Ketterer KuLi Series User manual

3215.72-01i01 Rev. A
Assembly instructions
„KuLi - electric short stroke linear actuator“
3215.00-XXXX
Ori inal assembly instructions for partly completed machines
Accordin to machinery directive 2006/42/EG
Attachment VI
Document No. 3215.72-01i01
04 / 2022

3215.72-01i01 Rev. A
B. Ketterer Söhne GmbH & Co. KG
Bahnhofstraße 20
78120 Furtwan en
Phone: [phone] / 6569-10
E-Mail: [email protected]
Internet: www.ketterer.de
© 2022 B. Ketterer Söhne GmbH & Co. KG • 78120 Furtwan en
All ri hts reserved, in particular the ri ht of reproduction, distribution and translation. No part of this
manual may be reproduced in any form or saved, processed, duplicated or distributed usin electronic
systems without the written consent of B. Ketterer Söhne GmbH & Co. KG.
Subject to modifications.

3215.72-01i01 Rev. A
Scope
1 Introduction 1
1.1 Content 1
1.2 Scope 1
1.3 Standards and directives 1
1.4 Warnin s and symbols used 2
1.4.1 Structure of the section-specific warnin s 5
1.4.2 Structure of the embedded warnin s 5
2 Safety Instructions 6
2.1 Personnel - Qualification und obli ations 6
2.2 Obli ations of the operator 7
2.3 General safety instructions 7
2.4 Use 8
2.4.1 Intended use 8
2.4.2 Foreseeable misuse 8
2.5 Residual risks 9
3 Product description 10
3.1 Description of the Kuli 10
3.2 Product Versions 10
3.2.1 Visualization of the possible connector positions 11
3.2.2 Available accessories 11
3.3 Technical data / operatin conditions 12
Technical data / operatin conditions 12
3.4 Dimensions 15
3.5 General requirements for the master control system 16
4 Packing / ransport / Unpacking / Storage 17
4.1 Packin / Transport 17
4.2 Unpackin 17
4.3 Stora e 17
5 Assembly 18
5.1 Mechanical mountin instructions 18
5.1.1 Fixin the KuLi in the application 19
5.1.2 Connection to the liftin plate 19
5.1.3 Effect of radial forces 20
5.2 Installation instructions for the qualified electrician 21
6 Start-Up 22
7 Programming 25
7.1 Parameterization with software versions DM / SM / PM / EX 25
7.1.1 Assembly and start-up of the Connect Box 26
7.1.2 Parameterization software 27
7.2 Pro rammin via master control 30

3215.72-01i01 Rev. A
7.2.1 Reference run durin operation 30
7.2.2 Teach run durin operation 31
7.2.3 Teachin the travel ran e after switchin on 32
8 Operation 33
9 Disassembly / Shutdown 35
10 Maintenance 37
11 Self-help and diagnosis in case of malfunction 38
12 Disposal 39
13 Repair 39
EC Declaration of incorporation 40

Introduction
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1 Introduction
1.1 Content
 This documentation is intended to help you work safely on and
with the "Kuli". It contains safety instructions that must be
followed for all work performed on and with the Kuli system.
 The documentation must be made accessible to all persons who
work on and with the Kuli. They must have understood the
documentation and follow the specifications and instructions
relevant to them.
 The documentation must be always complete and in a clearly
readable condition.
Please read these instructions carefully and fol
low the safety
instructions!
Depending on the version or modification status of the
product, there may be differences compared to these
instructions.
1.2 Scope
These instructions are valid for the partly incomplete machine
with article numbers:
3215.00-0005 to 3215.00-0020
3215.00-0034F001
Drawin s dated 21/02/2022 are applicable.
1.3 Standards and directives
The KuLi is an "incomplete machine" accordin to Article 2,
Para raph ), MRL 2006/42/EC.
The conformity assessment procedure was carried out in
accordance with Machinery Directive (MRL) 2006/42/EC.
The KuLi is desi ned accordin to compliance with 2011/65/EU
(RoHs) and 2014/30/EU (EMC).
he manufacturer of the overall system in which the KuLi is
installed must check and ensure compliance with the essential
requirements of the MRL before placing the overall system on
the market.

Introduction
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1.4 Warnings and symbols used
The safety si n visually represents a source of hazard. The safety
si ns in these assembly instructions comply with DIN EN ISO
7010.
The followin picto rams and si nal words are used in this
documentation to indicate hazards and important information:
Pictogram Description
Warning of a general hazard
This warnin si n is placed in front of activities where several causes
can lead to hazards.
Hot surface warning
This warnin si n stands in front of activities where there is a hazard
from hot surfaces which can lead to burns.
Warning of electric shock
This warnin si n stands in front of activities where there is a risk of
electric shock, possibly with lethal consequences.
Warning against non-ionizing radiation
This warnin si n indicates activities involvin hazards due to non-
ionizin radiation.
Warning of magnetic fields
This warnin si n indicates activities
involvin hazards due to
ma netic fields.

Introduction
3215.72-01i01 Rev. A P a e | 3
Pictogram Description
Warning of unexpected / automatic start-up.
This warnin si n stands in front of activities where an
unexpected / automatic start-
up of rotatin components can
occur.
Warning of crushing hazard
This warnin si n stands for activities where hazards exist due
to crushin and shearin points which can lead to crushin
injuries.
Follow instructions
Information

Introduction
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In these assembly instructions, the followin dan er levels are
used to indicate potentially hazardous situations and important
safety instructions:
Hazard level Description
Indicates a hazardous situation which, if not avoided, will
result in death or serious irreversible injury.
DANGER!
Indicates a hazardous situation which, if not avoided, could
result in death or serious irreversible injury.
WARNING
!
Indicates a hazardous situation which, if not avoided, could
result in minor or moderate injury.
CAU ION!
Indicates a potentially hazardous situation. If not avoided, the
equipment or somethin in its environment may be
dama ed.
INFORMA ION!

Introduction
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1.4.1 Structure of the section-specific warnings
The section-specific warnin s apply not only to one specific
action, but to several actions within a chapter. The hazard
symbols used indicate either a eneral or specific hazard.
The warnin is structured as follows:
SIGNAL WORD!
Nature of the hazard and its source.
Possible Consequence(s) of disre ard.
► Action(s) to avoid the hazard.
1.4.2 Structure of the embedded warnings
The embedded warnin s are directly inte rated into the action
before the dan erous action step.
The embedded warnin is structured as follows:
SIGNAL WORD! Nature of the hazard and its source.
Possible Consequence(s) of disre ard.
Action(s) to avoid the hazard.

Safety Instructions
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2 Safety Instructions
Read the safety instructions and information on safe operation
in these assembly instructions carefully before starting work.
Keep these assembly instructions in a safe place and give them
to others if necessary.
It is very important for your safety that you understand and
follow all safety instructions.
Non-observance may result in da
nger to the life and health of
persons and cause extensive damage to property.
2.1 Personnel - Qualification und obligations
Information
All activities on the KuLi may only be carried out by competent
and qualified persons.
he competent and qualified persons must...
...know and be able to apply the relevant accident prevention
re ulations and safety instructions in the technical
documentation.
...be suitably trained for electrical work (electrician).
...have been trained and instructed in accordance with the rules
of behaviour in the event of a malfunction.
...have the physical and mental capabilities to carry out his
responsibilities, tasks and activities at the KuLi.

Safety Instructions
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2.2 Obligations of the operator
Every person who works with the Kuli has a responsibility to
ensure safety and health protection. They must be trained in the
use of the Kuli.
A safety-related condition and use of the Kuli is a requirement
for safe operation. Therefore, the operator has the
responsibility to ensure that the followin points are complied
with:
 Ensure that the Kuli is only operated by trained and authorized
personnel!
 Prohibit safety-endan erin and dan erous workin methods!
Check the actions of the personnel!
 Always keep this document in a complete and readable
condition!
 Obli ate the operatin and maintenance personnel to report
occurrin and reco nizable safety defects immediately to their
superiors!
 Durin start-up and operation, the operator must ensure that
there are no persons in the dan er zone. The dan er zone
depends on the function and dimensions of the end product in
which the Kuli is installed.

2.3 General safety instructions
 General le al re ulations or uidelines on work safety, accident
prevention re ulations and environmental protection laws must
be observed.
o be provided by the integrator:
 A stop device for the emer ency of the KuLi (emer ency stop or
emer ency shutdown) shall be provided by the inte rator.
Personal Protective Equipment (PPE):
 The use of personal protective equipment (PPE) depends on the
environmental conditions of the actual operatin location in the
overall system and is to be defined by the operator.

Safety Instructions
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2.4 Use
The KuLi is only intended for industrial systems, for installation
in machines within the meanin of MRL 2006/42/EC.
The KuLi has been desi ned and built for use in accordance with
its intended use. If you use the KuLi for a purpose other than the
one listed, the manufacturer cannot be made liable for any
dama e resultin from this.
2.4.1 Intended use
The intended use of the KuLi is to perform a centric pressure- or
tension-loaded stroke. The loads can be moved, held or
positioned.
The KuLi may only be operated with an anti-rotation lock on the
plun er and in combination with a suitable hi her-level control
system.
The KuLi may only be used in indoor applications in industry.
The KuLi may only be operated within the operatin conditions
specified in this document (chapter 3.3 "Technical data /
Operatin conditions").
The KuLi may only be operated in one of the three operatin
modes. If operation outside of these modes is intended, this is
only possible in consultation with the manufacturer.
2.4.2 Foreseeable misuse
Misuses are:
 Any use other than the intended use without the written
consent of the manufacturer.
 Operation in the ran e outside the operatin conditions
specified in this document (chapter 3.3 "Technical data /
operatin conditions"), if these have not been a reed with the
manufacturer.
 Interventions in the components or in the system durin
operation.
 Non-functional assembly in which the plun er rod / uide is
firmly fixed and thus the housin of the KuLi carries out the
stroke movement
 If the KuLi is in extended state connected to the PC/laptop and
the Connect-Box and this link is disconnected when the supply
volta e is switched on, the KuLi moves to the inner reference
point.

Safety Instructions
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2.5 Residual risks
Despite all actions taken to inte rate safety in the desi n, safety
provisions and additional protective actions, non-obvious
residual risks cannot be completely avoided. You can reduce
residual risks by carefully followin the safety instructions and
the intended use.
Life phase / Activity
Residual risk
Packin
/ Transport /
Unpackin
/
Assembly / Maintenance / Disassembly /
Service / Repair
Cutting injuries
Despite strict quality controls, parts of the Kuli, as well as the
accessories and packa in , may have sharp ed es and
corners which can lead to cuts. Make sure that you wear
suitable protective ear whenever handlin the Kuli.
Start
-
Up
/
Operation
/
Maintenance
/
Disassembly / Service / Repair
Hot surfaces
Dependin on the load and environmental temperature, the
surfaces of the Kuli may reach temperatures of over 90 °C.
Only perform necessary activities directly with the Kuli after
it has cooled down completely.
Assembly
/
S
tart
-
Up
/
Operation
/
Maintenance / Disassembly / Service /
Repair
Electrical voltage / residual energy
Residual electrical ener y may remain in lines, electrical
components, equipment and devices when the Kuli is
switched off. Only allow work on the electrical supply to be
carried out by qualified electrical personnel. Make sure that
all phases and the complete electrical system are volta e-
free. There must be no residual volta e left in the system, so
wait at least 5 minutes after complete disconnection from
the power supply before carryin out the necessary work.
Start
-
Up
/
Operation
Uncontrolled movements
Incorrect assembly or control of the KuLi can lead to
uncontrolled movements. There is a risk of injury in this case.
Only use the KuLi after it has been correctly installed in
accordance with the installation instructions and only in
combination with a suitable master control system.
Maintenance
/
Disassembly
/ Service /
Repair
Automatic start
-
up
If the KuLi is not secured a ainst unauthorized restart when
it is shut down, there is a risk of unexpected start-up, which
can lead to serious injuries. Secure the mains disconnection
device by suitable means (key, lock).
Start
-
Up
/
Operation
/
Maintenance
rapping, pulling in, gripping, crushing
The stroke movement of the KuLi can cause objects, items of
clothin or body parts to be trapped, pulled in, ripped or
crushed. Therefore, never carry out activities on the KuLi
when it is in operation.
Start
-
Up
/
Operation
Breakage
Overloadin the KuLi above the specified load limits can lead
to breaka e and thus to injury or dama e to property.

Product description
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3 Product description
3.1 Description of the Kuli
The KuLi is a compact and fast electrically driven linear actuator.
The Kuli is intended for use in automation and material handlin
technolo y. There it can replace pneumatic cylinders, for
example. With a housin len th of 68 mm, the KuLi performs a
stroke of 40 mm. The push/pull forces are up to 300 N.
Maximum speed in load-free condition is 445 mm/s. Parameters
are set via a separately available connect box (described in
chapter 6.4). The entire electronics for control are inte rated.
3.2 Product Versions
Short-stroke linear actuator KuLi is available in different
versions. The versions are based on the orderin key shown
below.

Product description
3215.72-01i01 Rev. A P a e | 11
3.2.1 Visualization of the possible connector positions
 The followin connector positions are possible:
3.2.2 Available accessories
 Connect Box (part number 3215.49-01)
The KuLi "Connect-Box" parameterization adapter is desi ned to
transfer pro rammin from the PC to the KuLi and, in
combination with a PC software, it allows various parameters to
be set. The Connect-Box can also be used as a display for the
si nals of the PLC interface.

Product description
3215.72-01i01 Rev. A P a e | 12
3.3 echnical data / operating conditions
INFORMA ION!
 The data was determined at an ambient temperature of 20°C.
 The technical data applies to KuLi versions with 6mm spindle pitch
(KuLi-B6-XX-X-XX-X-X). The technical data for KuLi with 1mm pitch
(KuLi-B1-XX-X-EX-X-X) are available in consultation with the
manufacturer.
* One cycle = extend-pause-retract-pause
* Dependin on load and cycles, a chan e in repeatability due to wear is to be expected.
echnical data / operating conditions
Dimensions (without connector) Len th: 81.8 mm, Width: 49 mm, Hei ht: 90 mm
Wei ht 0,9 k
Material of the housin Zinc die castin ZP5 / aluminium
Stroke len th / Max. stroke 40 mm
Spindle pitch 6 mm
Max. Push / Pull force (dynamic) 300 N (B6) / 500 N (B1)
Max. Speed (load-free) 445 mm/s
Max. Holdin force (static) 500 N
Supply volta e 24V DC +10% / -25%
Current consumption 4 A
Max. Current consumption (peak) 10 A
Power consumption 240 W
Resolution of the encoder system +/- 0,15 mm
Repeatability* +/- 0,2 mm
IP protection class IP24
Ambient temperature +5 - +42°C
Lifetime at 10 N load * 20 Mio. Cycles
Shock resistance in static condition
accordin to IEC/DIN EN 60068-2-27 50 ; 11ms
Vibration resistance in static condition
accordin to IEC/DIN EN 60068-2-6 10…2000 Hz 5 10 frequency cycles

Product description
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Software-Version
Dynamic
Mode
Standard
Mode
Power
Mode
Max. Push / pull force [N]
(horizontal mountin position) 100 200 300
Avera e speed at 40mm* [mm/s]] 267 160 114
Avera e travel time [s] 150 250 350
Max. number of cycles*
[Cycles / min.] 46 29 12
Duty cycle ED
Time per cycle*
Holdin time per cycle*
23%
0,3 s
1 s
24 %
0,5 s
1,4 s
13 %
0,7 s
4,5s
* One cycle = extend-pause-retract-pause
If finer force/travel time settin s are required, this can be done
in 50N increments usin the parameterization software via PC
(see Chapter 7.1).
The Expert Mode software variant (EX: KuLi-BX-VS-X-EX-X-X)
offers a maximum of adaptation options to your application.
Individual parameterization in the EX software variant (Expert
Mode) must be carried out by Ketterer. After parameterization,
start-up must also be carried out in coordination with Ketterer.
The parameterization in Expert mode offers the followin value
ran es:
Expert Mode
KuLi-B6 (6mm)
Expert Mode
KuLi-B1 (1mm)
Max. Push / pull force [N] 0 - 300 0 - 500
Ø Speed at 40mm [mm/s] 455 - 114 75 - 15
Travel time 40 mm [s] 0,09 – 0,35 0,54 – 2,67
Max. number of cycles*
[Cycles / min.] 103 - 12 40 - 6
* One cycle = extend-pause-retract-pause

Product description
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The lifetime may vary dependin on operatin and installation conditions and is load dependent. See
followin fi ure.

Product description
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3.4 Dimensions
The dimensions of the KuLi for all possible connector positions
are shown below:

Product description
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3.5 General requirements for the master control system
The controller must have the followin functionalities:
I/O control:
The KuLi short-stroke linear actuator can be connected to the
control system usin a simple M12 cable.
In I/O mode, the actuator is controlled via the di ital input
(control input).
Operation commands:
0V at control input  push rod retracts
24V at control input  push rod extends