power off controller

    Hello Everyone,
    we plan to shut down the plant for 2 week. is it possible to shut down robot controller for that long? how can we check the back-up battery to make sure it still good?
    thank you in advance

  • Go to Best Answer

    Shutting the robot down for two weeks should be fine, as long as you are not receiving any error messages regarding battery (Accumulator) voltage.

    When the robot is powered down, the batteries allow the controller to keep running long enough to save critical status data, like the mastering values. As long as the batteries are sufficiently charged when you shut down the robot, the robot can remain shut down for weeks, months, or even years.

    The potential issue that can arise when the robot are re-started is that the batteries may have lost most of their charge during the down time. Once the robots are powered up, they should not be shut down again for several hours (12-24hrs preferrred). This will charge the batteries back to capacity. Otherwise, if the robots are shut down again before the batteries are recharged, loss of mastering could result.

    Exactly as SkyeFire said

    the batteries act as a UPS for the PC when you shut down the controller. It takes the time to save critical data (incl mastering info) to the hard disk and close Windows. After that you have no problem, even if you remove the batteries from the system.
    The next power up will also be no problem. The controller will read all the data from the hard disk and it will be OK. But if you shut down again without batteries or if your batteries are not sufficiently charged, the PC will just drop dead without having the time to save data. That's where you loose your mastering. It will ask you to re-master the next time you turn it on.

    Hi Fellows.

    One little hint to add : on KRC2 cabinet there is LED visualisation comming from Siemens recharging module, when this Led is blinking You have information voltage on batteries are below good value . When this LED is ON You are right that is everything fine with batteries and recharging process.

    Marek.

    This is exactly what happened to me as SkyeFire said

    It has not been connected to the power supply for a long time, the battery of the controller turns on after a few minutes of disconnection, which leads to the loss of Mastering and henceforth PAIN, and a big one. Maybe a reinstallation of KSS is next because there is an energy stop and the robot does not move! I don't know any other solution.

    Quote from valkamar

    Maybe a reinstallation of KSS is next because there is an energy stop and the robot does not move! I don't know any other solution.

    "energy stop"? Do you mean an emergency stop? Re-installing KSS will not help, that is a purely hardware problem. Check your safety wiring.

    Re-Mastering the robot should not be an issue. However, if your batteries are more than 3 years old, I recommend replacing them (and fully charging the new batteries) before re-Mastering.

    No. First I turned on the controller and I see an orange battery light. As you say - I had to leave it on for 12-20 hours to charge.

    Out of ignorance, I made a gross mistake, turned off the controller, replaced 3 pcs. batteries 1.5v,

    Error Z 217 appeared again on power on,

    EMERGENCY STOP, ALERX STOP

    This is what I think about reinstalling KSS.

    If there is another solution that would be great.

    It lost MASTERING, I can't fix it because the robot doesn't move. BAD

    Quote from valkamar

    replaced 3 pcs. batteries 1.5v

    What? The KRC2 uses 2 12V batteries. What batteries are you referring to? The only 1.5V battery I can think of in a KRC2 is the motherboard CMOS battery.

    Quote from valkamar

    Error Z 217 appeared again on power on,

    EMERGENCY STOP, ALERX STOP

    An Emergency Stop error will not be fixed by re-installing KSS. You need to track down the root cause.

    Is it internal or external E-Stop?

    even "ALERX STOP"? :winking_face:

    have no experience with KRC32 but as SkyFire stated, EStop message should be making safety circuit wiring is correct and hardware is ok. (blown fuse...?).

    the charging time that SkyFire mentioned is for the SLA batteries (2pcs 12V). they work as UPS for KRC PC.

    some robots have other batteries (or sets). an example is 3x 1.5V for encoder backup. this is NOT the same as SLA batteries in the controller. i recall seeing them on Denso arms but i do not think those are rechargeable type. also one should follow the instructions when replacing batteries. such batteries may need to be replaced while controller is powered up to prevent data loss. if replaced while powered off, encoders will lose power and thus mastering. then relevant procedure is to to be followed to master the robot...

    which is why i really like resolvers - no batteries on the robot arm, when servicing arm one can power down robot, unplug any cable (motor or feedback), do the measurements, connect the cables back, powerup and life is good. the only thing needed is to replace batteries when controller tells that they are weak. and even mastering procedure is so quick, simple and accurate. got to love that.

    1) read pinned topic: READ FIRST...

    2) if you have an issue with robot, post question in the correct forum section... do NOT contact me directly

    3) read 1 and 2

    • Best Answer
    Quote from panic mode

    even "ALERX STOP"? :winking_face:

    :face_with_tongue:

    The KRC32 had two batteries

    - Inside the A2 board, it had two NiCd packs, totaling 24V. Their job was to supply the resolvers for a couple of seconds until their values were stores into the system. If you lose the batteries, you lose the mastering; no big deal.

    - It had also a small battery box, with 3x alkaline 1.5V AA batts whose job was to suppy the eprom on the main cpu. That's were everything was stored. Programs, vars, the KSS of the era, everything...

    Leaving the robot running for hours, makes no difference, because the important batteries are non-rechargeable alkaline.

    Unlike modern KUKAs, you exchange the 1.5V batts only with power ON. Otherwise you loose everything. The error message in this case is

    A 217 /:EMERGENCY STOP FROM ACR

    (ALARM STOP) <-- "ALERX STOP"

    and you have to connect a laptop and re-upload everything (something like today's WoV)

    As for the orange battery light....

    On the cabinet one can see some buttons.

    There is this...


    and there is that...


    When the controller is powered ON, one light comes on for a couple of seconds, indicating that the system is booting.

    I cannot remember which one is it. But both icons can be misleading as "battery low".

    What looks like battery, is actually referring to Drives ON and what looks like thunder is Fault.

    KRC32....unforgettable experience :smiling_face:

    Edited once, last by RAS-Skordos GR: wrong use of "Quote" (March 28, 2024 at 3:51 PM).

    There is an inscription next to the orange lamp

    BATTERY. A red light glowed in the upper left corner.

    After replacing 3 pcs. 1.5v batteries each with controller on, orange and red lights gone.

    I don't know about 24v rechargeable batteries. If there are any, they have long since been replaced - the robot has not been turned on for more than 4 years.

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