PULSE Carrier Assembly Instructions Manual PDF

PULSE SYSTEM
PULSE Carrier Assembly Instructions Manual
Original Instructions
Revision: Release
Publication Date: October 11, 2017
PULSE_DM_DI_PULSECarrierAssemblyInstructionsManual_V.171011
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 ....................................................................................................... 3
1.4.1 Prohibiting Signs ....................................................................................................................... 4
1.4.2 Mandatory Signs....................................................................................................................... 4
1.4.3 Warning Signs ........................................................................................................................... 4
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 ................................................................................................................................................. 13
5.1 PULSE Floor Mounted System ................................................................................................ 13
5.1.1 Prerequisites........................................................................................................................... 13
5.1.2 Energy Control and Power Lockout (ECPL) ............................................................................. 18
5.1.3 Handling and Lifting Safety..................................................................................................... 20
5.2 PULSE Floor Mounted Material .............................................................................................. 21
5.3 Static Tower set-up ................................................................................................................. 22
5.4 Lifter Tower Set-Up ................................................................................................................. 37
5.5 Attach Rail Mounting Brackets ............................................................................................... 40
5.6 Attaching Rail to Mounting Brackets ...................................................................................... 42
5.6.1 Attach Rails to Rail Mounting Brackets................................................................................... 42
5.7 Lifter Drive and Drive Shaft Assembly .................................................................................... 44
5.8 PULSE Return Rail Mounting Kits ........................................................................................... 51
5.8.1 Mount Rails to the Return Rail Mounting Kits........................................................................ 51
5.8.2 Mounting Return Rail Mounting Kits...................................................................................... 52
5.8.3 Weld Angle Iron from the Return Rail Mounting Kits............................................................. 53
5.9 Chassis-Pallet Marriage Procedure......................................................................................... 58
PULSE Carrier Assembly Instructions Manual / Revision: Release

PULSE_DM_DI_PULSECarrierAssemblyInstructionsManual_V.171011/ Date: 10.11.2017
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5.10 Enclosure Installation Procedure ........................................................................................... 63
5.11 3-Phase Power Distribution.................................................................................................... 69
5.12 Ethernet Communications ..................................................................................................... 69
5.13 24VDC Power Distribution ..................................................................................................... 70
5.14 PULSE Hardware Installation Overview for Version 2 Panels ................................................. 71
5.15 PULSE Hardware “Best Practices” for Version 2 Panels ......................................................... 83
6 TRANSPORTATION .......................................................................................................................................... 84
6.1 Transporting using Lifting Tackle ............................................................................................ 84
6.2 Transportation by Fork Lift Truck ........................................................................................... 85
6.3 Transportation by Pallet Truck................................................................................................ 86
7 DECOMMISSIONING, STORAGE, & DISPOSAL................................................................................................ 88
7.1 Decommissioning ................................................................................................................... 88
7.2 Storage ................................................................................................................................... 88
7.3 Disposal .................................................................................................................................. 88
8 CONTACT INFORMATION................................................................................................................................ 89

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1 INTRODUCTION
1.1 System Background

The PULSE Carrier system consists of rail sections mounted as an elevated track. The carrier is conveyed from station
to station in the elevated state. Once the carrier is brought into a workstation, the carrier is lowered onto the work-
fixture directly below it. The means for lowering the carrier is accomplished through a set of vertical lifter stations.
Each lifter station comprises of two lift towers that raise and lower a section of rail. This manual is designed to assist
in proper installation of the PULSE Carrier system. 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 Carrier 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.
1.4 Safety Signs on the System
The following signs are attached to the machine:

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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.
1.4.3 Warning Signs

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

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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 Carrier 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 Carrier system must comply with the national laws and regulations.
Use
The PULSE Carrier 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 Carrier system and complying with the inspection and maintenance
directives.
Misuse
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

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• 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 Carrier system is partly completed machinery as defined by the EC Machinery Directive. The PULSE
Carrier system may only be put into operation if the following preconditions are met:
• The PULSE Carrier system is integrated into a machine or system.
Or: Together with other machines, the PULSE Carrier 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 Carrier 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 Carrier system may only be operated in accordance with country-specific
legislation, regulations and standards.
Declaration of incorporation
As partly completed machinery, the PULSE Carrier 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.
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.

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3 SAFETY
3.1 Disclaimer
The PULSE Carrier 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
Carrier system and other material property.
The PULSE Carrier 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 Carrier system will not cause any injuries or damage.
No modifications may be made to the PULSE Carrier 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 Carrier system. The user is liable for any damage that occurs on the PULSE
Carrier 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 Carrier system with additional safety equipment (safety
fencing in compliance with DIN EN 953 “Safety of machinery – Guards”).
The PULSE Carrier system has no EMERGENCY STOP pushbutton. The PULSE Carrier system must be integrated
into the EMERGENCY OFF or EMERGENCY STOP system of the machine or system in which the PULSE Carrier
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.
In the absence of functional safety devices, the PULSE

Carrier system can cause personal injury or material
damage. Safety devices must not be removed or
disabled.

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3.3 Personnel
All persons working on the PULSE Carrier system must be trained in its use and must have read and understood
the PULSE Carrier system documentation including the safety chapter.
The assembly instructions must always be at hand at the PULSE Carrier 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 Carrier 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 Carrier 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 Carrier 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.
• Work on the PULSE Carrier 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.

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System Integrator
The PULSE Carrier 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 Carrier system
• Connection of the PULSE Carrier system
• Implementation of the necessary safety equipment and safeguards
• Issue of the declaration of conformity for the machine or system in which the PULSE Carrier system is
integrated
• Creation of the operating instructions for the machine or system in which the PULSE Carrier 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 Carrier 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 Carrier 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 Carrier system is used only when in a safe and
reliable state!
• Operate the PULSE Carrier 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 Carrier system throughout working shifts. Report any changes (including changes in
the machine’s working behavior) to the competent organization/person immediately. If necessary, stop
the PULSE Carrier system immediately and lock it.

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• In the event of malfunctions, stop the PULSE Carrier system immediately and lock it. Have any defects
rectified immediately.
• Never make any modifications, additions or conversions on the PULSE Carrier 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
absolutely 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 Carrier 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 Carrier system for maintenance and
repair work, the safety measures implemented (e.g. enabling switch) must cause the PULSE Carrier 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
lifting gear and suspension systems with adequate lifting capacity. Never work or stand under suspended
loads.

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• The fastening of loads and the instructing of crane operators should be entrusted to experienced persons
only. The marshaler 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 Carrier 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 Carrier 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
Computer
Straight Edge

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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:
5 INSTALLATION
5.1 PULSE Floor 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

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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

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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
PULSE Lift Towers are equipped with Lockout Pins
Use the Lockout Pins to secure the Lift Platen in the down position (as shown)

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5.1.2 Energy Control and Power Lockout (ECPL)
Follow the instructions for proper lockout procedures
Instructions for Power Isolation and Discharge must be followed
Severe injury or Death can result if lockout 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.
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 END USERS OR INTEGRATOR’S EQUIPMENT for proper
lockout (see DANGER notice below).
DANGER
LOCKOUT OPERATIONS SHOULD BE PERFORMED AS INSTRUCTED ON
THE ECPL SIGN(S) POSTED ON THE END USER OR INTEGRATOR’S
EQUIPMENT. The information currently posted on the machine ECPL
DANGER
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.
THE END USER OR INTEGRATOR IS RESPONSIBLE FOR ALL SAFETY
EQUIPMENT AND SAFETY LOCKOUT PROCEDURES! 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.

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• Consult the graphic lockout procedure posted on the equipment by the End User or Integrator before
performing any maintenance or repair task. No person should begin maintenance repairs until the proper
ECPL procedures are completed. 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.
• 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.
• Please reference the PULSE NCP Lockout Procedure & SDP Lockout Procedure.
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.

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5.1.3 Handling and Lifting Safety
Note: The Lifter Towers and Static Towers have mountings for M20 Eyebolts (see below with
Upper Guard removed)
Caution: The Lift Towers with the Rail Brackets are top heavy and will topple if not properly
secured.

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5.2 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 Tower Columns
and the top of the Grout Plates (see below)!
• Establish an overall System Virtual Datum (X, Y, and Z in space)
• Verify the datum points on the balconies (located facing toward the inside of the line)
Static Towers – 25.0mm gap between Grout Plate and Bottom of Foot of Tower
Designed gap between bottom of Column to top of Grout Plate

Lifter Towers – 10.0mm gap between Grout Plate and Bottom of Foot of Tower
Designed gap between bottom of Column to top of Grout Plate

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Locate and Lag Grout Plates into Floor – using overhead Projection System
Drill Lag Bolts into Concrete
Note: Do not drill Through Concrete
Drill (12) holes for each Grout Plate – fill with epoxy as shown
Note: Lag bolt size for reference only
Image shows the ¾” (19.05mm) Lag Bolt correctly installed as a reference
5.3 Static Tower set-up

Use drawing dimension information to locate “Footpad” dimensions relative to the system Datum.
Note: Use Eye Bolts located on top of the Tower for Lifting and locating the Tower. Caution –
remove the Rail Mounting Bracket (causes the Tower to become top-heavy with a cantilevered
load and may fall over if not secured).
Ensure the Dowels are removed for the Rail Mounting Bracket (these will be used for the
Laser Targets)

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Sight in the Laser Tracker to establish the location of the Datum relative to X, Y, and Z axis
Continue to locate each dowel and surface in all planes, adjusting the Tower positions using Pry Bars, Hydraulic
Jacks, Mallets, and Socket Wrenches in an iterative (trial and error) process of small adjustments until the Tower is
located and leveled in place. Dowels and surface planes must be located within +/- .005” or .127mm Total
indicator reading (TIR).
Dowel #1 is located lower left and Dowel #2 is located upper right. Note – image shown is a
Lifter Tower, the Static Tower has the exact same hole pattern. Dowel hole numbers are
assigned by the Assembly Technician from the Layout Drawing.

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Image shows the Laser Target mounted into the Dowel (Position #1) for positioning the Tower in
the proper location relative to the X, Y, Z planes.
Image shows the Laser Target (magnetic mount) positioned in various locations on the mounting
surface to ensure that the surface plane is parallel to the X plane and perpendicular to the Y
plane. Note – image shown is for a Lifter Tower, the Static Tower has the exact same hole
pattern.

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Image shows the Laser Tracker (see below for picture of unit) and the Computer Screen (see
below for close up view of screen) with Dowel 1 & 2 locations relative to the X, Y, and Z Datum
Planes. The Towers will be fine-tuned using an iterative (trial and error) process until the proper
locations are achieved. This may take up to 5 hours per station.
Image of Laser Computer screen referencing Dowel locations relative to the Delta. Dowel 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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Image showing the X, Y, and Z axis relative to the PULSE Transfer System

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Dowel #1 is located lower left, and Dowel #2 is located upper right facing the Tower (both the
Static Tower and the Lifter Tower). Verify the geometric tolerancing.

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Using the “Tool Set Up” sheet information supplied for set up, locate each Tower (Dowels #1 and #2) per the X, Y,
and Z dimensions found on the following forms (examples only – see original Tool Set Up sheets supplied by
KUKA):
Image shows Dowel #1 and #2 locations for each set of Towers at each station

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(Examples only – see original Tool Set Up sheets supplied by KUKA):

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(Examples only – see original Tool Set Up sheets supplied by KUKA):

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Adjust position using an iterative (trial and error) process as shown below
Image shows fine tune adjustments being made to the Tower for vertical height adjustment, and
also establishing the mounting surface plane.
Image shows the use of a Wooden Mallet for side to side adjustment (X and Y direction) of the
Tower.

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Image shows the use of a Hydraulic Jack to position the Tower. Note how the Jack is positioned
between a piece of bar stock backed against threaded rods mounted in the Lag Bolt holes.
Image shows the use of a Small Pry Bar in adjusting the position of the Tower.

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Image shows the use of a Large Pry Bar in adjusting the position of the Tower.

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Once the Tower is in its proper location, the Foot of the Tower is welded in place using 3” Stitch Welds (see
photo).
• Important: Use 7018 Welding Rod or equivalent – this minimizes distortion of the Towers during
the welding sequence!
Note: Welding will continue to move the location of the Tower…continue to measure with the Laser
Tracker and adjust accordingly through the welding process.
Image shows section cut of set up – note the gap between the underside of the Mounting Plate and
the top of the Grout Plate.

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Image of Static Lifter with Foot welded in place
Image of Lifter Tower Foot welded in place

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5.4 Lifter Tower Set-Up
Note – use the same Grout Plate procedure as described for Static Tower
Note – use same alignment procedure (iterative trial and error process) as the Static Tower
Lifter Towers must be in the Full Up Position – Lockout Pin must be installed to ensure the Lifter is in the “Dwell
Position”. The pointer (see photo) will point at “zero”, but the Lockout Pin ensures accurate location.
• Note: Only one of the pair of Lifter Towers has a Pointer
Image shows pointer at “zero” position – indicating the Lifter is in the full up Dwell Position.

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Remove the Upper Guard (see photo)
Image shows Lifter Upper Guard in place

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Image shows Lifter with Upper Guard removed, and the Lifter in the full Up Position. Note the
pointers on the side of the unit – also indicating the full Up Position. Note: M20 Eyebolts are
not supplied with the Lifters.
The Rail Mounting Bracket must be removed before beginning the alignment process (the Bracket
causes a top heavy canter levered load that may cause the Tower to fall over). The Lifter may require
a Lift Assist (overhead crane or the like) to raise the Lifter Carriage to the full up position while
manually turning the Drive Shaft Flange. Be sure to use the Lockout Pin in the Up Position.
The Lockout Pin should be inserted through the Tower and into the Lift Screw. The Pin is located on
the lower right side. The Lockout Pin has a Pin Plug Disconnect.
Image shows the Lockout Pin inserted with Lifter in Up Position

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5.5 Attach Rail Mounting Brackets
Attach Rail Mounting Brackets AFTER the Tower Feet have been fastened and welded in place.
Image of Rail Brackets
Image shows Rail Bracket installed on Static Lift Tower

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Image shows Rail Bracket installed on Lifter
Note – use Laser Targets to verify (adjust if needed) Rail Mounting Surface Height, and ensure the
surface is level and the dowels are in the correct location +/- .010” or +/- .25mm.

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5.6 Attaching Rail to Mounting Brackets
5.6.1 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 Connector 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.
Image shows Rail Assemblies mounted to Rail Mounting Brackets on Static Tower (right) and
Lifter Tower (left).

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5.7 Lifter Drive and Drive Shaft Assembly
Locate and Lag Grout Plate for Lifter Drive into Floor – using overhead Projection System
Locate and Lag Grout Plate into floor

Drill Lag Bolts into Concrete
¾” (19.05mm) Lag Bolts (reference only)
Drill (12) holes for each Grout Plate – fill with epoxy as shown
Image shows ¾” (19.05mm) Lag Bolt set-up (reference only)

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Image showing Motor Plate Bolted to the Floor
Note: The Drive Shafts have compliance built in (angular and telescoping) – the Drive location is not
critical and can be +/- 3 degrees of misalignment relative to its designed location.

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Image shows Motor Plate Bolted on Floor
Note – The Brake Motor cannot be overcome by hand. Drive Shafts have a special assembly
sequence to the Lifter Towers.
Mount the Drive Shaft to the Motor Gearbox Flange first
Carefully remove the Lockout Pin from the Lifter and Rotate the Lifter Drive Shaft
Flange until the mounting holes of the Drive Shaft line up
Insert and properly Torque the Drive Shaft Screws

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Image shows Drive Shaft mounted to the Lifter Tower. The Drive Shaft will be mounted after it is
mounted to the Drive Gearbox Flange. Note that the bolts once torqued should be marked as
shown (see yellow markings).

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Connect All Electrical Pin Plug Connections
Connect all Electrical Pin Plug Connectors throughout the System
CAUTION: It is imperative that the identification numbers of the Pin Connectors match the Pin Plugs
exactly – especially the Motor Connectors – or serious damage may occur to the PULSE equipment.
Examples of various Pin Plug Connectors – Reference only

Refer to Schematics and Connector labels for proper connection

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Remove Lifter Tower Lockout Pins Before Cycling System
Lockout Pins Should be removed before cycling!
• Note: Check inside of the Lifter Tower to ensure the Ball Screw and the inside of the Column are
free of debris!
Image shows Lifter with Bellows in place

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Mount and Run Chassis Down System Before Powering
Mount the Chassis and run up and down the system in Jog Mode observing for any binds in the system, or any
interference with adjacent equipment, BEFORE running system in Hi Speed Automatic.

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5.8 PULSE Return Rail Mounting Kits
5.8.1 Mount Rails to the Return Rail Mounting Kits
Attach Rails (already upper and lower rail mounted together) to the Return Rail Mounting Kits. There are (3) Kits
per rail

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5.8.2 Mounting Return Rail Mounting Kits
Using a wire and level – adjust the Leveling screws of each Rail Mounting Kit until the Rails are aligned to each
other within 2mm and level. Level and locate the Rail Mounting Brackets using the Jack Screws and a Wooden
Mallet.

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5.8.3 Weld Angle Iron from the Return Rail Mounting Kits
Once the (3) Return Rail Mounting Kits are located – weld the Angle Iron (2 per each Kit) as shown. Check
alignment during the welding process, and adjust the Return Rail Mounting Kit position if required
Image shows Angle Iron welded in place
Image showing Angle Iron welded to the Return Rail Mounting Kit and the
Mounting Plate

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Note: Mount the Chassis and run up and down the system in Jog Mode before running the system in Hi Speed
Automatic. Check for interferences, loud noises, or binding – especially over the gaps in the Rails.
Image shows the Chassis Roller against the Rail on the Positive Side of the Rail
• Note: The magnetic field will always pull the Chassis against the Positive Side as shown. The Wheels
on this side will always be in contact with the Rail.

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Image shows the designed Chassis Roller gap (2 mm Clearance) on the opposite side of the Rail.
Due to the magnetic field – these Rollers will not touch the side of the Rails. They keep the
Chassis from tipping off of the Rails.
Ensure the Hard Stops are mounted to the ends of the Rails (in case of run-away condition)
Image shows Hard Stop mounted at the end of the Rail

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Connect All Electrical Pin Plug Connections
Connect all Electrical Pin Plug Connectors throughout the System
CAUTION: It is imperative that the identification numbers of the Pin Connectors match the Pin Plugs
exactly – especially the Motor Connectors – or serious damage may occur to the PULSE equipment.
Example of Pin Plug Connectors – Reference only

Refer to Schematics and Connector labels for proper connection

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Typical Pin Connectors – Ref. Only
Typical Pin Connectors – Ref. Only

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5.9 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 5.9.1: 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 5.9.2: 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 5.9.3: PULSE chassis assembly positioned on a pull-off cart.
Step 4: Utilize Lifting Straps to Pick Up the Pallet

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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 5.9.4: 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 5.9.5: Bottom side view of a pallet. Reference only.
Figure 5.9.6: Rough locators positioning over the chassis pin blocks.

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Figure 5.9.7: 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 5.9.8: 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.
3. To avoid damage to watches, instruments, and magnetic media (e.g. credit cards), keep these items 2 feet

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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.
5.10 Enclosure 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.

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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.
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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5.11 3-Phase Power Distribution
5.12Ethernet Communications

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5.13 24VDC Power Distribution

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5.14 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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5.15PULSE Hardware “Best Practices” for Version 2 Panels
1 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.
2 High speed static and flex cables look very similar. Read identification tags on the cables to differentiate
between the two.
3 When rolling out cable, unroll it as if the cable were on a spool. Try to avoid kinking the cable when unrolling.
4 Any cable showing end connector damage must be immediately set aside for further disposition.
5 Cables should be the correct size and not coiled up in the tray.
6 All power and communication cables should be separated in long cable trunking runs.
7 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 Carrier 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 Carrier system
to fall, resulting in injury.
Using unsuitable lifting tackle can damage the PULSE Carrier 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
2. Transport eyebolts on the enclosure

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

7. Slowly lift and transport the enclosure.
8. Slowly lower the enclosure at its destination.
9. Unhook the lifting tackle on the enclosure.
6.2 Transportation by Fork Lift Truck

Preconditions

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Procedure
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

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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.
• Chassis are not to be stored directly over ferrous material such as motors in a rail for
longer than one week at a time without moving the chassis. Failure to do so could
result in premature roller assembly failures.
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.

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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

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No access for those with metallic implants.

1.4.2 Mandatory Signs

1.4.3 Warning Signs

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Warning magnetic field!

Warning pressurized device!

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EC declaration of conformity and declaration of incorporation

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In the absence of functional safety devices, the PULSE

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Designed gap between bottom of Column to top of Grout Plate

Designed gap between bottom of Column to top of Grout Plate

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Image shows the ¾” (19.05mm) Lag Bolt correctly installed as a reference

5.3 Static Tower set-up

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Image of Lifter Tower Foot welded in place

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• Note: Only one of the pair of Lifter Towers has a Pointer

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Image shows Lifter Upper Guard in place

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Image shows the Lockout Pin inserted with Lifter in Up Position

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Image of Rail Brackets

Image shows Rail Bracket installed on Static Lift Tower

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