Kuka Pulse Instruction Manual
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Kuka Pulse Instruction Manual

Kuka Pulse Instruction Manual

Pallet assembly
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PULSE SYSTEM
PULSE Pallet Assembly Instructions Manual
Original Instructions
Revision: Release
Publication Date: April 19, 2018
PULSE_DM_DI_PULSEPalletAssemblyInstructionsManual_Master_V.180419
KUKA Systems North America LLC., 6600 Center Drive, Sterling Heights, MI 48312, USA T +586 795 2000 F +586 978 0429
ServiceCenter@kukanao.com www.kuka.com

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  • Page 1 PULSE SYSTEM PULSE Pallet Assembly Instructions Manual Original Instructions Revision: Release Publication Date: April 19, 2018 PULSE_DM_DI_PULSEPalletAssemblyInstructionsManual_Master_V.180419 KUKA Systems North America LLC., 6600 Center Drive, Sterling Heights, MI 48312, USA T +586 795 2000 F +586 978 0429 ServiceCenter@kukanao.com www.kuka.com...

  • Page 2: Table Of Contents

    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 KUKA PULSE FRP Rail Cutting Guidelines ....................41 Cross Transfer ............................45 Turntable ………………………………………………………………………………………………………………………………………… 49 Roller Assembly Locating Unit ....................... 51 Locating Actuator ........................... 53 Work Station Locating Assembly ......................
  • Page 3 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 TRANSPORTATION ............................. 88 Transporting using Lifting Tackle ....................88 Transportation by Fork Lift Truck ....................

  • Page 4: 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.

  • Page 5: Prohibiting Signs

    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. PULSE Pallet Assembly Instructions Manual / Revision: Release PULSE_DM_DI_PULSEPalletAssemblyInstructionsManual_Master_V.180419/ Date: 04.19.2018 4 / 92...

  • Page 6: Intended Use

    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. The PULSE Pallet system is intended exclusively as a transport system. It must only be operated in an industrial environment.
  • Page 7 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: •...

  • Page 8: Safety

    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.

  • Page 9: Personnel

    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.

  • Page 10: Safety Regulations

    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 •...
  • Page 11 • 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.

  • Page 12: Safety Instructions Governing Specific Operating Conditions

    • 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.
  • Page 13 • 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.

  • Page 14: Tools Required

    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: PULSE Pallet Assembly Instructions Manual / Revision: Release PULSE_DM_DI_PULSEPalletAssemblyInstructionsManual_Master_V.180419/ Date: 04.19.2018 13 / 92...

  • Page 15: Installation

    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 PULSE Pallet Assembly Instructions Manual / Revision: Release PULSE_DM_DI_PULSEPalletAssemblyInstructionsManual_Master_V.180419/ Date: 04.19.2018 14 / 92...
  • Page 16 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. PULSE Pallet Assembly Instructions Manual / Revision: Release PULSE_DM_DI_PULSEPalletAssemblyInstructionsManual_Master_V.180419/ Date: 04.19.2018 15 / 92...
  • Page 17 Use proper PPE (harnesses may be required where railings are not present) The Return Rails are mounted to the Balconies – be cautious working at heights PULSE Pallet Assembly Instructions Manual / Revision: Release PULSE_DM_DI_PULSEPalletAssemblyInstructionsManual_Master_V.180419/ Date: 04.19.2018 16 / 92...
  • Page 18 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). PULSE Pallet Assembly Instructions Manual / Revision: Release PULSE_DM_DI_PULSEPalletAssemblyInstructionsManual_Master_V.180419/ Date: 04.19.2018 17 / 92...

  • Page 19: Energy Control And Power Lockout (Ecpl)

    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. PULSE Pallet Assembly Instructions Manual / Revision: Release PULSE_DM_DI_PULSEPalletAssemblyInstructionsManual_Master_V.180419/ Date: 04.19.2018 18 / 92...
  • Page 20 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. PULSE Pallet Assembly Instructions Manual / Revision: Release PULSE_DM_DI_PULSEPalletAssemblyInstructionsManual_Master_V.180419/ Date: 04.19.2018 19 / 92...
  • Page 21 Anchor does not bottom out in the hole. Install the Hilti KH-EZ ¾” (19.05mm) x 4 ½” (114.3mm) (reference only) into the concrete as shown, applying 95-115 ft-lbs of torque. PULSE Pallet Assembly Instructions Manual / Revision: Release PULSE_DM_DI_PULSEPalletAssemblyInstructionsManual_Master_V.180419/ Date: 04.19.2018 20 / 92...

  • Page 22: Set-Up

    Mallets, Pinch Bars, and Socket Wrenches in an iterative (trial and error) process of small adjustments until the Mounting Bracket is located and leveled in place. Laser Targets and surface planes must be located within +/- .25 mm to the system Datum. PULSE Pallet Assembly Instructions Manual / Revision: Release PULSE_DM_DI_PULSEPalletAssemblyInstructionsManual_Master_V.180419/ Date: 04.19.2018 21 / 92...
  • Page 23 Note: Target location identifiers are assigned by the Assembly Technicians PULSE Pallet Assembly Instructions Manual / Revision: Release PULSE_DM_DI_PULSEPalletAssemblyInstructionsManual_Master_V.180419/ Date: 04.19.2018 22 / 92...
  • Page 24 X, Y, and Z Datum Planes. The Mounting Brackets will be fine-tuned using an iterative (trial and error) process until the proper locations are achieved. PULSE Pallet Assembly Instructions Manual / Revision: Release PULSE_DM_DI_PULSEPalletAssemblyInstructionsManual_Master_V.180419/ Date: 04.19.2018...
  • Page 25 Image of the Laser Computer screen referencing the Target locations relative to the Datum. Target hole numbers are assigned by the Assembly Technician from the Layout Drawing. Image of the Laser Tracker. PULSE Pallet Assembly Instructions Manual / Revision: Release PULSE_DM_DI_PULSEPalletAssemblyInstructionsManual_Master_V.180419/ Date: 04.19.2018 24 / 92...

  • Page 26: X, Y, Z Target Hole Locations For Each Sub-Assembly

    X, Y, Z Target Hole Locations for Each Sub-Assembly Turntable Image showing the X, Y, and Z axis relative to the PULSE Pallet System Note: X Axis is direction of Part Flow PULSE Pallet Assembly Instructions Manual / Revision: Release PULSE_DM_DI_PULSEPalletAssemblyInstructionsManual_Master_V.180419/ Date: 04.19.2018...
  • Page 27 Pallet Work Station Locating Assembly Image showing the X, Y, and Z axis relative to the PULSE Pallet System Note: X Axis is direction of Part Flow PULSE Pallet Assembly Instructions Manual / Revision: Release PULSE_DM_DI_PULSEPalletAssemblyInstructionsManual_Master_V.180419/ Date: 04.19.2018 26 / 92...
  • Page 28 Rail Support Bracket Image showing the X, Y, and Z axis relative to the PULSE Pallet System Note: X Axis is direction of Part Flow PULSE Pallet Assembly Instructions Manual / Revision: Release PULSE_DM_DI_PULSEPalletAssemblyInstructionsManual_Master_V.180419/ Date: 04.19.2018 27 / 92...
  • Page 29 Locating Actuator Image showing the X, Y, and Z axis relative to the PULSE Pallet System Note: X Axis is direction of Part Flow PULSE Pallet Assembly Instructions Manual / Revision: Release PULSE_DM_DI_PULSEPalletAssemblyInstructionsManual_Master_V.180419/ Date: 04.19.2018 28 / 92...
  • Page 30 In Process Actuated Stop Image showing the X, Y, and Z axis relative to the PULSE Pallet System Note: X Axis is direction of Part Flow PULSE Pallet Assembly Instructions Manual / Revision: Release PULSE_DM_DI_PULSEPalletAssemblyInstructionsManual_Master_V.180419/ Date: 04.19.2018 29 / 92...

  • Page 31: X, Y, And Z Laser Target Holes & Mounting Surface Tolerance Set-Up

    X, Y, and Z Laser Target Holes & Mounting Surface Tolerance Set-Up Laser Targets (assigned by the Assembly Technician) are located on the Assembly Drawings. All Target locations are to be +/- .25mm relative to the Datum. PULSE Pallet Assembly Instructions Manual / Revision: Release PULSE_DM_DI_PULSEPalletAssemblyInstructionsManual_Master_V.180419/ Date: 04.19.2018 30 / 92...

  • Page 32: Tool Setup Sheets

    Note – these are actual dimensions (based on the nominal dimensions on the Layout Drawings) recorded during the assembly process at KUKA, and will be repeated to record the actual dimensions at the final customer. PULSE Pallet Assembly Instructions Manual / Revision: Release PULSE_DM_DI_PULSEPalletAssemblyInstructionsManual_Master_V.180419/ Date: 04.19.2018...

  • Page 33: Adjusting Position Of Mounting Brackets Using Iterative (Trial And Error) Process

    Image shows the use of a Mallet (or Pinch Bar) for side adjustment (X and Y direction) of a typical Mounting Bracket. Once the Mounting Bracket is in its proper location, utilize weld clips. PULSE Pallet Assembly Instructions Manual / Revision: Release PULSE_DM_DI_PULSEPalletAssemblyInstructionsManual_Master_V.180419/ Date: 04.19.2018 32 / 92...
  • Page 34 Tracker and adjust accordingly through the welding process. Once the Mounting Bracket is located, tighten the HEX Jam Nut and mark the Leveling Screw assembly signifying that it is finally located. PULSE Pallet Assembly Instructions Manual / Revision: Release PULSE_DM_DI_PULSEPalletAssemblyInstructionsManual_Master_V.180419/ Date: 04.19.2018 33 / 92...
  • Page 35 There are NAAMS Leveling Screw assemblies used in the system. Simply turn to raise and lower the assembly. PULSE Pallet Assembly Instructions Manual / Revision: Release PULSE_DM_DI_PULSEPalletAssemblyInstructionsManual_Master_V.180419/ Date: 04.19.2018 34 / 92...
  • Page 36 Weld Clips to Floor Plates Image of Mounting Block welded in place PULSE Pallet Assembly Instructions Manual / Revision: Release PULSE_DM_DI_PULSEPalletAssemblyInstructionsManual_Master_V.180419/ Date: 04.19.2018 35 / 92...

  • Page 37: Attaching Rail To Mounting Brackets

    All Labels as shown in this photo should be on the same side of every rail (arrows in direction of part flow). Motor flow is denoted as upstream to downstream (from Drive Connectors to Sense Connector). This assures the correct orientation of the magnets and motors. PULSE Pallet Assembly Instructions Manual / Revision: Release PULSE_DM_DI_PULSEPalletAssemblyInstructionsManual_Master_V.180419/ Date: 04.19.2018 36 / 92...
  • Page 38 100mm on a Vertical Drop Lift (VDL) application. Image shows an example of FRP rails joining to share one Rail Mounting Bracket. PULSE Pallet Assembly Instructions Manual / Revision: Release PULSE_DM_DI_PULSEPalletAssemblyInstructionsManual_Master_V.180419/ Date: 04.19.2018...

  • Page 39: Alignment Of Sub-Assemblies

    All Targets and surfaces must be located +/- .25mm. Adjust the X, Y, and Z location as needed for alignment. Image shows Laser Beams Targeting Laser Targets mounted in Target Holes. PULSE Pallet Assembly Instructions Manual / Revision: Release PULSE_DM_DI_PULSEPalletAssemblyInstructionsManual_Master_V.180419/ Date: 04.19.2018 38 / 92...
  • Page 40 When correct alignment has been achieved, bolt down securely. Image shows Linear Rail being mounted onto Rail Mounting Brackets. Image shows how Linear Rail and Rail Mounting Brackets are secured. PULSE Pallet Assembly Instructions Manual / Revision: Release PULSE_DM_DI_PULSEPalletAssemblyInstructionsManual_Master_V.180419/ Date: 04.19.2018 39 / 92...
  • Page 41 Mount the second linear rail onto the second set of rail risers. Hand tighten the bolts in case adjustment is needed at a later point in installation. When correct alignment has been achieved, bolt down securely. PULSE Pallet Assembly Instructions Manual / Revision: Release PULSE_DM_DI_PULSEPalletAssemblyInstructionsManual_Master_V.180419/ Date: 04.19.2018 40 / 92...

  • Page 42: Kuka Pulse Frp Rail Cutting Guidelines

    When additional rail gap is needed in an elevator station, the rail adjacent to the elevator rail should be cut. An elevator rail should never be cut, as this would create an asymmetrical gap with the adjacent rail in the PULSE Pallet Assembly Instructions Manual / Revision: Release PULSE_DM_DI_PULSEPalletAssemblyInstructionsManual_Master_V.180419/ Date: 04.19.2018...
  • Page 43 Pictured below: When the elevator rail comes into position, 6.6mm of clearance exists between the PULSE Roller Assembly Locating Unit and the adjacent fixed FRP rail assembly. PULSE Pallet Assembly Instructions Manual / Revision: Release PULSE_DM_DI_PULSEPalletAssemblyInstructionsManual_Master_V.180419/ Date: 04.19.2018...
  • Page 44 Drawings: Workstation Reference: PULSE Pallet Assembly Instructions Manual / Revision: Release PULSE_DM_DI_PULSEPalletAssemblyInstructionsManual_Master_V.180419/ Date: 04.19.2018 43 / 92...
  • Page 45 Aervoe 403 Insulating Epoxy Coating • Product Data Sheet • Safety Data Sheet (SDS) Video: FRP Rail Cutting Reference Video Linked above: Demonstration video exhibiting FRP rail cutting procedure PULSE Pallet Assembly Instructions Manual / Revision: Release PULSE_DM_DI_PULSEPalletAssemblyInstructionsManual_Master_V.180419/ Date: 04.19.2018 44 / 92...

  • Page 46: Cross Transfer

    +/- .25mm. Adjust the X, Y, and Z location as needed for alignment. Continue to align the remaining rail risers for the cross transfer - Typical throughout. Image shows location of rail riser target locations. There are two (2) Targets per riser. PULSE Pallet Assembly Instructions Manual / Revision: Release PULSE_DM_DI_PULSEPalletAssemblyInstructionsManual_Master_V.180419/ Date: 04.19.2018 45 / 92...
  • Page 47 Linear Rails. Image shows location of cross transfer rail target locations. There are four (4) Targets in total. One at each end of both Linear Rails. PULSE Pallet Assembly Instructions Manual / Revision: Release PULSE_DM_DI_PULSEPalletAssemblyInstructionsManual_Master_V.180419/ Date: 04.19.2018 46 / 92...
  • Page 48 Using the Laser Tracker, locate the four Mid Position Risers. Image shows location of cross transfer mid riser target locations. There are eight (8) Targets in total, two on each Mid Position Riser. PULSE Pallet Assembly Instructions Manual / Revision: Release PULSE_DM_DI_PULSEPalletAssemblyInstructionsManual_Master_V.180419/ Date: 04.19.2018 47 / 92...
  • Page 49 Mount the linear rails onto the rail risers. Hand tighten the bolts in case adjustment is needed. When correct alignment has been achieved, bolt down securely. Finish assembly of Cross Transfer components. PULSE Pallet Assembly Instructions Manual / Revision: Release PULSE_DM_DI_PULSEPalletAssemblyInstructionsManual_Master_V.180419/ Date: 04.19.2018 48 / 92...

  • Page 50: Turntable

    Using the Laser Tracker, locate the Turntable Base Image shows location of turntable target locations. There are four (4) in total. Two on each side of the turntable base. PULSE Pallet Assembly Instructions Manual / Revision: Release PULSE_DM_DI_PULSEPalletAssemblyInstructionsManual_Master_V.180419/ Date: 04.19.2018 49 / 92...
  • Page 51 Use the adjustment screws to align the turntable rail to the linear rail. Align the rail with a ±.25mm tolerance. Image shows adjustment screw which can be used to move the rail angle up and down. PULSE Pallet Assembly Instructions Manual / Revision: Release PULSE_DM_DI_PULSEPalletAssemblyInstructionsManual_Master_V.180419/ Date: 04.19.2018 50 / 92...

  • Page 52: Roller Assembly Locating Unit

    When installing the Roller Assembly Locating Unit, ensure that a 94.45mm clearance is given from the bottom of the assembly to the ground. Also, ensure that when mounting other assemblies in the area that this clearance is considered. PULSE Pallet Assembly Instructions Manual / Revision: Release PULSE_DM_DI_PULSEPalletAssemblyInstructionsManual_Master_V.180419/ Date: 04.19.2018 51 / 92...
  • Page 53 The edge of magnet to motor search travel is approximately 112mm for the Turntable to establish or re-establish positioning sequence. Reference: Low-Profile Cable Tray System PULSE Pallet Assembly Instructions Manual / Revision: Release PULSE_DM_DI_PULSEPalletAssemblyInstructionsManual_Master_V.180419/ Date: 04.19.2018 52 / 92...

  • Page 54: Locating Actuator

    Image shows Locating Actuator mounted through the Rail Bridge Support Bracket. There are four (4) Laser Target Holes on the Locating Actuator, two on each end. PULSE Pallet Assembly Instructions Manual / Revision: Release PULSE_DM_DI_PULSEPalletAssemblyInstructionsManual_Master_V.180419/ Date: 04.19.2018 53 / 92...

  • Page 55: Work Station Locating Assembly

    Using the Laser Tracker, shoot in the four (4) Laser Roller Targets (Cat Eye Targets) for the locating the assembly in the Y-Axis. one (1) Laser Using the Laser Tracker, Locate the Work Station Lock / Locator Assembly. There is Roller PULSE Pallet Assembly Instructions Manual / Revision: Release PULSE_DM_DI_PULSEPalletAssemblyInstructionsManual_Master_V.180419/ Date: 04.19.2018 54 / 92...
  • Page 56 Target (Cat Eye Target) for the locating the assembly in the X-Axis. PULSE Pallet Assembly Instructions Manual / Revision: Release PULSE_DM_DI_PULSEPalletAssemblyInstructionsManual_Master_V.180419/ Date: 04.19.2018 55 / 92...

  • Page 57: In Process Actuated Stop

    5.8 In Process Actuated Stop Using the Laser Tracker, locate the In Process Actuated Stop. PULSE Pallet Assembly Instructions Manual / Revision: Release PULSE_DM_DI_PULSEPalletAssemblyInstructionsManual_Master_V.180419/ Date: 04.19.2018 56 / 92...

  • Page 58: Pallet Fixed Stop

    Locate the Pallet Fixed Stop to the end of the Cross Transfer. This sub assembly does not need to be shot in with the Laser Tracker. Image shows Pallet Fixed Stop located at the end of the Cross Transfer Rail. PULSE Pallet Assembly Instructions Manual / Revision: Release PULSE_DM_DI_PULSEPalletAssemblyInstructionsManual_Master_V.180419/ Date: 04.19.2018 57 / 92...

  • Page 59: Pull Off Cart Docking Unit With Pallet Stop

    Locate the Pull Off Cart Docking Unit with Pallet Stop to the end of the Pull Off Cart. This sub assembly does not need to be shot in with the Laser Tracker. PULSE Pallet Assembly Instructions Manual / Revision: Release PULSE_DM_DI_PULSEPalletAssemblyInstructionsManual_Master_V.180419/ Date: 04.19.2018...

  • Page 60: Part Cart Assembly

    Tapping plates are welded at assembly. See diagram and layout drawing. Use adjustment screws to align the FRP rail to the appropriate height. See diagram and layout drawing. PULSE Pallet Assembly Instructions Manual / Revision: Release PULSE_DM_DI_PULSEPalletAssemblyInstructionsManual_Master_V.180419/ Date: 04.19.2018 59 / 92...
  • Page 61 PULSE Pallet Assembly Instructions Manual / Revision: Release PULSE_DM_DI_PULSEPalletAssemblyInstructionsManual_Master_V.180419/ Date: 04.19.2018 60 / 92...

  • Page 62: Chassis-Pallet Marriage Procedure

    When introducing/removing a chassis assembly into the line, the first option should always be to use a PULSE Pull-Off Cart. Figure 5.12.1: PULSE Pull-Off Cart positioned at the end of the line. Step 2: Utilize Lifting Straps to Pick Up the Chassis Utilize lifting straps and a fork lift to pick up the chassis.
  • Page 63 Note: PULSE chassis assemblies utilize high strength Neodymium Iron Boron magnet arrays. Magnet arrays are always active and present a strong magnetic field. Never use chains or bring a forklift in direct contact with a magnet array. Failure to do so will result in potential injury and/or damage to equipment.
  • Page 64 Figure 5.12.4: Lifting straps attached to a pallet. Reference only. PULSE Pallet Assembly Instructions Manual / Revision: Release PULSE_DM_DI_PULSEPalletAssemblyInstructionsManual_Master_V.180419/ Date: 04.19.2018 63 / 92...
  • Page 65 Figure 5.12.5: Bottom side view of a pallet. Reference only. Figure 5.12.6: Rough locators positioning over the chassis pin blocks. PULSE Pallet Assembly Instructions Manual / Revision: Release PULSE_DM_DI_PULSEPalletAssemblyInstructionsManual_Master_V.180419/ Date: 04.19.2018 64 / 92...
  • Page 66 Figure 5.12.7: PULSE Chassis with a pallet loaded. Reference only. Step 6: Load the Chassis/Pallet onto the Line Once secured, load the chassis/pallet into the line via the pull-off cart. Figure 5.12.8: Operators utilizing the pull-off cart to insert a chassis/pallet.

  • Page 67: Plinth Installation Procedure

    On the bottom of plinth, remove the plastic covers by pressing down on the top edge of the cover and tilting back. This will give access to the anchor hole. PULSE Pallet Assembly Instructions Manual / Revision: Release PULSE_DM_DI_PULSEPalletAssemblyInstructionsManual_Master_V.180419/ Date: 04.19.2018...
  • Page 68 Use a marker to mark the hole location. It’s recommended that at least two diagonally opposite corners are anchored to give the enclosure stability from tipping over. PULSE Pallet Assembly Instructions Manual / Revision: Release PULSE_DM_DI_PULSEPalletAssemblyInstructionsManual_Master_V.180419/ Date: 04.19.2018 67 / 92...
  • Page 69 Step 4: Move Enclosure Aside Move the enclosure aside. Select the correct anchor to use in this application. PULSE Pallet Assembly Instructions Manual / Revision: Release PULSE_DM_DI_PULSEPalletAssemblyInstructionsManual_Master_V.180419/ Date: 04.19.2018 68 / 92...
  • Page 70 Allow for a minimum of 3/4” of anchor thread above the floor. Step 6: Clean Drill Dust Clean drill dust from anchor hole and surrounding area. PULSE Pallet Assembly Instructions Manual / Revision: Release PULSE_DM_DI_PULSEPalletAssemblyInstructionsManual_Master_V.180419/ Date: 04.19.2018 69 / 92...
  • Page 71 Step 8: Install Enclosure Once anchor is at proper depth, install the enclosure over the anchors. Install washer and nut and tighten down for a snug fit. PULSE Pallet Assembly Instructions Manual / Revision: Release PULSE_DM_DI_PULSEPalletAssemblyInstructionsManual_Master_V.180419/ Date: 04.19.2018 70 / 92...
  • Page 72 Step 9: Install Access Cover To install plastic access cover, place bottom of lip and then tilt forward to snap cover into place. Installation is now complete. PULSE Pallet Assembly Instructions Manual / Revision: Release PULSE_DM_DI_PULSEPalletAssemblyInstructionsManual_Master_V.180419/ Date: 04.19.2018 71 / 92...

  • Page 73: Connect All Electrical Pin Plug Connections

    Connect All Electrical Pin Plug Connections Connect all Electrical Pin Plug Connectors throughout the System. Typical Pin Connectors – Ref. Only Typical Pin Connectors – Ref. Only PULSE Pallet Assembly Instructions Manual / Revision: Release PULSE_DM_DI_PULSEPalletAssemblyInstructionsManual_Master_V.180419/ Date: 04.19.2018 72 / 92...

  • Page 74: 3-Phase Power Distribution

    5.15 3-Phase Power Distribution 5.16 Ethernet Communications PULSE Pallet Assembly Instructions Manual / Revision: Release PULSE_DM_DI_PULSEPalletAssemblyInstructionsManual_Master_V.180419/ Date: 04.19.2018 73 / 92...

  • Page 75: 24Vdc Power Distribution

    5.17 24VDC Power Distribution PULSE Pallet Assembly Instructions Manual / Revision: Release PULSE_DM_DI_PULSEPalletAssemblyInstructionsManual_Master_V.180419/ Date: 04.19.2018 74 / 92...

  • Page 76: Pulse Hardware Installation Overview For Version 2 Panels

    5.18 PULSE Hardware Installation Overview for Version 2 Panels The following are guidelines outlined in (5) steps for the Transformer Wiring Diagram, NCP Wiring, SDP Wiring, Motor Wiring, and Motor Controller Replacement: PULSE Pallet Assembly Instructions Manual / Revision: Release PULSE_DM_DI_PULSEPalletAssemblyInstructionsManual_Master_V.180419/ Date: 04.19.2018...
  • Page 77 PULSE Pallet Assembly Instructions Manual / Revision: Release PULSE_DM_DI_PULSEPalletAssemblyInstructionsManual_Master_V.180419/ Date: 04.19.2018 76 / 92...
  • Page 78 PULSE Pallet Assembly Instructions Manual / Revision: Release PULSE_DM_DI_PULSEPalletAssemblyInstructionsManual_Master_V.180419/ Date: 04.19.2018 77 / 92...
  • Page 79 PULSE Pallet Assembly Instructions Manual / Revision: Release PULSE_DM_DI_PULSEPalletAssemblyInstructionsManual_Master_V.180419/ Date: 04.19.2018 78 / 92...
  • Page 80 PULSE Pallet Assembly Instructions Manual / Revision: Release PULSE_DM_DI_PULSEPalletAssemblyInstructionsManual_Master_V.180419/ Date: 04.19.2018 79 / 92...
  • Page 81 PULSE Pallet Assembly Instructions Manual / Revision: Release PULSE_DM_DI_PULSEPalletAssemblyInstructionsManual_Master_V.180419/ Date: 04.19.2018 80 / 92...
  • Page 82 PULSE Pallet Assembly Instructions Manual / Revision: Release PULSE_DM_DI_PULSEPalletAssemblyInstructionsManual_Master_V.180419/ Date: 04.19.2018 81 / 92...
  • Page 83 PULSE Pallet Assembly Instructions Manual / Revision: Release PULSE_DM_DI_PULSEPalletAssemblyInstructionsManual_Master_V.180419/ Date: 04.19.2018 82 / 92...
  • Page 84 PULSE Pallet Assembly Instructions Manual / Revision: Release PULSE_DM_DI_PULSEPalletAssemblyInstructionsManual_Master_V.180419/ Date: 04.19.2018 83 / 92...
  • Page 85 PULSE Pallet Assembly Instructions Manual / Revision: Release PULSE_DM_DI_PULSEPalletAssemblyInstructionsManual_Master_V.180419/ Date: 04.19.2018 84 / 92...
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  • Page 87 PULSE Pallet Assembly Instructions Manual / Revision: Release PULSE_DM_DI_PULSEPalletAssemblyInstructionsManual_Master_V.180419/ Date: 04.19.2018 86 / 92...

  • Page 88: Pulse Hardware "Best Practices" For Version 2 Panels

    5.19 PULSE Hardware “Best Practices” for Version 2 Panels • When connecting RS-422 cables, be aware that the cable and receptacle are not keyed. Use care when aligning the cables, so as not to bend any pins in the motor controller’s receptacles.

  • Page 89: Transportation

    TRANSPORTATION The PULSE Pallet system may only be picked up and lifted in specified spots. Reference lift point stickers attached to FRP rails for proper moving methods. Incorrect use and attachment of lifting tackle can cause the PULSE Pallet system to fall, resulting in injury.

  • Page 90: Transportation By Fork Lift Truck

    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. PULSE Pallet Assembly Instructions Manual / Revision: Release PULSE_DM_DI_PULSEPalletAssemblyInstructionsManual_Master_V.180419/ Date: 04.19.2018 89 / 92...

  • Page 91: Transportation By Pallet Truck

    The anti-tipping bracket must be fastened to the enclosures. Procedure Figure 6-4: Transportation by pallet truck 1. Enclosure with anti-toppling bracket 2. Enclosure in raised position PULSE Pallet Assembly Instructions Manual / Revision: Release PULSE_DM_DI_PULSEPalletAssemblyInstructionsManual_Master_V.180419/ Date: 04.19.2018 90 / 92...

  • Page 92: Decommissioning, Storage, & Disposal

    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.

  • Page 93: Disposal

    7.3 Disposal When the PULSE system reaches the end of its useful life, it can be dismantled, and the materials can be disposed of properly by type. As the end user, the customer is legally required to return depleted batteries. Used batteries can be returned to the vendor or brought to the designated collection points (e.g.

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