ATS SuperTrak GEN3 User manual

Rev. 9, December 2021

SuperTrak™ GEN3 Conveyance Platform
Modular Conveyor
Operation and
Maintenance Manual

NOTICES
COPYRIGHT AND TRADEMARKS
© ATS Automation Tooling Systems Inc. All rights reserved.
ATS™ and, the ATS™ logo, SuperTrak™, TrakMaster™ and other names and logos related to companies, products and services of ATS
Automation Tooling Systems Inc. (ATS) and its affiliates are trademarks or service marks of ATS and its affiliates.
Windows® is a registered trademark of Microsoft Corporation, GOO GONE® is a registered trademark of Weiman Products, LLC. Other
third-party company and product names mentioned herein may be trademarks of their respective companies.
No license or other right in any trademark, service mark or other intellectual property is granted in this document.
REFERENCES
References in this document to products or services of third parties and links to third-party websites or information are provided solely as a
convenience to you and do not in any way constitute or imply ATS’s endorsement, sponsorship, or recommendation of the third party,
information, product, or service. ATS is not responsible for the content of any third-party documents or websites and does not make any
representation regarding the content or accuracy of such materials. If you decide to use any such third-party materials, or third-party
products or services, you do so entirely at your own risk.
GRAPHICS
All drawings, illustrations, and photographs included in this document are provided to expand and enhance the text. These graphics are
representations only and are not necessarily drawn to scale. For accurate drawings, see the Mechanical Drawing Package and Electrical
Drawing Package supplied to you.
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.
While ATS attempts to ensure that all information in this document is accurate and reliable, ATS assumes no obligation to update the
content in this document or advise on further developments concerning the subject matter mentioned. ATS does not warrant or make any
representation concerning the accuracy 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. ATS is not responsible for
printing or clerical errors.
CONDITIONS OF ACCEPTABILITY FOR CERTIFICATION
Track Module Assembly (Straight & Curved Sections)
a. Models are evaluated as an integrated component and intended to be a scalable interconnected system provided inline protection
fuse(s) are installed on the Bus connection and power supply lines. End user/integrator shall recognize ampacity limits of the bus bar
interconnect conductors per the National Electrical Code.
b. Models are to be powered by a certified SuperTrak motor power supply Assy / 25270337.
c. Models are evaluated with an optional accessory cable “Control Panel to Section Interconnect” Assy / 25240470 1.2 m, Assy /
125362696 2.0 m or Assy / 25221246 6.5 m (user can adjust the length of the 6.5 m).
d. The equipment is not evaluated for use in hazardous (classified) environments.
e. The equipment is not evaluated for use with flammable liquids or materials.
f. The equipment has been investigated for continuous operation at a maximum operating ambient temperature of 40°C at an altitude
up to 2000 m and relative humidity levels from 5-90%, non-condensing.
g. The equipment has been evaluated for indoor use in pollution degree 2 environments.
h. The equipment is to be installed by qualified personal in accordance with local and national installation/wiring requirements.
i. The motor’s epoxy resin (potting) is not investigated for flammability (UL94).
j. Emergency stop, disconnect devices for the SuperTrak system are provided via the mains supply to the SuperTrak motor power
supply. Integration and validation of system-wide emergency stops are the responsibility of the end user/integrator.
k. Functional Safety requirements are the responsibility of the end user/integrator of this component.
SuperTrak Motor Power Supply
a. SuperTrak power supply is evaluated as an integrated component and intended to be a scalable interconnected system provided
inline protection fuse(s) are installed on the bus connection and power supply lines. End user/integrator shall recognize ampacity
limits of the bus bar interconnect conductors per the National Electrical Code.
b. A suitable cable is to be provided for the plug/socket component (industrial twist lock) for connecting the mains supply.
c. SuperTrak motor power supply is for use only with a SuperTrak track module Assy (1060387 or 1060391) & SuperTrak 180 deg.
section Assy 1060638.

d. SuperTrak motor power supply is powered from an ATS SuperTrak conveyance platform control panel Assy / 25202161 or from other
appropriate power source with certified (North American listed) overcurrent protection, 10A UL489 breaker, type CC fuses or Type J
fuses.
e. The equipment is not evaluated for use in hazardous (classified) environments.
f. The equipment is not evaluated for use with flammable liquids or materials.
g. The equipment has been investigated for continuous operation at a maximum operating ambient temperature of 40°C at an altitude
up to 2000 m and relative humidity levels from 5-90%, non-condensing. All permitted mounting orientations. See Permitted mounting
orientations on page 273.
h. The equipment has been evaluated for indoor use in pollution degree 2 environments.
i. The equipment is to be installed by qualified personal in accordance with local and national installation/wiring requirements.
j. Emergency Stop, disconnect devices for the SuperTrak system are provided via the mains supply to the SuperTrak motor power
supply. Integration and validation of system-wide emergency stops are the responsibility of the end user/integrator.
k. 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.
b. SuperTrak GEN3 conveyor control panel is evaluated with scalable supply branches 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 liquids or materials.
e. The equipment has been investigated for continuous operation at a maximum operating ambient temperature of 40°C at an altitude of
up to 2000 m and relative humidity levels from 5-90%, non-condensing.
f. The equipment has been evaluated for indoor use in pollution degree 2 environments.
g. The equipment is to be installed by qualified personal in accordance with local and national installation/wiring requirements.
Adequate ground/bond connection is to be provided to the remote connected SuperTrak motor power supplies (<100mohms tested at
10Amps or greater).
h. Emergency stop, disconnect devices for the SuperTrak system are provided within this control panel. Integration and validation of
system-wide emergency stops are the responsibility of the end user/integrator.
i. Functional safety requirements are the responsibility of the end user/integrator of this component and the integrated system that
consists of the ATS SuperTrak conveyance platform system.
Model Variations:
Certified models SuperTrak GEN3 track module Assy / 1060387 or 1060391 are also represented as 8FZAM1.0A.A000-1 / SuperTrak
straight segment. Models are further supplemented by EN standards as models 25220499.
Certified model SuperTrak GEN3 180 deg section Assy / 1060638 is also represented as 8FZAM2.0A.A000-1 / SuperTrak curve segment.
Certified model SuperTrak motor power supply Assy / 25270337 is also represented as 8FZAP0.00.0100-1 / SuperTrak motor power
supply. Modes are further supplemented by EN standards as models 25195828, 25270354.

SuperTrak™ GEN3 System Operation and Maintenance Manual i
Rev. 9 (12-2021)
Table of Contents
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Documentation Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Official Website . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Style Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special Notations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Frame of Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Referenced Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
General Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Personal Protective Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Hazardous Energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Thermal Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Lockout 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
Label Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
SuperTrak Conveyance Platform Overview . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
SuperTrak Conveyance Platform Configurations . . . . . . . . . . . . . . . . . 20
SuperTrak Conveyance Platform Components . . . . . . . . . . . . . . . . . . . 22
Pallet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Straight Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Curved Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
IR Reader Assembly (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
IR Reader Mount Assembly (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Pallet Setup Tools (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Station Setup Tools (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

ii SuperTrak™ GEN3 System Operation and Maintenance Manual
Rev. 9 (12-2021)
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Install the SuperTrak Conveyance Platform . . . . . . . . . . . . . . . . . . . . 48
Install the SuperTrak Conveyance Platform on a SuperTrak GEN3 Frame . . . . . . . . . 49
Install the Sections with Custom Stands on a Custom Frame . . . . . . . . . . . . . . . . . 50
Install the SuperTrak Conveyance Platform in an Over/Under Configuration . . . . . . . 64
Lift a SuperTrak Conveyance Platform Section . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Install a SuperTrak Conveyance Platform Section on a SuperTrak GEN3 Frame . . . . . 81
Install the First SuperTrak Conveyance Platform Section . . . . . . . . . . . . . . . . . . . . 92
Level the Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Connect Two SuperTrak Conveyance Platform Sections Together . . . . . . . . . . . . . . 96
Align the SuperTrak Conveyance Platform Section Joints . . . . . . . . . . . . . . . . . . . . 98
Align the SuperTrak Conveyance Platform Section Heights . . . . . . . . . . . . . . . . . . . 99
Install a Wedge Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
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 Disconnect Switch . . . . . . . . . . . . 115
Uninterruptible Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Straight Section to Straight Section Connections . . . . . . . . . . . . . . . . . . . 116
Straight Section to 180 Deg. Section Connections . . . . . . . . . . . . . . . . . . 116
180 Deg. Section (500 mm) to SuperTrak Control Panel Connection . . . . . 116
Ethernet Port Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Main Power Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Safety Circuit Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
PLC Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Ethernet POWERLINK Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Gateway Network Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Operating Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Pre-Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Pre-Power ON Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
SuperTrak Behavior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
SuperTrak Conveyance Platform Power ON Behavior . . . . . . . . . . . . . . . . 137
SuperTrak Conveyance Platform Power OFF Behavior . . . . . . . . . . . . . . . . 138
TrakMaster Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Download TrakMaster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Login to TrakMaster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Access the TrakMaster Built-in Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Monitor the SuperTrak Conveyance Platform . . . . . . . . . . . . . . . . . . 142

SuperTrak™ GEN3 System Operation and Maintenance Manual iii
Rev. 9 (12-2021)
Technician Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Electrical Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Install a Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Replace a Coil Driver Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Replace a Gateway Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Replace an Encoder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Replace a Motor Thermistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Replace the Main Motor Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Replace a Coil Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Replace an Electrical Interconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Install an Electrical Interconnect Between a Curved Section and a SuperTrak
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Mechanical Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Install a Pallet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Remove a Pallet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
Inspect a Pallet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
Replace a Pallet Bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Replace the Pallet Flat Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
Replace the Pallet V-Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Replace 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 . . . . . . . . . . . . . . . . . . . . . . . . . 212
Install a Station Setup Fixture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Remove a Station Setup Fixture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Align a Pallet Encoder Strip Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Replace an Upper V-Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
Replace a Flat Wear Strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
Replace a Motor Cover Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
Replace a Straight Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
Replace a 180 Deg. Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
SuperTrak Conveyance Platform Components . . . . . . . . . . . . . . . . . . . . . 245
Electrical Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
Cleaning Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
Clean the SuperTrak Conveyance Platform . . . . . . . . . . . . . . . . . . . . . . . 247
Clean a Control Panel Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
Clean a Pallet Encoder Strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
Inspect a Pallet Encoder Strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
Replace a Power Supply Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
Lubrication Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
Lubricate the Pallet Lubrication Felt . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250

iv 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

SuperTrak™ GEN3 System Operation and Maintenance Manual v
Rev. 9 (12-2021)
Appendix C: Component Data Sheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
Pallet Data Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
Straight Section with FME Data Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . 314
Straight Section with RME Data Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . 317
180 Deg. Section (500 mm) with Standard-Height Stands Data Sheet . . . . 320
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) Data Sheet . . . . . . . . . . . . . . . . . . . . . 339
Pallet Setup Tools (Optional) Data Sheet . . . . . . . . . . . . . . . . . . . . . . . . 341
Pallet Removal Tool (Optional) Data Sheet . . . . . . . . . . . . . . . . . . . . . . . 343
SuperTrak GEN3 Frames . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
Interconnect Kit (Straight Section to Straight Section) . . . . . . . . . . . . . . . 349
Interconnect (SuperTrak Control Panel to Curved Section) . . . . . . . . . . . . 350
Appendix D: Unit Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353

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SuperTrak™ GEN3 System Operation and Maintenance Manual 1
Rev. 9 (12-2021)
Preface
This section provides the following SuperTrak conveyance platform documentation
package information:
•Documentation Package on page 1
•Official Website on page 1
•Style Conventions on page 2
•Special Notations on page 2
•Referenced Terms on page 4
Documentation Package
ATS supplies the following documentation and software for the SuperTrak
conveyance platform:
• SuperTrak™ GEN3 Operation and Maintenance Manual
• TrakMaster™ software (with built-in help)
• Design package, which includes:
• Electrical drawings
• Mechanical drawings
Official Website
The SuperTrak website, www.supertrakconveyance.com , provides resources such
as case studies, certification information, videos, and blog posts.

2 SuperTrak™ GEN3 System Operation and Maintenance Manual
Rev. 9 (12-2021)
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.
•Bold text indicates a button or control that requires action during a procedure.
•Grey Courier text indicates on-screen messages; for example, a fault or
warning message on an HMI screen.
•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,
or HMI message.
• Bulleted list indicates items where order is not relevant.
• Numbered list indicates a step-by-step procedure where order is relevant.
Special Notations
This document uses five (5) levels of notation:
Warns that failure to comply results in death or serious injury.
Warns that failure to comply could result in death or serious injury.
Warns that failure to comply could result in minor or moderate injury.
Warns that failure to comply may result in property damage.

Provides additional information, emphasizes a point, or provides a tip.

Preface
SuperTrak™ GEN3 System Operation and Maintenance Manual 3
Rev. 9 (12-2021)
Frame of Reference
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 installed.
• The direction of travel on each axis (positive or negative) varies
based on configuration.

4 SuperTrak™ GEN3 System Operation and Maintenance Manual
Rev. 9 (12-2021)
Preface
Referenced Terms
This section defines terms that are used throughout this document.
See Glossary on page 277 for additional definitions.
Term Description
SuperTrak conveyance
platform
Represents the SuperTrak™ GEN3.
TrakMaster Represents the TrakMaster™ software.
Power supply Represents the SuperTrak conveyance platform power supply.
Control panel Represents the SuperTrak conveyance platform control panel.
Pallet Represents the SuperTrak conveyance platform pallet.
User Represents all levels of SuperTrak conveyance platform users. It
includes operators, maintenance personnel, and technicians.
Operator Represents a user with basic mechanical knowledge.
Maintenance
Personnel
Represents a user with knowledge about routine cleaning, and
lubrication procedures. They are expected to complete adjustments
that are within validated ranges.
Technician Represents a user that specializes in a discipline such as electrical,
mechanical, or programming. They are expected to complete
complex SuperTrak conveyance platform procedures; such as,
replacement procedures or adjustments that are outside of validated
ranges.

SuperTrak™ GEN3 System Operation and Maintenance Manual 5
Rev. 9 (12-2021)
Safety Information
This section provides the following important safety information:
•Training on page 5
•General Safety Rules on page 6
•Personal 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 operating, or maintaining
the SuperTrak conveyance platform.
Training
SuperTrak conveyance platform training packages are available on request.
Contact the ATS Technical Services Department for additional information.

6 SuperTrak™ GEN3 System Operation and Maintenance Manual
Rev. 9 (12-2021)
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.
• Understand and be aware of potential energy sources that exist in the
SuperTrak conveyance platform after lockout and tagout (for example; the
strong permanent magnets when pallets are removed from the SuperTrak
conveyance platform).
• Long hair must be tied up and kept away from SuperTrak conveyance platform
devices to prevent entanglement.
• Do not wear loose clothing or dangling jewelry while operating or maintaining
the equipment, to prevent entanglement.
• Wear the appropriate personal protective equipment (PPE) for each task.
• Stay away and do not touch any live electrical 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 shields. Procedures that involve removing
guarding, covers or shields must only be performed by a trained, qualified
technician.
• Do not operate damaged equipment. Safety and protection features are
impaired in damaged equipment. Turn OFF energy sources immediately. Do not
use the automated equipment until a trained, qualified technician confirms it is
safe to operate.
Technicians:
• Do not perform service work alone. Only attempt internal service or
adjustments in the presence of a person capable of rendering first aid.
• Read the current SuperTrak™ GEN3 Operation and Maintenance Manual
before troubleshooting or servicing the equipment.
• Guarding, covers, or shields must not be removed, except for emergency or
maintenance purposes.
• If guarding is removed, clearly communicate (for example, with signs or
barriers) that the guarding is not functional.
• Guarding around moving devices that has been removed, must be replaced.

Safety Information
SuperTrak™ GEN3 System Operation and Maintenance Manual 7
Rev. 9 (12-2021)
• 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.
• Remove electrical power before changing fuses, or use approved fuse-pullers.
• Never use jumper wires or fuse substitutes to replace fuses.
• Replace the line fuses with fuses of the same voltage, current rating, and type.
Do not use repaired fuses or short-circuited 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 complete.
• Do not use compressed air to clean SuperTrak conveyance platform devices.
Use clean, lint-free cloths or a vacuum cleaner. Compressed air causes dirt and
lubricants to become airborne and contaminate assembly products and tooling.
Personal Protective Equipment
At a minimum, all users are recommended to wear the following personal
protective equipment (PPE) when working with or around the SuperTrak
conveyance platform:
• Safety glasses that meet the specific standard requirements the local
jurisdiction:
• North America - ANSI Z87.1
• Europe - EN 166 F
• Safety shoes that meet the specific standard requirements the local
jurisdiction:
• North America - ASTM F2413
• Europe - EN ISO 20345 S1

8 SuperTrak™ GEN3 System Operation and Maintenance Manual
Rev. 9 (12-2021)
Safety Information
Hazardous Energy
Any energy source that presents a risk of injury to a person working on equipment
is considered a hazardous energy source. The SuperTrak conveyance platform
contains the following hazardous energy sources:
•Electrical on page 8
•Mechanical on page 9
•Thermal Hazards on page 10
To prevent accidental or unauthorized start-ups, always lockout and tagout
hazardous energy before completing any service or maintenance procedures.
Lockout and tagout procedures control hazardous energy supplies, making the
SuperTrak conveyance platform inoperable.
See Lockout and Tagout on page 11.
Electrical
The control panel contains high voltages. Electrical hazards may be present from
damaged or broken wires, open electrical boxes, or open control panels.
The control panel is designed to be integrated with a main electrical panel, which
includes a main power 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 disconnect
switch to isolate the SuperTrak conveyance platform power and turn the UPS OFF. If
an electrical hazard occurs:
1. Stop the SuperTrak conveyance platform.
2. Turn the main power disconnect switch to the OFF position.
3. Turn the SuperTrak conveyance platform power disconnect switch to
the OFF position.
4. Allow stored energy of the UPS to discharge until the LED indicator of the UPS
is not illuminated.
Do not turn ON power to the SuperTrak conveyance platform until an electrical
technician has corrected the situation.
See Energy Controls on page 115.
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. Lock out and tag out the
switch before accessing and servicing the electrical panel. Only qualified
electrical technicians should perform service on the electrical panel.
See Lockout and Tagout on page 11.