1. Limits and purposes
This technical manual is performed for the purpose of performing maintenance of the controller in industrial systems using industrial robots. These procedures are performed when an increased temperature is detected in the cooling system, when a stable power supply is absent, or when a firmware update is missing. These actions are necessary to ensure the reliability, efficiency, and longevity of the controller.
2. Precautionary Measures
Turn off the controller power before starting work. Use the lockout/tagout (LOTO) procedure to prevent unexpected restoration of power during operation.
Використовуйте захисне обладнання. Надійність виконання робіт забезпечується за допомогою засобів індивідуальної захисту: рукавички, окуляри, шафти та інші засоби, відповідно до стандартів DSTU 3066-96 та EN 367:2007.
Turn off electrical power. Before performing any work on the controller, turn off the power supply and perform the disconnection of energy at the appropriate electrical distribution device.
3. Required Tools and Materials
| Tool Name | Specification | Quantity |
|---|---|---|
| Screwdriver bit | M4 – M12 | 1 |
| Bit key | 10 – 30 Nm | 1 |
| Multimeter | 0 – 500 V, 0 – 2000 Ω | 1 |
| Exhaust fan | Minimum power 2000 W | 1 |
| Gun with special adapter | For installation of the filter | 1 |
| Dry filter | Minimum area 150 mm² | 1 |
| Cleaning paper | Standard for electronics | 1 |
4. Subject Inspection
| Item | Check | Acceptance/Rejection Criterion | Notes |
|---|---|---|---|
| 1 | Power Off Confirmation | Absence of voltage on input contacts | Use a multimeter in the voltage mode |
| 2 | Vibration absence check | Vibrations not exceeding 0,5 mm/sec | Use the measuring instrument |
| 3 | Filter overview | Filter clean, no signs of damage | Filter removal is carried out taking into account the temperature |
| 4 | Equipment Preparation | Ensuring all necessary tools | Confirmation of availability of all tools |
5. Step by step procedure
- Power Off
Turn off the controller's power supply and perform lockout/tagout (LOTO). Log in using the tool for the inlet fan.
Error: Failure to perform LOTO may result in electric shock.
- Removal of the old filter
Use a hex key to loosen the filter. Carefully remove the filter, ensuring even displacement.
Let us remove the filter using the tool to avoid damage to the housing.
Error: improper removal may cause cracking.
- Cleaning of the housing and inlet openings
Use paper to clean the internal openings and housing. Ensure absence of dust and contamination.
Error: improper cleaning may lead to improper acceptance of the new filter.
- Installation of a new filter
Install the new filter in the appropriate location. Use a wrench to install the filter. Carry out the mounting using a torque of 5 Nm.
Check for gaps at the installation location.
Error: improper mounting may cause breakage.
- Battery Backup Check
Use a multimeter to check the battery voltage. The voltage should be in the range of 10.8 – 12.6 V.
Check for corrosion on contact surfaces.
Error: incorrect battery voltage may cause the controller to shut down.
- Firmware Update
Connect the controller to the network. Perform the firmware update using the appropriate software. Check that the firmware version is up to date.
After completion of the update, check the stability of the controller's operation.
Error: incorrect update may lead to data loss or shutdown.
- Power Restoration
Perform the power-up of the controller. Check for stable operation and absence of errors.
Error: Switching on without checking may cause shutdown.
6. After repair inspection
| Test | Expected result | Actual Result | Passed/Failed |
|---|---|---|---|
| 1 | Battery voltage | 10,8 – 12,6 V | |
| 2 | Fan operation | Normal operation | |
| 3 | Controller Stability | No errors | |
| 4 | Temperature in the system | Not higher than 50 °C |
7. Technical support
| Symptom | Probable cause | Recovery |
|---|---|---|
| Higher controller temperature | Improper cooling | Filter replacement |
| Unstable operation of the controller | Firmware error | Firmware update |
| Lack of power | Inactive battery | Checking and replacing the battery |
| Error in the system | Contamination of the filter | Filter replacement |
8. Recommended maintenance schedule
| The task | Frequency | Estimated duration | Skill level |
|---|---|---|---|
| Filter replacement | monthly | 15 min | Average |
| Battery check | Quarterly | 10 min | Average |
| Firmware update | Annually | 30 min | Tall |
9. List of spare parts
| Description of the spare part | Typical specification | UNITEC-D category |
|---|---|---|
| Fan filter | The minimum area is 150 mm² | 1100 |
| Backup battery | 10.8 - 12.6 V, 10 A·h | 1200 |
| Protective paper | Standard for electronics | 1300 |
Go to the UNITEC-D catalog for a complete list of spare parts.
10. List of documentation
This manual complies with DSTU 3066-96, EN 367:2007, ISO 12100:2010 standards, as well as CE and UkrSEPRO requirements. Additional documentation can be found in the controller manufacturer's documentation.
Note: Perform work only with appropriate skills and under the guidance of a qualified expert.
