ATS SuperTrak GEN3

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Table of Contents7
Preface13
Documentation Package13
Official Website13
Style Conventions14
Special Notations14
Frame of Reference15
Referenced Terms16
Safety Information17
Training17
General Safety Rules18
Personal Protective Equipment19
Hazardous Energy20
Electrical20
Mechanical21
Thermal Hazards22
Lockout and Tagout23
Lock Prerequisites23
Tag Prerequisites23
Lockout and Tagout Locations24
Label Descriptions25
Identification Label25
Marking Labels25
Mandatory Action Labels25
Other Labels26
Label Locations28
Supertrak Conveyance Platform Overview31
Features31
Supertrak Conveyance Platform Configurations32
Supertrak Conveyance Platform Components34
Pallet35
Straight Section37
Curved Sections44
Control Panel52
Power Supply54
IR Reader Assembly (Optional)55
IR Reader Mount Assembly (Optional)56
Pallet Setup Tools (Optional)57
Station Setup Tools (Optional)57
Installation59
Prerequisites59
Install the Supertrak Conveyance Platform60
Install the Supertrak Conveyance Platform on a Supertrak GEN3 Frame61
Install the Sections with Custom Stands on a Custom Frame62
Install the Supertrak Conveyance Platform in an Over/Under Configuration76
Lift a Supertrak Conveyance Platform Section86
Install a Supertrak Conveyance Platform Section on a Supertrak GEN3 Frame93
Install the First Supertrak Conveyance Platform Section104
Level the Frame107
Connect Two Supertrak Conveyance Platform Sections Together108
Align the Supertrak Conveyance Platform Section Joints110
Align the Supertrak Conveyance Platform Section Heights111
Install a Wedge Adjust112
Fine-Adjust the Upper V-Rail115
Install an IR Reader Mount Assembly122
Controls and Connections125
Trakmaster Software125
Guarding126
Energy Controls127
Supertrak Conveyance Platform Power Disconnect Switch127
Uninterruptible Power Supply127
Connections128
Straight Section to Straight Section Connections128
Straight Section to 180 Deg. Section Connections128
Deg. Section (500 MM) to Supertrak Control Panel Connection128
Ethernet Port Connection129
Main Power Connection130
Safety Circuit Connection131
PLC Connection132
Ethernet POWERLINK Connection133
Gateway Network Connections134
Operating Procedures141
Pre-Start Inspection142
Pre-Power on Checks144
Supertrak Behavior149
Supertrak Conveyance Platform Power on Behavior149
Supertrak Conveyance Platform Power off Behavior150
Trakmaster Procedures152
Download Trakmaster152
Login to Trakmaster153
Access the Trakmaster Built-In Help153
Monitor the Supertrak Conveyance Platform154
Technician Procedures155
Electrical Procedures156
Install a Power Supply157
Replace a Coil Driver Board162
Replace a Gateway Board169
Replace an Encoder Assembly177
Replace a Motor Thermistor180
Replace the Main Motor Fuse185
Replace a Coil Fuse186
Replace an Electrical Interconnect188
Install an Electrical Interconnect between a Curved Section and a Supertrak Control Panel191
Mechanical Procedures203
Install a Pallet203
Remove a Pallet205
Inspect a Pallet207
Replace a Pallet Bumper210
Replace the Pallet Flat Wheels211
Replace the Pallet V-Wheels213
Replace a Pallet Magnet Assembly217
Replace a Pallet Anti-Static Brush218
Adjust a Pallet Shim219
Replace a Pallet Lubrication Felt222
Replace a Pallet Spring223
Replace a Pallet Encoder Strip Assembly224
Install a Station Setup Fixture226
Remove a Station Setup Fixture226
Align a Pallet Encoder Strip Assembly227
Replace an Upper V-Rail242
Replace a Flat Wear Strip250
Replace a Motor Cover Label255
Replace a Straight Section256
Replace a 180 Deg. Section256
Maintenance257
Scheduled Maintenance257
Supertrak Conveyance Platform Components257
Electrical Enclosure258
Cleaning Procedures259
Clean the Supertrak Conveyance Platform259
Clean a Control Panel Air Filter259
Clean a Pallet Encoder Strip260
Inspect a Pallet Encoder Strip260
Replace a Power Supply Filter261
Lubrication Procedures262
Lubricate the Pallet Lubrication Felt262
Troubleshooting263
Communication Faults263
Pre-Power on Faults264
Power Faults267
Check Coil Resistance to Find Shorted or Mis-Wired Coils268
Pallet Faults270
Test Straight Section or Curved Section Hardware271
Test Encoder Functionality271
Test the Coil Functionality272
Test for a Reversed Polarity Coil274
Test the Status of the Hardware277
Test the Rail System278
Test a Magnetic Shunt278
Diagnostic Lights279
Controller Indicator Lights279
Gateway Board (ACB3040) Indicator Lights280
Coil Driver Board (ACB3000) Indicator Lights282
System Specifications283
Performance283
Environment Conditions284
Environmental Limits284
Installation Requirements285
Electrical Services287
Electromagnetic Compatibility (EMC) Requirements for High-Frequency Emissions287
Electromagnetic Compatibility (EMC) Requirements for Immunity to Disturbances288
Glossary289
Supertrak Conveyance Platform Service293
Contact ATS293
Return a Part to ATS for Warranty294
Request Service from ATS295
Appendix A: Hardware Torque Specifications297
Appendix B: Spare Parts301
Cables and Wires302
Other Spare Parts305
Appendix C: Component Data Sheets311
Pallet Data Sheet314
Straight Section with FME Data Sheet326
Straight Section with RME Data Sheet329
Deg. Section (500 MM) with Standard-Height Stands Data Sheet332
Deg. Section (500 MM) with Low-Profile Stands Data Sheet335
Deg. Section (800 MM)338
90 Deg. Section341
Control Panel Data Sheet344
Power Supply Data Sheet347
IR Reader Components (Optional) Data Sheet351
Pallet Setup Tools (Optional) Data Sheet353
Pallet Removal Tool (Optional) Data Sheet355
Supertrak GEN3 Frames356
Interconnect Kit (Straight Section to Straight Section)361
Interconnect (Supertrak Control Panel to Curved Section)362
Appendix D: Unit Conversions365

ATS SuperTrak GEN3 - Page 2

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