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1 of 19KRC2/ServElek/Wartung 10.00.04 en

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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1 Fundamentals


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


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)


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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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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12

Fig. 13 Hot surface warning sign Fig. 14 Hand injury warning sign

11

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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2.4 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.


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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43

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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2.4.2 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




(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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2.6 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




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


3 Repair work

If it is necessary to carry out repair work on the cabinet, the following safety

information must be observed:




We strongly recommend that repair work is only carried out by our Servicedepartment or by personnel trained at KUKA Roboter GmbH.

1


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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

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