Page 1 Operation and Maintenance Manual SuperTrak™ GEN3 Modular Conveyor Revision: 8 w w w . a t s a u t o m a t i o n . c o m...
Page 3 Operation and Maintenance Manual SuperTrak™ GEN3 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 Pallet Setup Tools (Optional) ......43 Station Setup Tools (Optional) ......43 Installation .
Page 9 Pre-Power ON Checks ........118 Measure the Resistance Between the Motor Power Connection and the Common Connection .
Page 10 Remove a Station Setup Fixture ......189 Align a Pallet Encoder Strip Bracket ..... . . 190 Replace an Upper V-Rail .
Page 11 Contact ATS ........
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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 conveyor: • SuperTrak™ GEN3 Operation and Maintenance Manual • TrackMaster software (with built-in help) • Design package, which includes: •...
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 conveyor 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 conveyor Represents the SuperTrak™ GEN3. TrackMaster Represents the TrackMaster™ software. Power supply Represents the SuperTrak conveyor power supply. Control panel Represents the SuperTrak conveyor control panel. Pallet Represents the SuperTrak conveyor pallet.
Page 17: Safety Information
Read this information thoroughly and completely before operating, or maintaining the SuperTrak conveyor. Training SuperTrak conveyor training packages are available on request. Contact the ATS Technical Services Department for additional information. SuperTrak™ GEN3 System Operation and Maintenance Manual Rev. 8 (03-2020)
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 conveyor contains the following hazardous energy sources: • Electrical on page 8 • Mechanical on page 9 •...
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 TrackMaster 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 conveyor 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 conveyor hazardous energy, complete one (1) of the following: • Lockout and tagout the main power disconnect switch when the SuperTrak conveyor power must be OFF, but the SuperTrak conveyor UPS power can be •...
Page 25: Label Descriptions
Safety Information Label Descriptions Labels are applied throughout the SuperTrak conveyor 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 conveyor 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 conveyor. 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 Conveyor Overview
Sealed system: resistant against debris from harsh environments and liquid- sealed • Low maintenance: has few moving parts Specifications on page 237 for a complete list of SuperTrak conveyor specifications. 1.Higher payloads are possible. Contact ATS with application details. SuperTrak™ GEN3 System Operation and Maintenance Manual Rev. 8 (03-2020)
Page 32: Supertrak Conveyor Configurations
SuperTrak Conveyor Overview SuperTrak Conveyor Configurations The standard SuperTrak conveyor is available in modular sections, to allow for various SuperTrak conveyor configurations. For example: Calculate the Installation Space on page 46 for additional information about the modular SuperTrak conveyor sections. SuperTrak™...
Page 33 SuperTrak Conveyor Overview The SuperTrak conveyor can also be comprised of sections with low stands in a horizontal or vertical (also known as over/under) configuration. For this method, the SuperTrak conveyor is mounted on a plate. For example: Straight Section with RME Data Sheet on page 281, and 180 Deg.
Page 34: Supertrak Conveyor Components
SuperTrak Conveyor Overview SuperTrak Conveyor Components SuperTrak conveyor components are configured, based on the required application. This illustration provides an example of one configuration. It describes the components that a typical SuperTrak conveyor includes. Control panel Pallet Control Panel on page 38. Pallet on page 23.
Page 35: Pallet
SuperTrak Conveyor Overview Pallet The pallet provides a transport platform for carrying production parts along a SuperTrak conveyor. The pallet shelf (not included) is customized for the customer product. Pallet Data Sheet on page 267 for additional information. Pallet - Front View Component Name Description Pallet base...
Page 36 SuperTrak Conveyor Overview Pallet - Back View Component Name Description Encoder strip bracket Contains the encoder strip. V-wheel (1 of 2) Travels on the upper v-rail of the straight 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 Conveyor 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 Conveyor Overview Straight Section - Electrical Door Closed Component Name Description Linear motor Produces the electromagnetic force that propels the pallets. The linear motor includes: • 20 potted coils. • An iron core lamination assembly. Coils on page 33 for information about coil numbering. Electrical door (closed) Encloses the electrical components.
Page 39 SuperTrak Conveyor 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. Assembly Name Description Electrical door (open) Provides access to the straight section circuit boards.
Page 40 SuperTrak Conveyor Overview Left Coil Driver Board • When a low power straight section is installed next to a high power straight section, make sure that a motor power connection is not used. • If the SuperTrak conveyor is programmed with more than one safety circuit (different guard zones), remove the 28VDC motor power connection from the zone boundaries.
Page 41 SuperTrak Conveyor Overview Left Coil Driver Board with a Power Supply Connected • When a low power straight section is installed next to a high power straight section, make sure that a motor power connection is not used. • If the SuperTrak conveyor is programmed with more than one safety circuit (different guard zones), remove the 28VDC motor power connection from the zone boundaries.
Page 42 SuperTrak Conveyor Overview Gateway Board The 24V power consumption of the gateway board for straight sections and 180 deg. sections is 6W. Left encoder cable port Gateway network port Right encoder cable port 24V digital power connection (battery backup) IR reader connection (optional) Gateway network port Ribbon cable connection - connects to Ribbon cable connection - connects to...
Page 43 SuperTrak Conveyor Overview Right Coil Driver Board The left coil driver board and the right coil driver board are the same. The connections to the boards are different, so they are referenced as the “left” or “right” coil driver board. The 180 deg. section also includes a “center”...
Page 44 SuperTrak Conveyor Overview Encoder Brackets Each straight section and 180 deg. section (500 mm) has two (2) encoder brackets: a left encoder bracket and a right encoder bracket. Every encoder bracket has eight (8) encoder read heads, which look like black squares on the top of the encoder bracket.
Page 45 SuperTrak Conveyor Overview Coils Each straight section and each 180 deg. section (500 mm) 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 46: 180 Deg. Section
SuperTrak Conveyor Overview 180 Deg. Section A 180 deg. section provides a 500 mm or 800 mm 180° turning radius for the pallets to travel on. Each SuperTrak conveyor has two (2). 180 Deg. Section (500 mm) with TS Data Sheet on page 283, 180 Deg.
Page 47 SuperTrak Conveyor 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 33 for information about coil numbering. Stand (1 of 3) Mounts the section to the SuperTrak conveyor frame. 180 deg.
Page 48 SuperTrak Conveyor 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 49 SuperTrak Conveyor Overview Component Name Description Ground wire Provides the single point earth ground for the SuperTrak conveyor. Although each SuperTrak conveyor 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 50: 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 conveyor only. It is designed to be integrated with a main electrical panel, and requires a protective earth connection from the main electrical enclosure.
Page 51 SuperTrak Conveyor Overview PLC connection (EtherNet/IP, UPS disconnect EtherCAT, or PROFINET) Bus controller (POWERLINK) SuperTrak conveyor power disconnect switch (3 phase) Power supply module Single point ground connection from the 180 deg. section Breaker - enclosure fan Terminals 13A breaker - All SuperTrak conveyor Power supply breakers (space for 6 or digital power 12 breakers)
Page 52: 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 53: Ir Reader Assembly (Optional)
SuperTrak Conveyor 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 54: Ir Reader Mount Assembly (Optional)
SuperTrak Conveyor 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 295, and Install an IR Reader Mount Assembly on page 98 for additional information.
Page 55: Pallet Setup Tools (Optional)
SuperTrak Conveyor Overview Pallet Setup Tools (Optional) The pallet setup tools are optional SuperTrak conveyor tools that allow you to align and calibrate SuperTrak pallet encoder strips. Pallet setup adjustable chip finder Pallet setup removable locate Pallet setup stationary mount Pallet Setup Tools (Optional) Data Sheet on page 297 for additional information.
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Page 57: Installation
Installation This section describes how to install the SuperTrak conveyor. Prerequisites The following services and components are required to successfully install the SuperTrak conveyor: • A non-compressing installation surface (for example; a concrete floor) • Electrical connections to the SuperTrak conveyor control panel: •...
Page 58: Calculate The Installation Space
Installation Calculate the Installation Space Use the following measurements to calculate the required SuperTrak conveyor installation space. Two Straight Sections with Prolato Frame (1m Linear Module Extension) Image Length Width Height Weight 1 m (3.28 ft) 0.55 m (1.8 ft) 1.1 m (3.6 ft) 272 kg (600 lbs) 180 Deg.
Page 59: Install The Supertrak Conveyor
Installation Install the SuperTrak Conveyor • Make sure the installation is done on a non-compressing surface (for example; concrete), so the sections can be leveled and aligned correctly. • A SuperTrak can contain a maximum of is sixty-two (62) sections: sixty (60) straight sections and two (2) 180 deg.
Page 60: Install The Supertrak Conveyor On A Prolato Base
Installation Install the SuperTrak Conveyor on a Prolato Base 1. Install the SuperTrak conveyor sections on prolato bases. Install the SuperTrak Conveyor on a Prolato Base on page 48. 2. Install the first SuperTrak conveyor section. Install the First SuperTrak Conveyor Section on page 82.
Page 61: Install The Supertrak Conveyor Sections With Custom Stands On A Custom Frame
This section describes how to install SuperTrak conveyor sections on custom stands and a custom frame. ATS stands and an ATS frame are shown for reference. 1. Inspect the frame to verify that it includes the correct features outlined in the SuperTrak conveyor Mechanical Drawings.
Page 62 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 63 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 64 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 65 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 66 Installation 9. Level the first straight section. Place the precision level on the t-slot behind the encoder bracket of the straight section when leveling. SuperTrak™ GEN3 System Operation and Maintenance Manual Rev. 8 (03-2020)
Page 67 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 Conveyor Section Joints on page 87, and Align the SuperTrak Conveyor Section Heights on page 88 for additional information.
Page 68 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 91. 13. Repeat steps 10 to 12 for the remaining sections on the same side of the SuperTrak conveyor.
Page 69 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 brackets. Level the opposing section with the first section. 15.
Page 70 Installation 16. Install the first 180 deg. section. 17. 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 71 Installation 18. Remove the top cover from the 180 deg. section, remove the covers from the 180 deg. section stands, and then level the 180 deg. section. Adjust the vertical, horizontal, and side-to-side positions until the upper v-rails align with the straight sections, and the 180 deg. section is centered between the straight sections.
Page 72 Installation 21. Align the upper v-rails by adjusting the wedge or adjusting the screws on the inside of the 180 deg. section. Fine-Adjust the Upper V-Rail on page 91. 22. Align the lower flat rails with the adjustment features mounted below the E- Turn plate.
Page 73 Installation 28. Install the pallets. Install a Pallet on page 166. 29. If required, fine-adjust the upper v-rail. Fine-Adjust the Upper V-Rail on page 91. SuperTrak™ GEN3 System Operation and Maintenance Manual Rev. 8 (03-2020)
Page 74: Install The Supertrak Conveyor In An Over/Under Configuration
180 deg. section. Lift a SuperTrak Conveyor Section on page 70. 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 conveyor sections.
Page 75 Installation 4. 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. This allows for adjustment when sections are connected together later. 5.
Page 76 Installation 6. 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]). 7. Verify that the following are aligned: •...
Page 77 Installation • Back of the laminations at all joints. Fix any major misalignment before proceeding with fine alignment. 8. Remove the top cover from the 180 deg. section, and level the 180 deg. section. The height of the 180 deg. section is fixed. Adjust the height of the straight sections to align with the 180 deg.
Page 78 Installation 9. Install the wedge adjust for the 180 deg. sections. Place the precision level on the t-slot behind the encoder bracket of the straight section when leveling. Install a Wedge Adjust - 180 Deg. Section on page 90. 10. Level the straight sections next to the 180 deg. sections. Place the precision level on the t-slot behind the encoder bracket of the straight section when leveling.
Page 79 Installation 11. 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 Conveyor Section Joints on page 87, and Align the SuperTrak Conveyor Section Heights on page 88 for additional information.
Page 80 Installation 13. 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. 14. Align the upper v-rails by adjusting the wedge or adjusting the screws on the inside of the 180 deg.
Page 81 Installation 17. Install the lower flat wear strips. Replace a Flat Wear Strip on page 189. 18. Lift the SuperTrak conveyor into position. Use correct lifting techniques with straps and a forklift. 19. Secure the base plate to the mounting frame. 20.
Page 82: Lift A Supertrak Conveyor Section
180 deg. 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 83 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 84 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 85 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 86: Install A Supertrak Conveyor Section On A Prolato Base
180 deg. section. Lift a SuperTrak Conveyor Section on page 70. ATS recommends that you obtain relevant information from your national Health and Safety Authority. This section describes how to install a straight section or a 180 deg. section on a prolato base.
Page 87 Installation 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. Install the first straight section on the frame: a.
Page 88 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 89 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 90 Installation Install a 180 Deg. Section (500 mm) on a Prolato Base 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. plate in position. 2.
Page 91 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 92 Installation Install a Wide 180 Deg. Section (800 mm) on a Prolato Base 1. Install the wide 180 deg. plate on the frame: a. Align the wide 180 deg. plate with the frame holes. b. Install twelve (12) screws to secure the wide 180 deg.
Page 93 Installation 4. Level the wide 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 stand. c.
Page 94: Install The First Supertrak Conveyor Section
180 deg. section. Lift a SuperTrak Conveyor Section on page 70. 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 95 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 96: Level The Frame
Installation Level the Frame To accommodate varying floor heights, the leveling feet of the SuperTrak conveyor 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 97: Connect Two Supertrak Conveyor Sections Together
180 deg. section. Lift a SuperTrak Conveyor Section on page 70. 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 conveyor sections are joined together, remove the upper v-rail from the connecting straight sections.
Page 98 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 99: Align The Supertrak Conveyor Section Joints
Installation Align the SuperTrak Conveyor 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 100: Align The Supertrak Conveyor Section Heights
Installation Align the SuperTrak Conveyor 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 conveyor 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 101: Install A Wedge Adjust
Installation Install a Wedge Adjust The wedge adjust compensates for excess tolerance between SuperTrak conveyor 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 102 Installation Install a Wedge Adjust - 180 Deg. 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 103: 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 104 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 105 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 106 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 107 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 108 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 109 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 110: 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 111 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 112 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 conveyor section that the IR reader is mounted on.
Page 113: Controls And Connections
Controls and Connections This section provides the following information about SuperTrak conveyor controls, and connections: • TrackMaster Software on page 101 • Guarding on page 102 • Energy Controls on page 103 • Connections on page 104 TrackMaster Software The lifespan of some SuperTrak components may be compromised when temperature-related TrackMaster configuration parameters are adjusted from the default value.
Page 114: 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 115: Energy Controls
Controls and Connections Energy Controls This section describes the energy controls on the SuperTrak conveyor. SuperTrak Conveyor 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 116: 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 117: Ethernet Port Connection
Controls and Connections Ethernet Port Connection The Ethernet port (ETH1) connection, located inside the control panel, provides TrackMaster 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 118: 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 119: Safety Circuit Connection
Controls and Connections Safety Circuit Connection The SuperTrak conveyor is integrated with a system safety circuit in the control panel. Wire the safety circuit as illustrated: Before After Connection Connection Description Number Type Safety circuit connection location. Reset out Required contactor safety monitoring connection. 24+ VDC Incoming from the safety circuit (fail safe output).
Page 120: 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: After Before Connection Connection Description Number Type PLC connection location.
Page 121: 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 122: 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 123 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 124 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 125 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 126 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 127: Operating Procedures
Operating Procedures This section provides the following SuperTrak conveyor operating procedures: • Pre-Start Inspection on page 116 • Pre-Power ON Checks on page 118 • SuperTrak Conveyor Power ON Behavior on page 123 • SuperTrak Conveyor Power OFF Behavior on page 124 •...
Page 128: Pre-Start Inspection
Operating Procedures Pre-Start Inspection Before the SuperTrak conveyor power is turned ON for the first time, complete the pre-power ON checks. Pre-Power ON Checks on page 118. In addition, complete one (1) or more of the following to make sure the upper v-rail is adequately lubricated: •...
Page 129 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 110. 10. Confirm that the ETH1 port is used for TrackMaster to communicate with SuperTrak.
Page 130: Pre-Power On Checks
Operating Procedures Pre-Power ON Checks • Before the SuperTrak conveyor power is turned ON for the first time, complete the pre-power ON checks. • If a straight section or 180 deg. section is added or removed, complete the pre-power ON checks. •...
Page 131: Measure The Resistance Between The Motor Power Connection And The Common Connection
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 132: Measure The Resistance Between The Ground (Frame) And The Common Connection
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 133: Measure The Resistance Between The Common Connection And The 24V Digital Power Connection
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 134: Measure The Resistance Between The Motor Power Connection And The 24V Digital Power Connection
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 135: Supertrak Conveyor Power On Behavior
Operating Procedures SuperTrak Conveyor Power ON Behavior The SuperTrak conveyor is typically integrated with a larger automation system. This section describes the SuperTrak conveyor power ON procedure and does not include any steps for the larger system. Each section has two (2) power connections: •...
Page 136: Supertrak Conveyor Power Off Behavior
Operating Procedures Multiple options are available to manage system startup after a cold start, for example: • The PLC can cycle all pallets around the SuperTrak conveyor, determine the pallet ID, return the pallets to the stations they left off, and continue running.
Page 137: Trackmaster Procedures
Operating Procedures TrackMaster Procedures TrackMaster is not required to operate the SuperTrak conveyor; however, it is useful for troubleshooting and configuring the SuperTrak conveyor. TrackMaster is a Windows-based application that monitors, configures, and is used to troubleshoot the SuperTrak conveyor. Download TrackMaster 1.
Page 138: Login To Trackmaster
Operating Procedures Login to TrackMaster 1. Open TrackMaster. 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 139: Monitor The Supertrak Conveyor
Operating Procedures Monitor the SuperTrak Conveyor It is important to be aware of the state of SuperTrak conveyor during operation. When you are aware of how the SuperTrak conveyor correctly works, it is easier to notice when a change occurs. Some things to notice include: •...
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Page 141: Technician Procedures
Technician Procedures This section provides the following technician procedures: • Electrical Procedures on page 129 • Mechanical Procedures on page 166 Electrical Procedures Completing any maintenance procedures with the SuperTrak conveyor electrically powered may result in serious injury or death. Lock out and tag out all electrical energy sources before part service or replacement.
Page 142 Technician Procedures 4. Unplug the two (2) ribbon cables. Pull each of the four (4) ribbon cable plugs straight out. 5. Unplug the five (5) coil plugs. Pull each coil plug straight out. 6. Remove the fourteen (14) screws that secure the coil driver board to the bus bar.
Page 143 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 144 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 145 Technician Procedures Install a Coil Driver Board - Straight Section or 180 Deg. Section (800 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 146 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 147: Replace A Gateway Board
Technician Procedures Replace a Gateway Board This section describes how to replace a gateway board in a straight section or in a 180 deg. section Remove a Gateway Board - Straight Section or 180 Deg. Section (800 mm) To prevent electrical board damage from electrostatic discharge (ESD), use an ESD wrist strap when working with the gateway board.
Page 148 Technician Procedures 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. 9. Remove the gateway board. As illustrated, verify that three (3) white plastic spacers are connected to each screw.
Page 149 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 150 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 151 Technician Procedures Install a Gateway Board - Straight Section or 180 Deg Section (800 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 152 Technician Procedures 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. Depending on how the screws and white spacers bind, it may be necessary to tighten each screw a thread at a time.
Page 153 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 154: Replace An Encoder Bracket
Technician Procedures Replace an Encoder Bracket There are two (2) encoder brackets on each straight section and on each 180 deg. section. Replace the encoder bracket if a SuperTrak conveyor fault indicates that replacement is required. Remove an Encoder Bracket - Straight Section 1.
Page 155 Technician Procedures Remove an Encoder Bracket - 180 Deg. Section 1. Turn the SuperTrak conveyor 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 bracket screw caps. 4.
Page 156 Technician Procedures Install an Encoder Bracket - Straight Section Power to the controller and gateways should OFF while installing encoders, and then turned ON before calibration. 1. If required, remove the old encoder bracket. Remove an Encoder Bracket - Straight Section on page 142.
Page 157: Replace A Motor Thermistor
Technician Procedures Replace a Motor Thermistor A thermistor replacement fault can be set to be ignored in the TrackMaster software. This allows the SuperTrak conveyor to continue to run until the thermistor can be replaced at a convenient time. See the TrackMaster built-in help for additional information. Motor thermistor connections are made with the coil driver boards.
Page 158 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 159 Technician Procedures Replace a Thermistor - 180 Deg. Section (500 mm) There are six (6) thermistors in each 180 deg. section. 1. Turn the SuperTrak conveyor power disconnect switch to the OFF position. 2. Lock out and tag hazardous energy. Lockout and Tagout Locations on page 12.
Page 160: 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 161 Technician Procedures Replace or Install a New Power Supply 1. Turn the SuperTrak conveyor 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: a.
Page 162 Technician Procedures 7. Feed the 28 VDC power output cable through the plug opening (step 3d) and then tighten the connection. 8. Connect the power supply cables to the left coil driver board: a. Remove the screw from the top of the 50A fuse, and the screw from the common connection wire.
Page 163 Technician Procedures Verify that the wiring is the same as the Left Coil Driver Board with a Power Supply Connected on page 29. 9. Feed the AC power input cable through the cable entry plate at the back of the control panel.
Page 164: 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 165: Replace A Coil Fuse
Technician Procedures Replace a Coil Fuse It is possible for the SuperTrak conveyor 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 166 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 167: Install An Electrical Interconnect
Technician Procedures Install an Electrical Interconnect For a wiring overview, see the wiring pin-out overview label located on the electrical door of each straight section and 180 deg. section during this procedure. Other Labels on page 14. Use these procedures to install electrical interconnects during initial system installation: •...
Page 168 Technician Procedures Remove an Electrical Interconnect - Straight Section 1. Turn the SuperTrak conveyor power disconnect switch to the OFF position. 2. Lock out and tag hazardous energy. Lockout and Tagout Locations on page 12. 3. Open the electrical door of the two (2) adjacent straight sections. 4.
Page 169 Technician Procedures Install an Electrical Interconnect Between Two Straight Sections 1. If required, remove the existing electrical interconnect. Remove an Electrical Interconnect - Straight Section on page 156. 2. Slide the metal conduit in through the cable access hole and the two (2) strain relief connectors.
Page 170 Technician Procedures Install an Electrical Interconnect Between a 180 Deg. Section and a SuperTrak Control Panel 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 171 Technician Procedures 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: • For the 500 mm section, remove the top cover to access the mounting location.
Page 172 Technician Procedures 2. As applicable, remove the black wire plug from the 180 deg section: • For the 500 mm section, the wire plug is located at the bottom. • For the 800 mm section, the wire plug is located on the back (inside).
Page 173 Technician Procedures 5. As applicable, connect the common connection wire (COM) to the 180 deg. section. Remove the mounting screw, align the common connection wire with the screw hole, and then reinstall the mounting screw: • For the 500 mm section, the connection is located near the bottom-right corner of the right coil driver board.
Page 174 Technician Procedures 6. As applicable, connect the 24 VDC digital power wire (DIG+) to the J17 connector on the gateway board of the 180 deg. section: • For the 500 mm section, the connection is located on the gateway board inside the section. •...
Page 175 Technician Procedures 7. As applicable, connect the two (2) Ethernet cables (left and right network cables) to the F-F coupler: • For the 500 mm section, connect the cables on the right side of the F-F coupler. • For the 800 mm section, connect the cables to the left side of the F-F coupler.
Page 176 Technician Procedures 10. Verify that a ferrite exists on the end of each gateway network cable entering the 180 deg. section from the adjoining straight section. Make sure each ferrite is within 10 cm (4 in.) of the connector. 11. As applicable, connect the gateway network cable from the adjoining straight section on the right to the F-F coupler: •...
Page 177 Technician Procedures 13. Feed the five (5) cables of the interconnect cable through the plug opening at the back of the SuperTrak control panel. 14. Secure the end of the interconnect cable in the opening of the control panel using the supplied lock nut. 15.
Page 178: Mechanical Procedures
Hazardous Energy on page 8. Some equipment requires periodic adjustment to re-establish the accuracy and desired output of the SuperTrak conveyor. ATS recommends replacing defective devices rather than repairing them. Only qualified technicians should perform maintenance tasks. Install a Pallet •...
Page 179 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 180: 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 181 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 182: 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 conveyor. Inspect the pallet: Pallet Inspection Resolution Component Anti-static Verify that the two (2) screws that...
Page 183 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 185. Verify that the lubrication felt contains Lubricate the lubrication felt.
Page 184 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 180. Visually inspect the magnet assembly for Clean dirt and debris off of the dirt or debris.
Page 185: Replace A Pallet Bumper
Technician Procedures Replace a Pallet Bumper 1. Remove the pallet from the SuperTrak conveyor. Remove a Pallet on page 168. 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 186: 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 269 for additional information. Remove the Pallet Flat Wheels 1.
Page 187 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 bracket.
Page 188: 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 189 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 190 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 bracket.
Page 191 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 192: Replace A Pallet Magnet Assembly
Technician Procedures Replace a Pallet Magnet Assembly 1. Remove the pallet from the SuperTrak conveyor. Remove a Pallet on page 168. 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 193: 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 194: 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 bracket and the SuperTrak conveyor encoder bracket. 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.). 1.
Page 195 Technician Procedures 3. Remove the two (2) outer set screws, located on the side of the pallet. 4. Loosen the two (2) inner set screws, located on the side of the pallet. 5. Remove the two (2) screws, two (2) lock washers, and two (2) flat washers that secure the encoder strip bracket in position.
Page 196 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 197: Replace A Pallet Lubrication Felt
Technician Procedures Replace a Pallet Lubrication Felt 1. Remove the pallet from the SuperTrak conveyor. Remove a Pallet on page 168. 2. Remove the two (2) lubrication locking block screws. 3. Remove the lubrication locking block. 4. Remove the lubrication holder. 5.
Page 198: 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 199: Replace A Pallet Encoder Strip
Technician Procedures Replace a Pallet Encoder Strip Pallet encoder strips can be damaged by magnets. Never clean a pallet encoder strip with a magnet. 1. Remove the pallet from the SuperTrak conveyor. Remove a Pallet on page 168. 2. Loosen the two (2) set screws on the side of the pallet.
Page 200 4. Lift and remove the encoder strip bracket. 5. Obtain a replacement encoder bracket with a new encoder strip mounted. Order this part from ATS. 6. Align the encoder strip bracket that has a new encoder strip with the pallet.
Page 201: 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 202: Align A Pallet Encoder Strip Bracket
Technician Procedures Align a Pallet Encoder Strip Bracket • 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 203 Technician Procedures The following diagram describes the setup tools that are used during this procedure. Pallet setup adjustable chip finder (chip finder) Pallet setup stationary mount (stationary mount) Adjust bock (1 of 2) Top thumb screw (1 of 2) Pallet setup removable locate (removable locate) Side thumb screw 1.
Page 204 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 205 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 206 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 192. 2. Install the chip finder on the left side of the stationary mount: a.
Page 207 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 208 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 209 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 210 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 bracket (master or reference pallet) is required for this procedure. 1.
Page 211 Technician Procedures 5. View the value displayed in step 2 on the TrackMaster 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. 8 (03-2020)
Page 212 Technician Procedures Reference the Encoder Position Complete this procedure to measure the physical distance between two encoders on the straight section encoder bracket. Redo this procedure if an encoder bracket is replaced on a straight section that has a stationary mount installed. 1.
Page 213 Technician Procedures Adjust the Pallet Encoder Bracket (Primary Encoder Strip) For optimal pallet-to-pallet repeatability, make sure all the pallets on the SuperTrak have the same encoder strip value in TrackMaster. It is more important for all pallet encoder strips to be set the same, than for the encoders to be set 0.
Page 214 Technician Procedures 6. On each side of the encoder bracket, 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 bracket. Aim for a pallet position that is within a few microns;...
Page 215 Technician Procedures Adjust a Secondary Encoder Strip During this procedure, do not over-tighten the side screws because it can bend the secondary strip. This procedure describes how to align the secondary encoder strip with the primary encoder strip. Complete this procedure if a pallet is causing faults, and the primary strip alignment has already been verified.
Page 216 Technician Procedures 6. On TrackMaster, 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 TrackMaster screen, and then complete one (1) of secondary strip the following: •...
Page 217: Replace An Upper V-Rail
Technician Procedures Replace an Upper V-Rail Replace the upper v-rail if it becomes damaged. Remove an Upper V-Rail - Straight Section 1. Turn the SuperTrak conveyor power disconnect switch to the OFF position. 2. Lock out and tag hazardous energy. Lockout and Tagout Locations on page 12.
Page 218 Technician Procedures 5. Remove ten (10) screws and ten (10) washers from the top cover of the 180 deg. section, and then lift and remove the top cover. 6. Remove eleven (11) screws from the top plate. 7. Lift the top plate straight up to remove it. 8.
Page 219 Technician Procedures 7. Verify joint alignment on both ends and adjust if necessary. Fine-Adjust the Upper V-Rail on page 91. 8. Calibrate the encoders. See the TrackMaster built-in help for the calibration procedure. Install an Upper V-Rail - 180 Deg. Section (500 mm) 1.
Page 220: 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 conveyor. 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 221 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 222 Technician Procedures 3. If required, install a locator: a. Align the locator with the slot of the SuperTrak conveyor 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 223 Technician Procedures Align a Flat Wear Strip The flat wear strip is not removable on the 180 deg. section. Adjustment tooling, located under the 180 deg. section, provides in-and-out adjustment of the flat wear strip on the 180 deg. section. 1.
Page 224: 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 conveyor logo in the bottom left corner. Replace the motor cover label if it becomes damaged. Remove the Damaged Motor Cover Label 1.
Page 225: Maintenance
Maintenance is an important part of the continued and proper operation of the SuperTrak conveyor. Failure to perform maintenance as required, and in accordance with your ATS contract, voids the warranty. Maintain accurate and complete records regarding SuperTrak conveyor maintenance and any completed service procedures.
Page 226: Electrical Enclosure
Maintenance Component Frequency Task Description Pallets Monthly Inspect Inspect each pallet for wear. Inspect a Pallet on page 170. Monthly, or as Lubricate Add lubricant to the pallet. determined Lubricate the Pallet Lubrication for your Felt on page 219. application Monthly Clean •...
Page 227: Cleaning Procedures
Maintenance Cleaning Procedures This section describes SuperTrak conveyor cleaning procedures. Clean the SuperTrak Conveyor After cleaning the SuperTrak conveyor 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 conveyor frame.
Page 228: 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 229: 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 230: Replace A Straight Section
Maintenance 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 255. Replace a 180 Deg. Section Although both options are available, Automation Tooling Systems recommends that 180 deg.
Page 231: 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.
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Page 233: Troubleshooting
Troubleshooting This section provides the following SuperTrak conveyor troubleshooting procedures for qualified technicians: • Communication Faults on page 221 • Pre-Power ON Faults on page 222 • Power Faults on page 224 • Pallet Faults on page 225 • Test Straight Section or 180 Deg. Section Hardware on page 226 •...
Page 234: 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 235 Troubleshooting Failure Resolution A short exists between the Determine if the short exists between a 24V digital power 24V digital power connection and a common connection or between a 24V digital connection and the common power connection and ground (frame): connection or ground 1.
Page 236: Power Faults
Troubleshooting Power Faults Fault Resolution Motor supply voltage • Make sure the motor power is ON before attempting to enable the SuperTrak conveyor. This is typically a PLC programming error. • Verify that the breakers in the SuperTrak conveyor control panel are ON.
Page 237: 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 170. • 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 238: Test Straight Section Or 180 Deg. Section Hardware
Troubleshooting Test Straight Section or 180 Deg. Section Hardware TrackMaster software is required for most of the straight section or 180 deg. section hardware testing procedures. This section describes how to test the functionality of straight section or 180 deg. section hardware components.
Page 239: 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 240: Test For A Reversed Polarity Coil
Troubleshooting 10. Enter a value of -5.00 into the field. Setpoint 11. Click Apply Test Setpoint. To pass, each should display a of -5.00 ±0.5. This verifies that Coil Current the current control works in both directions. 12. Click Clear Test Setpoints. Test for a Reversed Polarity Coil If a coil is connected backward it will have reversed polarity.
Page 241 Troubleshooting 3. Set the parameter to 50 mm/s. Maximum Velocity 4. Manually step the PLC until a pallet fully-travels the length of the straight section or 180 deg. section to be tested. The hardware passes if the pallet fully-travels the section without producing an fault.
Page 242 Troubleshooting 6. Note the value of the Velocity parameter, so that you can change the value back to this after the test. parameter to 7. Set the Velocity 50 mm/s. 8. Click the Pallet Control tab. 9. Under , select a Move to Target that is past the section to Target...
Page 243: Test The Status Of The Hardware
Troubleshooting Test the Status of the Hardware 1. Open TrackMaster. 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 244: 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 245: Diagnostic Lights
Troubleshooting Diagnostic Lights This section provides information about the indicator lights on the SuperTrak conveyor 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. Indicator Color Light State Normal...
Page 246: 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 247 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 248: 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 249: Specifications
800 µs typical a. Higher payloads are possible. Contact ATS with application details. b. Other protocols are possible. Contact ATS if other protocols are required. c. 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 250: Environment Conditions
Specifications Environment Conditions State Specification Straight Section or 180 Deg. 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 251: Dimensions And Weight
Specifications Dimensions and Weight This section provides the dimensions and weight of the SuperTrak conveyor sections and components. Appendix C: Data Sheets on page 265 for additional information. Two Straight Sections with Prolato Frame (1m Linear Module Extension) Specification Value Length 1 m (3.28 ft) Width...
Page 252: Installation Requirements
Specifications Installation Requirements Service Specification Value Power supply Input rating 1 phase x 200-240VAC (P/N: 25270337) 50/60 Hz Output rating 28VDC 47A continuous 70A peak 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 253: Electrical Services
Specifications Service Specification Value 180 deg. section Input rating 28VDC (800 mm) 150A peak (P/N: 25232698) 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 orientations Electrical Services...
Page 254: Electromagnetic Compatibility (Emc) Requirements For Immunity To Disturbances
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. Discharge through the air to plastic housing parts.
Page 255: Glossary
References a 180 deg. section (500 mm). Gateway network An ATS proprietary network, implemented using standard Ethernet cables; however, it is not Ethernet and should not be connected to Ethernet devices. It connects an array of gateway boards to the controller.
Page 256 Glossary Term Definition International Organization for Standardization ISO is an international organization composed of national standards bodies from over 75 countries. Lockout The placement of a locking device (such as a padlock) on an energy isolating device, in accordance with an established procedure, to make sure that the energy isolating device and the equipment being controlled cannot be operated until the locking device is removed.
Page 257 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 conveyor. The sections typically share a common power supply or multiple power supplies, and communicate with each other over a high speed data network.
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Page 259: Service
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 260: 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 261: Request Service From Ats
Service Request Service from ATS Contact ATS Post Automation Support if service is required on your SuperTrak conveyor. Please have the following information available when you call: • Company name • Contact name • Contact number • Project number See the electrical panel, or front cover of this manual for the project number.
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Page 263: 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 conveyor. 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 Zinc Plated 12.9...
Page 264 Appendix A: Hardware Torque Specifications Location Size Type Finish Class DIN Torque Description (Nm) interconnect 24VDC M5-0.8x14 SHCS Zinc Plated 12.9 motor and cable Int. Zinc Plated 6797 Tooth Washer Flat Zinc Plated Washer Interconnect com M6-1.0x14 SHCS Zinc Plated 12.9 cable Int.
Page 265 Appendix A: Hardware Torque Specifications Location Size Type Finish Class DIN Torque Description (Nm) Pallet - shoulder Shoulder Black 12.9 7379 screw 8MMX10MM Screw - oxide DIA, 10MM LONG, M6X1.0 Thread Pallet - 2-magnet M6-1.0x20 SHCS Zinc Plated 12.9 Pallet - 3-magnet M4-0.7x20 SHCS Zinc Plated 12.9...
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Page 267: 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 conveyor. SuperTrak™ GEN3 System Operation and Maintenance Manual Rev. 8 (03-2020)
Page 268 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) Lubrication felt SP-1060816 Medium Pallet encoder strip SP-1060543 assembly...
Page 269 Component Description Graphic Part Number Replacement Rec. Qty Critical Frequency Pallet V-wheel & bearing SP-1060527 10 (individual Medium (continued) sub-assembly wheels, not sets) Cabling and Encoder cable SP-1061547 Very Low wiring Ethernet network SP-3708400 Very Low cable Ribbon cable - SP-1060325 Very Low straight LH top...
Page 270 Component Description Graphic Part Number Replacement Rec. Qty Critical Frequency Cabling and Ribbon cable - 180 SP-125312033 1 (when Very Low wiring deg. section applicable) (continued) (800 mm) Ribbon cable - 125422331 Very Low straight, driver (465 mm long) (Only applicable for straight sections with RME) Ribbon cable -...
Page 271 Component Description Graphic Part Number Replacement Rec. Qty Critical Frequency Encoder 180 deg. section SP-1060408 (continued) (500 mm) RH encoder assembly 180 deg. section LH SP-1060415 encoder assembly 180 deg. section SP-25233511 (800 mm) LH encoder assembly 180 deg. section SP-25233529 (800 mm) center encoder assembly...
Page 272 Component Description Graphic Part Number Replacement Rec. Qty Critical Frequency Rail Wear strip SP-1060669 (continued) (full length) Wear strip locator SP-1060389 Misc. Coil driver fuse SP-4234040-PK Very low (pack of 10) (10-pk) Digital power cable SP-25194786 Very Low 180 deg. section SP-25194872 motor cover (500 mm)
Page 273 Component Description Graphic Part Number Replacement Rec. Qty Critical Frequency Misc. Frame ground cable - SP-1060437 Very Low 180 deg. section (continued) Frame ground cable - SP-1060655 Very Low straight Gateway board SP-1060614 Very Low ground cable Interconnect tube SP-1061529 Very Low IR reader assembly SP-25202314...
Page 274 Component Description Graphic Part Number Replacement Rec. Qty Critical Frequency Misc. Motor positive cable - SP-1060440 Very Low 180 deg. section (continued) Motor power supply 25270337 (no mount plate) Pallet removal tool SP-25172729 Very Low Plastic hole plugs; SP-3708389-PK Very Low size 15 (pack of 10) Power supply...
Page 275 Component Description Graphic Part Number Replacement Rec. Qty Critical Frequency Misc. High performance SP-4598804 1 (if used) SuperTrak conveyor (continued) controller Straight motor cover SP-25194869 Straight-to-straight SP-1060659 Very Low electrical interconnect Thermistor SP-1061479 Very Low a. This is the recommended on-hand quantity for a base assembly. Increase quantities, as required, for larger SuperTrak conveyors. b.
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Page 277: Appendix C: Data Sheets
Appendix C: Data Sheets The following table summarizes the SuperTrak products. Use the cross-references to located the data sheets for each product: Product Component Size Option 1 Option 2 Data Sheet GEN3 1000 mm Front-mounted Tall stands Straight Straight section (39.37 in.) electronics Section with...
Page 278 Appendix C: Data Sheets Product Component Size Option 1 Option 2 Data Sheet GEN3 Pallet removal Pallet (cont.) tool Removal Tool (Optional) Data Sheet on page 299. Control panel 180 Deg. Section (500 mm) with LS Data Sheet page 285. Power supply Power Supply Data...
Page 279: Pallet Data Sheet
Appendix C: 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. • 2-magnet pallet without an IR tag.
Page 280 Appendix C: Data Sheets Dimensions SuperTrak™ GEN3 System Operation and Maintenance Manual Rev. 8 (03-2020)
Page 281 Appendix C: 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 282 Appendix C: Data Sheets Pallet Shelf Mounting Surface Tolerances Technical Specifications Specification Applicable For Value 2-Magnet Assembly 3-Magnet Assembly Accelerating force of Straight section 120 N (26.97 lbf) 160 N (35.96 lbf) motor (max.) 180 deg. section 60 N (13.48 lbf) 80 N (17.98 lbf) 500 mm (19.68 in.)
Page 283 Appendix C: Data Sheets Specification Applicable For Value 2-Magnet Assembly 3-Magnet Assembly Magnetic field strength 2.5 to 268.0 Gs 3.0 to 1400.0 Gs 2-Magnet Pallet 3-Magnet Magnetic Pallet Magnetic Measurement Values Measurement on page 276, and Values on page 277 Pallet Magnet Pallet Magnet Recommendations...
Page 284 Appendix C: Data Sheets Specification Applicable For Value 2-Magnet Assembly 3-Magnet Assembly Straight section ±0.01 mm (±0.00039 in.) Repeatability (X-axis) Straight section ±0.015 mm (±0.00059 in.) (Y-axis) Straight section ±0.025 mm (±0.00098 in.) (Z-axis) 180 deg. section ±0.025 mm (±0.00098 in.) (X, Y, and Z-axis) Straight section 4 m/s (13.1 ft./s)
Page 285 Appendix C: Data Sheets Pallet Linear Acceleration Vs. Payload Pallet Maximum Velocity Vs. Payload on a 180 deg. Section On a 180 deg section in a vertically mounted system (over/under configuration), the maximum velocity for a 3-magnet pallet with a 4 kg payload with CoM ~90 mm is 2.5 m/s.
Page 286 Appendix C: Data Sheets Pallet Magnet Recommendations The maximum performance for the 180 deg. section in a vertically mounted system (over/under configuration) is 4 kg and 2 m/s. SuperTrak™ GEN3 System Operation and Maintenance Manual Rev. 8 (03-2020)
Page 287 Appendix C: 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) Pallet 2-magnet...
Page 288 Appendix C: 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 276 for the magnetic field strength measurement locations, and Frame of Reference on page 3 for a description of X, Y, and Z.
Page 289 Appendix C: 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 290 Appendix C: 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 291: Straight Section With Fme Data Sheet
Appendix C: 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 conveyor section transitions to provide a smooth, low-vibration transport surface for pallets.
Page 292 Appendix C: Data Sheets Dimensions 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 293: Straight Section With Rme Data Sheet
Appendix C: 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 conveyor section transitions to provide a smooth, low-vibration transport surface for pallets.
Page 294 Appendix C: Data Sheets Dimensions 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 295: 180 Deg. Section (500 Mm) With Ts Data Sheet
Appendix C: Data Sheets 180 Deg. Section (500 mm) with TS Data Sheet The 180 deg. section with TS (tall stands) generates and regulates the electromagnetic field for the pallets. Features • Bevels on the upper v-rail overlap at SuperTrak conveyor section transitions to provide a smooth, low-vibration transport surface for pallets.
Page 296 Appendix C: Data Sheets Dimensions Technical Specifications Specification Value Acceleration Pallet Linear Acceleration Vs. Payload on page 273. Material Aluminum anodized, stainless steel, polyamide (PA), polycarbonate (PC), epoxy resin. Voltage • 28VDC (motor) • 24VDC (digital) Weight 65 kg (143.3 lbs) SuperTrak™...
Page 297: 180 Deg. Section (500 Mm) With Ls Data Sheet
Appendix C: Data Sheets 180 Deg. Section (500 mm) with LS Data Sheet The 180 deg. section with LS (low stands) generates and regulates the electromagnetic field for the pallets. Features • Bevels on the upper v-rail overlap at SuperTrak conveyor section transitions to provide a smooth, low-vibration transport surface for pallets.
Page 298 Appendix C: Data Sheets Dimensions Technical Specifications Specification Value Acceleration Pallet Linear Acceleration Vs. Payload on page 273. Material Aluminum anodized, stainless steel, polyamide (PA), polycarbonate (PC), epoxy resin. Voltage • 28VDC (motor) • 24VDC (digital) Weight 64 kg (141.1 lbs) SuperTrak™...
Page 299: Deg. Section (800 Mm)
Appendix C: 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 conveyor section transitions to provide a smooth, low-vibration transport surface for pallets.
Page 300 Appendix C: Data Sheets Dimensions SuperTrak™ GEN3 System Operation and Maintenance Manual Rev. 8 (03-2020)
Page 301 Appendix C: Data Sheets Technical Specifications Specification Value Acceleration Pallet Linear Acceleration Vs. Payload on page 273. Material Aluminum anodized, stainless steel, polyamide (PA), polycarbonate (PC), epoxy resin. Voltage • 28VDC (motor) • 24VDC (digital) Weight 109.8 kg (242 lbs) SuperTrak™...
Page 302: Control Panel Data Sheet
Appendix C: Data Sheets Control Panel Data Sheet The control panel provides controls for monitoring individual modules and pallets. Features • System-specific emergency stop safety circuits can be implemented into the existing safety switching device accessories. • Available in two (2) options: •...
Page 303 Appendix C: Data Sheets Dimensions 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 304: Power Supply Data Sheet
Appendix C: Data Sheets Power Supply Data Sheet The power supply supplies power to straight sections and 180 deg. sections. Features • Provides a modular power system; adjust the number of SuperTrak conveyor power supplies based on the size and requirements of the system.
Page 305 Appendix C: Data Sheets Dimensions (with back plate) SuperTrak™ GEN3 System Operation and Maintenance Manual Rev. 8 (03-2020)
Page 306 Appendix C: Data Sheets Dimensions (without back plate) Technical Specifications Specification Value Cable length 1500 mm (59.05 in.) Class IP20 Frequency 50/60Hz Main voltage (input) 200-240VAC Material Aluminum, brass, nickel-plated, polyamide (PA), Max. number of power supplies Application-dependent Max. power 1500W Power supply (output) 28VDC...
Page 307: Ir Reader Components (Optional) Data Sheet
Appendix C: 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 conveyor. The IR tags assign a customized pallet ID to each pallet, and the IR reader tracks pallet positions. Features •...
Page 308 Appendix C: Data Sheets Dimensions 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 polyoxymethylene Aluminum, (POM) (POM), brass, anodized, steel nickel-plated, PVC SuperTrak™...
Page 309: Pallet Setup Tools (Optional) Data Sheet
Appendix C: Data Sheets Pallet Setup Tools (Optional) Data Sheet The pallet setup tools are optional SuperTrak conveyor tools that allow you to align and calibrate pallet encoder strips. Features • Provides easy alignment and calibration of pallet encoder strips. •...
Page 310 Appendix C: Data Sheets Dimensions Technical Specifications Specification Value Mass 2.2 kg (4.9 lbs) Material Aluminum, steel SuperTrak™ GEN3 System Operation and Maintenance Manual Rev. 8 (03-2020)
Page 311: Pallet Removal Tool (Optional) Data Sheet
Appendix C: 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 312: Prolato Bases (Frames)
Appendix C: Data Sheets Prolato Bases (Frames) The prolato base provides a stable adjustable mounting base for straight sections and 180 deg. sections. Features • Solidly welded frame. • Available in two (2) versions: • 1 m for mounting straight sections or 180 deg.
Page 313 Appendix C: Data Sheets Dimensions Technical Specifications Specification Value Prolato Base - 1 m Prolato Base - 180 Deg. Mount Mass 135 kg (297.6 lbs) 62 kg (136.7 lbs) Material Steel lacquered RAL7024, zinc die casting, steel, galvanized SuperTrak™ GEN3 System Operation and Maintenance Manual Rev.
Page 314: Interconnect Kit (Straight Section To Straight Section)
Appendix C: 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 Ethernet network cable...
Page 315: Interconnect (Supertrak Control Panel To 180 Deg. Section)
Appendix C: Data Sheets Interconnect (SuperTrak Control Panel to 180 Deg. Section) The control panel to 180 deg. section interconnect provides the wires that are required between the 180 deg. section and the control panel. Gateway Network Connections on page 110. Features The following items are included: Ferrite (1 of 3)
Page 316 Appendix C: Data Sheets Part Numbers Part Part Number 1.2 m control panel to 180 deg. section 25240470 interconnect 2 m control panel to 180 deg. section 125362696 interconnect 6.5 m control panel to 180 deg. section 25221246 interconnect SuperTrak™ GEN3 System Operation and Maintenance Manual Rev.
Page 317: 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. 8 (03-2020)
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