CONTROL CABINET

KR C2

Electrical Servicing

Maintenance / Repair

Issued: 26 Jul 2004

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Version: 04
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e Copyright

KUKA Roboter GmbH

This documentation or excerpts therefrom may not be reproduced or disclosed to third parties without the express permission of the publishers. Other functions not described in this documentation may be operable in the controller. The user has no claim to these functions, however, in the 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 a regular 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 2
2.1 2.2 2.3 2.4 2.4.1 2.4.2 2.5 2.6 2.7 2.8

Fundamentals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Plates on the KR C2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts list, rating plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal, installation of cabinet fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal, installation of internal fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal, installation of external fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal, installation of PC fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motherboard battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal, installation of batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exchanging the pressure relief plug filter insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 7
8 9 12 13 13 15 16 17 17 18

Repair work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Electrical Servicing

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Fundamentals

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 of the customer support service. If your company has a service technician trained by KUKA Roboter GmbH, we refer you to the Electrical Servicing seminar handbook. With the exception of battery replacement and the cleaning of the cooling system, all controller variants are maintenance--free. Preventive maintenance is recommended wherever dirt, corrosion and wear occur. Before any visual inspections, cleaning or maintenance work is started, the chapter Safety, KR C2, General (to be found in the control cabinet) must be observed. Before visual inspections, cleaning, maintenance or repair work is started, it must be ensured that the robot 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 to prevent it from being inadvertently energized again. Any adjacent live parts or elements must be covered or safeguarded. ON

ON

OFF

OFF
OFF

If it is essential for personnel to enter the working range of the robot system for visual inspection, maintenance or repair work, the safety measures must always be designed 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 out only by trained personnel aware of the hazards involved.

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Electrical Servicing Cleaning and preventive maintenance work is to be carried out in accordance with the 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 penetrate into electrical components. Compressed air may be used only when expressly specified.

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Maintenance work

Maintenance work

Clean with brush and vacuum up dirt

+ --

Service battery

Maintenance point (e.g. maintenance point 2) Maintenance point visible on drawing Maintenance point not visible on drawing

+ -

+ -

0 OFF

Side view

Front view

Rear view

Fig. 1 Maintenance work on control cabinet

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Electrical Servicing

2.1

Maintenance tables
Recommended operating times Article
Rec. operating time / MTBF acc. to manufacturer

Recommended exchange interval 2 years 5 years1) 5 years1) 5 years Depends on installation conditions and degree of clogging

Remarks

Battery PC fan Cabinet fan Motherboard battery Filter insert, pressure relief plug

3 years 60,000 hours 46,000 hours 10 years --

incl. allowance for capacity loss

Visual check: change filter insert if discolored (original color: white)

1) with

3-shift operation

Maintenance work Maintenance point (see Maintenance points) Maintenance interval Activity, specification
Time required [min]

Control cabinet cooling unit (optional) cabinet, heat sink, heat exchanger

Clean heat exchanger with brush

15 15

Side and rear of control Internal and

external control cabinet fans

Depends on installation conditions and degree of clogging; however, no later than every y 2 years y

Clean heat sink with brush and check that it is securely fastened Clean fans with brush. (clogged fan = insufficient cooling!) Exchange fan, see Section 2.4

15 20 2 20

Control cabinet
PC fan

X X

Exchange PC fan, see Section 2.5 Exchange motherboard battery, see Section 2.6 Exchange batteries, see Section 2.7 Exchange filter insert see Section 2.8

Control cabinet,
PC, motherboard battery

Interior of control cabinet,

batteries

X X

5 1

Filter insert,
pressure relief plug

The above activities may only be performed by qualified personnel with appropriate training.

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Maintenance work (continued)

2.2

Plates on the KR C2

Control cabinet, rear panel, interior

2 1 3 4 9 6
A1 Installation location of ESC--CI KR C2 door, interior view PC

5 7

Sectional drawing, right--hand side panel, interior view

Front view of PC frame

11

12 X1 X20

10

Rear panel, exterior view Fig. 2 Plates on the KR C2

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Connector X1 in the connector panel

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Electrical Servicing

KR C2 0122 00106204 2000 392.750- 36... 3x400V 50/60Hz 6A 16A ca. 185kg 12345

Fig. 3 Control cabinet rating plate (example) The control cabinet rating plate (1) can be found both inside the cabinet (see sectional drawing Fig. 2) and on the outside of the connector panel, right-hand side.

Fig. 5 Discharging time warning 10 of 19

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Maintenance work (continued)

KR C2

Fig. 6 Grounded neutral warning

Fig. 7 Reference to component fastening check

Fig. 10 PC rating plate

Fig. 8 White cable warning

Fig. 11 Fuse ratings

10

Fig. 9 Supply voltage warning

Fig. 12 Label, connector X1

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Electrical Servicing

11

12

Fig. 13 Hot surface warning sign

Fig. 14 Hand injury warning sign

2.3

Parts list, rating plates

Plate no. 1 2 3 4 5 6 7 8 9 10 11 12 Designation KR C2 rating plate Reference to operating instructions Note: Discharging time Note: Grounded neutral Fastening check warning, screws and terminals Note: White cable Note: Supply voltage warning PC rating plate Fuse ratings Note: Power plug Hot surface warning sign Hand injury warning sign Article no. 71--052--163 69--000--997 00--109--394 00--100--002 00--100--046 00--107--080 00--109--217 71--052--163 00--109--396 00--108--994 00--109--097 00--109--098

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Maintenance work (continued)

2.4

Removal, installation of cabinet fans

Before visual inspections, cleaning, maintenance or repair work is started, it must be ensured that the robot 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 to prevent it from being inadvertently energized again. Any adjacent live parts or elements must be covered or safeguarded. If it is essential for personnel to enter the working range of the robot system for visual inspection, maintenance or repair work, the safety measures must always be designed 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.

2.4.1

Removal, installation of internal fan

G (1) (2) (3) (4) (5) (6) (7) (8) REMOVAL Open cabinet door (1) (Fig. 15). Remove the two domed cap nuts and the two lock nuts underneath on the front of the fan plate (2) (Fig. 16). Tilt fan plate (3) downwards (Fig. 17). Unplug fan cable (4) (Fig. 18). Pull fan plate (3) forwards to remove (Fig. 17). Remove the hexagon nuts (5) on both sides of the fan holder from the fan plate (3) (Fig. 19). Separate holder together with fan (8) from fan plate (3) (Fig. 19). Unscrew (6) fan (7) from holder (8) and exchange fan (Fig. 19). Fan

Fig. 15 Cabinet door open

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Fig. 16 Fan plate fastening 13 of 19

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3 Fig. 17 Fan opened Fig. 18 Fan cable connector

5 3 7 6 8

Fig. 19 Fan with fan plate

G (1)

INSTALLATION Install internal fan by carrying out removal instructions in reverse.

Replace the lock nuts for the fan plate with new ones before tightening the domed cap nuts.

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Maintenance work (continued)

2.4.2

Removal, installation of external fan

(1) (2) (3) Undo the four screws (1) on the rear panel of the cabinet and remove the rear panel. Remove the two cable inlet screws (2) and then unplug the fan cable connector thus exposed (3). Once the two screws (4) have been removed, the fan holder (6) can be swung out complete with the fan (7). (It is necessary to cut through the cable straps attached to the fan cable. These must be replaced with new ones once reassembly is complete.) Separate the fan (7) from the holder (6) by removing the four screws (5) and exchange the fan.

(4)

Fig. 20 External fan removal/installation (standard cabinet)

G (1)

INSTALLATION Install external fan by carrying out removal instructions in reverse.

Use a new cable strap to fasten the cables.

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Electrical Servicing

2.5

Removal, installation of PC fan

Before visual inspections, cleaning, maintenance or repair work is started, it must be ensured that the robot 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 to prevent it from being inadvertently energized again. Any adjacent live parts or elements must be covered or safeguarded. If it is essential for personnel to enter the working range of the robot system for visual inspection, maintenance or repair work, the safety measures must always be designed 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. (1) (2) (3) (4) Unplug the fan cable connector (1). Undo the two screws (2) on the fan (3). Then remove the fan holder (4) complete with the fan (3). Remove the fan (3) from holder (4) and exchange it.

Fig. 21 Removal/installation of PC fan INSTALLATION Install PC fan by carrying out removal instructions in reverse.
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Maintenance work (continued)

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 must be ensured that the robot 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 to prevent it from being inadvertently energized again. Any adjacent live parts or elements must be covered or safeguarded. If it is essential for personnel to enter the working range of the robot system for visual inspection, maintenance or repair work, the safety measures must always be designed 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. If replacement batteries are used, please note that the terminal lugs of batteries from some manufacturers may have reversed polarity. For this reason, always make sure that the batteries have the correct polarity. G (1) (2) (3) (4) Removal Open cabinet door Unplug cables Press spring clamps downwards Remove battery blocks

Always exchange both battery blocks!

Fig. 22 Installation position of Hitachi batteries

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Electrical Servicing Installation Install battery blocks by carrying out removal instructions in reverse.

G (1)

The battery polarity shown in Fig. 23 must be strictly observed. Installing the batteries in the wrong position or with reversed polarity can damage the battery, the KPS and the low-voltage power supply unit. Rear panel of cabinet

Hitachi/Pbq battery connection Fig. 23 Polarity of the batteries 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 point inside the cabinet. This prevents excessive fouling inside the cabinet. If the filter insert turns a dark color, it must be exchanged, otherwise the effectiveness of the plug will be reduced. G (1) (2) (3) (4) Replacement Open the cabinet door. Remove the foam ring, Fig. 24 (2). Change the filter insert, Fig. 24 (3). Insert the foam ring so that it is flush with the pressure relief plug.

1 3 2

2 Pressure relief plug Filter insert with foam ring Fig. 24 Filter change 18 of 19
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Repair work

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 must be ensured that the robot 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 to prevent it from being inadvertently energized again. Any adjacent live parts or elements must be covered or safeguarded. If it is essential for personnel to enter the working range of the robot system for visual inspection, maintenance or repair work, the safety measures must always be designed 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.

We strongly recommend that repair work is only carried out by our Service

department 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

L
Labels 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

Index -- i