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Kawasaki Robot Controller

D Series

Installation and
Connection Manual

Kawasaki Heavy Industries, Ltd.

902021063DEB

D Series Controller
Kawasaki Robot Installation and Connection Manual
PREFACE
This manual describes the installation and connection of the D series controller for Europe/Japan
specification. Unless otherwise indicated, descriptions herein apply to both specifications.
Read and understand the contents of this and safety manuals thoroughly and strictly observe all rules
for safety before proceeding with any operation. Kawasaki cannot take any responsibility for any
accidents and/or damages caused by operations that are based on only the limited part of this manual.
This manual describes only the installation and connection of the Control Unit, the wiring, and
the primary power source. Please refer to the following manuals for information on the robot
arm.
INSTALLATION AND CONNECTION =ROBOT ARM =

This Manual describes the following controller models.


D40, 42, 43, 44

1. This manual does not constitute a guarantee of the systems in which the robot is utilized.
Accordingly, Kawasaki is not responsible for any accidents, damages, and/or problems
relating to industrial property rights as a result of using the system.
2. It is recommended that all personnel assigned for activation of operation, teaching,
maintenance or inspection of the robot attend the necessary education/training course(s)
prepared by Kawasaki, before assuming their responsibilities.
3. Kawasaki reserves the rights to change, revise, or update this manual without prior notice.
4. This manual may not, in whole or in part, be reprinted or copied without the prior written
consent of Kawasaki.
5. Store this manual with care and keep it available for use at any time. In the event the
manual is lost or damaged severely, contact your Kawasaki agent.
6. Though this manual was prepared to be as thorough and accurate as possible, the authors
apologize should any information be found incomplete or erroneous.
All rights reserved. Copyright 2004 by Kawasaki Heavy Industries Ltd.
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D Series Controller
Kawasaki Robot Installation and Connection Manual
SYMBOLS
The items that require special attention in this manual are designated with the following symbols.
Ensure proper and safe operation of the robot and prevent physical injury or property damage by
complying with the safety matters given in the boxes with these symbols.

DANGER
Failure to comply with indicated matters can result in
imminent injury or death.

WARNING
Failure to comply with indicated matters may possibly lead
to injury or death.

CAUTION
Failure to comply with indicated matters may lead to
physical injury and/or mechanical damage.
[ NOTE ]
Denotes precautions regarding robot specification,
handling, teaching, operation and maintenance.

Comply with the cautionary instructions described in the manual. Failure to observe these
instructions may result in serious injury to personnel or damage to the robot system.

WARNING

1. The accuracy and effectiveness of the diagrams, procedures, and detail


explanations given in this manual cannot be confirmed with absolute
certainty. Accordingly, it is necessary to give ones fullest attention when
using this manual to perform any of the following procedures: robot
operations, maintenance, adjustment, repair, etc.
2. Persons operating or maintaining the robot must always observe all safety
rules. Never replace components or perform adjustments inside the robot
system while the power is ON.
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D Series Controller
Kawasaki Robot Installation and Connection Manual

CONTENTS
1.0 Safety 1
1.1 Precautions during Transportation and Storage 1
1.2 Installation Environments of Robot Controller 2
1.3 When Connecting the Harness 3
1.4 When Connecting the Primary Power 4
1.5 Warning Label 5

2.0 Workflow Robot Controller Installation and Connection 6

3.0 Appearance and Specification of Robot Controller 8


3.1 D40 Controller Appearance 8
3.2 D42 Controller Appearance 9
3.3 D43 Controller Appearance 10
3.4 D44 Controller Appearance 11
3.5 Teach Pendant Appearance 12
3.6 D40, 42, 43, 44 Controller Specification 13

4.0 Transportation of Robot Controller 14


4.1 By Crane Lifting 14
4.2 By Forklift Truck 15
4.3 By Caster 16

5.0 Arrangement of Robot Controller 17

6.0 Connection Instructions 19


6.1 Connection Instructions between Controller and Robot 19
6.2 Connection Instructions between Controller and Teach Pendant 24

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D Series Controller
Kawasaki Robot Installation and Connection Manual
7.0 Connection of Primary Power 25

8.0 Connection of Peripheral Control Equipment 29


8.1 Instructions at the Connection 30
8.2 Connection of DI/O General Purpose Signal 31
8.3 Connection of DI/O Hardware Dedicated Signal 32
8.4 Connection of Personal Computer (Option) 33
8.5 Connection of RS232C Serial Signal (Option) 33
8.6 Connection of Ethernet Communication Signal (Option) 33

Appendix 1.0 Connection of Sensor Cable A-1


Appendix 1.1 Sensor Cable (Option) A-2
Appendix 1.2 Connecting Proximity and Limit Switches A-4
Appendix 1.3 Using Solenoid Signals A-5
Appendix 1.4 Using Sensor Signals A-6

Appendix 2.0 Solenoid Valve Wiring Diagram A-7

Appendix 3.0 Sensor Wiring Diagram A-10

Appendix 4.0 Protecting Sensor Line from Noise A-17

Index I-1

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D Series Controller
Kawasaki Robot Installation and Connection Manual

1. Safety

1.0 Safety
This chapter only describes safety precautions during installation and connection of the Controller
Unit. For all other safety matters, refer to the SAFETY MANUAL, a separate-volume.
1.1 Precautions during Transportation and Storage
When the controller is to be transported to its installation position, strictly observe the following
precautions:

WARNING
1. When transporting a controller with a crane or a forklift, never support
the controller manually.
2. During the transportation, stay out from under the lifted controller.

CAUTION
1. Since the controller is composed of precision parts, be careful not to
apply excessive shocks or vibrations to the controller during
transportation.
2. To carry out smooth and safe installation, remove all obstacles before
installing a controller. Clear a passage for the transportation of
controller before using a crane or forklift.
3. When transporting or storing a controller:
keep the ambient temperature within the range of - 10C - 60C
keep the relative humidity within the range of 35% - 85% RH
(Non condensing)
keep free from excessively large shock and vibration.

D Series Controller
Kawasaki Robot Installation and Connection Manual

1. Safety

1.2 Installation Environments of Robot Controller


Install the controller in a site that satisfies all the following environmental conditions:
1. Ambient temperature during operation: within 0 C - 45 C.
2. Relative humidity: 35 - 85 %RH (Non condensing)
3. Free from dust, smoke, water, oil, etc. (Controller protection grade: IP53)
(Except for NFB handle section, transformer section and heat sink section. See the figure
below.)
IP53

IP22
4. Free from flammable and/or corrosive liquid and gas.
5. Free from excessively strong vibration.
6. Free from electrical noise interference.
(Controller primary power noise: 1KV/1s or less)

CAUTION
If the controller is installed near equipment that generates a lot of electrical
noise, be sure to provide appropriate surge killers around that equipment.
Noise producing equipment includes: induction motors, electromagnetic
brakes, solenoids, or contact equipment, etc.
7. Place where power is supplied within specifications. (Variance +/-10 % or less)
8. Place where dedicated earthing is provided. (100 or less)
9. Outside the safety fence with margin (min. 1 m) from the motion range of robot arm (with
hands and guns).

D Series Controller
Kawasaki Robot Installation and Connection Manual

1. Safety

In addition, ensure the followings:


Enough space for easy access to the controller during maintenance
Installing an entrance gate with a safety plug to the safety fence
Referring the requirements established in each region for details of the safety fence
e.g. EN953, EN294, EN811, EN1088, ISO13852, ISO13854, and ISO/NP14120
Approx. 1 m

Motion range of robot arm


Approx. 1 m

(hand and gun included)


Mechanical
Mechanical
stopper

Approx.
1m

Approx. 1 m

stopper

Approx.

Safety fence

1m
Gate with
safety plug

Controller part

1.3 When Connecting the Harness


Strictly observe the following precautions when connecting the Robot Arm with the Robot
Controller.

WARNING
Do not connect the primary power until connections between the Robot Arm
and Robot Controller are completed.
Accidents may occur, such as electric shock, etc.

CAUTION
1. Be careful when connecting the harness. Be sure to use the correct
harness cable and check that the connector fittings match between the
harness and robot/controller before attempting connection. Using an
incorrect harness, or forcing or misconnecting the harness may damage
connectors or cause a break in the electrical system.
2. Use conduits, ducts, etc. to prevent people or equipment (forklift, objects,
etc.) from stepping on or riding over the signal and motor harness lines.
An unprotected harness may become damaged causing breaks in the
electrical system.
3. Separate the harness from any nearby high voltage lines (min. 1 m apart).
Do not bundle or run the harnesses in parallel with other power lines. The
noise generated from power lines will cause malfunctions.
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Kawasaki Robot Installation and Connection Manual

1. Safety

1.4 When Connecting the Primary Power


Strictly observe the following precautions when connecting the primary power.

DANGER
Before beginning the connection work, confirm that the primary power supply
for the controller is cut off at the source. To prevent primary power from
being turned ON accidentally, tag the breaker and indicate clearly that work
is in progress. Or, assign a supervisor in front of the breaker until all the
connections are complete. Connecting components while power is supplied is
extremely dangerous and may cause electric shock.

WARNING
1. Connect with earth wires to prevent against electrical noise and shock.
2. Use dedicated earth wire (100 or less), which is equal to or larger than the
recommended power cable size (3.5 ~ 8.0 mm2).
3. Never use a minus pole (base metal) or a common earth wire for both
controller and another machine (weld machine, etc.).
4. In arc welding applications, connect the minus pole of the weld power supply
to a jig or directly to base metal. Insulate the robot body and controller so
that they do not share a common earth line.
5. Without fail, before turning ON the primary power to controller, make sure
the power supply is connected and all the covers reattached properly.
Failure to do so may cause electric shock.

CAUTION
1. Prepare primary power that meets the specifications of the controller in
terms of momentary power interruption, voltage fluctuation, power
capacity, etc.
If the power is interrupted or the voltage goes out of the controllers
specified range (above/below ratings), then the power monitoring circuit
activates cutting off the power, and an error is returned.
2. If the primary power emits a lot electrical noise, set up a noise filter to
reduce the interference.
3. Install a separate primary power switch (breaker) for the robot,
independent and unconnected to the weld machine.
4. To prevent shorting or accidental leakage on the primary power switch,
install a breaker with anti-leak specification. (Use a Time Delay Relay and
sensitivity of 100 mA or more.)
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Kawasaki Robot Installation and Connection Manual

1. Safety

1.5 Warning Label

WARNING
Pay attention to warning labels listed in the drawings on this page during
operation.

The terminals are still live if the


Control Power Switch is OFF.

Control Power
Switch

DC Power
Supply (AVR)

D Series Controller
Kawasaki Robot Installation and Connection Manual

2. Workflow - Robot Controller


Installation and Connection

2.0 Workflow Robot Controller Installation and Connection

Install Work

Prep. Work

This workflow describes only the Robot Controller. For the Mechanical Unit, refer to
INSTALLATION AND CONNECTION =Arm.
Examine installation
position (includes wire) and
environment

Refer to 3.0 Appearance and


specification of Robot
Controller.

Confirm power supply


voltage and power capacity

Refer to 3.0 Appearance and


specification of Robot
Controller.

Transport Robot Controller

Refer to 4.0 Transportation of


Robot Controller.

Arrange and install


Robot Controller

Refer to 5.0 Arrangement of


Robot Controller.

Connect Teach Pendant


and separation harness

Refer to 6.0 Wiring


Instructions.
See also Installation and
Connection =Arm.

Connect ambient control


system and equipment

Refer to 8.0 Connection of


Peripheral Control Equipment.

Connect primary power

Refer to 7.0 Connection of the


Primary Power.

Work after connecting


Robot Controller with the Robot

D Series Controller
Kawasaki Robot Installation and Connection Manual

2. Workflow - Robot Controller


Installation and Connection

Turn on and confirm


Control Power

Note: To control power supply


externally, see External I/O
Manual.

Turn on and confirm


Motor Power

Note: To use external emergency


stop, see External I/O Manual.

Confirm operation of
robot arm and tool
(Teach Mode)

Refer to Operation manual.

Also, confirm other,


various functions

Refer to Operation manual.

Work completion

[ NOTE ]
This manual only describes installation procedures, up to the step
where primary power is connected.

D Series Controller
Kawasaki Robot Installation and Connection Manual

3. Appearance and Specification


of Robot Controller

3.0 Appearance and Specification of Robot Controller


3.1 D40 Controller Appearance
600
Teach Pendant
Lifting eyebolt
Control
power
switch

Operation Panel
T/P Connector

Primary power
intake port
1200

Hook

Accessory Panel
Coin lock

Left

Front

550

Teach pendant
holder (option)

Connector for
separation harness
Rear

Right
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D Series Controller
Kawasaki Robot Installation and Connection Manual

3. Appearance and Specification


of Robot Controller

3.2 D42 Controller Appearance


600
Teach pendant
Lifting eyebolt
Operation Panel

Control
power
switch

T/P Connector

Primary power
intake port
1200

Hook

Accessory panel
Coin lock

Left

Front

550

Teach pendant
holder (option)

Connector for
separation harness
Rear

Right

D Series Controller
Kawasaki Robot Installation and Connection Manual

3. Appearance and Specification


of Robot Controller

3.3 D43 Controller Appearance


600
Teach pendant
Lifting eyebolt
Operation panel

Control
power
switch

T/P Connector

Primary power
intake port
1200

Hook

Accessory panel
Coin lock

16

Left

Front

550

Teach pendant
holder (option)

Connector for
separation harness
Rear

Right

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D Series Controller
Kawasaki Robot Installation and Connection Manual

3. Appearance and Specification


of Robot Controller

3.4 D44 Controller Appearance


600
Teach pendant
Lifting eyebolt
Control
power
switch

Operation panel
T/P Connector

Primary power
intake port
1200

Hook

Coin lock

Accessory panel

Front

Left
550

Teach pendant
holder (option)

Connector for
separation harness
Rear

Right

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D Series Controller
Kawasaki Robot Installation and Connection Manual

3. Appearance and Specification


of Robot Controller

3.5 Teach Pendant Appearance

Liquid crystal display


Emergency stop switch

Teach lock switch

Teach pendant
Operation panel
T/P
Connector

Lifting eyebolt
Control
power
switch
Accessory
panel

Coin lock

Hook

D42 Controller

12

Teach pendant
holder (option)

D Series Controller
Kawasaki Robot Installation and Connection Manual

3. Appearance and Specification


of Robot Controller

3.6 D40, 42, 43, 44 Controller Specification


Construction

Approx. 200 kg (with transformer)

Mass
Ambient
Environment
Power Source

Self-sustaining fully closed, indirect cooling system


Approx. 120 kg (without transformer)

Temperature

0 45 C

Japan spec.

35 85 %RH (Non condensing)


AC 200 V (50 Hz) /AC 220 V (60 Hz) +/-10 %

Europe spec.

AC 380/400/415/440 V +/-10 % 50/60 Hz 3 Phase

Humidity

Power Capacity
Earthing
Length of
Teach Pendant Cable

Refer to the table below.


Dedicated earthing (100 or less)
5 m/10 m/15 m (10 m, 15 m are options.)

Length of Separation Harness* 5 m/10 m/15 m (10 m, 15 m are options.)


Note* Harness length between Robot Arm and Controller

Reference

Model
Small F Series (6-20)
Large F Series (30-60, FS10X)
ZX/ZT/ZD Series
MX/MD Series

Power
Capacity

Recommended Power Cable Size


(Including earth wire)

5.4 KVA
11 KVA
11 KVA
11 KVA

3.5 mm2 or more (AWG #12 or more)


8.0 mm2 or more (AWG #8 or more)
8.0 mm2 or more (AWG #8 or more)
8.0 mm2 or more (AWG #8 or more)

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D Series Controller
Kawasaki Robot Installation and Connection Manual

4. Transportation of Robot Controller

4.0 Transportation of Robot Controller


When transporting the controller, strictly observe the precautions given in the sections below for
whichever transport method is chosen.
4.1 By Crane Lifting

WARNING
1. Never support the controller manually while it is being lifted up. And,
never go under or stay too close to the controller during transport.
2. Hook the wire at the lifting eyebolts as shown below.
3. Ensure that the lifting eyebolts are not loose. Check each one and
retighten if loose. Otherwise, the controller may fall and suffer damage.

Wire
1 m or more
Lifting
eyebolt

Hook

CAUTION
1. Prepare wire and crane capable of
hoisting 200kg or more, sufficient for a
controller loaded with full options.
2. Remove the teach pendant and teach
pendant holder before lifting with the
wire sling.
3. Wire length: 1m or more as shown in
left figure.
4. Be careful as the controller may lean
when lifted up.
5. Be careful not to let the wire snag on
other equipment.

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D Series Controller
Kawasaki Robot Installation and Connection Manual

4. Transportation of Robot Controller

4.2 By Forklift Truck

WARNING
To stop the controller from toppling over, fasten it to the
forklift with a belt as shown below.

Falling prevention belt

CAUTION
1. Remove the teach pendant and teach
pendant holder. Pass the fork under
the controller body as shown on the left.
2. Be careful not to shock the controller
during transport.
3. Be careful not to get caught on other
equipment, cables, etc.

Pass the fork through this position.

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D Series Controller
Kawasaki Robot Installation and Connection Manual

4. Transportation of Robot Controller

4.3 By Caster

WARNING
1. If the transport path is completely flat then the controller can be
moved on its casters.
Otherwise, it is assumed that moving on an incline or an uneven
surface will topple the controller, and cause serious damage.
2. The controller falls if it is inclined as follows.
Back or forth
: Approx. 10 or more
Right or left
: Approx. 15 or more

CAUTION
1. Release the stoppers on the two casters in front of the controller
when moving the controller. (Push the OFF side pedal.)
2. Relock the casters after the transport is complete.
(Push the ON side pedal for locking.)

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Kawasaki Robot Installation and Connection Manual

5. Arrangement of Robot Controller

5.0 Arrangement of Robot Controller


In order for the controller to maintain the proper internal temperature, the installation site must
conform to the four points below.

1. Arrange the controller on a horizontal


floor.

2. Separate the controller right side from the


wall by 100 mm or more.
200 mm
or
more

100 mm
or
more

3. Separate the controller left side from the


wall by 200 mm or more.

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D Series Controller
Kawasaki Robot Installation and Connection Manual

5. Arrangement of Robot Controller

4. The inlet port for air-cooling is on the


rear upside and left of the controller, and
the air exhaust port is on the rear
downside.

CAUTION

200 mm
or
more

Do not block the air inlet and exhaust


ports when arranging the controller.
Separate the controller backside from
the wall by 200 mm or more.

1000 mm
or
more

5. Make fixing bracket(s), and fix the


controller with M12 bolts. See the
figure below for reference.

CAUTION
1. Release the stoppers on the two casters in front of the controller
when moving the controller. (Push the OFF side pedal.)
2. Relock the casters after the transport is complete.
(Push the ON side pedal for locking.)

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Kawasaki Robot Installation and Connection Manual

6. Connection Instructions

6.0 Connection Instructions


6.1 Connection Instructions between Controller and Robot

WARNING

Do not connect the primary power until connections between controller and
robot are completed. Accidents may occur, such as electric shock, etc.

CAUTION

1. Be careful when connecting the harness. Be sure to use the correct


harness cable and check that the connector fittings match between the
harness and robot/controller before attempting connection. Using an
incorrect harness, or forcing or misconnecting the harness may damage
connectors or cause a break in the electrical system.
2. Use conduits, ducts, etc. to prevent people or equipment (forklift, objects,
etc.) from stepping on or riding over the signal and motor harness lines.
An unprotected harness may become damaged causing breaks in the
electrical system.
3. Separate the harness from any nearby high voltage lines (min. 1 m apart).
Do not bundle or run the harnesses in parallel with other power lines.
The noise generated from power lines will cause malfunctions.
4. Separate the motor harness from the communication and sensor cables,
and distribute the lines so they are neither bundled nor running in parallel.
Moreover, connect the communication and sensor cables using shield mesh
wire that includes twisted pair lines and an adequate FG terminal. (See
Appendix 4.) These measures stop PWM noise from the robots motor
control from radiating through the various cables and causing
communication errors.
5. Separate the welder secondary cable from the robots signal harness. Do
not wire them in the same duct.
6. The motor harness (power line) between the robot and controller will
generate switch noise due to the PWM control driving the motors. This
noise may cause interference with signal lines. Prevent interference using
these countermeasures:
(1) Separate the power and signal lines as much as possible.
(2) Use the shortest possible length for the power line.
(3) Avoid bundling, wiring in parallel the power and signal lines as much
as possible.
(4) Ground the shield of the power line securely with the FG terminal.
(5) Do not wire the power and signal line within the same duct/conduit.
(6) Set and secure a firm earth line connection for the controller.

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Kawasaki Robot Installation and Connection Manual

6. Connection Instructions

Connect the separation harnesses to their designated ports as shown below.


1. Controller side

Wrist axis
motor harness (X5)
Major axis
motor harness (X4)

Motor harness (X4)


Signal harness (X3)

Signal harness (X3)


D40

D42, 43

CAUTION

Fix each connector securely. The robot may


malfunction if connectors loosen or detach.

Wrist axis
motor harness (X4-2)
Motor harness (X5)
Major axis
motor harness (X4-1)
Signal harness (X3)
D44
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D Series Controller
Kawasaki Robot Installation and Connection Manual

6. Connection Instructions

2. Arm side
FS06/FA06, FS10E/N/C
(C001)

X4A

X3A
Signal harness

Motor harness

FS10L, FS20/FA20
(C001)

X4A

X3A
Signal harness

Motor harness

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D Series Controller
Kawasaki Robot Installation and Connection Manual

6. Connection Instructions

FS30/45/60/10X
(C001)

X4A

X5A

X3A
Signal harness
Wrist axis motor harness
Major axis motor harness

ZX/ZT/ZD
(C001)

X4A

X5A

X3A

Signal harness
Wrist axis motor harness
Major axis motor harness

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D Series Controller
Kawasaki Robot Installation and Connection Manual

6. Connection Instructions

MX/MD
(C001)

X5A

X5A

X4A2

X4A1
X4A1

X3A

Signal harness
Major axis motor harness
Wrist axis motor harness
Motor harness

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D Series Controller
Kawasaki Robot Installation and Connection Manual

6. Connection Instructions

6.2 Connection Instructions between Controller and Teach Pendant


1. Connect the teach pendant cable with the connector, lower right of operation panel. Pull
down the lever and lock after pulling it up and inserting the connector.
2. Place the teach pendant in its holder (option) on top of the controller as shown below. Then,
hang the teach pendant cable on the hook.

Teach pendant holder


(option)
Hook

T/P Connector (X1)

CAUTION
The hook should only be used for
hanging the teach pendant or cable.

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D Series Controller
Kawasaki Robot Installation and Connection Manual

7. Connection of Primary Power

7.0 Connection of Primary Power

DANGER

Confirm that primary power supply for the controller is cut off before
starting connection process. It is extremely dangerous to connect
power terminals with the power supply turned ON and accidents may
occur, electric shock, etc. To prevent primary power from being
turned ON, tag the breaker to indicate clearly that work is in progress.
Or, assign a supervisor in front of the breaker until all connections are
complete.

WARNING

1. Make sure the power supply meets the specifications listed on the
label on the controllers left side panel. Connecting to a power
source outside specifications may damage internal components.
2. Install a dedicated earth wire (100 or less). Also, install a
separate earth wire for the weld machine, do not use a common
earth wire.

CAUTION

1. Check for fluctuations in the power supply before making any power
connections to the robot. Ensure a stable power supply, fluctuations
of +/-10 % or more will degrade the robots efficiency.
2. If there is danger of electrical noise coming through the power line
from other equipment, then be sure to place noise filters. (Noise
level: 2kv/1s or more)
3. Likewise, PWM noise coming through the power line from the robot
motors may also affect machines with low noise tolerance, resulting
in malfunction. Plan and arrange the system so that all the
peripheral equipment* can withstand the PWM noise.
Note* Beware that some devices/configurations are easily exposed to
PWM noise, e.g.: proximity switch coupled directly to power
supply, etc. (See also App. 4.)

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Kawasaki Robot Installation and Connection Manual

7. Connection of Primary Power

Connect the primary power according to the


following procedure.
1. Turn OFF the primary power for the
controller.
Connect with the primary power
circuit breaker at the installation site.
CONTROL POWER Switch

2. Set CONTROL POWER switch on the


controller door to the OFF side.

3. Feed the primary power cable into the


intake port on the left side of controller.
Primary power intake port

Detailed procedure of fixing a cable is shown below.


Cut a cable gland (supplied with the controller) in
accordance with the diameter of the cable.
Pass the cable through the cable gland.
Tighten the screw after adjusting length of the cable.
Pass the cable through the intake port and tighten
the lock nut.

Inside

Outside
Tightening screw
Cable
9 12
11 14
14 17
17 19
Controller enclosure
Lock nut

Cutting position
(: diameter of cable

CAUTION

Confirm current requirements and select a power cable with adequate capacity.
Do not to install wire that is too small in diameter, the voltage may drop or the
cable may overheat.
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D Series Controller
Kawasaki Robot Installation and Connection Manual

4. Attach round, crimp-type terminals on the


ends of the individual wires of the power
cable. Use round insulators on each of
these wires to prevent contact between the
crimped part and metal. (See left figure.)

Primary power cable

Earth
wire
Breaker

Lock detent

Primary power cable


connection terminal cover

7. Connection of Primary Power

5. Connect the primary power cable with the


breaker terminal (3 screws), and the
dedicated earth terminal.

Push

WARNING

Tighten the terminals securely.


Opening the robot with loose terminals
is very dangerous and may lead to
electric shock, robot malfunction, or
breakdown of the electrical system.

Connect the earth wire with the earth terminal


as shown below.

Earth terminal 6. Install the primary power cable connection


terminal cover.

DANGER

Mount the primary power cable


connection terminal cover when the
wiring is complete.
Failing to install the cover may lead
to electric shock if the terminals are
touched.

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D Series Controller
Kawasaki Robot Installation and Connection Manual

7. Connection of Primary Power

Primary Input Voltage


Change the connection of the transformer connector before changing the primary input
voltage.
Primary Input Voltage

Connect

380/400/415 V
440 V

X601A
X601B

To change the connection, remove the bottom panel on the left side of the cabinet.

X601A, B

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D Series Controller
Kawasaki Robot Installation and Connection Manual

8. Connection of Peripheral
Control Equipment

8.0 Connection of Peripheral Control Equipment


According to application or specification, connect each connector in the Controller Unit
described below with the Peripheral Control Equipment. Especially for DC (under 24V)
wiring, use the Harness support.

Harness support

1GW/1HW Board
(Option)
External DI/O Connector
CN2 (Output)
Terminal block
X7 Connector
Terminal block
X8 Connector
Terminal block
X9 Connector

Ethernet port (Option)


External DI/O Connector
CN4 (Input)
1KN Board (Option)
RS232C Port

RS232C Port

1KA Board

Accessory Panel

1KB Board
1KP Board

29

D Series Controller
Kawasaki Robot Installation and Connection Manual

8. Connection of Peripheral
Control Equipment

8.1 Instructions at the Connection

WARNING

Turn OFF the power supply to the controller and peripheral equipment
when connecting external I/O. Prevent accidental turn ON of the power
until all connections are complete by tagging the breaker to indicate that
work is in progress or by assigning a supervisor to stand in front of the
breaker. Failure to do so is extremely dangerous and may result in electric
shock or damage to the electrical system.

CAUTION

1. Take the necessary noise countermeasures on equipment with external


I/O connections to the controller. Electrical noise that interferes with
the I/O may cause malfunction or damage to the electrical system.
2. Do not mistake pin Nos. on the connectors when connecting external
I/O. Misconnecting pins may cause breakdown of the electrical
system.
3. Prevent people or equipment (forklift, objects, etc.) from stepping on
or riding over the external I/O cables. An unprotected cable may
become damaged causing breaks in the electrical system.
4. Avoid wiring the external I/O cable and the power line close together
or in parallel as much as possible. Separate the cables and lines by at
least 20 cm. Electromagnetic induction from the robot motor cable,
the power lines for peripheral equipment, welding cable, etc. (either in
or outside the controller) may cause noise interference in the I/O cable
and lead to malfunction.
5. When connecting with a light load such as sequencers, we recommend
using a shield harness.
6. Fix the external I/O cable with tying bands in the harness support set
on top the Controller Unit. This protects the connector on the
terminal block from excessive force. (pulling, snagging of cable, etc.)
7. Install the protector so that external I/O cable never causes insulation
failure or disconnection at the intake port.

30

D Series Controller
Kawasaki Robot Installation and Connection Manual

8. Connection of Peripheral
Control Equipment

8.2 Connection of DI/O General Purpose Signal


The robot can operate synchronously with the peripheral equipment or another robot when
connecting DI/O signals to the peripheral control equipment with connectors CN2 and CN4
on the 1GW/1HW board.
1. Insert the cable into I/O signal intake port on the left of the controller.
The example of installing the cable(s) is shown below.
Select the cable-sized seal connectors.
Remove the plate fixed on the intake port. I/O Signal intake port
Make a hole in the plate suitable for the seal connector.
Pass the cable through the seal connector, then tighten
the nut(s) of the seal connector.
plate

seal connector
inside
outside
hole
cable
2. Take off connectors CN2 and CN4 installed in the controller.
3. Remove the connector cover for CN2 and CN4, and wire for general
purpose signal.
4. Solder the connector pin.
5. Strip off the cable coating by 2-3mm and apply solder to the wire end.
6. Solder the cable to the connector pin.
7. Cover the connector pin with the insulation tube.
[ NOTE ]
1. Use an insulation tube of heat shrinkage type, or bind the
tube ends on each line so as not to come off.
2. We recommend using AWG22-24 or equivalent for cables.

31

D Series Controller
Kawasaki Robot Installation and Connection Manual

8. Connection of Peripheral
Control Equipment

8. After wiring is complete, attach connector cover and fix securely by turning the harness
clamp screw.
9. Insert the connector into 1GW/1HW board and fix with locking screws at both ends.
[ NOTE ]
Tighten the screw thoroughly. The connection may fail if
the screw is loose and the connector pins are exposed to
above standard stress/force.
Connector
CN2 DC-37S-N (JAE) or equivalent
CN4 DC-37P-N (JAE) or equivalent

Stripped
wire
Harness

Harness clamp
Cover DC19678-3
(JAE) or equivalent

Insulation

Locking screw
CN2 D20419-16J (JAE) or equivalent: M2.6
CN4 D20419-21J (JAE) or equivalent: M2.6

Connector pin

8.3 Connection of DI/O Hardware Dedicated Signal


It is possible to construct a safety circuit using the hard circuit by connecting the external
emergency stop signal or hold signal with the terminal connector on the 1KP board. Refer to
External I/O Manual for more details about signals and their connection to each terminal
block.
Terminal block connections are held in place
by springs.
Push a thin flat-head screwdriver (width:2.5
mm or less) into the hole on the right to open
spring in the left hole. Then insert the wire
there for connection.

KP Board

XConnector
(X8 Connector)
(X9 Connector)

We recommend using AWG22-24 or equivalent for cables.


(Stripped wire length:7mm)

32

Insert driver for


Connection connection
side

D Series Controller
Kawasaki Robot Installation and Connection Manual

8. Connection of Peripheral
Control Equipment

8.4 Connection of Personal Computer (Option)


It is possible to use a PC as terminal for the Robot Controller, when connecting a PC loaded
with KRterm/KCwin32 software with the RS232C Port in the Accessory Panel. Refer to AS
Language Reference Manual for more details.
8.5 Connection of RS232C Serial Signal (Option)
Data communication is possible between the host computer and 1KA board, when connecting
to the RS232C Port on the 1KA board with an RS232C cable. Refer to Option Manual for
details.
8.6 Connection of Ethernet Communication Signal (Option)
It is possible to build an Ethernet LAN of 10baseT/100baseTX using the communication port
on the 1KN board which can be added on the 1KA board. Refer to the specific Option
Manual because cables differ according to application or specification.

33

D Series Controller
Kawasaki Robot Installation and Connection Manual
MEMO

34

D Series Controller
Kawasaki Robot Installation and Connection Manual

Appendix1. Connection of
Sensor Cable

Appendix 1.0 Connection of Sensor Cable

WARNING

Turn off the control power when connecting the sensor


cable. Failure to do so is dangerous and may result in
accidental electric shock.

CAUTION

Be sure to confirm the signal name when connecting sensor


lines via faston terminals. Misconnected terminals cause
breakdowns in the electrical system in the controller.

[ NOTE ]
Ensure that the proximity and limit switches are suitable for
the robot system and compatible with its electrical specs.

A-1

D Series Controller
Kawasaki Robot Installation and Connection Manual

Appendix1. Connection of
Sensor Cable

Appendix 1.1 Sensor Cable (Option)


FS6/10/20/30/45/60
Faston terminal for sensor

Taking-out port for sensor cable


Prepare the terminal
connector according
to application specs.

Sensor cable (option)


Approx. 1.5 m

A-2

D Series Controller
Kawasaki Robot Installation and Connection Manual

Appendix1. Connection of
Sensor Cable

F series
Sensor cable
Sensor input signal 1

XSIG1

Sensor input signal 2

XSIG2

Sensor input signal 3

XSIG3

Sensor input signal 4

XSIG4

I/O24V
I/O24G

Blue
Black
Purple
Black
Gray
Black
Pink
Black
Brown
Black
Red
Black

X24V
X24G

RFV-K38
(0.3Sq 6P Outside diameter : 11mm)

[ NOTE ]
1. It is also possible to use external +24V power supply for the internal
sensor and valve. In this case, remove jumpers between 9-10, 11-12
pins of X9 connector, and connect +24V to 10 pin, 24G to 12 pin.
When using an internal +24V power supply, short between 9-10, 11-12
pins. (Wiring at shipment.)
2. Select a proximity sensor, etc. that does not exceed the current capacity
of the built-in power supply.
Current capacity: 0.2 A or less.
(Approx. 10 mA is necessary for each channel, SIG1~4.)

A-3

D Series Controller
Kawasaki Robot Installation and Connection Manual

Appendix1. Connection of
Sensor Cable

Appendix 1.2 Connecting Proximity and Limit Switches


It is possible to connect proximity or limit switches with a faston terminal and to download it as a
WX signal. As per below, take note that connections differ between proximity and limit
switches and these are for non-Europe controller. (Refer to page A-16 for Europe controller.)
Connecting a proximity switch
Faston/Connector
Proximity switch
+24V
SIG1
24G

(5)
(1)
(6)

+24V
SIG
GND

Connecting a limit switch


Faston/Connector
SIG1
+24G

Limit switch

(1)
(6)

Connecting a proximity and limit switch together


Faston/Connector
Proximity switch
+24V
SIG1
24G

(5)
(1)
(6)

SIG2

(2)

+24V
SIG
GND

Limit switch

CAUTION

1. For various reasons the sensor cable may receive noise interference from the
axis motors, due to wiring of the cables inside the arm, the type of proximity
switch being used, etc. This noise may cause the robot to malfunction.
Take the following measures to reduce noise:
(1) Connect the sensor by wiring the cable outside the robot arm.
(2) Use a proximity switch specified for high noise resistance.
(3) Take the necessary noise counter-measures.
(Refer to Appendix 4.0 Protecting Sensor Line from Noise)
2. Use twisted pair shield line when wiring the harness outside the robot arm.

A-4

D Series Controller
Kawasaki Robot Installation and Connection Manual

Appendix1. Connection of
Sensor Cable

Appendix 1.3 Using Solenoid Signals


When using solenoid valve signals SOL1-7 via the internal valve wiring in handling specification,
they are assigned to the general purpose output signals OUT9-15. Set them in Aux. 0605 to
correspond to clamp signals.
Signal Name

Signal No.

SOL1 (SIGO1)

OUT9

SOL2 (SIGO2)

OUT10

SOL3 (SIGO3)

OUT11

SOL4 (SIGO4)

OUT12

SOL5 (SIGO5)

OUT13

SOL6 (SIGO6)

OUT14

SOL7 (SIGO7)

OUT15

CAUTION

1. To assign solenoid valve signals via internal valve wiring, select


USED/NOT USED in Aux. 0610. Refer to Operation Manual.
2. OUT9-16 cannot be used for general purpose signals once they
are set as internal wiring valve signals.

CAUTION

Set jumpers JT3 and JT4 on the 1GW/1HW board without fail as
shown below.

J3
1
2
3
4
5
6

J4

{{{
{{{
{{{
{{{
{{{
{{{

1
2
3
4
5
6

A B C

{{{
{{{
{{{
{{{
{{{
{{{
A B C

A-5

D Series Controller
Kawasaki Robot Installation and Connection Manual

Appendix1. Connection of
Sensor Cable

Appendix 1.4 Using Sensor Signals


When using sensor signals SIG1-4 via the internal wiring, they are assigned to the general
purpose input signals IN13-16.
Signal Name

Signal No.

Sensor signal 1 (SIG1)

IN13

Sensor signal 2 (SIG2)

IN14

Sensor signal 3 (SIG3)

IN15

Sensor signal 4 (SIG4)

IN16

CAUTION

1. To assign sensor signals via internal wiring, select USED/NOT


USED in Aux. 0610. Refer to Operation Manual.
2. IN13-16 cannot be used for general purpose signals once they
are set as internal wiring sensor signals.
.

CAUTION

Set jumper J5 on the 1GW/1HW board without fail as shown


below.

1GW/1HW board

J5
1
2
3
4
5

{{ {
{{ {
{{ {
{{ {
{{ {
A B C

A-6

D Series Controller
Kawasaki Robot Installation and Connection Manual

Appendix2. Solenoid Valve


Wiring Diagram

Appendix 2.0 Solenoid Valve Wiring Diagram


(1) FS06/10/20 etc.

Controller

Robot

Note* These are for Europe controller. Replace


8 with 9 and I/O24G with I/O24V for
non-Europe controller.

(2) FS30/45/60/10X

Controller

Robot

Note* These are for Europe controller. Replace


8 with 9 and I/O24G with I/O24V for
non-Europe controller.

A-7

D Series Controller
Kawasaki Robot Installation and Connection Manual

Appendix2. Solenoid Valve


Wiring Diagram

(3) ZX/ZT

Controller

Note*

Robot

These are for Europe controller.


Replace 8 with 9 and I/O24G with
I/O24V for non-Europe controller.

(4) ZD

Controller

Note*

Robot

These are for Europe controller.


Replace 8 with 9 and I/O24G with
I/O24V for non-Europe controller.
A-8

D Series Controller
Kawasaki Robot Installation and Connection Manual

Appendix2. Solenoid Valve


Wiring Diagram

(5) MX/MD

Controller

Robot

Note*

These are for Europe controller.


Replace 8 with 9 and I/O24G with
I/O24V for non-Europe controller.

Function Diagram for Non-Europe Specification


I/O24V

I/O24V

SOL

I/O24G
1KP board
Function Diagram for Europe Specification
I/O24V

I/O24G

SOL

I/O24G

1KP board
[ NOTE ]
Be aware that solenoid driving conditions are different as shown above
between Non-Europe and Europe Specifications.

A-9

D Series Controller
Kawasaki Robot Installation and Connection Manual
Appendix 3.0 Sensor Wiring Diagram
(1) FS06/10/20 etc.

Controller
1KB board

1KX board

Robot

A-10

Appendix3. Sensor Wiring Diagram

D Series Controller
Kawasaki Robot Installation and Connection Manual
(2) FS30/45/60/10X

Controller
1KB board

1KX board

Robot

A-11

Appendix3. Sensor Wiring Diagram

D Series Controller
Kawasaki Robot Installation and Connection Manual

Appendix3. Sensor Wiring Diagram

(3) ZX/ZT

Controller
1KB board

1KX board

Robot
1GV board
1FG board

A-12

D Series Controller
Kawasaki Robot Installation and Connection Manual

Appendix3. Sensor Wiring Diagram

(4) ZD

Controller
1KB board

1KX board

Robot
1GV board
1FG board

A-13

D Series Controller
Kawasaki Robot Installation and Connection Manual

Appendix3. Sensor Wiring Diagram

(5) MX/MD

Controller
1KB board

1KX board

Robot
1GV board
1FG board

A-14

D Series Controller
Kawasaki Robot Installation and Connection Manual

Appendix3. Sensor Wiring Diagram

Function Diagram for Non-Europe Specification


For a proximity switch
Proximity switch

I/O24V* I/O24V
I/O24V

Photo coupler

SIG1-4

OUT

I/O24G
I/O24G
For a limit switch
I/O24V*
Photo coupler
Limit switch

I/O24G
1KB board
NOTE* Confirm that Dip Switch S10on the 1KB board is set to filled circle side for 24 V
supply. (See below.)

CAUTION

1. For various reasons the sensor cable may receive noise interference from the
axis motors, due to wiring of the cables inside the arm, the type of proximity
switch being used, etc. This noise may cause the robot to malfunction.
Take the following measures to reduce noise:
(1) Connect the sensor by wiring the cable outside the robot arm.
(2) Use a proximity switch specified for high noise resistance.
(3) Take the necessary noise counter-measures.
(Refer to Appendix 4.0 Protecting Sensor Line from Noise)
2. Use twisted pair shield cable when wiring the harness outside the robot arm.

A-15

D Series Controller
Kawasaki Robot Installation and Connection Manual

Appendix3. Sensor Wiring Diagram

Function Diagram for Europe Specification


For a proximity switch
Photo coupler

I/O24G* I/O24V
I/O24V
SIG1-4
I/O24G

Proximity switch

OUT

I/O24G
For a limit switch
Photo coupler

I/O24G* I/O24V
Limit switch

I/O24G
1KB board
NOTE* Confirm that Dip Switch S10on the 1KB board is set to non-filled circle side for
connection to I/O 24 ground. (See below.)

CAUTION

1. For various reasons the sensor cable may receive noise interference from the
axis motors, due to wiring of the cables inside the arm, the type of proximity
switch being used, etc. This noise may cause the robot to malfunction.
Take the following measures to reduce noise:
(1) Connect the sensor by wiring the cable outside the robot arm.
(2) Use a proximity switch specified for high noise resistance.
(3) Take the necessary noise counter-measures.
(Refer to Appendix 4.0 Protecting Sensor Line from Noise)
2. Use twisted pair shield cable when wiring the harness outside the robot arm.

A-16

D Series Controller
Kawasaki Robot Installation and Connection Manual

Appendix4. Protecting Sensor Line


from Noise

Appendix 4.0 Protecting Sensor Line from Noise


(1) Use a twisted pair shield cable for the sensor connection line. And, connect the shield jacket
with the appropriate FG terminal.
Make as short as possible.

Twisted pair line

Shield jacket

Earth the shield jacket directly


by the metal harness clamp, etc.

or

Make as short as possible.

Draw the shield jacket without patching via general electric wiring.
(Or, connect it with a similar wire mesh.) Fasten it to the controller
case with a screw. However, be sure to remove any insulating
material such as paints between the screw and casing/paneling when
fixing the shield jacket.

(2) Install the earth line between the noise source and AC power supply(0V side) with a capacitor.
AC sensor

AC power supply
Capacitor (Example; 0.22F, 630V)
Place the capacitor near the sensor to optimize the shielding. When possible, we recommend
pulling the sensor from the terminal board to reduce slack in the line.
(3) Put insulator between the sensor and installation table (metal). (Plastic, rubber, etc.)
Sensor

Insulator

Installation table (metal)

A-17

D Series Controller
Kawasaki Robot Installation and Connection Manual
MEMO

A-18

D Series Controller
Kawasaki Robot Installation and Connection Manual

INDEX
A
ambient temperature

J
jumper

2, 12

A-5, A-6

capacitor A-17
communication cable 19
control power switch 26
crimp-type terminal 27

limit switch

M
major axis motor harness 20, 22, 23
motor harness 19, 20, 21, 23

D
duct/conduit

19

N
noise filter

E
earthing 12
earth terminal 27
earth wire 4, 12, 25, 27
exhaust port 17

4, 25

P
photo coupler
power capacity

A-15, A-16
12, A-3

power cable size 4, 12


power source 12, 25
proximity switch A-4, A-15, A-16
PWM noise 19, 25

F
falling prevention belt 14
faston terminal A-1, A-2
FG terminal 19, A-17
function diagram A-9, A-15, A-16

R
relative humidity 2, 12
RS232C port 29, 32

G
general purpose input signal A-6
general purpose output signal A-5

S
sensor cable 19
signal harness 19, 20, 21, 22, 23

I
inlet port

A-4, A-15, A-16

17

I-1

D Series Controller
Kawasaki Robot Installation and Connection Manual

W
wrist axis motor harness
WX signal A-4

20, 22, 23

Numerical
1GW/1HW board 29, 31, A-5, A-6
1KA board 29, 32
1KB board 29, A-15, A-16
1KN board 29, 32
1KP board 29, 32, A-9

I-2

Kawasaki Robot Controller D Series


INSTALLATION AND CONNECTION MANUAL
September 2002 : 1st Edition
March 2004 : 2nd Edition
Publication : KAWASAKI HEAVY INDUSTRIES, LTD.
90202-1063DEB
All rights reserved. Copyright 2004 by KAWASAKI HEAVY INDUSTRIES, LTD.

Kawasaki Robotics
(UK) Limited

Kawasaki Robotics
(USA), Inc.

ki

R b i

Kawasaki Robotics GmbH


Kawasaki Machine
Systems Korea
Taiwan
Kawasaki

Kawasaki Robotics
San Jose Office

Kawasaki Heavy
Industries, LTD.
Tokyo Head Office

KAWASAKI HEAVY INDUSTRIES, LTD.


ROBOT DIVISION

Kawasaki Heavy
Industries, Ltd.

41, 2-Chome Hamamatsu-cho Minato-ku Tokyo,


105-6116 JAPAN(World Trade Center building)

TEL 81-(0)3-3435-250
FAX 81-(0)3-3437-988

Kawasaki Robotics
(USA), Inc.

28059 Center Oaks Court Wixom,


Michigan, 48393 U.S.A

TEL 1 - 2 4 8 - 3 0 5 - 7 6 1 0
FAX 1 - 2 4 8 - 3 0 5 - 7 6 1 8

Kawasaki Robotics
San Jose Office.

1020 Commercial Street, Suites 104-106


San Jose, CA95112 U.S.A

TEL 1 - 4 0 8 - 3 9 2 - 0 2 9 0
FAX 1 - 4 0 8 - 3 9 2 - 0 2 9 4

Kawasaki Robotics
GmbH

29 Sperberweg, 41468 Neuss, GERMANY

TEL 49-(0)2131-3426-0
FAX 49-(0)2131-3426-22

Kawasaki Robotics
(UK) Limited

Units 6&7, Easter Court, Europa Boulevard


Westbrook, Warrington, WA5 5ZB, England

TEL 44 -1925-71-3000
FAX 44 1925-71-3001

Kawasaki Machine
Systems Korea, Ltd

3Fl(307), Industrial Complex Support Bldg.,


637 Kojan-Don, Namdong-Gu, Inchon, 405-310 Korea

TEL 82-32-821-6941/5
FAX 8 2 - 3 2 - 8 2 1 - 6 9 4 7

Taiwan Kawasaki
Robot Center

1F 122 Ching Hsan 7 Street, Hsinchu,


Taiwan R.O.C.

TEL 8 8 6 - 3 - 6 6 6 - 1 5 5 8
FAX 8 8 6 - 3 - 6 6 6 - 1 5 5 9

Kawasaki Heavy
Industries, Akashi

1-1,

TEL 81-(0)78-921-1560
FAX 81-(0)78-923-6548

Kawasaki-cho Akashi, 673-8666 JAPAN

All descriptions in this booklet are subject to change for improvement without prior notice.