Issued: 01.07.2009

Version: KUKA Servicesteckdose AC230V mit FI V1 en

KUKA Roboter GmbH

Controller Option

KUKA.Service Socket AC 230 V

Power Infeed via X1 before Main Switch with RCCB

For KR C2 edition2005

Installation

© Copyright 2009

KUKA Roboter GmbH
Zugspitzstraße 140
D-86165 Augsburg
Germany

This documentation or excerpts therefrom may not be reproduced or disclosed to third parties without
the express permission of the KUKA Roboter GmbH.

Other functions not described in this documentation may be operable in the controller. The user has
no claims 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, how-
ever, and necessary corrections will be incorporated in the subsequent edition.

Subject to technical alterations without an effect on the function.

Translation of the original operating instructions

KIM-PS5-DOC

KUKA.Service Socket AC 230 V

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Publication:

Pub KUKA.Servicesteckdose AC230V mit FI en

Book structure: KUKA Servicesteckdose AC230V mit FI V1.2
Label:

KUKA Servicesteckdose AC230V mit FI V1

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Contents

1

Introduction ..................................................................................................

5

1.1

Target group ..............................................................................................................

5

1.2

Robot system documentation ....................................................................................

5

2

Product description .....................................................................................

7

2.1

Overview of the robot controller .................................................................................

7

2.2

Scope of supply .........................................................................................................

7

3

Safety ............................................................................................................

9

3.1

Representation of warnings and notes ......................................................................

9

3.2

Description .................................................................................................................

9

3.3

Designated use ..........................................................................................................

9

4

Installation ...................................................................................................

11

4.1

Preconditions .............................................................................................................

11

4.2

Overview ....................................................................................................................

11

4.3

Liability .......................................................................................................................

11

4.4

Installation ..................................................................................................................

11

4.4.1

Installing “Socket AC 230 V before Main Switch with RCCB” ...............................

11

4.4.2

Installing “Power infeed via X1” ............................................................................

15

4.4.3

Ground conductor connections .............................................................................

17

4.4.4

Commissioning .....................................................................................................

17

4.4.5

Removal ................................................................................................................

17

5

KUKA Service ..............................................................................................

19

5.1

Requesting support ....................................................................................................

19

5.2

KUKA Customer Support ...........................................................................................

19

Index .............................................................................................................

25

Contents

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KUKA.Service Socket AC 230 V

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1. Introduction

1

Introduction

1.1

Target group

This documentation is aimed at KUKA service and repair personnel. Its use
presupposes the following prior knowledge:

„

Safety instruction

„

Advanced knowledge of electrical and electronic systems

Personnel

1.2

Robot system documentation

The robot system documentation consists of the following parts:

„

Operating instructions for the robot

„

Operating instructions for the robot controller

„

Operating and programming instructions for the KUKA System Software

„

Documentation relating to options and accessories

Each of these sets of instructions is a separate document.

For optimal use of our products, we recommend that our customers take part
in a course of training at KUKA College. Information about the training pro-
gram can be found at www.kuka.com or can be obtained directly from our
subsidiaries.

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2. Product description

2

Product description

2.1

Overview of the robot controller

The following systems are operated with the robot controller:

„

KUKA robots

„

KUKA Motion Control

„

External kinematics

The robot controller consists of the following components:

„

Control PC

„

Power unit

„

KCP teach pendant

„

Safety logic ESC

„

KCP coupler (optional)

„

Service socket (optional)

„

Connection panel

2.2

Scope of supply

The following components are supplied for installation:

„

Socket with label

„

N-type miniature circuit-breaker (4 A), 1-pole

„

Installation panel for socket

Fig. 2-1: Overview of the robot controller

Item

Description

Item

Description

1

Power unit

6

Safety logic (ESC)

2

Control PC

7

KCP coupler card (optional)

3

KCP coupler (optional)

8

Connection panel

4

KCP

9

Service socket (optional)

5

Mounting plate for customer
components

10

Main switch

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KUKA.Service Socket AC 230 V

„

Connecting cables and assembly parts

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3. Safety

3

Safety

3.1

Representation of warnings and notes

Safety

Warnings marked with this pictogram are relevant to safety and must be ob-
served.

Notes

Notes marked with this pictogram contain tips to make your work easier or ref-
erences to further information.

3.2

Description

„

The service socket must be installed and operated in accordance with the
applicable national laws, regulations and standards.

3.3

Designated use

Use

The service socket serves as a power supply for test and diagnosis equip-
ment. The socket is designed for a load current of max. 4 A.

Danger!
This warning means that death, severe physical injury or substantial material
damage will occur, if no precautions are taken.

Warning!
This warning means that death, severe physical injury or substantial material
damage may occur, if no precautions are taken.

Caution!
This warning means that minor physical injuries or minor material damage
may occur, if no precautions are taken.

Tips to make your work easier or references to further information.

Danger!
Before installation or removal work is started, it must be ensured that the
power supply cable to the robot controller has been disconnected from the
mains on the plant side. The power supply cable must be deenergized and
secured against being reenergized.
An N-conductor must also be connected.

Danger!
The option “Service Socket AC 230 V with RCCB”:

„

“Power infeed via X1” before the main switch

is energized even with main switch turned off!

Caution!
A service socket with residual-current circuit-breaker must be selected if
plant regulations or regulations of the power utility concerned stipulate that a
residual-current circuit-breaker is required for this circuit. Operation of this
device only with grounded-neutral power supply systems.
The residual-current circuit-breaker is tripped by residual currents of 10 mA.

Before installing and connecting the option “Service Socket AC 230 V”,
please refer to the accompanying circuit diagram and cabling description.

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KUKA.Service Socket AC 230 V

Misuse

Any use or application deviating from the designated use is deemed to be im-
permissible misuse. The manufacturer cannot be held liable for any damage
resulting from such use. The risk lies entirely with the user.

Any use or application deviating from the designated use is deemed to be im-
permissible misuse; examples of such misuse include:

„

Operation outside the permissible operating parameters

„

Connection of power tools

„

Permanent power source for external devices

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4. Installation

4

Installation

4.1

Preconditions

Necessary
equipment

Standard installation tools, e.g.

„

Phillips screwdriver

„

Slotted screwdriver

„

M6 socket wrench

4.2

Overview

Use

The service socket serves as a power supply for test and diagnosis equip-
ment.

The option “Service Socket AC 230 V before Main Switch with RCCB” is avail-
able for integration into the robot controller.

4.3

Liability

4.4

Installation

4.4.1

Installing “Socket AC 230 V before Main Switch with RCCB”

Overview

Caution!
The service socket must be protected against overload using the miniature
circuit-breaker F4 supplied with it.

Caution!
Installation or exchange of this option or individual components thereof may
be performed only by specialist personnel specially trained for this purpose
and acquainted with the risks involved.
These are people who, due to their specialist training, knowledge and expe-
rience, and their familiarization with the relevant standards, are able to as-
sess the work to be carried out and detect any potential dangers.
The specialist personnel must have read and understood the installation in-
structions.

Caution!
Securely tighten all screwed contacts. The wire insulation and the end sleeve
insulation must not be screwed into the contacts.

Detailed information about all connections is contained in the accompanying
circuit diagrams and cabling description.

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KUKA.Service Socket AC 230 V

Precondition

Procedure

1. Open the cabinet door.
2. Loosen screw in main switch and remove main switch cover.

Fig. 4-1: Installation position, front view

Item

Description

1

Mounting panel

2

Cable W42030

3

Miniature residual-current circuit-breaker / terminal block X3

4

Top-hat rail

Fig. 4-2: Installation position, side view

Item

Description

1

Main switch

2

Service socket

3

Power supply connection X1

4

Cable W42030

Warning!

„

Before installation or removal work is started, it must be ensured that the
power cable to the robot controller is deenergized on the plant side and
secured against being reenergized.

„

The main switch is in the OFF position.

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4. Installation

3. Remove 4 screws under the main switch cover.

4. Remove the 3 locking elements by unscrewing the flat head screws.

5. Remove front panel from the robot controller.
6. Carefully remove the precut mounting aperture in the cabinet wall using a

suitable tool.

Fig. 4-3: Main switch (front view)

Item

Description

1

Screw

Fig. 4-4

Item

Description

1

Screw

Fig. 4-5: Installation position, locking elements

Item

Description

1

Front plate

2

Flat head screws

3

Locking unit

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KUKA.Service Socket AC 230 V

7. Deburr the edges of the opening using an appropriate tool.
8. Install the new panel with the cut-out for the socket and fasten the 3 locking

elements.

9. Remove wire F4/2 of cable W42030 from miniature circuit-breaker F4.
10. Remove wire X3/1 from terminal block X3.

11. From the outside, push the loose ends of the socket connections through

the opening that has just been created until the service socket is seated in
the opening.

12. Insert a small screwdriver into the lower opening and lift the plastic cover

of the service socket forwards and outwards.

13. Tighten the 3 screws that are now visible by turning them clockwise to

bring the terminals mounted on the back into the correct position and fas-
ten the service socket.

Fig. 4-6: Installation position of service socket

Item

Description

1

Precut cover plate

Prevent metal chips from entering the interior of the robot controller when
knocking out the cover plate.

For installation of the option CEE power infeed, do not remove wire X3/1.

Fig. 4-7: X01

Item

Description

1

Opening

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4. Installation

14. Push the plastic cover back into position – it must click audibly into posi-

tion.

15. Close the cover flap of the service socket.

Installation of the service socket into the frame of the robot controller is now
complete.

4.4.2

Installing “Power infeed via X1”

Precondition

Procedure

The “Service Socket AC 230 V with RCCB” package includes flush-mounting
miniature circuit-breaker F4, the residual-current circuit-breaker and terminal
block X3.

Fig. 4-8: X01

Item

Description

1

Screw

Fig. 4-9: X01 with cover flap

Warning!

„

Before installation or removal work is started, it must be ensured that the
power cable to the robot controller is deenergized on the plant side and
secured against being reenergized.

„

The main switch is in the OFF position.

Caution!
Securely tighten all screwed contacts. The wire insulation and the end sleeve
insulation must not be screwed into the contacts.

Detailed information about all connections is contained in the accompanying
circuit diagrams and cabling description.

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KUKA.Service Socket AC 230 V

1. Snap miniature circuit-breaker F4 and terminal block X3 with retaining clip

onto the bottommost top-hat rail in the robot controller.

2. Route the wires of the socket connection in the white flexible tube along

the left cable harness to the circuit-breaker unit F4/FI4 and terminal block
X3.

3. Reconnect wire F4/2, that was disconnected before the installation, to ter-

minal 2 of miniature circuit-breaker F4.

4. Connect wire X3/1 from above to terminal block X3/1.
5. Route wire Q1.1 (phase L1 of the service socket) from circuit-breaker FI4

along the left inner side of the control cabinet to main switch Q1.

6. Remove the switch cover and loosen the screw of terminal Q1/1 on the

main switch.

7. Pinch the released wire L1 and wire Q1/1 (from F4/1) in the red wire end

ferrule 10 mm²/12 and connect this to main switch Q1/1 (check that both
wires are fitted correctly). Fasten switch cover to Q1.

8. Unscrew power supply connector X1 from the underside of the robot con-

troller and pull it out.

9. Connect the free end of wire X1/4 to power supply connector X1/4 (neutral

terminal).

10. Press power supply connector X1 back into the installation opening and

screw it back on.

11. Check the installation against the connection diagram.

Fig. 4-10: Connection diagram for F4 / FI

Item

Description

1

Wire X3/1 to socket X01/N

2

X1/4 neutral conductor to power supply connector X1

3

Wire Q1/1 to main switch Q1/1

4

Wire F4/2 to socket X01/L

Warning!
In the case of the option Power infeed via X1, the service socket is still en-
ergized when the main switch is turned off.

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4. Installation

4.4.3

Ground conductor connections

„

Route the ground conductor from socket X01 to the ground conductor rail
on the cabinet floor and there connect it to a free terminal.

This completes the installation of the service socket.

4.4.4

Commissioning

„

After carrying out a visual inspection, reconnect the robot controller to the
mains supply and turn on the main switch.

Once these tasks have been completed, the Service Socket AC 230 V is ready
for operation.

4.4.5

Removal

Precondition

Remove the Service Socket before Main Switch by reversing the installation
procedure.

(

>>>

4.4.1 "Installing “Socket AC 230 V before Main Switch with RCCB”"

page 11)

Caution!
Before turning on the main power switch, check that all of the cables and
screws are correctly fitted and securely fastened.

Warning!
The cabinet may only be operated with the supply voltage specified on the
rating plate.

Caution!

„

Once the main switch has been turned on, check the robot controller for
offset voltage.

„

Test the function of the Service Socket AC 230 V using a suitable test de-
vice.

Warning!

„

Before installation or removal work is started, it must be ensured that the
power cable to the robot controller is deenergized on the plant side and
secured against being reenergized.

„

The main switch is in the OFF position.

Caution!
Securely tighten all screwed contacts. The wire insulation and the end sleeve
insulation must not be screwed into the contacts.

Detailed information about all connections is contained in the accompanying
circuit diagrams and cabling description.

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KUKA.Service Socket AC 230 V

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5. KUKA Service

5

KUKA Service

5.1

Requesting support

Introduction

The KUKA Roboter GmbH documentation offers information on operation and
provides assistance with troubleshooting. For further assistance, please con-
tact your local KUKA subsidiary.

Information

The following information is required for processing a support request:

„

Model and serial number of the robot

„

Model and serial number of the controller

„

Model and serial number of the linear unit (if applicable)

„

Version of the KUKA System Software

„

Optional software or modifications

„

Archive of the software

„

Application used

„

Any external axes used

„

Description of the problem, duration and frequency of the fault

5.2

KUKA Customer Support

Availability

KUKA Customer Support is available in many countries. Please do not hesi-
tate to contact us if you have any questions.

Argentina

Ruben Costantini S.A. (Agency)
Luis Angel Huergo 13 20
Parque Industrial
2400 San Francisco (CBA)
Argentina
Tel. [phone]
Fax [phone]
[e-mail]

Australia

Marand Precision Engineering Pty. Ltd. (Agency)
153 Keys Road
Moorabbin
Victoria 31 89
Australia
Tel. [phone]
Fax [phone]
[e-mail]

Faults leading to production downtime should be reported to the local KUKA
subsidiary within one hour of their occurrence.

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KUKA.Service Socket AC 230 V

Austria

KUKA Roboter Austria GmbH
Vertriebsbüro Österreich
Regensburger Strasse 9/1
4020 Linz
Austria
Tel. [phone]
Fax [phone]
[e-mail]
www.kuka-roboter.at

Belgium

KUKA Automatisering + Robots N.V.
Centrum Zuid 1031
3530 Houthalen
Belgium
Tel. [phone]
Fax [phone]
[e-mail]
www.kuka.be

Brazil

KUKA Roboter do Brasil Ltda.
Avenida Franz Liszt, 80
Parque Novo Mundo
Jd. Guançã
CEP 02151 900 São Paulo
SP Brazil
Tel. [phone]
Fax [phone]
[e-mail]

Chile

Robotec S.A. (Agency)
Santiago de Chile
Chile
Tel. [phone]
Fax [phone]
[e-mail]
www.robotec.cl

China

KUKA Flexible Manufacturing Equipment (Shanghai) Co., Ltd.
Shanghai Qingpu Industrial Zone
No. 502 Tianying Rd.
201712 Shanghai
P.R. China
Tel. [phone]
Fax [phone]
[e-mail]
www.kuka.cn

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5. KUKA Service

France

KUKA Automatisme + Robotique SAS
Techvallée
6, Avenue du Parc
91140 Villebon S/Yvette
France
Tel. [phone]
Fax [phone]
[e-mail]
www.kuka.fr

Germany

KUKA Roboter GmbH
Zugspitzstr. 140
86165 Augsburg
Germany
Tel. [phone]
Fax [phone]
[e-mail]
www.kuka-roboter.de

Hungary

KUKA Robotics Hungaria Kft.
Fö út 140
2335 Taksony
Hungary
Tel. [phone]
Fax [phone]
[e-mail]

India

KUKA Robotics, Private Limited
621 Galleria Towers
DLF Phase IV
122 002 Gurgaon
Haryana
India
Tel. [phone]
[e-mail]
www.kuka.in

Italy

KUKA Roboter Italia S.p.A.
Via Pavia 9/a - int.6
10098 Rivoli (TO)
Italy
Tel. [phone]
Fax [phone]
[e-mail]
www.kuka.it

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KUKA.Service Socket AC 230 V

Japan

KUKA Robotics Japan K.K.
Daiba Garden City Building 1F
2-3-5 Daiba, Minato-ku
Tokio
135-0091
Japan
Tel. [phone]
Fax [phone]
[e-mail]

Korea

KUKA Robot Automation Korea Co. Ltd.
4 Ba 806 Sihwa Ind. Complex
Sung-Gok Dong, Ansan City
Kyunggi Do
425-110
Korea
Tel. [phone] or -9938
Fax [phone]
[e-mail]

Malaysia

KUKA Robot Automation Sdn Bhd
South East Asia Regional Office
No. 24, Jalan TPP 1/10
Taman Industri Puchong
47100 Puchong
Selangor
Malaysia
Tel. [phone] or -0614
Fax [phone]
[e-mail]

Mexico

KUKA de Mexico S. de R.L. de C.V.
Rio San Joaquin #339, Local 5
Colonia Pensil Sur
C.P. 11490 Mexico D.F.
Mexico
Tel. [phone]
Fax [phone]
[e-mail]

Norway

KUKA Sveiseanlegg + Roboter
Bryggeveien 9
2821 Gjövik
Norway
Tel. [phone]
Fax [phone]
[e-mail]

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5. KUKA Service

Portugal

KUKA Sistemas de Automatización S.A.
Rua do Alto da Guerra n° 50
Armazém 04
2910 011 Setúbal
Portugal
Tel. [phone]
Fax [phone]
[e-mail]

Russia

OOO KUKA Robotics Rus
Webnaja ul. 8A
107143 Moskau
Russia
Tel. [phone]
Fax [phone]
kuka-robotics.ru

South Africa

Jendamark Automation LTD (Agency)
76a York Road
North End
6000 Port Elizabeth
South Africa
Tel. [phone]
Fax [phone]
www.jendamark.co.za

Spain

KUKA Sistemas de Automatización S.A.
Pol. Industrial
Torrent de la Pastera
Carrer del Bages s/n
08800 Vilanova i la Geltrú (Barcelona)
Spain
Tel. [phone]
Fax [phone]
[e-mail]
www.kuka-e.com

Sweden

KUKA Svetsanläggningar + Robotar AB
A. Odhners gata 15
421 30 Västra Frölunda
Sweden
Tel. [phone]
Fax [phone]
[e-mail]

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KUKA.Service Socket AC 230 V

Switzerland

KUKA Roboter Schweiz AG
Riedstr. 7
8953 Dietikon
Switzerland
Tel. [phone]
Fax [phone]
[e-mail]
www.kuka-roboter.ch

Taiwan

KUKA Robot Automation Taiwan Co. Ltd.
136, Section 2, Huanjung E. Road
Jungli City, Taoyuan
Taiwan 320
Tel. [phone]
Fax [phone]
[e-mail]
www.kuka.com.tw

Thailand

KUKA Robot Automation (M)SdnBhd
Thailand Office
c/o Maccall System Co. Ltd.
49/9-10 Soi Kingkaew 30 Kingkaew Road
Tt. Rachatheva, A. Bangpli
Samutprakarn
10540 Thailand
Tel. [phone]
Fax [phone]
[e-mail]
www.kuka-roboter.de

UK

KUKA Automation + Robotics
Hereward Rise
Halesowen
B62 8AN
UK
Tel. [phone]
Fax [phone]
[e-mail]

USA

KUKA Robotics Corp.
22500 Key Drive
Clinton Township
48036 Michigan
USA
Tel. [phone]
Fax [phone]
[e-mail]
www.kukarobotics.com

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Index

Index

C
Commissioning 17
Connection panel 7
Control PC 7

D
Description 9
Designated use 9
Documentation, robot system 5

G
Ground conductor connections 17

I
Installation 11
Installation, power infeed via X1 15
Installing Socket AC 230 V before Main Switch
with RCCB 11
Introduction 5

K
KUKA Customer Support 19

L
Liability 11

O
Overview 11
Overview of the robot controller 7

P
Power unit 7
Preconditions 11
Product description 7

R
Removal 17
Robot controller 7

S
Safety 9
Safety instructions 9
Safety logic 7
Scope of supply 7
Service, KUKA Roboter 19
Support request 19

T
Target group 5
Teach pendant 7
Training program 5

W
Warnings 9

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KUKA.Service Socket AC 230 V