krc2fl service en

CONTROL CABINET
KR C2 edition2005
User Manual
Service Work
Issued: 25 Jan 2005
BedHbKRC2FL--Service 11.04.00 en
Version: 00
1 of 41
e Copyright
2004
KUKA Roboter GmbH
Zugspitzstrasse 140
D--86165 Augsburg
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.
2 of 41
BedHbKRC2FL--Service 11.04.00 en
Contents
1
Fundamentals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
1.1
Work regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
1.2
Cleaning and preventive maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
2
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
3
Maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
3.1
Maintenance points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
3.2
Explanation of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
3.3
Maintenance tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
3.4
3.4.1
3.4.2
3.4.3
3.4.4
3.4.5
Exchanging the cabinet fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing the internal cabinet fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the internal cabinet fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing the external cabinet fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing the external cabinet fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
10
10
12
13
13
3.5
3.5.1
3.5.2
3.5.3
3.5.4
Exchanging PC components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing the PC fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the PC fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motherboard battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
14
14
15
15
3.6
3.6.1
3.6.2
3.6.3
Exchanging the batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing the batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16
16
16
17
3.7
3.7.1
Pressure relief plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filter change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18
18
4
Plates on the KR C2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19
4.1
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19
4.2
Plate designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20
4.3
Views of the plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21
5
Repair work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25
5.1
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25
5.2
Exchanging the PC chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26
5.3
Exchanging the motherboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27
5.4
Exchanging the DIMM memory modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27
5.5
5.5.1
5.5.2
Exchanging the hard drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28
28
28
5.6
Exchanging the floppy disk drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
29
BedHbKRC2FL--Service 11.04.00 en
3 of 41
User Manual
5.6.1
5.6.2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
29
30
5.7
5.7.1
5.7.2
Exchanging the CD--ROM drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31
31
32
5.8
5.8.1
5.8.2
5.8.3
Exchanging the KUKA VGA card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
KVGA card settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
33
33
33
34
5.9
5.9.1
5.9.2
Exchanging the multi--function card (MFC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
35
35
35
5.10
5.10.1
5.10.2
5.10.3
Exchanging the DSE--IBS card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Visual inspection of the LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
36
36
37
37
5.11
5.11.1
5.11.2
Exchanging the KPS--600 power supply unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
38
38
39
5.12
5.12.1
5.12.2
Exchanging the KPS--27 low--voltage power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40
40
40
5.13
5.13.1
5.13.2
Exchanging the KSD servo drive modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
41
41
41
4 of 41
BedHbKRC2FL--Service 11.04.00 en
BedHbKRC2FL--Service 11.04.00 en
5 of 41
User Manual
1
Fundamentals
Requirements:
G
Qualified technical personnel (skilled workers) trained in the handling of systems and
machines.
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.
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.
1.1
Work regulations
G
Maintenance and repair work may be performed only by trained personnel aware of the
hazards involved.
G
Observe ESD guidelines when carrying out work on the control cabinet.
Cleaning tools must be ESD--compliant.
G
The manufacturer’s instructions must be observed when using cleaning agents.
G
It must be ensured that no cleaning fluid enters electrical components.
G
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.
1.2
Cleaning and preventive maintenance work
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 4.2).
6 of 41
BedHbKRC2FL--Service 11.04.00 en
2
2
Safety
Safety
Before any visual inspection, cleaning or maintenance work is started, the chapter
“Safety, KR C2, General” (to be found in the control cabinet) must be observed.
Before visual inspection, 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
OFF
Fig. 1 Main switch in the “OFF” position and locked
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
switch the robot system off immediately should an unintended situation arise.
BedHbKRC2FL--Service 11.04.00 en
7 of 41
User Manual
3
Maintenance work
Requirements:
G
3.1
Qualified technical personnel (skilled workers) trained in the handling of systems and
machines.
Maintenance points
3
2
+ -
+ -
6
5
4
2
0
OFF
7
A
B
A = Side view
C
B = Rear view
C = Front view
Fig. 2 Maintenance points in the control cabinet
3.2
Explanation of symbols
+ -2
A
B
C
D
A
Maintenance point in the drawing
C
Maintenance point number (here: no. 2)
B
Service battery
D
Clean with brush and vacuum up dirt
Fig. 3 Maintenance symbols
8 of 41
BedHbKRC2FL--Service 11.04.00 en
3
3.3
Maintenance work (continued)
Maintenance tables
Recommended operating times
Article
Rec. operating time /
MTBF* acc. to
manufacturer
Recommended
exchange interval
Battery
3 years
2 years
PC fan
70 000 hours
5 years1)
Cabinet fan
70 000 hours
5 years1)
Motherboard battery
10 years
5 years
Filter insert, pressure
relief plug
--
Depends on installa- Visual check:
tion conditions and
change filter insert if
degree of clogging
discolored (original
color: white)
1)with
Remarks
incl. allowance for
capacity loss
3--shift operation
Maintenance work
Maintenance point
(see Maintenance points)
¡
Control cabinet cooling unit
(optional)
© Side and rear of
control cabinet, heat sink,
heat exchanger
¢ Internal and external control
cabinet fans
£ Control cabinet,
PC fan
¤ Control cabinet,
PC,
motherboard battery
¥ Interior of control cabinet,
batteries
¦ Filter insert,
pressure relief plug
Maintenance
interval
Depends on
installation
conditions and
degree
of
g
clogging;
l
i
however, no
later than every
2 years
X
X
Activity, specification
Time
required
[min]
Clean heat exchanger with
brush
15
Clean heat sink with brush
and check that it is securely
fastened
15
Clean fans with brush.
(clogged fan = insufficient
cooling!)
15
Exchange fan,
see Section 3.4
Exchange PC fan,
see Section 3.5
Exchange motherboard
battery,
see Section 3.5.4
20
2
20
X
Exchange batteries,
see Section 3.6
5
X
Exchange filter insert,
see Section 3.7
1
* MTBF = Mean Time Between Failure
BedHbKRC2FL--Service 11.04.00 en
9 of 41
User Manual
3.4
Exchanging the cabinet fans
3.4.1
Safety
3.4.2
(1)
Switch the control cabinet off and secure the main switch in position with a padlock.
(2)
Deenergize the power cable.
(3)
Observe the ESD directives.
Removing the internal cabinet fan
If existing cable straps are removed, these must be replaced with new ones once
reassembly is complete.
(1)
Open the control cabinet door.
(2)
Remove the two domed cap nuts and the two lock nuts underneath on the front of the
fan plate (Fig. 4 [1]).
1
Fig. 4 Fastening the fan plate in the cabinet
10 of 41
BedHbKRC2FL--Service 11.04.00 en
3
(3)
Tilt fan plate downwards (Fig. 5 [2]).
(4)
Disconnect the fan cable (Fig. 5 [3]).
(5)
Pull fan plate forwards to remove.
Maintenance work (continued)
3
2
Fig. 5 Unplug fan cable
(6)
Unscrew the fan from the mounting (Fig. 6 [4]).
4
4
Fig. 6 Fan with fan plate
BedHbKRC2FL--Service 11.04.00 en
11 of 41
User Manual
3.4.3
Installing the internal cabinet fan
Replace the lock nuts for the fan plate with new ones before tightening the domed cap nuts.
12 of 41
(1)
Screw the new internal fan of the same type onto the mounting.
(2)
Push the tab side of the fan plate into the fan aperture in the cabinet.
(3)
Connect the fan cable.
(4)
Swing the fan plate upwards.
(5)
Tighten the new lock nuts and domed cap nuts.
(6)
Install the internal fan by carrying out the removal instructions in reverse.
(7)
Re--energize the power cable.
(8)
Remove the padlock from the main switch and turn the controller back on.
BedHbKRC2FL--Service 11.04.00 en
3
3.4.4
Maintenance work (continued)
Removing the external cabinet fan
If existing cable straps are removed, these must be replaced with new ones once
reassembly is complete.
(1)
Undo the two screws and the transport safeguard (Fig. 7 [1]) on the rear panel of the
cabinet and remove the rear panel.
(2)
Remove the two cable inlet screws (Fig. 7 [2]) and then unplug the fan cable connector
thus exposed (Fig. 7 [3]).
(3)
Undo the two screws (Fig. 7 [4]) and swing the fan mounting (Fig. 7 [5]) out complete
with the fan.
(4)
Exchange the fan complete with the mounting.
1
2
5
4
3
Fig. 7 Removal, installation of external fan
3.4.5
Removing the external cabinet fan
(5)
BedHbKRC2FL--Service 11.04.00 en
Install the external fan by carrying out the removal instructions in reverse.
13 of 41
User Manual
3.5
Exchanging PC components
3.5.1
Safety
3.5.2
(1)
Switch the control cabinet off and secure the main switch in position with a padlock.
(2)
Deenergize the power cable.
(3)
Observe the ESD directives.
Removing the PC fan
(1)
Remove the cable straps (Fig. 8 [1]) in the cable harness.
(2)
Unplug the fan cable connector (Fig. 8 [2]).
(3)
Undo the fan fastening screws (Fig. 8 [3]).
(4)
Then remove the fan complete with the fan grille.
(5)
Remove the fan grille and exchange the fan.
3
2
1
3
Fig. 8 Removal/installation of PC fan
14 of 41
BedHbKRC2FL--Service 11.04.00 en
3
3.5.3
Installing the PC fan
(1)
3.5.4
Maintenance work (continued)
Install PC fan by carrying out removal instructions in reverse and strap the cables in the
cable harness together again.
Motherboard battery
The motherboard battery may only be removed by authorized maintenance
personnel in consultation with the KUKA customer support service.
BedHbKRC2FL--Service 11.04.00 en
15 of 41
User Manual
3.6
Exchanging the batteries
3.6.1
Safety
3.6.2
(1)
Switch the control cabinet off and secure the main switch in position with a padlock.
(2)
Deenergize the power cable.
(3)
Observe the ESD directives.
(4)
In the case of different battery types, make sure that the batteries have the correct
polarity.
Removing the batteries
Info
Always exchange both battery blocks!
(1)
Open the cabinet door.
(2)
Unplug battery cables.
(3)
Press the spring clamp downwards (Fig. 9 [1]).
(4)
Remove both battery blocks.
1
Fig. 9 Installation position of “pbq” batteries
16 of 41
BedHbKRC2FL--Service 11.04.00 en
3
3.6.3
Maintenance work (continued)
Installing the batteries
(1)
Install battery blocks by carrying out removal instructions in reverse.
(2)
Check the polarity when connecting the cables.
The battery polarity shown in Fig. 10 must be strictly observed.
Installing the batteries in the wrong position or with reversed polarity can damage
the batteries, the KPS and the low--voltage power supply unit.
Rear panel of cabinet
+
-
+
-
Hitachi/pbq battery connection
Fig. 10 Polarity of the batteries
Storage instruction
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.
BedHbKRC2FL--Service 11.04.00 en
17 of 41
User Manual
3.7
Pressure relief plug
The pressure relief plug is used to generate an overpressure 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.
3.7.1
Filter change
(1)
Open the cabinet door.
(2)
Remove the foam ring.
(3)
Change the filter insert.
(4)
Insert the foam ring so that it is flush with the pressure relief plug.
3
1
2
1
Foam ring
2
Filter insert
3
1
Pressure relief plug
Fig. 11 Pressure relief plug with filter insert and foam ring
18 of 41
BedHbKRC2FL--Service 11.04.00 en
4
4
Plates on the KR C2
4.1
Overview
Plates on the KR C2
1
5
A
B
2
PC
3
6
4
8
9
7
ESC
11
X1
12
X20
10
D
C
A
B
Right--hand side panel -- interior view
Rear view (PC = front view)
C
D
Connector X1 on connector panel
Rear panel -- exterior view
Fig. 12 Overview of plates
BedHbKRC2FL--Service 11.04.00 en
19 of 41
User Manual
4.2
Plate designations
Plate no.
20 of 41
Designation
1
Reference to operating instructions
2
KR C2 rating plate
3
Discharging time warning
4
Fuse ratings
5
PC rating plate
6
Grounded neutral warning
7
White cable warning
8
Fastening check warning, screws and terminals
9
Supply voltage warning
10
Power plug warning
11
Hot surface warning sign
12
Hand injury warning sign
BedHbKRC2FL--Service 11.04.00 en
4
4.3
Plates on the KR C2 (continued)
Views of the plates
The plates may vary slightly from the examples illustrated above depending on the specific
cabinet type or as a result of updates.
The numerical order of the plates corresponds to the numbers in the overview
(Fig. 12).
(1)
Reference to operating instructions
(2)
Rating plate
KR C2
0122
00106204
2000
392.750-- 36...
3x400 V
50/60 Hz
6A
16 A
approx. 185 kg
12345
The rating plate can be found both inside the cabinet (Fig. 12) and on the outside of the
connection panel, right--hand side.
BedHbKRC2FL--Service 11.04.00 en
21 of 41
User Manual
22 of 41
(3)
Rating plate
(4)
Fuse ratings
(5)
PC rating plate
BedHbKRC2FL--Service 11.04.00 en
4
BedHbKRC2FL--Service 11.04.00 en
(6)
Grounded neutral warning
(7)
White cable warning
(8)
Fastening check warning
(9)
Supply voltage warning
Plates on the KR C2 (continued)
23 of 41
User Manual
(10) Power plug warning
(11) Hot surface warning sign
(12) Hand injury warning sign
24 of 41
BedHbKRC2FL--Service 11.04.00 en
5
5
Repair work
Repair work
Requirements:
G
5.1
Qualified technical personnel (skilled workers) trained in the handling of systems and
machines.
Safety
We strongly recommend that repair work is only carried out by our Service
department or by personnel trained by KUKA Roboter GmbH.
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
OFF
Fig. 13 Main switch in the “OFF” position and locked
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
switch the robot system off immediately should an unintended situation arise.
BedHbKRC2FL--Service 11.04.00 en
25 of 41
User Manual
5.2
Exchanging the PC chassis
The PC is mounted, in its chassis, on the door of the KR C2.
Normally, the whole chassis must be exchanged as a single unit.
(1)
Turn the main switch to “OFF” and take measures to prevent it from being turned on
again.
(2)
Deenergize the power cable.
(3)
Observe the ESD directives.
(4)
Switch off the robot controller and wait until the battery--backed shutdown storage
procedure has been completed.
(5)
Open the cabinet door.
The PC chassis (Fig. 14 [1]) is mounted on the inside of the cabinet door.
(6)
Disconnect, at the PC chassis, the power supply and all other cable connections to the
PC chassis (Fig. 14 [2]).
Disconnect the mouse and keyboard if applicable.
(7)
Using a Phillips screwdriver, remove the transport safeguard screw (Fig. 14 [3]).
(8)
Loosen the two knurled nuts (Fig. 14 [4]).
(9)
Lift the PC chassis vertically and remove.
(10) Package the PC chassis and send it to KUKA Roboter GmbH with a detailed description
of the fault.
(11) Install the PC chassis by reversing the removal sequence.
4
3
4
2
2
1
Fig. 14 PC chassis
26 of 41
BedHbKRC2FL--Service 11.04.00 en
5
5.3
Repair work (continued)
Exchanging the motherboard
A defective motherboard is considered together with the PC frame as a single
exchange part and is therefore not exchanged separately.
5.4
Exchanging the DIMM memory modules
(1)
Turn the main switch to “OFF” and take measures to prevent it from being turned on
again.
(2)
Deenergize the power cable.
(3)
Observe the ESD directives.
(4)
Switch off the robot controller and wait until the battery--backed shutdown storage
procedure has been completed.
(5)
Using your thumbs, carefully open the side tabs (Fig. 15 [1]) in the direction indicated
by the arrows. Opening the tabs releases the DIMM memory module (Fig. 15 [2]) and
simultaneously lifts it out of the DIMM socket ([3]).
(6)
Carefully push the new DIMM memory modules into the groove in the DIMM socket until
they lock into place.
The memory modules possess two asymmetrical notches on the underside (Fig. 15 [4])
making it physically impossible to put them in the wrong way round.
G
When inserting the memory modules, begin with memory bank 0.
2
4
1
1
Side view of the DIMM socket
3
Plan view of the DIMM socket
Fig. 15 Exchanging the memory modules
When inserting the memory modules, make sure that the notches on the connector of the
memory module match up with the coding on the DIMM socket.
The processor voltage and the clock rate are automatically detected by the motherboard and
require no configuration.
More detailed information can be found in the user manual provided by the motherboard
manufacturer.
BedHbKRC2FL--Service 11.04.00 en
27 of 41
User Manual
5.5
Exchanging the hard drive
5.5.1
Removal
(1)
Turn the main switch to “OFF” and take measures to prevent it from being turned on
again.
(2)
Deenergize the power cable.
(3)
Observe the ESD directives.
(4)
Switch off the robot controller and wait until the battery--backed shutdown storage
procedure has been completed.
(5)
Open the door of the PC controller (Fig. 16 [1]).
(6)
Remove the hard drive retaining clip (Fig. 16 [2]).
(7)
Disconnect the interface cable and the hard drive power supply cable.
1
2
Fig. 16 Exchanging the hard drive
5.5.2
28 of 41
Installation
(1)
Check the new hard drive for mechanical damage.
(2)
Configure the hard drive as the master drive.
(Depending on the type of hard drive, it may be necessary to reposition a jumper on the
rear of the drive. Instructions on how to do this can be found in the manufacturer
documentation.)
(3)
Connect the interface cable and the power supply cable.
(4)
Place the hard drive on the holder and secure it with the retaining clip.
BedHbKRC2FL--Service 11.04.00 en
5
5.6
Exchanging the floppy disk drive
5.6.1
Removal
Repair work (continued)
(1)
Turn the main switch to “OFF” and take measures to prevent it from being turned on
again.
(2)
Deenergize the power cable.
(3)
Observe the ESD directives.
(4)
Switch off the robot controller and wait until the battery--backed shutdown storage
procedure has been completed.
(5)
Slacken the knurled screw (Fig. 17 [2]) on the floppy disk and CD--ROM drive module
(Fig. 17 [1]) (the knurled screw is spring--loaded to prevent it from falling out). A slotted
screwdriver is required for this.
(6)
Pull the drives module away from the setscrews on the door in the direction indicated
by the arrow (Fig. 17 [4]).
Make a note of the number of the pin (pin 34 or pin 1) connected to the side of the 34--strand
interface cable marked in red.
(7)
Disconnect the power supply and data cables from the floppy disk and CD--ROM drives.
3
4
2
1
Fig. 17 Mounting the floppy disk drive
In order to prevent damage to the drives, ensure that the drives module cannot
be dropped when removing the cables!
The floppy disk drive is fastened at the side with four Phillips screws (Fig. 17 [3]).
(8)
BedHbKRC2FL--Service 11.04.00 en
Remove the screws and pull the drive out of the drives module in the same direction
as that in which the disks are ejected.
29 of 41
User Manual
Installation
(1)
Insert a new floppy disk drive into the opening in the drives module and fasten it with
the four screws at the side.
(2)
Connect the 34--strand interface cable with the plug--in connection after the cable
crossover (A drive) to the floppy disk drive. The red marking on the cable must be
situated at pin 1 (rear of floppy disk drive).
yellow
black
black
red
5.6.2
1
Fig. 18 Floppy disk drive (rear view)
(3)
Reconnect the power supply to the floppy disk and CD--ROM drives.
(4)
Reconnect the 40--strand interface cable to the CD--ROM drive.
The 40--strand interface cable (CD--ROM) must be connected the same way round as
before (red marking at pin 1) -- see Fig. 18, [1].
(5)
Reinstall the drives module.
If Windows is newly installed, a default setting is entered for the floppy drive in Control
Panel/System/Device Manager.
After installing the KUKA software, a yellow exclamation mark is displayed in front of the
floppy disk in the Device Manager. The reason for this is that the 32--bit driver has been
removed by the KUKA software. This procedure makes it safer to access the floppy disk
when the system is running.
30 of 41
BedHbKRC2FL--Service 11.04.00 en
5
5.7
Exchanging the CD--ROM drive
5.7.1
Removal
Repair work (continued)
(1)
Turn the main switch to “OFF” and take measures to prevent it from being turned on
again.
(2)
Deenergize the power cable.
(3)
Observe the ESD directives.
(4)
Switch off the robot controller and wait until the battery--backed shutdown storage
procedure has been completed.
(5)
Slacken the knurled screw (Fig. 19 [2]) on the floppy disk and CD--ROM drive module
(Fig. 19 [1]).
The knurled screw is spring--loaded to prevent it from falling out.
(6)
Pull the drives module away from the setscrews on the door in the direction indicated
by the arrow (Fig. 19 [4]).
Make a note of the number of the pin (pin 40 or pin 1) connected to the side of the 40--strand
interface cable (HDD and CD--ROM) marked in red.
(7)
Disconnect the power supply and data cables from the floppy disk and CD--ROM drives.
2
4
3
3
1
Fig. 19 Installing the CD--ROM drive
In order to prevent damage to the drives, ensure that the drives module cannot
be dropped when removing the cables!
The CD--ROM drive is fastened at the sides with four Phillips screws (Fig. 19 [3]).
(8)
BedHbKRC2FL--Service 11.04.00 en
Remove the screws and pull the drive out of the drives module in the direction of the
CD--ROM drawer.
31 of 41
User Manual
5.7.2
Installation
(1)
Insert a new CD--ROM drive into the opening in the drives module and fasten it with the
four screws at the side.
(2)
Reconnect the power supply and the 40--strand interface cable of the floppy disk and
CD--ROM drives.
2
1
Fig. 20 CD--ROM drive (rear view)
The interface cables to the drives must be connected the same way round as before
(red marking at pin 1) – see Fig. 20, [1].
In order to configure the CD--ROM drive as a master drive, the jumper on the back must
be set as illustrated in Fig. 20, [2].
(3)
32 of 41
Reinstall the drives module.
BedHbKRC2FL--Service 11.04.00 en
5
5.8
Exchanging the KUKA VGA card
5.8.1
Removal
Repair work (continued)
(1)
Turn the main switch to “OFF” and take measures to prevent it from being turned on
again.
(2)
Deenergize the power cable.
(3)
Observe the ESD directives.
(4)
Switch off the robot controller and wait until the battery--backed shutdown storage
procedure has been completed.
(5)
Open the door in the PC chassis mounted on the rear of the cabinet door.
(6)
Disconnect the cables to the KVGA card (Fig. 21 [1]).
If connected, disconnect VGA cable for external monitor (Fig. 21 [2]).
(7)
Release the KVGA card fastenings and pull the card carefully out of the PCI slot.
1
2
Fig. 21 KVGA card
5.8.2
Installation
(1)
Check the new card for mechanical damage.
(2)
Plug the card into the PCI slot and fasten in place. When plugging in the KVGA card,
hold the front plate of the card in one hand and the opposite edge of the card in the other
and push the card into the slot, holding it straight.
(3)
Reconnect cable connection (Fig. 21 [1]) (if present, connect VGA cable for external
monitor (Fig. 21 [2])).
(4)
Close and lock the door of the PC chassis.
(5)
Switch on the robot controller and check the display on the screen (connect an external
monitor if necessary).
(6)
If there is a display, start the controller. Look out for any errors in the display (incorrect
colors, characters, graphic display).
Info
Operate the system for about an hour in order to preclude the risk of thermally induced
errors.
BedHbKRC2FL--Service 11.04.00 en
33 of 41
User Manual
5.8.3
KVGA card settings
After booting the system, the settings can be made at Expert level via the Windows Control
Panel.
(1)
Toggle to the Windows interface.
(2)
In the Start menu, select the menu items:
--
Control Panel
--
Display
--
Properties
--
Settings
--
Advanced
and press the button:
--
Chips.
In the “Display Device” window, the following options are available for selection:
G
CRT
(external monitor)
G
LCD
(KCP operation)
G
BOTH
(both display options)
Info
The graphics card driver file is “Chips XPm.sys”.
34 of 41
BedHbKRC2FL--Service 11.04.00 en
5
Repair work (continued)
5.9
Exchanging the multi--function card (MFC)
5.9.1
Removal
(1)
Turn the main switch to “OFF” and take measures to prevent it from being turned on
again.
(2)
Deenergize the power cable.
(3)
Observe the ESD directives.
(4)
Switch off the robot controller and wait until the battery--backed shutdown storage
procedure has been completed.
(5)
Unlock and open the PC chassis door.
(6)
Disconnect the cables to the MFC (Fig. 22 [1]) and DSE--IBS3 (Fig. 22 [2]).
(7)
Release the MFC card fastenings (Fig. 22 [3]) and pull the card carefully out of the PCI
slot.
(8)
Undo the screw fastenings of the DSE--IBS3 (Fig. 22 [4]) and carefully pull it off the
MFC.
3
1
2
4
4
Fig. 22 MFC card with DSE card inserted
5.9.2
Installation
BedHbKRC2FL--Service 11.04.00 en
(1)
Check that the new card is valid (manufacturer’s release) and mechanically
undamaged.
(2)
Plug the DSE--IBS3 onto the new MFC and secure the fastenings.
(3)
Plug the complete card into the PCI slot and fasten it in place.
When plugging the MFC card in, hold the front plate of the card in one hand and the
opposite edge of the card in the other and push the card into the slot, holding it straight.
(4)
Reconnect all cables.
(5)
Close and lock the PC chassis door.
35 of 41
User Manual
5.10
Exchanging the DSE--IBS card
Since the DSE--IBS is plugged into the MFC card, the MFC must first be removed from the
PC.
5.10.1
Removal
(1)
Turn the main switch to “OFF” and take measures to prevent it from being turned on
again.
(2)
Deenergize the power cable.
(3)
Observe the ESD directives.
(4)
Switch off the robot controller and wait until the battery--backed shutdown storage
procedure has been completed.
(5)
Unlock and open the PC chassis door.
(6)
Remove the MFC card (Section 5.9 “Exchanging the multi--function card (MFC)”).
(7)
After removing the MFC, unscrew the two DSE--IBS fastening screws (Fig. 23 [1]).
(8)
Pull the DSE--IBS off the MFC taking care not to bend the contacts.
1
2
1
3
1
Fastening screws
2
Connector to the MFC
3
LED flashes when the link between the MFC and the DSE--IBS has been established
Fig. 23 Two DSE--IBS modules plugged onto the MFC
36 of 41
BedHbKRC2FL--Service 11.04.00 en
5
5.10.2
Repair work (continued)
Installation
(1)
Plug the connector of the DSE--IBS (Fig. 24 [2]) into the socket on the MFC.
(2)
Securely fasten the DSE--IBS to the MFC by means of the fastening screws (Fig. 23
[1]).
(3)
Install the MFC in the PC (see Section 5.9 “Exchanging the multi--function card
(MFC)”).
1
2
1
X4 Connection to the drive servos
2
X810 Connection to the MFC, 50--contact
Fig. 24 DSE--IBS
5.10.3
Visual inspection of the LEDs
BedHbKRC2FL--Service 11.04.00 en
(1)
Switch the system on.
(2)
After initialization (DSE--IBS has booted), check that the LED (Fig. 23 [3]) on the
DSE--IBS flashes (once per second).
37 of 41
User Manual
5.11
Exchanging the KPS--600 power supply unit
5.11.1
Removal
(1)
Turn the main switch to “OFF” and take measures to prevent it from being turned on
again.
(2)
Deenergize the power cable.
(3)
Observe the ESD directives.
(4)
Switch off the robot controller and wait until the battery--backed shutdown storage
procedure has been completed.
(5)
Wait until the intermediate circuit has discharged and then open the cabinet door.
(6)
Unplug the connecting cables to the cabinet.
(7)
Unscrew the two Allen screws (Fig. 25 [1]) on the top of the KPS--600 using an Allen
key (Fig. 25 [2]).
1
2
Fig. 25 Removing the KPS
38 of 41
BedHbKRC2FL--Service 11.04.00 en
5
(8)
Repair work (continued)
Lift the supply unit slightly, tip the top downwards and lift the KPS--600 out of the lower
holder (Fig. 26).
1
2
3
Fig. 26 Releasing the KPS
5.11.2
Installation
BedHbKRC2FL--Service 11.04.00 en
(1)
Slot the KPS--600 into the lower holder and hang it in the upper holder. Tighten the Allen
screws.
(2)
Plug in the connecting cables leading to the cabinet.
39 of 41
User Manual
5.12
Exchanging the KPS--27 low--voltage power supply
The KPS--27 low--voltage power supply is mounted on a mounting plate inside the control
cabinet, on the left--hand side.
5.12.1
Removal
(1)
Turn the main switch to “OFF” and take measures to prevent it from being turned on
again.
(2)
Deenergize the power cable.
(3)
Observe the ESD directives.
(4)
Switch off the robot controller and wait until the battery--backed shutdown storage
procedure has been completed.
(5)
Wait until the intermediate circuit has discharged and then open the cabinet door.
(6)
Disconnect the mains supply and outgoing cables (Fig. 27 [1]).
(7)
Using a screwdriver, remove the knurled screw (Fig. 27 [2]) on the left--hand side of the
KPS--27.
(8)
Pull the mounting plate with the power supply unit to the left (Fig. 27 [3]) out of the
holders (Fig. 27 [4]).
(9)
Using a Phillips screwdriver, remove the 4 fastening screws of the power supply unit
on the back of the mounting plate.
4
2
3
4
1
Fig. 27 Removal
5.12.2
40 of 41
Installation
(1)
Fasten the new power supply unit to the mounting plate.
(2)
Push the right--hand side of the mounting plate into the holders and fasten it with the
knurled screw.
(3)
Connect the mains supply and outgoing cables.
BedHbKRC2FL--Service 11.04.00 en
5
5.13
Exchanging the KSD servo drive modules
5.13.1
Removal
Repair work (continued)
(1)
Turn the main switch to “OFF” and take measures to prevent it from being turned on
again.
(2)
Deenergize the power cable.
(3)
Observe the ESD directives.
(4)
Switch off the robot controller and wait until the battery--backed shutdown storage
procedure has been completed.
(5)
Wait until the intermediate circuit has discharged and then open the cabinet door.
(6)
Unplug the intermediate circuit connector X1 and motor connector X2 (optionally also
X3), as well as Interbus cables X13 and X14.
(7)
Lift the upper retaining clip with a screwdriver (Fig. 28 [1]) until the two locking devices
(Fig. 28 [2]) are free. Tilt the upper surface slightly forwards, so that the KSD1 cannot
snap back into the locking devices.
(8)
The underside of the KSD has the same kind of fastening.
Lift the retaining clip on the underside in the same way, using the screwdriver, and
remove the KSD by pulling it in the direction of the door opening.
1
2
1
Fig. 28 Removing the KSD
5.13.2
Installation
(1)
Insert the KSD evenly and straight into the opening until the upper and lower retaining
clips snap into the locking devices.
(2)
Plug in connectors X1 and X2 (optionally also X3), as well as Interbus cables X13 and
X14.
1
BedHbKRC2FL--Service 11.04.00 en
41 of 41
Index
C
M
CD--ROM drive, 31
Clock rate, 27
Maintenance interval, 9
Maintenance point, 9
Maintenance tables, 9
D
Maintenance work, 9
Malfunction, 6
DIMM memory modules, 27
DSE--IBS, 36
MFC card, 35
Motherboard, 27
F
Motherboard battery, 15
Floppy disk drive, 29
P
H
PC chassis, 26
Hard drive, 28
Plates, 6
Pressure relief plug, 18
I
Installing the batteries, 17
Installing the internal cabinet fan, 12
Installing the PC fan, 15
Processor voltage, 27
R
Recommended operating times, 9
K
Removing the batteries, 16
KPS--27, 40
KPS--600, 38
KSD, 41
KVGA card, 33
Removing the external cabinet fan, 13
Removing the internal cabinet fan, 10
Removing the PC fan, 14
V
L
Labels and plates, 6
Visual inspection, 37
Index -- i