PULSE Commissioning & Troubleshooting Manual

KUKA Systems North America LLC., 6600 Center Drive, Sterling Heights, MI 48312, USA T +586 795 2000 F +586 978 0429

[email protected] 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

http://www.kuka.com/

PULSE Commissioning & Troubleshooting Manual / Revision: Release 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

7 Repair ...........................................................................................................................................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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1 INTRODUCTION

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, recording or 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. +1 (586) 795-2000 (x9)

https://www.kuka.com/en-us/services/service-vor-ort

Authorized Representative:

KUKA Systems GmbH

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

https://www.kuka.com/en-us/services/service-vor-ort


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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. +1 (586) 795-2000 (x 5230) Cell +1 (586) 899 5123 [email protected] | www.kuka.com

Joe Moceri Program Manager - PULSE ------------------------------------------------------------------------------- KUKA Systems North America LLC 6600 Center Drive | Sterling Heights | MI | 48312 | USA Tel. +1 (586) 795-2000 (x 4437) Cell +1 (586) 224 9535 [email protected] | www.kuka.com

Joe Godlewski Production Control Engineer - PULSE ------------------------------------------------------------------------------- KUKA Systems North America LLC 6600 Center Drive | Sterling Heights | 48312 | MI | USA Tel. +1 (586) 795-2000 (x 4576) Cell. +1 (586) 265 0249 [email protected] | 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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2 TECHNICAL 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


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Figure 3


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2.1.2 Node Controller Panel Grounding Installation

The Node Controller Panel has three points of grounding. Please refer to the diagram below for further information


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2.2 NCP Lockout Procedure

2.2.1.1 To Lock Out Incoming AC Power to the Node Controller Panel:

1) Rotate panel disconnect to the

“OFF” position

2) Pull metal clip out of handle and insert padlock

In this state, the door cannot be opened, and the power cannot be turned on. To lock out incoming AC power to the Node Controller Panel with the door open: 1) Rotate panel disconnect past

the “OFF” position

2) Release the Rittal handle, door

will open

3) Identify the lock out bracket at the base of the

main circuit breaker

4) Insert padlock into the lock out bracket

In this state, the door is open, and the power cannot be turned on.


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2.2.1.2 To Work on the Node Controller Panel with the Incoming AC Power On:

In this state, the door is open, and the incoming AC power is on.

To lock out the 24V DC Power Supplied by the Node Controller Panel:

1) Identify the 24V DC Power

enclosure inside of the Node

Controller Panel.

2) Turn the disconnect to the “OFF”

position.

3) Using a screwdriver, verify the mechanical door

lock has the door held shut.

4) Pull the plastic clip out of the handle and insert a

padlock.

In this state, the 24V DC power is locked out, and the door cannot be opened. however please consider the following:

1) Some of the 24V DC created by the panel is on a battery backup system and will remain live for up to

an hour after the disconnect is turned off.


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2.2.1.3 To Lock out the 24V DC Power Supplied by the Node Controller Panel with the 24V DC Panel Door Open:

1) Identify the 24V DC Power

enclosure inside of the Node

Controller Panel.

2) Turn the disconnect to the “OFF”

position.

3) Open the mechanical door lock with a screwdriver.

4) Insert a padlock on the bracket near where

the rotary disconnect shaft meets the circuit

breaker.

In this state, the 24V DC power is locked out, however please consider the following:

1) Some of the 24V DC created by the panel is on a battery backup system and will remain live for up to

an hour after the disconnect is turned off.


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2.3 Station Drive Panel

Station Drive Panel (SDP) houses the motor controllers and associated control hardware required to monitor and control the linear motor controllers including the power supply and regeneration handling capabilities unique to a linear motor transport system. The SDP provides high voltage DC power (~340VDC) to the motor controllers which are located at the bottom of the panel. It enables the power to the motors through safety outputs and monitors different parameters such as temperature of certain components, status of breakers and contactors. This panel offers a modular configuration that can be configured for a maximum of 5 motor controllers.

There are two variants of Magnemotion motor controllers that can be used in this panel:

• QSMC-2 - Motor Controller for the 0.5 m QSHT motors. One motor controller is required for every two consecutive motors.

• QSMC – Motor Controller for the 1m QSHT motors. One motor controller is required for each 1m motor.

• Input Power: 240VAC 3 phase 50Hz/60Hz 40A & 24VDC UPS @ 6A (from NCP).

• Output for 1 to 5 Motors: 400 VAC, 3 phase,10A RMS cont., 15 A RMS max.

Common features found on the exterior of the main electrical enclosure include:

• Main Disconnect switch – This switch is used to enable/disable electrical power to the panel.

• Ethernet Port – Incoming communication from NCP.

• 240VAC IN- Incoming power from NCP

• 24VDC – DC power for control components

This panel is designed to maintain control power to the MC’s, allowing motor configuration without enabling the propulsion power.

CAUTION!

Linear motors will produce an induced voltage on the motor cables when the chassis is pushed along the rail segment even though the main power disconnect is open. Ensure that all motor cables are properly installed to avoid any shock.


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The panel has a safety GuardLogix module 1791-IB8XOBV4. This module requires to be configured according to the manufacturer’s specifications. Please refer to Guard I/O Ethernet/IP Safety Modules.pdf / Chapter 5- Configure the I/O Modules

DANGER! Never unplug any connector during operation. This creates a hazard with the risk of death, severe injury or equipment damage.

WARNING!

Servicing an electrical panel that is still connected to its power source may cause injury or death. Unless directed otherwise, turn the Main Disconnect switch to the OFF position. Lock out and tag out the switch before accessing and servicing the electrical panel. Only trained electrical technicians should perform service on the electrical panel.

Station Drive Panel (External View)

Station Drive Panel (Internal View)

Motor Drives

Safety I/O

Main Disconnect

DC Bus power supply DC Bus braking module

Braking Resistors

http://literature.rockwellautomation.com/idc/groups/literature/documents/um/1791es-um001_-en-p.pdf


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Power connections may still be live, even though the motor is not moving. Never disconnect the electrical connections to the motor while a voltage is present. This can cause flashover with injury to persons and damage to equipment. After disconnecting the drive from the supply power, wait at least five minutes before touching any components which are normally live (e.g. contacts, screw connections) or opening any connections. The capacitors in the drive can still carry a dangerous voltage up to five minutes after switching off the supply voltages.

WARNING!

Risk of burns from hot surfaces of the braking resistor. When in use, the braking resistor surface temperature rises. Do not touch the braking resistor during operation and only when it has cooled sufficiently.

2.3.1 RS-422 Communication Jumpers

Jumpers are used between motor controllers to create the data link and physical path. Downstream to Upstream and repeat until the controllers are linked together internally. Please note the panels come by default with jumpers between motor controllers and they need to be configured according to the track requirements.

Jumpers in Station Drive Panel


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The example below shows the rail/ turn table combo. The high-speed rail in this example has its own station drive panel and a dedicated drive panel for the turn table. RS422 cables and jumpers are shown in yellow color. In this example, the jumper between Slot2 and Slot3 in SDP-2 needs to be removed.

2.3.2 Best Practices

2.3.2.1.1 Inrush Current

Motor controllers are protected from inrush current by a PTC during power up. This device requires a cool down period before it can protect from another inrush. Therefore, we require a two-minute inrush to inrush timer in software to protect the motor controllers from damage. Refer to the software template to implement the motor controller protection in the PLC logic.


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2.3.2.1.2 PULSE SDP Power On Verification

2.3.2.1.3 Station Drive Panel Configurations

PULSE Control panels come in different variations depending on how the track is laid out. Components in the upper portion of the SDP are common. The difference between panel types is given by number and type of motor controllers installed in the five motor controller slots located at bottom of the panel.

WARNING!

At least one motor controller must be connected to the DC Bus during power up. Turning the Power ON with no motor controllers connected will cause catastrophic damage to the braking transistor and rectifier unit.

Station Drive Panel Options


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The serial number of the panels follows the structure below. This nomenclature defines the number and type of motors installed in each panel.

Slot 1 Slot 2 Slot 3 Slot 4 Slot 5 HS LS

Empty

Slots Code

KUKA

Ordering

Number

HS HS HS HS HS 5 0 0 *SDP-50 1109050.2

HS HS HS HS 0 4 0 1 SDP-40 1109040.2

HS HS HS 0 0 3 0 2 SDP-30 1109030.2

LS LS LS HS HS 2 3 0 *SDP-23 1109023.2

LS LS HS HS 0 2 2 1 SDP-22 1109022.2

LS HS HS 0 0 2 1 2 SDP-21 1109021.2

HS HS 0 0 0 2 0 3 SDP-20 1109020.2

LS LS LS HS 0 1 3 1 SDP-13 1109013.2

LS LS HS 0 0 1 2 2 SDP-12 1109012.2

LS HS 0 0 0 1 1 3 SDP-11 1109011.2

LS LS LS 0 0 0 3 2 SDP-03 1109003.2

LS LS 0 0 0 0 2 3 SDP-02 1109002.2

LS 0 0 0 0 0 1 4 SDP-01 1109001.2

0 0 0 0 0 0 0 5 SDP-00 1109000.2

*Under special circumstances, the 5th slot can only be used when managed properly from a motor coverage and usage standpoint.

Example of Serial Number for an SDP


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Serial Numbers for NCPs are much simpler. Job#, Unit# and serial number designator. For example: 45011-U17-010. NCPs are of a one-design so the enclosure design is a standard.

2.3.2.1.4 Station Drive Panel Grounding Installation

The Station Drive Panel has two points of grounding. Please refer to the diagram below for further information.


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2.3.3 Rail Layout Practices

2.3.3.1 Best Practices

• Filler rails should always be motor #1 in a path at the beginning or end of the line.

• When designing production track, do not exceed 4 motor controllers per SDP.

• Always use high speed stators in filler rails.

• Separate RS-422, 24V, Ethernet from 480vac. All Ethernet cables must be shielded.

• All motors should be installed into rails identically. Motor flow is denoted as upstream to downstream (from Drive Connector to Sense Connector) forward direction of travel.


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2.3.4 SDP Lockout Procedure

2.3.4.1 To Lock Out Incoming AC Power to the Station Drive Panel with the Door Closed:


“OFF” position

2) Verify the Rittal handle is shut and the

panel door is closed

3) Push in the two sliding covers to reveal the lock out bracket and insert a padlock

In this state, the incoming AC power is locked out, and the panel door cannot be opened.


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2.3.4.2 To Lock Out Incoming AC Power to the Station Drive Panel with the Door Open:


“OFF” position

2) Release the Rittal handle, door will open

3) Identify the NFPA79 lock out bracket, on the main switch near where the rotary disconnect shaft

meets the switch.

4) Insert padlock through the bracket

In this state, the door is open, and the power cannot be turned on. However please consider the following: The 24V DC inside the SDP is fed from the NCP and some of the 24V DC is on a battery backup system,

and will remain live for up to an hour after the both the SDP and NCP have been locked out


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2.3.4.3 To work on the Station Drive Panel with Door Open and the Incoming AC Power On:


“OFF” position

2) Release the Rittal handle, door will open

3) Identify the NFPA-79

Intermediate Handle on the

rotary disconnect shaft

4) Grasp the handle and pull

outward gently to engage the

override mechanism. Then

rotate the handle clockwise to

turn the power on. Rotating

counter clockwise will turn the

power off.

In this state, the door is open, and the incoming AC power is on.


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2.4 Motor Types

Quick Stick motors employ Hall Effect Sensor (HES) technology for position feedback. Two different motor types are used in the PULSE system:

• 1-meter motor with two internal blocks

• ½ meter motor with one internal block Both motors have the embedded Hall Effect sensors which act as a position encoder.

2.5 Communications

Data is exchanged between the PLC and the NCP using Ethernet, and RS422 communication protocol is used to exchange data between the NCP and the motor controllers in the SDPs. Additional safety I/O data is monitored from the Station Drive Panel to the PLC via Ethernet.

Ideally, each automation line served by PULSE would have multiple auto zones, each zone having its own PLC and multiple NCPs with their corresponding SDPs.

• PLCs to PLC communications

• Each zone has 1 master Node Controller (NC), which is designated as the High Level Controller (HLC). The HLC manages the communication between all Node Controllers in the transport system. Any additional NC’s are slaves to the master/HLC

• A PLC only communicates to the master NC

High Speed Motor

Low Speed Motor


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2.5.1 Communication Protocol

1. Ethernet/IP 2. Physical Layer 3. Data Link Layer 4. Network Layer 5. Transport Layer 6. Application Layer

(Refer to OEM document 990000437 section 4)

2.6 Wiring and Grounding

When routing wiring to a PULSE Panel, it is recommendable to separate high voltage power and motor leads from RS-422, 24V, and Ethernet to avoid potential noise problems. To maintain separate routes, route these in separate conduit or use tray dividers.

Spacing Notes: 1. Both outgoing and return current carrying conductors are pulled in the same conduit or laid adjacent in tray. 2. The following cable levels can be grouped together: • Level 1: Equal to or above 6011V.


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• Levels 2, 3, & 4 may have respective circuits pulled in the same conduit or layered in the same tray. • Levels 5 & 6 may have respective circuits pulled in the same conduit or layered in the same tray. NOTE: Bundle may not exceed conditions of NEC 310. • Levels 7 & 8 may have respective circuits pulled in the same conduit or layered in the same tray. NOTE: Encoder cables run in a bundle may experience some amount of EMI coupling. The circuit application may dictate separate spacing. • Levels 9, 10, & 11 may have respective circuits pulled in the same conduit or layered in the same tray. NOTE: Communication cables run in a bundle may experience some amount of EMI coupling and corresponding communication faults. The circuit application may dictate separate spacing. 3. Level 7 through Level 11 wires must be shielded per recommendations. 4. In cable tray, steel separators and advisable between the class groupings. 5. If conduit is used, it must be continuous and composed of metallic steel. 6. Spacing of Communication Cables Levels 2 through 6 is the following:

2.6.1 Excess Cable

Observe these guidelines when handling excess cable:

• Do not coil excess cable of different types (for example, motor power and feedback) together. An efficient transformer is formed at HF.

• Cable lengths should ideally be trimmed to fit the application.

• If excess cable cannot be trimmed, it should be laid in an ‘S’ or figure eight pattern (refer to the figure below).


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2.7 Power Distribution


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2.8 Panel Maintenance

Recommended replacement intervals for air filters mats are after 2,000 hours of use. Every panel (NCP and SDP) has two filters located in the upper and lower sections of the enclosure. The Power Supply enclosure located within the NCP also has filters that need to be replaced at regular intervals. See Electrical Drawing Bill of Material for part number.


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2.9 Track Section Chassis Placement

When laying down a track design, there are certain rules that must be applied.

• Long sections of low speed track must always contain one less chassis than there are rail segments.

• High speed rail segments are usually dedicated to a work station. This

results in only one chassis occupying that rail segment at any one time. High speed track segments have a dedicated station drive panel.

Filler rails are never to be used as a staging section for a chassis. They are to be used only as a bridge for the chassis to pass from one motion element to another,

Low Speed Track

High Speed Track


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i.e. Rail to turn table. Filler rails are used when a full section rail cannot be fitted as the last rail segment.


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3 SAFETY

3.1 General

3.1.1 Liability

The PULSE system is built using state-of-the-art technology and in accordance to recognized safety rules. Misuse of the PULSE system may constitute a risk to life and limb or cause damage to the PULSE system and to other material property. The PULSE system may only be used in perfect technical condition in accordance with its intended use and only by safety-conscious persons who are fully aware of the risks involved in its operation. Use of the PULSE system is subject to compliance with this document and with the declaration of incorporation supplied together with the PULSE system. Any functional disorders affecting the safety of the PULSE system must be rectified immediately. Safety information cannot be held against KUKA Systems NA. Even if all safety instructions are followed, this is not a guarantee that the PULSE system will not cause personal injuries or material damage. No modifications may be carried out to the PULSE system without the authorization of KUKA Systems NA. Additional components (tools, software, etc.), not supplied by KUKA Systems NA, may be integrated into the PULSE system. The user is liable for any damage these components may cause to the PULSE system or to other material property. In addition to the Safety chapter, this document contains further safety instructions. These must also be observed.

3.1.2 Intended Use of the PULSE System

The PULSE system is intended exclusively for the use designated in the “Purpose” chapter of the operating instructions or assembly instructions. Using the PULSE system for any other or additional purpose is considered impermissible misuse. The manufacturer cannot be held liable for any damage resulting from such use. The risk lies entirely with the user. Operating the PULSE system within the limits of its intended use also involves observance of the operating and assembly instructions for the individual components, with particular reference to the maintenance specifications.

Misuse


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Any use or application deviating from the intended use is deemed to be impermissible misuse. This includes e.g.:

• Transportation of persons and animals

• Use as climbing aid

• Operation outside of the permissible operating parameters

• Use in potentially explosive environments

• Operation without additional safeguards

• Outdoor operation

3.1.3 Residual Risks

Please adhere to plant safety guidelines and wear all required Personal Protective Equipment (PPE), including:

• Safety Glasses

• Protective Footwear

• Ear Protection (*The PULSE system has a sound level < 70 dB (A))

• Gloves, arm sleeves, etc.

Operators should be aware of inherent risks when inside a work cell. It is important that good posture is maintained if moving a heavy load. Sharp angled corners and potential pinch points present potential risks when inside the cell.

3.1.4 EC DOC & DOI

This PULSE system constitutes partly completed machinery as defined by the EC Machinery Directive. The PULSE system may only be put into operation if the following preconditions are met:

• The PULSE system is integrated into a complete system. Or: The PULSE system, together with other machinery, constitutes a complete system. Or: All safety functions and safeguards required for operation in the complete machine as defined by the EC Machinery Directive have been added to the PULSE system.

• The complete system complies with the EC Machinery Directive. This has been confirmed by means of an assessment of conformity.

Declaration of Conformity

The system integrator must issue a declaration of conformity for the complete system in accordance with the Machinery Directive. The declaration of conformity forms the basis for the CE mark for the system. The PULSE system must be operated in accordance with the applicable national laws, regulations and standards. The PULSE system is CE certified under the EMC Directive and the Low Voltage Directive.


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Declaration of Incorporation

The PULSE system as partly completed machinery is supplied with a declaration of incorporation in accordance with Annex II B of the EC Machinery Directive 2006/42/EC. The assembly instructions and a list of essential requirements complied with in accordance with Annex I are integral parts of this declaration of incorporation. The declaration of incorporation declares that the start-up of the partly completed machinery remains impermissible until the partly completed machinery has been incorporated into machinery, or has been assembled with other parts to form machinery, and this machinery complies with the terms of the EC Machinery Directive, and the EC declaration of conformity is present in accordance with Annex II A. The declaration of incorporation, together with its annexes, remains with the system integrator as an integral part of the technical documentation of the complete machinery.


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4 TRANSPORTATION

4.1 Transporting using Lifting Tackle

Preconditions

• The enclosures 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.

Fig. 4-1: 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.


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4.2 Transportation by Fork Lift Truck

Preconditions





• The anti-tipping bracket must be fastened to the enclosures.

Procedure

Fig. 4-2 Example of transportation by fork lift truck

Fig. 4-3 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


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4.3 Transportation by Pallet Truck

Preconditions





• The anti-tipping bracket must be fastened to the enclosures.

Procedure

Figure 4-4: Transportation by pallet truck

1. Enclosure with anti-toppling bracket 2. Enclosure in raised position

Figure 4-5: Picture of eyelets installed on enclosure


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5 START-UP AND RECOMISSIONING

5.1 Start-up Overview

Rail/Turntable

Step Description 1. Carry out a visual inspection of all rails. Ensure all rails are cleared

of any debris. 2. If a turntable is installed, manually swing turntable to ensure no

collisions with other objects or other rail sections and to verify rail gap.

3. If PULSE rail is mounted on a lift, manually jog lift to ensure no collision and verify rail gap.

Electrical System

Step Description 2. Carry out a visual inspection of all NCPs and SDPs. 3. Make sure that no condensation has formed in the enclosures. 4. Install the NCPs and SDPs. 5. Connect the connecting cables (NCP to SDP’s). 6. Connect the NCP to the power supply (Customer Supplied Power). 7. Reverse the battery discharge protection measures (Connect the

battery). 8. Switch on the NCP and connected SDPs. Enable each SDP circuit

breaker one at a time. 9. Verify configuration. 10. Start-up mode. 11. Check the safety equipment. 12. Configure the Communications between the NCP and the PLC.

Software

Step Description 13. Check the machine date. 14. Check the software limit switches and adapt them if required. 15. Calibrate the rail. 16. Enter the configuration data.

5.2 Installing the PULSE System

Please reference the PULSE Carrier Assembly Instructions Manual and PULSE Pallet Assembly Instructions Manual for all necessary installation guidelines and procedures.


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6 MAINTENANCE

Maintenance work must be performed at the specified maintenance intervals after commissioning by the customer. The PULSE system must be powered down before maintenance is performed. Please reference the PULSE Maintenance Instructions document for additional information.


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Unit Component Interval Work to be Performed

FRP RailVisual inspection for wear, cracks/physical damage

Wipe excess debris from rail

Motors Wipe motors clean with cloth




Rollers

Visual inspection for wear/degradation (urethane diameter)

Estimated life expectancy of 15 years at 60 JPH. Replace, as needed

Magnet ArraysVisual inspection

Clean magnet arrays with cloth/adhesive tape, as needed

Cables, HosesVisual inspection

Check for wear/damage, functionality

FRP Rail Visual inspection

MemolubVisual inspection. Replace, as necessary. Lubricator system will alert "Low Lube" fault signaling a low

reservoir fluid

THK RailVisual inspection

Check for wear/physical damage, functionality

SEW GearboxVisual inspection


Cardan ShaftVisual inspection


U08: Pallet Work Station Locating Assembly McGill Cam Followers During routine plant maintenanceVisual inspection

Replace every 5,000,000 cycles

Welker UB4 Shot Pin Visual inspection

McGill Cam FollowersVisual inspection


Hoses, Switch, Wiper SealVisual inspection


Kaydon BearingVisual inspection

Re-lubrication is recommended every 800 operating hours

THK LM Guide BlockVisual inspection


McGill Cam FollowerVisual inspection



Magnet ArraysVisual inspection

Clean magnet arrays with cloth/adhesive tape, as needed

CablesVisual inspection


SMC Air Cylinder

Wedge

Seals, Hoses, Flow Controls, Switches

SMC Air Cylinder

Seals, Hoses, Flow Controls, Switches

SMC Air Cylinder Clevis

Limit Switches

Arm

Wheel Casters During routine plant maintenanceVisual inspection


Caster Pivot Bearing 1Y Re-lubricate with multi-purpose NLGI Grade 2 grease

Rittal Fan Filters Every 2,000 operating hours Replace (2) sets

UPS Battery Module 6M-2Y Electronically monitored. Replace when receiving low battery warning/fault

Rittal Fan Filters Every 2,000 operating hours Replace (1) set

Motor Controller Fans 6MOpen cabinet door to check motor controller fans (3-5, depending on panel configuration) and

vacuum, as required

U25: TransformerEntire unit During routine plant maintenance

Visual inspection


Fan Filter Every 2,000 operating hours Replace

UPS Battery Module 6M-2Y Electronically monitored. Replace when receiving low battery warning/fault




U38: Roller Assembly Locating Unit McGill Cam Follower During routine plant maintenanceVisual inspection


U33: Medium Speed Rails

U27: Operator Station Panel

U02: Low Speed Rail

U01: High Speed Rail

U03: Chassis

U04: Carrier Lifter System Pair w/ Rail Mounting Brackets

U10: Turntable

U09: Pallet Work Station Lock/Locator Assembly

U14: In Process Actuated Stop

U15: Docking Unit

U17: Node Controller Panel

U41: Station Drive Panel

U11: Locating Actuator

U16: Pull-Off Cart

During routine plant maintenance







Visual inspection


Visual inspection


Visual inspection






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7 REPAIR

7.1 Repair and Procurement of Spare Parts

Repair

Repairs to the PULSE system may only be carried out by KUKA customer support personnel or by customers who have taken part in a relevant course of training held by KUKA.

Procurement of Spare Parts

The article numbers of the spare parts are outlined in the spare parts list. KUKA Systems NA provides the following types of spare parts for repairs to the PULSE system.

• New parts Once the new part has been installed, the part that has been removed can be disposed of.

• Exchange parts Once the exchange part has been installed, the part that has been removed is returned to KUKA Systems NA


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8 PULSE TROUBLESHOOTING

This section describes fault recovery procedures that an operator or technician can employ to recover from faults that may occur.

Most faults prevent the equipment from operating until the fault is corrected. An extensive system of workpiece and hardware sensing though the PLC provides the operator with information for assessing and resolving most fault conditions.

8.1 PULSE Panel Troubleshooting

8.1.1 Hardware Troubleshooting

Verify that all wiring between the panels, transformer and motors are correctly in place.

8.1.2 Transformer Wiring Diagram

Transformer is a 51kVA Delta – Wye drive isolation transformer. It has +/- 5% taps on the secondary to help tune in the desired voltage on the DC bus. Verify the following conditions are accomplished. Review transformer wiring for proper voltage connection and output.

• 480/400VAC power on the primary (H1, H2, H3)

• 240VAC power on the secondary (X1, X2, X3)

• Center of the Wye is grounded (X0)


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8.1.3 PULSE NCP Wiring

The NCP is primarily a distribution panel for 3 phase power, 24V DC, Ethernet and RS422 communication. Verify the following conditions are accomplished.

• Incoming power to the NCP is 400VAC(EU) or 480VAC (US), 3 Phase, plus ground.

• Transformer is wired correctly (8.1.1)

• 3 phase power to SDPs are 240VAC

8.1.4 PULSE SDP Wiring

The SDP houses the rectifier that powers the motor controllers and the safety hardware to turn power on and off. It is best to follow the check list below prior to enabling power via the safety contactors. Verify the following conditions are accomplished.

• Incoming power is 240VAC

• Semiconductor fuses are OK. Note: these fuses do not create an open circuit when blown and will still pass continuity. You must check the resistance of the fuse or the voltage across it to see if it is good. Best practice is to replace all three fuses if one fuse blows.

• At least one motor controller is wired to the DC bus. If power is applied with no motor controllers on the DC bus, this will damage the rectifier module.

• DC Bus is not grounded. The DC bus is a floating or ungrounded system, if either the negative or positive lead of the bus is connected to ground then it will cause a direct short inside the power supply and blow the semiconductor fuses immediately.

• Power is not being turned on during the 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.

The following check list is best done once power has been turned on.

• Verify the DC Bus is ~340V. If the voltage does not seem correct, then check the semiconductor fuses.

• Verify brake transistor operates at 390V. This can be done by watching for the light to come on during pallet braking.


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8.1.5 PULSE Motor Wiring

Motor wiring connections are more critical than they seem, and loose connections can cause issues with damaging motor controllers or problems reading the encoder feedback. The power and sensor cables utilize a reverse bayonet cable connector.

• Verify the Stator Drive cable is tightened until you feel it “click” in to a detent. This must be checked at both ends – the motor controller and the motor.

• Tighten the Stator Sense cable until it no longer turns. Then grab the plug body and gently pull out and push in a few times. You will often then be able to screw the connector in a little more. This must be done at both ends – the motor controller and the motor.

8.1.6 Clearing a Fault

IMPORTANT!

Only qualified maintenance technicians should clear fault and emergency stop conditions where the cause is not obvious.

Depending on the type and scope of the fault, the operator may be able to correct the problem and resume production; in most cases, however, the assistance of a service technician will be required. All fault management is performed through the HMI consoles (provided by others).

When all faults are cleared:

• the station is ready to resume processing


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8.1.6.1 General Fault Recovery Methods

If Then

Everything appears okay Clear any alarms as needed.

An obvious problem exists, such as a device jam

Notify a maintenance technician to manually recover the device from the condition.

Defective tooling or device apparent

Notify a maintenance technician to correct the defect.

Unable to identify the problem

Notify a maintenance technician.

8.1.7 Troubleshooting Table

The following table is provided as a convenience for technicians to document solutions to problems that arise as the machine wears in. Recording this information in the manual will facilitate any future repairs.

Symptom Probable Cause Corrective Action

8.2 PULSE Power Fault Recovery

Refer to OEM document 990000496 section 7.


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a. Power Related Fault Recovery-

▪ Power Lights – (Page 7-6)

▪ Motor Power - (Page 7-6)

▪ Speed not same as initial installation – (Page 7-6 / 7-10)

▪ Node Controller logs do not reflect the correct time – (NC Page 7-8)

▪ PULSE drive not responding to Host Controller – (Page 7-9 / 7-10)

▪ Stack Light functionality – (Page 7-10)

8.3 PULSE HLC Jammed, Hindered & Stall Faults

Hindered is a signal from the HLC (High Level Controller) that indicates the vehicle had permission to move, but the destination was not reached. The hindered condition could be mechanical jam or power off on the propulsion power (there is no force available to move the vehicle). The HLC will enable the hindered bit for the vehicle when the E-Stop is removed, the propulsion power and the [LG1] vehicle are larger than the arrival tolerance in the XML configuration. When lack of propulsion power is the cause of the vehicle not arriving at its destination, restoring power will allow the control loop to bring the vehicle back to where it belongs, and the hinder condition will clear. If the arrival position tolerance in the XML configuration is too tight it could lead to unwanted hinder reports – The XML config in use should be reviewed to determine how tight the tolerances are set.

The stall bit for the vehicle (reported in the extended vehicle) indicates the motor has driven until a true jam condition therefore the motor reduces force but keeps trying indefinitely to reach the position. A motor stall is a better indicator of a real jam than the hindered condition. The hinder message from the HLC informs against thresholds, but it is not a true measure to determine a true stall/jam. The [LG2] information is available in the host interface. Removing the propulsion power while the carrier is in transition or not reaching to the final position may trigger the Hinder bit. To recover, it is imperative to perform a system reset and a system startup.

8.4 Ghost Vehicles

The OneShotting vehicle command is critical in preventing the presence of multiple ghost vehicles. Standard PULSE reference logic will be validated at installation and during the final buy-off at the end user site.


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9 PULSE SOFTWARE HELPFUL HINTS

The purpose of this section is to provide guidance and helpful hints in the implementation of the PULSE equipment.

9.1 Software Requirements and Revision Level

MagneMotion QSHT configuration tool rev 7.4.4 (KUKA standard configuration tool)

MagneMotion NC Host TCP interface utility 7.3.5 (Used for debug or manual motion with no PLC)

Web base to node controller Default 192.168.0.1 (Used for setup\backup\upload\download .XML files to controller.)

MagneMotion Software will run on Windows versions XP, 7 and 10

Rockwell Programming Software will operate on Windows 7 (Ver 25.x)

9.2 Node Controller Standard Files

Node Controller Configuration File: node_configuration.xml (NOTE THESE FILES ARE ALWAYS EVOLVING, YOU MUST GET CURRENT REV) Motor Type Files for 1 meter and ½ meter motors: QS_Gen2_HT_motor_type.xml the Rev is 20255 Magnet Array Type Files: QS_HT_magnet_array_type.xml the Rev is 21911

9.2.1 Nodes

The following types of Nodes are mainly used in the KUKA PULSE system.

• Relay Node is used mainly between paths that are controlled by one HLC (High Level Controller).

• Gateway is used mainly to go from one HLC to the another HLC.

• Terminus is used mainly at pull-off stations and system-to-system hand-offs.

• OT (Over travel) is used only on a “closed loop path”. Example would be turntable.

• Simple is used to begin a stand-alone Path, which is a Path not connected to anything else at the upstream end and where no vehicles enter or exit3.

9.3 Motors

The motor power and motor signals (see Figure 1 Motor Electrical Connections) are controlled and monitored by the motor controller located in the Station Drive Panel


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Figure 1 Motor Electrical Connections

9.4 Commission a HLC/NC (High Level Controller/Node Controller)

PULSE uses two programs and one web navigator to configure and load software to the equipment.

• MagneMotion QS Configurator Tool

• MagneMotion NC Host TCP Interface Utility

• Internet Explorer or Google Chrome

9.5 Go Online with the Node Controller for First Time

To be able to see the node controller for first time you

need to set up the properties of the computer

Ethernet adapter

• Change Adapter Setting. Start>Settings>

Network and Ethernet> Ethernet> Change

Adaptor Settings.

Select the current Ethernet connection, right click> Properties. Select “Internet Protocol Version 4 (TCP/IPv4)> Properties> Alternate Configuration

Note: The last octet of the IP address should be unique. No duplicates are allowed between users.

1.1 Connect to the computer to the Node Controller

(HLC/NC) using an Ethernet cable.

2.1 Verify the connection using the command prompt window. Start, type “cmd” in the search, select the

“Command Prompt”. Type, “ping”. Verify there is exchange of packets.


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9.6 Load the Configuration Files

• Using the MagneMotion configurator software

verify the IP Address assigned by opening program

“MagneMotion Configurator”. Click on the Node

Controller on the left menu and verify the IP

Address.

• The KUKA standard files are loaded from web base

software (e.g. explorer or chrome) to the node

controller under the “Configurations files” tab.

• A HLC/NC is usually commissioned as follows. Open

Internet Explorer or Google Chrome type the

address “192.168.0.1”.

• A window will prompt be asking for user/ password

use:

• User: admin

• Password: admin

Figure 3 Configuration Files

Figure 2 MagneMotion Configurator Window


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• Upgrade Software to current revisions select “Upgrade software” on the left menu>Browse –

Select the file “Controller_image_xxx””

• Upgrade>Activate, and select “Reboot Controller” from the left menu > Reboot. Refresh page after 1 minute.

• Load the 3 motor ERF files > Browse – select files with extension *.mdf. Load the three files one by one. Restart services after loading is complete.

• Click on > Distribute to all NC

Figure 4 Upgrade Software


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• Program the motor controllers inside the Station Drive Panels. Select three motors as master> Reboot Controller> Reboot

• Program the motors on the rails. Before you can do this step, you need to master the guard logix block inside the station drive panels. Since the motors require power to be updated. Select three motor as slave

•

• Assign the IP Address. On the explorer Window, select “IP Settings” on the left menu. E.g.

• IP Address: 10.138.020.154

• Subnet Mask: 255.255.0.0

• Broadcast IP Address: 10.138.20.154

• Default Gateway: leave blank

• Apply changes. Now type for the Default Gateway

• Default Gateway: 0.0.0.0

• Apply changes and select “Reboot Controller” from the left menu >Reboot.


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• Upload the .XML files.

Node controller configuration file >Browse (Select the file)>Upload File

Magnet Array Type Files >Browse (Select the file)>Upload File

• Motor types and Magnet arrays.

• Download all the files to the controller.

• Reboot the controller.

9.7 PID Loop Chart

This is located in the MagneMotion Configurator, Paths, motors then motor defaults. There is a section for “control loop parameters” you have 16 options. However, KUKA always defaults Set 0 and set 15 for 0 to be all gains set to zero and 15 is always used for startup. 15 is usually based off of the average gain settings for weights on the line that HLC/NC is used on. 2 thru 14 are used to set the gains accordingly as carrier/pallet get weight added onto it.


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9.8 Motor Gaps

Motor gaps need to be checked and set specifically to each gap downstream to the next motor. Even from path to path. Now if these are off a little the PULSE system will still run and position in tolerance. However, this may lead to vehicle jerk or not moving smoothly as possible.

Motor gaps are defined and specified by KUKA. No Modifications or Alterations are required. Failure to adhere to original specifications may avoid warranty. For more information, contact the Supplier.

9.9 Recommended Virtual Machine Settings

The MagneMotion software requires Windows 7 to operate properly. If using a programming device with Windows 10, you may need to work in a virtual machine environment to properly run the Rockwell ControlLogix V25.x or greater version software.


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Figure 5 Virtual Machine Wi-Fi settings


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10 PULSE VEHICLE RECOVERY SCENARIOS

10.1 Mainline Station Recovery Rules

Physical Clearance Requirement(s) –

• X# Motor Blocks available for Vehicle Master Acquisition in either Forward or Reverse Directions

Vehicle Positioning Permissive(s) –

• To Command Motion within an Auto Zone, that Auto Zone MUST have Safeties enabled and

Control Power ON.

• To Command Motion between Auto Zones, each Auto Zone MUST have Safeties enabled and

Control Power ON.

• Auto or Manual Mode Enabled

• Obstructions Clear of Vehicle/Product


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11 DECOMMISSIONING, STORAGE, AND DISPOSAL

11.1 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.

11.2 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.

11.3 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.


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12 ISO HAZARD LABELS

Labels are applied throughout the station to warn personnel of hazards and safety requirements. Read this section carefully and comply with the required actions, warnings, or prohibitions.

12.1 Description of Labels

12.1.1 Marking Labels

CE marking

This label will be affixed adjacent to the nameplate on the main electrical enclosure. This label indicates that the system is CE-marked.

PE Marking

This label will be affixed to the Protective Earth (PE) connection in the main electrical enclosure. This label identifies the location of the PE connection of the incoming electrical power supply.

12.1.2 Mandatory Action

Read and Understand the Manual

This label is affixed to the electrical enclosure and the HMI panel. The technician should read and understand the maintenance manual before conducting any work or service in the referenced area. The operator should thoroughly read this manual before operating the machine.

Mandatory Electrical Lockout

This label is affixed to each electrical enclosure. For more information on hazardous energy sources and the appropriate lockout procedures.


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Mandatory Lockout

This label is affixed at non-electrical lockout points. For more information on hazardous energy sources and the appropriate lockout procedures.

Wear Eye Protection

This label is affixed where eye protection is required.

Forklift Lift Point Right

This label is affixed to the bottom right cell guarding, where forklift access from the right side is recommended.

Forklift Lift Point Left

This label is affixed to the bottom left cell guarding, where forklift access from the left side is recommended.

Connect an Earth Terminal to the Ground

This label is affixed next to the Earth Terminal (Ground) connection in the main electrical enclosure. This label indicates that a ground connection is required for the system’s electrical circuits.


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12.1.3 Prohibition Labels

All Guards in Place Warning

This label affixed to all protective panels that shield operators from the various hazards associated with the unit’s electrical, mechanical, and motorized systems.

To avoid injury, do NOT operate the machine without all guards in place!

No Stepping on Surface

This label warns personnel from stepping on the labeled components and/or surfaces.

12.1.4 Hazard Labels

Electricity Hazard

This label is placed where personnel may encounter electrical energy, and where high-voltage electrical energy and a potential for shock hazard may be present. Only qualified technicians should perform work in these areas.

12.1.5 OEM Hazard Labels

Additional hazard labels found on third party equipment are provided by the OEM manufacturer. For more detailed information regarding these labels and their associated hazards, refer to the appropriate OEM literature.


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13 OEM REFERENCES

13.1 Node Controller Panel OEM Information

• Web Interface User’s Manual from MagneMotion “3rd 990000377-

MANUAL_NODE_CONTROLLER_WEB_INTERFACE.pdf” (Refer to OEM

990000377 Section: 5-1 to 5-5)

• Battery Module - instruction_manual_pvua_24.pdf

13.2 Station Drive Panel OEM Information

• BLOCK Choke specifications B1601017_Datasheet.pdf

• BONITRON 3 Phase Bridge “D_M3713DM_cman_vall_01j.pdf”

• BONITRON Braking Transistor “M3575T-M3675T_111009_20150225.pdf”

13.3 Linear Motors OEM Information

• Refer to OEM document QuickStick® HT User’s Manual. Section 3 & 4

13.4 QuickStick High Thrust Gap Permission Blocks

• QuickStick High Thrust Gap Permission Blocks_Ver. 01

13.5 PULSE Lubrication Information

• Refer to PULSE Lubrication Information PowerPoint for instructions pertaining to mechanical components maintenance

http://www.bonitron.com/PDFs/Manuals/D_M3713DM_cman_vall_01j.pdf

http://www.bonitron.com/PDFs/Manuals/D_M3575T_CMAN_VALL_07i.pdf

Documents

PULSE Commissioning & Troubleshooting Manual