Kuka Pulse User manual

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 Pallet Assembly Instructions Manual
Original Instructions
Revision: Release
Publication Date: April 19, 2018
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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
2INTENDED USE..................................................................................................................................................5
3SAFETY .............................................................................................................................................................. 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
4TOOLS REQUIRED............................................................................................................................................13
4.1 Tools Required for PULSE Installation ....................................................................................................13
5INSTALLATION .................................................................................................................................................14
5.1 PULSE Pallet Mounted System...............................................................................................................14
5.1.1 Prerequisites ..........................................................................................................................................14
5.1.2 Energy Control and Power Lockout (ECPL).............................................................................................18
5.1.3 Set-up ……………………………………………………………………………………………………………………………………………… 21
5.1.4 X, Y, Z Target Hole Locations for Each Sub-Assembly .............................................................................25
5.1.5 X, Y, and Z Laser Target Holes & Mounting Surface Tolerance Set-Up ...................................................30
5.1.6 Tool Setup Sheets...................................................................................................................................31
5.1.7 Adjusting Position of Mounting Brackets Using Iterative (Trial and Error) Process ...............................32
5.1.8 Attaching Rail to Mounting Brackets......................................................................................................36
5.1.9 Alignment of Sub-Assemblies ................................................................................................................38
5.2 KUKA PULSE FRP Rail Cutting Guidelines ...............................................................................................41
5.3 Cross Transfer.........................................................................................................................................45
5.4 Turntable ………………………………………………………………………………………………………………………………………… 49
5.5 Roller Assembly Locating Unit ...............................................................................................................51
5.6 Locating Actuator...................................................................................................................................53
5.7 Work Station Locating Assembly............................................................................................................54
5.8 In Process Actuated Stop .......................................................................................................................56
5.9 Pallet Fixed Stop.....................................................................................................................................57

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5.10 Pull Off Cart Docking Unit with Pallet Stop..................................................................................... 58
5.11 Part Cart Assembly ......................................................................................................................... 59
5.12 Chassis-Pallet Marriage Procedure................................................................................................. 61
5.13 Plinth Installation Procedure .......................................................................................................... 66
5.14 Connect All Electrical Pin Plug Connections ................................................................................... 72
5.15 3-Phase Power Distribution............................................................................................................ 73
5.16 Ethernet Communications.............................................................................................................. 73
5.17 24VDC Power Distribution.............................................................................................................. 74
5.18 PULSE Hardware Installation Overview for Version 2 Panels ......................................................... 75
5.19 PULSE Hardware “Best Practices” for Version 2 Panels.................................................................. 87
6TRANSPORTATION..................................................................................................................................... 88
6.1 Transporting using Lifting Tackle .................................................................................................... 88
6.2 Transportation by Fork Lift Truck.................................................................................................... 89
6.3 Transportation by Pallet Truck........................................................................................................ 90
7DECOMMISSIONING, STORAGE, & DISPOSAL.......................................................................................... 91
7.1 Decommissioning ........................................................................................................................... 91
7.2 Storage............................................................................................................................................ 91
7.3 Disposal........................................................................................................................................... 92
8CONTACT INFORMATION .......................................................................................................................... 92

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1 INTRODUCTION
1.1 System Background
The PULSE Pallet system consists of rail sections mounted as a ground level track system. The pallet is conveyed
from station to station, traveling at the same elevation throughout the rail system. Once the pallet is brought into a
workstation, the pallet is raised slightly by the pallet ski guides in the workstation that is comprised of a geo-locating
fixture. This manual covers the mechanical installation of this system. Please also refer to the controls system O&M
manuals, as well as the interactive manuals provided with this system. It is recommended that this manual be read
in full before installation of the rail system begins.
It is highly recommended that the system integrator performs a risk assessment after the equipment has been
properly installed. This will identify any areas that will require further safety enhancements.
1.2 Information about these Instructions
This documentation describes all components that can be used in operation with the PULSE Pallet system.
The scope of the machine includes the manufacturers’ operating instructions for the components supplied with it.
1.3 Representation of Warnings and Notes
Safety
These warnings are provided for safety purposes and must be observed.
These warnings mean that it is certain or highly probable that death or severe
physical injury will occur if no precautions are taken.
These warnings mean that death or severe physical injury may occur if no
precautions are taken.
These warnings mean that minor physical injury may occur, if no precautions are
taken.
These warnings mean that property damage may occur if no safety measures are
taken.
These warnings contain references to safety-related information or general safety
measures. These warnings do not refer to individual hazards or individual
precautionary measures.
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.
2INTENDED USE
The PULSE Pallet system constitutes partly completed machinery as defined by Directive 2006/42/EC (Machinery
Directive) and will be called “machine” in the following text.
The user of the PULSE Pallet system must comply with the national laws and regulations.
Use
The PULSE Pallet system is intended exclusively as a transport system. It must only be operated in an industrial
environment.
Using it for any other or additional purposes is considered contrary to its intended use. The manufacturer cannot
be held liable for any damage resulting from such use. The risk lies entirely with the user.
Operation within the limits of the intended use also involves observing these assembly instructions – particularly
the preconditions for operation of the PULSE Pallet system and complying with the inspection and maintenance
directives.
Misuse
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 Pallet system is partly completed machinery as defined by the EC Machinery Directive. The PULSE
Pallet system may only be put into operation if the following preconditions are met:
•The PULSE Pallet system is integrated into a machine or system.
Or: Together with other machines, the PULSE Pallet system constitutes a system.
Or: All safety functions and safety equipment required for completed machinery as defined by the EC
Machinery Directive have been added to the PULSE Pallet system.
•The completed machinery or system conforms to the EC Machinery Directive. This has been ascertained
by means of a conformity assessment procedure.
Declaration of Conformity for the Overall System
The system integrator must create a declaration of conformity in accordance with the Machinery Directive for the
overall machine or system. The declaration of conformity forms the basis for the CE conformity mark of the
machine or system. The PULSE Pallet system may only be operated in accordance with country-specific legislation,
regulations and standards.
Declaration of Incorporation
As partly completed machinery, the PULSE Pallet system is supplied with a declaration of incorporation in
accordance with Annex II 1 B of Directive 2006/42/EC. Integral parts of this declaration of incorporation include a
list of the essential requirements stipulated in Annex I of the Machinery Directive that have been complied with
and these assembly instructions.
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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3SAFETY
3.1 Disclaimer
The PULSE Pallet system has been built in accordance with state-of-the-art standards and the recognized safety
rules. Nevertheless, its inadmissible misuse may constitute a risk to life and limb, or cause damage to the PULSE
Pallet system and other material property.
The PULSE Pallet system must only be used in technically perfect condition in accordance with its intended use,
and only by safety-conscious persons who are fully aware of the hazards involved in its operation. It must be used
in compliance with these assembly instructions. Any functional disorders, especially those affecting safety, must
be rectified immediately.
Safety Information
Information about safety may not be construed against KUKA Systems North America. Even if all safety instructions
are followed, it cannot be ensured that the PULSE Pallet system will not cause any injuries or damage.
No modifications may be made to the PULSE Pallet system without the permission of KUKA Systems North
America. It is possible for additional components not included in the scope of supply of KUKA Systems North
America to be integrated on the PULSE Pallet system. The user is liable for any damage that occurs on the PULSE
Pallet system or other property as a result of these components.
External Cross-References and Links
KUKA Systems North America expressly disclaims all ownership of or responsibility for the contents of any linked
Web pages. This declaration applies to all external links and Internet cross-references appearing in this
documentation.
3.2 Safety Equipment
System integrator and user must safeguard the PULSE Pallet system with additional safety equipment (safety
fencing in compliance with DIN EN 953 “Safety of machinery – Guards”).
The PULSE Pallet system has no EMERGENCY STOP pushbutton. The PULSE Pallet system must be integrated into
the EMERGENCY OFF or EMERGENCY STOP system of the machine or system in which the PULSE Pallet system is
installed.
The operating personnel must be instructed with regard to the location and function of the EMERGENCY OFF or
EMERGENCY STOP pushbuttons and maintenance gates.
In the absence of functional safety devices, the PULSE
Pallet system can cause personal injury or material
damage. Safety devices must not be removed or
disabled.

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3.3 Personnel
All persons working on the PULSE Pallet system must be trained in its use and must have read and understood the
PULSE Pallet system documentation including the safety chapter.
The assembly instructions must always be at hand at the PULSE Pallet system.
Before work is started, the personnel must be instructed at regular intervals about the type and scope of the work
and potential hazards. Instruction must be provided again after particular incidents or technical modifications.
The personnel include the user and the operator of the PULSE Pallet system.
Installation, exchange, setting, operation,
maintenance and repair may be performed only by
personnel specially trained for this purpose as
specified in the assembly instructions.
User
The user of the PULSE Pallet system is responsible for its use and operation. He must ensure faultless operation in
terms of safety and lay down all safety regulations for the personnel.
At certain self-defined intervals, the user should check that the personnel are working in compliance with the
assembly instructions and paying attention to hazards and safety factors.
The user is responsible for complying with the national laws, regulations and standards.
Operator
The responsibilities of the personnel for commissioning, operation, maintenance and repair must be defined.
•The personnel must meet the following requirements:
•They must have read and understood the complete PULSE Pallet system documentation including the
safety chapter.
•They must be trained and instructed with regard to the work to be performed.
•They must use the personal protective equipment.
•The machine may be operated only by persons at least 18 years old.
•Work on the PULSE Pallet system may be performed only by qualified personnel. This means persons who
are capable of assessing the work to be performed and recognizing potential hazards on account of their
professional training and experience as well as their knowledge of the relevant standards.
•These requirements must be adapted by the user in accordance with country-specific legislation,
regulations and standards.

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System Integrator
The PULSE Pallet system must be integrated into a machine or system by the system integrator in compliance with
all safety requirements.
The system integrator is responsible for the following tasks:
•Proper installation of the PULSE Pallet system
•Connection of the PULSE Pallet system
•Implementation of the necessary safety equipment and safeguards
•Issue of the declaration of conformity for the machine or system in which the PULSE Pallet system is
integrated
•Creation of the operating instructions for the machine or system in which the PULSE Pallet system is
integrated.
Instruction
The following points must be observed regarding instruction or training:
•The person receiving instruction must confirm participation in the training with their signature.
•The person receiving instruction must be familiarized with the work under the supervision of an
experienced and authorized user.
3.4 Safety Regulations
The PULSE Pallet system must only be used in technically perfect condition in accordance with its intended use,
and only by safety-conscious persons. Operator errors can result in personal injury and damage to property.
If any defects or malfunctions affecting the operational safety or reliability are detected, the PULSE Pallet system
must be immediately switched off or not put into operation.
•Avoid any operational mode that might be prejudicial to safety.
•Take the necessary precautions to ensure that the PULSE Pallet system is used only when in a safe and
reliable state!
•Operate the PULSE Pallet system only if all protective and safety-oriented devices, such as removable
safeguards, EMERGENCY OFF and EMERGENCY STOP equipment, and working range limitations, are in
place and fully functional.
•Pneumatic parts may only be moved with the maintenance gate closed.
•Monitor the PULSE Pallet system throughout working shifts for obvious damage and defects. Report any
changes (including changes in the machine’s working behavior) to the competent organization/person
immediately. If necessary, stop the PULSE Pallet system immediately and lock it.

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•In the event of malfunctions, stop the PULSE Pallet system immediately and lock it. Have any defects
rectified immediately.
•Never make any modifications, additions or conversions on the PULSE Pallet system which might affect
safety without the manufacturer’s approval.
•Spare parts must comply with the technical requirements stipulated by the manufacturer. Spare parts
from original equipment manufacturers can be relied on to do so.
•Pneumatic hoses must be exchanged at appropriate intervals (after 6 years), even if no safety-relevant
defects are evident (hose ageing).
•Adhere to prescribed intervals or those specified in the assembly instructions for routine checks and
inspections.
•For the execution of maintenance work, tools and workshop equipment adapted to the task on hand are
indispensable.
•The personnel must be familiar with the location and operation of fire extinguishers.
•Observe all fire-warning and fire-fighting procedures.

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3.5 Safety Instructions Governing Specific Operating Conditions
3.5.1 Commissioning
During start-up and shut-down procedures always watch the indicators in
accordance with the assembly instructions.
Before starting up or setting the PULSE Pallet system in motion, make sure that
nobody is at risk!
Before putting the PULSE Pallet system into operation, check that all protective
devices, limit switches and other safety measures are complete and functioning
correctly. All machine parts must be checked for foreign bodies.
No persons or objects are allowed in the danger zone during start-up.
It is to be ensured when first commissioning the machine that the correct
machine data have been entered.
Ensure all gearboxes are adequately filled with lubrication prior to start-up.
Before powering on the system, confirm software has been successfully loaded!
Failing to do so will result in damage to equipment.
Do not power on during motor controller inrush cool down period. There is a 2-
minute delay for inrush to inrush, between powering up the motor controllers.
Powering on the motor controllers during the cool down period can cause
excessive inrush current and result in damage to the motor controller or
blowing the semiconductor fuses.
3.5.2 Maintenance Work
•Comply with the adjusting, maintenance and inspection activities and intervals set out in the assembly
instructions, including information on the replacement of parts and equipment. These activities may be
executed by skilled personnel only. Please reference the PULSE Maintenance Instructions document for
additional information.
•In any work concerning the operation, conversion or adjustment of the PULSE Pallet system and its safety-
oriented devices or any work related to maintenance, inspection and repair, always observe the start-up
and shut-down procedures set out in the assembly instructions and the information on maintenance
work.
•If it is essential for personnel to enter the working area of the PULSE Pallet system for maintenance and
repair work, the safety measures implemented (e.g. enabling switch) must cause the PULSE Pallet system
to be stopped immediately if an unintended situation should arise.
•To avoid the risk of accidents, individual parts and large assemblies being moved for replacement
purposes must be carefully attached to lifting tackle and secured. Use only suitable and technically perfect
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 marshal giving the instructions must be within sight or sound of the operator.
•For carrying out overhead assembly work always use specially designed or otherwise safety-oriented
ladders and working platforms. Never use machine parts as a climbing aid! Wear a safety harness when
carrying out maintenance work at greater heights.
•Clean the PULSE Pallet system, especially connections and threaded unions, of any traces of oil, dirt, dust,
swarf or preservatives, and treat with corrosion protection before carrying out maintenance/repair. Never
use aggressive detergents. Use lint-free cleaning rags.
•Appropriate protective clothing must be worn when using prescribed consumables which are specified as
aggressive or toxic.
•After cleaning, remove all covers and tapes applied for that purpose.
•After cleaning, examine all pneumatic hoses for leaks, loose connections, chafe marks and damage! Any
defects found must be rectified without delay.
•Always tighten any screwed connections that have been loosened during maintenance and repair; do so
with the specified tightening torque and in accordance with the drawing.
•Any safety devices removed for set-up, maintenance or repair purposes must be refitted and checked
immediately upon completion of the maintenance and repair work.
•Ensure that all consumables and replaced parts are disposed of safely and with minimum environmental
impact.
•The PULSE Pallet system must be depressurized before any work is carried out on the pneumatic system.
Beware of unexpected movements.

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4TOOLS 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
•Projection System – or other equipment for initial floor location of grout plates
•Allen Wrenches – socket and ratchet styles (all screws are Metric)
•Metric Torque Chart:

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

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

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Image showing the Magnets mounted on the underside of the chassis
Be cautious about working at heights
Use proper PPE (harnesses may be required where railings are not present)
The Return Rails are mounted to the Balconies – be cautious working at heights

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Cross Transfer Mid Risers are equipped with Lockout Pins
Use the Lockout Pins to secure the Cross Transfer in the up position (as shown)
Images show lockout pin securing Cross Transfer (shown on the left), as well as the lockout pin in the Mid Riser
lockout pin holder (shown on the right).
Pull Off Cart Docking Units with Pallet Stops are equipped with a lock out pin
Use the lockout Pin to secure the Part Cart Assembly to the Docking Unit.
Images show lockout pin in the locked position (shown on the left), and in the stored position (shown on the
right).

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

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•Please reference the PULSE NCP Lockout Procedure & SDP Lockout Procedure.
ECPL Signs and Tags (continued)
•Before shutting down the equipment to lockout energy sources, the employee performing the procedure
or the supervisor shall inform affected employees of the intention to shut down the equipment.
If the machine or equipment is operating, it must be shut down using normal shutdown procedures.
Essentially Lockout Tags are utilized as a method of warning personnel of a potential hazard associated with a
particular energy source. They are attached to or are placed in close proximity to energy isolating devices.
Lockout Tags alone do not provide the physical restraint on the energy device, this can only be provided by a lock.
Understanding the proper meaning of a Lockout Tag is necessary to prevent a false sense of security around
potential hazards on the machine. Lockout Tags identify the energy source lockout device. When the energy
source is locked out, they cannot become inadvertently or accidentally detached. The Lockout Tags shown below
illustrate some of the most common lockout designations.
PULSE Floor Mounted Material
•Floor foundation must be adequately sound for installation
•Floor surface fluctuations MUST BE taken into account
•High and Low points across the system
•Must balance the Highs and Lows – note the designed gap between the bottom of the Mounting Brackets
and the top of the Grout Plates are found on the layout drawings (see below).
•Establish an overall System Virtual Datum (X, Y, and Z in space)
Note: Consult the layout drawings for the designed gap between Grout Plate and Bottom of each mounting
bracket.