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CONTROL CABINET
KR C2
Electrical Servicing
Maintenance / Repair
Issued: 26 Jul 2004 Version: 04
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KRC2/ServElek/Wartung 10.00.04 en
e Copyright KUKA Roboter GmbHThisdocumentation or excerpts therefrom may notbe reproduced or disclosed to third parties without theexpress permission of thepublishers.Other functions not described in this documentation may be operable in the controller. The user has no claim to these functions, however, inthe case of a replacement or service work.We have checked the content of this documentation for conformity with the hardware and software described. Nevertheless, discrepancies
cannot be precluded, for which reason we are not able to guarantee total conformity. The information in this documentation is checked on aregular basis, however, and necessary corrections will be incorporated in subsequent editions.Subject to technical alterations without an effect on the function.
PD Interleaf
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Contents
1 Fundamentals 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 Maintenance work 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1 Maintenance tables 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2 Plates on the KR C2 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3 Parts list, rating plates 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4 Removal, installation of cabinet fans 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4.1 Removal, installation of internal fan 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4.2 Removal, installation of external fan 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5 Removal, installation of PC fan 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.6 Motherboard battery 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.7 Removal, installation of batteries 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.8 Exchanging the pressure relief plug filter insert 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 Repair work 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Electrical Servicing
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1 Fundamentals
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1 Fundamentals
The customer support service of KUKA Roboter GmbH should always be informed
in the event of a malfunction.The diagnosis and exchange of defective components is the sole responsibility ofthe customer support service.
If your company has a service technician trained by KUKA Roboter GmbH, we referyou to the Electrical Servicing seminar handbook.
With the exception of battery replacement and the cleaning of the cooling system, all control-ler variants are maintenance--free. Preventive maintenance is recommended wherever dirt,corrosion and wear occur.
Before any visual inspections, cleaning or maintenance work is started, thechapterSafety, KR C2, General (to be found in the control cabinet) must be observed.
Before visual inspections, cleaning, maintenance or repair work is started, it mustbe ensured that therobot system is switched off and that the main switch is securedwith a padlock to prevent unauthorized persons from switching it on again.The incoming power cable must be deenergized and measures must be taken toprevent it from being inadvertently energized again. Any adjacent live parts orelements must be covered or safeguarded.
ON
OFFOFF
ON
OFF
If it is essential for personnel to enter the working range of the robot system forvisual inspection, maintenance or repair work, the safety measures must always bedesigned in such a way (e.g. enabling switches) that the robot system is switched
off immediately should an unintended situation arise.
Observe ESD guidelines when carrying out work on the control cabinet.Cleaning tools must be ESD--compliant.
It is particularly important to ensure that maintenance and repair work is carried outonly by trained personnel aware of the hazards involved.
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Cleaning and preventive maintenance work is to be carried out in accordance withthe following instructions:
G Loosen and vacuum up any dust deposits.
G Clean control cabinet with a cloth soaked with a mild cleaning agent.
G Clean cables, plastic parts and hoses with solvent--free cleaning agents.
G Replace damaged, illegible or missing inscriptions, labels and plates (see 2.3).
The manufacturers instructions must be observed when using cleaning agents.
It must be ensured that no cleaning fluid enters electrical components.
Do not use compressed air to clean the system, as this could cause dirt to penetrateinto electrical components.Compressed air may be used only when expressly specified.
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2 Maintenance work
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2 Maintenance work
Clean with brush and vacuum up dirt
+ --Service battery
Maintenance point
Maintenance point
2
(e.g. maintenance point 2)
visible on drawing
Maintenance pointnot visible on drawing
3 56 4
+ --
2
0OFF
+ --
2
Side view Front view Rear view
7
Fig. 1 Maintenance work on control cabinet
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2.1 Maintenance tables
Recommended operating times
Article Rec. operating time /MTBF acc. tomanufacturer
Recommendedexchange interval Remarks
Battery 3 years 2 yearsincl. allowance
for capacity loss
PC fan 60,000 hours 5 years1)
Cabinet fan 46,000 hours 5 years1)
Motherboard battery 10 years 5 years
Filter insert, pressure
relief plug
-- Depends oninstallationconditions and
degree of clogging
Visual check: change
filter insert if discolored
(original color: white)
1) with 3--shift operation
Maintenance work
Maintenance point Maintenance Activity, specification Timesee a n enance po n s n erva requ red
[min]
Control cabinetcooling unit (optional)
Clean heat exchanger with
brush15
Side and rear of controlcabinet, heat sink, heat
exchanger
Depends oninstallation
conditions andde ree of clo -
Clean heat sink with brush
and check that it is securely
fastened
15
Internal andexternal control cabinet fans
-ging; however,no later thanevery 2 years
Clean fans with brush.
(clogged fan = insufficient
cooling!)
15
Exchange fan,
see Section 2.4
20
Control cabinet
PC fan XExchange PC fan, see
Section 2.5
2
Control cabinet,
PC,
motherboard battery
XExchange motherboard
battery,
see Section 2.6
20
Interior of control cabinet,batteries X
Exchange batteries,see Section 2.7
5
Filter insert,pressure relief plug X
Exchange filter insert
see Section 2.8
1
The above activities may only be performed by qualified personnelwith appropriate training.
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2 Maintenance work (continued)
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2.2 Plates on the KR C2
8
2
4
KR C2 door,interior view
Front view of PC frame
Sectional drawing,
right--hand side panel, interior view
5
6
11 12
Installation location ofESC--CI
1
Rear panel, exterior view
Fig. 2 Plates on the KR C2
7
PC
3
9
A1
Connector X1 in the connectorpanel
X20X1
10
Controlc
abinet,rearpanel,interior
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1
KR C2
00106204
2000392.750--36...
0122
50/60Hz6A
3x400V
12345
ca. 185kg
16A
Fig. 3 Control cabinet rating plate (example)
The control cabinet rating plate (1) can be found both inside the cabinet (seesectional drawing Fig. 2) and on the outside of the connector panel, right--handside.
2
Fig. 5 Discharging time warning
3
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2 Maintenance work (continued)
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4
5
KR C2
8
6
Fig. 6 Grounded neutral warning
Fig. 7 Reference to component
fastening check
Fig. 8 White cable warning
Fig. 9 Supply voltage warning
Fig. 10 PC rating plate
Fig. 11 Fuse ratings
Fig. 12 Label, connector X1
7
9
10
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Fig. 13 Hot surface warning sign Fig. 14 Hand injury warning sign
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2.3 Parts list, rating plates
Plate no. Designation Article no.
1 KR C2 rating plate 71--052--163
2 Reference to operating instructions 69--000--997
3 Note: Discharging time 00--109--394
4 Note: Grounded neutral 00--100--002
5 Fastening check warning, screws and terminals 00--100--046
6 Note: White cable 00--107--080
7 Note: Supply voltage warning 00--109--217
8 PC rating plate 71--052--163
9 Fuse ratings 00--109--396
10 Note: Power plug 00--108--994
11 Hot surface warning sign 00--109--097
12 Hand injury warning sign 00--109--098
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2 Maintenance work (continued)
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2.4 Removal, installation of cabinet fans
Before visual inspections, cleaning, maintenance or repair work is started, it mustbe ensured that therobot system is switched off and that the main switch is secured
with a padlock to prevent unauthorized persons from switching it on again.The incoming power cable must be deenergized and measures must be taken toprevent it from being inadvertently energized again. Any adjacent live parts orelements must be covered or safeguarded.
If it is essential for personnel to enter the working range of the robot system forvisual inspection, maintenance or repair work, the safety measures must always bedesigned in such a way (e.g. enabling switches) that the robot system is switchedoff immediately should an unintended situation arise.
Observe ESD guidelines when carrying out work on the control cabinet.Cleaning tools must be ESD--compliant.
2.4.1 Removal, installation of internal fan
G REMOVAL
(1) Open cabinet door (1) (Fig. 15).
(2) Remove the two domed cap nuts and the two lock nutsunderneath on the front of the fan plate (2) (Fig. 16).
(3) Tilt fan plate (3) downwards (Fig. 17).
(4) Unplug fan cable (4) (Fig. 18).
(5) Pull fan plate (3) forwards to remove (Fig. 17).
(6) Remove the hexagon nuts (5) on both sides of the fan holder
from the fan plate (3) (Fig. 19).
(7) Separate holder together with fan (8) from fan plate (3) (Fig. 19).
(8) Unscrew (6) fan (7) from holder (8) and exchange fan (Fig. 19).
1 2
Fig. 15 Cabinet door open Fig. 16 Fan plate fastening
Fan
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Fig. 17 Fan opened Fig. 18 Fan cable connector
5
6
7
8
Fig. 19 Fan with fan plate
3
G INSTALLATION
(1) Install internal fan by carrying out removal instructions in reverse.
Replace the lock nuts for the fan plate with new ones before tighteningthe domed cap nuts.
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2 Maintenance work (continued)
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2.4.2 Removal, installation of external fan
(1) Undo the four screws (1) on the rear panel of the cabinet and remove the rear panel.
(2) Remove the two cable inlet screws (2) and then unplug the fan cable connector thus
exposed (3).
(3) Once the two screws (4) have been removed, the fan holder (6) can be swung out com-plete with the fan (7).(It is necessary to cut through the cable straps attached to the fan cable. These mustbe replaced with new ones once reassembly is complete.)
(4) Separate the fan (7) from the holder (6) by removing the four screws (5) and exchangethe fan.
23
1
45
5 2
6
7
Fig. 20 External fan removal/installation (standard cabinet)
G INSTALLATION
(1) Install external fan by carrying out removal instructions in reverse.
Use a new cable strap to fasten the cables.
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2.5 Removal, installation of PC fan
Before visual inspections, cleaning, maintenance or repair work is started, it mustbe ensured that therobot system is switched off and that the main switch is securedwith a padlock to prevent unauthorized persons from switching it on again.The incoming power cable must be deenergized and measures must be taken toprevent it from being inadvertently energized again. Any adjacent live parts orelements must be covered or safeguarded.
If it is essential for personnel to enter the working range of the robot system forvisual inspection, maintenance or repair work, the safety measures must always bedesigned in such a way (e.g. enabling switches) that the robot system is switchedoff immediately should an unintended situation arise.
Observe ESD guidelines when carrying out work on the control cabinet.Cleaning tools must be ESD--compliant.
(1) Unplug the fan cable connector (1).
(2) Undo the two screws (2) on the fan (3).
(3) Then remove the fan holder (4) complete with the fan (3).
(4) Remove the fan (3) from holder (4) and exchange it.
3
1
4
42 3
Fig. 21 Removal/installation of PC fan
G INSTALLATION
(1) Install PC fan by carrying out removal instructions in reverse.
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2 Maintenance work (continued)
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2.6 Motherboard battery
The motherboard battery may only be removed by authorized maintenance
personnel in consultation with the KUKA customer support service.
2.7 Removal, installation of batteries
Before visual inspections, cleaning, maintenance or repair work is started, it mustbe ensured that therobot system is switched off and that the main switch is securedwith a padlock to prevent unauthorized persons from switching it on again.The incoming power cable must be deenergized and measures must be taken toprevent it from being inadvertently energized again. Any adjacent live parts orelements must be covered or safeguarded.
If it is essential for personnel to enter the working range of the robot system forvisual inspection, maintenance or repair work, the safety measures must always bedesigned in such a way (e.g. enabling switches) that the robot system is switchedoff immediately should an unintended situation arise.
Observe ESD guidelines when carrying out work on the control cabinet.Cleaning tools must be ESD--compliant.
If replacement batteries are used, please note that the terminal lugs of batteriesfromsome manufacturers may havereversed polarity. For this reason, always makesure that the batteries have the correct polarity.
G Removal
(1) Open cabinet door
(2) Unplug cables
(3) Press spring clamps downwards
(4) Remove battery blocks
Always exchange both battery blocks!
Fig. 22 Installation position of Hitachi batteries
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G Installation
(1) Install battery blocks by carrying out removal instructions in reverse.
The battery polarity shown in Fig. 23 must be strictly observed.Installing the batteries in the wrong position or with reversed polarity can damagethe battery, the KPS and the low--voltage power supply unit.
Fig. 23 Polarity of the batteries
--+ --+
Rear panel of cabinet
Hitachi/Pbq battery connection
In case of long--term storage the batteries may become depleted, resulting in damage
to the batteries. In such cases the batteries must be recharged every 6 months.
2.8 Exchanging the pressure relief plug filter insert
The pressure relief plug, Fig. 24 (1), is used to generate an overpressure at a defined pointinside the cabinet. This prevents excessive fouling inside the cabinet. If the filter insert turnsa dark color, it must be exchanged, otherwise the effectiveness of the plug will be reduced.
G Replacement
(1) Open the cabinet door.
(2) Remove the foam ring, Fig. 24 (2).
(3) Change the filter insert, Fig. 24 (3).
(4) Insert the foam ring so that it is flush with the pressure relief plug.
1
2
23
Fig. 24 Filter change
Pressure relief plug Filter insert with foam ring
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3 Repair work
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3 Repair work
If it is necessary to carry out repair work on the cabinet, the following safety
information must be observed:
Before visual inspections, cleaning, maintenance or repair work is started, it mustbe ensured that therobot system is switched off and that the main switch is securedwith a padlock to prevent unauthorized persons from switching it on again.The incoming power cable must be deenergized and measures must be taken toprevent it from being inadvertently energized again. Any adjacent live parts orelements must be covered or safeguarded.
If it is essential for personnel to enter the working range of the robot system forvisual inspection, maintenance or repair work, the safety measures must always bedesigned in such a way (e.g. enabling switches) that the robot system is switchedoff immediately should an unintended situation arise.
Observe ESD guidelines when carrying out work on the control cabinet.Cleaning tools must be ESD--compliant.
We strongly recommend that repair work is only carried out by our Servicedepartment or by personnel trained at KUKA Roboter GmbH.
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Index
C
Cabinet fan, 13
E
External fan, 15
F
Filter insert, pressure relief plug, 18
I
Inner fan, 13
LLabels and plates, 6
M
Maintenance interval, 8
Maintenance point, 8
Maintenance tables, 8
Maintenance work, 8
Malfunction, 5
Motherboard battery, 17
P
Parts list, rating plates, 12
Plates, 6
Plates on the KR C2, 9
R
Recommended operating times, 8
Removal, installation of batteries, 17
Removal, installation of PC fan, 16