Kuka Pulse Quick start guide

KUKA Systems North America LLC., 6600 Center Drive, Sterling Heights, MI 48312, USA T [phone] F [phone]
[e-mail] www.kuka.com
PULSE SYSTEM
PULSE Commissioning & Troubleshooting Manual
Original Instructions
Revision: Release
Publication Date: August 15, 2019
PULSE_DC_OM_Commissioning&TroubleshootingManual_V.190815

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TABLE OF CONTENTS
1 INTRODUCTION.....................................................................................................................................................4
1.1 About This Manual.........................................................................................................................4
1.1.1 Important.......................................................................................................................................4
1.1.2 Copyright Notice ............................................................................................................................4
1.1.3 Graphics and Illustrations ..............................................................................................................4
1.1.4 Contact Information.......................................................................................................................4
1.1.5 Special Notations ...........................................................................................................................5
1.2 Documentation Overview..............................................................................................................6
1.2.1 Documentation Package Contents.................................................................................................6
1.2.2 OEM Literature...............................................................................................................................7
1.2.3 Health & Safety Statement ............................................................................................................8
1.2.4 Glossary..........................................................................................................................................9
1.3 Panel Identification......................................................................................................................11
1.3.1 Electrical Nameplate Example .....................................................................................................11
1.4 PULSE System Definition/Description..........................................................................................12
1.5 Benefits of PULSE System.............................................................................................................12
2 TECHNICAL DATA - ARCHITECTURE OF CONTROLS..............................................................................................13
2.1 Node Controller Panel..................................................................................................................15
2.1.1 Master Slave Hardware Configuration.........................................................................................18
2.1.2 Node Controller Panel Grounding Installation.............................................................................21
2.2 NCP Lockout Procedure ...............................................................................................................22
2.3 Station Drive Panel.......................................................................................................................25
2.3.1 RS-422 Communication Jumpers .................................................................................................27
2.3.2 Best Practices...............................................................................................................................28
2.3.3 Rail Layout Practices ....................................................................................................................32
2.3.4 SDP Lockout Procedure................................................................................................................33
2.4 Motor Types.................................................................................................................................36
2.5 Communications ..........................................................................................................................36
2.5.1 Communication Protocol .............................................................................................................37

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2.6 Wiring and Grounding..................................................................................................................37
2.6.1 Excess Cable .................................................................................................................................38
2.7 Power Distribution.......................................................................................................................39
2.8 Panel Maintenance ......................................................................................................................40
2.9 Track Section Chassis Placement .................................................................................................41
3 SAFETY ………………………………………………………………………………………………………………………………………………………….43
3.1 General ……………..........................................................................................................................43
3.1.1 Liability ………................................................................................................................................43
3.1.2 Intended Use of the PULSE System..............................................................................................43
3.1.3 Residual Risks...............................................................................................................................44
3.1.4 EC DOC & DOI...............................................................................................................................44
4 TRANSPORTATION ...............................................................................................................................................46
4.1 Transporting using Lifting Tackle..................................................................................................46
4.2 Transportation by Fork Lift Truck .................................................................................................47
4.3 Transportation by Pallet Truck .....................................................................................................48
5 START-UP AND RECOMMISSIONING....................................................................................................................49
5.1 Start-up Overview........................................................................................................................49
5.2 Installing the PULSE System .........................................................................................................49
6 MAINTENANCE....................................................................................................................................................50
7Repair...........................................................................................................................................52
7.1 Repair and Procurement of Spare Parts.......................................................................................52
8 PULSE TROUBLESHOOTING.................................................................................................................................53
8.1 PULSE Panel Troubleshooting ......................................................................................................53
8.1.1 Hardware Troubleshooting ..........................................................................................................53
8.1.2 Transformer Wiring Diagram........................................................................................................53
8.1.3 PULSE NCP Wiring........................................................................................................................54
8.1.4 PULSE SDP Wiring ........................................................................................................................54
8.1.5 PULSE Motor Wiring ....................................................................................................................55
8.1.6 Clearing a Fault ............................................................................................................................55
8.1.7 Troubleshooting Table..................................................................................................................56
8.2 PULSE Power Fault Recovery........................................................................................................56
8.3 PULSE HLC Jammed, Hindered & Stall Faults...............................................................................57

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8.4 Ghost Vehicles..............................................................................................................................57
9 PULSE SOFTWARE HELPFUL HINTS......................................................................................................................58
9.1 Software Requirements and Revision Level.................................................................................58
9.2 Node Controller Standard Files....................................................................................................58
9.2.1 Nodes ...........................................................................................................................................58
9.3 Motors..........................................................................................................................................58
9.4 Commission a HLC/NC (High Level Controller/Node Controller).................................................59
9.5 Go Online with the Node Controller for First Time......................................................................59
9.6 Load the Configuration Files ........................................................................................................60
9.7 PID Loop Chart .............................................................................................................................63
9.8 Motor Gaps..................................................................................................................................64
9.9 Recommended Virtual Machine Settings ....................................................................................64
10 PULSE VEHICLE RECOVERY SCENARIOS.............................................................................................................66
10.1 Mainline Station Recovery Rules..................................................................................................66
11 DECOMMISSIONING, STORAGE, AND DISPOSAL...............................................................................................67
11.1 Decommissioning.........................................................................................................................67
11.2 Storage .........................................................................................................................................67
11.3 Disposal........................................................................................................................................67
12 ISO HAZARD LABELS ..........................................................................................................................................69
12.1 Description of Labels....................................................................................................................69
12.1.1 Marking Labels.............................................................................................................................69
12.1.2 Mandatory Action .......................................................................................................................69
12.1.3 Prohibition Labels ........................................................................................................................71
12.1.4 Hazard Labels ...............................................................................................................................71
12.1.5 OEM Hazard Labels ......................................................................................................................71
13 OEM REFERENCES .............................................................................................................................................72
13.1 Node Controller Panel OEM Information.....................................................................................72
13.2 Station Drive Panel OEM Information..........................................................................................72
13.3 Linear Motors OEM Information..................................................................................................72
13.4 QuickStick High Thrust Gap Permission Blocks............................................................................72
13.5 PULSE Lubrication Information ....................................................................................................72

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1INTRODUCTION
1.1 About This Manual
1.1.1 Important
At KUKA, we make every effort to ensure that our documentation accurately describes the operation
and maintenance of our products. However, KUKA cannot guarantee the accuracy of printed material
or accept responsibility for errors or omissions.
1.1.2 Copyright Notice
Copyright ©2016 by KUKA.
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or
transmitted in any form or by any means, electronic, mechanical, photocopying, recordingor otherwise,
without the prior written permission of KUKA.
1.1.3 Graphics and Illustrations
All drawings, illustrations and photographs are provided to expand and enhance the text. These
graphics are representations only. They are not drawn to scale. For accurate drawings, refer to the
Mechanical Drawing Package and Electrical Drawing Package supplied by KUKA.
1.1.4 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. [phone] (x9)
https://www.kuka.com/en-us/services/service-vor-ort
Authorized Representative:
KUKA Systems GmbH
Blücherstrasse 144 | 86165 Augsburg | Germany
Tel. [phone]

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1.1.5 Special Notations
This guide uses five levels of notation:
DANGER!
Danger messages alert readers to situations that will result in serious injury or
death.
WARNING!
Warning messages alert readers to situations that may result in serious injury
or death.
CAUTION!
Caution messages alert readers to situations that may result in minor or
moderate injury.
IMPORTANT!
Caution messages with an exclamation mark alerts reader to situations that
may result in equipment damage.
NOTE
Note messages provide additional information, emphasize a point or provide a
tip.
MAGNETIC FIELD HAZARD
Indicates a strong magnetic field is present that could cause personal injury.
Safety notes
The execution of work by persons with cardiac pacemakers is forbidden! The
function of the cardiac pacemaker can be impaired by the magnetic fields;
severe injuries could be the result.
The strong magnetic fields, which are present, constitute a hazard for persons
with implants that can be influenced by magnetic fields. As a general rule, all
persons who may suffer impairment to health through the influence of strong
magnetic fields must keep a safe distance of at least 1 meter from the
magnets.
Always wear gloves when working on the chassis. Because of the high
magnetic attraction forces, special care must be taken in surroundings of
about 8in (20cm) from the magnetic plates. Inside this area, objects heavier
than 2.2lbs (>1kg) or larger than 4in² (>1dm²) of steel or iron must not be held
in the hand.

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1.2 Documentation Overview
This manual describes PULSE system hardware, including an overview, operating instructions, fault
recovery procedures and maintenance information.
1.2.1 Documentation Package Contents
This manual is part of a package of documentation KUKA provides with this system. The entire package
consists of:
•Operations and Maintenance Manuals
•Mechanical Drawings
•Electrical Drawings
•Mechanical BOM
•Electrical BOM
•Spare Parts List
•Software Programs
•OEM Literature
Together, these documents provide comprehensive information for operating, maintaining, and
troubleshooting the system.
We have reviewed the contents of this publication to ensure consistency with the hardware and
software described. Since variance cannot be precluded entirely, we cannot guarantee full consistency.
However, the information in this publication is reviewed regularly and any necessary corrections are
included in subsequent edition revisions.

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1.2.2 OEM Literature
KUKA compiles an organized package of OEM literature as it is received from our suppliers.
Please note the following:
•If the OEM literature for a specific device is not included in the package provided by KUKA,
please contact KUKA Systems directly for the information.
•Suppliers often revise and update their information. For the most current version of the
literature, please contact the manufacturer directly.
Victor Schoenek
Product Manager - PULSE
-------------------------------------------------------------------------------
KUKA Systems North America LLC
6600 Center Drive | Sterling Heights | MI |48312 | USA
Tel. [phone] (x 5230)
Cell [phone]
[e-mail] | www.kuka.com
Joe Moceri
Program Manager - PULSE
-------------------------------------------------------------------------------
KUKA Systems North America LLC
6600 Center Drive | Sterling Heights | MI |48312 | USA
Tel. [phone] (x 4437)
Cell [phone]
[e-mail] | www.kuka.com
Joe Godlewski
Production Control Engineer - PULSE
-------------------------------------------------------------------------------
KUKA Systems North America LLC
6600 Center Drive | Sterling Heights | 48312 | MI | USA
Tel. [phone] (x 4576)
Cell. [phone]
[e-mail] | www.kuka.com

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1.2.3 Health & Safety Statement
KUKA makes every effort to design automation systems that operate in a safe and predictable manner.
It is the customer's responsibility to service and maintain the system, including periodic testing of safety
devices to ensure they function properly.
It is also the customer's responsibility to ensure that personnel using the system are properly trained in
the system's operating, safety and emergency procedures, industry safety standards and to ensure that
these procedures and practices are adhered to.
Any system modifications (including software and hardware) not authorized by KUKA may affect the
safe operation of the system and result in personal injury.
Failure to meet these responsibilities or any unauthorized attempt to modify the system will void KUKA-
provided warranties.

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1.2.4 Glossary
Term
Description
Filler Rail
A section of FRP rail installed at
the beginning or end of the line
used to bridge the gap between
the main line and a transitional
unit, i.e. a PULSE Turntable or
Vertical Drop Lifter (VDL).
Hall Effect Sensor (HES)
A transducer that varies its output
in response to changes in a
magnetic field.
Hall Effect Sensors (HES) are used
by MagneMotion LSM’s for
vehicle positioning
and speed detection.
JPH
Jobs per hour
Linear Motor
A linear motor is an electric
motor that has had
its stator and rotor "unrolled" so
that instead of producing
a torque (rotation) it produces a
linear force along its length.
Linear Synchronous Motor (LSM)
A linear synchronous motor is a
linear motor that when placed in an
array of other linear motors, acts as
one in a synchronous manner
through hardware and software.
Magnet Array
The high flux magnet array for the
QuickStick HT motors is an
arrangement of neodymium
iron boron (NdFeB) permanent
magnets in a Halbach-type array
that augments the magnetic
field on the side of the array facing
the motor while cancelling the field
to near zero on the
other side, with the magnets placed
perpendicular to the direction of
motion. They come in
several lengths and widths, with full
magnets of alternating polarity in
the middle of the array
and a North oriented half magnet at
each end of the array.
Magnetic Field
A region around a magnetic
material or a moving electric

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charge within which the force of
magnetism acts.
MTBF
Mean Time Between Failures is a
measure of how reliable a hardware
product or component is. For most
components, the measure is
typically in thousand or even tens of
thousands of hours between
failures.
MTTR
Mean Time To Repair is a basic
measure of the maintainability of
repairable items. It represents the
average time required to repair a
failed component or device.
NC
Node Controller
NCP
Node Control Panel
OSP
Operator Safety Panel
PLC
Programmable Logic Computer
PULSE
Propulsion Using Linear
Synchronous Energy
QSMC
QuickStick Motor Controller
SDP
Station Drive Panel
Stator
The stationary part of the motor
over which the magnet array
moves.

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1.3 Panel Identification
1.3.1 Electrical Nameplate Example

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1.4 PULSE System Definition/Description
PULSE is a KUKA proprietary electromagnetic propulsion technology designed for use in Automotive
BIW transfer systems. At the core of the system, is the revolutionary use of Linear Synchronous Motor
(LSM) technology with powerful motion controls. The use of this technology instantly reduces the
overall number of electrical and mechanical components. From a maintenance standpoint alone, this
will dramatically increase MTBF and reduce MTTR providing more uptime for demanding production
schedules. Another advantage of the PULSE system is the embedded anti-collision control capabilities
which greatly reduces the risk of in-process damage from occurring to the product(s) being
manufactured. By leveraging the combination of advanced motion control, an efficient and
environmentally friendly alternative to traditional transfer systems has been achieved. With the
availability of flexible, innovative and scalable designs, the PULSE transport system provides the ability
to achieve new heights of manufacturing capabilities.
1.5 Benefits of PULSE System
•PULSE transfer system is faster than the conventional transfer. For a targeted 90 JPH
production line, the faster PULSE transfer system increases productivity by 7%.
•Shared components from end to end (e.g. motors, controllers, cables), reduces component
inventory.
•Linear Synchronous Motors require less sensors, cord sets and items susceptible to damage.
No moving parts within the motors.
•Embedded position monitoring in the motors that allows chasing and precise location. Less
maintenance, reduction of downtime and increase of throughput.
•Anti-collision feature embedded in the control hardware equipment
•Safe and unique advantage: optimum acceleration and deceleration. Positive response.
•Reduces cycle time by allowing chase between vehicles.
•Reduced noise emissions compared to conventional transfer technologies.
•Distributed control of rail sections allows for smaller control enclosures.

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2TECHNICAL DATA - ARCHITECTURE OF CONTROLS
The PULSE system’s control scheme is a distributed control system. The PULSE hardware consists of
three types of panels:
•NCP –Node Controller Panel
•SDP –Station Drive Panel
•OSP –Operator Safety Panel
The Node Controller Panel is a power and communication distribution panel and the NC is essentially a
traffic manager of the motor controllers. Every NCP is paired with a transformer with different
configurations depending of the country of destination
•51KVA 480VΔ-Y 60 Hz Isolation Transformer (North America)
•51KVA 400VΔ -Y 50 Hz Isolation Transformer (EU/UK)
.
Architecture Layout
VDC

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Consider the following during installation:
•Ventilation
•Weight Load
•Clean Environment
•Accessibility
•Proper Ground Techniques
•Input Source Voltage
•Distribution Power
•Room Temperature
•Clearances
Station Drive Panel
Node Controller Panel

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2.1 Node Controller Panel
Node Controller Panel (NCP) –typically communicates one-to-one with a PLC. It acts as the power
distribution panel for the PULSE SDPs and contains the NC-12 Node Controller module that provides an
Ethernet port to establish communication with the PLC. It also utilizes twelve RS-422 ports used to
coordinate all Station Drive Panel operations. One NCP provides power and communication for up to
four Station Drive Panels.
Main Disconnect
24VDC Power Supply
Above Disconnect
NC-12
Transformer Circuit
Breaker
Battery
(24VDC)
24VDC Circuit Breakers
for Station Panels
Node Controller Internal View

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•Input Power: 400VAC 3 phase 50Hz 100A (EU)
480 VAC 3 phase 60Hz 100A (North America)
•Output Power: 240 VAC 3 phase 50/60Hz
24 VDC @ 40A
NOTE: FLOOR MOUNTED TRANSFORMER SHOULD BE MOUNTED AS CLOSE
TO THE NCP PANEL AS PHYSICALLY POSSIBLE BUT ALSO NOT IMPEDE
EQUIPMENT PLACEMENT.
Power Distribution Example

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Common features found on the exterior of the Node Control Panel enclosure includes:
•Main Disconnect switch –This switch is used to enable/disable electrical power to the panel,
however the small power supply enclosure inside the panel remains powered after the
disconnect is open.
•Ethernet Ports –Five ports are provided. Port ETH0 is the incoming communication port from
the Customer’s PLC while ports ETH1-ETH4 are designated for the Station Drive Panels.
•480/400VAC IN - Incoming power from Customer Power Distribution Panel
•480/400VAC OUT- Outgoing power to feed the Transformer
•240VAC IN- Incoming power from the Transformer
Node Controller Panel

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•240 VAC OUT1 to OUT4 -Outgoing power feeds to the Station Drive Panels.
The power supply enclosure is small enclosure located within the NCP. It contains the 24VDC Power
Supply and provides 24VDC to all PULSE hardware.
Certain devices of the PULSE hardware use a battery backup system for safety. For detailed information
on the contents of the main electrical enclosure, refer to the appropriate electrical schematic included
in the Electrical Drawing Package supplied by KUKA.
2.1.1 Master Slave Hardware Configuration
When more than one NCP is used per PLC zone, the NC-12 node controller must be set up in a
master-slave configuration. If there is a path that allows vehicles to travel through the boundary
between master and slave NC-12s, then that path must start in one NC and end in the next NC. This
requires the SDP to wire to both NCPs. The software configuration must match according to the
physical cabling. The following graphics show two methods of utilizing the SDP as a communication
bridge between a master NCP and a slave NCP, and one example where no communication bridge is
needed.
Power Supply Enclosure

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Figure 1
Figure 2