PULSE Pallet Assembly Instructions Manual

PULSE SYSTEM
PULSE Pallet Assembly Instructions Manual

Original Instructions
Revision: Release
Publication Date: April 19, 2018
PULSE_DM_DI_PULSEPalletAssemblyInstructionsManual_JLR_V.180419
KUKA Systems North America LLC., 6600 Center Drive, Sterling Heights, MI 48312, USA T +586 795 2000 F +586 978 0429
ServiceCenter@kukanao.com www.kuka.com
TABLE OF CONTENTS
1 INTRODUCTION ............................................................................................................................................... 3
1.1 System Background ....................................................................................................................... 3
1.2 Information about these instructions............................................................................................ 3
1.3 Representation of Warnings and Notes ........................................................................................ 3
1.4 Safety Signs on the System ............................................................................................................ 4
1.4.1 Prohibiting Signs ........................................................................................................................... 4
1.4.2 Mandatory Signs ............................................................................................................................ 4
1.4.3 Warning Signs ................................................................................................................................ 5
2 INTENDED USE ................................................................................................................................................ 5
3 SAFETY ……... ................................................................................................................................................... 7
3.1 Disclaimer ...................................................................................................................................... 7
3.2 Safety Equipment .......................................................................................................................... 7
3.3 Personnel ....................................................................................................................................... 8
3.4 Safety Regulations ......................................................................................................................... 9
3.5 Safety Instructions Governing Specific Operating Conditions ..................................................... 11
3.5.1 Commissioning ............................................................................................................................ 11
3.5.2 Maintenance Work ...................................................................................................................... 11
4 TOOLS REQUIRED .......................................................................................................................................... 12
4.1 Tools Required for PULSE Installation .......................................................................................... 12
5 INSTALLATION................................................................................................................................................ 14
5.1 PULSE Pallet Mounted System..................................................................................................... 14
5.1.1 Prerequisites ................................................................................................................................ 14
5.1.2 Energy Control and Power Lockout (ECPL) .................................................................................. 18
5.1.1 Set-up........................................................................................................................................... 21
5.1.2 X, Y, Z Target Hole Locations for Each Sub-Assembly ................................................................... 26
5.1.3 X, Y, and Z Laser Target Holes & Mounting Surface Tolerance Set-Up ......................................... 31
5.1.4 Tool Setup Sheets ........................................................................................................................ 32
PULSE Pallet Assembly Instructions Manual / Revision: Release

PULSE_DM_DI_PULSEPalletAssemblyInstructionsManual_JLR_V.180419/ Date: 04.19.2018
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5.1.5 Adjusting Position of Mounting Brackets Using Iterative (Trial and Error) Process..................... 33
5.1.6 Attaching Rail to Mounting Brackets ........................................................................................... 37
5.1.7 Alignment of Sub-Assemblies ...................................................................................................... 39
5.2 KUKA PULSE FRP Rail Cutting Guidelines..................................................................................... 42
5.3 Turntable ..................................................................................................................................... 46
5.4 Roller Assembly Locating Unit ..................................................................................................... 49
5.5 Locating Actuator ........................................................................................................................ 51
5.6 Work Station Locating Assembly ................................................................................................. 52
5.7 In Process Actuated Stop ............................................................................................................. 54
5.8 Pallet Fixed Stop .......................................................................................................................... 55
5.9 Pull Off Cart Docking Unit with Pallet Stop ................................................................................. 56
5.10 Part Cart Assembly ...................................................................................................................... 57
5.11 Chassis-Pallet Marriage Procedure.............................................................................................. 60
5.12 Plinth Installation Procedure ....................................................................................................... 65
5.13 Connect all Electrical Pin Plug Connectors throughout the System ............................................ 71
5.14 3-Phase Power Distribution ......................................................................................................... 72
5.15 Ethernet Communications........................................................................................................... 72
5.16 24VDC Power Distribution ........................................................................................................... 73
5.17 PULSE Hardware Installation Overview for Version 2 Panels ...................................................... 74
5.18 PULSE Hardware “Best Practices” for Version 2 Panels............................................................... 87
6 TRANSPORTATION......................................................................................................................................... 88
6.1 Transporting using Lifting Tackle ................................................................................................. 88
6.2 Transportation by Fork Lift Truck................................................................................................. 89
6.3 Transportation by Pallet Truck ..................................................................................................... 90
7 DECOMMISSIONING, STORAGE, & DISPOSAL .............................................................................................. 91
7.1 Decommissioning ........................................................................................................................ 91
7.2 Storage......................................................................................................................................... 91
7.3 Disposal ....................................................................................................................................... 92
8 CONTACT INFORMATION .............................................................................................................................. 92

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1 INTRODUCTION
1.1 System Background

The PULSE Pallet system consists of rail sections mounted as a ground level track system. The pallet is conveyed
from station to station, traveling at the same elevation throughout the rail system. Once the pallet is brought into a
workstation, the pallet is raised slightly by the pallet ski guides in the workstation that is comprised of a geo-locating
fixture. This manual covers the mechanical installation of this system. Please also refer to the controls system O&M
manuals, as well as the interactive manuals provided with this system. It is recommended that this manual be read
in full before installation of the rail system begins.
It is highly recommended that the system integrator performs a risk assessment after the equipment has been
properly installed. This will identify any areas that will require further safety enhancements.
1.2 Information about these instructions

This documentation describes all components that can be used in operation with the PULSE Pallet system.
The scope of the machine includes the manufacturers’ operating instructions for the components supplied with it.
1.3 Representation of Warnings and Notes
Safety
These warnings are provided for safety purposes and must be observed.
These warnings mean that it is certain or highly probable that death or severe
physical injury will occur if no precautions are taken.
These warnings mean that death or severe physical injury may occur if no
precautions are taken.
These warnings mean that minor physical injury may occur, if no precautions are
taken.
These warnings mean that property damage may occur if no safety measures are
taken.
These warnings contain references to safety-related information or general safety

measures. These warnings do not refer to individual hazards or individual
precautionary measures.

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1.4 Safety Signs on the System
The following signs are attached to the machine:
1.4.1 Prohibiting Signs
Authorized personnel only!
An area so designated may only be entered by personnel who have express
permission to carry out a task, e.g. due to work being performed there; no other
persons are permitted to enter.
Do not reach in!
Identifies danger zones where hands must not be able to reach through free
spaces in the safety fence or into unguarded parts of machines.
Do not step!
Identifies a zone that should not be walked or stepped on.
No access for those with metallic implants.

Identifies a zone containing a strong magnetic field that should not be accessed by
those possessing metallic implants.
No access for those with implanted cardiac devices.
Identifies a zone containing a strong magnetic field that should not be accessed by
those wearing implanted cardiac devices.
1.4.2 Mandatory Signs

Wear gloves!
Wearing appropriate protective gloves substantially reduces the risk of injury, e.g.
when working with heavy, hot or sharp-edged items. The wearing of gloves is not
permitted for any work on the machine that is carried out in the vicinity of rotating
parts or tools where there is danger of snagging.
Lift point
To ensure safe and proper transportation of equipment, material should be lifted in
the areas designated.

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1.4.3 Warning Signs
Warning hazardous voltage!
Means “STOP” at dangerous areas in which there are live parts carrying voltages.
Warning arc flash!

Means there is a potential arc flash and shock hazard present.
Warning magnetic field!

Means there is an area of strong magnetic field.
Warning pressurized device!

Means there is pressurized equipment present and there is a potential
explosion/release of pressure hazard.
Warning pinch point!
Means when equipment is moved, there is a potential hand-entanglement/pinch
point hazard.
2 INTENDED USE
The PULSE Pallet system constitutes partly completed machinery as defined by Directive 2006/42/EC (Machinery
Directive) and will be called “machine” in the following text.
The user of the PULSE Pallet system must comply with the national laws and regulations.
Use
The PULSE Pallet system is intended exclusively as a transport system. It must only be operated in an industrial
environment.
Using it for any other or additional purposes is considered contrary to its intended use. The manufacturer cannot
be held liable for any damage resulting from such use. The risk lies entirely with the user.
Operation within the limits of the intended use also involves observing these assembly instructions – particularly
the preconditions for operation of the PULSE Pallet system and complying with the inspection and maintenance
directives.
Misuse

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Any applications deviating from the intended use are regarded as inadmissible misuse; these include:
• Applications not specified under intended use
• Failure to comply with the recommended maintenance intervals, or performing maintenance incorrectly
• Installation of non-approved spare parts and wearing parts
• Use of non-approved consumables, cleaning, and other products
• Insufficiently trained specialist personnel are entrusted with performing work on the machine
• Operation of the machine in potentially explosive environments or in rooms with a corrosive atmosphere
• Use outside the permissible technical operating limits
• Use as a climbing aid
• Use outdoors
• Using the machine for transportation of persons and animals
EC Declaration of Conformity and Declaration of Incorporation

This PULSE Pallet system is partly completed machinery as defined by the EC Machinery Directive. The PULSE
Pallet system may only be put into operation if the following preconditions are met:
• The PULSE Pallet system is integrated into a machine or system.
Or: Together with other machines, the PULSE Pallet system constitutes a system.
Or: All safety functions and safety equipment required for completed machinery as defined by the EC
Machinery Directive have been added to the PULSE Pallet system.
• The completed machinery or system conforms to the EC Machinery Directive. This has been ascertained
by means of a conformity assessment procedure.
Declaration of Conformity for the Overall System
The system integrator must create a declaration of conformity in accordance with the Machinery Directive for the
overall machine or system. The declaration of conformity forms the basis for the CE conformity mark of the
machine or system. The PULSE Pallet system may only be operated in accordance with country-specific legislation,
regulations and standards.
Declaration of Incorporation
As partly completed machinery, the PULSE Pallet system is supplied with a declaration of incorporation in
accordance with Annex II 1 B of Directive 2006/42/EC. Integral parts of this declaration of incorporation include a
list of the essential requirements stipulated in Annex I of the Machinery Directive that have been complied with
and these assembly instructions.

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The declaration of incorporation declares that the partly completed machinery must not be put into operation
until it has been installed in a machine or assembled with other parts to form a machine, that this machine
conforms with the provisions of the EC Machinery Directive, and that the EC declaration of conformity is present
in accordance with Annex II 1 A.
The declaration of incorporation with its annexes remains with the system integrator as part of the technical
documentation of the completed machinery.
3 SAFETY
3.1 Disclaimer
The PULSE Pallet system has been built in accordance with state-of-the-art standards and the recognized safety
rules. Nevertheless, its inadmissible misuse may constitute a risk to life and limb, or cause damage to the PULSE
Pallet system and other material property.
The PULSE Pallet system must only be used in technically perfect condition in accordance with its intended use,
and only by safety-conscious persons who are fully aware of the hazards involved in its operation. It must be used
in compliance with these assembly instructions. Any functional disorders, especially those affecting safety, must
be rectified immediately.
Safety Information
Information about safety may not be construed against KUKA Systems North America. Even if all safety instructions
are followed, it cannot be ensured that the PULSE Pallet system will not cause any injuries or damage.
No modifications may be made to the PULSE Pallet system without the permission of KUKA Systems North
America. It is possible for additional components not included in the scope of supply of KUKA Systems North
America to be integrated on the PULSE Pallet system. The user is liable for any damage that occurs on the PULSE
Pallet system or other property as a result of these components.
External Cross-References and Links
KUKA Systems North America expressly disclaims all ownership of or responsibility for the contents of any linked
Web pages. This declaration applies to all external links and Internet cross-references appearing in this
documentation.
3.2 Safety Equipment
System integrator and user must safeguard the PULSE Pallet system with additional safety equipment (safety
fencing in compliance with DIN EN 953 “Safety of machinery – Guards”).
The PULSE Pallet system has no EMERGENCY STOP pushbutton. The PULSE Pallet system must be integrated into
the EMERGENCY OFF or EMERGENCY STOP system of the machine or system in which the PULSE Pallet system is
installed.
The operating personnel must be instructed with regard to the location and function of the EMERGENCY OFF or
EMERGENCY STOP pushbuttons and maintenance gates.

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In the absence of functional safety devices, the PULSE
Pallet system can cause personal injury or material
damage. Safety devices must not be removed or
disabled.
3.3 Personnel
All persons working on the PULSE Pallet system must be trained in its use and must have read and understood the
PULSE Pallet system documentation including the safety chapter.
The assembly instructions must always be at hand at the PULSE Pallet system.
Before work is started, the personnel must be instructed at regular intervals about the type and scope of the work
and potential hazards. Instruction must be provided again after particular incidents or technical modifications.
The personnel include the user and the operator of the PULSE Pallet system.
Installation, exchange, setting, operation,
maintenance and repair may be performed only by
personnel specially trained for this purpose as
specified in the assembly instructions.
User
The user of the PULSE Pallet system is responsible for its use and operation. He must ensure faultless operation in
terms of safety and lay down all safety regulations for the personnel.
At certain self-defined intervals, the user should check that the personnel are working in compliance with the
assembly instructions and paying attention to hazards and safety factors.
The user is responsible for complying with the national laws, regulations and standards.
Operator
The responsibilities of the personnel for commissioning, operation, maintenance and repair must be defined.
• The personnel must meet the following requirements:
• They must have read and understood the complete PULSE Pallet system documentation including the
safety chapter.
• They must be trained and instructed with regard to the work to be performed.
• They must use the personal protective equipment.
• The machine may be operated only by persons at least 18 years old.

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• Work on the PULSE Pallet system may be performed only by qualified personnel. This means persons who
are capable of assessing the work to be performed and recognizing potential hazards on account of their
professional training and experience as well as their knowledge of the relevant standards.
• These requirements must be adapted by the user in accordance with country-specific legislation,
regulations and standards.
System Integrator
The PULSE Pallet system must be integrated into a machine or system by the system integrator in compliance with
all safety requirements.
The system integrator is responsible for the following tasks:
• Proper installation of the PULSE Pallet system
• Connection of the PULSE Pallet system
• Implementation of the necessary safety equipment and safeguards
• Issue of the declaration of conformity for the machine or system in which the PULSE Pallet system is
integrated
• Creation of the operating instructions for the machine or system in which the PULSE Pallet system is
integrated.
Instruction
The following points must be observed regarding instruction or training:
• The person receiving instruction must confirm participation in the training with their signature.
• The person receiving instruction must be familiarized with the work under the supervision of an
experienced and authorized user.
3.4 Safety Regulations
The PULSE Pallet system must only be used in technically perfect condition in accordance with its intended use,
and only by safety-conscious persons. Operator errors can result in personal injury and damage to property.
If any defects or malfunctions affecting the operational safety or reliability are detected, the PULSE Pallet system
must be immediately switched off or not put into operation.
• Avoid any operational mode that might be prejudicial to safety.
• Take the necessary precautions to ensure that the PULSE Pallet system is used only when in a safe and
reliable state!

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• Operate the PULSE Pallet system only if all protective and safety-oriented devices, such as removable
safeguards, EMERGENCY OFF and EMERGENCY STOP equipment, and working range limitations, are in
place and fully functional.
• Pneumatic parts may only be moved with the maintenance gate closed.
• Monitor the PULSE Pallet system throughout working shifts for obvious damage and defects. Report any
changes (including changes in the machine’s working behavior) to the competent organization/person
immediately. If necessary, stop the PULSE Pallet system immediately and lock it.
• In the event of malfunctions, stop the PULSE Pallet system immediately and lock it. Have any defects
rectified immediately.
• Never make any modifications, additions or conversions on the PULSE Pallet system which might affect
safety without the manufacturer’s approval.
• Spare parts must comply with the technical requirements stipulated by the manufacturer. Spare parts
from original equipment manufacturers can be relied on to do so.
• Pneumatic hoses must be exchanged at appropriate intervals (after 6 years), even if no safety-relevant
defects are evident (hose ageing).
• Adhere to prescribed intervals or those specified in the assembly instructions for routine checks and
inspections.
• For the execution of maintenance work, tools and workshop equipment adapted to the task on hand are
indispensable.
• The personnel must be familiar with the location and operation of fire extinguishers.
• Observe all fire-warning and fire-fighting procedures.

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3.5 Safety Instructions Governing Specific Operating Conditions
3.5.1 Commissioning
During start-up and shut-down procedures always watch the indicators in
accordance with the assembly instructions.
Before starting up or setting the PULSE Pallet system in motion, make sure that
nobody is at risk!
Before putting the PULSE Pallet system into operation, check that all protective
devices, limit switches and other safety measures are complete and functioning
correctly. All machine parts must be checked for foreign bodies.
No persons or objects are allowed in the danger zone during start-up.
It is to be ensured when first commissioning the machine that the correct
machine data have been entered.
Ensure all gearboxes are adequately filled with lubrication prior to start-up.
Before powering on the system, confirm software has been successfully loaded!
Failing to do so will result in damage to equipment.
Do not power on during motor controller inrush cool down period. There is a 2-
minute delay for inrush to inrush, between powering up the motor controllers.
Powering on the motor controllers during the cool down period can cause
excessive inrush current and result in damage to the motor controller or
blowing the semiconductor fuses.
3.5.2 Maintenance Work
• Comply with the adjusting, maintenance and inspection activities and intervals set out in the assembly
instructions, including information on the replacement of parts and equipment. These activities may be
executed by skilled personnel only. Please reference the PULSE Maintenance Instructions document for
additional information.
• In any work concerning the operation, conversion or adjustment of the PULSE Pallet system and its safety-
oriented devices or any work related to maintenance, inspection and repair, always observe the start-up
and shut-down procedures set out in the assembly instructions and the information on maintenance
work.
• If it is essential for personnel to enter the working area of the PULSE Pallet system for maintenance and
repair work, the safety measures implemented (e.g. enabling switch) must cause the PULSE Pallet system
to be stopped immediately if an unintended situation should arise.
• To avoid the risk of accidents, individual parts and large assemblies being moved for replacement
purposes must be carefully attached to lifting tackle and secured. Use only suitable and technically perfect

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lifting gear and suspension systems with adequate lifting capacity. Never work or stand under suspended
loads.
• The fastening of loads and the instructing of crane operators should be entrusted to experienced persons
only. The marshal giving the instructions must be within sight or sound of the operator.
• For carrying out overhead assembly work always use specially designed or otherwise safety-oriented
ladders and working platforms. Never use machine parts as a climbing aid! Wear a safety harness when
carrying out maintenance work at greater heights.
• Clean the PULSE Pallet system, especially connections and threaded unions, of any traces of oil, dirt, dust,
swarf or preservatives, and treat with corrosion protection before carrying out maintenance/repair. Never
use aggressive detergents. Use lint-free cleaning rags.
• Appropriate protective clothing must be worn when using prescribed consumables which are specified as
aggressive or toxic.
• After cleaning, remove all covers and tapes applied for that purpose.
• After cleaning, examine all pneumatic hoses for leaks, loose connections, chafe marks and damage! Any
defects found must be rectified without delay.
• Always tighten any screwed connections that have been loosened during maintenance and repair; do so
with the specified tightening torque and in accordance with the drawing.
• Any safety devices removed for set-up, maintenance or repair purposes must be refitted and checked
immediately upon completion of the maintenance and repair work.
• Ensure that all consumables and replaced parts are disposed of safely and with minimum environmental
impact.
• The PULSE Pallet system must be depressurized before any work is carried out on the pneumatic system.
Beware of unexpected movements.
4 TOOLS REQUIRED
4.1 Tools Required for PULSE Installation
• Mallet – Wood or Rubber end – various sizes
• Pinch Bar
• Laser Equipment
• Laser Tracker
• Targets (dowel and magnetic mount styles)
• Scale Bar

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• Computer
• Straight Edge
• Projection System – or other equipment for initial floor location of grout plates
• Allen Wrenches – socket and ratchet styles (all screws are Metric)
• Metric Torque Chart:

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5 INSTALLATION
5.1 PULSE Pallet Mounted System
5.1.1 Prerequisites
Adhere to plant safety guidelines and wear all required Personal Protective Equipment (PPE), including:
• Safety Glasses
• Protective Footwear
• Gloves
Ensure you are aware of Laser safety around the Laser Tracker system
• Do not look directly into the Laser Beam – severe eye damage may occur

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Image of Laser Tracker Head around machinery
Be cautious around high strength Neodymium Iron Boron magnets
When a chassis is positioned over a motor, a strong magnetic attraction will be present between the motor and
magnet.

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Image showing the Magnets mounted on the underside of the chassis
Be cautious about working at heights

Use proper PPE (harnesses may be required where railings are not present)
The Return Rails are mounted to the Balconies – be cautious working at heights

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Pull Off Cart Docking Units with Pallet Stops are equipped with a lock out pin
Use the lockout Pin to secure the Part Cart Assembly to the Docking Unit.
Images show lockout pin in the locked position (shown on the left), and in the stored position (shown on the
right).

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5.1.2 Energy Control and Power Lockout (ECPL)
Follow the instructions on the ECPL Placard for proper lockout procedures
Instructions for Power Isolation and Discharge are found on the ECPL Placard
Severe injury or Death can result if ECPL procedures are not followed
ECPL (Energy Control and Power Lockout) is a set of safety standards used to describe all potential hazards
associated with a machine. These hazards include all electrical energy (i.e. motors, switches) as well as any stored
energy (i.e. pneumatic and hydraulic pressure). Through the use of ECPL standards operating and maintenance
work on the machine and associated mechanical devices can be performed in a safe manner. For each station on
the machine an ECPL sign (sometimes referred to as a placard) is posted nearby in a location that is easily
accessible to the operating and maintenance personnel. The ECPL sign contains information regarding the location
of all lockouts and potential hazards associated with the machine. These lockout and hazardous locations are
designated with a Lockout Tag (i.e. E1, e1, P1, p1, RH, CG...) that will be posted nearby for easy identification. Also,
the proper lockout and verification procedures are prominently displayed on the sign. The image at right illustrates
a typical ECPL sign.
ALWAYS follow the instructions on the ECPL sign for proper machine lockout and verification procedures.
The ECPL Sign(s) shows the system's lockout points and lists procedures for proper machine lockout. ALWAYS
follow the instructions on the sign(s) POSTED ON THE EQUIPMENT for proper lockout (see DANGER notice below).
DANGER
LOCKOUT OPERATIONS SHOULD BE PERFORMED AS
INSTRUCTED ON THE ECPL SIGN(S) POSTED ON THE
DANGER EQUIPMENT. The information currently posted on the machine
ECPL placard(s) is the authoritative, current procedure. Due to
the possibility of future changes being made to the equipment,
this section cannot be guaranteed to be current.
AN EXAMPLE OF THE ECPL SIGN(S) IS INCLUDED HERE FOR
REFERENCE ONLY! Please refer to the sign(s) posted on the
equipment. Failure to observe the lockout procedures AS
POSTED ON THE EQUIPMENT could result in injury or death
and/or could cause severe equipment damage.
• Consult the graphic lockout procedure posted on the equipment before performing any maintenance or
repair task. No person should begin maintenance repairs until the proper ECPL procedures are completed.

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The employee should contact his/her immediate supervisor if there are any questions about the
identification of potential energy sources.
• When service or maintenance is to be conducted, equipment must be put in the OFF position via energy
isolating devices such as electrical disconnects and valves.
• Please reference the PULSE NCP Lockout Procedure & SDP Lockout Procedure.
ECPL Signs and Tags (continued)
• Before shutting down the equipment to lockout energy sources, the employee performing the procedure
or the supervisor shall inform affected employees of the intention to shut down the equipment.
If the machine or equipment is operating, it must be shut down using normal shutdown procedures.
Essentially Lockout Tags are utilized as a method of warning personnel of a potential hazard associated with a
particular energy source. They are attached to or are placed in close proximity to energy isolating devices.
Lockout Tags alone do not provide the physical restraint on the energy device, this can only be provided by a lock.
Understanding the proper meaning of a Lockout Tag is necessary to prevent a false sense of security around
potential hazards on the machine. Lockout Tags identify the energy source lockout device. When the energy
source is locked out, they cannot become inadvertently or accidentally detached. The Lockout Tags shown below
illustrate some of the most common lockout designations.
PULSE Floor Mounted Material

• Floor foundation must be adequately sound for installation
• Floor surface fluctuations MUST BE taken into account
• High and Low points across the system
• Must balance the Highs and Lows – note the designed gap between the bottom of the Mounting Brackets
and the top of the Grout Plates are found on the layout drawings (see below).
• Establish an overall System Virtual Datum (X, Y, and Z in space)
Note: Consult the layout drawings for the designed gap between Grout Plate and Bottom of each mounting
bracket.

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Typical Mounting
Bracket
Locate and Lag Grout Plates into Floor – using overhead Projection System
Note: The following is reference only using a Hilti style anchor as an example – consult your layout drawings
for anchor type.
Drill 3/4" (19.05mm) diameter x 6" (152.4mm) hole into the concrete ensuring the Screw
Anchor does not bottom out in the hole.
Install the Hilti KH-EZ ¾” (19.05mm) x 4 ½” (114.3mm) (reference only) into the concrete as
shown, applying 95-115 ft-lbs of torque.

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Image shows the Hilti Screw Anchor (reference only) correctly installed - mark the Hex Head indicating the Anchor
is properly torqued
5.1.1 Set-up
Use drawing dimensional information to locate Laser Target Holes and Dowels relative to the system Datum.
Note: The Drawing may relate the Datum to a customer’s building column.
• The Laser Target Holes will be used for mounting the Laser Targets.
Sight in and “zero” the Laser Tracker to establish the location of the Datum relative to X, Y, and Z axis.
Continue to locate each Laser Target and surface in all planes, adjusting the Mounting Brackets position using
Mallets, Pinch Bars, and Socket Wrenches in an iterative (trial and error) process of small adjustments until the
Mounting Bracket is located and leveled in place. Laser Targets and surface planes must be located within +/-
.25 mm to the system Datum.

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Note: Target location identifiers are assigned by the Assembly Technicians

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Image shows the Laser Tracker and the Computer Screen (see below for close up view of screen) with Target
locations relative to the X, Y, and Z Datum Planes. The Mounting Brackets will be fine-tuned using an iterative (trial
and error) process until the proper locations are achieved.

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Image of the Laser Computer screen referencing the Target locations relative to the Datum. Target hole numbers
are assigned by the Assembly Technician from the Layout Drawing.

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Image of the Laser Tracker.
Note: Be cautious of looking into laser beam, severe injury to eyesight is possible.

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5.1.2 X, Y, Z Target Hole Locations for Each Sub-Assembly
Turntable
Image showing the X, Y, and Z axis relative to the PULSE Pallet System
Note: X Axis is direction of Part Flow

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Pallet Work Station Locating Assembly

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Rail Support Bracket

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Locating Actuator

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In Process Actuated Stop

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5.1.3 X, Y, and Z Laser Target Holes & Mounting Surface Tolerance Set-Up
Laser Targets (assigned by the Assembly Technician) are located on the Assembly Drawings. All Target locations
are to be +/- .25mm relative to the Datum.

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5.1.4 Tool Setup Sheets
Using the Layout Drawings to determine the Laser Target Hole locations, and create the “Tool Set Up” sheet
documenting the set-up at KUKA for each station’s Laser Target Hole locations (Target Hole Locations
assigned by the Assembly Technician). The KUKA “Tool Set Up Sheet” will look like the example below:
Image shows Laser Target Hole locations for each set of Mounting Brackets at each station. Note
– these are actual dimensions (based on the nominal dimensions on the Layout Drawings) recorded
during the assembly process at KUKA, and will be repeated to record the actual dimensions at the final
customer.

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5.1.5 Adjusting Position of Mounting Brackets Using Iterative (Trial and Error) Process
Adjust the position (leveling) of a typical Mounting Brackets in the Z axis direction using an open-ended wrench on
the E&E Leveling Jack Screw (EMLJ-2475-CAM).
Image shows fine tune adjustments being made to the Mounting Brackets for vertical height adjustment, and also
establishing the mounting surface plane.
Adjusting the position of the Mounting Brackets in the X and Y axis direction
Image shows the use of a Mallet (or Pinch Bar) for side adjustment (X and Y direction) of a typical Mounting
Bracket.

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Once the Mounting Bracket is in its proper location, the Mounting Block on the E&E Leveling Jack Screw (EMLJ-
2475-CAM) is welded in place.
Note: Welding may continue to move the location of the Mounting Bracket…continue to measure with the Laser
Tracker and adjust accordingly through the welding process.
Once the Mounting Bracket is located, tighten the Jam Nut and mark the Leveling Jack screw assembly signifying
that it is finally located.
Image shows section cut of set up of the E&E Leveling Jack Screw (EMLJ-2475-CAM). Note the gap between the
underside of the Mounting Bracket and the top of the Grout Plate.

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There are also NAAMS Leveling Screw assemblies used in the system. Simply turn to raise and lower the assembly.

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Weld Leveling Jack Screw Mounting Block
Image of Mounting Block welded in place
Mark the Leveling Jack Screw when final located signifying the final location
Image of Leveling Jack Screw with Marked line

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5.1.6 Attaching Rail to Mounting Brackets
Attach Rails to Rail Mounting Brackets.
Note: The Rail ends will require alignment. The Rail ends should be aligned within .25mm up and
down, and side to side. Loosen the mounting screws and using a Straight Edge to align one rail to
another. Once the rails are aligned tighten the mounting screws.
Note that there is typically a 2mm gap between rail assemblies.
The Rails are mounted with Screws (no Dowels) to the Rail Mounting Brackets. M10 x 40mm Screws
are recommended.
Note the orientation of the Labels shown below:
All Labels as shown in this photo should be on the same side of every rail (arrows in direction of part flow). Motor
flow is denoted as upstream to downstream (from Drive Connectors to Sense Connector). This assures the correct
orientation of the magnets and motors.

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Image shows Rail Assemblies mounted to Rail Mounting Brackets. Note the typical 2mm gap between rail
assemblies, with an allowable gap of up to 100mm on a Vertical Drop Lift (VDL) application.
Image shows an example of FRP rails joining to share one Rail Mounting Bracket.

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5.1.7 Alignment of Sub-Assemblies
Rail Mounting Brackets
Using the Laser Tracker, locate the Rail Riser to the Laser Target dimensions from the assembly drawing. The
datum may be established relative to a customer building column). All Targets and surfaces must be
located +/- .25mm. Adjust the X, Y, and Z location as needed for alignment.
Image shows Laser Beams Targeting Laser Targets mounted in Target Holes.

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Mount the linear rail onto the first set of rail risers. Hand tighten the bolts in case adjustment is needed at a later
point in installation. When correct alignment has been achieved, bolt down securely.
Image shows Linear Rail being mounted onto Rail Mounting Brackets.
Image shows how Linear Rail and Rail Mounting Brackets are secured.

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Mount the second linear rail onto the second set of rail risers. Hand tighten the bolts in case adjustment is
needed at a later point in installation. When correct alignment has been achieved, bolt down
securely.

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Align the second rail to the first one within a .25mm tolerance up and down, and side to side using a straight edge.
Note there is typically a 2mm gap left between the two rails. Continue to mount the remaining
linear rails using the same process - Typical throughout.
5.2 KUKA PULSE FRP Rail Cutting Guidelines
Introduction:
Recommended guidelines for cutting a FRP rail to accommodate additional rail gap
Objective:
To ensure proper technique and safety procedures are practiced when FRP rails are cut in the field
Plan:
1. Adhere to all plant safety and Personal Protective Equipment (PPE) guidelines. Safety gloves,
facemasks, eyeglasses, and protective sleeves should be worn when cutting a FRP rail.
2. With the use of clamps, secure the rail onto the cutting surface.
3. Measure and mark FRP rail to desired length.
4. Utilize a reciprocating saw to cut the FRP rail to the desired length. Employ proper saw handling
technique to safely cut the rail.
5. Use a wet/dry vacuum to collect excess rail debris.
6. Once cut, apply Aervoe 403 Insulating Epoxy Coating to seal and protect any sharp edges/rail
imperfections. Please see the product and safety data sheets below and reference the
demonstration video displaying the FRP rail cutting process.

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NOTES:
When additional rail gap is needed in an elevator station, the rail adjacent to the elevator rail should be cut.
An elevator rail should never be cut, as this would create an asymmetrical gap with the adjacent rail in the
overhead station. Pictured below: When the elevator rail comes into position, 6.6mm of clearance exists
between the PULSE Roller Assembly Locating Unit and the adjacent fixed FRP rail assembly.

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Drawings:
Workstation Reference:

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Pictures:

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References:
Aervoe 403 Insulating Epoxy Coating
• Product Data Sheet
• Safety Data Sheet (SDS)
Video:
FRP Rail Cutting Reference Video
Linked above: Demonstration video exhibiting FRP rail cutting procedure
5.3 Turntable
Using the Laser Tracker, locate the Turntable Base

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Image shows location of turntable target locations. There are four (4) in total. Two on each side of the turntable
base.

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Use the adjustment screws to align the turntable rail to the linear rail. Align the rail with a ±.25mm
tolerance.
Image shows adjustment screw which can be used to move the rail angle up and down.

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5.4 Roller Assembly Locating Unit
When installing the Roller Assembly Locating Unit, ensure that a 94.45mm clearance is given from the
bottom of the assembly to the ground. Also, ensure that when mounting other assemblies in the area
that this clearance is considered.

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Note, a low-profile cable tray solution should be utilized to satisfy the allotted ground clearance, as well
as required startup overtravel clearance. The edge of magnet to motor search travel is approximately
112mm for the Turntable to establish or re-establish positioning sequence.
Reference: Low-Profile Cable Tray System

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5.5 Locating Actuator
Using the Laser Tracker, locate the Locating Actuator.
Image shows Locating Actuator mounted through the Rail Bridge Support Bracket. There are four (4) Laser Target
Holes on the Locating Actuator, two on each end.

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5.6 Work Station Locating Assembly
Using the Laser Tracker, shoot in the two (2) laser targets located at each end of the Work Station Locating
Assembly. These two target holes will roughly locate the Work Station Locating Assembly for the locating
the assembly in the X-Axis.
Using the Laser Tracker, shoot in the four (4) Laser Roller Targets (Cat Eye Targets) for the locating the
assembly in the Y-Axis.

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Using the Laser Tracker, Locate the Work Station Lock / Locator Assembly. There is one (1) Laser Roller
Target (Cat Eye Target) for the locating the assembly in the X-Axis.

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5.7 In Process Actuated Stop
Using the Laser Tracker, locate the In Process Actuated Stop.

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5.8 Pallet Fixed Stop
Locate the Pallet Fixed Stop to the end of the Cross Transfer. This sub assembly does not need to be shot
in with the Laser Tracker.
Image shows Pallet Fixed Stop located at the end of the Cross Transfer Rail.

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5.9 Pull Off Cart Docking Unit with Pallet Stop
Locate the Pull Off Cart Docking Unit with Pallet Stop to the end of the Pull Off Cart. This sub assembly
does not need to be shot in with the Laser Tracker.

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5.10 Part Cart Assembly
Tapping plates are welded at assembly. See diagram and layout drawing.
Use adjustment screws to align the FRP rail to the appropriate height. See diagram and layout drawing.

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5.11 Chassis-Pallet Marriage Procedure
Step 1: Utilize PULSE Pull-Off Cart
When introducing/removing a chassis assembly into the line, the first option should always be to
use a PULSE Pull-Off Cart.
Figure 5.11.1: PULSE Pull-Off Cart positioned at the end of the line.
Step 2: Utilize Lifting Straps to Pick Up the Chassis

Utilize lifting straps and a fork lift to pick up the chassis. The lifting straps should be equally
distanced on the chassis assembly and fed to both forks to ensure the weight is balanced and
securely transferred.
Figure 5.11.2: Lifting straps attached to a PULSE chassis assembly.

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Note: PULSE chassis assemblies utilize high strength Neodymium Iron Boron magnet arrays.
Magnet arrays are always active and present a strong magnetic field. Never use chains or bring a forklift in
direct contact with a magnet array. Failure to do so will result in potential injury and/or damage to
equipment.
Step 3: Load Chassis onto Pull-Off Cart

Slowly lower and load the chassis onto the pull-off cart, being careful to not get the chassis magnet array
close to any ferrous material.
Figure 5.11.3: PULSE chassis assembly positioned on a pull-off cart.

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Step 4: Utilize Lifting Straps to Pick Up the Pallet
In similar fashion, utilize lifting straps and a forklift to pick up the pallet. The lifting straps should be
equally distanced on the pallet and fed to both forks to ensure the weight is balanced and securely
transferred.
Figure 5.11.4: Lifting straps attached to a pallet. Reference only.

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Step 5: Join the Pallet to the Chassis
Carefully join the pallet to the chassis assembly by noting the orientation and aligning and
lowering the rough locators of the pallet onto the pin blocks of the chassis.
Figure 5.11.5: Bottom side view of a pallet. Reference only.
Figure 5.11.6: Rough locators positioning over the chassis pin blocks.

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Figure 5.11.7: PULSE Chassis with a pallet loaded. Reference only.
Step 6: Load the Chassis/Pallet onto the Line

Once secured, load the chassis/pallet into the line via the pull-off cart.
Figure 5.11.8: Operators utilizing the pull-off cart to insert a chassis/pallet.
General Safety:
1. Do not place any body parts (e.g. finger) between a magnet and any ferrous material or another magnet.
2. To avoid serious injury, people with pacemakers and other medical electronic implants must stay away
from the magnets.

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3. To avoid damage to watches, instruments, and magnetic media (e.g. credit cards), keep these items 2 feet
from the magnets.
4. Always utilize lifting straps when attempting to lift a chassis assembly or pallet. Never use chains or bring
a forklift in direct contact with a magnet array. Failure to do so will result in potential injury and/or damage
to equipment.
5. Only lift a single chassis or a single pallet at a time.
Note: A chassis should not simultaneously be lifted with a pallet adjoined.
5.12 Plinth Installation Procedure

Step 1: Determine Location
The first step is to determine the location of the electrical panel. Place the electrical panel in its
desired location.

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Step 2: Remove Plastic Access Covers
On the bottom of plinth, remove the plastic covers by pressing down on the top edge of the cover
and tilting back. This will give access to the anchor hole.
Step 3: Mark Hole Location

Use a marker to mark the hole location. It’s recommended that at least two diagonally opposite
corners are anchored to give the enclosure stability from tipping over.

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Step 4: Move Enclosure Aside
Move the enclosure aside. Select the correct anchor to use in this application.

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Step 5: Drill into Concrete
Begin by using the correct masonry bit to drill into the concrete floor. Drill to correct depth based
on manufacturers product guidelines. Allow for a minimum of 3/4” of anchor thread above the
floor.
Step 6: Clean Drill Dust

Clean drill dust from anchor hole and surrounding area.

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Step 7: Place Anchor
Place anchor in hole and hammer to proper depth to allow for expansion of the anchor foot. Take
care not to damage anchor threads.
Step 8: Install Enclosure

Once anchor is at proper depth, install the enclosure over the anchors. Install washer and nut and
tighten down for a snug fit.

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Step 9: Install Access Cover
To install plastic access cover, place bottom of lip and then tilt forward to snap cover into place.
Installation is now complete.

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5.13 Connect all Electrical Pin Plug Connectors throughout the System
Connect all Electrical Pin Plug Connectors throughout the System.
Typical Pin Connectors – Ref. Only
Typical Pin Connectors – Ref. Only

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5.14 3-Phase Power Distribution
5.15 Ethernet Communications

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5.16 24VDC Power Distribution

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5.17 PULSE Hardware Installation Overview for Version 2 Panels
The following are guidelines outlined in (5) steps for the Transformer Wiring Diagram, NCP Wiring,
SDP Wiring, Motor Wiring, and Motor Controller Replacement:

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5.18 PULSE Hardware “Best Practices” for Version 2 Panels
• When connecting RS-422 cables, be aware that the cable and receptacle are not keyed. Use care when
aligning the cables, so as not to bend any pins in the motor controller’s receptacles.
• High speed static and flex cables look very similar. Read identification tags on the cables to differentiate
between the two.
• When rolling out cable, unroll it as if the cable were on a spool. Try to avoid kinking the cable when
unrolling.
• Any cable showing end connector damage must be immediately set aside for further disposition.
• Cables should be the correct size and not coiled up in the tray.
• All power and communication cables should be separated in long cable trunking runs.
• Warning – Faulty RS-422 installation in reference to the motor placement may result in motion not
consistent with what is being commanded through the PLC. Motor flow should be followed strictly
according to the system installation drawings. See flow information.

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6 TRANSPORTATION
The PULSE Pallet system may only be picked up and lifted in specified spots.
Reference lift point stickers attached to FRP rails for proper moving methods.
Incorrect use and attachment of lifting tackle can cause the PULSE Pallet system to
fall, resulting in injury.
Using unsuitable lifting tackle can damage the PULSE Pallet system. Only lifting
tackle and attachment points with sufficient load-bearing capacity may be used.
The system can also be transported by means of a fork lift or crane.
6.1 Transporting using Lifting Tackle

Preconditions
• The enclosures/equipment must be powered off.
• No cables may be connected to the enclosures.
• All enclosures must be closed.
• All enclosures must be upright.
• The anti-tipping bracket must be fastened to the enclosures.
Necessary Equipment
Lifting tackle with or without lifting frame
Procedure
1. Attach the lifting tackle with or without a lifting frame to all 4 transport eye-bolts on the
enclosure.

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Fig. 6-1: Transportation using lifting tackle
1. Transport eyebolts on the enclosure

2. Correctly attached lifting tackle
3. Correctly attached lifting tackle
4. Incorrectly attached lifting tackle
2. Attach the lifting tackle to the crane.

3. Slowly lift and transport the enclosure.
4. Slowly lower the enclosure at its destination.
5. Unhook the lifting tackle on the enclosure.
6.2 Transportation by Fork Lift Truck

Preconditions
Procedure

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Fig. 6-2 Example of transportation by fork lift truck
Fig. 6-3 Example of packaged enclosures prepared for transportation by fork lift truck. Note,
enclosures should be secured to pallets with all cables protected when being transported via fork
lift truck
6.3 Transportation by Pallet Truck

Preconditions
Procedure
Figure 6-4: Transportation by pallet truck
1. Enclosure with anti-toppling bracket

2. Enclosure in raised position

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Figure 6-5: Picture of eyelets installed on enclosure
7 DECOMMISSIONING, STORAGE, & DISPOSAL

7.1 Decommissioning
Description
This section describes all the work required for decommissioning the PULSE system. After
decommissioning, it is prepared for storage or for transportation to a different location.
Following its removal, the PULSE system may only be transported with lifting tackle and a fork
lift truck or pallet truck.
Precondition
• The removal site must be accessible with a crane or with a fork lift truck for transportation.
• The crane and fork lift truck have an adequate carrying capacity.
• There is no hazard posed by system components.
7.2 Storage
Preconditions
If the PULSE system must be put into long-term storage, the following points must be
observed:
• The place of storage must be as dry and dust-free as possible.
• Avoid temperature fluctuations.
• Avoid wind and drafts.
• Avoid condensation (80% humidity, non-condensing).
• Observe and comply with the permissible temperature ranges for storage (-20°C ~
40°C).
• Select a storage location in which the packaging materials cannot be damaged.
• Only store the PULSE system indoors.

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7.3 Disposal
When the PULSE system reaches the end of its useful life, it can be dismantled, and the
materials can be disposed of properly by type.
As the end user, the customer is legally required to return depleted batteries. Used batteries
can be returned to the vendor or brought to the designated collection points (e.g. the
communal refuse collection facilities or commercial centers) free of charge. The batteries can
also be sent to the vendor by post.
Magnets must be properly removed and disposed of by a certified contractor/handler of

hazardous materials. Under no condition should magnets be disposed of with other wastes.
Follow all facility, local, and national procedures for the disposal of hazardous materials.
8 CONTACT INFORMATION
Please contact KUKA Systems North America’s Service Center for assistance, questions or comments regarding
the operation or maintenance of your equipment.
KUKA Systems North America- Service Center

6600 Center Drive | Sterling Heights | 48312 | MI | USA
Tel. +1 (586) 795-2000 (x9)
https://www.kuka.com/en-us/services/service-vor-ort
Authorized CE Representative:
KUKA Systems GmbH

Blücherstrasse 144 | 86165 Augsburg | Germany
Tel. +49-821-797-0

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1.1 System Background

1.2 Information about these instructions

1.3 Representation of Warnings and Notes

These warnings contain references to safety-related information or general safety

PULSE Pallet Assembly Instructions Manual / Revision: Release

No access for those with metallic implants.

1.4.2 Mandatory Signs

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Warning arc flash!

Warning magnetic field!

Warning pressurized device!

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EC Declaration of Conformity and Declaration of Incorporation

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Be cautious about working at heights

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ECPL Signs and Tags (continued)

PULSE Floor Mounted Material

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Image of Mounting Block welded in place

Image of Leveling Jack Screw with Marked line

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5.2 KUKA PULSE FRP Rail Cutting Guidelines

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