Kuka PULSE Commissioning Manual
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Kuka PULSE Commissioning Manual

Kuka PULSE Commissioning Manual

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PULSE SYSTEM
PULSE Commissioning & Troubleshooting Manual
Original Instructions
Revision: Release
Publication Date: August 15, 2019
PULSE_DC_OM_Commissioning&TroubleshootingManual_V.190815
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 Commissioning & Troubleshooting Manual Original Instructions Revision: Release Publication Date: August 15, 2019 PULSE_DC_OM_Commissioning&TroubleshootingManual_V.190815 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

    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 Motor Types ..........................36 Communications ..........................36 2.5.1 Communication Protocol ......................37 PULSE Commissioning & Troubleshooting Manual / Revision: Release PULSE_DC_OM_Commissioning&TroubleshootingManual_V.190815 1 / 72...
  • Page 3 PULSE SDP Wiring ........................54 8.1.5 PULSE Motor Wiring ........................55 8.1.6 Clearing a Fault ..........................55 8.1.7 Troubleshooting Table ........................56 PULSE Power Fault Recovery ......................56 PULSE HLC Jammed, Hindered & Stall Faults ................57 PULSE Commissioning & Troubleshooting Manual / Revision: Release PULSE_DC_OM_Commissioning&TroubleshootingManual_V.190815 2 / 72...
  • Page 4 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 PULSE Commissioning & Troubleshooting Manual / Revision: Release PULSE_DC_OM_Commissioning&TroubleshootingManual_V.190815 3 / 72...

  • Page 5: Introduction

    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.

  • Page 6: Special Notations

    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. PULSE Commissioning & Troubleshooting Manual / Revision: Release PULSE_DC_OM_Commissioning&TroubleshootingManual_V.190815 5 / 72...

  • Page 7: 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 •...

  • Page 8: 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. •...

  • Page 9: Health & Safety Statement

    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.

  • Page 10: Glossary

    North oriented half magnet at each end of the array. Magnetic Field A region around a magnetic material or a moving electric PULSE Commissioning & Troubleshooting Manual / Revision: Release PULSE_DC_OM_Commissioning&TroubleshootingManual_V.190815 9 / 72...
  • Page 11 Programmable Logic Computer PULSE Propulsion Using Linear Synchronous Energy QSMC QuickStick Motor Controller Station Drive Panel Stator The stationary part of the motor over which the magnet array moves. PULSE Commissioning & Troubleshooting Manual / Revision: Release PULSE_DC_OM_Commissioning&TroubleshootingManual_V.190815 10 / 72...

  • Page 12: Panel Identification

    Panel Identification 1.3.1 Electrical Nameplate Example PULSE Commissioning & Troubleshooting Manual / Revision: Release PULSE_DC_OM_Commissioning&TroubleshootingManual_V.190815 11 / 72...

  • Page 13: Pulse System Definition/Description

    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.

  • Page 14: Technical Data - Architecture Of Controls

    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.
  • Page 15 Weight Load • Clean Environment • Accessibility • Proper Ground Techniques • Input Source Voltage • Distribution Power • Room Temperature • Clearances Station Drive Panel Node Controller Panel PULSE Commissioning & Troubleshooting Manual / Revision: Release PULSE_DC_OM_Commissioning&TroubleshootingManual_V.190815 14 / 72...

  • Page 16: 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.
  • Page 17 24 VDC @ 40A Power Distribution Example NOTE: FLOOR MOUNTED TRANSFORMER SHOULD BE MOUNTED AS CLOSE TO THE NCP PANEL AS PHYSICALLY POSSIBLE BUT ALSO NOT IMPEDE EQUIPMENT PLACEMENT. PULSE Commissioning & Troubleshooting Manual / Revision: Release PULSE_DC_OM_Commissioning&TroubleshootingManual_V.190815 16 / 72...
  • Page 18 • 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 PULSE Commissioning & Troubleshooting Manual / Revision: Release PULSE_DC_OM_Commissioning&TroubleshootingManual_V.190815 17 / 72...

  • Page 19: Master Slave Hardware Configuration

    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.
  • Page 20 Figure 1 Figure 2 PULSE Commissioning & Troubleshooting Manual / Revision: Release PULSE_DC_OM_Commissioning&TroubleshootingManual_V.190815 19 / 72...
  • Page 21 Figure 3 PULSE Commissioning & Troubleshooting Manual / Revision: Release PULSE_DC_OM_Commissioning&TroubleshootingManual_V.190815 20 / 72...

  • Page 22: Node Controller Panel Grounding Installation

    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 PULSE Commissioning & Troubleshooting Manual / Revision: Release PULSE_DC_OM_Commissioning&TroubleshootingManual_V.190815 21 / 72...

  • Page 23: Ncp Lockout Procedure

    4) Insert padlock into the lock out bracket 2) Release the Rittal handle, door will open In this state, the door is open, and the power cannot be turned on. PULSE Commissioning & Troubleshooting Manual / Revision: Release PULSE_DC_OM_Commissioning&TroubleshootingManual_V.190815 22 / 72...
  • Page 24 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. PULSE Commissioning & Troubleshooting Manual / Revision: Release PULSE_DC_OM_Commissioning&TroubleshootingManual_V.190815...
  • Page 25 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. PULSE Commissioning & Troubleshooting Manual / Revision: Release PULSE_DC_OM_Commissioning&TroubleshootingManual_V.190815...

  • Page 26: Station Drive Panel

    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. PULSE Commissioning & Troubleshooting Manual / Revision: Release PULSE_DC_OM_Commissioning&TroubleshootingManual_V.190815 25 / 72...
  • Page 27 Only trained electrical technicians should perform service on the electrical panel. DANGER! Never unplug any connector during operation. This creates a hazard with the risk of death, severe injury or equipment damage. PULSE Commissioning & Troubleshooting Manual / Revision: Release PULSE_DC_OM_Commissioning&TroubleshootingManual_V.190815 26 / 72...

  • Page 28: Rs-422 Communication Jumpers

    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 PULSE Commissioning & Troubleshooting Manual / Revision: Release PULSE_DC_OM_Commissioning&TroubleshootingManual_V.190815 27 / 72...

  • Page 29: Best Practices

    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. PULSE Commissioning & Troubleshooting Manual / Revision: Release PULSE_DC_OM_Commissioning&TroubleshootingManual_V.190815 28 / 72...
  • Page 30 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.
  • Page 31 1109000.2 *Under special circumstances, the 5 slot can only be used when managed properly from a motor coverage and usage standpoint. Example of Serial Number for an SDP PULSE Commissioning & Troubleshooting Manual / Revision: Release PULSE_DC_OM_Commissioning&TroubleshootingManual_V.190815 30 / 72...
  • Page 32 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. PULSE Commissioning & Troubleshooting Manual / Revision: Release PULSE_DC_OM_Commissioning&TroubleshootingManual_V.190815 31 / 72...

  • Page 33: Rail Layout Practices

    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. PULSE Commissioning & Troubleshooting Manual / Revision: Release PULSE_DC_OM_Commissioning&TroubleshootingManual_V.190815 32 / 72...

  • Page 34: Sdp Lockout Procedure

    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. PULSE Commissioning & Troubleshooting Manual / Revision: Release PULSE_DC_OM_Commissioning&TroubleshootingManual_V.190815...
  • Page 35 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 PULSE Commissioning & Troubleshooting Manual / Revision: Release PULSE_DC_OM_Commissioning&TroubleshootingManual_V.190815...
  • Page 36 In this state, the door is open, outward gently to engage the and the incoming AC power is override mechanism. Then rotate the handle clockwise to turn the power on. Rotating PULSE Commissioning & Troubleshooting Manual / Revision: Release PULSE_DC_OM_Commissioning&TroubleshootingManual_V.190815 35 / 72...

  • Page 37: Motor Types

    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.

  • Page 38: Communication Protocol

    (Refer to OEM document 990000437 section 4) 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.

  • Page 39: Excess Cable

    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). PULSE Commissioning & Troubleshooting Manual / Revision: Release PULSE_DC_OM_Commissioning&TroubleshootingManual_V.180905 38 / 72...

  • Page 40: Power Distribution

    Power Distribution PULSE Commissioning & Troubleshooting Manual / Revision: Release PULSE_DC_OM_Commissioning&TroubleshootingManual_V.180905 39 / 72...

  • Page 41: Panel Maintenance

    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. PULSE Commissioning & Troubleshooting Manual / Revision: Release PULSE_DC_OM_Commissioning&TroubleshootingManual_V.180905 40 / 72...

  • Page 42: Track Section Chassis Placement

    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, PULSE Commissioning & Troubleshooting Manual / Revision: Release PULSE_DC_OM_Commissioning&TroubleshootingManual_V.180905...
  • Page 43 Rail to turn table. Filler rails are used when a full section rail cannot be fitted as the last rail segment. PULSE Commissioning & Troubleshooting Manual / Revision: Release PULSE_DC_OM_Commissioning&TroubleshootingManual_V.180905 42 / 72...

  • Page 44: Safety

    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.

  • Page 45: Residual Risks

    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.
  • Page 46 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.

  • Page 47: Transportation

    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. PULSE Commissioning & Troubleshooting Manual / Revision: Release PULSE_DC_OM_Commissioning&TroubleshootingManual_V.180905 46 / 72...

  • Page 48: 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 PULSE Commissioning & Troubleshooting Manual / Revision: Release PULSE_DC_OM_Commissioning&TroubleshootingManual_V.180905 47 / 72...

  • Page 49: Transportation By Pallet Truck

    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 PULSE Commissioning & Troubleshooting Manual / Revision: Release PULSE_DC_OM_Commissioning&TroubleshootingManual_V.180905 48 / 72...

  • Page 50: Start-Up And Recommissioning

    If a turntable is installed, manually swing turntable to ensure no collisions with other objects or other rail sections and to verify rail gap. If PULSE rail is mounted on a lift, manually jog lift to ensure no collision and verify rail gap. Electrical System...

  • Page 51: Maintenance

    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. PULSE Commissioning & Troubleshooting Manual / Revision: Release PULSE_DC_OM_Commissioning&TroubleshootingManual_V.180905...
  • Page 52 Wipe excess debris from rail Motors Wipe motors clean with cloth Visual inspection U38: Roller Assembly Locating Unit McGill Cam Follower During routine plant maintenance Replace every 5,000,000 cycles PULSE Commissioning & Troubleshooting Manual / Revision: Release PULSE_DC_OM_Commissioning&TroubleshootingManual_V.180905 51 / 72...

  • Page 53: Repair

    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.

  • Page 54: Pulse Troubleshooting

    • 480/400VAC power on the primary (H1, H2, H3) • 240VAC power on the secondary (X1, X2, X3) • Center of the Wye is grounded (X0) PULSE Commissioning & Troubleshooting Manual / Revision: Release PULSE_DC_OM_Commissioning&TroubleshootingManual_V.180905 53 / 72...

  • Page 55: Pulse Ncp Wiring

    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. PULSE Commissioning & Troubleshooting Manual / Revision: Release PULSE_DC_OM_Commissioning&TroubleshootingManual_V.180905 54 / 72...

  • Page 56: Pulse Motor Wiring

    All fault management is performed through the HMI consoles (provided by others). When all faults are cleared: • the station is ready to resume processing PULSE Commissioning & Troubleshooting Manual / Revision: Release PULSE_DC_OM_Commissioning&TroubleshootingManual_V.180905 55 / 72...

  • Page 57: Troubleshooting Table

    Recording this information in the manual will facilitate any future repairs. Symptom Probable Cause Corrective Action PULSE Power Fault Recovery Refer to OEM document 990000496 section PULSE Commissioning & Troubleshooting Manual / Revision: Release PULSE_DC_OM_Commissioning&TroubleshootingManual_V.180905 56 / 72...

  • Page 58: Pulse Hlc Jammed, Hindered & Stall Faults

    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. PULSE Commissioning & Troubleshooting Manual / Revision: Release PULSE_DC_OM_Commissioning&TroubleshootingManual_V.180905...

  • Page 59: Pulse Software Helpful Hints

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

  • Page 60: Commission A Hlc/Nc (High Level Controller/Node Controller)

    Figure 1 Motor Electrical Connections 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 •...

  • Page 61: Load The Configuration Files

    “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.
  • Page 62 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. Figure 4 Upgrade Software • Click on > Distribute to all NC PULSE Commissioning & Troubleshooting Manual / Revision: Release PULSE_DC_OM_Commissioning&TroubleshootingManual_V.180905 61 / 72...
  • Page 63 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. PULSE Commissioning & Troubleshooting Manual / Revision: Release PULSE_DC_OM_Commissioning&TroubleshootingManual_V.180905 62 / 72...

  • Page 64: 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.

  • Page 65: 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.
  • Page 66 Figure 5 Virtual Machine Wi-Fi settings PULSE Commissioning & Troubleshooting Manual / Revision: Release PULSE_DC_OM_Commissioning&TroubleshootingManual_V.180905 65 / 72...

  • Page 67: Pulse Vehicle Recovery Scenarios

    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 PULSE Commissioning & Troubleshooting Manual / Revision: Release PULSE_DC_OM_Commissioning&TroubleshootingManual_V.180905 66 / 72...

  • Page 68: Decommissioning, Storage, And Disposal

    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.
  • Page 69 Under no condition should magnets be disposed of with other wastes. Follow all facility, local, and national procedures for the disposal of hazardous materials. PULSE Commissioning & Troubleshooting Manual / Revision: Release PULSE_DC_OM_Commissioning&TroubleshootingManual_V.180905 68 / 72...

  • Page 70: Iso Hazard Labels

    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. PULSE Commissioning & Troubleshooting Manual / Revision: Release PULSE_DC_OM_Commissioning&TroubleshootingManual_V.180905 69 / 72...
  • Page 71 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. PULSE Commissioning & Troubleshooting Manual / Revision: Release PULSE_DC_OM_Commissioning&TroubleshootingManual_V.180905 70 / 72...

  • Page 72: Prohibition 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. PULSE Commissioning & Troubleshooting Manual / Revision: Release PULSE_DC_OM_Commissioning&TroubleshootingManual_V.180905 71 / 72...

  • Page 73: Oem References

    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 PULSE Commissioning & Troubleshooting Manual / Revision: Release PULSE_DC_OM_Commissioning&TroubleshootingManual_V.180905 72 / 72...

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