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SuperTrak™ GEN3 System Operation and Maintenance Manual

Rev. 9 (12-2021)

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251

Communication Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
Pre-Power ON Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
Power Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255

Check Coil Resistance to Find Shorted or Mis-wired Coils . . . . . . . . . . . . . 256

Pallet Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
Test Straight Section or Curved Section Hardware . . . . . . . . . . . . . . 259

Test Encoder Functionality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259

Test the Coil Functionality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260

Test for a Reversed Polarity Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262

Test the Status of the Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265

Test the Rail System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266

Test a Magnetic Shunt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266

Diagnostic Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267

Controller Indicator Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267

Gateway Board (ACB3040) Indicator Lights . . . . . . . . . . . . . . . . . . . . . . . 268

Coil Driver Board (ACB3000) Indicator Lights . . . . . . . . . . . . . . . . . . . . . 270

System Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271

Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271

Environment Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272

Environmental Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272

Installation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273

Electrical Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275

Electromagnetic Compatibility (EMC) Requirements for High-Frequency Emis-

sions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275

Electromagnetic Compatibility (EMC) Requirements for Immunity to Disturbances

276

Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277

SuperTrak Conveyance Platform Service . . . . . . . . . . . . . . . . . . . . . . . . . . 281

Contact ATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281

Return a Part to ATS for Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282

Request Service from ATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283

Appendix A: Hardware Torque Specifications . . . . . . . . . . . . . . . . . . . . . . 285

Appendix B: Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289

Cables and Wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
Other Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293

Summary of Contents for SuperTrak GEN3

Page 1: ...Rev 9 December 2021...

Page 2: ......

Page 3: ...SuperTrak GEN3 Conveyance Platform Modular Conveyor Operation and Maintenance Manual...

Page 4: ...cy or reliability of the content in this document or any documents or websites referenced in this document The content of documents and websites referenced herein are subject to change without notice...

Page 5: ...to supply 1 12 SuperTrak motor power supplies Assy 25270337 c The equipment is not evaluated for use in hazardous classified environments d The equipment is not evaluated for use with flammable liquid...

Page 6: ......

Page 7: ...out and Tagout 11 Lock Prerequisites 11 Tag Prerequisites 11 Lockout and Tagout Locations 12 Label Descriptions 13 Identification Label 13 Marking Labels 13 Mandatory Action Labels 13 Other Labels 14...

Page 8: ...Fine Adjust the Upper V Rail 103 Install an IR Reader Mount Assembly 110 Controls and Connections 113 TrakMaster Software 113 Guarding 114 Energy Controls 115 SuperTrak Conveyance Platform Power Disco...

Page 9: ...a Pallet Magnet Assembly 205 Replace a Pallet Anti Static Brush 206 Adjust a Pallet Shim 207 Replace a Pallet Lubrication Felt 210 Replace a Pallet Spring 211 Replace a Pallet Encoder Strip Assembly 2...

Page 10: ...hts 267 Controller Indicator Lights 267 Gateway Board ACB3040 Indicator Lights 268 Coil Driver Board ACB3000 Indicator Lights 270 System Specifications 271 Performance 271 Environment Conditions 272 E...

Page 11: ...20 180 Deg Section 500 mm with Low Profile Stands Data Sheet 323 180 Deg Section 800 mm 326 90 Deg Section 329 Control Panel Data Sheet 332 Power Supply Data Sheet 335 IR Reader Components Optional Da...

Page 12: ...This page is intentionally blank...

Page 13: ...Notations on page 2 Referenced Terms on page 4 Documentation Package ATS supplies the following documentation and software for the SuperTrak conveyance platform SuperTrak GEN3 Operation and Maintenan...

Page 14: ...reen Courier text indicates software code CAPITALIZED TEXT indicates an operational state for example ON OFF MANUAL mode First Letter Capitalized Text indicates the name of an HMI screen screen menu o...

Page 15: ...e This document describes tooling movement using the following frame of reference The SuperTrak conveyance platform image is for representational purposes only It may not reflect the system you have i...

Page 16: ...Represents the SuperTrak conveyance platform pallet User Represents all levels of SuperTrak conveyance platform users It includes operators maintenance personnel and technicians Operator Represents a...

Page 17: ...Protective Equipment on page 7 Hazardous Energy on page 8 Lockout and Tagout on page 11 Label Descriptions on page 13 Label Locations on page 16 Read this information thoroughly and completely before...

Page 18: ...ectrical wires or circuits Qualified technicians must wear PPE appropriate to the electrical hazard Do not tamper remove or make safety controls ineffective Operators Do not remove guarding covers or...

Page 19: ...ed fuse holders Be prepared to handle electrical fires by keeping dry powder or carbon dioxide extinguishers on hand at all times Verify that all fittings and connections are tight once repair work is...

Page 20: ...wer disconnect switch Use the main power disconnect switch to turn OFF SuperTrak conveyance platform power but maintain UPS power in the control panel Use the SuperTrak conveyance platform power disco...

Page 21: ...n 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...

Page 22: ...lp on page 141 to access the TrakMaster built in help for more information about configuration parameters Allow adequate time for hot surfaces to cool before commencing work Wear the appropriate PPE w...

Page 23: ...g any other key Tag Prerequisites A good tag should Have a clear warning Be easy to read that is legible and understandable Have the identification mark of the person who applied it Be secure enough t...

Page 24: ...ut and tagout the main power disconnect switch when the SuperTrak conveyance platform power must be OFF but the SuperTrak conveyance platform UPS power can be ON Lockout and tagout the main power disc...

Page 25: ...l the SuperTrak conveyance platform will not work properly and damage may occur Marking Labels Mandatory Action Labels Label Label Name Description Ground This label is affixed next to grounded connec...

Page 26: ...rns users of arc flash and shock hazard Follow ALL requirements in NFPA 70E for safe work practices and for Personal Protective Equipment Label number C459 53 Warning UPS Voltage Present This label wa...

Page 27: ...ork in these areas Disconnect power before opening the electrical cabinet working within Close the electrical cabinet before turning the power ON Label number C459 49 Caution Strong Magnetic Field Thi...

Page 28: ...perTrak conveyance platform Pallet Label The pallet has the following label Power Supply Label This power supply has the following label ID Label Location A Caution Strong Magnetic Field Label number...

Page 29: ...ut Label number 6013X ISO See Mandatory Action Labels on page 13 Outside door of the control panel B Read and Understand the Manual Label number 6017X ISO See Mandatory Action Labels on page 13 C Dang...

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Page 31: ...0 SuperTrak Conveyance Platform Components on page 22 Features Some features of the SuperTrak conveyance platform include Integration flexibility works with any programmable logic controller PLC Fast...

Page 32: ...Trak Conveyance Platform Configurations The standard SuperTrak conveyance platform is available in modular sections to allow for various SuperTrak conveyance platform configurations See Appendix C Com...

Page 33: ...ons with low profile stands in a horizontal or vertical also known as over under configuration For this method the SuperTrak conveyance platform is mounted on a plate See Straight Section with RME Dat...

Page 34: ...yance platform includes A Control panel See Encoder Assemblies on page 38 G Pallet setup adjustable chip finder B SuperTrak GEN3 frame H Pallet may also be referred to as a shuttle See Pallet on page...

Page 35: ...rries the customer product from station to station The pallet shelf is customer specific The illustration is provided for reference only C IR tag optional Provides a unique pallet number for each pall...

Page 36: ...her 2 magnet or 3 magnet E Flat wheel 1 of 2 Travels on the flat wear strip of the section F Anti tip block 1 of 2 Protects the pallet during unexpected impact and keeps the pallet on the SuperTrak co...

Page 37: ...ics panel at the front or rear Front mounted electronics FME Rear mounted electronics RME See Straight Section with FME Data Sheet on page 314 and Straight Section with RME Data Sheet on page 317 for...

Page 38: ...Measures the pallet position using encoder read heads See Encoder Assemblies on page 38 for information about encoder numbering D Right encoder assembly E Upper v rail Provides a track for the pallet...

Page 39: ...er board and the right coil driver board are the same The connections to the gateway boards are different so they are referenced as the left or right coil driver board ID Assembly Name Description A E...

Page 40: ...Replace the Main Motor Fuse on page 173 G Common connection B Motor power connection for a power supply H Ribbon cable connection connects to the far left of the coil driver board C Coil fuse 1 of 10...

Page 41: ...rTrak Conveyance Platform Electrical Drawings for additional information The left coil driver board and the right coil driver board are the same The connections to the gateway boards are different so...

Page 42: ...way network port C Ribbon cable connection connects to the top right of the coil driver board I 24V digital power connection D IR reader connection optional J Gateway network port E Ribbon cable conne...

Page 43: ...ection connects to the bottom right of the coil driver board B Thermistor connector 1 of 5 G 24V digital power cable battery backup C Coil connection 1 of 5 two coils for each connection H Gateway net...

Page 44: ...Section 500 mm with Standard Height Stands Data Sheet on page 320 180 Deg Section 500 mm with Low Profile Stands Data Sheet on page 323 and 180 Deg Section 800 mm on page 326 for additional informatio...

Page 45: ...nt earth ground wire The single point earth ground wire is connected from the bottom plate of the 180 deg section to the main electrical panel F Wedge adjust Connects the 180 deg section to a straight...

Page 46: ...Name Description A 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 B Motor Produces the electromagnetic forc...

Page 47: ...Board on page 28 E Gateway board 1 of 2 See Gateway Board on page 30 F Wedge adjust and a magnetic shunt Aligns curved sections to adjacent sections and improves the continuity of the magnetic field G...

Page 48: ...Upper v rail Provides a track on which the the pallet v wheels can travel The upper v rail of the 90 deg section is 1003 3 mm 39 5in in length C Adjustable stand 1 of 3 Allows height adjustment and l...

Page 49: ...earth ground wire is connected from the bottom plate of the 90 deg section to the main electrical panel H Ground cable connection point Points the connection of the ground wire G I Power supply entry...

Page 50: ...y The encoders are used for pallet position feedback Encoder numbering begins at the left side of a left encoder assembly and ends at the right side of the right encoder assembly The following diagram...

Page 51: ...ve 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 The coils are numbered 0 to 19 from left to right...

Page 52: ...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 Lockout and tagout the switch before accessing and...

Page 53: ...ower disconnect switch 3 phase b F Power supply module P Single point ground connection G Breaker enclosure fan Q Terminals H 13A breaker All SuperTrak conveyance platform digital power R Power supply...

Page 54: ...sted If this label does not exist or an unauthorized replacement power supply is used contact ATS for the correct power supply replacement See Power Supply Data Sheet on page 335 and Replace the Main...

Page 55: ...atform is Plug and play External PLC programming is not required See IR Reader Components Optional Data Sheet on page 339 and IR Reader Mount Assembly Optional on page 44 for additional information Th...

Page 56: ...Mount Assembly Optional The infrared IR reader mount assembly is an optional assembly for mounting the IR reader assembly See IR Reader Components Optional Data Sheet on page 339 and Install an IR Re...

Page 57: ...blies See Pallet Setup Tools Optional Data Sheet on page 341 for additional information Station Setup Tools Optional The station setup tools are optional SuperTrak conveyance platform tools that allow...

Page 58: ...This page is intentionally blank...

Page 59: ...veyance platform control panel AC incoming power from the main electrical cabinet North America 208Y120 PE 40A or 20 30A on smaller systems Europe 400Y230 PE 40A or 20 30A on smaller systems Safety ci...

Page 60: ...eyance Platform in an Over Under Configuration on page 64 3 Install the required cable connections See Connections on page 116 4 Verify that the upper v rail is adequately lubricated If required add a...

Page 61: ...wenty 20 locations at the top and bottom of each section join that is indicated by an arrow See step 7 from Connect Two SuperTrak Conveyance Platform Sections Together on page 96 if additional informa...

Page 62: ...ds are parallel the stands allow for Y axis and Z axis adjustment and the stands include the correct hole pattern b Lift the section See Lift a SuperTrak Conveyance Platform Section on page 74 c As re...

Page 63: ...ration and Maintenance Manual 51 Rev 9 12 2021 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 tig...

Page 64: ...ce Manual Rev 9 12 2021 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 adjus...

Page 65: ...t 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 linea...

Page 66: ...and Maintenance Manual Rev 9 12 2021 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 bef...

Page 67: ...SuperTrak GEN3 System Operation and Maintenance Manual 55 Rev 9 12 2021 9 Level the first straight section Place the precision level on the t slot behind the encoder assembly of the straight section w...

Page 68: ...the upper v rails with the first straight section while keeping the section level See Align the SuperTrak Conveyance Platform Section Joints on page 98 and Align the SuperTrak Conveyance Platform Sect...

Page 69: ...e 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 See Fine Adjust the Upper V Rail on page 103 13 Repea...

Page 70: ...traight section and lay a flat bar across it and the opposing straight section Make sure the flat bar rests on the t slot and not the encoder assemblies Level the opposing section with the first secti...

Page 71: ...erify 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 m...

Page 72: ...and Maintenance Manual Rev 9 12 2021 Installation 18 Adjust the vertical horizontal and side to side positions until the upper v rails align with the straight sections and the curved section is cente...

Page 73: ...over form the 180 deg section remove the covers from the 180 deg section stands and then level the 180 deg section For 180 deg 800 mm and 90 deg curved sections Level the curved section a Place a prec...

Page 74: ...n e Use a level to verify that the curved section is level f If the curved section is not level repeat steps 4c 4d g Tighten the upper lock nut 19 Tighten each of the three 3 stands to the custom fram...

Page 75: ...22 for the second curved section 24 Tighten the four 4 screws at the base of each straight section stand 25 For 180 deg 500 mm sections only reinstall the sections top covers and then reinstall the s...

Page 76: ...ses with the slotted cut outs facing up Always use appropriate lifting devices for example a forklift or crane and use safe lifting practices and procedures when lifting a straight or curved section S...

Page 77: ...nual 65 Rev 9 12 2021 3 Install the two 2 180 deg sections a If not already attached install three 3 mounting plates on the bottom of the 180 deg sections with two 2 screws each b Align the 180 deg se...

Page 78: ...ir electrical boxes facing inwards starting with the sections closest to the 180 deg sections 5 Loosely install four 4 screws into each straight section stand base It is very important that the screws...

Page 79: ...Operation and Maintenance Manual 67 Rev 9 12 2021 6 Verify that the following are aligned Upper v rails and flat wear strip pockets Back of the laminations at all joints Fix any major misalignment bef...

Page 80: ...exists between all sections between the track structure or aluminum extrusion not between the linear motors or motor laminations 8 Install the wedge adjust for the 180 deg sections Place the precisio...

Page 81: ...N3 System Operation and Maintenance Manual 69 Rev 9 12 2021 9 Level the straight sections next to the 180 deg sections Place the precision level on the t slot behind the encoder assembly of the straig...

Page 82: ...ust them vertically to align the upper v rails with the other straight sections See Align the SuperTrak Conveyance Platform Section Joints on page 98 and Align the SuperTrak Conveyance Platform Sectio...

Page 83: ...ge adjust screws are loose and measure when the wedge adjust screws are tight 13 Align the upper v rails by adjusting the wedge or adjusting the screws on the inside of the 180 deg section See Fine Ad...

Page 84: ...ch straight section stand base 16 Add wear strip locators to straight sections with the tabs directed towards the center of the each section 17 Install the wear strips to the straight sections See Rep...

Page 85: ...bles are secured to locations indicated by grounding symbol stickers 19 Lift the SuperTrak conveyance platform into position Use correct lifting techniques with straps and a forklift 20 Secure the bas...

Page 86: ...configuration See Lift a 180 Deg Section 800 mm on page 77 Always use appropriate lifting devices and use safe lifting practices when moving a section The following tools are required for this procedu...

Page 87: ...g 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 sect...

Page 88: ...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 str...

Page 89: ...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 Use an appropriate lifting device such as a forklift to lift the 180...

Page 90: ...may be used for conveyors up to 4m long or for sections up to 5m with one e turn The brackets must be positioned to balance the load on each side of the brackets and a spreader bar must be used so tha...

Page 91: ...ed reposition lifting brackets so that the mounting holes needed to attach the conveyor to the frame are accessible Move shackle to the upper of the lifting holes on one side only 3 Lift so that the l...

Page 92: ...Manual Rev 9 12 2021 Installation 5 Lift into vertical position As mentioned previously use of a spreader bar is required 6 Once this change in orientation is complete mount to frame and then remove l...

Page 93: ...les b Align a dowel pin with the cross brace positioning hole Make sure the threaded end is up c Use a mallet to tap the dowel pin through the cross brace hole and into the frame The top of the dowel...

Page 94: ...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 fr...

Page 95: ...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 3 Repeat step 2 for the...

Page 96: ...ligned 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 s...

Page 97: ...a SuperTrak GEN3 Frame 1 Install the 180 deg plate on the frame a Align the 180 deg plate with the frame holes b Install six 6 screws to secure the 180 deg plate in position 2 Lift and position a 180...

Page 98: ...r feet that requires adjustment For more precise measurements remove the top cover from the 180 deg section before leveling b Loosen the upper lock nut c Turn the leveling screw as required to raise o...

Page 99: ...perTrak GEN3 Frame 1 Install the 180 deg 800 mm plate on the frame a Align the 180 deg plate with the frame holes b Install four 4 screws to secure the 180 deg plate in position 2 Lift and position a...

Page 100: ...feet that requires adjustment b Loosen the four 4 screws on each of the three stands c Loosen the upper lock nut d Turn the leveling screw as required to raise or lower the side of the 180 deg sectio...

Page 101: ...Trak GEN3 Frame 1 Install the 90 deg plate on the frame a Align the 90 deg plate with the frame holes NOTE When the overall conveyor arrangement is longer than it is wide orient the mounting plates so...

Page 102: ...ion a 90 deg section on the 90 deg plate 3 Loosely install two 2 lock washers and two 2 screws in each of the three 3 stand bases 4 Level the 90 deg section a Place a precision spirit level across the...

Page 103: ...s c Loosen the upper lock nut d Turn the leveling screw as required to raise or lower the side of the 90 deg section e Use a level to verify that the 90 deg section is level f If the 90 deg section is...

Page 104: ...n the directions illustrated to determine if additional adjustment is required Always use appropriate lifting devices for example a forklift or crane and use safe lifting practices and procedures when...

Page 105: ...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 pla...

Page 106: ...5 Install four 4 screws in the top connection plate to secure it in position NOTE If you are using compact frames to support 180 deg sections use the sup plied stepped dowels to attach the connector k...

Page 107: ...etermine the leveling foot or feet that requires adjustment 2 If installed remove the anchor bolt and hold down toe 3 Loosen the upper lock nut 4 Turn the leveling foot as required to raise or lower t...

Page 108: ...Frame on page 95 5 Loosely install four 4 screws in the top connection plate to secure section B in position Always use appropriate lifting devices for example a forklift or crane and use safe liftin...

Page 109: ...rames 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 sur...

Page 110: ...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 Loosen the four 4 screws on the b...

Page 111: ...n the SuperTrak conveyance platform sections are not aligned The image below illustrates a possible validation process where two 2 indicators are mounted to a pallet to measure the offset between the...

Page 112: ...wn in the photo 2 Place the magnetic shunt into the opening between the two 2 straight sections The magnetic shunt is an iron block that improves the continuity of the magnetic field for shuttle attra...

Page 113: ...SuperTrak conveyance platform sections The magnetic shunt is an iron block that improves the continuity of the magnetic field for shuttle attraction It has no mechanical alignment purpose Slide the m...

Page 114: ...9 12 2021 Installation 4 Loosely install four 4 washers and four 4 screws on the straight section side and then install and tighten two 2 washers and two 2 screws on the side of the 180 deg section No...

Page 115: ...over the upper v rail joint proceed to step 4 otherwise the procedure is complete 4 Determine which section is higher and by how much and then complete one 1 of the following If the upper v rail requ...

Page 116: ...cal 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 Loosen the four 4 wedge screws c Turn the...

Page 117: ...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 Turn the wedge adjustment knob as required to adjust the upper v rai...

Page 118: ...l 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 Turn th...

Page 119: ...quires adjustment a Loosen the four 4 stand screws This allows the stand to shift rather than flex against the rigid stand b Loosen the four 4 wedge screws c Turn the wedge adjustment knob as required...

Page 120: ...the encoder assembly that was removed in step 1 5 Repeat steps 2 to 4 of Fine Adjust the Upper V Rail on page 103 This is a specialized procedure that is not generally required The most important alig...

Page 121: ...he encoder assembly that was removed in step 1 5 Repeat steps 2 to 4 of Fine Adjust the Upper V Rail on page 103 This is a specialized procedure that is not generally required The most important align...

Page 122: ...ght section electrical door Across the joint of two 2 adjacent straight sections This installation location prevents interference with the electrical door of the straight section During this procedure...

Page 123: ...e 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 To prevent joint plat...

Page 124: ...er connection on the gateway board It must be connected to the gateway board of the SuperTrak conveyance platform section that the IR reader is mounted on See Gateway Board on page 30 7 Slide a pallet...

Page 125: ...monitors configures and is used to troubleshoot the SuperTrak conveyance platform The lifespan of some SuperTrak components may be compromised when temperature related TrakMaster configuration parame...

Page 126: ...and should only be opened by a qualified technician A tool is required to unlock and remove a panel and to lock a panel in position These panels are not usually equipped with a safety switch therefore...

Page 127: ...e control panel The UPS provides power to the controller and digital electronics This maintains pallet position information and allows network communications to continue The UPS does not provide motor...

Page 128: ...n page 121 Gateway Network Connections on page 122 Straight Section to Straight Section Connections See Replace an Electrical Interconnect on page 176 Straight Section to 180 Deg Section Connections S...

Page 129: ...nection located inside the control panel provides TrakMaster software communication Any computer for example a laptop or HMI can connect to ETH1 with an Ethernet cable ID Connection Number Connection...

Page 130: ...r drop connection phase orientation does not matter ID Connection Number Connection Type Description A N A N A Main power connection location B N A Main power cable Main power supply incoming port at...

Page 131: ...Trak GEN3 System Operation and Maintenance Manual 119 Rev 9 12 2021 Safety Circuit Connection The SuperTrak conveyance platform is integrated with a system safety circuit in the control panel Wire the...

Page 132: ...wired through the back of the panel and into the 14K1 PLC connection as illustrated ID Connection Number Connection Type Description A N A N A Safety circuit connection location B 206 Reset out Requi...

Page 133: ...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 ID Connection Number Connection Type D...

Page 134: ...erconnect to the controller 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 Et...

Page 135: ...rts and connect from the controller downstream using the right network ports Gateway network cables should never cross one another ID Connection Type Description A N A Left gateway network B N A Right...

Page 136: ...etwork port connected D RJ45 Left network port not connected E RJ45 Right network port connected F N A Right head section G N A Ferrite 1 of 6 H RJ45 F F coupler I RJ45 Ethernet cable right network ca...

Page 137: ...lowing image illustrates some of the gateway network connections The black line through the center of the image joins two 2 images together A Control panel electrical interconnect D Ethernet cable lef...

Page 138: ...t cable not connected D RJ45 Left network port not connected E RJ45 Right network port connected F N A Right head section G N A Left head section H N A Left network patch cable I N A Ferrite 1 of 6 J...

Page 139: ...ons SuperTrak GEN3 System Operation and Maintenance Manual 127 Rev 9 12 2021 Straight Sections with 90 Deg Sections ID Connection Type Description A RJ45 Left network port connected B RJ45 Right netwo...

Page 140: ...cted F N A Right head section G N A Left head section H N A Left network patch cable I N A Ferrite 1 of 6 J RJ45 F F coupler K RJ45 Ethernet cable left network cable from controller connected L RJ45 E...

Page 141: ...ng SuperTrak conveyance platform operating procedures Pre Start Inspection on page 130 Pre Power ON Checks on page 132 SuperTrak Conveyance Platform Power ON Behavior on page 137 SuperTrak Conveyance...

Page 142: ...whereas curved sections may have significant movement For systems where pallet collisions are not acceptable use the PLC code or TrakMaster before startup to determine which sections contain unrecogni...

Page 143: ...d Advanced Firmware 13 Calibrate the encoders See the TrakMaster built in help for the calibration procedure 14 Verify stable motion of a single SuperTrak pallet 1 Install a single SuperTrak pallet on...

Page 144: ...the Motor Power Connection and the Common Connection on page 133 Ground frame and the common connection See Measure the Resistance Between the Ground Frame and the Common Connection on page 134 Commo...

Page 145: ...s shown below 2 Look at the value displayed on the multimeter screen and determine if the resistance is acceptable Pass The value is initially 10 and then slowly rises to 10 This occurs because the ca...

Page 146: ...e 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 1 Fail The value...

Page 147: ...shown below 2 Look at the value displayed on the multimeter screen and determine if the resistance is acceptable Pass The value is initially 500 and then quickly rise to 1000 This occurs because the...

Page 148: ...nd 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 10 Fail...

Page 149: ...yance platform control panel which turns the SuperTrak conveyance platform motor power supplies ON This must only occur when the guard doors are closed and the system is in a safe state to start opera...

Page 150: ...rm determine the pallet ID return the pallets to the stations they left off and continue running If the PLC knows that the line was purged the pallets can all go to the first processing station by def...

Page 151: ...mmediately drops the enable signal to the SuperTrak conveyance platform This causes pallets to decelerate to a controlled stop At the same time the system safety circuit maintains the fail safe output...

Page 152: ...avigate to http atsautomation leapfile com 3 Click File Portal 4 Enter your Login ID and Password and then click Login 5 Click SuperTrak G3 6 Complete one 1 of the following Select the checkbox es of...

Page 153: ...accounts Administrator Programmer Maintenance and Operator All passwords are initially password 4 Click Login If login is successful TrakMaster displays the SuperTrak Connections dialog otherwise Trak...

Page 154: ...orm and notify a service technician Be aware of the speed at which the components function If they appear to move slower than usual or are progressively getting slower maintenance may be required Watc...

Page 155: ...rical Interconnect on page 176 Mechanical Procedures on page 191 Install a Pallet on page 191 Inspect a Pallet on page 195 Replace a Pallet Bumper on page 198 Replace the Pallet Flat Wheels on page 19...

Page 156: ...Trak conveyance platform electrically powered may result in serious injury or death Lock out and tag out all electrical energy sources before part service or replacement See Hazardous Energy on page 8...

Page 157: ...e same for all power supplies on the same system to obtain the correct voltage and power balancing It is recommend to distribute the power supplies as evenly as possible around the SuperTrak conveyanc...

Page 158: ...ounting plate holes c Secure the mounting plate to the frame with four 4 screws d As required remove the black plug in the section before connecting e Proceed to step 5 4 If you are replacing an exist...

Page 159: ...he section 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...

Page 160: ...erconnect and the negative common wire of the power supply with the common connection These two 2 wires both have a white stripe on them e Repeat step 8c f Verify that the wiring is the same as the Le...

Page 161: ...trol panel The control panel can have six 6 or twelve 12 breakers The base control panel includes six 6 with an option to increase to twelve 12 11 As required complete one 1 of the following to connec...

Page 162: ...to the OFF position 2 Lock out and tag hazardous energy See Lockout and Tagout Locations on page 12 3 Use a flat head screwdriver to unlock the five 5 locks and then open the electrical door 4 Unplug...

Page 163: ...secure the coil driver board to the bus bar Note that one 1 screw is nylon This screw is located in the upper left corner of the coil driver board 7 Pull the coil driver board straight down and out a...

Page 164: ...Locations on page 12 3 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 4 Unplug the two 2 ribbon cables Pull each of the four 4...

Page 165: ...itch to the OFF position 2 Lock out and tag hazardous energy See Lockout and Tagout Locations on page 12 3 Use a flat head screwdriver to remove the screws from the electrical door and then set the el...

Page 166: ...w coil driver board to make sure it contains ten 10 15 A fuses 3 Connect the five 5 thermistor connections 4 Align the coil driver board with the screw holes inside the straight section or curved sect...

Page 167: ...12 2021 5 Secure the coil driver board in position with fourteen 14 screws Make sure that the screw in the upper left corner of the coil driver board is nylon and that the coil driver board wires are...

Page 168: ...s 3 Align the coil driver board with the screw holes inside the straight section or 180 deg section 4 Secure the coil driver board in position with fourteen 14 screws Make sure that the screw in the u...

Page 169: ...the lock screws to open the electrical door access Straight section pictured at right there are five lock screws on the access door 180 deg 800 mm section there are two gateway boards one in the right...

Page 170: ...Manual Rev 9 12 2021 Technician Procedures 5 As required unplug one 1 or two 2 motor network connection cables 6 Unplug the four 4 ribbon cables 7 Disconnect the two 2 encoder cables right and left 8...

Page 171: ...9 12 2021 9 Remove the gateway board As illustrated verify that three 3 white plastic spacers are connected to each screw 10 If the gateway board is being returned for repair remove the hardware screw...

Page 172: ...us energy See Lockout and Tagout Locations on page 12 3 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 4 Disconnect the two 2...

Page 173: ...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 If the gateway board is b...

Page 174: ...a Install a toothed washer on each of the four 4 screws b Install flat washer on each of the four 4 screws c Insert each of the four 4 screws through the gateway board d Install three 3 white plastic...

Page 175: ...orking 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 6 Torque each of the four 4 screws to 1...

Page 176: ...s inside the 180 deg section 3 Secure the gateway board in position with four 4 screws 4 Connect the ground wire 5 As required connect one 1 or two 2 motor network connection cables 6 Connect the two...

Page 177: ...conveyance platform fault indicates that replacement is required Remove an Encoder Assembly Straight Section 1 Turn the SuperTrak conveyance platform power disconnect switch to the OFF position 2 Lock...

Page 178: ...Lock out and tag hazardous energy See Lockout and Tagout Locations on page 12 3 Remove the five 5 encoder assembly screw caps Note The images in these instructions show the 180 deg 500 mm section but...

Page 179: ...encoder assembly with the locating dowels 4 To prevent damage to the RJ11 connection make sure it is aligned with the RJ11 opening 5 Press the encoder assembly firmly down onto the locating dowels 6 S...

Page 180: ...2nd 9th thermistors 1 Turn the SuperTrak conveyance platform power disconnect switch to the OFF position 2 Lock out and tag hazardous energy See Lockout and Tagout Locations on page 12 3 Open the sec...

Page 181: ...thermistor connector into the electrical board 9 Route the thermistor wire under the electrical board 10 If required connect any coil connections that were disconnected in step 4 Replace the Outer The...

Page 182: ...which is located through the small hole in the cabinet A is blocked by the electrical interconnect B Remove the electrical interconnect See Replace an Electrical Interconnect on page 176 4 Once the e...

Page 183: ...GEN3 System Operation and Maintenance Manual 171 Rev 9 12 2021 5 Replace the thermistor at the end of the wire 6 Thread the wire with the new thermistor back through the hole in the cabinet 7 Reinsta...

Page 184: ...agout Locations on page 12 3 Remove the 180 deg section top cover 4 Unplug the thermistor connector from the coil driver board 5 Pull the old thermistor wire straight out from the thermistor hole 6 Sl...

Page 185: ...Tagout Locations on page 12 3 As required complete one 1 of the following to access the left coil driver board For all straight 180 deg 800 mm and 90 deg sections Open the electrical door at the base...

Page 186: ...ted correctly The images below indicate correct and incorrect fuse installation Replace a Coil Fuse Straight Section 90 Deg Section or 180 Deg Section 800 mm 1 Turn the SuperTrak conveyance platform p...

Page 187: ...ect any coil connections that were disconnected in step 4 Replace a Coil Fuse 180 Deg Section 500 mm 1 Turn the SuperTrak conveyance platform power disconnect switch to the OFF position 2 Lock out and...

Page 188: ...gh the metal conduit 5 Loosen the strain relief connectors on the side of the two 2 adjacent sections 6 Slide the metal conduit out through the cable access hole Slide the metal conduit to the right s...

Page 189: ...ect switch to the OFF position 2 Lock out and tag hazardous energy See Lockout and Tagout Locations on page 12 3 Access the interior of the sections by For 180 deg 500 mm sections remove screws and wa...

Page 190: ...ectors 4 Feed the required wiring through the metal conduit and connect as required then replace the sections electrical doors and or top covers See Straight Section Left Coil Driver Board on page 28...

Page 191: ...des a left network patch cable not shown an F F coupler and three 3 ferrites Use only ATS approved network cables for connecting the SuperTrak G3 Controller to the first section otherwise the system m...

Page 192: ...ler 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 180 deg 500 mm section remove the top cover to access the mountin...

Page 193: ...2021 b As applicable secure the F F coupler in position using a screw For the 500 mm section the F F coupler installation is as shown at right For 180 deg 800 mm sections the F F coupler installation...

Page 194: ...ed at the bottom For the 180 deg 800 mm section the wire plug is located on the back inside For the 90 deg section the wire plug is located on the back inside at the bottom to the left of center 3 Fee...

Page 195: ...e mounting screw align the common connection wire with the screw hole and then reinstall the mounting screw For the 180 deg 500 mm section the connection is located near the bottom right corner of the...

Page 196: ...nnection is located on the right side of the right coil driver board that is in the left electrical panel 6 As applicable connect the 24 VDC digital power wire DIG to the J17 connector on the gateway...

Page 197: ...ion and Maintenance Manual 185 Rev 9 12 2021 For the 180 deg 800 mm section the connection is located on the gateway board in the left electrical panel For the 90 deg section the connection is located...

Page 198: ...he 180 deg 500 mm section connect the cables on the right side as indicated of the F F coupler For the 180 deg 800 mm section connect the cables to the left side as indicated of the F F coupler For th...

Page 199: ...e opposite from the left network cable For the 180 deg 800 mm section connect the cable opposite from the left network cable For the 90 deg section connect the cable opposite from the left network cab...

Page 200: ...the 180 deg 500 mm section connect the cable opposite from the right network cable For the 180 deg 800 mm section connect the cable opposite from the right network cable For the 90 deg section connec...

Page 201: ...pening 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 Install a ferrite on the end of the lef...

Page 202: ...Technician Procedures 18 Connect the 24VDC digital power wire DIG to X2 111 in the SuperTrak control panel This is a red wire or blue wire depending on the system version 19 Connect the digital shiel...

Page 203: ...erated 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 mate...

Page 204: ...ned at the top of the pallet 5 Hold the pallet removal tool firmly Rest the top left corner of the pallet on the upper v rail of the SuperTrak conveyance platform and then align the anti tip block of...

Page 205: ...the pallet and the implant location The magnetic field may also induce magnetic materials into motion creating potential projectiles or pinch points Various electronic equipment and magnetic data carr...

Page 206: ...imately 15 degrees the magnetic pull decreases and the pallet can be removed from the motor 4 Slide a keeper plate over the pallet magnet assembly with the polycarbonate side of the keeper plate again...

Page 207: ...he anti static brush See Replace a Pallet Anti Static Brush on page 206 Bumpers Verify that all bumpers are installed and compliant with the SuperTrak conveyance platform application If required insta...

Page 208: ...l lubrication felts require lubricant Lubricate the lubrication felt See Lubricate the Pallet Lubrication Felt on page 250 Test the lubrication felt spring compliance Manually push the lubrication fel...

Page 209: ...at wheel and make sure that the spacers are present Check each v wheel for vertical movement If the v wheel does not sit firmly in position tighten the screw at the top of the v wheel See Replace the...

Page 210: ...Remove the pallet from the SuperTrak conveyance platform See Remove a Pallet on page 193 2 Turn the bumper counter clockwise and remove the bumper 3 Align the replacement bumper threads with the bump...

Page 211: ...emove the Pallet Flat Wheels 1 Remove the pallet from the SuperTrak conveyance platform See Remove a Pallet on page 193 2 Loosen the two 2 wheel set screws For ease of disassembly rest the pallet on t...

Page 212: ...the hole in the pallet body 3 Position a dowel over the pallet body hole with the flat side of the shaft facing the set screw 4 Attempt to manually push the shaft in If tight use a mallet to gently ta...

Page 213: ...ents to your process limits and recognize when replacement is necessary See Typical Pallet Wheel Lifespan on page 304 for additional information Remove the Pallet V Wheels 1 Remove the pallet from the...

Page 214: ...cures 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 Repeat step...

Page 215: ...ew v wheel and insert them into the pallet body For ease of assembly rest the pallet on the shoulder screws or upside down on the encoder strip assembly 3 Align the spacer and v wheel holes with the h...

Page 216: ...ocedures 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...

Page 217: ...let 4 While supporting the magnet assembly remove the two 2 or four 4 magnet assembly screws as required 5 Align the new magnet assembly 2 magnet or 3 magnet as required with the pallet dowel holes Th...

Page 218: ...nti Static Brush 1 Remove the pallet from the SuperTrak conveyance platform See Remove a Pallet on page 193 2 Remove the two 2 screws that secure the anti static brush in position 3 Remove the anti st...

Page 219: ...et shim if the gap is outside of the range of 0 5 mm 0 02 in 0 3 mm 0 01 in 1 With the pallet installed measure the gap between the pallet encoder strip assembly and the SuperTrak conveyance platform...

Page 220: ...measure the encoder strip gap Make sure that the encoder strip assembly is secure and flush with the encoder assembly If required replace the encoder strip assembly and then re measure the encoder st...

Page 221: ...m ATS 10 Align the new pallet shim with the pallet dowels and then place in position The shim can only be installed one way 11 Position the pallet encoder strip assembly in position 12 Secure the pall...

Page 222: ...move the pallet from the SuperTrak conveyance platform See Remove a Pallet on page 193 2 Remove the two 2 lubrication locking block screws 3 Remove the lubrication locking block 4 Remove the lubricati...

Page 223: ...er into the pallet Make sure the V groove of the lubrication Felt is horizontal with the pallet V wheels 9 Install the lubrication locking block over the base of the lubrication holder 10 Secure the l...

Page 224: ...veyance platform See Remove a Pallet on page 193 2 Loosen the two 2 set screws on the side of the pallet There is one set screw on each side of the pallet 3 Remove the two 2 screws two 2 lock washers...

Page 225: ...llet 7 Secure the pallet encoder strip assembly in position with two 2 screws two 2 lock washers and two 2 flat washers 8 Align the pallet encoder strip assembly See Adjust the Pallet Encoder Strip As...

Page 226: ...oosen the side thumb screw 2 Loosen the two 2 top thumb screws 3 Lift the station setup removable locate straight up to remove it from the pallet 4 As required complete one of the following procedures...

Page 227: ...ved section The following diagram describes the setup tools that are used during this procedure Improper use of a pallet setup fixture may cause damage to the pallets or tools Do not move or adjust a...

Page 228: ...ion encoder assembly See Center a Pallet Setup Stationary Mount with an Encoder on page 219 4 Verify that the pallet setup stationary mount is in the correct position See Verify the Pallet Setup Stati...

Page 229: ...the 4th encoder from the left 2 Install shims between the encoder assembly and the stationary mount to bias the stationary mount to the back of the t slot In the example on the right a green and white...

Page 230: ...the pallet from left to right along the stationary mount 4 Based on the dial indicator results complete one 1 of the following If the dial indicator measurements are the same on each side of the stati...

Page 231: ...the chip finder with the left side of the stationary mount b Loosely secure the chip finder in position using the thumb screw c Firmly hold the chip finder back and to the left corner crowd and then...

Page 232: ...ide of the stationary mount b Loosely secure the chip finder in position using the thumb screw c Firmly hold the chip finder back and to the left and then tighten the thumb screw 9 For step 3 on the T...

Page 233: ...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 12 Click the first Accept button again to resta...

Page 234: ...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 mou...

Page 235: ...humb screws 2 Lock a pallet in position a Lift the side thumb screw up b Slowly position a pallet with a correctly adjusted encoder assembly under the removable locate This pallet is the master refere...

Page 236: ...m Operation and Maintenance Manual Rev 9 12 2021 Technician Procedures 5 View the value displayed in step 2 on the TrakMaster screen If the stationary mount is good the value should be within 4 micron...

Page 237: ...the encoder that the stationary mount is aligned with 4 Click Capture Live Counts The primary reference values display 5 Click Begin Sweep 6 Remove the pallet from the pallet setup removable locate a...

Page 238: ...n the TrakMaster software expand Diagnostic and then click Encoders 3 Click the Encoder Strip Setup tab 4 View the value below step 2 Adjust the encoder strip bracket on the TrakMaster screen and then...

Page 239: ...two 2 encoder strip assembly screws from step 5 9 Verify that the pallet position did not change see step 4 If the value did change repeat steps 4 to 8 Adjust a Secondary Encoder Strip This procedure...

Page 240: ...ment Make sure the hex key is fully engaged with the screw to avoid stripping the screw head 4 Install an M2 5 x10 mm screw into each side of the pallet encoder strip assembly Do not over tighten the...

Page 241: ...4 the required amount and in the required direction until the value is good green The secondary strip is pinched between the side screws Do not over adjust the screws because it could bend the second...

Page 242: ...assemblies See Remove an Encoder Assembly Straight Section on page 165 4 Remove eleven 11 screws from the upper v rail 5 Note the position of the 0 25 mm 0 01 in shim and then place the shim in a safe...

Page 243: ...of the upper v rail while keeping the back of the upper v rail biased to the structure 6 Reinstall the left and right encoder assemblies See Install an Encoder Assembly Straight and Curved Sections on...

Page 244: ...ils Do not remove them completely but loosening them will make it easier to install the new V rails on the 180 deg 800 section See Remove an Upper V Rail Straight Section on page 230 7 Slide entire cu...

Page 245: ...note of during the removal procedure 5 Install the twenty one 21 screws into the top of the upper v rail while keeping the back of the upper v rail biased to the structure 6 Reinstall the left and ri...

Page 246: ...position of the 0 25 mm 0 01 in shim and then place the shim in a safe location 6 Lifting the section of interest free adjacent V slots between this section and adjacent sections so that the V rail i...

Page 247: ...v rail biased to the structure 6 Reinstall the encoder assemblies on the 90 deg section and adjacent sections See Install an Encoder Assembly Straight and Curved Sections on page 167 Replace an Upper...

Page 248: ...ion and Maintenance Manual Rev 9 12 2021 Technician Procedures 6 Remove eleven 11 screws from the top plate 7 Lift the top plate straight up to remove it 8 Clean the top of the 180 deg section with a...

Page 249: ...180 deg section The top plate must align with features in the top of the 180 deg section To prevent damage to the RJ11 connections make sure the cables are aligned with the RJ11 openings in the top pl...

Page 250: ...with straight and 180 deg 500 mm sections the flat wear strip bridges the join between each SuperTrak conveyance platform section The flat wear strip must be installed before pallets move on the Super...

Page 251: ...in position with permanent magnets Use the magnet to pull the flat wear strip away from the permanent magnets 4 Remove any dirt or debris from the flat wear strip channel See Clean the SuperTrak Conv...

Page 252: ...other b Install a screw to secure the locator in position 4 Align the flat wear strip slot with the locator tab 5 Release the flat wear strip The channel magnets pull the flat wear strip into the chan...

Page 253: ...ips varies slightly depending on the type of curved section as outlined below 180 Deg 500 mm Section 1 Loosen the two 2 screws that secure the flat wear strip adjustment tooling in position 2 Turn the...

Page 254: ...242 SuperTrak GEN3 System Operation and Maintenance Manual Rev 9 12 2021 Technician Procedures 90 Deg Section To align the wear strip use the screws as labeled to adjust the wear strip in and out...

Page 255: ...age 12 3 Peel off the old cover label 4 Clean off any adhesive residue from the motor face Use an adhesive residue cleaner such as Goo Gone to remove the adhesive residue and then clean the motor with...

Page 256: ...s are available Automation Tooling Systems recommends that straight sections be repaired rather than replaced See Appendix B Spare Parts on page 289 Replace a 180 Deg Section Although both options are...

Page 257: ...and must read and understand the SuperTrak conveyance platform process and safety guidelines See Safety Information on page 5 This section provides the following SuperTrak conveyance platform maintena...

Page 258: ...n pull it off Clean the pallet encoder strip See Clean a Pallet Encoder Strip on page 248 Power supply Monthly Inspect Inspect the air filter for dirt and debris If required replace the filter See Rep...

Page 259: ...ropyl alcohol or equivalent 2 Dry with a clean soft cloth or chamois Clean a Control Panel Air Filter Air filters are located on the side of the control panel 1 Carefully remove the front plastic filt...

Page 260: ...s not damaged See Inspect a Pallet Encoder Strip on page 248 Inspect a Pallet Encoder Strip Inspect the encoder strip with magnetic viewing film to verify that the poles appear correctly Each pole sho...

Page 261: ...1 Carefully compress one end of the filter retention clip until one end releases from the power supply cabinet tab 2 Remove the filter retention clip 3 Remove the old filter 4 Clean away any excess g...

Page 262: ...tes the upper v rail Place five 5 to ten 10 drops of lubricant into the lubrication hole at the top of the pallet Determine and maintain a lubrication schedule for your application to ensure that the...

Page 263: ...oller Attempt to retrieve diagnostic information using the following website http controller_IP_address sdm The IP address of the controller is required for this procedure Check the controller LEDs Se...

Page 264: ...nection and ground frame 1 Disconnect and isolate one 1 end of the common bonding jumper located in the 180 deg section that contains the control panel electrical interconnect 2 Use a multimeter to me...

Page 265: ...a motor power connection in the middle of the isolated half of the system 4 Repeat step 2 5 Locate the connection between the motor power connection and the common connection or ground frame A short e...

Page 266: ...system The half of the system with a measurement of 1000 is the half containing the short 3 Disconnect a 24V digital power connection in the middle of the isolated half of the system 4 Repeat step 2 5...

Page 267: ...let acceleration duty cycle or payload are not exceeded Reduce if required The fault indicates the location Check the pallet stability Watch the pallet during operation for abnormal oscillation Contac...

Page 268: ...en the 1st and 2nd pin first and second as counted from the left A resistance range of 0 1 0 6 Ohms indicates that the coil is functioning properly 3 Check the resistance between the 3rd and 4th pin A...

Page 269: ...l is shorted The coils are not serviceable so the motor may need to be returned for repair 6 Measure the resistance between the motor body and the 3rd pin on the terminal block plug Same as prior step...

Page 270: ...ich will trigger a following error See Replace a Coil Fuse on page 174 Check for a damaged upper v rail flat wear strip or motor cover label Pallet lost position Check the encoder strip to make sure t...

Page 271: ...tion to test 5 By hand slowly move a pallet across the section you selected in step 4 As you move the pallet watch the grey Xs on the left side of the screen The Xs beginning with Encoder 0 or 15 depe...

Page 272: ...nerally done by turning the system power ON when the safety circuit is closed 3 Open TrakMaster 4 In the left pane click Advanced Coil Control 5 Click Check All 6 Verify that the section is disabled a...

Page 273: ...splay a Current of 5 00 0 5 9 Click Clear Test Setpoints 10 Enter a value of 5 00 into the Setpoint field 11 Click Apply Test Setpoint To pass each Coil should display a Current of 5 00 0 5 for standa...

Page 274: ...can place the PLC in MANUAL mode and step the system through process steps otherwise see Test Manually with TrakMaster on page 263 1 Open the Global Parameters window in TrakMaster 2 Note the value of...

Page 275: ...emove all pallets from the straight section or 180 deg section to be tested and the sections on each side of it c Position a pallet directly on the right or left side of the section to be tested 2 Ope...

Page 276: ...then click Go 11 With the SuperTrak power supply power ON click Diagnostic Pallet and then click Enable Section for the section being tested and the sections on each side of it Do not enable power to...

Page 277: ...the exception of the 180 deg 800 mm section which has three 3 Each coil driver board has five 5 thermistor connections straight sections and 90 deg sections have ten 10 thermistors while 180 deg 800mm...

Page 278: ...t feel for any resistance in pallet motion 4 Verify that the alignment of the upper v rail is correct between every straight section and between the straight sections and curved sections 5 Verify that...

Page 279: ...he APC910 User s Manual for additional information Indicator Color Light State Normal A Problem May Exist Power Green Solid Blinking A controller hardware problem exists Contact your vendor for assist...

Page 280: ...e Wait several minutes Red Solid A controller software problem exists Contact your vendor for assistance Blinking The gateway board image may not reflect the latest version of the gateway board ID LED...

Page 281: ...the encoder board or in the encoder board cable OFF F 1 STAT a Green ON Blinking very slow The network is not configured Blinking slow The FPGA is not configured Blinking fast The FPGA is ready but in...

Page 282: ...xt does not correlate to the LED function d TEMP stands for temperature Note that the text may not correlate to the LED function Gateway boards that were manufactured before mid 2016 and have not rece...

Page 283: ...cation details Stop repeatability straight section 0 01 mm 0 00039 in Stop repeatability curved sections 0 025 mm 0 001 in Communication EtherNet IP PROFINET POWERLINK and EtherCAT2 2 Other protocols...

Page 284: ...ing 20 to 90 Storage Temperature ambient 25 C 13 F to 55 C 131 F 20 C 4 F to 75 C 167 F Humidity relative 5 to 95 non condensing 20 to 90 Transport Temperature ambient 25 C 13 F to 70 C 158 F 20 C 4 F...

Page 285: ...Horizontal with the access panel facing down Any orientation if mounted inside a sufficient enclosure with adequate cooling Power supply low power Input rating 1 phase x 200 to 240VAC 50 60 Hz Output...

Page 286: ...or vertical over under 180 deg section 800 mm Input rating 28VDC 150A peak Output rating Force of up to 150N pallet Fuses circuit breaker 50A fuses Terminal connection cross section 16 mm2 cables ter...

Page 287: ...ne voltage 208Y120VAC PE Or 400Y230VAC PE Frequency 50 60 Hz Phases 3 ph 5 wire Short circuit current rating 5kA Largest load 20A Control voltage 24VDC digital power supplied from the control panel 28...

Page 288: ...the system will continue to operate as intended without operator interven tion No degradation of performance or loss of function is allowed after the application of the phenomena below a performance l...

Page 289: ...of tooling a sensor or a cylinder Control interface A protocol that provides isolated bi directional communication from the SuperTrak conveyance platform controller to local cell controllers This pro...

Page 290: ...ding automated equipment to prevent access to moving devices and to guard users from potentially hazardous conditions ISO International Organization for Standardization ISO is an international organiz...

Page 291: ...can be used Shuttle A pallet may also be referred to as a shuttle Stand An adjustable metal apparatus that mounts a section to the SuperTrak GEN3 frame Stands may be standard height or low profile Sta...

Page 292: ...igh speed data network TrakMaster Software that provides configuration programming diagnostics and control over a supervisory data network TrakMaster communicates over Ethernet TrakMaster is not requi...

Page 293: ...ce questions or comments regarding the operation or maintenance of your equipment ATS Automation Tooling Systems Inc 730 Fountain Street North Cambridge ON N3H 4R7 Canada Tel 519 653 6500 Fax 519 650...

Page 294: ...g or replacing the part Proceed to step 7 For purchased parts for example motors or amplifiers ATS sends the defective part to the original manufacturer The original manufacturer validates the warrant...

Page 295: ...ATS Post Automation Support if service is required on your SuperTrak conveyance platform Please have the following information available when you call Company name Contact name Contact number Project...

Page 296: ...This page is intentionally blank...

Page 297: ...4 80 Curved section mount plates M10 1 5x40 SHCS Zinc Plated 12 9 912 4 80 M10 O S Washer Zinc Plated 7349 4 M8 1 25x40 SHCS Zinc Plated 12 9 912 8 40 M8 O S Washer Zinc Plated 7349 8 Straight section...

Page 298: ...th Washer Zinc Plated 6797 2 M5 Flat Washer Zinc Plated 125 2 Interconnect com cable M6 1 0x14 SHCS Zinc Plated 12 9 912 2 11 M6 Int Tooth Washer Zinc Plated 6797 2 M6 Flat Washer Zinc Plated 125 2 In...

Page 299: ...M LONG M6X1 0 Thread Black oxide 12 9 7379 2 10 Pallet 2 magnet M6 1 0x20 SHCS Zinc Plated 12 9 912 2 16 Pallet 3 magnet M4 0 7x20 SHCS Zinc Plated 12 9 912 4 4 5 Pallet anti tip blocks M4 0 7x10 SHCS...

Page 300: ...This page is intentionally blank...

Page 301: ...ion and Maintenance Manual 289 Rev 9 12 2021 Appendix B Spare Parts This section provides the recommended spare parts information for the SuperTrak conveyance platform Be aware that the graphics in th...

Page 302: ...cable 548mm SP 1061547 Straight Section FME 180 Degree Section 500mm 180 Degree Section 800mm 90 Degree Section 1 Very Low Yes Encoder cable 700mm SP 125420384 Straight Section RME 1 Very Low Yes The...

Page 303: ...able 152mm SP 1060484 180 Degree Section 500mm 1 Very Low Yes Ribbon cable 241mm SP 1060483 180 Degree Section 500mm 180 Degree Section 800mm 90 Degree Section 1 Very Low Yes Ribbon cable 273mm SP 106...

Page 304: ...Rev 9 12 2021 Appendix B Spare Parts Ribbon cable 130mm SP 125449498 Straight Section RME 1 Very Low Yes Ribbon cable 180mm SP 125422700 Straight Section RME 1 Very Low Yes Description Graphic Part N...

Page 305: ...25210148 PK 1 10 pk Medium Yes Anti tip block SP 1060536 10 Low No Flat wheel and bearing sub assembly SP 1060558 10 individual wheels not sets Medium No V wheel bearing sub assembly SP 1060527 10 in...

Page 306: ...viewing film pack of 5 SP 1837179 1 Very Low No Pallet removal tool SP 25172729 0 Very Low No Circuit boards Coil driver board SP 25211311 2 Low Yes Gateway board SP 25211309 1 Low Yes Encoder Straig...

Page 307: ...00mm section LH encoder assembly SP 25233511 1 Low Yes 180 deg 800mm section center encoder assembly SP 25233529 1 Low Yes 180 deg 800mm section RH encoder assembly SP 25234158 1 Low Yes 90 deg sectio...

Page 308: ...180 deg 500mm section transition SP 1060640 1 Low Yes Wear strip 180 deg 800mm section transition SP 25284328 1 Low Yes Wear strip 90 deg section to 90 deg section transition SP 125595093 1 Low Yes W...

Page 309: ...ery low Yes Straight motor cover SP 25194869 2 Low No 180 deg 500mm section motor cover SP 25194872 1 Low No 180 deg 800mm section motor cover SP 25237933 1 Low No 90 deg section motor cover SP 125564...

Page 310: ...Yes High performance SuperTrak conveyance platform controller N A SP 7325131 1 if used Low Yes a This is the recommended on hand quantity for a base assembly Increase quantities as required for larger...

Page 311: ...arizes the SuperTrak GEN3 components Use the cross references to located the data sheets for each component Component Size Option 1 Option 2 Data Sheet Straight sectiona 1000 mm 39 37 in lengtha No st...

Page 312: ...diameter wide Standard height standsa 345 mm 13 58 in See 180 Deg Section 800 mm on page 326 Pallet 152 mm 5 98 in width 2 magnetsa See Pallet Data Sheet on page 302 3 magnetsb Pallet setup tools See...

Page 313: ...Maintenance Manual 301 Rev 9 12 2021 SuperTrak GEN3 frame See SuperTrak GEN3 Frames on page 344 a Denotes the standard deliverable b The pallet pitch must be 200 mm See the product specifications for...

Page 314: ...t an IR tag See Pallet Magnet Recommendations on page 309 for magnet selection guidance Includes A keeper plate assembly that when installed shields the magnetic field of the magnets when the pallet i...

Page 315: ...Appendix C Component Data Sheets SuperTrak GEN3 System Operation and Maintenance Manual 303 Rev 9 12 2021 Dimensions Dimensions for reference only See SuperTrak Design Package for detailed drawings...

Page 316: ...s with rail lubrication 50 000 km 31 068 mi Up to 4 m sec 13 1 ft sec 0 050 mm 0 0019 in wear from radius See Flat Wheel Nominal Dimensions on page 304 and V Wheel Nominal Dimensions on page 304 for a...

Page 317: ...alues on page 312 and Pallet Magnet Recommendations on page 309 Magnetic force Straight section 860 N 193 34 lbf 1290 N 290 00 lbf 180 deg section 500 mm 19 68 in 430 N 96 67 lbf 645 N 145 00 lbf 180...

Page 318: ...00 mm 7 87 in 90 deg section 163 mm 6 42 in 200 mm 7 87 in Payload Pallets See Pallet Linear Acceleration Vs Payload on page 308 Pallet Linear Acceleration Vs Payload on page 308 and Pallet Magnet Rec...

Page 319: ...n of power consumption to be done with a TrakMaster simulation c Includes process force product fixture mass and product mass The rotation point for the moment load is calculated from the flat wheels...

Page 320: ...ear Acceleration m s 2 Payload kg Center of mass 90mm from the tool mount surface Linear Acceleration vs Payload Straight section 2 Magnet Pallet Straight section 3 Magnet Pallet 180deg 500mm section...

Page 321: ...Appendix C Component Data Sheets SuperTrak GEN3 System Operation and Maintenance Manual 309 Rev 9 12 2021 Pallet Magnet Recommendations...

Page 322: ...he TrakMaster built in Scope feature and an external laser interferometer iii A target is placed at the 0 mm 0 in and 1000 mm 39 37 in position on a straight section Constant Velocity mm s Laser Inter...

Page 323: ...surement Locations on page 311 for the magnetic field strength measurement locations and Frame of Reference on page 3 for a description of X Y and Z 2 Magnet Pallet Enabled at a Standstill 2 Magnet Pa...

Page 324: ...43 23 Q 8 8 23 180 249 221 R 17 3 21 140 268 171 S 13 15 32 180 200 155 a Peak force measurements are captured when the coils are at maximum current This electromagnetic field is a momentary field tha...

Page 325: ...22 38 3 22 39 4 P 22 38 3 22 39 4 Q 116 70 180 1210 270 606 R 250 38 280 1400 450 1135 S 64 65 90 260 96 100 a Peak force measurements are captured when the coils are at maximum current This electrom...

Page 326: ...sitions to provide a smooth low vibration transport surface for pallets Includes Encoders for contact free position tracking of pallets Three 3 8 mm T slots for mounting brackets cable ducts and other...

Page 327: ...ed drawings Technical Specifications Specification Value 24V digital bus FLA 250mA Accelerating force max 120 N with 2 magnet pallets 160 N with 3 magnet pallets Material Aluminum anodized stainless s...

Page 328: ...kconveyance com certifications Region Certifications North America Certified to UL 61800 5 1 2017 PowerDrive Systems UL508 2013 CAN CSA C22 2 No 14 2013 Industrial Control European Economic Area CE ma...

Page 329: ...are mounted in the rear Low profile stands allow for a low profile installation Includes Encoders for contact free position tracking of pallets Eight 8 slots for mounting brackets cable ducts and oth...

Page 330: ...318 SuperTrak GEN3 System Operation and Maintenance Manual Rev 9 12 2021 Appendix C Component Data Sheets Dimensions Dimensions for reference only See SuperTrak Design Package for detailed drawings...

Page 331: ...ss steel polyamide PA polycarbonate PC epoxy resin Peak FLA Amps on 28VDC motor bus 100A Voltage 28 VDC motor 24 VDC digital Weight 41 kg 90 4 lbs without stands 52 kg 114 6 lbs with low profile stand...

Page 332: ...p at SuperTrak conveyance platform section transitions to provide a smooth low vibration transport surface for pallets Mountable in an upright orientation Includes Encoders for contact free position t...

Page 333: ...ak Design Package for detailed drawings Technical Specifications Specification Value 24V digital bus FLA 500mA Acceleration See Pallet Linear Acceleration Vs Payload on page 308 Material Aluminum anod...

Page 334: ...onveyance com certifications Region Certifications North America Certified to UL 61800 5 1 2017 PowerDrive Systems UL508 2013 CAN CSA C22 2 No 14 2013 Industrial Control European Economic Area CE mark...

Page 335: ...upper v rail overlap at SuperTrak conveyance platform section transitions to provide a smooth low vibration transport surface for pallets Mountable in an upright or vertical over under orientation In...

Page 336: ...ak Design Package for detailed drawings Technical Specifications Specification Value 24V digital bus FLA 500mA Acceleration See Pallet Linear Acceleration Vs Payload on page 308 Material Aluminum anod...

Page 337: ...onveyance com certifications Region Certifications North America Certified to UL 61800 5 1 2017 PowerDrive Systems UL508 2013 CAN CSA C22 2 No 14 2013 Industrial Control European Economic Area CE mark...

Page 338: ...at SuperTrak conveyance platform section transitions to provide a smooth low vibration transport surface for pallets Includes Encoders for contact free position tracking of pallets Access hole for pow...

Page 339: ...tion and Maintenance Manual 327 Rev 9 12 2021 Dimensions Dimensions for reference only See SuperTrak Design Package for detailed drawings NOTE If desired the shipping brace indicated in graphic at rig...

Page 340: ...age 308 Material Aluminum anodized stainless steel polyamide PA polycarbonate PC epoxy resin Peak FLA Amps on 28VDC motor bus 150A Voltage 28VDC motor 24VDC digital Weight 109 8 kg 242 lbs Region Cert...

Page 341: ...rTrak conveyance platform section transitions to provide a smooth low vibration transport surface for pallets Includes Encoders for contact free position tracking of pallets Access hole for power supp...

Page 342: ...rak Design Package for detailed drawings Technical Specifications Specification Value 24V digital bus FLA 250mA Acceleration See Pallet Linear Acceleration Vs Payload on page 308 Material Aluminum ano...

Page 343: ...yance com certifications Region Certifications North America Certified to UL 61800 5 1 2017 PowerDrive Systems UL508 2013 CAN CSA C22 2 No 14 2013 Industrial Control European Economic Area CE markings...

Page 344: ...en interface to programmable logic controller PLC PROFINET EtherNet IP EtherCAT or PowerLink Part Number The control panel part number is configurable it consists of five parts A Base Panel B Breaker...

Page 345: ...Appendix C Component Data Sheets SuperTrak GEN3 System Operation and Maintenance Manual 333 Rev 9 12 2021 Dimensions Dimensions for reference only See SuperTrak Design Package for detailed drawings...

Page 346: ...otor power supplied from the power supplies Frequency 50 60 Hz Full load amps 36A Largest load 20A Line voltage 400Y230VAC PE 208Y120VAC PE Materials Steel sheet lacquered RAL7024 polyamide PA Phases...

Page 347: ...power system adjust the number of SuperTrak conveyance platform power supplies based on the size and requirements of the system Includes A 28VDC power output cable An AC power input plug One 1 air fil...

Page 348: ...erTrak GEN3 System Operation and Maintenance Manual Rev 9 12 2021 Appendix C Component Data Sheets Dimensions with back plate Dimensions for reference only See SuperTrak Design Package for detailed dr...

Page 349: ...e for detailed drawings Technical Specifications Specification Value Cable length 1500 mm 59 05 in Class IP20 Frequency 50 60Hz Main voltage input 200 240VAC Efficiency 85 typical Material Aluminum br...

Page 350: ...iled information on SuperTrak component certifications visit https supertrakconveyance com certifications Region Certifications North America Certified to UL 61010 1 2018 CAN CSAC22 2 No 61010 1 2018...

Page 351: ...t Provides data integrity when pallets are manually removed Provides tracking of individual pallets Allows pallet IDs to be read on the fly pallets do not stop at the IR reader assembly Batteries are...

Page 352: ...nsions for reference only See SuperTrak Design Package for detailed drawings Technical Specifications Specification Value IR Tag IR Reader Head Assembly Mount Laser Class 1 Mass 0 1 kg 0 2 lbs 0 3 kg...

Page 353: ...eatures Provides easy alignment and calibration of pallet encoder strips Includes the following tools Pallet setup stationary mount which provides a fixed mounting surface for the pallet setup tools P...

Page 354: ...ntenance Manual Rev 9 12 2021 Appendix C Component Data Sheets Dimensions Dimensions for reference only See SuperTrak Design Package for detailed drawings Technical Specifications Specification Value...

Page 355: ...rom straight sections or 180 deg sections Features Provides leverage to easily overcome the magnetic forces of the pallets Includes two locking latches to safely secure the pallet Part Numbers Dimensi...

Page 356: ...stable mounting foundation for straight sections and curved sections Features Robust welded frame Available in six formats to accommodate the different types and widths of track sections Modular desig...

Page 357: ...Rev 9 12 2021 Part Numbers Part Part Number SuperTrak GEN3 Frame 500 x 1 m 125354246 SuperTrak GEN3 Frame 500 x 2 m 125767467 SuperTrak GEN3 Frame 500 Compact 125354247 SuperTrak GEN3 Frame 800 x 1 m...

Page 358: ...hardware Middle Connection Kit 500 125354248 End Connection Kit 500 125354250 Middle Connection Kit 800 125659677 Straight Section Mounting Kit 500 125354251 Straight Section Mounting Kit 800 25249251...

Page 359: ...nt Data Sheets SuperTrak GEN3 System Operation and Maintenance Manual 347 Rev 9 12 2021 Dimensions Frame Segment Dimensions SuperTrak GEN3 Frame 500 x 1 m SuperTrak GEN3 Frame 500 x 2 m SuperTrak GEN3...

Page 360: ...Package for detailed drawings Technical Specifications SuperTrak GEN3 Frame 800 x 1 m SuperTrak GEN3 Frame 800 Compact SuperTrak GEN3 Frame 90 Deg Value Specification SuperTrak GEN3 frame 1 m SuperTra...

Page 361: ...lly Features The following items are included Part Numbers A Flat rail C Straight to straight electrical interconnect B Wedge adjust D Ethernet network cablea Part Part Number Ethernet network cablea...

Page 362: ...required between the curved section and the control panel See Gateway Network Connections on page 122 Features The following items are included A Ferrite 1 of 3 E Common connection B Left network patc...

Page 363: ...eration and Maintenance Manual 351 Rev 9 12 2021 Part Numbers Part Part Number 1 2 m control panel to curved section interconnect 25240470 2 m control panel to curved section interconnect 125362696 6...

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Page 365: ...ns To Convert Into Multiply By psi kPa 6 8948 psi bar 0 068947 psi inHg 2 03602 kPa psi 0 145038 kPa bar 0 01 kPa inHg 0 295301 bar psi 14 503773773 bar KPa 100 0 bar inHg 29 5301 inHg psi 0 491154 in...

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Summary of Contents for SuperTrak GEN3

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