screws into the tool slots.

  • Page 205: Remove A Pallet

    Technician Procedures Remove a Pallet • The magnetic field generated by the pallet magnets can be harmful to pacemaker wearers. Maintain a minimum distance of 31 cm (12 in.) between the pallet and the implant location. The magnetic field may also induce magnetic materials into motion, creating potential projectiles or pinch points.
  • Page 206 Technician Procedures 3. Pry or tilt the pallet away from the motor: firmly hold both pallet removal tool handles, and then pull the right handle while resisting with the left handle At approximately 15 degrees the magnetic pull decreases and the pallet can be removed from the motor.

  • Page 207: Inspect A Pallet

    Technician Procedures Inspect a Pallet Handle pallets carefully to avoid damage to the pallet components. Inspect pallets for wear on a regular basis and each time a pallet is removed from the SuperTrak conveyance platform. Inspect the pallet: Pallet Inspection Resolution Component Anti-static...
  • Page 208 Technician Procedures Pallet Inspection Resolution Component Lubrication felt Visually inspect the lubrication felt. Make If required, replace the sure the felt is in good condition. lubrication felt. Replace a Pallet Lubrication Felt on page 210. Verify that the lubrication felt contains Lubricate the lubrication felt.
  • Page 209 Technician Procedures Pallet Inspection Resolution Component Magnet Visually inspect the magnet assembly for Replace the pallet magnet assembly damage or wear (for example; cracks or assembly. flaking magnet plating). Replace a Pallet Magnet Assembly on page 205. Visually inspect the magnet assembly for Clean dirt and debris off of the dirt or debris.

  • Page 210: Replace A Pallet Bumper

    Technician Procedures Replace a Pallet Bumper 1. Remove the pallet from the SuperTrak conveyance platform. Remove a Pallet on page 193. 2. Turn the bumper counter-clockwise and remove the bumper. 3. Align the replacement bumper threads with the bumper spacer (if used) or with the bumper hole on the pallet.

  • Page 211: Replace The Pallet Flat Wheels

    Technician Procedures Replace the Pallet Flat Wheels Inspect the flat wheels and spacers. Replace the flat wheels if they are worn (vertical play exceeds 0.5 mm [0.02 in.]) or damaged. Typical Pallet Wheel Lifespan on page 304 for additional information. Remove the Pallet Flat Wheels 1.
  • Page 212 Technician Procedures Install the Pallet Flat Wheels 1. Hold a spacer on each side of the bearing of the new flat wheel and insert the flat wheel into the pallet body. For ease of assembly, rest the pallet on the shoulder screws or upside down on the encoder strip assembly.

  • Page 213: Replace The Pallet V-Wheels

    Technician Procedures Replace the Pallet V-Wheels It is recommended to replace the pallet v-wheels in pairs. Inspect the v-wheels for gouges, pits, or wear; replace if they are worn or damaged. Pallet v-wheel wear varies depending on the system application. It is recommended that you verify the accuracy of critical pallet features over time, as required by the application.
  • Page 214 Technician Procedures 6. Remove the screw and washer that secures the v-wheel in position. 7. Repeat step 6 for the second v-wheel. 8. Attempt to manually pull the v-wheel shaft out. If snug, thread a dowel puller into the shaft and pull the shaft out. 9.
  • Page 215 Technician Procedures Install the Pallet V-Wheels 1. Hold the new v-wheel so that the side with the groove is facing up. 2. Hold a spacer on the bottom of the new v-wheel and insert them into the pallet body. For ease of assembly, rest the pallet on the shoulder screws or upside down on the encoder strip assembly.
  • Page 216 Technician Procedures 6. Install and a washer and screw into each of the two (2) v-wheel shafts, and then tighten. 7. Install a plastic cap over each of the two (2) screws. 8. Install an anti-tip block in position, and then secure it in position with two (2) screws.

  • Page 217: Replace A Pallet Magnet Assembly

    Technician Procedures Replace a Pallet Magnet Assembly 1. Remove the pallet from the SuperTrak conveyance platform. Remove a Pallet on page 193. 2. Remove the four (4) screws and two (2) shoulder bolts from the front cover plate. 3. Remove the front cover plate from the pallet.

  • Page 218: Replace A Pallet Anti-Static Brush

    Technician Procedures Replace a Pallet Anti-Static Brush The anti-static bristles can be bent out of shape if mishandled. Take care not to damage the anti-static bristles during this procedure. The nominal length of a new anti-static brush is 4.05 mm (0.159 in.). When 0.5 mm (0.02 in.) of the anti-static brush is worn away, it will not make contact with the upper v-rail.

  • Page 219: Adjust A Pallet Shim

    Technician Procedures Adjust a Pallet Shim The pallet shim is factory-set to obtain a 0.5 mm (0.02 in.) gap between the pallet encoder assembly and the SuperTrak conveyance platform encoder assembly. Adjust the pallet shim if the gap is outside of the range of 0.5 mm (0.02 in.) +/- 0.3 mm (0.01 in.).
  • Page 220 Technician Procedures 2. If the gap is greater than 0.5 mm (0.02 in.) +/- 0.3 mm (0.01 in.), verify that the pallet shim is the problem (not the v-wheels or pallet encoder strip assembly): • Make sure that the v-wheels are secure with no vertical play. If the v-wheels have vertical movement;...
  • Page 221 8. Measure the current combined shim thickness. 9. Use shims to adjust the gap to 0.5 mm (0.02 in.). Shims are available in a range of sizes from ATS. 10. Align the new pallet shim with the pallet dowels, and then place in position.

  • Page 222: Replace A Pallet Lubrication Felt

    Technician Procedures Replace a Pallet Lubrication Felt 1. Remove the pallet from the SuperTrak conveyance platform. Remove a Pallet on page 193. 2. Remove the two (2) lubrication locking block screws. 3. Remove the lubrication locking block. 4. Remove the lubrication holder. 5.

  • Page 223: Replace A Pallet Spring

    Technician Procedures 6. Position a new lubrication felt into the lubrication holder. Make sure the V-groove of the lubrication felt aligns with the V-groove of the lubrication holder. 7. Install one (1) screw in the back of the lubrication holder and into the lubrication felt.

  • Page 224: Replace A Pallet Encoder Strip Assembly

    Technician Procedures Replace a Pallet Encoder Strip Assembly Pallet encoder strips can be damaged by magnets. Never clean a pallet encoder strip with a magnet. 1. Remove the pallet from the SuperTrak conveyance platform. Remove a Pallet on page 193. 2.
  • Page 225 4. Lift and remove the pallet encoder strip assembly. 5. Obtain a replacement encoder assembly with a new encoder strip mounted. Order this part from ATS. 6. Align the pallet encoder strip assembly that has a new encoder strip with the pallet.

  • Page 226: Install A Station Setup Fixture

    Technician Procedures Install a Station Setup Fixture • Improper use of a station setup fixture may cause damage to the pallets or tools. • Do not move or adjust a station setup fixture without the assistance of a trained technician. •...

  • Page 227: Align A Pallet Encoder Strip Assembly

    Technician Procedures Align a Pallet Encoder Strip Assembly • Improper use of a pallet setup fixture may cause damage to the pallets or tools. • Do not move or adjust a pallet setup fixture without the assistance of a trained technician. •...
  • Page 228 Technician Procedures 1. Install a pallet setup stationary mount on a straight section. Install a Pallet Setup Stationary Mount on page 217. 2. Optionally, for systems that require tight tolerances, verify that the pallet setup stationary mount is parallel with the upper-v-rail. Verify Pallet Setup Stationary Mount Parallelism on page 218.
  • Page 229 Technician Procedures Install a Pallet Setup Stationary Mount 1. Position a stationary mount on a straight section. Make sure the datum surface, which is etched with the a “D”, faces toward the encoders. Roughly center the stationary mount with an odd-numbered encoder. In the example below, all odd-numbered encoders are circled.
  • Page 230 Technician Procedures Verify Pallet Setup Stationary Mount Parallelism This procedure is optional. It is okay if the nominal for a particular system is slightly off from true nominal (for example; off by 10-20 µm). The important thing is that all pallets on the SuperTrak system are adjusted to the same nominal.
  • Page 231 Technician Procedures Center a Pallet Setup Stationary Mount with an Encoder 1. If required, install a stationary mount. Install a Pallet Setup Stationary Mount on page 217. 2. Install the chip finder on the left side of the stationary mount: a.
  • Page 232 Technician Procedures 7. Remove the chip finder from the left side of the stationary mount and turn it 180°. 8. Install the chip finder on the right side of the stationary mount: a. Align the chip finder with the left side of the stationary mount.
  • Page 233 Technician Procedures 11. As required, adjust the position of the pallet setup station locate: a. Slightly loosen the two (2) stationary mount screws. b. Use a wrench to loosen the lock nut. c. Use a wrench to turn the hex head bolts as required to fine-adjust the position of the pallet setup station locate.
  • Page 234 Technician Procedures 15. Snug the two (2) hex head bolts against the stationary mount. 16. Tighten the two (2) station locate lock nuts. 17. Loosen the adjust block screws, snug them up to each end of the stationary mount, and then tighten the screws. 18.
  • Page 235 Technician Procedures Verify the Pallet Setup Stationary Mount Position Complete this procedure to verify that the stationary mount is in the correct position. A pallet with a correctly aligned encoder assembly (master or reference pallet) is required for this procedure. 1.
  • Page 236 Technician Procedures 5. View the value displayed in step 2 on the TrakMaster screen. If the stationary mount is good, the value should be within ±4 microns, like the example below. SuperTrak™ GEN3 System Operation and Maintenance Manual Rev. 9 (12-2021)
  • Page 237 Technician Procedures Reference the Encoder Position Complete this procedure to measure the physical distance between two encoders on the straight section encoder assembly. Redo this procedure if an encoder assembly is replaced on a straight section that has a stationary mount installed. 1.
  • Page 238 Technician Procedures Adjust the Pallet Encoder Strip Assembly (Primary Encoder Strip) For optimal pallet-to-pallet repeatability, make sure all the pallets on the SuperTrak have the same encoder strip assembly value in TrakMaster. It is more important for all pallet encoder strips to be set the same, than for the encoders to be set 0.
  • Page 239 Technician Procedures 6. On each side of the encoder strip assembly, insert a hex key into the hole and engage the recessed set screw. 7. Turn the hex key(s) the required amount in the required direction to correctly adjust the encoder strip assembly. Aim for a pallet position that is within a few microns;...
  • Page 240 Technician Procedures 3. Loosen the three (3) screws on the edge of the pallet encoder strip assembly. Only loosen the screws enough to make a fine movement. Make sure the hex key is fully-engaged with the screw to avoid stripping the screw head.
  • Page 241 Technician Procedures 6. On TrakMaster, click + Advanced. If required, click Diagnostic > Encoders, and then click the Encoder strip Setup tab first. 7. View the value below step 3 ( Make a coarse adjustment to the ) on the TrakMaster screen, and then complete one (1) of secondary strip the following: •...

  • Page 242: Replace An Upper V-Rail

    Technician Procedures Replace an Upper V-Rail Replace the upper v-rail if it becomes damaged. Replace an Upper V-Rail - Straight Section Remove an Upper V-Rail - Straight Section 1. Turn the SuperTrak conveyance platform power disconnect switch to the OFF position. 2.
  • Page 243 Technician Procedures 3. Equally divide the gap between the ends of the upper v-rail. The gap should be close to 0.5 mm (0.02 in.) on both sides. 4. Install the 0.25 mm (0.01 in.) shims. Restore them to the position you made note of during the removal procedure.
  • Page 244 Technician Procedures 4. Remove twenty one (21) screws from the upper v-rail. 5. Loosen the screws that attach the section’s stands to the frame as indicated at right. 6. Loosen the adjacent straight sections’ V-rails. Do not remove them completely, but loosening them will make it easier to install the new V-rails on the 180 deg.
  • Page 245 Technician Procedures 9. Clean the top of the section with a soft cloth to remove any debris. Install an Upper V-Rail - 180 Deg. (800 mm) Section 1. Hold the new upper v-rail horizontally, with the counter-bore side up. 2. Slide the new upper v-rail between the upper v-rails of the adjacent sections. 3.
  • Page 246 Technician Procedures 4. Remove fifteen (15) screws from the upper v-rail, and remove the screws from the adjacent sections as well. Replace an Upper V-Rail - Straight Section on page 230. 5. Note the position of the 0.25 mm (0.01 in.) shim, and then place the shim in a safe location.
  • Page 247 Technician Procedures Install an Upper V-Rail - 90 Deg. Section 1. Hold the new upper v-rail horizontally, with the counter-bore side up. 2. Slide the new upper v-rail between the upper v-rails of the adjacent sections. 3. Equally divide the gap between the ends of the upper v-rail. The gap should be close to 0.5 mm (0.02 in.) on both sides.
  • Page 248 Technician Procedures 6. Remove eleven (11) screws from the top plate. 7. Lift the top plate straight up to remove it. 8. Clean the top of the 180 deg. section with a soft cloth to remove any debris. SuperTrak™ GEN3 System Operation and Maintenance Manual Rev.
  • Page 249 Technician Procedures 9. Verify joint alignment on both ends and adjust if necessary. Fine-Adjust the Upper V-Rail on page 103. 10. Calibrate the encoders. See the TrakMaster built-in help for the calibration procedure. Install an Upper V-Rail - 180 Deg. Section 180 Deg. (500 mm) Section 1.

  • Page 250: Replace A Flat Wear Strip

    Technician Procedures Replace a Flat Wear Strip • The flat wear strip must be installed before pallets move on the SuperTrak conveyance platform. If a flat wear strip is not installed, pallets will jam against the motors. • The distance between flat wear strips must be 0.5 mm (0.02 in.). Replace a flat wear strip if it becomes damaged.
  • Page 251 Technician Procedures Remove a Flat Wear Strip 1. Open the safety circuit. 2. Place a strong magnet on the front surface of one end of the wear strip. 3. Holding onto the magnet, pull the wear strip straight out of the channel. The flat wear strip is held in position with permanent magnets.
  • Page 252 Technician Procedures 3. If required, install a locator: a. Align the locator with the slot of the SuperTrak conveyance platform section so that the tab faces the long opening. The screw hole is not centered in the slot, one side of the slot is longer than the other. b.
  • Page 253 Technician Procedures Align a Flat Wear Strip Adjustment tooling, located under the curved section, provides in-and-out adjustment of the flat wear strip on the curved section. The process for aligning the flat wear strips varies slightly depending on the type of curved section, as outlined below.
  • Page 254 Technician Procedures 90 Deg. Section To align the wear strip, use the screws as labeled to adjust the wear strip in and out. SuperTrak™ GEN3 System Operation and Maintenance Manual Rev. 9 (12-2021)

  • Page 255: Replace A Motor Cover Label

    Technician Procedures Replace a Motor Cover Label Each motor includes a protective motor cover label. This is the black label with the SuperTrak conveyance platform logo in the bottom left corner. Replace the motor cover label if it becomes damaged. Remove the Damaged Motor Cover Label 1.

  • Page 256: Replace A Straight Section

    Technician Procedures Replace a Straight Section Although both options are available, Automation Tooling Systems recommends that straight sections be repaired rather than replaced. Appendix B: Spare Parts on page 289. Replace a 180 Deg. Section Although both options are available, Automation Tooling Systems recommends that 180 deg.

  • Page 257: Maintenance

    Maintenance is an important part of the continued and proper operation of the SuperTrak conveyance platform. Failure to perform maintenance as required, and in accordance with your ATS contract, voids the warranty. Maintain accurate and complete records regarding SuperTrak conveyance platform maintenance and any completed service procedures.

  • Page 258: Electrical Enclosure

    Maintenance Component Frequency Task Description Pallets Monthly Inspect Inspect each pallet for wear. Inspect a Pallet on page 195. Monthly, or as Lubricate Add lubricant to the pallet. determined Lubricate the Pallet Lubrication for your Felt on page 250. application Monthly Clean •...

  • Page 259: Cleaning Procedures

    Maintenance Cleaning Procedures This section describes SuperTrak conveyance platform cleaning procedures. Clean the SuperTrak Conveyance Platform After cleaning the SuperTrak conveyance platform frame, clean up all spills and excess water immediately. Liquid on floors causes a slip hazard. Never use razor blades, scrapers, squeegees, brushes or any other abrasive tools to clean the SuperTrak conveyance platform frame.

  • Page 260: Clean A Pallet Encoder Strip

    Maintenance Clean a Pallet Encoder Strip Never use a magnet to clean the encoder strip. Contact with magnetic material will cause permanent damage to the magnetic encoder strip. 1. Gently wipe the encoder strip with a soft, dry, clean cloth. 2.

  • Page 261: Replace A Power Supply Filter

    Maintenance Replace a Power Supply Filter Be careful not to bend the power supply filter retention clip out of shape when removing it. The power supply filter prevents particles from entering the power supply through the cooling fans. Particulate build-up on the power supply filter impedes air flow and may cause the power supply to overheat.

  • Page 262: Lubrication Procedures

    Use an oil lubricant with a viscosity similar to ISO grade 46, SAE grade 20. ATS uses a food grade NSF registered H1 machine oil for the broadest application range.

  • Page 263: Troubleshooting

    Troubleshooting This section provides the following SuperTrak conveyance platform troubleshooting procedures for qualified technicians: • Communication Faults on page 251 • Pre-Power ON Faults on page 252 • Power Faults on page 255 • Pallet Faults on page 258 • Test Straight Section or Curved Section Hardware on page 259 •...

  • Page 264: Pre-Power On Faults

    Troubleshooting Pre-Power ON Faults Failure Resolution A short exists between the Determine if the short exists between a motor power connection motor power connection and a common connection or between a motor power and the common connection connection and ground (frame): or ground (frame).
  • Page 265 Troubleshooting Failure Resolution Continued from previous Isolate the short: page 1. Disconnect a motor power connection at each end of the system. This divides the system in half electrically. 2. Use a multimeter to measure the resistance of each half of the system.
  • Page 266 Troubleshooting Failure Resolution Continued from previous 2. Use a multimeter to measure the resistance between the page 24V digital power connection and the common connection. If the value displayed on the multimeter screen is OL, a short exists between the 24V digital power connection and the ground (frame).

  • Page 267: Power Faults

    Troubleshooting Power Faults Fault Resolution Motor supply voltage • Make sure the motor power is ON before attempting to enable the SuperTrak conveyance platform. This is typically a PLC programming error. • Verify that the breakers in the SuperTrak conveyance platform control panel are ON.

  • Page 268: Check Coil Resistance To Find Shorted Or Mis-Wired Coils

    Troubleshooting Check Coil Resistance to Find Shorted or Mis-wired Coils Use a multimeter to check for shorted or mis-wired coils. Instruction Graphic Desired Result/Action 1. Turn the SuperTrak power supply power OFF. 2. Detach the first green A resistance range of terminal block plug Ω...
  • Page 269 Troubleshooting 5. Measure the The resistance should resistance between Ω show higher than 0.6 the motor body and If the resistance is 0.6 or the 1st pin on the lower, the coil is shorted. terminal block plug. The coils are not serviceable , so the motor may need to be returned for repair.

  • Page 270: Pallet Faults

    Troubleshooting Pallet Faults Fault Resolution Pallet following error • Check for mechanical or other interference with the pallet (for example, a jammed part). The fault indicates the location. • Inspect the pallet. Inspect a Pallet on page 195. • Verify that a coil fuse is not blown. If a pallet travels across a coil with a blown fuse, pallet momentum is usually adequate to allow acceptable control.

  • Page 271: Test Straight Section Or Curved Section Hardware

    Troubleshooting Test Straight Section or Curved Section Hardware TrakMaster software is required for most of the straight section or curved section hardware testing procedures. This section describes how to test the functionality of straight section or curved section hardware components. Test Encoder Functionality 1.

  • Page 272: Test The Coil Functionality

    Troubleshooting Test the Coil Functionality 1. Remove all pallets from the straight section or 180 deg. section to be tested. 2. Turn the SuperTrak power supply power ON. This is generally done by turning the system power ON when the safety circuit is closed.
  • Page 273 Troubleshooting 8. Click Apply Test Setpoint. To pass, each should display Coil of 5.00 ±0.5 Current 9. Click Clear Test Setpoints. 10. Enter a value of -5.00 into the field. Setpoint 11. Click Apply Test Setpoint. To pass, each should display Coil of -5.00 ±0.5 for standard sections or 1.00±0.5 for collaborative Current...

  • Page 274: Test For A Reversed Polarity Coil

    Troubleshooting Test for a Reversed Polarity Coil If a coil is connected backward it will have reversed polarity. There are two (2) methods to test for reversed polarity in a coil: • Test with the PLC in MANUAL Mode on page 262 If this option is available, it is easier and quicker to use this test.
  • Page 275 Troubleshooting Test Manually with TrakMaster Before starting this test, manually block any system tooling that could interfere with pallet motion. Failure to do so, could result in system damage. During this test, a pallet is manually commanded across the straight section or 180 deg.
  • Page 276 Troubleshooting 7. Set the parameter to 50 mm/s. Velocity 8. Click the Pallet Control tab. 9. Under , select a Move to Target that is past the section to Target be tested and in the direction that will cause the pallet to travel over the section to be tested.

  • Page 277: Test The Status Of The Hardware

    Troubleshooting Test the Status of the Hardware 1. Open TrakMaster. 2. In the left pane, click Diagnostic > Hardware Status. 3. Verify that the of all motor temperature sensors is set to State Monitored 4. Verify that the for: Value •...

  • Page 278: Test The Rail System

    Troubleshooting Test the Rail System 1. Inspect both the flat and upper v-rail for any damage or debris build-up. 2. Inspect the flat rail, to verify that the wear strip is correctly seated in the groove of the track structure. 3.

  • Page 279: Diagnostic Lights

    Troubleshooting Diagnostic Lights This section provides information about the indicator lights on the SuperTrak conveyance platform hardware. Controller Indicator Lights The controller has four (4) indicator lights: Power, HDD, Link, and Run. The following table summarizes the indicator light behavior. See the APC910 User’s Manual for additional information.

  • Page 280: Gateway Board (Acb3040) Indicator Lights

    Troubleshooting Indicator Color Light State Normal A Problem May Exist Green Solid  Blinking The controller startup sequence is not  yet complete. Wait several minutes. Solid A controller software problem exists. Contact your vendor for assistance. Blinking Gateway Board (ACB3040) Indicator Lights The gateway board image may not reflect the latest version of the gateway board.
  • Page 281 Troubleshooting LED # Color Light State Normal A Problem May Exist Power is disabled due to excessive current draw, A short-circuit exists in the encoder board or in the encoder board cable.  Green A software diagnostic LED. This indicator is for development purposes only.

  • Page 282: Coil Driver Board (Acb3000) Indicator Lights

    Troubleshooting LED # Color Light State Normal A Problem May Exist Yellow The gateway board is the last in the  10 (TEMP) network. The gateway board is not the last in  the network. a. STAT stands for status. b.

  • Page 283: System Specifications

    800 µs typical 1. Higher payloads are possible. Contact ATS with application details. 2. Other protocols are possible. Contact ATS if other protocols are required. 3. Power consumption varies depending on the aggressiveness of the application: it may be less with less demanding requirements or more with more demanding requirements.

  • Page 284: Environment Conditions

    System Specifications Environment Conditions State Specification Straight Section or Curved Power Supply Value Section Value Operation Temperature 5°C (41°F) to 55°C (131°F) -20°C (-4°F) to 71°C (159.8°F) (ambient) Humidity 5% to 85% non-condensing 20% to 90% (relative) Storage Temperature -25°C (-13°F) to 55°C (131°F) -20°C (-4°F) to 75°C (167°F) (ambient) Humidity...

  • Page 285: Installation Requirements

    System Specifications Installation Requirements Service Specification Value Power supply Input rating 1 phase x 200-240VAC (high power) 50/60 Hz Output rating 28VDC 1500W Fuses/circuit breaker 10 A UL489 breaker Type CC fuses, or type J fuses Terminal connection Connect as per local requirements for 10A cross-section Permitted mounting •...
  • Page 286 System Specifications Service Specification Value 180 deg. section Input rating 28VDC (500 mm) 100A peak Output rating Force of up to 150N/pallet Fuses/circuit breaker 50A fuses Terminal connection 16 mm cables terminated with a wire lug cross-section Permitted mounting Horizontal upright, or vertical over/under orientations 180 deg.

  • Page 287: Electrical Services

    System Specifications Electrical Services Service Specification Value Control panel Line voltage 208Y120VAC+PE 400Y230VAC+PE Frequency 50/60 Hz Phases 3 ph, 5-wire Short circuit current rating Largest load Control voltage 24VDC (digital power supplied from the control panel) 28VDC (motor power supplied from the power supplies) Full load amps UPS (located...

  • Page 288: Electromagnetic Compatibility (Emc) Requirements For Immunity To Disturbances

    System Specifications Electromagnetic Compatibility (EMC) Requirements for Immunity to Disturbances The following table provides high-frequency disturbance limits in accordance with EN 61000-6-2: Disturbance Test Description Limit Requirement Type Accordance Electrostatic EN 61000-4-2 Contact discharge discharge to powder-coated and bare metal housing parts.

  • Page 289: Glossary

    Glossary This section contains an alphabetized list of terms and acronyms that may be used in this document. Term Definition Automation Tooling Systems, Inc. Bus board A capacitor bank that filters out spikes or ripples in the electrical supply to provide smooth DC voltage. A bus board is mounted behind each linear motor.
  • Page 290 References a 180 deg. section (500 mm). Frame A metal base that can be used to set up the SuperTrak conveyance platform system off the floor. SuperTrak GEN3 Frames are designed to work with SuperTrak conveyance platforms. Gateway network An ATS proprietary network, implemented using standard Ethernet cables;...
  • Page 291 A pallet may also be referred to as a shuttle. Stand An adjustable metal apparatus that mounts a section to the SuperTrak GEN3 frame. Stands may be standard height or low profile. Station Two (2) or more devices that work together to complete a task.
  • Page 292 Glossary Term Definition Track section A 1 m (3.28 ft.) long piece of conveyor track that can be joined with other sections of conveyor to produce a length of SuperTrak conveyance platform. The sections typically share a common power supply or multiple power supplies, and communicate with each other over a high speed data network.

  • Page 293: Supertrak Conveyance Platform Service

    SuperTrak Conveyance Platform Service This section describes how to contact ATS Service Support for customer assistance. Contact ATS Please contact ATS for assistance, questions or comments regarding the operation or maintenance of your equipment. ATS Automation Tooling Systems, Inc 730 Fountain Street North...

  • Page 294: Return A Part To Ats For Warranty

    Be aware that some manufacturers require a purchase order (PO) to test returned parts. If a PO is required, ATS will contact you for a PO before additional action is taken. 5. Depending on the original manufacturer response, ATS contacts you with a list of options: •...

  • Page 295: Request Service From Ats

    SuperTrak Conveyance Platform Service Request Service from ATS Contact ATS Post Automation Support if service is required on your SuperTrak conveyance platform. Please have the following information available when you call: • Company name • Contact name • Contact number •...
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  • Page 297: Appendix A: Hardware Torque Specifications

    Appendix A: Hardware Torque Specifications The following table provides the hardware torque specifications to use during the installation of the SuperTrak conveyance platform. Location Size Type Finish Class DIN Torque Description (Nm) Top connection plate M10-1.5x40 SHCS Zinc Plated 12.9 Side connection M10-1.5x40 SHCS...
  • Page 298 Appendix A: Hardware Torque Specifications Location Size Type Finish Class DIN Torque Description (Nm) 180 deg. (500 mm) M5-0.8x10 SHCS Zinc Plated 12.9 section top cover Encoder M3-0.5x8 SHCS Zinc Plated 12.9 Upper v-rail M6-1.0x14 SHCS Zinc Plated 12.9 180 deg. (500 mm) Upper v-rail M8-1.25x16 SHCS...
  • Page 299 Appendix A: Hardware Torque Specifications Location Size Type Finish Class DIN Torque Description (Nm) Gateway board to M4-0.7x16 SHCS Zinc Plated 12.9 bus bar Int. Zinc Plated 6797 Tooth Washer Pallet - front cover M5-0.8x8 BHSCS Zinc Plated 10.9 7380 Pallet - shoulder Shoulder Black...
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  • Page 301: Appendix B: Spare Parts

    Appendix B: Spare Parts Be aware that the graphics in this section are not to scale. This section provides the recommended spare parts information for the SuperTrak conveyance platform. SuperTrak™ GEN3 System Operation and Maintenance Manual Rev. 9 (12-2021)

  • Page 302: Cables And Wires

    Cables and Wires Description Graphic Part Number Where Used Replacement Rec. Qty Critical Frequency Encoder cable SP-1061547 •All Sections Very Low Encoder cable - SP-1061547 •Straight Section FME Very Low 548mm •180 Degree Section 500mm •180 Degree Section 800mm •90 Degree Section Encoder cable - SP-125420384 •Straight Section RME...
  • Page 303 Description Graphic Part Number Where Used Replacement Rec. Qty Critical Frequency Ribbon cable - SP-1060325 •Straight Section FME Very Low 298mm Ribbon cable - SP-1060322 •Straight Section FME Very Low 57mm Ribbon cable - SP-1060323 •Straight Section FME Very Low 32mm Ribbon cable - SP-1060484...
  • Page 304 Description Graphic Part Number Where Used Replacement Rec. Qty Critical Frequency Ribbon cable - SP-125449498 •Straight Section RME Very Low 130mm Ribbon cable - SP-125422700 Straight Section RME Very Low 180mm...

  • Page 305: Other Spare Parts

    Other Spare Parts Component Description Graphic Part Number Replacement Rec. Qty Critical Frequency Pallet Anti-static brush SP-25210148-PK 1+ Medium (pack of 10) (10-pk) Anti-tip block SP-1060536 Flat wheel and SP-1060558 10 (individual Medium bearing sub- wheels, not assembly sets) V-wheel & bearing SP-1060527 10 (individual Medium...
  • Page 306 Component Description Graphic Part Number Replacement Rec. Qty Critical Frequency Pallet Pallet magnet SP-1060516 5 (if used) (continued) assembly - 3 magnets Magnetic encoder SP-1837179 Very Low strip viewing film (pack of 5) Pallet removal tool SP-25172729 Very Low Circuit Coil driver board SP-25211311 boards...
  • Page 307 Component Description Graphic Part Number Replacement Rec. Qty Critical Frequency Encoder 180 deg. (500mm) SP-1060415 (continued) section LH encoder assembly 180 deg. (800mm) SP-25233511 section LH encoder assembly 180 deg. (800mm) SP-25233529 section center encoder assembly 180 deg. (800mm) SP-25234158 section RH encoder assembly 90 deg.
  • Page 308 Component Description Graphic Part Number Replacement Rec. Qty Critical Frequency Rail Straight upper v-rail - SP-1060390 Very Low 999.5mm Wear strip - SP-1060640 180 deg. (500mm) section transition Wear strip - SP-25284328 180 deg. (800mm) section transition Wear strip - SP-125595093 90 deg.
  • Page 309 Component Description Graphic Part Number Replacement Rec. Qty Critical Frequency Misc. Coil driver fuse SP-4234040-PK Very low (pack of 10) (10-pk) Straight motor cover SP-25194869 180 deg. (500mm) SP-25194872 section motor cover 180 deg. (800mm) SP-25237933 section motor cover 90 deg. section SP-125564940 motor cover IR reader assembly...
  • Page 310 Component Description Graphic Part Number Replacement Rec. Qty Critical Frequency Misc. Motor power supply 25270337 (no mount plate) (continued) Plastic hole plugs; SP-3708389-PK Very Low size 15 (pack of 10) Power supply SP-3708611-PK Very Low 50a fuse (pack of 5) (5-pk) Power supply exhaust SP-0405-0144-...

  • Page 311: Appendix C: Component Data Sheets

    Be sure you are using the most current version of this user manual. The following table summarizes the SuperTrak GEN3 components. Use the cross- references to located the data sheets for each component.
  • Page 312 Appendix C: Component Data Sheets Component Size Option 1 Option 2 Data Sheet 500 mm Standard-height 180 Deg. 180 deg. section Section (500 diameter stands mm) with (narrow) 345 mm (13.58 Standard- in.) Height Stands Data Sheet page 320. Low-profile 180 Deg.
  • Page 313 Appendix C: Component Data Sheets Component Size Option 1 Option 2 Data Sheet SuperTrak GEN3 SuperTrak frame GEN3 Frames on page 344. a. Denotes the standard deliverable. b. The pallet pitch must be >200 mm. See the product specifications for additional in- formation.

  • Page 314: Pallet Data Sheet

    Appendix C: Component Data Sheets Pallet Data Sheet The pallet provides low friction transport with precise product positioning. Features • Variable load is centered by the v-wheels. • Available in four (4) options: • 2-magnet pallet with an IR tag. •...
  • Page 315 Appendix C: Component Data Sheets Dimensions Dimensions for reference only. See SuperTrak Design Package for detailed drawings. SuperTrak™ GEN3 System Operation and Maintenance Manual Rev. 9 (12-2021)
  • Page 316 Appendix C: Component Data Sheets Typical Pallet Wheel Lifespan Pallet Wheel Velocity Rating Distance Upper v-wheels with 50,000 km Up to 4 m/sec <0.050 mm rail lubrication (31,068 mi) (13.1 ft/sec) (<0.0019 in.) wear from radius Lower flat wheels 25,000 km Flat Wheel (15,534 mi) Nominal Dimensions...
  • Page 317 Appendix C: Component Data Sheets Value Specification Applicable For 2-Magnet Assembly 3-Magnet Assembly 1 kg (2.20lb) 40 m/s2 (131.2 ft./s2) Acceleration (max.) payload Pallet Linear Acceleration Vs. Payload on page 308. 10 kg (22.05 lb) 10 m/s2 (32.8 ft./s2) payload Pallet Linear Acceleration Vs.
  • Page 318 Appendix C: Component Data Sheets Value Specification Applicable For 2-Magnet Assembly 3-Magnet Assembly Minimum pitch from Straight section 167 mm (6.57 in.) 200 mm (7.87 in.) center-to-center of (with bumpers) two (2) pallets (as Straight section 154 mm (6.06 in.) 200 mm (7.87 in.) measured along the flat (without bumpers)
  • Page 319 Appendix C: Component Data Sheets Value Specification Applicable For 2-Magnet Assembly 3-Magnet Assembly Weight (without keeper Pallets 2.02 kg (4.45 lbs) 2.4 kg (5.29 lbs) plate) Weight (with keeper Pallets 2.2 kg (1.85 lbs) 2.7 kg (5.95 lbs) plate) a.Values depend on the application. Repeatability axes for straight sections are defined in the graphic below.
  • Page 320 Appendix C: Component Data Sheets Pallet Linear Acceleration Vs. Payload Linear Acceleration vs Payload Straight section - 2 Magnet Pallet Straight section - 3 Magnet Pallet 180deg. (500mm) section - 2 Magnet Pallet 180deg. (500mm) section - 3 Magnet Pallet 180 deg.
  • Page 321 Appendix C: Component Data Sheets Pallet Magnet Recommendations SuperTrak™ GEN3 System Operation and Maintenance Manual Rev. 9 (12-2021)
  • Page 322 Appendix C: Component Data Sheets Pallet Motion at a Constant Velocity A 3* standard deviation for following error is provided to show the +/- positioning tolerance of the pallet 99.7% of the time. Constant Velocity Laser SuperTrak Component (mm/s) Interferometer Encoders (+/- microns) (+/- microns)
  • Page 323 Appendix C: Component Data Sheets Pallet Magnetic Field Strength Measurement Locations 2-Magnet Pallet Magnetic Measurement Values All measurements in the following table are in Gauss units. Pallet Magnetic Field Strength Measurement Locations on page 311 for the magnetic field strength measurement locations, and Frame of Reference on page 3 for a description of X, Y, and Z.
  • Page 324 Appendix C: Component Data Sheets 2-Magnet Pallet Enabled at a 2-Magnet Pallet at Peak Force Standstill Location a. Peak force measurements are captured when the coils are at maximum current. This electromagnetic field is a momentary field that could exist during acceleration at the maximum rate for a given payload.
  • Page 325 Appendix C: Component Data Sheets 3-Magnet Pallet Enabled at 3-Magnet Pallet at Peak Force Standstill Position 1210 1400 1135 a. Peak force measurements are captured when the coils are at maximum current. This electromagnetic field is a momentary field that could exist during acceleration at the maximum rate for a given payload.

  • Page 326: Straight Section With Fme Data Sheet

    Appendix C: Component Data Sheets Straight Section with FME Data Sheet The straight section with front mounted electronics (FME) generates and regulates the electromagnetic field for the pallets. Features • Bevels on the upper v-rail overlap at SuperTrak conveyance platform section transitions to provide a smooth, low-vibration transport surface for pallets.
  • Page 327 Appendix C: Component Data Sheets Dimensions Dimensions for reference only. See SuperTrak Design Package for detailed drawings. Technical Specifications Specification Value 24V digital bus FLA 250mA Accelerating force (max.) • 120 N (with 2-magnet pallets) • 160 N (with 3-magnet pallets) Material Aluminum anodized, stainless steel, polyamide (PA), polycarbonate (PC), epoxy...
  • Page 328 Appendix C: Component Data Sheets Straight Section with FME Certifications Region Certifications North America Certified to UL 61800-5-1:2017 PowerDrive Systems, UL508:2013 & CAN/CSA C22.2 No 14:2013 Industrial Control. European Economic Area EU- Declaration of Conformity per LVD (CE markings) 2014/35/EU: EN 61800-5-1:2017 Power Drive Systems & EN 619:2010 Continuous Handling Equipment 2014/30/EU –...

  • Page 329: Straight Section With Rme Data Sheet

    Appendix C: Component Data Sheets Straight Section with RME Data Sheet The straight section with rear mounted electronics (RME) generates and regulates the electromagnetic field for the pallets. Features • Bevels on the upper v-rail overlap at SuperTrak conveyance platform section transitions to provide a smooth, low-vibration transport surface for pallets.
  • Page 330 Appendix C: Component Data Sheets Dimensions Dimensions for reference only. See SuperTrak Design Package for detailed drawings. SuperTrak™ GEN3 System Operation and Maintenance Manual Rev. 9 (12-2021)
  • Page 331 Appendix C: Component Data Sheets Technical Specifications Specification Value 24V digital bus FLA 250mA Accelerating force (max.) • 120 N (with 2-magnet pallets) • 160 N (with 3-magnet pallets) Material Aluminum anodized, stainless steel, polyamide (PA), polycarbonate (PC), epoxy resin. Peak FLA (Amps) on 28VDC motor bus 100A Voltage...

  • Page 332: Deg. Section (500 Mm) With Standard-Height Stands Data Sheet

    Appendix C: Component Data Sheets 180 Deg. Section (500 mm) with Standard-Height Stands Data Sheet The 180 deg. section with standard-height stands generates and regulates the electromagnetic field for the pallets. Features • Bevels on the upper v-rail overlap at SuperTrak conveyance platform section transitions to provide a smooth, low-vibration transport surface...
  • Page 333 Appendix C: Component Data Sheets Dimensions Dimensions for reference only. See SuperTrak Design Package for detailed drawings. Technical Specifications Specification Value 24V digital bus FLA 500mA Acceleration Pallet Linear Acceleration Vs. Payload on page 308. Material Aluminum anodized, stainless steel, polyamide (PA), polycarbonate (PC), epoxy resin.
  • Page 334 Appendix C: Component Data Sheets 180 Deg. (500 mm) Section Certifications Region Certifications North America Certified to UL 61800-5-1:2017 PowerDrive Systems, UL508:2013 & CAN/CSA C22.2 No 14:2013 Industrial Control. European Economic Area EU- Declaration of Conformity per LVD (CE markings) 2014/35/EU: EN 61800-5-1:2017 Power Drive Systems &...

  • Page 335: Deg. Section (500 Mm) With Low-Profile Stands Data Sheet

    Appendix C: Component Data Sheets 180 Deg. Section (500 mm) with Low-Profile Stands Data Sheet The 180 deg. section with low-profile stands generates and regulates the electromagnetic field for the pallets. Features • Bevels on the upper v-rail overlap at SuperTrak conveyance platform section transitions to provide a smooth, low-vibration transport surface for pallets.
  • Page 336 Appendix C: Component Data Sheets Dimensions Dimensions for reference only. See SuperTrak Design Package for detailed drawings. Technical Specifications Specification Value 24V digital bus FLA 500mA Acceleration Pallet Linear Acceleration Vs. Payload on page 308. Material Aluminum anodized, stainless steel, polyamide (PA), polycarbonate (PC), epoxy resin.
  • Page 337 Appendix C: Component Data Sheets 180 Deg. (500 mm) Section Certifications Region Certifications North America Certified to UL 61800-5-1:2017 PowerDrive Systems, UL508:2013 & CAN/CSA C22.2 No 14:2013 Industrial Control. European Economic Area EU- Declaration of Conformity per LVD (CE markings) 2014/35/EU: EN 61800-5-1:2017 Power Drive Systems &...

  • Page 338: Deg. Section (800 Mm)

    Appendix C: Component Data Sheets 180 Deg. Section (800 mm) The 180 deg. section (800 mm) generates and regulates the electromagnetic field for the pallets. Features • Bevels on the upper v-rail overlap at SuperTrak conveyance platform section transitions to provide a smooth, low-vibration transport surface for pallets.
  • Page 339 Appendix C: Component Data Sheets Dimensions Dimensions for reference only. See SuperTrak Design Package for detailed drawings. NOTE: If desired, the shipping brace (indicated in graphic at right) can be removed from the section after final installation. SuperTrak™ GEN3 System Operation and Maintenance Manual Rev.
  • Page 340 Appendix C: Component Data Sheets Technical Specifications Specification Value 24V digital bus FLA 500mA Acceleration Pallet Linear Acceleration Vs. Payload on page 308. Material Aluminum anodized, stainless steel, polyamide (PA), polycarbonate (PC), epoxy resin. Peak FLA (Amps) on 28VDC motor bus 150A Voltage •...

  • Page 341: 90 Deg. Section

    Appendix C: Component Data Sheets 90 Deg. Section The 90 deg. section generates and regulates the electromagnetic field for the pallets. Features • Bevels on the upper v-rail overlap at SuperTrak conveyance platform section transitions to provide a smooth, low- vibration transport surface for pallets.
  • Page 342 Appendix C: Component Data Sheets Dimensions Dimensions for reference only. See SuperTrak Design Package for detailed drawings. Technical Specifications Specification Value 24V digital bus FLA 250mA Acceleration Pallet Linear Acceleration Vs. Payload on page 308. Material Aluminum anodized, stainless steel, polyamide (PA), polycarbonate (PC), epoxy resin.
  • Page 343 Appendix C: Component Data Sheets 90 Deg. Section Certifications Region Certifications North America Certified to UL 61800-5-1:2017 PowerDrive Systems, UL508:2013 & CAN/CSA C22.2 No 14:2013 Industrial Control. European Economic Area EU- Declaration of Conformity per LVD (CE markings) 2014/35/EU: EN 61800-5-1:2017 Power Drive Systems & EN 619:2010 Continuous Handling Equipment 2014/30/EU –...

  • Page 344: Control Panel Data Sheet

    Appendix C: Component Data Sheets Control Panel Data Sheet The control panel provides controls for monitoring individual modules and pallets. Features • Integration with the automation system safety circuit utilizes dual channel input with a feedback loop via provided terminals. •...
  • Page 345 Appendix C: Component Data Sheets Dimensions Dimensions for reference only. See SuperTrak Design Package for detailed drawings. SuperTrak™ GEN3 System Operation and Maintenance Manual Rev. 9 (12-2021)
  • Page 346 Appendix C: Component Data Sheets Technical Specifications Specification Value Control voltage • 24VDC (digital power supplied from the control panel) • 28VDC (motor power supplied from the power supplies) Frequency 50/60 Hz Full load amps Largest load Line voltage 400Y230VAC+PE 208Y120VAC+PE Materials Steel sheet, lacquered, RAL7024, polyamide (PA)

  • Page 347: Power Supply Data Sheet

    Appendix C: Component Data Sheets Power Supply Data Sheet The power supply supplies power to straight and curved sections. Features • Provides a modular power system; adjust the number of SuperTrak conveyance platform power supplies based on the size and requirements of the system.
  • Page 348 Appendix C: Component Data Sheets Dimensions (with back plate) Dimensions for reference only. See SuperTrak Design Package for detailed drawings. SuperTrak™ GEN3 System Operation and Maintenance Manual Rev. 9 (12-2021)
  • Page 349 Appendix C: Component Data Sheets Dimensions (without back plate) Dimensions for reference only. See SuperTrak Design Package for detailed drawings. Technical Specifications Specification Value Cable length 1500 mm (59.05 in.) Class IP20 Frequency 50/60Hz Main voltage (input) 200-240VAC Efficiency (%) 85% (typical) Material Aluminum, brass, nickel-plated, polyamide (PA), PUR...
  • Page 350 Appendix C: Component Data Sheets Power Supply Certifications Region Certifications* North America Certified to UL 61010-1:2018, CAN/CSAC22.2 No. 61010- 1:2018 & UL 508:2013 Industrial Control. European Economic Area EU- Declaration of Conformity per LVD (CE markings) 2014/35/EU: EN 61010:2010 Safety Electrical Equipment for Measurement, Control.

  • Page 351: Ir Reader Components (Optional) Data Sheet

    Appendix C: Component Data Sheets IR Reader Components (Optional) Data Sheet The infrared (IR) components are optional. The IR reader mount assembly allows for easy installation of the IR reader on a SuperTrak conveyance platform. The IR tags assign a unique pallet ID to each pallet, and the IR reader reads the IR tag on the pallet.
  • Page 352 Appendix C: Component Data Sheets Dimensions Dimensions for reference only. See SuperTrak Design Package for detailed drawings. Technical Specifications Specification Value IR Tag IR Reader Head Assembly Mount Laser Class 1 Mass 0.1 kg (0.2 lbs) 0.3 kg (0.7 lbs) 2.4 kg (5.3 lbs) Material Polyoxymethylene...

  • Page 353: Pallet Setup Tools (Optional) Data Sheet

    Appendix C: Component Data Sheets Pallet Setup Tools (Optional) Data Sheet The pallet setup tools are optional SuperTrak conveyance platform tools that allow you to align and calibrate pallet encoder strips. Features • Provides easy alignment and calibration of pallet encoder strips. •...
  • Page 354 Appendix C: Component Data Sheets Dimensions Dimensions for reference only. See SuperTrak Design Package for detailed drawings. Technical Specifications Specification Value Mass 2.2 kg (4.9 lbs) Material Aluminum, steel SuperTrak™ GEN3 System Operation and Maintenance Manual Rev. 9 (12-2021)

  • Page 355: Pallet Removal Tool (Optional) Data Sheet

    Appendix C: Component Data Sheets Pallet Removal Tool (Optional) Data Sheet The pallet removal tool allows for quick and easy removal of pallets from straight sections or 180 deg. sections. Features • Provides leverage to easily overcome the magnetic forces of the pallets.

  • Page 356: Supertrak Gen3 Frames

    Appendix C: Component Data Sheets SuperTrak GEN3 Frames The SuperTrak GEN3 frames provide a stable adjustable mounting foundation for straight sections and curved sections. Features • Robust welded frame. • Available in six formats to accommodate the different types and widths of track sections.
  • Page 357 Appendix C: Component Data Sheets Part Numbers Part Part Number SuperTrak GEN3 Frame 500 x 1 m 125354246 SuperTrak GEN3 Frame 500 x 2 m 125767467 SuperTrak GEN3 Frame 500 Compact 125354247 SuperTrak GEN3 Frame 800 x 1 m 125721554...
  • Page 358 Appendix C: Component Data Sheets Part Part Number Middle Connection Kit (500) 125354248 End Connection Kit (500) 125354250 Middle Connection Kit (800) 125659677 Straight Section Mounting Kit (500) 125354251 Straight Section Mounting Kit (800) 25249251 Mounting Kit - 180 Deg. Section (500) 125354252 Mounting Kit - 180 Deg.
  • Page 359 Appendix C: Component Data Sheets Dimensions Frame Segment Dimensions SuperTrak GEN3 Frame 500 x 1 m SuperTrak GEN3 Frame 500 x 2 m SuperTrak GEN3 Frame 500 Compact SuperTrak™ GEN3 System Operation and Maintenance Manual Rev. 9 (12-2021)
  • Page 360 800 Compact SuperTrak GEN3 Frame 90 Deg. Dimensions for reference only. See SuperTrak Design Package for detailed drawings. Technical Specifications Value SuperTrak GEN3 frame - 180 Deg. Specification SuperTrak GEN3 frame - 1 m Mount Mass 135 kg (297.6 lbs) 62 kg (136.7 lbs)

  • Page 361: Interconnect Kit (Straight Section To Straight Section)

    Appendix C: Component Data Sheets Interconnect Kit (Straight Section to Straight Section) The interconnect kit provides all the necessary hardware to physically connect two (2) adjacent straight sections with FME mechanically, electrically, and functionally. Features The following items are included: Flat rail Straight-to-straight electrical interconnect Wedge adjust...

  • Page 362: Interconnect (Supertrak Control Panel To Curved Section)

    Appendix C: Component Data Sheets Interconnect (SuperTrak Control Panel to Curved Section) The control panel to curved section interconnect provides the wires that are required between the curved section and the control panel. Gateway Network Connections on page 122. Features The following items are included: Ferrite (1 of 3) Common connection...
  • Page 363 Appendix C: Component Data Sheets Part Numbers Part Part Number 1.2 m control panel to curved section 25240470 interconnect 2 m control panel to curved section 125362696 interconnect 6.5 m control panel to curved section 25221246 interconnect SuperTrak™ GEN3 System Operation and Maintenance Manual Rev.
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  • Page 365: Appendix D: Unit Conversions

    Appendix D: Unit Conversions To Convert Into Multiply By 6.8948 0.068947 inHg 2.03602 0.145038 0.01 inHg 0.295301 14.503773773 100.0 inHg 29.5301 inHg 0.491154 inHg 3.38638816 inHg 0.03386388158 0.3937 2.54 3.2808 0.3048 SuperTrak™ GEN3 System Operation and Maintenance Manual Rev. 9 (12-2021)
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