C Cont Electrical Mant.

COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY
Kawasak
C SERIES CONTROLLER
ELECTRICAL MAINTENANCE MANUAL
MPECCON118E-12
Kawasak
Kawasaki Robotics (USA), Inc.
This publication contains proprietary information of Kawasaki Robotics (USA), Inc. and
is furnished solely for customer use only. No other uses are authorized or permitted with-
out the express written permission of Kawasaki Robotics (USA), Inc. The contents of this
manual cannot be reproduced, nor transmitted by any means, e.g., mechanical, electri-
cal, photocopy, facsimile, or electronic data media, without the express written permis-
sion of Kawasaki Robotics (USA), Inc.
All Rights Reserved.
Copyright © 2007, Kawasaki Robotics (USA), Inc.

Wixom, Michigan 48393
The descriptions and specifications in this manual were in effect when it was submitted
for publishing. Kawasaki Robotics (USA), Inc. reserves the right to change or discon-
tinue specific robot models and associated hardware and software, designs, descrip-
tions, specifications, or performance parameters at any time and without notice, without
incurring any obligation whatsoever.
This manual presents information specific to the robot model listed on the title page of
this document. Before performing maintenance, operation, or programming procedures,
all personnel are recommended to attend an approved Kawasaki Robotics (USA), Inc.
training course.
KAWASAKI ROBOTICS (USA), INC. TRAINING
Training courses covering operation, programming, electrical maintenance, and me-

chanical maintenance are available from Kawasaki Robotics (USA), Inc. These courses
are conducted at our training facility in Wixom, Michigan, or on-site at the customer’s
location.
For additional information contact:

Training and Documentation Dept.
28140 Lakeview Drive
Wixom, Michigan 48393
Kawasak C SERIES CONTROLLER

INTRODUCTION
I.0 INTRODUCTION ............................................................................................ I-2

I.1 Mechanical Unit .............................................................................................. I-2
I.1.1 Mechanical Unit Design Specifications ........................................................... I-3
I.2 Robot Controller .............................................................................................. I-9
I.2.1 Robot Controller Design Specifications ........................................................ I-10
March 28, 2002 I-1


INTRODUCTION
I.0 INTRODUCTION
The C Series Controller Electrical Maintenance Manual is designed to assist the user
whose primary responsibility is to operate and troubleshoot Kawasaki robot systems on
a daily basis. This manual provides specific information on robot safety, power distribu-
tion, circuitry, user interfaces, servo system, zeroing, and error information.
I.1 MECHANICAL UNIT
The Kawasaki F-series, K-series, U-series and Z-series AC servo driven robots are
articulated coordinate-type robots, designed for many applications in the industrial
environment. The robot, with its AC servo closed-loop drive system, is built with high
rigidity. This design allows it to perform tasks that require high accuracy, speed, and
wrist load capacities. The robot achieves this, with significant energy reductions,
through the use of high efficiency brushless AC servo motors.
The mechanical unit has six or seven axes, depending upon the robot configuration.
Major axes:
• JT1 (R-axis) rotary; rotation of the base

• JT2 (O-axis) out and in; rotation of the lower arm
• JT3 (D-axis) down and up; rotation of the upper arm
Minor axes:
• JT4 (S-axis) swivel; sets orientation of JT5 for pitch/yaw motion

• JT5 (B-axis) bend; provides pitch/yaw wrist motion
• JT6 (T-axis) twist; provides rotation of the tool only
KE610 minor axes:
• JT4 (S-axis) swivel; sets orientation of JT5 for pitch/yaw motion

• JT5 (B-axis) swivel; provides pitch/yaw wrist motion
• JT6 (T-axis) swivel; provides rotation of the tool only
Auxiliary axis (optional):
• JT7 (V-axis) traverse; linear positioning of the mechanical unit
I-2 March 28, 2002


INTRODUCTION
The Kawasaki robot system supports Cartesian coordinate system motion, which in-
cludes Base (World) and Tool coordinate systems.
These coordinate systems are used when manually operating the robot in teach mode,
and with various program instructions for shifting program positional data, defining tool
center points, and recording positional data.
When describing Kawasaki robot systems, the left-hand rule is used to determine the
orientation of base and tool coordinate systems.
I.1.1 MECHANICAL UNIT DESIGN SPECIFICATIONS
Table I-1 provides design specifications for mechanical units that utilize C-series control-
lers.
March 28, 2002 I-3


INTRODUCTION
Table I-1 Robot Specifications
ROBOT MODEL FC06N FS06L FS06N FW06N FS10C FS10E FS10L
Number of Axes 6 (7)* 6 (7)* 6 (7)* 6 (7)* 6 (7)* 6 (7)* 6 (7)*
JT1 240°/sec 200°/sec 240°/sec 240°/sec 200°/sec 200°/sec 160°/sec

Maximum JT4 430°/sec 360°/sec 430°/sec 430°/sec 360°/sec 360°/sec 330°/sec
Velocity

1,200 mm/sec 1,200 mm/sec 1,200 mm/sec 1,200 mm/sec 1,200 mm/sec 1,200 mm/sec 1200 mm/sec
JT7
(47.24) (47.24) (47.24) (47.24) (47.24) (47.24) (47.24)
Maximum Linear 8,000 mm/sec 9,200 mm/sec 8,000 mm/sec 8,000 mm/sec 6,200 mm/sec 8,800 mm/sec 9,400 mm/sec
Tool Tip Speed (314.9) (362.2) (314.9) (314.9) (244) (346.4) (370)
JT1 ±160° ±160° ±160° ±160° ±160° ±160° ±160°
JT2 +140°/-105° +140°/-105° +140°/-105° +140°/-105° +140°/-105° +140°/-105° +140°/-105°
JT3 +295°/-225° +295°/-225° +295°/-225° +295°/-225° +295°/-225° +295°/-225° +295°/-225°

Work
Envelope JT4 ±270° ±270° ±270° ±270° ±270° ±270° ±270°
(Stroke)
JT5 ±145° ±145° ±145° ±145° ±145° ±145° ±145°
JT6 ±360° ±360° ±360° ±360° ±360° ±360° ±360°

Custom Custom Custom Custom Custom Custom Custom
JT7
Lengths Lengths Lengths Lengths Lengths Lengths Lengths
Max. Payload (lbs.) 6 (13) 6 (13) 6 (13) 6 (13) 10 (22) 10 (22) 10 (22)
21.5 N m 21.5 N m 21.5 N m
JT4 12 N m (8.8) 12 N m (8.8) 12 N m (8.8) 12 N m (8.8)
(15.8) (15.8) (15.8)
Wrist Rated
Torque 21.5 N m 21.5 N m 21.5 N m
JT5 12 N m (8.8) 12 N m (8.8) 12 N m (8.8) 12 N m (8.8)
(ft. lbs.) (15.8) (15.8) (15.8)
JT6 6 N m (4.4) 6 N m (4.4) 6 N m (4.4) 6 N m (4.4) 9.8 N m (7.2) 9.8 N m (7.2) 9.8 N m (7.2)
2 2 2 2 2 2
0.24 kg m s 0.24 kg m s 0.24 kg m s 0.24 kg m s 0.63 kg m s 0.63 kg m s 0.63 kg m s2
JT4
(1.72 ) (1.72 ) (1.72 ) (1.72 ) (4.56) (4.56) (4.56)
Wrist Rated
0.24 kg m s2 0.24 kg m s2 0.24 kg m s2 0.24 kg m s2 0.63 kg m s2 0.63 kg m s2 0.63 kg m s2
Moment of JT5
(1.72) (1.72) (1.72) (1.72) (4.56) (4.56) (4.56)
Inertia
JT6
(0.51) (0.51) (0.51) (0.51) (1.08 ) (1.08 ) (1.08 )
Repeatability (in.) ±0.05 (0.002) ±0.1 (0.004) ±0.05 (0.002) ±0.05 (0.002) ±0.05 (0.002) ±0.1 (0.004) ±0.1 (0.004)
JT1 1.0 kw (1.34) 1.0 kw (1.34) 1.0 kw (1.34) 1.0 kw (1.34) 1.0 kw (1.34) 1.0 kw (1.34) 2.1 kw (2.82)
JT3 475 w (0.64) 475 w (0.64) 475 w (0.64) 475 w (0.64) 475 w (0.64) 475 w (0.64) 1.0 kw (1.34)
Drive
JT4 100 w (0.13) 100 w (0.13) 100 w (0.13) 100 w (0.13) 100 w (0.13) 100 w (0.13) 200 w (0.27)
Source (hp)
JT5 100 w (0.13) 100 w (0.13) 100 w (0.13) 100 w (0.13) 100 w (0.13) 100 w (0.13) 200 w (0.27)
JT6 100 w (0.13) 100 w (0.13) 100 w (0.13) 100 w (0.13) 100 w (0.13) 100 w (0.13) 200 w (0.27)
Weight 6
110 kg (243) 125 kg (276) 110 kg (243) 110 kg (243) 110 kg (243) 120 kg (265) 220 kg (485)
(lbs.) Axes
I-4 March 28, 2002


INTRODUCTION
Table I-1 Robot Specifications (Continued)
ROBOT MODEL FS20C FS20N FS30L FS30N FS45C FS45N KE610 KF121
Number of Axes 6 (7)* 6 (7)* 6 (7)* 6 (7)* 6 (7)* 6 (7)* 6 (7)* 6 (7)*
JT1 160°/sec 160°/sec 160°/sec 160°/sec 160°/sec 160°/sec 145°/sec 220°/sec

Maximum JT4 330°/sec 330°/sec 240°/sec 240°/sec 240°/sec 240°/sec 420°/sec 430°/sec
Velocity

1200 mm/sec 1200 mm/sec 1200 mm/sec 1200 mm/sec 1200 mm/sec 1200 mm/sec 1,200 mm/sec 1,200 mm/sec
JT7
(47.24) (47.24) (47.24) (47.24) (47.24) (47.24) (47.24) (47.24)
Maximum Linear 6,900 mm/sec 8,500 mm/sec 11,100 mm/sec 8,900 mm/sec 8,900 mm/sec 9,700 mm/sec 2000 mm/sec 5000 mm/sec
Tool Tip Speed (271.6) (334.6) (437) (350.3) (350.3) (381.8) (78.74) (196.85)
JT1 ±160° ±160° ±160° ±160° ±160° ±160° ±90° ±320°
JT2 +140°/-105° +140°/-105° +140°/-105° +140°/-105° +140°/-105° +140°/-105° +60°/-110° ±180°
JT3 +295°/-225° +295°/-225° +295°/-225° +295°/-225° +295°/-225° +295°/-225° +90°/-80° ±480°

Work
Envelope JT4 ±270° ±270° ±270° ±270° ±270° ±270° ±720° ±540°
(Stroke)
JT5 ±145° ±145° ±130° ±130° ±130° ±130° ±720° ±290°
JT6 ±360° ±360° ±360° ±360° ±360° ±360° ±210° ±720°

Custom Custom Custom Custom Custom Custom Standard Standard
JT7
Lengths Lengths Lengths Lengths Lengths Lengths 3000 mm 3000 mm
Max. Payload
20 (44) 20 (44) 30 (66) 30 (66) 45 (99) 45 (99) 15 (33) 5 (11)
(lbs.)
39.3 N m 39.3 N m 176.4 N m 176.4 N m 176.4 N m 176.4 N m 69.9 Nm
JT4 7.8 Nm (5.75)
Wrist (28.9) (28.9) (130.1) (130.1) (130.1) (130.1) (51.55)
Rated 39.3 N m 39.3 N m 176.4 N m 176.4 N m 176.4 N m 176.4 N m 50.3 Nm
JT5 7.8 Nm (5.75)
Torque (28.9) (28.9) (130.1) (130.1) (130.1) (130.1) (37.1)
(ft. lbs.) 19.6 N m 19.6 N m 98.0 N m 98.0 N m 98.0 N m 98.0 N m 18.4 Nm
JT6 2.9 Nm (2.14)
(14.4) (14.4) (72.2) (72.2) (72.2) (72.2) (13.57)
2 2 2 2 2 2
0.88 kg m s 0.88 kg m s 7.2 kg m s 7.2 kg m s 10.8 kg m s 10.8 kg m s 3.40 kg m s 2
.058 kg m s2
JT4
Wrist (6.37) (6.37) (52.08) (52.08) (78.12) (78.12) (24.58 ) (0.42 )
Rated 0.88 kg m s2 0.88 kg m s2 7.2 kg m s2 7.2 kg m s2 10.8 kg m s2 10.8 kg m s2 1.94 kg m s2 .058 kg m s2
JT5
Moment of (6.37) (6.37) (52.08) (52.08) (78.12) (78.12) (14.03) (0.42)
Inertia 0.25 kg m s2 0.25 kg m s2 3.3 kg m s2 3.3 kg m s2 5.0 kg m s2 5.0 kg m s2 0.30 kg m s2 .058 kg m s2
JT6
(1.81 ) (1.81 ) (23.87 ) (23.87 ) (36.17 ) (36.17 ) (2.2) (0.42)
Repeatability (in.) ±0.1 (0.004) ±0.1 (0.004) ±0.15 (0.006) ±0.15 (0.006) ±0.15 (0.006) ±0.15 (0.006) ±1.0 (0.04) ±0.2 (0.008)
JT1 2.1 kw (2.82) 2.1 kw (2.82) 4.2 kw (5.63) 4.2 kw (5.63) 4.2 kw (5.63) 4.2 kw (5.63) 5.6 kw (7.5) 1 kw (1.4)
JT2 2.1 kw (2.52) 2.1 kw (2.82) 4.2 kw (5.63) 4.2 kw (5.63) 4.2 kw (5.63) 4.2 kw (5.63) 5.6 kw (7.5) 1 kw (1.4)
JT3 1.0 kw (1.34) 1.0 kw (1.34) 3.1 kw (4.16) 3.1 kw (4.16) 3.1 kw (4.16) 3.1 kw (4.16) 3 kw (4) 0.4 kw (.54)
Drive
JT4 200 w (0.27) 200 w (0.27) 475 w (0.64) 475 w (0.64) 475 w (0.64) 475 w (0.64) 0.75 kw (1) 0.1 kw (.54)
Source (hp)
JT5 200 w (0.27) 200 w (0.27) 475 w (0.64) 475 w (0.64) 475 w (0.64) 475 w (0.64) 0.75 kw (1) 0.1 kw (.54)
JT6 200 w (0.27) 200 w (0.27) 475 w (0.64) 475 w (0.64) 475 w (0.64) 475 w (0.64) 0.75 kw (1) 0.1 kw (.54)
JT7 2.5 kw (3.35) 2.5 kw (3.35) 2.5 kw (3.35) 2.5 kw (3.35) 2.5 kw (3.35) 2.5 kw (3.35) 0.75 kw (1) 0.1 kw (.54)
Weight 6
205 kg (452) 210 kg (463) 580 kg (1279) 540 kg (1191) 540 kg (1191) 550 kg (1213) 810 kg (1782) 130 kg (286)
(lbs.) Axes
March 28, 2002 I-5


INTRODUCTION
ROBOT MODEL UT100 UT120 UT150 UX70 UX100 UX120 UX150 UX200
Number of Axes 6 (7)* 6 (7)* 6 (7)* 6 (7)* 6 (7)* 6 (7)* 6 (7)* 6 (7)*

Velocity

1000 mm/sec 1000 mm/sec 1000 mm/sec 1000 mm/sec 1000 mm/sec 1000 mm/sec 1000 mm/sec 1000 mm/sec
JT7
(39.37) (39.37) (39.37) (39.37) (39.37) (39.37) (39.37) (39.37)
Maximum Linear 2400 mm/sec 2400 mm/sec 2400 mm/sec 2400 mm/sec 2400 mm/sec 2400 mm/sec 2400 mm/sec 2400 mm/sec
Tool Tip Speed (94.49) (94.49) (94.49) (94.49) (94.49) (94.49) (94.49) (94.49)
JT1 ±180° ±180° ±180° ±180° ±180° ±180° ±180° ±180°
JT2 +55°/-80° +55°/-80° +55°/-80° +70°/-65° +70°/-65° +70°/-65° +70°/-65° +70°/-65°
JT3 +95°/-105° +95°/-105° +95°/-105° +90°/-119° +90°/-119° +90°/-119° +90°/-119° +90°/-119°

Work
Envelope JT4 ±280° ±280° ±280° ±280° ±280° ±280° ±280° ±280°
(Stroke)
JT5 ±125° ±125° ±125° ±125° ±125° ±125° ±125° ±125°
JT6 ±360° ±360° ±360° ±360° ±360° ±360° ±360° ±360°

Custom Custom Custom Custom Custom Custom Custom Custom
JT7
Lengths Lengths Lengths Lengths Lengths Lengths Lengths Lengths
Max. Payload
100 (220) 120 (264) 150 (330) 70 (154) 100 (220) 120 (264) 150 (330) 200 (440)
(lbs.)
539 N m 686 N m 833 N m 490 N m 539 N m 686 N m 833 N m 1176 N m
JT4
Wrist (398) (506) (615) (362) (398) (506) (615) (868)
Rated 539 N m 686 N m 833 N m 490 N m 539 N m 686 N m 833 N m 1176 N m
JT5
Torque (398) (506) (615) (362) (398) (506) (615) (868)
(ft. lbs.) 343 N m 392 N m 441 N m 294 N m 343 N m 392 N m 441 N m 686 N m
JT6
(253) (289) (325) (217) (253) (289) (325) (506)
4.0 kg m s2 5.0 kg m s2 7.3 kg m s2 5.0 kg m s2 4.0 kg m s2 5.0 kg m s2 7.3 kg m s2 12.7 kg m s2
JT4
Wrist (28.92) (36.15) (52.78) (36.15) (28.92) (36.15) (52.78) (91.82)
Rated 4.5 kg m s2 5.5 kg m s2 7.3 kg m s2 5.5 kg m s2 4.5 kg m s2 5.5 kg m s2 7.3 kg m s2 12.7 kg m s2
JT5
Moment of (32.54) (39.77) (52.78) (39.77) (32.54) (39.77) (52.78) (91.82)
Inertia 2.5 kg m s2 2.8 kg m s2 3.2 kg m s2 2.8 kg m s2 2.5 kg m s2 2.8 kg m s2 3.2 kg m s2 7.9 kg m s2
JT6
(18.08) (20.24) (23.14) (20.24) (18.08) (20.24) (23.14) (57.12)
±0.5mm ±0.5mm ±0.5mm ±0.5mm ±0.5mm ±0.5mm ±0.5mm ±0.5mm
Repeatability (in.)
(0.20) (0.20) (0.20) (0.20) (0.20) (0.20) (0.20) (0.20)
JT1 5.0 kw (6.7) 5.0 kw (6.7) 5.0 kw (6.7) 5.0 kw (6.7) 5.0 kw (6.7) 5.0 kw (6.7) 5.0 kw (6.7) 5.0 kw (6.7)
Drive
Source (hp)
Weight 6 1500 kg 1500 kg 1500 kg 1430 kg 1400 kg 1400 kg 1500 kg 1550 kg
(lbs.) Axes (3300) (3300) (3300) (3150) (3080) (3080) (3300) (3410)
I-6 March 28, 2002


INTRODUCTION
ROBOT MODEL UX300 UZ100 UZ120 UZ150 ZT130S ZT130U ZT165U
Number of Axes 6 (7)* 6 (7)* 6 (7)* 6 (7)* 6 (7)* 6 (7)* 6 (7)*

Maximum JT4 80°/sec 150°/sec 150°/sec 125°/sec 180°/sec 140°/sec 135°/sec
Velocity

1000 mm/sec 1000 mm/sec 1000 mm/sec 1000 mm/sec 1000 mm/sec 1000 mm/sec 1000 mm/sec
JT7
(39.37) (39.37) (39.37) (39.37) (39.37) (39.37) (39.37)
Maximum Linear 2400 mm/sec 2400 mm/sec 2400 mm/sec 2400 mm/sec 2500 mm/sec 2500 mm/sec 2500 mm/sec
Tool Tip Speed (94.49) (94.49) (94.49) (94.49) (98.42) (98.42) (98.42)
JT1 ±180° ±180° ±180° ±180° ±180° ±180° ±180°
JT2 +70°/-60° +70°/-75° +70°/-75° +70°/-75° +60°/-75° +60°/-75° +60°/-75°
JT3 +90°/-126° +283°/-105° +283°/-105° +283°/-105° +165°/-95° +165°/-95° +165°/-95°

Work
Envelope JT4 ±280° ±280° ±280° ±280° ±360° ±360° ±360°
(Stroke)
JT5 ±120° ±125° ±125° ±125° ±130° ±130° ±130°
JT6 ±360° ±360° ±360° ±360° ±360° ±360° ±360°

Custom Custom Custom Custom Custom Custom Custom
JT7 Lengths Lengths Lengths Lengths Lengths Lengths Lengths
Max. Payload (lbs.) 300 (660) 100 (220) 120 (264) 150 (330) 130 (286.6) 130 (286.6) 130 (286.6)
1626 N m 911.4 N m
JT4 539 N m (398) 686 N m (506) 833 N m (615) 735 N m (542) 735 N m (542)
(1201) (672.2)
Wrist Rated
1626 N m 911.4 N m
Torque JT5 539 N m (398) 686 N m (506) 833 N m (615) 735 N m (542) 735 N m (542)
(1201) (672.2)
(ft. lbs.)
421.4 N m 421.4 N m 450.8 N m
JT6 715 N m (528) 343 N m (253) 392 N m (289) 441 N m (325)
(310.8) (310.8) (332.5)
13.7 kg m s2 5.2 kg m s2 6.3 kg m s2 7.3 kg m s2 5.3 kg m s2 5.3 kg m s2 8 kg m s2
JT4
(99.05) (37.56) (45.55) (52.78) (38.3) (38.3) (57.38)
Wrist Rated
13.7 kg m s2 5.2 kg m s2 6.3 kg m s2 7.3 kg m s2 5.3 kg m s2 5.3 kg m s2 8 kg m s2
Moment of JT5
(99.05) (37.56) (45.55) (52.78) (38.3) (38.3) (57.8)
Inertia
JT6
(53.50) (20.24) (21.69) (23.14) (20.2) (20.2) (29.6)
Repeatability (in.) ±0.5mm (0.20) ±0.3mm (0.12) ±0.3mm (0.12) ±0.3mm (0.12) ±0.3mm (0.12) ±0.3mm (0.12) ±0.3mm (0.12)
Drive
Source (hp)
Weight 6 1700 kg 1400 kg 1400 kg 1400 kg 1750 kg 1750 kg 1750 kg
(lbs.) Axes (3740) (3080) (3080) (3080) (3850) (3850) (3850)
March 28, 2002 I-7


INTRODUCTION
ROBOT MODEL ZT200S ZX130L ZX130S ZX130U ZX165U ZX200S ZX200U ZX200W
Number of Axes 6 (7)* 6 (7)* 6 (7)* 6 (7)* 6 (7)* 6 (7)* 6 (7)* 6 (7)*

Velocity

1000 mm/sec 1000 mm/sec 1000 mm/sec 1000 mm/sec 1000 mm/sec 1000 mm/sec 1000 mm/sec 1000 mm/sec
JT7
(39.37) (39.37) (39.37) (39.37) (39.37) (39.37) (39.37) (39.37)
Maximum Linear 2500 mm/sec 2500 mm/sec 2500 mm/sec 2500 mm/sec 2500 mm/sec 2500 mm/sec 2500 mm/sec 2500 mm/sec
Tool Tip Speed (98.42) (98.42) (98.42) (98.42) (98.42) (98.42) (98.42) (98.42)
JT1 ±180° ±180° ±180° ±180° ±180° ±180° ±180° ±180°
JT2 +60°/-75° +70°/-60° +75°/-60° +75°/-60° +75°/-60° +75°/-60° +75°/-60° +75°/-60°
JT3 +165°/-95° +250°/-120° +250°/-120° +250°/-120° +250°/-120° +250°/-120° +250°/-120° +250°/-120°

Work
Envelope JT4 ±360° ±360° ±360° ±360° ±360° ±360° ±360° ±360°
(Stroke)
JT5 ±120° ±130° ±130° ±130° ±130° ±120° ±130° ±130°
JT6 ±360° ±360° ±360° ±360° ±360° ±360° ±360° ±360°

Custom Custom Custom Custom Custom Custom Custom Custom
JT7
Lengths Lengths Lengths Lengths Lengths Lengths Lengths Lengths
130 kg 130 kg 130 kg 165 kg 200 kg 200 kg 200 kg
Max. Payload (lbs.) 200 (440)
(286.6) (286.6) (286.6) (286.6) (440) (440) (440)
1274 N m 735 N m 735 N m 735 N m 911.4 N m 1274 N m 980 N m 1274 N m
JT4
(939.6) (542) (542) (542) (672.2) (939.5) (722.7) (939.6)
Wrist Rated
1274 N m 735 N m 735 N m 735 N m 911.4 N m 1274 N m 980 N m 1274 N m
Torque JT5
(939.6) (542) (542) (542) (672.2) (939.5) (722.7) (939.6)
(ft. lbs.)
686 N m 421.4 N m 421.4 N m 421.4 N m 450.8 N m 686 N m 490 N m 686 N m
JT6
(505.9) (310.8) (310.8) (310.8) (332.5) (505.9) (361.4) (505.9)
12 kg m s2 5.3 kg m s2 5.3 kg m s2 5.3 kg m s2 8 kg m s2 12 kg m s2 9.5 kg m s2 12 kg m s2
JT4
(86.8) (38.3) (38.3) (38.3) (57.38) (86.8) (68.7) (86.8)
Wrist Rated
12 kg m s2 5.3 kg m s2 5.3 kg m s2 5.3 kg m s2 8 kg m s2 12 kg m s2 9.5 kg m s2 12 kg m s2
Moment of JT5
(86.8) (38.3) (38.3) (38.3) (57.38) (86.8) (68.7) (86.8)
Inertia
6.5 kg m s2 2.8 kg m s2 2.8 kg m s2 2.8 kg m s2 4.1 kg m s2 6.5 kg m s2 4.2 kg m s2 6.5 kg m s2
JT6
(47) (20.2) (20.2) (20.2) (29.6) (47) (30.4) (47)
±0.3 mm ±0.3 mm ±0.3 mm ±0.3 mm ±0.3 mm ±0.3 mm ±0.3 mm
Repeatability (in.) ±0.3mm (0.12)
(0.12) (0.12) (0.12) (0.12) (0.12) (0.12) (0.12)
Drive
Source (hp)
JT7 2.5 kw (3.35) 2.5 kw (3.35) 2.5 kw (3.35 2.5 kw (3.35 2.5 kw (3.35 2.5 kw (3.35) 2.5 kw (3.35 2.5 kw (3.35
Weight 6 1800 kg 1550 kg 1500 kg 1500 kg 1500 kg 1550 kg 1700 kg 1750 kg
(lbs.) Axes (3960) (3410) (3300) (3300) (3300) (3410) (3740) (3850)
I-8 March 28, 2002


INTRODUCTION
I.2 ROBOT CONTROLLER
The controller model used, depends on the type of mechanical unit. Table I-2 lists the
controller model (Cxx) used for each robot model. The Kawasaki C controller consists of
the following major components:
• Primary power cable

• Main disconnect
• Transformer
• Card rack with AVR power supply and printed circuit boards
• Power distribution relay chassis
• Servo amplifiers
• Operator interface—multi function panel (MFP), type 2 teach pendant (TP), explo-
sion-proof (EP) type TP, or small teach pendant
• Operation panel
• Optional interface panel
• Explosion proof unit (EP type C controller only)
• Separate harnesses—connect the C controller to the mechanical unit
Table I-2 Controller Models
Controller Model Controller Model

Robot Model (N. American Spec.) Robot Model (N. American Spec.)
FS02N C7 0 FS30L C31
FS03N C7 0 FS30N C31
FA06E C30 FS45C C31
FA06L C3 0 FS45N C31
FA06N C30 FW06N C31
FA20N C30 KE610 C35
FC06N C30 KF121 C37
FS06L C30 UT/UX/UZ100–150 C32
FS06N C30 UX200–300 C32
FS10C C30 ZT/ZX130 C32
FS10E C3 0 ZT/ZX165 C32
FS10L C3 0 ZT/ZX200 C32
FS20C C3 0 ZT/ZX300 C32
FS20N C30
March 28, 2002 I-9


INTRODUCTION
I.2.1 ROBOT CONTROLLER DESIGN SPECIFICATIONS
Control System: 32 bit RISC main CPU

32 bit RISC CPU for MFP or type 2 TP
32 bit RISC servo CPU controller (one per 3 axes)
Software controlled AC servo drive system using pulse width modu-
lation (PWM) circuitry.
Number of Axes: 6 standard, 7th optional
Motion Control: Teach mode— Joint

Base
Tool
Repeat mode— Joint move

Linear move
Circular move (optional)
FLIN move (optional)
Memory: CMOS RAM
Memory Capacity: Standard—1024 KB (approx. 4,000 steps)

Optional—4096 KB (approx. 34,000 steps)
Accuracy: Four levels of accuracy for block step programs
F-series
Adjustable between 0.05 mm – 5,000 mm
KE610
KF121
UT/UX/-series and KE610

UZ-series
Z-series
I-10 March 28, 2002


INTRODUCTION
Speed: 10 levels of speed for block step programs

(adjustable between 10% - 100%)
Data Editing: Step insertion, deletion, copying and pasting; and

rewriting of auxiliary and positional data.
Software Features: Continuous path motion control - CP ON/OFF

Time delays
Coordinate modification
Process control programs (3)
Peripheral equipment control
Interrupt signal control
Error interrupt control
Input of real, string, and integer variables
Local variables
Subroutine calls with arguments (maximum stack = 20)
Program weld schedules
Servo shutdown timer
Auto start function
I/O Signals: Robot internal 256 (1GA/1HA board)
1GW I/O board(s) 1 standard, 4 maximum (option);

32 inputs/32 outputs per board
(inc. dedicated signals)
1FS RI/O board 1 maximum (option)
Robot I/O 256 I/O (inc. dedicated signals)

A-B PLC 64 I/O
Weld controller 32 I/O
Non-retentive 128
Retentive 16
Timers 16
Counters 16
Message display 64
Slogic status 16
ControlNet (option)
March 28, 2002 I-11


INTRODUCTION
Dedicated Output Signals: Motor power ON

Error occurrence
Automatic
CYCLE_START
Teach mode
HOME1
HOME2
Power ON
RGSO
External program select (RPS) enabled
Dedicated Input Signals: External Motor Power ON

External error reset
External cycle start
External program select start (JUMP)
JUMP_ON
JUMP_OFF
JUMP_ST
External program select start (RPS)
RPS_ON
RPS_ST
Number of RPS code signal
First signal number of RPS code
Program reset
External Hold (EXT_IT)
External condition wait (EXT_WAIT)
External slow repeat mode
Error Messages: Error code messages, self-diagnosis, error logging,

operation logging
Special Features: Program check mode

Adjustable hard stops - F-series JT1, JT2, JT3
U- and Z-series JT1
Terminal box on robot arm (optional)
Robot application interface panel (optional)
Overtravel limit switch - JT1 (JT2, JT3 option)
Power lockout
Ethernet (option)
I-12 March 28, 2002


INTRODUCTION
Multi Function Panel: Two-position enabling devices

18 cm (7.2 in) color LCD/touch panel
Teach lock switch
Emergency stop switch
Pen for touch panel
PC card insertion section
Type 2 Teach Pendant: Three-position enabling devices

18 cm (7.2 in) color LCD/touch panel
Teach lock switch
Soft key keypad
Pen for touch panel
PC card insertion section
Explosion-Proof Teach Pendant: LCD display

Membrane switch panel
Three-position enabling devices
Teach lock function
Small Teach Pendant (option): Two-position enabling devices

Teach lock switch
Membrane switch keypad
Alphanumeric LCD
Supplemental Data Storage: PC Flash RAM Memory Card, PCMCIA 2.1 Slot
Floppy disk drive (option)
Personal computer (option)
March 28, 2002 I-13


INTRODUCTION
Power Requirements: Standard Spec.: 3-phase 200/220 VAC
N. American Spec.: 3-phase 400/440/460/480/515/575 VAC
European Spec.: 3-phase 380/400/415/440/460/480 VAC
Tolerance: ± 10%
Frequency: 50/60 Hz
Rated Load: 10.5 kVA
Ground: Less than 100 Ω ground line, separated

from welder power ground
Dimensions: N. American Spec.: WxDxH: 550 mm x 500 mm x 1150 mm

(inches: 21.7 x 19.7 x 45.3)
EP Type, N. American Spec.: WxDxH, 850 mm x 500 mm x

1150 mm (inches: 33.5 x 19.7 x 45.3)
Weight: N. American Spec.: 250 kg (550 lb)
EP Type, N. American Spec.: 280 kg (616 lb)
I-14 March 28, 2002


OVERVIEW
1.0 OVERVIEW .................................................................................................... 1-2

1.1 Major Features of the Robot System ............................................................. 1-2
1.2 Major Components of the Robot System ....................................................... 1-3
1.3 User Interface Devices ................................................................................... 1-7
1.3.1 Multi Function Panel ...................................................................................... 1-8
1.3.2 Type 2 Teach Pendant .................................................................................. 1-10
1.3.3 EP Teach Pendant ....................................................................................... 1-12
1.3.4 Flash RAM PC Card .................................................................................... 1-13
1.3.5 Small Teach Pendant ................................................................................... 1-13
1.3.6 Operation Panel ........................................................................................... 1-14
1.3.7 Personal Computer ...................................................................................... 1-16
1.3.8 Optional Interface Panels ............................................................................. 1-16
1.3.9 Software Interface Panel .............................................................................. 1-17
1.3.10 Floppy Disk Drive Unit.................................................................................. 1-17
1.4 Printed Circuit Board Overview .................................................................... 1-18
1.4.1 1HZ Motherboard ......................................................................................... 1-20
1.4.2 1GA/1HA Main CPU .................................................................................... 1-20
1.4.3 1GS Serial Interface..................................................................................... 1-21
1.4.4 1GW Parallel I/O and Analog Output ........................................................... 1-21
1.4.5 1FS Remote I/O and ControlNet .................................................................. 1-21
1.4.6 1HS Remote I/O and CC-Link...................................................................... 1-21
1.4.7 1HP Power Circuit Control ........................................................................... 1-21
1.4.8 1HY Relay Board ......................................................................................... 1-22
1.4.9 1GB Servo CPU ........................................................................................... 1-22
1.4.10 1GM Current Sensor Interface ..................................................................... 1-22
1.4.11 1GC/1GD/1JK Power Block ......................................................................... 1-22
1.4.12 1LU Explosion-Proof Barrier ........................................................................ 1-23
1.4.13 1LW Encoder Barrier.................................................................................... 1-23
1.4.14 1LT E-Stop and Enabling Device Distribution .............................................. 1-23
1.4.15 ZEBA Teach Pendant Barrier ....................................................................... 1-24
1.5 C Series Controller Digital Servo Control Overview ..................................... 1-25
1.6 Mechanical Unit Overview ........................................................................... 1-28
March 28, 2002 1-1


OVERVIEW
1.0 OVERVIEW
1.1 MAJOR FEATURES OF THE ROBOT SYSTEM
The Kawasaki F-series, K-series, U-series, and Z-series robot systems consist of a
mechanical unit, controller, controller software, and supporting peripheral equipment.
The following major features are supported by the C controller:
• Joint coordinate movement
• Linear movement in base and tool coordinate systems
• Fixed linear interpolation (FLIN) movement (optional)
• Circular movement (optional)
• Block step programming
• AS Language programming
• User friendly menu system for programming and system configuration
• Multi-tasking with the capability to run three Process Control programs
• Error message display, self diagnosis
• Error and operation logging
• Digital input and output interface
• PC programming
• Remote I/O with Slogic programming or ControlNet, Ethernet compatible (option)
• Bilingual menus
• Program editing, storage, and monitoring via personal computer
• Software controlled AC servo drive system and excellent mechanical unit design
provide accurate, repeatable, high speed program playback.
• High mechanical unit efficiency and smooth arm movement are achieved through
the use of close tolerance bearings, gears, and speed reducers.
1-2 March 28, 2002


OVERVIEW
The robot system, with the appropriate tooling and communication interfaces, is capable
of performing many tasks in the industrial environment including material handling, spot
welding, arc welding, sealing, spray painting, and palletizing.
1.2 MAJOR COMPONENTS OF THE ROBOT SYSTEM
The two major components of the robot system are the controller and mechanical unit.
The various versions of the C controller are illustrated in figure 1-1:
• Original production with multi function panel (MFP)
• New production with type 2 teach pendant (TP)
• Explosion-proof (EP) type with MFP and EP type TP
The F-series, K-series, U-series, and Z-series mechanical units are illustrated in figures
1-2 through 1-5.
Original Production New Production EP Type Controller

Controller w/MFP Controller w/Type 2 TP w/EP TP and MFP
ON OFF
T.LOCK
ON OFF
ENA SHIFT SPEED CNT
TEACH LOCK
1 4
— —
X Rx
2 5
— —
Y Ry CHECK
3 6
— —
Z Rz
CL1 CL2
REC
EMERGENCY STOP
ERROR MOTOR POWER

ERROR MOTOR POWER
ERROR RESET CYCLE START

TEACH REPEAT HOLD RUN
HOST
MFP
AC115V 1A
X1
CONTROL POWER
Figure 1-1 North American C Controllers
March 28, 2002 1-3


OVERVIEW
Figure 1-2 F-Series Mechanical Units
Figure 1-3 K-Series Mechanical Units
1-4 March 28, 2002


OVERVIEW
UX Series
UT Series
UZ Series
Figure 1-4 UX, UT, and UZ Series Mechanical Units
March 28, 2002 1-5


OVERVIEW
ZX Series
ZT Series
ZD Series
Figure 1-5 ZX, ZT, and ZD Series Mechanical Units
1-6 March 28, 2002


OVERVIEW
1.3 USER INTERFACE DEVICES
The user interface devices include the following:
• Multi function panel (MFP) or type 2 teach pendant (TP)
• Explosion-proof (EP) type TP (EP type C controller only)
• Optional small teach pendant
• PC (personal computer) card
• Optional floppy disk drive
• Operation panel
• Personal computer using KCMON or KCWIN monitor software (option)
• Optional interface panel
• Optional MFP or type 2 TP software interface panel
March 28, 2002 1-7


OVERVIEW
1.3.1 MULTI FUNCTION PANEL
The multi function panel (MFP), shown in figure 1-6, is equipped with the following:
• Backlit 18 cm (7.2 in) color liquid crystal display (LCD)/touch panel
• Emergency stop switch
• TEACH LOCK switch
• Two 2-position enabling devices (left and right)
• Contrast adjustment control
• Flash random access memory (RAM) PC card slot
To 1FT Board CN1
TEACH LOCK Switch

Emergency Stop Switch
ON OFF
Enabling Device Enabling Device
TEACH LOCK
LCD/Touch Panel
Touch Panel Pen
Contrast Adjustment
PC Card Slot (JM8)
Figure 1-6 Multi Function Panel
1-8 March 28, 2002


OVERVIEW
All robot functions are accessible through the MFP (original production controllers only,
not EP type controllers), including system configuration, teaching, and program editing.
Program and robot data upload/downloads and system software downloads are accom-
plished using a flash random access memory (RAM) PC card; the PC card is inserted
into the MFP PC card slot (Figure 1-6).
For the EP type controller, the MFP does not include emergency stop or TEACH LOCK
switches, or enabling devices; these functions are located on the EP type TP. The EP
type MFP is used for entering and editing data and performing check operations.
March 28, 2002 1-9


OVERVIEW
1.3.2 TYPE 2 TEACH PENDANT
The type 2 teach pendant (TP), shown in figures 1-7 and 1-8, is equipped with the
following:
• T.LOCK (teach lock) switch
• Brightness adjustment control
• Soft key keypad with LED indicators
A VIEW A B
Emergency Stop
Switch
ON OFF
Teach Lock Switch

T.LOCK
Brightness
Liquid Crystal Control
Display/
Touch Panel
PC Card Slot
Coordinate Check
System Mode
Key Key
Enable Key ENA SHIFT SPEED CNT
1 4
— —
X Rx
5
Axis Keys 2
—
Y
—
Ry CHECK
Check Keys
3
—
6
—
Enabling
Z Rz
Device
Interface Panel Key CL1 CL2

Clamp Keys
REC
Record Key
Figure 1-7 Type 2 Teach Pendant (Front/Side Views)
1-10 March 28, 2002


OVERVIEW
VIEW B
A
PC Card Slot
3-Position 3-Position
Figure 1-8 Type 2 Teach Pendant (Rear View)
All robot functions are accessible through the type 2 TP, including system configuration,
teaching, and program editing. Program and robot data upload/downloads and system
software downloads are accomplished using a flash random access memory (RAM) PC
card; the PC card is inserted into the type 2 TP PC card slot (Figures 1-7 and 1-8).
March 28, 2002 1-11


OVERVIEW
1.3.3 EP TEACH PENDANT
The explosion-proof (EP) teach pendant (TP)(Figure 1-9) is equipped with the following:
• Backlit 34 × 127 character (64 × 240 dpi), black and white,

liquid crystal display (LCD)
• Emergency stop (E-stop) switch
Liquid
Crystal
Display
0 SPEED 1 SPRAY 2X=OUT 3X=IN 4 SMOTH
. A GUN B TABLE CSENS
5 DATA 6 TIMER 7 CALL 8 JUMP 9 CONVR
- D E MOVE F
SHIFT CLR END SUSPND SET

Keypad
SWING BEND TURN
RT FRNT UP
RT FRNT UP
SWING BEND TURN
LFT BCK DWN LFT BCK DWN
SERVO ROB TBL

H L
STORE
3-Position
ROB TRV C
Enabling Devices
M POS
TBL L J
RMT MOTION
FRAME EQPMT SPEED
CRCT
SPRAY TEACH STEP

ON/OFF LOCK NEXT
STEP
RESET SPRAY STEP BACK
1/2
Emergency Stop
Switch
Front View Rear View
Figure 1-9 Explosion-Proof Teach Pendant
The EP TP is equipped with keys for manual robot operation, teaching programs, and
entering and editing data.
1-12 March 28, 2002


OVERVIEW
1.3.4 FLASH RAM PC CARD
A flash RAM PC card is used to upload/download programs and system configuration

data, and install new AS, MFP or type 2 TP, and servo system software.
For a backup copy of data, download the contents of the PC card onto a PC floppy disk
or hard disk.
1.3.5 SMALL TEACH PENDANT
The small teach pendant (Figure 1-10) provides basic teaching and manual operation
capabilities. Program editing and system configuration are not accessible through the
small teach pendant.
EMERGENCY
STOP Switch
TEACH/LOCK Switch
Liquid Kawasak
Crystal
Display
ARM
WRIST
2Y
3Z
1
X
1
X
Two-Position
3Z 2Y
TRG TRG
Enabling Devices
W A
J
REC B
T JOG
Jog Key
CL3 CL4
RST S CHK
CL1 CL2
Figure 1-10 Small Teach Pendant
March 28, 2002 1-13


OVERVIEW
1.3.6 OPERATION PANEL
The operation panel (Figures 1-11 and 1-12) has switches that allow the operator to
perform the following functions:
• Apply motor power
• Cycle start programs
• Hold or stop programs
• Select teach or repeat operation modes
• Reset errors
An ERROR lamp is also included on the operation panel. An hour meter and control
power lamp are located on the left side of the controller, to the left of the controller door.
EMERGENCY STOP
ERROR MOTOR POWER
X2
AC115V 1A
Figure 1-11 Operation Panel
1-14 March 28, 2002


OVERVIEW
MOTOR
ERROR
POWER
ERROR CYCLE
RESET START
REMOTE LOCAL X2
Figure 1-12 Operation Panel, EP Type C Controller
March 28, 2002 1-15


OVERVIEW
1.3.7 PERSONAL COMPUTER
A PC can be connected to the C controller for program upload/download and editing,

and system monitoring. The PC requires the Kawasaki KCMON or KCWIN interface
software to communicate with the robot controller.
1.3.8 OPTIONAL INTERFACE PANELS
Optional interface panels (Figure 1-13) interface with peripheral equipment that is con-
nected to the robot. Interface panels are located on the robot controller door and are
available in many configurations, including custom designs to suit specific applications.
Figure 1-13 Optional Interface Panel (Spot Welding)
1-16 March 28, 2002


OVERVIEW
1.3.9 SOFTWARE INTERFACE PANEL
The optional software interface panel (Figure 1-14) is programmed and displayed using
the MFP or type 2 TP. The software interface panel allows the operator to set up the
C Controller to peripheral automated equipment interfaces.
INTERFACE PANEL (1/2)

AUTO MANU OFF LINE ENABLE
OFF AUTO WORK PROGRAM
HOME PALLET KIND No.
REMOVE 0022 0022
MODE MODE
MANUAL OFF
AUTO OFF-LINE 022 022
AUTO
00 00
0 0
Figure 1-14 Software Interface Panel (Palletizing Application)
1.3.10 FLOPPY DISK DRIVE UNIT
The optional floppy disk drive (FDD) unit (Figure 1-15) is a portable disk drive used to
upload and download programs and data. The FDD unit is connected to the operation
panel (Figures 1-11 and 1-12) host communication port (X2) and AC outlet.
For more information about program upload and download procedures, refer to the
C Controller Operations and Programming Manual, MROCCONTO87E.
Figure 1-15 Floppy Disk Drive Unit
March 28, 2002 1-17


OVERVIEW
1.4 PRINTED CIRCUIT BOARD OVERVIEW
This section provides general information about C controller circuit board functions; for
detailed information, refer to unit 6, Printed Circuit Boards.
For the following discussion, refer to figure 1-16.
1-18 March 28, 2002


OVERVIEW
EP TYPE
TEACH PENDANT
MULTI FUNCTION PANEL 1GA/1HA (Z-SERIES)
OR TYPE 2 TEACH PENDANT
RISC PROCESSOR EXPLOSION-PROOF
1FT
MEMORY UNIT
COLOR LCD
MULTI FUNCTION PANEL I/F TP BARRIER UNIT
TOUCH PANEL
PATH PLANNING
PC CARD READER
COORDINATE CONVERSION
1GS 1LT
VOLTAGE MONITORING
CONTROL PANEL
AVR
SWITCHES & LAMPS
+5 VDC
1HZ (VME BUS) +12 VDC
-12 VDC
+24 VDC
1HP 1GW 1FS/1HS (OPTION) OPTION PCBs

POWER CONTROL I/O RELAYS REMOTE I/O VISION
ANALOG OUTPUT CONTROL NET ARC I/F
VOLTAGE MON.
(OPTIONAL)
SERIAL COMM. EXPLOSION-PROOF
UNIT
H32KT/
1LU 1LW M30KT
ENCODER
1GB
BRAKE
A B C
SERVO
JOINTS 1, 2, 3 JOINTS 4, 5, 6 JOINT 7, CONVEYOR MOTOR
CPU CPU CPU
ENCODER I/F ENCODER I/F ENCODER I/F
BRAKE CONTROL SEQUENCE
1GM
PWM CURRENT BRAKE

FEEDBACK
ENCODER
FEEDBACK
1GC/1JK (Large Type)
or
1GD (Small Type)
IPM SERVO MOTOR
CURRENT DETECT MODULES

1FG/1HG (F-SERIES)
210 VAC POWER UNIT
BATTERY
+12 VDC to +5
H20/M21
ENCODER
Figure 1-16 Circuit Board Functional Block Diagram
March 28, 2002 1-19


OVERVIEW
1.4.1 1HZ MOTHERBOARD
The 1HZ is located in the back of the card rack. It is the backplane for the standard
VME chassis that provides a point of interconnection for circuit boards and the AVR
power supply G1.
1.4.2 1GA/1HA MAIN CPU
The 1GA/1HA board is the C controller main central processing unit (CPU) board. It is
equipped with a 32-bit reduced instruction set computer (RISC) processor, with a clock
speed of 32 MHz (166MHz for 1HA).
The 1GA/1HA board performs the following functions:
• Stores AS software (controller operating system) and servo software in flash

memory.
• Stores user programs and system configuration data in static random access
memory (SRAM).
• Executes user defined AS software programs.
• Controls servo position loop operations.
• Coordinate conversions.
• Path planning.
• Communication with the 1GB servo CPU board.
• Communication with the MFP, type 2 (TP), EP type TP, or small TP.
• VME bus interface communication with other circuit boards.
• Industry Pack (IP) interface.
• RS-232C serial communication with external equipment (e.g., personal computer).
• Monitors DC power supply voltages for abnormal +5 VDC, +12 VDC, and -12 VDC
levels.
• Checks AS software for errors when the power supply or motor power are set to
ON; hardware is monitored continuously.
1-20 March 28, 2002


OVERVIEW
1.4.3 1GS SERIAL INTERFACE
The 1GS board is the EP type TP to 1HA serial interface board. This is an IP board that
mounts directly to the 1HA board.
1.4.4 1GW PARALLEL I/O AND ANALOG OUTPUT
The 1GW board is the parallel I/O board. It provides 32 input and 32 output channels.
Up to four 1GW boards can be installed. The 1GW board provides the capability to
output signals to control solenoids and receive input sensor signals (e.g., proximity
switches). An optional configuration of the 1GW board provides two analog output
channels.
1.4.5 1FS REMOTE I/O AND CONTROLNET
The C controller provides the capability to control remote input/output functions using
Slogic programming with two configurations of the 1FS board. These two configurations
are the remote input/output (RI/O) and RS-485, and ControlNet. The RI/O version board
can be configured as a remote rack of a programmable logic controller (PLC) and pro-
vides serial PLC and weld timer communication. The 1FS board is equipped with a
32-bit RISC processor running at 20 MHz and 2 MB or 4 MB of flash memory for soft-
ware and Slogic program storage.
1.4.6 1HS REMOTE I/O AND CC-LINK
The optional 1HS board functions as a remote device station of a Mitsubishi Control &
Communication Link (CC-Link) master station general purpose programmable logic
controller (PLC).
1.4.7 1HP POWER CIRCUIT CONTROL
The 1HP board controls the C controller power up sequence. It receives AS software
commands from the 1GA/1HA board, which control the operation of software controlled
relays on the 1HP board. These relays control distribution of +24 VDC to relays on the
1HY board. This, in turn, controls distribution of +24 VDC to the K1 and K2 contactors
for repeat and teach modes of operation respectively. The 1HP board also provides
safety circuits, which include emergency stop switches, limit switches, and enabling
devices (refer to unit 4 Alarm Circuity). The 1HP board also controls routing of 24 VDC
to the brakes. Another function of the 1HP board is to provide a point of connection
between the MFP, type 2 TP, or small teach pendant and the 1GA/HA board.
March 28, 2002 1-21


OVERVIEW
1.4.8 1HY RELAY BOARD
The 1HY board is mounted to the relay chassis. It provides +24 VDC and ground for
1HY board relays CR2, CR3, and CR4 (refer to unit 6 for a detailed description of relay
operation). It routes signals CND-K1 and CND-K2 (+24 VDC) from contactor K1 and K2
contacts to the 1HP board to indicate that the contactor K1 or K2 contacts are closed.
The 1HY board also distributes 210 VAC to fans, hour meter, control power lamp, K3
contactor coil, and EP unit AVR encoder power supply, and +24 VDC to the brakes.
1HY board LEDs indicate emergency stop and motor power ON conditions (refer to
unit 6).
1.4.9 1GB SERVO CPU
The 1GB board is the servo CPU. The board is available in six and eight axis configura-
tions. Servo software is installed on the 1GA/1HA board flash memory. When the
controller is powered up, the servo software is downloaded to the 1GB board static
random access memory (SRAM). The 1GB board provides the encoder communication
interface. It receives commands from the 1GA/1HA board and performs current and
speed loop processing. The 1GB board outputs pulse width modulation (PWM) signals
to the 1GC/1GD board (power block). It also routes limit switch signals to the 1HP board
and detects encoder hardware and communication errors.
1.4.10 1GM CURRENT SENSOR INTERFACE
The 1GM board is a small printed circuit board mounted to the 1GB board. It converts
current values detected by the current sensors (located on the power block) to voltage
levels, and then scales the voltage level for output to and processing by the 1GB board.
1.4.11 1GC/1GD/1JK POWER BLOCK
The function of the power block is to supply precisely controlled current to the AC servo
motors, one motor per robot joint, which produces motor rotation and mechanical unit
motion.
The power block receives 3-phase 60/210 VAC, for teach/repeat modes respectively.
The 3-phase 60/210 VAC is rectified to 86/300 VDC by a diode module. This rectified
86/300 VDC is routed back to the relay chassis, where inrush current protection and
discharge control are performed. Also located on the relay chassis is filter capacitor C1.
Capacitor C1 filters AC ripple from the 86/300 VDC output from the power block diode
module. The filtered 86/300 VDC is routed back to the power block and is supplied to
the insulated gate bipolar transistors (IGBTs) located in the intelligent power modules
(IPMs), one per axis, via the P and N bus bars. Hybrid integrated circuits (HICs) receive
PWM signals from the 1GB board and route them to control ICs that gate the IGBTs.
When gated, the IPMs output the current that drives the AC servo motors.
1-22 March 28, 2002


OVERVIEW
NOTE
The following components are located in the EP type C
controller explosion-proof unit.
1.4.12 1LU EXPLOSION-PROOF BARRIER
The 1LU explosion-proof (EP) barrier board is located in and mounted to the rear wall of
the EP unit. The 1LU board is one of the main EP components. The 1LU board, in
conjunction with the encoder barrier modules (EBMs, mounted to connectors on the
1LU board), provides the 1GB/encoder interfaces. The EBMs, with 1LW boards, provide
the intrinsically safe portion of the 1GB/encoder interface and the encoder transmit/
receive (ET/R) circuit (located on the 1LU board) controls data routing. In addition to
encoder data, the 1LU board routes +6 VDC from the encoder AVR power supply G21
to the EBMs. The EBMs regulate the +6 VDC to +5 VDC for the encoder logic circuits.
The 1LU board also provides +5 VDC (vcc) to the 1LW board for the non-intrinsically
safe portion of the 1LW board isolation circuit.
The 1LU board also includes the relay interlock circuit (RIC). The RIC, in conjunction
with zener barriers ZB1–ZB4, provides the interface for pressure switches, flow meters,
purge valve solenoids, and limit switches. The zener barriers provide the intrinsically
safe portion of the interface. The RIC also controls +24 VDC to the brakes and motor
thermal (MTH) switch circuit, and interlock and emergency stop signals to the 1HP
board and K21 relay. The K21 relay controls power to the encoder AVR power supply
G21.
1.4.13 1LW ENCODER BARRIER
The 1LW encoder barrier boards are located in the encoder barrier modules (EBMs).
The EP type C controller supports up to 10 encoders, using 10 EBMs. Each EBM is
mounted to a pair of connectors on the 1LU board. The The 1LW boards provide the
intrinsically safe interfaces for the encoders.
1.4.14 1LT E-STOP AND ENABLING DEVICE DISTRIBUTION
The 1LT board is located in the EP unit and is mounted to the ZEner BArrier (ZEBA)
unit. The 1LT board routes EP teach pendant (TP) transmit and receive data to/from the
1HA board. It also includes a relay distribution circuit (RDC) that routes emergency stop
(E-stop) and enabling device switch status from the TP to the 1HP board.
March 28, 2002 1-23


OVERVIEW
1.4.15 ZEBA TEACH PENDANT BARRIER
The ZEner BArrier (ZEBA) board is mounted in the ZEBA unit. It provides the intrinsi-
cally safe interface for the EP TP. Intrinsic safety for the TP is provided by zener barrier
circuits and fuses; if the load for a particular TP circuit exceeds specifications, the fuse
blows.
1-24 March 28, 2002


OVERVIEW
1.5 C SERIES CONTROLLER DIGITAL SERVO CONTROL OVERVIEW
This section provides general information about the operation of the digital servo drive
system. For additional information, refer to unit 7, Servo System.
There are four major components in the C controller servo drive system:
• Power block assembly
• 1GB board and servo software
• AC servo motor assembly
• Hybrid encoder assembly
The 1GB board receives path data from the 1GA/1HA board, encoder data from the
robot axes and conveyor, and load data from the current detect modules. The servo
software uses these signals to calculate and produce a digital command signal. The
command signal is combined with a triangular wave reference signal to determine the
sampling rate of the command signal and to generate the PWM signals that are sent to
the power block IPMs.
A PWM signal is a pulsed signal with a width or duration that is changed proportionally
to motor demands. For example, when the motor starts from a stopped condition, the
width of the PWM signals are very wide in order to overcome inertia, in comparison to
the PWM signals required to sustain motor velocity.
March 28, 2002 1-25


OVERVIEW
The power block is comprised of two sections: the power unit and the servo amplifier
(Figure 1-17). The power unit receives 60/210 VAC/60 Hz input power from the main
transformer assembly. This voltage is filtered and rectified to provide 86/300 VDC to the
IPMs.
IPM
P IGBT IGBT IGBT
SERVO MOTOR
Control Control Control CD U
R IC IC IC
S DIODE
210 VAC Uø CD
MODULE Vø
IGBT IGBT
Wø IGBT
T
V W
Control Control Control
IC IC IC
VOLTAGE REGENERATION
ERROR SIGNAL SIGNAL
+15 VDC
MONITORING
+12 VDC
TO H20/M21
PWM HIC ENCODER
1GB
BOARD IPM ERR
CURRENT FEEDBACK
ENCODER SIGNAL
Figure 1-17 Servo Amplifier Block Diagram
The amplifier section receives the PWM signals from the 1GB board. The PWM signals
are used by the IPMs to control current flow through the servo motor windings. The
IPMs use six insulated gate bipolar transistors (IGBTs) that are arranged in pairs; each
pair is connected to a specific motor winding. When the IGBTs are gated by the PWM
signals, current flows through the U, V, and W phases of the AC servo motor, causing
motor rotation.
1-26 March 28, 2002


OVERVIEW
Current detect modules located on the power block provide feedback to indicate the
current levels of the U and V phases. Signals from the modules are sent to the 1GB
board where they are used to:
• Calculate the W phase current
• Determine torque requirements
• Detect overcurrent errors
• Detect current limiter conditions that could damage the servo motor and power
block.
The hybrid (both absolute and incremental data) encoder assembly is mounted to the
servo motor shaft. Its function is to sense the servo motor shaft position, direction of
rotation, and velocity. This data is sent to the 1GB board for phase calculation and
processing by the software position and velocity loop amplifiers.
March 28, 2002 1-27


OVERVIEW
1.6 MECHANICAL UNIT OVERVIEW
The mechanical unit consists of arms, linkages, and drive mechanisms (Table 1-1).
These components provide smooth, accurate, and repeatable robot motion for consis-
tent teaching and program playback.
The typical mechanical unit provides six axes of motion and is available in a variety of
configurations that are suited for numerous applications under a variety of conditions.
Table 1-1 lists the basic drive components of the robot axes.
Table 1-1 Drive Mechanisms
FS06/10/20 FS30/40 KE610 KF121 UT/UX/UZ ZT/ZX
Cycloidal
Cycloidal Rota-Vector Cycloidal Cycloidal
JT1 Helical Gears Reduction Unit,
Reduction Unit Reduction Unit Reduction Unit Reduction Unit
Spur Gears
Cycloidal Rota-Vector Cycloidal Cycloidal Cycloidal Cycloidal

JT2
Reduction Unit Reduction Unit Reduction Unit Reduction Unit Reduction Unit Reduction Unit
Cycloidal
Cycloidal Rota-Vector Cycloidal Spur Gears, Cycloidal
JT3 Reduction Unit,
Reduction Unit Reduction Unit Reduction Unit Bevel Gears Reduction Unit
Helical Gears
Cycloidal Cycloidal
Rota-Vector Spur Gears,
JT4 Harmonic Drive Spur Gears Reduction Unit, Reduction Unit,
Reduction Unit Bevel Gears
Spur Gears Spur Gears
Cycloidal Cycloidal
Rota-Vector Spur Gears, Reduction Unit, Reduction Unit,
JT5 Harmonic Drive Spur Gears
Reduction Unit Bevel Gears Spur Gears, Spur Gears,
Bevel Gears Bevel Gears
Cycloidal Cycloidal
Rota-Vector Spur Gears, Reduction Unit, Reduction Unit,
JT6 Harmonic Drive Spur Gears
Reduction Unit Bevel Gears Bevel Gears, Bevel Gears,
Spur Gears Spur Gears
1-28 March 28, 2002


SAFETY
2.0 SAFETY ......................................................................................................... 2-2

2.1 Introduction .................................................................................................... 2-2
2.1.1 Terminology ................................................................................................... 2-3
2.1.2 Safety Information Contacts ........................................................................... 2-6
2.2 Warning and Caution Symbols ...................................................................... 2-8
2.3 Safety Categories .......................................................................................... 2-9
2.3.1 Personal Safety .............................................................................................. 2-9
2.3.2 Safety During Operation .............................................................................. 2-11
2.3.3 Safety During Programming ......................................................................... 2-11
2.3.4 Safety During Inspection, Maintenance and Repair ..................................... 2-12
2.4 Safety Features ............................................................................................ 2-13
2.5 Restricted Space Drawings .......................................................................... 2-14
2.5.1 FC06N/FS06N/FS10C/FW06N .................................................................... 2-14
2.5.2 FP20N .......................................................................................................... 2-15
2.5.3 FS02N/FS03N ............................................................................................. 2-16
2.5.4 FS06L .......................................................................................................... 2-17
2.5.5 FS10E .......................................................................................................... 2-18
2.5.6 FS10L .......................................................................................................... 2-19
2.5.7 FS10N .......................................................................................................... 2-20
2.5.8 FS20C .......................................................................................................... 2-21
2.5.9 FS20N .......................................................................................................... 2-22
2.5.10 FS30L .......................................................................................................... 2-23
2.5.11 FS30N/FS45C ............................................................................................. 2-24
2.5.12 FS45N .......................................................................................................... 2-25
2.5.13 KE610 .......................................................................................................... 2-26
2.5.14 KF121 .......................................................................................................... 2-27
2.5.15 UB150 .......................................................................................................... 2-28
2.5.16 UT100/150/200 ............................................................................................ 2-29
2.5.17 UX70 ............................................................................................................ 2-30
2.5.18 UX100/120/150 ............................................................................................ 2-31
2.5.19 UX200 .......................................................................................................... 2-32
2.5.20 UX300 .......................................................................................................... 2-33
2.5.21 UZ100/120/150 ............................................................................................ 2-34
2.5.22 ZD130 .......................................................................................................... 2-35
2.5.23 ZD165 .......................................................................................................... 2-36
2.5.24 ZT130 .......................................................................................................... 2-37
2.5.25 ZT165 .......................................................................................................... 2-38
2.5.26 ZT200 .......................................................................................................... 2-39
2.5.27 ZX130L ........................................................................................................ 2-40
2.5.28 ZX130U ........................................................................................................ 2-41
2.5.29 ZX165U ........................................................................................................ 2-42
2.5.30 ZX200S ........................................................................................................ 2-43
2.5.31 ZX200U ........................................................................................................ 2-44
2.5.32 ZX300S ........................................................................................................ 2-45
November 2, 2001 2-1


SAFETY
2.0 SAFETY
2.1 INTRODUCTION
Safety is the most important consideration when using industrial automated and robotic
equipment. All operators, teachers, maintenance, and repair personnel must be aware
of all automated, peripheral, and robotic equipment that occupy the safeguarded space
(refer to section 2.1.1 below), and their associated operational, maintenance, and repair
procedures. For this reason it is recommended that all personnel who operate, teach,
maintain, and repair Kawasaki industrial robots (hereafter referred to as robots), attend
a Kawasaki approved training course that pertains to each employee’s specific job
responsibilities.
The information in this unit is intended to enhance existing safety guidelines that are
provided by municipal, state, or national governments; it does NOT supersede existing
rules, regulations, or guidelines. Because safety is the primary responsibility of the user,
owner, and employer, Kawasaki recommends that specific safety guidelines and recom-
mendations be adopted from safety design and implementation professionals.
All safety issues and descriptions, presented in written or oral form by a representative
of Kawasaki Robotics (USA), Inc., are intended to provide general safety precautions
and procedures. These safety precautions and procedures are NOT intended to provide
all safety measures necessary for the protection of personnel and equipment in the work
environment.
Kawasaki robots are safe for use when all safety guidelines are followed. It is the re-
sponsibility of the end user to follow robot operation safety guidelines for the protection
of personnel and equipment.
2-2 November 2, 2001


SAFETY
2.1.1 TERMINOLOGY
The following terms are used in this safety section and throughout Kawasaki Robotics
(USA), Inc. documentation.
automatic mode Operating mode in which the control system operates in accordance
with the task program.
automatic operation The state in which the robot is executing its programmed task.
continuous path control 1 A type of robot control in which the robot moves according
to a replay of closely spaced points, programmed on a constant time base during teach-
ing. The points are first recorded as the robot is taught along a desired path, and the
position of each axis is recorded by the control unit on a constant time basis by scan-
ning axis encoders during the robot motion. The replay algorithm attempts to duplicate
that motion. 2 Interpolation of a desired path curve between a few taught points.
continuous path system A type of robot movement in which the tool performs the task
while the motion axes are moving. All motion axes may move simultaneously, each at a
different velocity, in order to trace a required path or trajectory.
controller The manipulator power supply and control system. The controller contains
microprocessors; memory for the operating system, programs, and data; operator and
equipment interfaces; communication hardware and software; and servo amplifiers to
drive the manipulator servo motors.
emergency stop The operation of a circuit that overrides all other robot controls, re-
moves drive power, causes all moving parts to stop, and removes power from other
hazardous functions present in the safeguarded space, and does not cause additional
hazards.
enabling device (formerly known as trigger switch or deadman switch) A manually

operated device which, when continuously activated, permits robot motion.
hazard a potential source of harm.
industrial robot An automatically controlled, multipurpose manipulator, programmable

in three or more axes. It may be either fixed in place or mobile for use in industrial
automation applications.
limit switch (also overtravel limit switch) An electrical switch positioned so that when
physical contact with an object occurs, the switch is activated.


SAFETY
manipulator (also known as mechanical unit) a mechanism, usually consisting of a

series of segments or links, jointed or sliding relative to one another, usually in several
degrees of freedom. It is remotely operated using a controller. The term refers to the
mechanical portion of the robot.
operator The person designated to start, monitor, and stop the operation of a robot or
robot system. The operator may also interface with a robot for production purposes.
path The path traced by the tool center point (TCP) during the execution of a task
program.
peripheral equipment The equipment used in conjunction with the robot for a com-
plete robotic system. This equipment includes grippers, dispensers, weld guns, convey-
ors, part positioners, part or material feeders, and any equipment located within the
safeguarded space that is not part of the robot.
pinch point Any point where it is possible for a part of the body to be injured between
the moving or stationary part of a robot and the moving or stationary part of associated
equipment, or between the material and moving part of the robot or associated equip-
ment.
point-to-point control A robot motion control in which the robot is programmed to

move from one position to the next. The intermediate paths between these points can-
not be specified.
point-to-point system Robot movement in which the robot moves to a numerically

defined position and stops, performs an operation, and then moves to another numeri-
cally defined position and stops, and so on.
restricted space (formerly known as work envelope) The space defined by the maxi-
mum reach of the manipulator, including the end-effector and work piece, in all direc-
tions, after a limiting device is actuated.
safeguarded space (formerly known as work cell) The space defined by the perimeter
safeguarding devices.
safeguarding device A device that detects or prevents access to a hazard.
slow speed control A mode of robot motion control where the speed is limited to
250 mm/sec. This allows the teacher to either withdraw from hazardous motion or stop
the robot.


SAFETY
teach pendant (also multi function panel) A portable hand-held programming device
that interfaces with the robot controller. It contains keys (soft or touch keys), switches
(e.g., emergency stop, enabling device, teach/automatic mode), indicators, and a dis-
play. Used to direct the controller to position the robot, record positional and auxiliary
data information, and interface with auxiliary equipment.
teach programming A method of entering a control program into the robot controller.
The robot is manually moved by an operator using a teach pendant. The teacher
records positions and other data which is saved to the robot controller as the robot is
moved through the desired path.
teacher A person who provides the robot with a set of instructions to perform a task.


SAFETY
2.1.2 SAFETY INFORMATION CONTACTS
Four recommended sources for national safety laws and regulations are:
1. Occupational Safety and Health Administration (OSHA)
U.S. Department of Labor

Office of Public Affairs
Occupational Safety and Health Administration - Room: 3647
200 Constitution Avenue
Washington, DC 20210
Phone: (202) 693-1999
http://www.osha-slc.gov/SLTC/robotics/index.html
2. Mine Safety and Health Administration (MSHA)
http://www.msha.gov
3. National Institute for Occupational Safety and Health (NIOSH)
Phone: (800) 35-NIOSH {(800) 356-4674}

Outside the U.S.: (513) 533-8328
http://www.cdc.gov/niosh/homepage.html
4. American National Standards Institute (ANSI)
Headquarters
American National Standards Institute

1819 L Street, NW
Washington, DC 20036
Phone: (202) 293-8020

Fax: (202) 293-9287
Customer Service: (212) 642-4980

General Inquiries: (212) 642-4900
http://www.ansi.org


SAFETY
To order the Industrial Robots And Robot Systems - Safety Requirements

(ANSI/RIA R15.06-1999):
http://webstore.ansi.org/ansidocstore/find.asp
In the “Standards Search/Lookup:” field, enter “robot” to locate

ANSI/RIA R15.06-1999.
Customer Service: (212) 642-4900, or E-mail: storemanager@ansi.org


SAFETY
2.2 WARNING AND CAUTION SYMBOLS
The following symbol and its enclosed text, when presented in Kawasaki Robotics
(USA), Inc. documentation, provides EXTREMELY IMPORTANT personnel safety infor-
mation. The information relates to the text that directly follows the symbol.
! WARNING
Warning symbols indicate processes or procedures that,
if not followed properly, can result in serious injury or
death to personnel.
The following symbol and its enclosed text, when presented in Kawasaki Robotics
(USA), Inc. documentation, provides VERY IMPORTANT equipment protection informa-
tion. The information relates to the text that directly follows the symbol.
! CAUTION
Caution symbols indicate processes or procedures that,
if not followed properly, can result in equipment
damage.


SAFETY
2.3 SAFETY CATEGORIES
Personnel safety is described in one of the following four categories:
• Personal safety
• Safety during operation
• Safety during programming
• Safety during inspection, maintenance, and repair.
Each safety category is described in the following sections.
2.3.1 PERSONAL SAFETY
All applicable safety procedures must be followed consistently and be an integral part of
standard operating procedures.
The following are personal safety guidelines:
• Comply with ALL applicable OSHA, NIOSH, MSHA, local, state, national, and
facility safety specifications and procedures.
• Before operating, teaching, maintaining, or repairing the robot controller or me-

chanical unit, ensure ALL operating, programming, maintenance, and repair proce-
dures are fully understood.
• When performing robot controller or mechanical unit maintenance or repair, do not

wear loose clothing, scarves, wrist watches, rings, or jewelry. It is also recom-
mended that if a necktie is worn, it be a clip-on (NOT tied) type.
• When required by facility safety regulations, ALWAYS wear safety glasses or

goggles, approved safety shoes, hard hats, and other protective equipment.
• Know the ENTIRE safeguarded space, including peripheral devices.
• Know the extent of the ENTIRE mechanical unit restricted space.
• Know the location of ALL emergency stop (E-stop) switches.
• AVOID trap points where personnel can become trapped between moving and
stationary devices.


SAFETY
• Before initiating robot motion, ensure that ALL personnel are clear of the safe-
guarded space and know how the robot will perform when motion is initiated.
• Before operating the robot, ensure the work area is free of tools, lubricants, clean-
ing equipment, and debris.
• If unsafe working conditions are observed, IMMEDIATELY report them to the super-
visor or facility safety coordinator.
• ALL robot operators must be able to identify, by name and function, ALL switches,
control devices, and signals that initiate robot motion.
• NEVER defeat, render useless, jumper out, or bypass any mechanical or electrical
safety device.
• To ensure personnel safety, ALL safety devices approved for use in the facility must
be properly installed and maintained.
• During robot operation, NEVER attempt to stop or brake the mechanical unit with a
part of your body.
• Use E-stop switches to stop mechanical unit motion in emergency situations ONLY.
• During automatic operation, NEVER enter the safeguarded space.
2-10 November 2, 2001


SAFETY
2.3.2 SAFETY DURING OPERATION
• Before operating the robot, know the boundaries of the restricted space.
• ALWAYS keep the work area clean and free of debris which includes, but is not
limited to, oil, water, tools, and electronic test equipment.
• Because the teach pendant has provisions to protect the operator during teaching
operations, the ONLY person allowed in the safeguarded space is the person oper-
ating the teach pendant. Teach pendant safety provisions include an E-stop switch
and enabling device.
• Before performing teach operations, ALWAYS have a planned retreat path.
• NEVER block the operator’s retreat path.
• AVOID trap points.
2.3.3 SAFETY DURING PROGRAMMING
• Before operating the robot, know the boundaries of the restricted space.
• Because the teach pendant has provisions to protect the operator during teaching
operations, the ONLY person allowed in the safeguarded space is the person oper-
ating the teach pendant. Teach pendant safety provisions include an E-stop switch
and enabling device.
• AVOID trap points.
• Before operating the robot in point-to-point mode, the operator must be COM-
PLETELY clear of the safeguarded space. During point-to-point playback opera-
tions, the robot has information about its present location and the next point to
which it is programmed to move. If an object lies between these two points, the
robot will impact the object.
• Playback accuracy and speed affect path coordinate geometry. When changing
program accuracy or speed, ALWAYS test a program in the point-to-point mode, or
at a slow speed, before performing continuous path operation in the repeat mode.
• For a newly created program, before performing high-speed playback operation in

the repeat mode, ALWAYS run the new program in the point-to-point mode, or at a
slow speed.
November 2, 2001 2-11


SAFETY
2.3.4 SAFETY DURING INSPECTION, MAINTENANCE AND REPAIR
Before entering the safeguarded space to perform inspection, maintenance, or repair

procedures, set the robot controller main disconnect to OFF and tag and lock it out.
! WARNING
When the robot controller’s main disconnect is set to
OFF, the input side may still be energized. Before per-
forming maintenance on the main disconnect, ALWAYS
set the source disconnect to OFF and tag and lock it
out.
• If an axis is not supported when the servo drive motor is removed, the axis will fall.
The brake assembly is part of the servo drive motor.
• If an axis is not supported and the brake release switch is activated, the axis will fall.
• Before working on pneumatic or high pressure water supplies, turn the supply
pressure off, and purge ALL lines to remove residual pressure.
• Assign ONLY qualified personnel to perform ALL maintenance or repair procedures.
• Before performing maintenance or repair procedures, review ALL available docu-

mentation related to the procedure.
• Use ONLY Kawasaki Robotics (USA), Inc. approved replacement parts.
• Robot controller interlock control circuits are identified with yellow wiring. BEFORE
adjusting or repairing an interlock control circuit device, locate the disconnect sup-
plying power to the device and set it to OFF.
• During inspection, maintenance, or repair procedures, if the system is equipped

with safety fences and safety plugs, REMOVE and HOLD the safety plug while
performing these procedures. In addition to this safety plug procedure, ALL safety
procedures described above must be followed.
2-12 November 2, 2001


SAFETY
2.4 SAFETY FEATURES
To safeguard the user, Kawasaki robot systems are equipped with many safety features,
including the following:
• All E-stops are hard-wired.
• The teach pendant or multi function panel, small teach pendant, and operation
panel are equipped with red mushroom-type E-stop switches. If an optional inter-
face panel is installed, the operation panel E-stop switch is relocated to the optional
interface panel.
• All robot axes are monitored by the robot controller for velocity and deviation errors.
If an over-velocity or deviation condition is detected, the robot faults in a velocity or
deviation error condition.
• Teach and check mode velocities are limited to a maximum of 250 mm/sec
(9.843 in/sec).
• All robot axes have software limits.
• JT1 is equipped with overtravel limit switches. Optional overtravel limit switches are
available for JT2 and JT3.
• All F-series, U-series, and Z-series mechanical units have overtravel hardstops on
the JT1, JT2, JT3, and JT5 axes.
• All robot axes are equipped with 24 VDC electromechanical brakes that engage
when power is removed. If the robot loses power unexpectedly, the mechanical unit
arm is held in position by the brakes and does not fall.
November 2, 2001 2-13


SAFETY
2.5 RESTRICTED SPACE DRAWINGS
2.5.1 FC06N/FS06N/FS10C/FW06N
Figure 2-1 FC06N/FS06N/FS10C/FW06N Restricted Space
2-14 November 2, 2001


SAFETY
2.5.2 FP20N
Figure 2-2 FP20N Restricted Space
November 2, 2001 2-15


SAFETY
2.5.3 FS02N/FS03N
Figure 2-3 FS02N/FS03N Restricted Space
2-16 November 2, 2001


SAFETY
2.5.4 FS06L
Figure 2-4 FS06L Restricted Space
November 2, 2001 2-17


SAFETY
2.5.5 FS10E
Figure 2-5 FS10E Restricted Space
2-18 November 2, 2001


SAFETY
2.5.6 FS10L
November 2, 2001 2-19


SAFETY
2.5.7 FS10N
Figure 2-7 FS10N Restricted Space
2-20 November 2, 2001


SAFETY
2.5.8 FS20C
Figure 2-8 FS20C Restricted Space
November 2, 2001 2-21


SAFETY
2.5.9 FS20N
2-22 November 2, 2001


SAFETY
2.5.10 FS30L
November 2, 2001 2-23


SAFETY
2.5.11 FS30N/FS45C
Figure 2-11 FS30N/FS45C Restricted Space
2-24 November 2, 2001


SAFETY
2.5.12 FS45N
November 2, 2001 2-25


SAFETY
2.5.13 KE610
(5428)
1558.5 230
6028
149
(1100)200
1400
750
5339
(4779)
200
715
(1100)
1400
(4305)
4707
750
(2011) (703)
(1040)
1143
(2714) (2065)
2371 644
3014 2325
Figure 2-13 KE610 Restricted Space
2-26 March 28, 2002


SAFETY
2.5.14 KF121
X
160˚
160˚
JT6: 720˚
Z
JT5: 290˚
80
JT4: 540˚
550
JT3: 480˚
˚
90
90
˚
1630
1240
150
R1
600
JT1: 320˚
R3
02
JT2: 180˚
50
R5 R5
150˚ 150˚ 50
400
18
off-set 90
Figure 2-14 KF121 Restricted Space
March 28, 2002 2-27


SAFETY
2.5.15 UB150
Figure 2-15 UB150 Restricted Space
2-28 November 2, 2001


SAFETY
2.5.16 UT100/150/200
Figure 2-16 UT100/120/150 Restricted Space
November 2, 2001 2-29


SAFETY
2.5.17 UX70
Figure 2-17 UX70 Restricted Space
2-30 November 2, 2001


SAFETY
2.5.18 UX100/120/150
Figure 2-18 UX100/120/150 Restricted Space
November 2, 2001 2-31


SAFETY
2.5.19 UX200
2-32 November 2, 2001


SAFETY
2.5.20 UX300
November 2, 2001 2-33


SAFETY
2.5.21 UZ100/120/150
Figure 2-21 UZ100/120/150 Restricted Space
2-34 November 2, 2001


SAFETY
2.5.22 ZD130
Figure 2-22 ZD130 Restricted Space
November 2, 2001 2-35


SAFETY
2.5.23 ZD165
Figure 2-23 ZD165 Restricted Space
2-36 November 2, 2001


SAFETY
2.5.24 ZT130
Figure 2-24 ZT130 Restricted Space
November 2, 2001 2-37


SAFETY
2.5.25 ZT165
2-38 November 2, 2001


SAFETY
2.5.26 ZT200
November 2, 2001 2-39


SAFETY
2.5.27 ZX130L
Figure 2-27 ZX130L Restricted Space
2-40 November 2, 2001


SAFETY
2.5.28 ZX130U
Figure 2-28 ZX130U Restricted Space
November 2, 2001 2-41


SAFETY
2.5.29 ZX165U
2-42 November 2, 2001


SAFETY
2.5.30 ZX200S
Figure 2-30 ZX200S Restricted Space
November 2, 2001 2-43


SAFETY
2.5.31 ZX200U
2-44 November 2, 2001


SAFETY
2.5.32 ZX300S
Figure 2-32 ZX300S Restricted Space
November 2, 2001 2-45


POWER DISTRIBUTION
3.0 POWER DISTRIBUTION ............................................................................... 3-2

3.1 Major Components......................................................................................... 3-2
3.1.1 Main Circuit Breaker F1 ................................................................................. 3-2
3.1.2 Transformer T1 ............................................................................................. 3-11
3.1.3 Relay Chassis .............................................................................................. 3-12
3.1.3.1 1HY Board ................................................................................................... 3-15
3.1.4 1HZ Board ................................................................................................... 3-18
3.1.4.1 AVR Power Supply G1 ................................................................................. 3-20
3.1.4.2 1HP Board ................................................................................................... 3-25
3.2 Description of Primary Power Distribution.................................................... 3-27
3.2.1 Connection of Primary Power ...................................................................... 3-36
3.2.2 Transformer T1 Connection .......................................................................... 3-37
3.3 Controller/Mechanical Unit Connection ........................................................ 3-42
3.3.1 Separate Harnesses - FS06/10/20 .............................................................. 3-42
3.3.2 Separate Harnesses - FS30/45 and U-Series ............................................. 3-44
3.3.3 Separate Harnesses - KF121 and KE610 ................................................... 3-46
3.4 Optional FS06/10/20/30/45 Sensor Cable Connection ................................ 3-49


POWER DISTRIBUTION
3.0 POWER DISTRIBUTION
This section describes C controller power distribution. For additional drawings, refer to
the C Series Controller Electrical Schematics Manual, Vol. 1.
! WARNING
When the C controller main circuit breaker F1 is set to
OFF, the input side (top) is still energized. Before
performing maintenance on F1, ensure that the source
circuit breaker that provides power to F1 is set to OFF
and locked-out.
3.1 MAJOR COMPONENTS
This section describes the location and function of C controller components that control
and distribute power.
3.1.1 MAIN CIRCUIT BREAKER F1
The main circuit breaker F1, shown in figures 3-1 and 3-2 (standard C controller), and
3-4 and 3-5 (explosion-proof [EP] type C controller) is a 3-pole circuit breaker rated at
15 A, 600 VAC. It is controlled by an Allen-Bradley toggle type operator (main discon-
nect), shown in figures 3-7 and 3-8, that is interlocked with the enclosure door to prevent
the door from being opened while the controller is ON.
A grounding bar with two machine bolts is mounted on the main circuit breaker mounting
bracket, to the right of F1.
Figure 3-3 shows the standard C controller as viewed from the left side of the cabinet
looking toward the right side of the cabinet.
Figure 3-6 shows the EP type C controller as viewed from the right side of the cabinet
looking toward the left side of the cabinet, with the EP unit cover removed.
3-2 March 28, 2002


POWER DISTRIBUTION
Card Rack AVR

B A Power
Grounding Bar Supply
(G1)
F1
1HZ
C
Power Block
K1 (1GC/1GD)
C1 Servo CPU
(1GB)
F2
Relay
Chassis
K3
1HY
TB2
B A
Figure 3-1 Standard C Controller, Major Components (Front View)
April 13, 2000 3-3


POWER DISTRIBUTION
View A
F1
Operation
Panel
Relay
Chassis
Accessory
Panel
X1
TB2
T1
Figure 3-2 Standard C Controller, Major Components (View A)


POWER DISTRIBUTION
View B
AVR
Power
Supply
(G1)
Operation
Card Panel
Rack
Servo CPU
(1GB)
Accessory
Panel
Power Block
(1GC/1GD)
X1
T1
Figure 3-3 Standard C Controller, Major Components (View B)
March 28, 2002 3-5


POWER DISTRIBUTION
1GW/1HW Board
Card Rack 1HA Board
AVR Power Supply (G1)
A B
1HP Board
F1
Power Block
(1GC/1GD/IJK)
1HZ Board
Explosion-Proof Unit
Servo CPU
(1GB)
TB2
Figure 3-4 EP Type C Controller, Major Components (Front View)
3-6 March 28, 2002


POWER DISTRIBUTION
F1
K1 Relay Chassis
F3, F4, F5
TB1
F2 C1
V1
1HY Board Z2
K3
T1
Figure 3-5 EP Type C Controller, Major Components (View A)
March 28, 2002 3-7


POWER DISTRIBUTION
TB4 1LT Board
ZEner BArrier
(ZEBA) Encoder AVR
Unit Power Suppy G21
ZEBA Board
Encoder Barrier Modules

with 1LW Boards
1LU Board
Zener Barriers
(ZB1–ZB4)
TB3
Figure 3-6 EP Type C Controller, Major Components (View B)
3-8 March 28, 2002


POWER DISTRIBUTION
Type 2
Teach Pendant ON OFF
T.LOCK
ENA SHIFT SPEED CNT
1 4
— —
X Rx
2 5
— —
Y Ry CHECK
3 6
— —
Z Rz
CL1 CL2
REC
Main Disconnect
Operation Panel
ERROR MOTOR POWER

Accessory Panel
Power Indicator X1
X1
CONTROL POWER
Hour Meter
Figure 3-7 Standard C Controller Cabinet (Front View)
March 28, 2002 3-9


POWER DISTRIBUTION
Multi Function Panel
Operation Panel
Main Disconnect
Accessory Panel
EP Teach Pendant
Power Indicator
Hour Meter
X1A
Figure 3-8 EP Type C Controller Cabinet (Front View)
3-10 March 28, 2002


POWER DISTRIBUTION
3.1.2 TRANSFORMER T1
Transformer T1 (Figures 3-2, 3-3, and 3-5) is an open core, open coil power transformer.
Available primary inputs are 400/440/460/480/515/575 VAC, 3-phase, 60 Hz. Outputs
are shown in table 3-1. The 60/210 VAC 3-phase power is supplied to the power block,
which outputs the current that drives the AC servo motors.
Table 3-1 Transformer T1 Outputs
Part Number 60621-1099 60621-1111 60621-1098 60621-1110

3-Phase Output 60/210 VAC, 10 A 60/210 VAC, 25 A
115/210 VAC, 8/5 A
Single-Phase Outputs
26 VAC, 15 A
There are two rating capacities available, 5.4 kVA and 10.9 kVA; the rating capacity
requirement depends on the the payload capacity of the mechanical unit. The different
rating capacities are related to their 60/210 VAC 3-phase output currents. In the teach
mode, 60 VAC is supplied to the power block, in the repeat mode 210 VAC is supplied to
the power block. The 5.4 kVA transformer and small power block with the 1GD board is
used for robots with payloads of less than 30 kg. The large transformer and large power
block with the1GC board is used for robots with payloads of 30 kg or greater.
For C controllers using the type 2 teach pendant (TP) and EP type C controllers, a new
style of transformer is used. The primary difference between the original production
transformer and the new style transformer is the connection to the transformer primary
(refer to section 3.2.2 for connection information); the original production transformer
has fixed input connections and jumpers are used to select the primary taps; the new
style transformer primary connections are made at particular terminals depending on
the input voltage.
March 28, 2002 3-11


POWER DISTRIBUTION
3.1.3 RELAY CHASSIS
The relay chassis is located on the left side of the cabinet (Figures 3-1, 3-2, and 3-5). It
distributes all power from the secondary of transformer T1 to components throughout
the C controller.
For the following discussion of relay chassis components, refer to figure 3-9.
The relay chassis contains the following components:
• circuit breakers F2, F3, F4, F5
• contactors K1, K2, K3
• terminal block TB1
• filter Z2
• spark arrester Z3
• resistors RS1 and RS2
• full-wave bridge rectifier V1
• capacitor C1
• relay board 1HY
Relay chassis circuit breakers F2, F3, F4, and F5 provide overcurrent protection for the
following:
• F2: 230 VAC, 40 A, 100 kVA interrupt — 60 VAC (teach mode)/210 VAC (repeat
mode) motor power to the power block.
• F3: 5 A — 210 VAC to AVR power supply (G1), fans, hour meter, control power
lamp, and contactor K3.
• F4: 3 A — 115 VAC outlet, located behind the access door on the operation panel.
• F5: 12 A — 26 VAC brakes.
3-12 March 28, 2002


POWER DISTRIBUTION
F3 (210 VAC to G1, fans, etc.)

K2 (motor power
in teach mode) F4 (AC outlet)
K1 (motor power F5 (brakes)

in repeat mode)
TB1
C1 (filter capacitor)
Z2 (filter)
F2 (motor power)
V1 (full wave
bridge rectifier)
K3 (inrush/discharge - +
and brake control)
RS1 (inrush)
1HY (relay board) RS2 (discharge)
Z3 (spark arrester)
Figure 3-9 Relay Chassis Components
March 28, 2002 3-13


POWER DISTRIBUTION
Contactors K1 and K2 control power to the power block. In repeat mode, K1 is ener-
gized and 3-phase 210 VAC is applied to the power block. In teach mode, K2 is ener-
gized and 3-phase 60 VAC is applied to the power block.
Contactors K1 and K2 are controlled by relays CR2, CR3, and CR4 on the 1HY board.
Contactor K3 controls inrush and discharge circuits, and power to the brakes.
Diode array V1 is a full wave bridge rectifier. Its output is +24 VDC, which is used to
control the brakes.
module.
Two-stage general-purpose filter Z2 reduces electromagnetic interference (EMI) and

radio frequency interference (RFI), providing reduced noise for the input power to the
AVR power supply G1.
Resistor RS1 provides inrush current protection.
Resistor RS2 controls discharge current.
Terminal block TB1 distributes single-phase 210 VAC from T1, via F3 and Z2, to the AVR
power supply. It also distributes single-phase 210 VAC, via the 1HY board, to the card
rack fans, power block fans, transformer fans, power lamp, hour meter, and the K3 coil.
3-14 March 28, 2002


POWER DISTRIBUTION
3.1.3.1 1HY BOARD
The 1HY relay board (Figures 3-9 and 3-10) is mounted to the relay chassis, and per-
forms the following functions:
• Routes +24 VDC to the K1 or K2 contactors.
The 1HP power circuit control board provides +24 VDC and ground for 1HY board
relays CR2, CR3, and CR4. When these relays are energized, contacts for these
relays close and +24 VDC from the AVR power supply, via 1HZ-CN10, is applied to
the K1 or K2 contactor coils.
When the K1 or K2 contactors are energized (repeat or teach mode, respectively),

sets of contacts are closed, and 3-phase 210/60 VAC is applied to the power block;
motor power is now available to the AC servo motors.
• Distributes 210 VAC to fans, hour meter, control power lamp, and the K3 contactor
coil.
• Routes CND-K1 and CND-K2 (+24 VDC) from contactor K1 and K2 contacts to the
1HP board. These signals indicate that the contactor K1 or K2 contacts are closed.
March 28, 2002 3-15


POWER DISTRIBUTION
210 VAC
Hour Power Card Rack Power Block EP Controller T1 CN2 NOTE
K3 Coil Encoder Power
Meter Lamp Fans Fans Supply G21 Fans 1
Motor power ON
2
Motor power OFF
not used
GND
GND
GND
GND
GND
1 CN5 5 1 CN6 3 1 CN7 3 1 CN8 3 1 CN9 3 1 CN10 3 24 VDC from V1 N
P
for brakes
CR1 E-Stop 1
A1 B1 210 VAC from TB1
1HY-31
BRK-P
BRK-P1
CR1
ON: run A2 B2 0 VAC from TB1
CN2
(GREEN)
BRK-N
OFF: E-Stop
LD1
2
Kawasak
BRK-P2
A3 B3
Ground for 210 VAC
D1
R1
3 (CN1-B1/B2)
BRK-N
CN1
A4 B4
A5 B5
CR2 +24 VDC +24 VDC G
24 VDC G for K1/K2 coils 1HZ
A6 B6
+24 VDC +24 VDC G CN10
REPEAT (G1)
(GREEN)
24 VDC
LD2
to K1/K2 coils
D2
R2
24 VDC to brakes
Relay Chassis
1GB-CN4 via K3 contacts
24 VDC (K1ON) to K1 coil
CR3
A1 B1
TEACH/REPEAT A2 B2 K1 coil
(GREEN)
LD3
CN3
A3 B3
D3
R3
A4 B4 K2 coil
24 VDC (CND-K1)
A5 B5
CR4 from K1 contacts
24 VDC (CND-K2)
A6 B6
from K2 contacts
TEACH
(GREEN)
LD4
24 VDC to K1/K2 contacts

D4
R4

R5
CN4
1 12
On the 1HY board

10
12
11
9
7
3
8
4
5
2
1
CND-K1
CND-K2
not used
GND for CR1, CR2, CR4 coils

24 VDC to CR1 coil
24 VDC to CR4 coil
GND for CR3 coil

24 VDC to CR3 coil
24 VDC to CR2 coil

17
10
18
19
1HP Board CN3

20
7
6
9
4
Figure 3-10 1HY Board Components and Connections
3-16 March 28, 2002


POWER DISTRIBUTION
The 1HY board also routes +24 VDC to the brakes. When motor power is ON and K3 is
energized, it routes +24 VDC for the brakes from V1 to the 1GB board, via the normally
open K3 contacts.
When motor power is OFF, K3 is not energized. If there are no E-stop conditions (CR1
energized), K3 routes +24 VDC from V1 to the normally open brake release switches,
via CR1 contacts and the normally closed K3 contacts. When a brake release switch is
pressed, the brakes are then released.
Mechanical Unit
JT1
BRAKE
4 X105 1
Machine Harness, M2
For the explosion-proof
X5A C controller, +24 VDC
2 1
is routed to the brakes via
the 1LU board.
Separate Harness, Motor B
2 X5 1
Controller
Motor Harness B
1LU
Brake
CN6 9 1 Release
1GB Switch
1HY TP1 JT1
CN1 CN2 CN4 CN5
TB1-2 N BR24G R1 D1
Y20 A2 3 3 1
CR1 TP2 220
24
T1 V1 VDC 2 K3
2 C2
8
(26 VAC) F5 (12 A) 4700 pF
P A1 K3 BR24V
9
X20 1 1
4 3
Solid
State U1
CR1 Relay
2 1
Vcc
CN4
RA19
1 8
1 10 12
CP69 470 18
0.1 mF
U34
19 2
4 18 20 /BRK REQ
CN3
24 VDC
1HP
Figure 3-11 24 VDC Routing to the Brakes
March 28, 2002 3-17


POWER DISTRIBUTION
3.1.4 1HZ BOARD
The 1HZ board (Figure 3-12) is located in the back of the card rack. It distributes power
from the AVR power supply G1 to the following components:
• +5 VDC (VCC), +12 VDC, and –12 VDC to circuit boards in the card rack.
• +5 VDC (VCC), +12 VDC, and –12 VDC to the 1GB servo CPU board.
• +12 VDC to the 1FG encoder battery board.
• +24 VDC to K1 and K2 repeat/teach contactors on the relay chassis,

via the 1HY board.
Two 3.6 V lithium batteries (mounted to the left side of the card rack chassis) are con-
nected to the 1HZ board at connector CN1. These batteries charge the super capacitor
located on the 1GA/1HA board. The super capacitor maintains the memory on the 1GA/
1HA board when the controller power is OFF.
Table 3-2 provides a description of each 1HZ connector function.
Table 3-2 1HZ Board Connector Descriptions
Connector Description
HZ-CN1 To the 3.6V lithium batteries for 1GA/1HA board backup
HZ-CN2 DC power supply harness to the 1GB board; +5 VDC, +12 VDC, –12 VDC, GND
HZ-CN3 DC power supply to 1FG board through separate harness assembly; +12 VDC, GND
HZ-CN4 Signal harness from the 1GA board to the 1GB board
HZ-CN5, Optional overtravel limit switch and additional connections to the 1HP board.
HZ-CN6, Jumpers on these connectors complete the limit switch path. For a description
HZ-CN7 of the limit switch path see Unit 4, Alarm Circuitry.
HZ-CN8, Built-in signal (SIGIN1, SIGIN2, SIGIN3, SIGIN4) harness to 1GW board
HZ-CN9 (CN9 is optional; double arm).
HZ-CN10 DC supply (24 VDC, 24 VDC GND) harness to 1HY board.
3-18 March 28, 2002


POWER DISTRIBUTION
1HP 6 5 4 3 2 1 1GA G1
CN1
RA1
RA2
RA3
R1
1
3A 2A 1A
1B
1B
1C
1C
1B
1B
1B
1B
1B
1A
1B
1A
1C
1C
1C
1C
1C
1C
1A
1A
1A
1A
1A
1A
C1
RA5
RA4
RA6
JP32
C2
Batteries 3B 2B 1B
4
CN2 C3
C4 4
1GB CN3 +
2
JP31
1 2
JP27
1 2
JP23
1 2
JP19
1 2
JP15
1 2
JP11
1 C5 6
1
JP30 JP26 JP22 JP18 JP14 JP10
(+5 VDC, 2 1 2 1 2 1 2 1 2 1 2 1 C6
CP2
CP4
CP3
+
CP7 CP5
A1 JP29 JP25 JP21 JP17 JP13 JP9
B1 2 1 2 1 2 1 2 1 2 1 2 1 C7
+12 VDC,
CP1
CP8
2 1 2 1 2 1 2 1 2 1 2 1
A3 B3
–12 VDC)
CP6
5
RA7
RA9
1FG
RA10
RA12
+
RA8
RA11
(+12 VDC)
CP10
CP11
CP12
CP9 +
CP13
CP16
1
1
Signal
CP14
CP15
Harness
RA16
RA18
to 1GB
RA13
RA15
CN5
CN4
+
RA14
RA17
Jumpers for +
32B
32B
32B
32B
32B
32B
32C
32C
32C
32A
32C
32C
32C
32B
32B
32A
32A
32A
32A
32A
32C
32C
32A
32A
CP24
CP22
CP23
32 30
CP21
Optional S8 S7 S6 S5 S4 S3 S2 S1 S15
CP24
CP21
CP22
CP23
33
34
33
Limit
34
Switches
S14 S13 S9
S12 S11 S10
1B
1C
1A
1B
1C
1A
1B
1C
1A
1B
1B
1B
1C
1C
1C
1A
1A
1A
1
Jumpers for
CN7
CN6
Optional
Limit
Switches
33
33
34
34
Optional SIG 1-4

1
CN8 6 1
CN9 6
SIG 1-4 to
1FR CN3 1HZ-50
32B
CN10
32C
32A
32B
32C
32A
32B
32B
32C
32C
32A
32A
32B
32C
32A
32B
32C
32A
1HY 1 4
(+24 VDC,
+24 VDC GND)
Figure 3-12 1HZ Board
March 28, 2002 3-19


POWER DISTRIBUTION
3.1.4.1 AVR POWER SUPPLY G1
The auto voltage regulator (AVR) multi-output switching DC power supply G1 is located
in the rightmost position of the card rack (Figure 3-13).
There are two models of AVR power supplies used in the C controller; S82W-618 and
S82W-619. The difference between the two models is their rated input and output
currents (Table 3-3).
When optional circuit boards are installed, it may be necessary to use the model S82W-
619 power supply to provide the additional current needed for these circuit boards.
Table 3-3 AVR Power Supply Ratings
Input Output
Voltage Current (A)

(VDC) (S82W-618/619)
Voltage Rating 210 VAC, 50/60Hz V1 +5 10/20
Max. Voltage Rating 300 VAC V2 +12 4/10
Voltage Range 168~252 VAC V3 -12 1.5/3
Max. Current Rating (S82W-618/619) 3.8A/5.0A V4 +24 5.0/5.0
The input to the AVR power supply is single-phase, 210 VAC. The AVR power supply
provides outputs of +5 VDC (VCC) for TTL logic, +12 VDC and –12 VDC for analog
circuits, and +24 VDC for relays and contactors.
Test points for these voltages are available on the 1GA/1HA board at:
• TP1 (GND)
• TP2 (–12 VDC)
• TP3 (+12 VDC)
• TP4 (+5 VDC);
and on the 1HP board at :
• TP1 (+24 VDC)
• TP1G (+24 VDC GND)
3-20 January 9, 2004


POWER DISTRIBUTION
Visual indication for these voltages is provided by 1HP board LEDs:
• LD1 (VCC, +5 VDC)
• LD2 (+12 VDC)
• LD3 (–12 VDC)
• LD4 (+24 VDC)
Adjustment of the +5 VDC, +12 VDC, and –12 VDC is accomplished using three potenti-
ometers, accessible at the front of the AVR power supply. The +24 VDC power supply is
not adjustable.
! CAUTION
If the +5 VDC, +12 VDC, or –12 VDC adjustment poten-
tiometers are turned too quickly, damage to the AVR
power supply can occur - full rotation is less than 360
degrees.
When making adjustments, turn the potentiometers

very slowly.
Prior to removal of the AVR power supply, allow seven

minutes for residual power depletion after disconnection
of the main power.
March 28, 2002 3-21

3-22
AVR
Overtravel Limit
Power
Switch Override 1GW 1FS 1GA/1HA Supply
1HZ (G1)
1HP SLOT6 SLOT5 SLOT4 SLOT3 SLOT2 SLOT1 1GA G1
CN1
1GA/1HA Board LEDs Status
3.6V Lithium Analog Output Vcc, +5 VDC (±0.05 V) LD7: 1HA w/Ethernet Option (green)
CN2 CN1 OFF: no LAN receive
Batteries LD5 green LD3 ON: LAN receiving
red green
CN3 SW1 LD4
1HP Board LEDs Status LD6: 1HA w/Ethernet Option (green)
LD3 green +12 VDC (±0.1 V) OFF: no LAN collision
LD1 (Vcc, +5 VDC) green LD2 red ON: LAN collision
LD2 CN1
LD1 green green
LD2 (+12 VDC) green green AC INPUT LD5: 1HA w/Ethernet Option (green)
LD5
LD101 red –12 VDC (±0.1 V) OFF: LAN link not working
LD3 (–12 VDC) green
LD6 green S1 ON: LAN link working
LD1
LD4 (+24 VDC) S2 red
green
Kawasak
LD7 red LD4: 1HA w/Ethernet Option (green)

These LEDs are located directly behind
NOTE CN2 OFF: no LAN transmit
LD8 red GND 1FS Board LEDs Status ON: LAN transmit
LD5, LD6, LD7, and LD8. DIP switches 1GA/S2 and 1FS/S1
DSP
DSP
are shown in their default setting. LD5 (CPU Run)
1 2 3 4 5 6 7 8
LD5 (MPWON) LD3: 1GA/1HA (green)
Blinks 1.2 sec./cycle
1 2 3 4 5 6 7 8
OFF: motor power OFF OFF: CPU self-test ends with an error
OFF ON: CPU self-test ends without an error
ON: motor power ON OFF LD4 (Error)
CN3 OFF: normal
LD6 (SVCN) SW1 LD2: 1GA/1HA (green)
ON: error
ON: servo control from the 1GB board OFF: during AS system restart
CN5
CN4
ON: blinks 1/sec after AS system restart
LD7 LD3 (ControlNet Status)
LD7 (SVERR)
CN1
CN2
green ON: during ControlNet
OFF: normal LD5 LD1: 1GA/1HA (red)
communication
ON: servo error from the 1GB board green OFF: normal
ControlNet LD2 (ControlNet Error) ON: ACFAIL or CPU error
LD8 (ERR) OFF: normal
OFF: normal BNC Connectors CN3
ON: error
ON: servo control error, 1HP board LD4
green LD1 (RI/O Status)
CN4 CN2 LD6 ON: during RI/O communication
green
LD101 (Watch Dog Timer)
CN2
POWER DISTRIBUTION
OFF: normal
ON: error
System Reset
CN1 (1GA)
CN4 CN1
CN7
CN6
CN3
CN4
+5 VDC ADJ
+12 VDC ADJ
TP1 –12 VDC ADJ

CN8 (+24 VDC)
CN9
TP1G
CN10
Figure 3-13 Card Rack, with Test Points and Indicators

C SERIES CONTROLLER
March 28, 2002


POWER DISTRIBUTION
The AVR power supply outputs AC error signals ACERØ and ACER1 to the 1HP board
for the following variations of input voltage:
• momentary power failure — Short duration (20-30 ms) drops to a detection level
of 130-145 VAC
• low level — 1-2 sec. duration at a detection level of 159-167 VAC.
• high level — 1-2 sec. duration at a detection level of 253-263 VAC.
When the error signals are received by the 1HP board:
• the 1HP board generates a /DCPWR-CUT signal
• this energizes a relay, which opens a normally closed relay contact
This normally closed contact is connected across the REMOTE-P and REMOTE-N
inputs to the AVR power supply. When the circuit opens, the power supply shuts down
the DC outputs.
The power supply is controlled remotely by the 1GA/1HA and 1HP boards. The 1GA/
1HA board monitors the +5 VDC (VCC), +12 VDC, and –12 VDC AVR power supply
outputs. The 1HP board monitors the +24 VDC output.
When the 1GA/1HA board detects a voltage that is out of tolerance:
• the 1GA/1HA board sends a command to the 1HP board
• the 1HP board generates the /DCPWR-CUT signal
• the AVR power supply shuts down
Similarly, when the 1HP board detects a loss of +24 VDC power supply:
• the /DCPWR-CUT signal generates
• the AVR power supply shuts down.
For a detailed discussion of how the 1HP board controls the AVR power supply re-
motely, refer to section 3.1.4.2. For AVR power supply specifications, refer to table 3-4.
Refer to section 4.7 for additional information about voltage monitoring and how it is
applies to alarm circuitry.
March 28, 2002 3-23


POWER DISTRIBUTION
Table 3-4 AVR Power Supply Specifications
Characteristic Value Description

V1 20 mV max. Output voltage fluctuation with a gradual
V2 30 mV max. change of input voltage from 168 to 252 VAC
Input Variation at rated output (Note 1).
V3 30 mV max.
V4 40 mV max.
V1 80 mV max. Output voltage fluctuation with a gradual
V2 100 mV max. change of output current from min. to the rated
Load Variation output (Note 1).
V3 300 mV max.
V4 *200/400 mV max.
V1 120 mV (P-P) max. Measured at the rated output (Note 1).
V2 240 mV (P-P) max.
Ripple
Voltage change from the rated output (Note 1)
Temperature Variation 0.05% per °C max.
from 0 to 60 °C.
V1 5% max. Combined input, load, and temperature
Output Voltage V2 variations.
Fluctuation V3 8% max.
V4
V1 Variable - adjusted with the "V.ADJ" at the
front panel for V1, V2, and V3 (50% rated
V2 ±10% min. output current ) (Note 2).
Voltage Adjustment
Range V3
Voltage is increased with a clockwise rotation
Fixed, set at 24.3 VDC and decreased with a counterclockwise
V4
(±0.4 VDC) rotation.
V1 Output voltage rises to 90% of the rated output
0.8 sec. min., voltage (Note1).
V2
Rise Time less than 2 sec.
V3
V4 700 ms min.
V1 Time from loss of power until the output
V2 160 ms min. exceeds regulation limits.
Hold Time
V3
V4 10 ms max.
105% min. for V1, V2, V3 and V4. If an overload condition continues for
Overload Protection more than 5s, the output is shut off. The input power must be set to
OFF/ON to reset the power supply.
120 (±5%) of the rated output voltage for V1, V2, V3, and V4. The input
Overvoltage Protection
power must be set to OFF/ON to reset the power supply.
Note 1:
Rated input and output conditions:
At rated input voltage, frequency, output voltage, output current, and room temperature and humidity
(25°C, 60%).
Note 2:
When the "V.ADJ" is adjusted to its maximum, overvoltage protection may be activated.
*S82W-618/S82W-619
3-24 March 28, 2002


POWER DISTRIBUTION
3.1.4.2 1HP BOARD
The 1HP board, located in the leftmost slot of the card rack, controls the C controller
power up sequence. It receives AS software commands from the 1GA/1HA board,
which control the operation of software controlled relays on the 1HP board.
Software controlled relays RY2, RY3 and RY4 control distribution of +24 VDC to relays
CR2, CR3 and CR4 on the 1HY board; which in turn control distribution of +24 VDC to
the K1 and K2 contactors for repeat and teach modes of operation, respectively.
The 1HP board also provides safety circuits, which include emergency stop switches,
limit switches, and enabling devices. These safety circuits and distribution of the +24
VDC to the K1 and K2 contactors is discussed in detail in unit 4, Alarm Circuitry.
The 1GA/1HA and 1HP boards monitor the AVR power supply DC outputs. When they
detect voltages that are out of tolerance, they power down the controller.
The 1GA/1HA board monitors the VCC (+5 VDC), +12 VDC, and –12 VDC outputs of the
AVR power supply. When a voltage is out of tolerance:
• the _dcfail and _acfail_vme signals are generated
• the 1GA/1HA board red LED LD1 “ACFAIL or CPU” (Figure 3-9) lights
• the 1HP board senses the /ACFAIL signal, and generates the /DCPWR-CUT signal
• the RY1 relay energizes
When there is a loss of the +24 VDC output of the AVR power supply:
• the 1HP board generates the +24VFAIL and /DCPWR-CUT signals
• the RY1 relay energizes
March 28, 2002 3-25


POWER DISTRIBUTION
When the RY1 relay energizes:
• the normally closed RY1 contacts open
• the AVR power supply senses the open contacts at the REMOTE-P and
REMOTE-N inputs, and shuts down the DC outputs
• an automatic error condition is repeated until the power supply voltage is

within tolerances
1GA/1HA 1HP
dvme(15:0) P1A/S1A S8A/P1A
1 1
2 2 +24 VDC
PC22
3 3 +24 VDC
+24 VDC
4 4
5 5
6 6
7 7 Vcc
+24VFAIL
8 8
Vcc12 RY1
D (0..7)
Vcc
P1B/S1B S8B/P1B
Vee12 _dcfail _acfail_vme /ACFAIL Logic /DCPWR-CUT
3 3
Vcc Circuits
Vcc G1 AVR Power Supply
Vcc +5 VDC
+12 VDC
P2C/S14C S15C/CN5 –12 VDC
13 22 ACERØ +24 VDC
14 24 ACER1
15 26 REMOTE-P
RY1
Optional
16 28 REMOTE-N
Remote Controller ON
When used, jumper on TB2 XHP-CN1 XHP-CN3

TB2-3/4 is removed.
4 4 26
RY5
+24 VDC
3 3 25
2 2 24
1 1 23
RY5
Figure 3-14 1HP Board Voltage Monitoring and Control
3-26 March 28, 2002


POWER DISTRIBUTION
3.2 DESCRIPTION OF PRIMARY POWER DISTRIBUTION
For the following discussion, refer to figures 3-15 and 3-16, and the C Series Controller
Electrical Schematics Manual, Vol. 1.
The C controller primary power requirement is 3-phase 400-575 VAC (refer to section
3.2.2, for setting taps to accommodate a particular input voltage). Primary power is
applied to the primary of transformer T1 via main circuit breaker F1. Transformer T1
provides single-phase outputs of:
• 26 VAC
• 115 VAC
• 210 VAC;
and 3-phase outputs of:
• 60 VAC
• 210 VAC
Single-phase 26 VAC is applied to full wave bridge rectifier V1. The +24 VDC output of
V1 is applied to CN4 of the 1GB servo CPU board (via the 1HY board), and is used for
the brakes.
The single-phase 115 VAC output is available at a receptacle on the operation panel,
located behind the accessory cover, via 3 A circuit breaker F4.
Single-phase 210 VAC is connected to TB1 via 5 A circuit breaker F3 and filter Z2. TB1
distributes the 210 VAC to the AVR power supply. It also distributes the 210 VAC, via the
1HY board, to the:
• card rack fans
• power block fans
• transformer fans
• power lamp
• hour meter
• K3 contactor coil
March 28, 2002 3-27


POWER DISTRIBUTION
Transformer T1 applies 3-phase 60/210 VAC to the power block via the K2/K1 relay
contacts, and circuit breaker F2. When teach mode is selected:
• contactor K2 energizes, closing its contacts
• transformer T1 applies 60 VAC to the power block
When repeat mode is selected:
• contactor K1 energizes, closing its contacts
• transformer T1 applies 210 VAC to the power block
This 3-phase 60/210 VAC connects to power block connector X2-SA pins A1/B1/A2, and
to the diode module (a full-wave bridge rectifier located on the power block assembly).
The output of the diode module is 86/300 VDC.
The diode module routes the 86/300 VDC to the inrush current protection circuit located
on the relay chassis (via power block connector X3-SA pins A1/B1), and back to the
power block at connector X3-SA pins A2/B2. Capacitor C1, on the relay chassis, filters
AC ripple from the 86/300 VDC.
This filtered 86/300 VDC is routed back to the power block at X3-SA pins A2/B2, and is
supplied to the insulated gate bipolar transistors (IGBTs) located in the intelligent power
modules (IPMs). There is one IPM per axis.
Figure 3-17 shows EP type C Controller power distribution.
3-28 March 28, 2002

March 28, 2002
Kawasak
POWER DISTRIBUTION
Figure 3-15 Standard C Controller, Power Distribution

C SERIES CONTROLLER
3-29
3-30
CR1 CN2
4 3
CN1 2 24 VDC
COM NO To 1GB Board
P A1 1 24 VDC
24 VDC From V1 CN4 (brakes)
N A2 3 24 VDC G CN3
24 VDC G B6 B1
From 24 VDC G (K1 coil)
24 VDC G B5 B2
1HZ-CN10
(G1) 24 VDC A6 B3
24 VDC A5 CR2 CR2 CR3 CR3 B4 24 VDC G (K2 coil)
210 VAC B2 34 33 14 13 23 24 43 44 A1
From TB1 B1 NO COM NO COM NO COM NO COM A2 K1ON (24 VDC to K1 coil) To
A3 A3 Relay
A4 CR3 CR3 CR4 CR4 A4 K2ON (24 VDC to K2 coil) Chassis
B3 34 33 14 13 23 24 43 44 A5 24 VDC (to K1 contacts)
B4 NO COM NO COM NO COM NO COM B5 CND-1 (24 VDC from K1 contacts)
A6 24 VDC (to K2 contacts)
CN6 B6 CND-2 (24 VDC from K2 contacts)
3
Kawasak
C/R FAN 2
1
CN4
CN7 8 CND-K2 To
3 7 CND-K1 1HP-CN3
24 VDC
P/B FAN 2 9 24 VDC
1 11 24 VDC
5 CR 1 EMG-RESET
1 24 VDC
1
CN8 2 24 VDC
D1
3 3
K3 COIL 2 4 24 VDC 1HP-CN3
LD1
1 R1 5
2.2K 6 24 VDC
CN9 24 VDC G
10
3
A2 CR A1 12
HEAT EXCHANGER 2
2
1
D2
CN10
3 LD2
R2
TRANSFORMER FAN 2
POWER DISTRIBUTION
2.2K
1
A2 CR A1
CN5 3
5 D3
LAMP
4
3 LD3
HOUR METER 2 R3
CR2
1 24 23 2.2K
NO COM
A2 CR A1
CR4 4
13 14
D4
NO COM
LD4
R5 R4
0 2.2K
Figure 3-16 1HY Board Schematic Diagram

C SERIES CONTROLLER
March 28, 2002

Transformer
Servo Amp Unit
(Power Block)
AC Outlet 1HY Board
Noise Hour Meter

Filter Z2 Thermal
Control Power ON
March 28, 2002

On card rack
Fan
(3)
Around power block
Fan
(4)
On transformer
Kawasak
On explosion-proof unit
1HZ Board
AVR for
Control 1 GB board
Power Power for brake
AVR for Encoder
Emergency
POWER DISTRIBUTION
Stop
Repeat 1 Power for
1LU Encoder
Repeat/Teach 2
Figure 3-17 EP Type C Controller, Power Distribution

C SERIES CONTROLLER
3-31

POWER DISTRIBUTION
Connection from the power block to the separate harnesses is provided by motor har-
ness A for the JT1–JT3 motors (Figure 3-18), and motor harness B for the JT4–JT6 and
optional JT7 axis motors (Figure 3-19). The separate harness cables then connect the
controller to the mechanical unit.
X4 CONNECTOR PLATE
LOWER
X4 23 EARTH BAR
UPPER
UPPER JT1-MOTOR U
XM1-SA
1 A1
JT1-MOTOR V
2 B1
1 JT1-MOTOR W XM1-SA
3 A2
2 3
B2
4
5 6 X4 4
JT2-MOTOR U
A1
7 JT2-MOTOR V
5 B1
8 9 JT2-MOTOR W
XM2-SA
6 A2
10
XM2-SA
a b JT3-MOTOR U
7 B2
JT3-MOTOR V
LOWER 8 A3
JT3-MOTOR W
9 B3
a TH P
1
TH N XTH
b XTH 2
Figure 3-18 Motor Harness A
3-32 March 28, 2002


POWER DISTRIBUTION
JT4-MOTOR U
5 A1
JT4-MOTOR V
6 B1
JT4-MOTOR W
7 A2
JT5-MOTOR U
15 B2
XM3-SA
JT5-MOTOR V
16 A3
JT5-MOTOR W
17 B3
JT6-MOTOR U
XM3-SA
25 A4
JT6-MOTOR V
26 B4
JT6-MOTOR W
27 A5
JT7-MOTOR U
35 B5
JT7-MOTOR V
36 A6
JT7-MOTOR W
37 B6
40 11 EARTH BAR
UPPER X5 22 EARTH BAR
LOWER X5 CONNECTOR PLATE
UPPER
1 11 21 31
JT1-BRAKE P
1 1
JT1-BRAKE N
2 9
X5 11
JT2-BRAKE P
2
JT2-BRAKE N 10
12
JT3-BRAKE P
21 3
JT3-BRAKE N
22 XGB-CN6
11
10 20 30 40 JT4-BRAKE P
3 4
JT4-BRAKE N
LOWER 4 12
JT5-BRAKE P
13 5
14
JT5-BRAKE N
13 XGB-CN6
JT6-BRAKE P
23 6
JT6-BRAKE N
24 14
JT7-BRAKE P
33 7
JT7-BRAKE N
34
1 8
XTH 2 XTH 15
SIG0-1 1
8
SIG0-2 2
9
SIG0-3 3
18
XSOL
SIG0-4 4
19
28
SIG0-5 5 XSOL
SIG0-6 6
29
SIG0-7 7
38
SIG0-8 8
39
Figure 3-19 Motor Harness B
March 28, 2002 3-33


POWER DISTRIBUTION
The signal harness (Figure 3-20) routes:
• data from the encoders to the 1GB board via the 1FG board
• battery alarm signal from the 1FG board to the 1GB board
• limit switch signals LS1 and LS2 from the mechanical unit to the 1GB board
• external +24 VDC power supply to the 1GW board
• external input signals SIGIN1-SIGIN4 from the 1FG board to the 1GW board
• +12 VDC from the 1HZ board to the 1FG board
3-34 March 28, 2002


POWER DISTRIBUTION
20 Ga. AWG (UL1015)

UPPER X3 21 EARTH BAR
LOWER X3 CONNECTOR PLATE
JT1-ENCP
1 1
JT1-ENCN
11 20
JT3-ENCP
21 2
JT3-ENCN
31 21
JT4-ENCP
2 3
JT4-ENCN
12 22
JT6-ENCP
22 4
JT6-ENCN
32 23
JT2-ENCP
3 5
JT2-ENCN
13 24
JT7-ENCP
23 6
JT7-ENCN
33 25
JT5-ENCP
4 7
JT5-ENCN
14 26
XGB-CN2
BAT-ALP
24 8
UPPER 34
BAT-ALN
27 XGB-CN2
1 11 2131
LS1P
6 9
LS1N
16 28
LS2P
26 10
X3 LS2N
36 29
24 VDC
7 12
24 VDC G
17 31
24 VDC
27 13
10 20 30 40 24 VDC G
37 32
LOWER
SIGIN-1
5 14
SIGIN-2
15 33
SIGIN-3
25 18
SIGIN-4
35 37
+12 VDC
8 A1
GND
18 B1
28
XHZ-CN3
+12 VDC
9 A2
GND XHZ-CN3
19 B2
29
+12 VDC
10 A3
GND
20 A4
30
EPVP
38 1
EPVN XEPV
39 XEPV 2
Figure 3-20 Signal Harness
March 28, 2002 3-35


POWER DISTRIBUTION
3.2.1 CONNECTION OF PRIMARY POWER
Primary 3-phase power is connected to the input of main circuit breaker F1

(Figure 3-21).
460 VAC 3-Phase

Primary Power
Ground Terminal
ON OFF
TEACH LOCK
ERROR MOTOR POWER
X1
CONTROL POWER
To the Primary
of T1
Figure 3-21 Connection to Main Circuit Breaker F1
3-36 March 28, 2002


POWER DISTRIBUTION
3.2.2 TRANSFORMER T1 CONNECTION
! WARNING
When the C controller main circuit breaker F1 is set to
OFF, the input side (top) is still energized. Before per-
forming maintenance on F1, ensure that the source cir-
cuit breaker that provides power to F1 is set to OFF and
locked-out.
NOTE
Prior to setting the taps on the original production trans-
former T1 (part No. 60621-1098 or 60621-1099)(Figure
3-22) or making connections to the new style trans-
former T1 (part No. 60621-1110 or 60621-1111)(Figure
3-23), the incoming line voltage must be measured. The
two procedures that are described here are acceptable;
however, procedure one is preferred.
March 28, 2002 3-37

March 28, 2002

C SERIES CONTROLLER
NC
H21 575V 575V
515V 515V
H18 480V 480V
H15 TI-H1 460V 460V
460 VAC From F1
440V 440V
H12
400V 400V
H9 575V 575V
Figure 3-22 T1, Original Production
NC H6 515V 515V
480V 480V
Y20
Figure 3-23 T1, New Style

H3 TI-H2 460V 460V
POWER DISTRIBUTION
X20 H20 440V 440V

400V 400V
From T1 Secondary
Y10 H17
To Relay Chassis
575V 575V
To T1 Primary
X10 H14 515V 515V

From F1
480V 480V
X30 H11
TI-H3 460V 460V
T6 H8 440V 440V
S6 400V 400V
H5
TI-210V 210V 210V
R6 H2 TI-210V 210V 210V
T H19 K1 TI-210V 210V 210V
TI-60V 60V 60V
S H16 TI-60V 60V 60V
Kawasak
R H13 K2 TI-60V 60V 60V

H10 TI-210V 210V 210V
H7 F3-1 TI-115V 115V 115V
F4-1 TI-0V 0V 0V
H4
TB1-1 TI-0V 0V 0V
H1 TB1-4
NC TI-26V 26V 26V
F5-1 TI-0V 0V 0V
GND TB1-2
3-38

POWER DISTRIBUTION
Table 3-5 T1, Original Production, Primary Tap Settings
Voltage Tap Setting

(VAC) H1- H2- H3-
400 H5 H6 H4
440 H8 H9 H7
460 H11 H12 H10
480 H14 H15 H13
515 H17 H18 H16
575 H20 H21 H19
K1 T1-210V R 210V 575V H19

K2 T1-60V R6 60V 515V H16
480V H13 jumper
F5-1 T1-26V X20 26V 460V H10
440V H7
TB1-2 T1-0V Y20 0V 400V H4
H1 T1-H1
K1 T1-210V S 210V 575V H20
K2 T1-60V S6 60V 515V jumper
H17
To N2 480V H14
Relay
Chassis 460V H11
F3-1 T1-210V X30 210V 440V H8
400V H5
F4-1 T1-115V 460 VAC
X10 115V H2 T1-H2
From F1
K1 T1-210V T 210V 575V H21
K2 T1-60V T6 60V 515V jumper
H18
480V H15
460V H12
TB1-1 T1-0V 0V 440V H9
TB1-4 Y10
T1-0V 0V 400V H6
H3 T1-H3
T1
Figure 3-24 Original Production T1 Connections (460 VAC Input)
March 28, 2002 3-39


POWER DISTRIBUTION
Procedure No. 1 (voltage strip chart recorder)
1. Obtain a voltage strip chart recorder.
2. Set the controller main disconnect to OFF.
3. Set the circuit breaker that supplies power to the controller to OFF and lock it out.
4. Connect the strip chart recorder to the input side of the controller main circuit
breaker.
5. Remove the lock out for circuit breaker that supplies power to the controller and set
it to ON.
6. Monitor the voltage at the input to the controller main circuit breaker. The longer the
voltage can be monitored, the more accurately the voltage range can be deter-
mined. Measurements should be taken during periods of maximum and minimum
plant activity (e.g., during full production, between shifts, or on the weekend).
7. Record the highest and lowest voltage reading. Determine the average voltage and
record this value.
9. Remove the strip chart recorder.
10. Check the tap settings on transformer T1 and note the setting, refer to figures 3-22
and 3-24, and table 3-5. Ensure that the tap settings are correct for the measured
average voltage from step 7.
it to ON.
3-40 March 28, 2002


POWER DISTRIBUTION
Procedure No. 2 (digital volt meter)
1. Obtain a digital voltmeter.
2. Set the controller main disconnect to OFF.
4. Connect the digital voltmeter to the input side of the circuit breaker.
5. Remove the lock out for the circuit breaker that supplies power to the controller and
set it to ON.
6. Monitor the voltage at the input to the controller main circuit breaker. Readings can
be taken hourly and recorded. The longer the voltage can be monitored, the more
accurately the voltage range can be determined. Measurements should be taken
during periods of maximum and minimum plant activity (e.g., during full production,
between shifts, or on the weekend).
7. Note the highest and lowest voltage reading. Determine the average voltage and
record this value.
9. Remove the digital voltmeter.
10. Check the tap settings on transformer T1 and note the setting, refer to figures 3-22
and 3-24, and table 3-5. Ensure that the tap settings are correct for the measured
average voltage from step 7.
it to ON.
March 28, 2002 3-41


POWER DISTRIBUTION
3.3 CONTROLLER/MECHANICAL UNIT CONNECTION
3.3.1 SEPARATE HARNESSES - FS06/10/20
The C controller is connected to the FS06/10/20 robots using two ‘separate

harnesses’ with Molex type connectors (Figures 3-25 through 3-27). The signal cable,
with connectors X3 and X3A, is used for encoder feedback and overtravel limit switch
sensing. The motor harness, with connectors X4 and X4A, is used for both the major
(R, O, D) and minor axis (S, B, T) drive signals, traverse axis (V) drive signals, electro-
mechanical brake voltage for all axes, and motor thermal sensors.
Connectors X3 and X4 are connected to the controller. Connectors X3A and X4A are
connected to the mechanical unit.
The separate harnesses must lay flat and not be twisted or have any kinks. A cable duct
or trough should be used to protect the cables from water or other contaminants.
ON OFF
TEACH LOCK
ON
OFF
CN3 CN4 CN1 CN5
CN7
CN8
CN1 CN13
HOUR METER
h
CN2
CN12
CN4
CN6 CN10
CN9
CN5
CN2 M1 M2 M3
X3 X4
X3A
X4A
Figure 3-25 C Controller/Medium F-Series Separate Harness Connections
3-42 March 28, 2002


POWER DISTRIBUTION
UPPER LOWER
10 20 30 40
1 11 21 31
X3A
X3
1 11 21 31
10 20 30 40
LOWER UPPER
UPPER LOWER
13 26 39 52
1 14 27 40
X4A
X4
1 14 27 40
13 26 39 52
LOWER UPPER
Figure 3-27 Motor Harness
March 28, 2002 3-43


POWER DISTRIBUTION
3.3.2 SEPARATE HARNESSES - FS30/45 AND U-SERIES
The C controller is connected to the FS30/45 and U-series robots using three ‘separate
harnesses’ with Molex type connectors (Figures 3-28 through 3-31).
The signal cable, with connectors X3 and X3A, is used for encoder feedback and over-
travel limit switch sensing. Motor harness A, with connectors X4 and X4A, is used for
major axis (R, O, D) drive signals. Motor harness B, with connectors X5 and X5A, is
used for minor axis (S, B, T) drive signals, traverse axis (V) drive signals, electrome-
chanical brake voltage for all axes, and motor thermal sensors.
Connectors X3, X4, and X5 are connected to the controller. Connectors X3A, X4A, and
X5A are connected to the mechanical unit.
The separate harnesses must lay flat and not be twisted or have any kinks. A cable duct
or trough should be used to protect the cables from water or other contaminants.
ON OFF
TEACH LOCK
ON
OFF
CN3 CN4 CN1 CN5
CN7
CN8
CN1 CN13
HOUR METER
h
CN2
CN12
CN4
CN6 CN10
CN9
CN5
CN2 M1 M2 M3
X3 X4 X5
X5A
X4A
X3A
Figure 3-28 C Controller Separate Harness Connections
3-44 March 28, 2002


POWER DISTRIBUTION
UPPER
LOWER
|X4A|
|X4|
LOWER
UPPER
Figure 3-29 Motor Harness A
UPPER
1 11 21 31
LOWER
40 30 20 10
|X5A|
|X5|
10 20 30 40
LOWER
31 21 11 1
UPPER
Figure 3-30 Motor Harness B
UPPER LOWER
X3A
X3
LOWER UPPER
March 28, 2002 3-45


POWER DISTRIBUTION
3.3.3 SEPARATE HARNESSES - KF121 AND KE610
The EP type C controller is connected to the KF121 robot using four ‘separate har-
nesses’; V1A/V1B and V3A/V3B (Figure 3-32). The ‘B harnesses’ are outside of the
hazardous area and the ‘A harnesses’ are within the hazardous area. The interior space
of the ‘A harnesses’ is coupled to the explosion-proof KF121 mechanical unit.
The EP type C controller is connected to the KE610 robot using eight ‘separate har-
nesses’ (Figure 3-33); V1A/V1B, V2A/V2B, V3A/V3B, and V4A/V4B. The ‘B harnesses’
are outside of the hazardous area and the ‘A harnesses’ are within the hazardous area.
The interior space of the ‘A harnesses’ is coupled to the explosion-proof KE610 me-
chanical unit.
3-46 March 28, 2002

MANIPULATOR
PRESSURIZED
COMPARTMENT
CONTROLLER
March 28, 2002

Kawasak
POWER DISTRIBUTION
SEPARATE HARNESS MACHINE HARNESS
Figure 3-32 KF121 Separate and Machine Harnesses

C SERIES CONTROLLER
3-47
MECHANICAL UNIT
3-48
Kawasak
POWER DISTRIBUTION
SEPARATE HARNESS MACHINE HARNESS
Figure 3-33 KE610 Separate and Machine Harnesses

C SERIES CONTROLLER
March 28, 2002


POWER DISTRIBUTION
3.4 OPTIONAL FS06/10/20/30/45 SENSOR CABLE CONNECTION
The FS06/10/20/30/45 robots (Figure 3-34) can be supplied with an optional sensor
cable that is used to connect limit switches, proximity switches, or a combination of both.
This cable is connected to wiring harness S5, which is located inside the joint three
housing and is accessible by removing the side access cover. The proximity and limit
switches are typically used with a gripper or similar end effector to signal to the control-
ler that the switch is open or closed.
Faston terminal for sensor
Opening for sensor cable

Cable connector specified 1.5 m sensor cable (option)
by customer’s application
Figure 3-34 FS06/10/20/30/45 Sensor Cable Routing
The sensor cable option allows the use of four sensor signals, identified as
SIGIN1–SIGIN4. The sensor wiring (Figure 3-35) is connected to the S5 harness with
Faston connectors for easy termination. In addition to connecting the sensor cable to
wiring harness S5, jumper J5 (Figure 3-36) on the 1GW board (Figure 3-37) must be set
according to table 3-6.
March 28, 2002 3-49


POWER DISTRIBUTION
C30 (1GW) F-Series Robot
XGW-CN3 X3 X3A Faston Terminal

7 5 5 SIG1
8 15 15 SIG2
14 25 25 SIG3
15 35 35 SIG4
5 7 7 24V
I/O24V
27 27
13 17 17 24G
I/O 0V
37 37
Figure 3-35 FS06/10/20 Sensor Wiring
Table 3-6 1GW Board J5 Settings
Signal
No. Name Setting, 1GW Connector, Function Std. Note
B–C CN3 Sensor All signals share a
1 24V A–B common 24 VDC,
A–B CN4 General purpose I/O
therefore pins 1–5
B–C CN3 SIGIN1 must be set the
2 WX13 A–B same way; i.e.,
A–B or B–C.
B–C CN3 SIGIN2
3 WX14 A–B
A–B CN4 General purpose I/O However, when
B–C is used,
B–C CN3 SIGIN3
4 WX15 A–B these signals are
A–B CN4 General purpose I/O not available as
B–C CN3 SIGIN4 general purpose
5 WX16 A–B I/O (see figure
A–B CN4 General purpose I/O 3-28).
3-50 March 28, 2002


POWER DISTRIBUTION
Transistor OUT 1-8,17-32

Output Reset C
Circuit Array C N
32 2
OUT9-16
Outputs B
J3/J4
A
Solenoid
Signals
C
P VME I/F
N
1 a:16/d:16
3
Sensor Signals
SIGIN1-SIGIN4
+24 VDC, GND
C
IN13-16
Photo B J5
Coupler C
32 A N
Inputs IN1-12, 17-32 4
Figure 3-36 1GW Board Block Diagram
March 28, 2002 3-51


POWER DISTRIBUTION
C1
A1 B1
UNI
1 2 34
±10
SW2 0-15
ON
0-10
1 DA2 U14
UNI
1 2 34
2
3
CN1 SW1 ±10
0-15
ON
0-10
4 DA1
1
20
P1
CN2
C32
A32B32
37
19
A B C A12 B12
1 24V
1 B1 A1 2 OX9
9 3 OX10
4 OX11
5
6
OX12
24G J7 U29
CN3 CN2 DA OPT I/O
J3
A B C
NO.1 NO.2
SIGOUT ADDRESS
CN3 1
A B C
24V
CN5 2 OX13 CN6
3 OX14
96-128
65-96
33-64
4 OX15
J2
1-32
5 OX16
ADDR
15 6 24G
ESS
CN3 CN2
8 SIGOUT J4
1
2
3
4
A B C
19 B8 A8 1 24V
25-32
2 WX13 17-24
9-16
37 J1
1-8
3 WX14 A1 B1
ON OFF
A B C
4 WX15 RESET
5 WX16
CN4 CN3
SIGIN J5
1
3
2
4
ON OFF OPT
J6
RESET I/O
DA
A B C
CN4
20
1
Figure 3-37 1GW Board Jumpers
3-52 March 28, 2002


ALARM CIRCUITRY
4.0 ALARM CIRCUITRY ...................................................................................... 4-2

4.1 Safety Circuits ................................................................................................ 4-2
4.2 Axes Overtravel Circuit ................................................................................ 4-12
4.3 External Hold ............................................................................................... 4-16
4.4 Motor Over Temperature Circuit ................................................................... 4-17
4.5 Regenerative Resistor and Controller Thermal Circuit ................................. 4-18
4.6 Abnormal P-N Voltage Detection Circuit ...................................................... 4-20
4.7 Voltage Monitor Circuits ............................................................................... 4-21


ALARM CIRCUITRY
4.0 ALARM CIRCUITRY
The alarm circuitry section provides information for these circuits:
• safety
• axes overtravel
• external hold
• motor over temperature
• regenerative resistor and controller over-temperature
• abnormal voltage detection.
This information is provided to assist the technician in the troubleshooting and repair of
these circuits.
4.1 SAFETY CIRCUITS
The safety circuits (Figures 4-1 through 4-3) consist of two series circuits, that include
the following components:
• 1HP board
• 1HY board
• multi function panel (MFP) or type 2 teach pendant (TP)
• operation panel
• TB2 terminal block or connector CJ44


ALARM CIRCUITRY
The primary function of the safety circuit is to control the supply of 3-phase power to the
power block. This power is used by the servo system to drive the robot. Components
that affect the safety circuit are:
• EMERGENCY STOP switches
• enabling devices
• TEACH/REPEAT switches
• external hold switches
• overtravel limit switches (refer also to section 4.2)
• safety fence switches
• 1HP board relays RY2, RY3, and RY4
• 1HY board relays CR1, CR2, CR3, and CR4
• AS system software


ALARM CIRCUITRY
NOTE
Although not considered a part of the safety circuit,
relay CR1 is mentioned here because it is controlled by
the E-stop switches. The branch of the safety circuit
that controls relay CR1 is shown in gray in figure 4-1
and
4-2.
The safety circuits are powered by 24 VDC. Relay RY2 provides 24 VDC to safety circuit
1, and ground to safety circuit 2, through its contacts. Safety circuits 1 and 2 are pro-
tected by 0.3 A fuses F1 and F3, respectively.
Safety circuit 1 controls relays CR1, CR2, and CR4, while safety circuit 2 controls relay
CR3. Relays CR2, CR3, and CR4 energize contactors K1 and K2, to provide high or
low 3-phase voltage to the power block. Relay CR1 provides 24 VDC to the manual
brake release switches.
Additionally, the AS system software also controls the safety circuits through relays RY2,
RY3, and RY4.


ALARM CIRCUITRY
Power for safety circuit 1 is supplied through the following devices, in the order shown,
to the TEACH/REPEAT switch:
• normally open RY2 contact
• external E-stop
• operation panel E-stop
• MFP or type 2 TP E-stop
• overtravel limit switch circuit LS1P/LS1N
When the TEACH/REPEAT switch is in the TEACH position (as shown in figure 4-1 and
4-2), power continues through the MFP or type 2 TP enabling devices, and the normally
open RY3 contact to relay CR4 (if the switch is in the REPEAT position, power travels
through the normally open RY4 contact to relay CR2).
Power for safety circuit 2 is applied to relay CR3. The ground for relay CR3 is supplied
through the following devices in the order shown:
• TEACH/REPEAT switch (REPEAT or TEACH position)
• overtravel limit switch circuit LS2P/LS2N
• MFP or type 2 TP E-stop
When the safety circuit is complete:
• power is applied to contactor K1 or K2 to provide 3-phase power to the power block
• contactor K1 supplies 210 VAC for repeat mode operation
• contactor K2 supplies 60 VAC for teach mode operation
• auxiliary K1/K2 contacts provide feedback to indicate the operational state of the
contactor.


ALARM CIRCUITRY
The safety circuit is monitored at various points on the 1HP board to determine circuit
integrity. The circled numbers in figures 4-1 and 4-2 indicate the monitoring points on
the 1HP board. Figure 4-3 is a continuation of the monitoring points, showing communi-
cation to the 1GA/1HA board.
The loss of a signal anywhere in these circuits results in motor power being turned off,
with an error message that points to the cause of the shutdown.
A number of switches can be connected to the safety circuit at terminal block TB2 or
connector CJ44. Figures 4-3 and 4-4 show the connection points of TB2 and CJ44
functions. Switches can be installed for external E-stops, safety fences, external hold
and external trigger functions.
For more information about interfacing external devices with the C controller, refer to the
C Series Controller I/O Interface Manual, MREICCON28E.

Operation Panel
E-Stop
REPEAT/TEACH Switch
(TEACH position shown)
A1 B1 A2 B2 A3 B3 A4 B4 B5 A5 XR-SW1****
5 6 7 8 13 14 15 16 18 17 XHP-CN2
January 10, 2007

1HP 1HY
+24 XHP-CN3 XHY-CN4
Vcc 4 CR1
VDC
4 1 CR2 CR2 CR3 CR3 XHY-CN3
34 33 14 13 23 24 43 44 K1ON K2
RY2 RY2 5 2 NO COM NO COM NO
A2 K1
CR2 COM NO COM 21 22 A1(+) A1(-)
RY2 6 4 B2
34 33 14 13 23 24 43 44 K2ON K1
LS1-N*
LS2-P*
7 5 CR3 NO COM NO COM NO COM NO COM
A4 21 22 A1(+)
K2
A1(-)
8 6 CR3 CR3 CR4 CR4 B4
F1 1 +24 VDC K1
External 9 7 A5 13 14
0.3 A
CR4
/+24VON
10 8 B5 CND-K1
E-Stop 2
+24 VDC K2
+24 17 9 A6
SW1**
TB2 XHP-CN1 13 14
VDC 18 10 B6 CND-K2
5 5
19 11
Kawasak
6 6
20 12 XHY-CN1
7 7
8 8 A1 BRK-P
F3 3 4 CR1
3 B1 210 VAC
0.3 A
9 9 NO COM
LS1-P*
LS2-N*
10 10 A2 BRK-N
11 11 B2 0 VAC
+24 A3
12 12 VDC
15 13 B3
Safety Fence A4
RY3
RY4
RY4
16 14 5
6 B4
17 15
18 16 A5 +24 VDC
21 21 7 Vcc Vcc B5 +24 VDC GND
22 22 A6 +24 VDC
23 23 B6 +24 VDC GND
RY3 RY4
24 24 8 1 3 2 XHY-CN2 2 3 1 XHY-CN8
25 25 10
External Trigger 26 26
ALARM CIRCUITRY
27
/STG-B
/STG-A
27 9
28 28
43 31 K3
13 14
12 11 13 14 15 16 17 18 XHP-CN4 K3 K3 K3
44 32
Customer Connections***
Figure 4-1 MFP Safety Circuit (1)

12 11 17 18 13 14 19 20 X1
CN1 B6 A6 A9 B9 A7 B7
MFP XGB-CN4
1 3 2 1 2 3 4 X1-SA
CN4 1 2 3 4 1GB 1GB
CN10 1 2 CN12
1 2
5 4 CN3 BR24V PC3 CN13B
CN9
XGB-CN5 BR24G 9 9 /MSON
8 10 10
9 11 11 +24 VDC
12 12 +24 VDC GND
MSON+
E-Stop Enabling Devices 19 19 Vcc
SSR1 MSON- /MSCNT
Notes: 20 20
*LS1/LS2 limit switch circuits - see Figures 4-6 through 4-9 for more detail
1GC/1GD
**SW1 limit switch override switch is located at the top front of the 1HP board
***Customer Connections - example only. See Figures 4-3 and 4-4, or interface drawings, for more detail POWER BLOCK
****Reference interface drawings where applicable
C SERIES CONTROLLER
4-7
Operation Panel
E-Stop
4-8
REPEAT/TEACH Switch
(TEACH position shown)
A1 B1 A2 B2 A3 B3 A4 B4 B5 A5 XR-SW1****
5 6 7 8 13 14 15 16 18 17 XHP-CN2
1HP 1HY
+24 XHP-CN3 XHY-CN4
Vcc 4 CR1
VDC
4 1 CR2 CR2 CR3 CR3 XHY-CN3
34 33 14 13 23 24 43 44 K1ON K2
RY2 RY2 5 2 NO COM NO COM NO
A2 K1
CR2 COM NO COM 21 22 A1(+) A1(-)
RY2 6 4 B2
34 33 14 13 23 24 43 44 K2ON K1
LS1-N*
LS2-P*
7 5 CR3 NO COM NO COM NO COM NO COM
A4 21 22 A1(+)
K2
A1(-)
8 6 CR3 CR3 CR4 CR4 B4
F1 1 +24 VDC K1
External 9 7 A5 13 14
0.3 A
CR4
/+24VON
10 8 B5 CND-K1
E-Stop 2
+24 VDC K2
+24 17 9 A6
SW1**
TB2 XHP-CN1 13 14
VDC 18 10 B6 CND-K2
5 5
19 11
Kawasak
6 6
20 12 XHY-CN1
7 7
8 8 A1 BRK-P
F3 3 4 CR1
3 B1 210 VAC
0.3 A
9 9 NO COM
LS1-P*
LS2-N*
10 10 A2 BRK-N
11 11 B2 0 VAC
+24
12 12 A3
VDC
15 13 B3
Safety Fence A4
RY3
RY4
RY4
16 14 5
6 B4
17 15
18 16 A5 +24 VDC
21 21 7 Vcc Vcc B5 +24 VDC GND
22 22 A6 +24 VDC
23 23 B6 +24 VDC GND
RY3 RY4
24 24 8 1 3 2 XHY-CN2 2 3 1 XHY-CN8
25 25 10
External Trigger 26 26
ALARM CIRCUITRY
/STG-B
/STG-A
27 27 9
28 28
43 31 K3
13 14
12 11 13 14 15 16 17 18 XHP-CN4 K3 K3 K3
44 32
Customer Connections***
12 11 17 18 13 14 19 20 X1
Figure 4-2 Type 2 TP Safety Circuit (1)

Type 2 CN1 B6 A6 A9 B9 A7 B7 A10 B10
XGB-CN4
Teach 1 3 2 1 2 3 4 X1-SA
CN4 1 2 3 4 1GB 1GB
Pendant CN10
1 2 1 2 CN12
1 2 3 4 CN5 BR24V PC3 CN9 CN13B
XGB-CN5 BR24G 9 9 /MSON
8 10 10
9 11 11 +24 VDC
12 12 +24 VDC GND
MSON+
E-Stop Enabling Devices 19 19 Vcc
SSR1 MSON- /MSCNT
Notes: 20 20
*LS1/LS2 limit switch circuits - see Figures 4-6 through 4-9 for more detail
1GC/1GD
**SW1 limit switch override switch is located at the top front of the 1HP board
***Customer Connections - example only. See Figures 4-3 and 4-4, or interface drawings, for more detail POWER BLOCK
****Reference interface drawings where applicable
C SERIES CONTROLLER
January 10, 2007

1HP Board
PC11
1
/MCON
PC12
2
November 2, 2001
PC14 /M-EMG
3
1 - Contactor K1
PC15 /M-LS
2 - Contactor K2 4
Kawasak
3 - Emergency stop
HP-P1A / HZ-S8A HZ-S1A / GA-P1A
4 - Overtravel limit switches PC16 /M-RPT
5 1 1
EPLD 2 2
5 - Repeat mode 4 4
5
1GA/1HA
5
6 - Safety fence PC17 6 6 BOARD
/M-SF VME
6 7 7
BUS
7 - External hold 8 8
8 - Teach mode
PC18 /M-EHLD
ALARM CIRCUITRY
9 - Trigger switch 7
Figure 4-3 Safety Circuit (2)

10 - External trigger switch
PC19 /M-TCH
8
PC20 /M-TRG
9
PC21 /M-ETRG
10
C SERIES CONTROLLER
4-9

ALARM CIRCUITRY
1HP-CN1 TB2
EXT CONTROL POWER-P EXT 24 VDC 24 VDC INPUT
1 1 EXT CONTROL
EXT CONTROL POWER-N EXT 24 VDC G POWER ON/OFF
2 2 (SHORT STANDARD)
REMOTE-P
3 3
REMOTE-N
4 4
INTERNAL-EMG1-P
5 5
EMG1-P
6 6
INT EMG1-N
7 7 EXT E-STOP
24 VDC EMG1-N CONNECTION
8 8
INT EMG2-P
relay 9 9
EMG2-P
10 10
INT EMG2-N
relay 11 11
EMG2-N
12 12
SAFETY FENCE1-P
13 15
SAFETY FENCE1-N
14 16 SAFETY FENCE INPUT
(REPEAT MODE ONLY,
SAFETY FENCE2-P
15 17 STOP WHEN OPEN)
SAFETY FENCE2-N
16 18
EXT HOLD-P
17 19 EXT HOLD INPUT
(REPEAT MODE ONLY,
EXT HOLD-N
21 21
22 22 (NOT USED)
23 23
24 24
EXT TRG1-P
25 25
EXT TRG1-N
26 26 EXT TRIGGER INPUT
(TEACH MODE ONLY,
EXT TRG2-P
EXT TRG2-N
28 28
EXT MOTOR POWER -P
29 29 EXTERNAL
MOTOR POWER ON
EXT MOTOR POWER -N
30 30 (WHEN CLOSED)
TEACH SW-P
35 31 INT TEACH SW OUTPUT
TEACH SW-N (CLOSED IN TEACH MODE)
36 32
INT 24 VDC
37 33 INT 24 VDC OUTPUT
INT 24 VDC G
38 34 I/O 24 VDC INPUT
I/O 24 VDC
39 35 INT 24 VDC G OUTPUT
I/O 24 VDC G
40 36 I/O 24 VDC G INPUT
Figure 4-4 1HP to TB2 Connections
4-10 March 28, 2002


ALARM CIRCUITRY
XHP-CN1
EXT CONTROL POWER-P 1

EXT CONTROL POWER-N 2
REMOTE-P 3
REMOTE-N 4
INTERNAL-EMG1-P 5
INTERNAL-EMG1-N 6
INTERNAL-EMG2-P 7
INTERNAL-EMG2-N 8
EMG1-P 9
EMG1-N 10
EMG2-P 11
EMG2-N 12
SAFETY FENCE1-P 13 CJ44

SAFETY FENCE1-N 14
SAFETY FENCE2-P 15 1
SAFETY FENCE2-N 16 2
EXT HOLD-P 17 3
EXT HOLD-N 18 4
19 5
20 6
21
22
23
24
EXT TRG1-P 25
EXT TRG1-N 26
EXT TRG2-P 27
EXT TRG2-N 28
EXT MOTOR POWER-P 29
EXT MOTOR POWER-N 30
31
32
33
34
TEACH SW-P 35
TEACH SW-N 36
INT24 VDC 37
INT 24 VDC G 38
I/O 24 VDC 39
I/O24 VDC G 40
Figure 4-5 1HP to CJ44 Connections
November 2, 2001 4-11


ALARM CIRCUITRY
4.2 AXES OVERTRAVEL CIRCUIT
The axes overtravel circuit is a branch of the safety circuit, designed to protect the
mechanical unit in case of movement beyond the JT1 software limits. Refer to section
4.1 for additional information about the safety circuit.
JT2 and JT3 typically do not have overtravel limit switches. However, optional limit
switches can be added to these axes, if desired.
The normally closed overtravel limit switches are wired in series, as shown in figures 4-6
through 4-9. When one of the limit switches opens:
• relay CR2 or CR4 on the 1HY board (Figures 4-1 and 4-2) turns off
• the safety circuit senses the open condition, and turns off relay CR3 on the
1HY board
• the CR2, CR3, and CR4 contacts supplying power to the K1 or K2 contactor
opens, turning motor power off
• the brakes are applied, stopping the robot in the same manner as an
emergency stop
• error -1602 (Limit switch signal line is broken), or error -1601

(Limit switch of jt x is on) then displays on the MFP
An overtravel condition should never occur under normal circumstances, due to the
software limit which keeps the axis from moving beyond the limit set in Function 51
(AUX menu). However, if either the hardware or software limit is improperly set, the limit
switch may be actuated and causes the robot to go into the overtravel condition.
To recover from this error, the operator must:
1. press and hold the red override switch located on the 1HP board
2. then reset the error by pressing the ERROR RESET switch on the operation
panel, MFP, or type 2 TP.
With the red override switch still being held, servo power can be applied and the robot
can be jogged off of the limit switch.
4-12 November 2, 2001


ALARM CIRCUITRY
The operator can also recover from this error by:
1. pressing the brake release switch for JT1
2. manually moving the robot away from the overtravel limit switch
Once the operator has recovered from the error, the original problem causing the error
must be corrected. This is typically caused by one or more of the following:
• an improperly set software limit
• improperly adjusted “dogs” that trip the overtravel limit switch rocker arm
• robot zeroing was not performed correctly
• the limit switch and/or associated wiring is defective
November 2, 2001 4-13

1HP 1HZ 1GB FS06N Mechanical Unit (Standard) FS06N Mechanical Unit (Optional)
HP-P2A Overtravel
HZ-S14A XHZ-CN4 XGB-CN1 XGB-CN2 X3 X3A X126 X3A X126 Limit Switches
4-14
P 25 27 27 9 6 6 1 6 1
LS1 LS1
N 26 28 28 28 16 16 2 16 2
P 27 29 29 10 26 26 3 26 3
LS2 LS2 LS2
N 28 30 30 29 36 36 4 36 4
HZ-CN6
28 X120 X120
LS1 1 1
27 LS1 LS1 Overtravel
29 2 2 Limit Switches
30 3 3
4 LS2 4
HZ-CN7
28 X121 X127 X121 X127
LS1
27 1 1 1 1
LS1 LS1 Overtravel
29 2 2 2 2 Limit Switches
30 3 3 3 3
LS2
4 4 4 4
HZ-CN5
28
LS1
27
29
30
Kawasak
Figure 4-6 F-Series Overtravel Limit Switch Circuit

ALARM CIRCUITRY
Figure 4-7 UT/UX-Series Overtravel Limit Switch Circuit

C SERIES CONTROLLER
November 2, 2001
November 2, 2001
Kawasak
Figure 4-8 UZ-Series Overtravel Limit Switch Circuit

ALARM CIRCUITRY
Figure 4-9 Z-Series Overtravel Limit Switch Circuit

C SERIES CONTROLLER
4-15

ALARM CIRCUITRY
4.3 EXTERNAL HOLD
The external hold circuit (Figure 4-10) is controlled by a normally closed external switch
or contact that affects robot operation in the repeat mode only. Thus, teach mode
operations can still be performed during an external hold condition.
When the external hold circuit is open, the external hold signal on the 1HP board is
turned off. The low status of this signal is sent to the 1GA/1HA board which provides
path data to decelerate the robot to a stop before holding program execution. Once the
robot has stopped, the brakes are engaged, and power is removed from the motors. At
this point the motor power circuits are still engaged, meaning that when the external
hold signal is restored the robot can resume program execution.
The method of recovery from an external hold condition is dependant upon whether the
external hold reset dedicated input signal is used. If the external hold reset input is not
dedicated, simply restoring the external hold circuit will cause program execution to
resume. If the signal is dedicated, it must be toggled from low to high before the robot
will resume program execution. For more information about dedicated signals, refer to
the C Series Controller Operations and Programming Manual, MROCCONTO87E, and
the C Series Controller I/O Interface Manual, MREICCON28E.
Switch or
Relay Contact HP-P1A / HZ-58A HZ-S1A / GA-P1A
PC13 1 1 1GA/1HA
/CON-RS-STOP /M-RS-STOP EPLD 2 BOARD
19 17 2
4 4
20 18
5 5
+24 VDC 6 6
VME
7 BUS 7
8 8
Figure 4-10 External Hold Circuit
4-16 November 2, 2001


ALARM CIRCUITRY
4.4 MOTOR OVER TEMPERATURE CIRCUIT
The motor over temperature circuit (Figure 4-11) is designed to protect the servo motors
from high temperature damage. This is especially important for F-series robots, whose
servo motors are internally enclosed.
The servo motors utilize normally closed thermal switches which are bonded to the
stator windings, and wired in series. When the internal motor temperature reaches
130°C (266°F), the thermal switch opens:
• turning off the motor thermal signal to the 1GB board
• displays error message -1501 (Motor hot) on the MFP
The thermal switches self reset when the motor temperature cools. If the switch does
not reset, the servo motor must be replaced. If an overheat condition exists, the cause
should be determined before normal operation continues.
Typical causes for motor overheat errors are overloaded axes due to:
• excessive payloads
• mechanical damage
• brake system failures
1GB Board
MECHANICAL
+24 VDC UNIT
GB-CN6 XTH X4 X4A
MTHP
8 1 a a
MTHN
15 2 b b
GATE ARRAY RISC CPU

B COMMAND LINE
B
PC2
MT-ER
RISC CPU SERVO ERROR

A
+24 VDC G
Figure 4-11 U-Series Motor Thermal Protection Circuit
November 2, 2001 4-17


ALARM CIRCUITRY
4.5 REGENERATIVE RESISTOR AND CONTROLLER THERMAL CIRCUIT
The C controller utilizes self resetting thermal switches to monitor the controller and
regenerative resistor temperatures (Figure 4-12). The overheat temperature is 70°C
(158°F) for the controller, and 140°C (284°F) for the regenerative resistors. The optional
additional regenerative resistor unit utilizes regenerative resistor and heat sink thermal
switches, rated at 140°C (284°F) and 90°C (194°F), respectively.
The controller thermal switch is mounted above the card file on the roof of the controller,
and is connected to power block connector X5-SA. The regenerative resistor thermal
switch is located on the back of the power block, and is connected internally to the
1GC/1GD board. The optional additional regenerative resistor unit is connected at
power block connector X5-SA.
The controller cabinet does not require a heat exchanger for cooling; fans inside of the
controller cabinet maintain temperatures by circulating the internal air. The regenerative
resistors are isolated in a separate compartment, and utilize fans to circulate outside air
across the resistors for cooling.
Since the thermal switches are wired in series, the AS system software cannot differenti-
ate between the devices in the circuit. When an overheat condition occurs:
• error -1570 (Regenerative resistor hot [Servo (A)] or controller hot)

displays on the multi function panel
• motor power turns off
• the brakes are engaged
Temperature measurements should then be taken to isolate the device that caused the
error. Once the thermal switch has cooled and reset, the cause of the overheat condi-
tion should be determined before robot operation continues.
4-18 November 2, 2001


ALARM CIRCUITRY
Thermal
(140° C)
Motor Power Motor Power Circuit
(MS, Resistance, Etc.) Regenerative
Resistance
Motor Power
Command
(P-N)
Line
CPU A
Additional
Voltage Monitor Regenerative
Servo Circuit Resistance
Error between P-N Drive Circuit
Signal /Regenerative (1GJ Board)
Gate Array-A
Resistance Regenerative
Control Circuit Resistance
Thermal Heat Sink

(140° C) Thermal
Servo Board (90° C)
(1GB PC Board) Power Block
Servo Unit Additional
Regenerative
Controller Thermal Resistance Unit
(70° C)
Controller
Figure 4-12 Controller Thermal Circuit
November 2, 2001 4-19


ALARM CIRCUITRY
4.6 ABNORMAL P-N VOLTAGE DETECTION CIRCUIT
Figure 4-13 illustrates the P-N (Positive-Negative) voltage detection circuit. The average
voltage in the P-N line during the execution of a program is about 300 VDC, depending
on the speed of the program and payload. However, abnormal voltage errors can be
caused by:
• incorrect transformer tap settings
• a defective regenerative resistor
• high voltage during power regeneration, due to excessive load inertia
The voltage in the P-N line is monitored by a comparator circuit located on the 1GC or
1GD boards. If the voltage in the circuit drops below 60 VDC, or exceeds 410 VDC:
• the corresponding low voltage or high voltage error is sent to the 1GB board
• motor power turns off
• which removes 24 VDC brake coil voltage, engaging the brakes
• error code 1568 (Servo unit P-N low voltage [Servo (A)]) or
error code 1569 (Servo unit P-N high voltage [Servo (A)]),
is displayed on the multi function panel.
Motor Power Circuit

(MS, Resistance, Etc.)
Command Motor Power Additional

Line (P-N) Regenerative
CPU A Resistance
Unit
Voltage Monitor
Servo Circuit
Error Regenerative
between P-N Resistance
Signal /Regenerative
Gate Array-A
Resistance
Control Circuit
Voltage Lower Voltage Monitor
Error Circuit Each IPM
between between P-N
Servo Board P-N Line
(1GB PC Board) Power Block
Servo Unit
Figure 4-13 P-N Voltage Detection Circuit
4-20 November 2, 2001


ALARM CIRCUITRY
4.7 VOLTAGE MONITOR CIRCUITS
The voltage monitoring circuits, shown in figure 4-14, ensure voltage levels are within
proper limits for robot operation. The AVR power supply G1 monitors its primary power
input levels, while the outputs are monitored by the 1GA/1HA and 1HP boards. The
voltage monitoring functions are described below. Operational and error voltage levels
are shown in table 4-1.
The 1GA/1HA board monitors the +5 VDC, –12 VDC, and +12 VDC power supply out-
puts. If an abnormality occurs in any of these outputs, the:
• 1GA/1HA board generates the /ACFAIL error signal
• 1GA/1HA board LED LD1 turns on
• 1HP board LEDs LD1, LD2, LD3, and LD4 cycle on and off
The 1HP board monitors the 24 VDC AVR power supply output. If an abnormality oc-
curs:
• The 1HP board generates the +24VFAIL error signal
• The 1HP board LEDs LD1, LD2, LD3, and LD4 cycle on and off
The AVR power supply monitors 200/220 VAC primary power from the T1 transformer.
Primary power errors cause the AVR power supply to generate the ACER error signal.
The error signals are processed by the 1HP board, which:
• energizes on-board relay RY1
• RY1 contacts open the external control power circuit (REMOTE-P, REMOTE-N),
causing the AVR power supply to shut down its outputs.
After a short time delay, the 1HP board:
• de-energizes relay RY1, closing the RY1 contacts
• re-energizes the AVR power supply
If a voltage error still exists, the shut down/start up cycle is repeated, and continues until
the problem is corrected.
November 2, 2001 4-21


ALARM CIRCUITRY
Table 4-1 Controller Voltage Levels
Voltage Errors
Voltage Tolerence Error Level
< +4.85 VDC
+5 VDC ±0.05 VDC
> +5.45 VDC
+12 VDC ±0.1VDC < +10.75 VDC
–12 VDC ±0.1VDC > –10.4 VDC
+24 VDC Non-adjustable < +21.6 VDC
< 150–158 VAC, 1-2 sec.
200/220 VAC Non-adjustable
> 267–277 VAC, 1-2 sec.
Figure 4-14 Voltage Monitoring Circuits
4-22 November 2, 2001


USER INTERFACES
5.0 USER INTERFACES ..................................................................................... 5-2

5.1 Operation Panel ............................................................................................. 5-2
5.1.1 Switches and Indicators ............................................................................... 5-13
5.1.1.1 ERROR Indicator ......................................................................................... 5-13
5.1.1.2 MOTOR POWER Switch/Indicator ............................................................... 5-13
5.1.1.3 EMERGENCY STOP Switch ....................................................................... 5-14
5.1.1.4 TEACH/REPEAT Switch .............................................................................. 5-15
5.1.1.5 CYCLE START Switch/Indicator .................................................................. 5-15
5.1.1.6 ERROR RESET Switch ............................................................................... 5-16
5.1.1.7 HOLD/RUN Switch ....................................................................................... 5-16
5.1.2 Switch/Lamp Replacement Procedures ....................................................... 5-17
5.1.2.1 MOTOR POWER, CYCLE START, ERROR RESET, and HOLD/RUN ......... 5-17
5.1.2.2 EMERGENCY STOP and ERROR .............................................................. 5-19
5.1.2.3 TEACH/REPEAT .......................................................................................... 5-19
5.1.2.4 MOTOR POWER and CYCLE START ......................................................... 5-20
5.1.2.5 ERROR ........................................................................................................ 5-20
5.1.2.6 Allen-Bradley Switches ................................................................................ 5-21
5.2 Multi Function Panel .................................................................................... 5-23
5.2.1 EP Type C Controller Multi Function Panel .................................................. 5-27
5.2.2 Flash RAM PC Card .................................................................................... 5-28
5.3 Type 2 Teach Pendant .................................................................................. 5-29
5.4 Explosion-Proof Teach Pendant ................................................................... 5-33
5.5 Small Teach Pendant ................................................................................... 5-36
5.6 Personal Computer ...................................................................................... 5-37
5.6.1 Installing AS Monitor Software ..................................................................... 5-37
5.6.1.1 Installing KCMON AS Monitor Software ...................................................... 5-38
5.6.1.2 Installing KCWIN AS Monitor Software ........................................................ 5-40
5.6.2 Enabling Terminal Operation ........................................................................ 5-40
5.7 Floppy Disk Drive ......................................................................................... 5-41
5.7.1 Setup ........................................................................................................... 5-43
5.7.2 Testing ......................................................................................................... 5-44
5.7.2.1 AS Language Commands ............................................................................ 5-44
5.7.2.2 Auxiliary Function Commands ..................................................................... 5-46
March 28, 2002 5-1


USER INTERFACES
5.0 USER INTERFACES
User interface components for the C controller system include the following:
• Operation panel
• Optional interface panel (see Appendix)
• Multi function panel (MFP), type 2 teach pendant (TP), or

explosion-proof (EP) TP
• Small teach pendant
• Personal computer (PC)
• Floppy disk drive
5.1 OPERATION PANEL
The operation panel, shown in figures 5-1 through 5-10, allows the user to perform the
following:
• Set MOTOR POWER switch to ON
• Select the teach or repeat modes of operation
• Select the hold or run states
• Enable cycle start
• Observe and reset error conditions
• Select the emergency stop function
5-2 March 28, 2002


USER INTERFACES
Type 2
Teach Pendant ON OFF
T.LOCK
ENA SHIFT SPEED CNT
1 4
— —
X Rx
2 5
— —
Y Ry CHECK
3 6
— —
Z Rz
CL1 CL2
REC
Main Disconnect
Operation Panel
ERROR MOTOR POWER

Accessory Panel
Power Indicator X1
X1
CONTROL POWER
Hour Meter
Figure 5-1 Standard C Controller, Cabinet (Front View)
March 28, 2002 5-3


USER INTERFACES
Operation Panel
Main Disconnect
Accessory Panel
EP Teach Pendant
Power Indicator
Hour Meter
X1A
Figure 5-2 EP Type C Controller, Cabinet (Front View)
5-4 March 28, 2002


USER INTERFACES
EMERGENCY STOP
ERROR MOTOR POWER
X2
AC115V 1A
Figure 5-3 Standard C Controller, Operation Panel (Front View)
March 28, 2002 5-5


USER INTERFACES
MOTOR
ERROR
POWER
ERROR CYCLE
RESET START
REMOTE LOCAL X2
Figure 5-4 EP Type C Controller, Operation Panel (Front View)
5-6 March 28, 2002


USER INTERFACES
The operation panel interfaces with the 1HP board via the XHP-CN2 cable harness
(Figures 5-5 through 5-9). An additional XR-SW1 harness (Figure 5-10), which is con-
nected to the XHP-CN2 harness, allows for connection of the EMERGENCY STOP and
TEACH/REPEAT switches.
The accessory panel includes connector X2 for RS-232C serial communication with the
1GA/1HA board via the XGA-CN1 cable harness, and a 115 VAC utility outlet.
4 XR-SW1
SW1 (EMERGENCY STOP)
SW2
L1 12
SW3
SW4
6
SW6
TEACH/REPEAT
X2
XGA-CN1
XHP-CN2
24
115 VAC
To T1
Figure 5-5 Standard C Controller, Operation Panel (Rear View)
March 28, 2002 5-7


USER INTERFACES
1HZ CN1 BATTERY
CN10
AVR CN1
1GA/1HACN1
CN8
1GW CN3
CN3
CN1 TB2
1HP CN4
CONTROLLER
CN2
CN2
CN4
CN3
T1
XRSW1
ERROR
MOTOR POWER
DOOR
ERROR RESET
CYCLE START OPERATION
HOLD/RUN PANEL
EMERGENCY STOP
TEACH/REPEAT
X1 X2 115 VAC
MULTI FUNCTION PANEL,

TYPE 2 TEACH PENDANT
OR
SMALL TEACH PENDANT PC
Figure 5-6 Standard C Controller, Operation Panel Interconnection Diagram
5-8 March 28, 2002


USER INTERFACES
MFP
EP EP
Teach Teach
Pendant Pendant
1HZ
Barrier
Unit
Battery
Option
Option
Option
Option
Option
Operation
Panel
Operation
Panel
Relay
Fan
Figure 5-7 EP Type C Controller, Operation Panel Interconnection Diagram
March 28, 2002 5-9

5-10
1HP
PC2
EPLD
PC3
Kawasak
XHP-CN2
TEACH/REPEAT Switch 1GA/1HA
(TEACH position shown) XR-SW1 34 +12 VDC
33 +12 VDC HP-P1A / HZ-S8A HZ-S1A / GA-P1A
B7
HOLD/RUN 0 0
A7 31
PC4 1 VME 1
30
CYCLE START 2 BUS 2
29
MOTOR POWER 28 4 4
ERROR RESET 27 5 5
25 6 6
24 PC5 7 7
CYCLE START 23
PC6
USER INTERFACES
MOTOR POWER
ERROR RESET
Figure 5-8 Operation Panel Interface

C SERIES CONTROLLER
March 28, 2002

3
4
X2 Normally
Open
March 28, 2002

LAMP
L1-X2
SW3-3
SW3-3
3
4
X2
X1
L1
40
SW3
X1
(ERROR)
39
38
37 (ERROR RESET)
L1-X1
36
35
26
22
21
34
33
31
30
Kawasak
29
28
27
25
24
23
XHP-CN2
XHP-CN2 20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
USER INTERFACES
1
SW2-3
SW2-4
SW4-3
SW4-4
SW6-R3
SW6-R4
3
4
3
4
3
4
SW2
SW4
SW6
4
3
X1
X2
X1
X2
(HOLD/RUN)
(CYCLE START)
(MOTOR POWER)
SW2-X1
SW2-X2
SW4-X1
SW4-X2
3
4
Normally
3
4
3
4
XR-SW1 Normally Normally Open

Open Open
Normally
B8 A8 B7 A7 B6 A6 B5 A5 B4 A4 B3 A3 B2 A2 B1 A1
4
3
Open
LAMP LAMP
X1
X2
X1
X2
XR-SW1
Figure 5-9 Operation Panel Harness

C SERIES CONTROLLER
5-11
5-12
TEACH/REPEAT
SW5-L3
SW5-L4
SW5-U3
SW5-U4
SW5-M3
SW5-M4
3
4
3
4
3
4
UP
SW5
LOW
MIDDLE
2
1
2
1
2
1
SW5-L2
SW5-L1
SW5-U2
SW5-U1
Kawasak
SW5-M2
SW5-M1
3
4
Normally Open
USER INTERFACES
Normally Closed
2
1
Normally Closed
11
12
SW1
XR-SW1 Normally Closed
22
21
(EMERGENCY STOP)
11
12
B8 A8 B7 A7 B6 A6 B5 A5 B4 A4 B3 A3 B2 A2 B1 A1
SW1-11 SW1-12
XR-SW1
SW1-22 SW1-21
22
21
Figure 5-10 Operation Panel, EMERGENCY STOP and TEACH/REPEAT Switch Harness
C SERIES CONTROLLER
March 28, 2002


USER INTERFACES
5.1.1 SWITCHES AND INDICATORS
For the following discussion, refer to figures 5-3 and 5-4.
5.1.1.1 ERROR INDICATOR
The red ERROR indicator illuminates when there is a hardware, software, or program
error. When the error condition is corrected, the ERROR RESET switch on the opera-
tion panel is pressed to clear the error; the ERROR indicator extinguishes.
5.1.1.2 MOTOR POWER SWITCH/INDICATOR
The MOTOR POWER switch/indicator is a combination switch and amber indicator.

When illuminated, it indicates power is applied to the AC servo motors. When the
MOTOR POWER switch is pressed and the robot is in repeat mode, power is applied to
the AC servo motors if the following conditions exist:
• main disconnect is set to ON
• controller software initialization is complete
• the HOLD/RUN switch is set to RUN
• there are no external hold signals
• there is no E-stop condition
• servo amplifiers are not in an error condition
NOTE
In teach mode, in addition to the above conditions, one
of the enabling devices must also be pressed and held
to apply and maintain motor power.
March 28, 2002 5-13


USER INTERFACES
5.1.1.3 EMERGENCY STOP SWITCH
! CAUTION
The EMERGENCY STOP switch should ONLY be used
for emergencies, and NOT to stop the robot during
normal operations. When the EMERGENCY STOP
switch is used, the mechanical unit stops suddenly,
which puts abnormal stresses on the brakes and other
components.
The EMERGENCY STOP switch is a large red push button type switch. When pressed:
• power to the AC servo motors is removed
• the electromechanical brakes are applied
• the mechanical unit stops quickly
When pressed, the switch latches; to reset the switch, rotate it clockwise until it pops
out.
An additional emergency stop switch is available on the MFP (standard C controller),

type 2 TP, EP TP, and small TP.
For a detailed discussion of the safety circuits, refer to Unit 4, Alarm Circuitry.
5-14 March 28, 2002


USER INTERFACES
5.1.1.4 TEACH/REPEAT SWITCH
The TEACH/REPEAT switch is a two-position switch that selects the teach or repeat
modes of operation. If the switch is moved from the REPEAT to the TEACH position
during the repeat mode of operation:
• power to the AC servo motors is removed
• the electromechanical brakes are applied
• an error may occur
If an error occurs, perform the following:
1. set the TEACH/REPEAT switch to REPEAT
2. press the ERROR RESET switch to clear the error
3. press the MOTOR POWER switch to apply power to the AC servo motors
4. press the CYCLE START switch to resume the cycle
5.1.1.5 CYCLE START SWITCH/INDICATOR
The CYCLE START switch/indicator is a combination momentary push button switch

and green indicator, providing the following two functions:
1. When the CYCLE START switch is pressed, the selected program executes when
the following conditions exist:
• motor power is on
• TEACH/REPEAT switch is set to REPEAT
• the HOLD/RUN switch is set to RUN
• there are no external hold signals
• there is no E-stop condition
• there is no error condition
2. When the robot is operating in the repeat mode, the CYCLE START lamp is illumi-
nated.
March 28, 2002 5-15


USER INTERFACES
! WARNING
When the CYCLE START switch is pressed, the robot
moves from its present position to the position it is
directed to go, along the shortest path. If objects are
along this path, the robot will impact the object.
The operator must be aware of the robot’s position in

the program, and where it will move when the CYCLE
START switch is pressed.
5.1.1.6 ERROR RESET SWITCH
The ERROR RESET switch is a yellow momentary push button switch. If the error
condition no longer exists, pressing the button both clears the error, and turns off the
ERROR indicator.
5.1.1.7 HOLD/RUN SWITCH
The HOLD/RUN switch is a two-position rotary switch. In both the repeat and teach
modes of operation, it places the robot either in the hold or run condition.
When the switch is moved from the RUN to HOLD position, during the repeat mode of
operation, the following occur:
• the robot decelerates to a stop
• the servo motors hold their positions
• the brakes are applied
• power is then removed from the servo motors
See section 7.4.3, 24 VDC Brake Assembly.
5-16 March 28, 2002


USER INTERFACES
When the switch is set back to the RUN position:
• motor power is applied to hold position
• the brakes are released
• motor power is increased
• the robot continues executing the current program
See section 7.4.3, 24 VDC Brake Assembly.
5.1.2 SWITCH/LAMP REPLACEMENT PROCEDURES
! WARNING
Before replacing operation panel switches or lamps, set
the C controller main disconnect to OFF and lock it out.
When the replacement procedure is complete, remove
the lockout, and set the main disconnect to ON.
5.1.2.1 MOTOR POWER, CYCLE START, ERROR RESET, AND HOLD/RUN
The following operation panel switches and switch/indicators are secured using retaining
rings, located on the inside of the operation panel:
• MOTOR POWER
• CYCLE START
• ERROR RESET
• HOLD/RUN
These switches and switch/indicators are constructed in two sections, a front section
and a switch body. A #2 Phillips head screwdriver is required to disconnect the wires
from the switch terminals. To separate the two sections, a small flat head screwdriver is
required.
March 28, 2002 5-17


USER INTERFACES
To replace these switches and switch/indicators, use the following procedure:
1. Using the #2 Phillips head screwdriver, disconnect the wires.
2. With the blade of the small flat head screwdriver, remove the yellow locking tab
(Figure 5-11) by prying up on the tab. Removing the tab exposes a locking lever
with a slot (Figure 5-12).
3. Insert the blade of the small flat head screwdriver into the locking lever slot, and
move the the lever to the left to release the body of the switch from the switch front
section. Remove the switch body.
4. Unscrew (CCW) and remove the retaining ring from the front section of the switch.
5. Remove the front section of the switch from the operation panel by pulling it out
through the front of the panel.
6. Insert the new switch front section into the operation panel.
7. Secure the switch front section with the retaining ring.
8. Position the switch body onto the switch front section, lock it in place with the lock-
ing lever by moving the lever to the right and install the yellow locking tab.
9. Connect the wires.
10. Verify proper operation.
Locking Locking
Tab Lever
Slot
Figure 5-11 Motor Power Switch Figure 5-12 Motor Power Switch
(Rear View) (Rear View, Locking Tab Removed )
5-18 March 28, 2002


USER INTERFACES
5.1.2.2 EMERGENCY STOP AND ERROR
The EMERGENCY STOP switch and ERROR indicator are one piece units. To replace
these units, use the following procedure:
1. Using the #2 Phillips head screwdriver, disconnect the wires.
2. Unscrew (CCW) and remove the retaining ring from the the switch/indicator.
3. Remove the switch/indicator from the operation panel, by pulling it out through the
front of the panel.
4. Insert the new switch/indicator into the operation panel.
5. Secure the switch/indicator with the retaining ring.
5.1.2.3 TEACH/REPEAT
To replace the TEACH/REPEAT switch, use the following procedure:
1. Using the #2 Phillips head screwdriver, remove the wires.
2. Unscrew (CCW) the retaining ring, located on the front side of the operation panel.
3. To remove the retaining ring and control knob from the switch body, hold the switch
body, grasp the retaining ring firmly and pull.
4. Remove the switch from the operation panel by pulling it out through the rear of the
panel.
5. Insert the new switch into the operation panel.
6. Secure the switch with the retaining ring.
7. Install the control knob.
8. Connect the wires (Figure 5-10).
March 28, 2002 5-19


USER INTERFACES
5.1.2.4 MOTOR POWER AND CYCLE START
This procedure describes the lamp replacement for operation panel switch/indicators
MOTOR POWER and CYCLE START. These switch/indicators are constructed in two
sections, a front section and a switch body. To separate the two sections, a small flat
head screwdriver is required. To replace the lamps in these switch/indicators, use the
following procedure:
1. With the blade of the small flat head screwdriver, remove the yellow locking tab
(Figure 5-11) by prying up on the tab. Removing the tab exposes a locking lever
with a slot.
2. Insert the blade of the small flat head screwdriver into the locking lever slot
(Figure 5-12) and move the the lever to the left to release the body of the switch
from the switch front section. Remove the switch body from the front section to gain
access to the lamp.
3. Remove the lamp by pressing down, turning CCW, and pulling out.
4. Install the new lamp.
5. Position the switch body onto the switch front section, lock it in place with the lock-
ing lever by moving the lever to the right and install the yellow locking tab.
5.1.2.5 ERROR
To replace the operation panel ERROR indicator lamp only, use the following procedure:
1. Unscrew the red lens (CCW) to gain access to the lamp.
2. Remove the lamp by pressing down, turning CCW, and pulling out.
3. Insert the new lamp.
4. Install the lens.
5-20 March 28, 2002


USER INTERFACES
5.1.2.6 ALLEN-BRADLEY SWITCHES
This procedure describes the replacement of Allen-Bradley switches (Figure 5-13).

These switches are constructed in two sections, a front section and a switch body. A #2
Phillips head screwdriver is required to disconnect the wires from the switch terminals.
Switch Body Front Section

Side View Rear View
Upper Catch
Upper Slot
Upper Catch
Lower Catch
Lower Slot
Lower Catch
Figure 5-13 Allen-Bradley Switch
To separate the two sections, a small flat head screwdriver is required. The front section
of the switch is attached to the interface panel with a retaining ring. To replace these
switches and switch/indicators, use the following procedure:
1. Using the #2 Phillips head screwdriver, disconnect the wires from the switch body.
2. Insert the the blade of the small flat head screwdriver into the switch body upper
slot, pry up to release the upper portion of the switch body and gently pull out.
3. Insert the the blade of the small flat head screwdriver into the switch body lower
slot, pry down to release the lower portion of the switch and pull out.
4. Remove the switch body.
March 28, 2002 5-21


USER INTERFACES
5. Unscrew (CCW) and remove the retaining ring from the front section of the switch.
6. Remove the front section of the switch from the operation panel by pulling it out
through the front of the panel.
7. Insert the new switch front section into the operation panel.
8. Secure the switch front section with the retaining ring.
9. Position the switch body onto the front section, snap it in place.
5-22 March 28, 2002


USER INTERFACES
5.2 MULTI FUNCTION PANEL
The standard C Controller multi function panel (MFP), shown in figure 5-14, is equipped
with the following:

• Emergency stop (E-stop) switch
• Two enabling devices (left and right)
To 1FT Board CN1
TEACH LOCK Switch

ON OFF
TEACH LOCK
LCD/Touch Panel
Touch Panel Pen
Contrast Adjustment
PC Card Slot (JM8)
Figure 5-14 Standard C Controller, Multi Function Panel
For the following discussion refer to figures 5-14 and 5-15.
All robot functions are accessible from the multi function panel, including system con-
figuration, teaching, and program editing.
The flash RAM PC card slot provides a means to upload or download data to/from a
flash RAM PC card. Programs and system configuration data may be uploaded or
downloaded, system software is download only.
March 28, 2002 5-23


USER INTERFACES

EMERGENCY
Backlight STOP
Contrast
CN CN Switch
Adjustment
Power
2 1
Supply
CN7 CN4 CN8
CN CN
LCD 1FU 20 7
CN
PC
22 Controller
Board CN CN
1 RS-485
21
1FT Board
CN Debug
CN 2 RS-232C
42
J1 CN JM8
41
Touch Panel CN3
J2 Flash RAM
PC Card
Deadman TEACH Deadman
Switch LOCK Switch
(left) Switch (right)
Figure 5-15 Multi Function Panel, Functional Block Diagram
The MFP 1FT board is the display and touch panel processor board. It contains a 32-bit
RISC CPU, 4MB of memory, and 1MB of RAM.
The 1FT board communicates with the controller 1GA board via an RS-485 full duplex
serial interface (Figure 5-15 and 5-16, and Table 5-1). There is also an RS-232C serial
interface ,1FT-CN2, for connection to a personal computer (PC) for troubleshooting.
The 1FT receives AS software (controller operating system) display information and
routes video data to the 1FU board (video board, mounted to the 1FT board) for display
on the LCD. The 1FT board also receives touch panel user input data for routing to the
1GA/1HA board for processing.
5-24 March 28, 2002


USER INTERFACES
X1 CN1
Figure 5-16 Multi Function Panel, Harness X1-CN1
Table 5-1 MFP, X1-CN1 Harness Configuration
Signal Name No. Destination Color

TXD (+) 1 A1 blue
TXD (-) 2 B1 white
RXD (+) 3 A2 yellow
RXD (-) 4 B2 white
+12V 5 A3 green
GND 6 B3 white
+12V 7 A4 red
CN1
GND 8 B4 white
+12V 9 A5 purple
GND 10 B5 white
EMG TP1-P 11 A6 blue
EMG TP1-N 12 B6 brown
TRIG1-P 13 A7 yellow
TRIG1-N 14 B7 brown
15
TP-TYPE 16
EMG TP2-P 17 A9 green
CN1
TRIG2-P 19 20 blue,
X1
TRIG2-N 20 19 22 ga. AWG
shield,
SHIELD
22 ga. AWG
March 28, 2002 5-25


USER INTERFACES
The 1FT board also receives inputs from the following switches and controls, located on
the MFP:
• Enabling device (left and right)
Multi function panel software is installed in the 1FT board flash memory using a Flash
RAM PC card. The card is inserted into the PC card slot JM8 on the 1FT board.
DIP switch SW1, located next to the PC card slot, is set to enable loading MFP software
from the flash RAM card to the 1FT board’s flash memory (Table 5-2).
The flash RAM PC card is also used to load AS (controller operating system) and servo
software to the 1GA/1HA board, and FS (I/O system) software to the 1FS board.
For a complete description of software download procedures, refer to the C Series

Controller Software Download Procedures manual.
Table 5-2 1FT SW1 Settings
Setting
1 2 Function Note
OFF OFF Normal
ON OFF Enables writing MFP software from the SRAM
card to the 1FT board FLASH memory
ON ON Enables system start up from the 1FT EPROM Not used
5-26 March 28, 2002


USER INTERFACES
5.2.1 EP TYPE C CONTROLLER MULTI FUNCTION PANEL
The EP type C controller multi function panel (MFP)(Figure 5-17) is primarily used as a
display device to view various monitor and status screens. It is also used to display and
set auxiliary functions, set up the software interface panel, and enter AS language
commands via the keyboard screen. The EP MFP does not include emergency stop (E-
stop), enabling device, or TEACH LOCK switches, and is not used to teach programs.
The EP MFP includes the flash random access memory (RAM) PC card slot for software
downloading and data storage. For additional information about using the EP type C
controller MFP, refer to the C Series Controller EP Type Operations and Programming
Manual.
Serial Communication to 1HA Board
LCD/Touch Panel
Touch Panel Pen
Contrast Adjustment
PC Card Slot
Figure 5-17 EP Type C Controller, Multi Function Panel
March 28, 2002 5-27


USER INTERFACES
5.2.2 FLASH RAM PC CARD
The flash random access memory (RAM) PC card (Figure 5-18) is used to upload or
download AS, multi function panel or TP, and servo system software and system con-
figuration data.
PC cards are available in 4 MB, 8 MB and 12 MB capacities. A PC card is required for

C controller software downloads.
For more secure data backup, download the contents of the PC card to a PC floppy or
hard disk.
Figure 5-18 Flash RAM PC Card (Actual Size)
5-28 March 28, 2002


USER INTERFACES
5.3 TYPE 2 TEACH PENDANT
The type 2 teach pendant (TP), shown in figures 5-19 and 5-20, is equipped with the
following:

• T.LOCK (teach lock) switch
• Three-position enabling devices (left and right)
• Brightness adjustment control
A VIEW A B
Emergency Stop
Switch
ON OFF
Teach Lock Switch

T.LOCK
Brightness
Liquid Crystal Control
Display/
Touch Panel
PC Card Slot
Coordinate Check
System Mode
Key Key
Enable Key ENA SHIFT SPEED CNT
1 4
— —
X Rx
5
Axis Keys 2
—
Y
—
Ry CHECK
Check Keys
3
—
6
—
Enabling
Z Rz
Device
Interface Panel Key CL1 CL2

Clamp Keys
REC
Record Key
Figure 5-19 Type 2 Teach Pendant (Front/Side Views)
March 28, 2002 5-29


USER INTERFACES
VIEW B
A
PC Card Slot
3-Position 3-Position
Figure 5-20 Type 2 Teach Pendant (Rear View)
5-30 March 28, 2002


USER INTERFACES
For the following discussion refer to figures 5-19 through 5-21.
All robot functions are accessible from the type 2 TP, including system configuration,
teaching, and program editing.
The flash RAM PC card slot provides a means to upload or download data to/from a
flash RAM PC card (Figure 5-18). Programs and system configuration data may be
uploaded or downloaded, system software is downloaded only.
Board A is the type 2 TP display/touch panel/keypad processor board. It contains a

32-bit RISC CPU, 4MB of memory, and 1MB of RAM.
Type 2 Teach Pendant
Backlight
CN CN
Power Emergency Contrast
2 1 Stop Adjustment
Suppy Switch
Flexible
Circuit Board
CN7 CN4 CN8
CN20
Video
LCD CN6
Board
CN22 CN Controller
1 RS-485
Board A
CN
J1 Debug
42 CN
2 RS-485
J2 CN
41
Touch Panel
JM8
CN3 CN5 CN9
T. LOCK
Switch Flash RAM
3-Position 3-Position PC Card
Enabling Enabling
Device Device
(Left) (Right) CN11 CN12
Board B
Soft Keys/LEDs
Figure 5-21 Type 2 Teach Pendant, Functional Block Diagram
March 28, 2002 5-31


USER INTERFACES
Board A communicates with the controller 1HA board via an RS-485 full duplex serial
interface (Figure 5-21 and 5-22, and Table 5-3). There is also an RS-232C serial inter-
face for connection to a personal computer (PC) for troubleshooting.
Board A receives AS software (controller operating system) display information and

routes video data to the video board for display on the LCD. Board A also receives
touch panel and board B soft key user input data for routing to the 1HA board for pro-
cessing.
CN1
X1
Figure 5-22 Type 2 Teach Pendant, Harness X1-CN1
Table 5-3 Type 2 Teach Pendant, Harness X1-CN1
CN1
Signal Name No. Destination AWG Color
TXD (+) 1 A1 blue
TXD (-) 2 B1 white
RXD (+) 3 A2 yellow
RXD (-) 4 B2 white
+12V 5 A3 green
GND 6 B3 white
+12V 7 A4 red
GND 8 B4 white
+12V 9 A5 purple
25
GND 10 B5 white
EMG TP1-P 11 A6 blue
TRIG1-P 13 A7 yellow
TRIG1-N 14 B7 brown
EMG TP2-P 17 A9 green
TRIG2-P 19 A10 red
TRIG2-N 20 B10 brown
5-32 March 28, 2002


USER INTERFACES
5.4 EXPLOSION-PROOF TEACH PENDANT
The explosion-proof (EP) teach pendant (TP)(Figure 5-23 and 5-24) is the intrinsically
safe device that is used to jog the robot and teach programs. It includes the emergency
stop (E-stop), enabling device, and teach lock switches.
• 44 key/14 LED keypad

• Liquid crystal display (LCD), black and white, 34 × 127 characters (64 × 240 dpi)
• E-stop switch
• ANSI 3-position enabling devices
• RS-422 serial interface
• Buzzer
March 28, 2002 5-33


USER INTERFACES
LCD
Keypad
Buzzer
Enabling Devices
Rear View
Figure 5-23 EP Teach Pendant
5-34 March 28, 2002


USER INTERFACES
EP Teach Pendant
CPU Board
RS-422 serial data to/from CPU

ZEBA
Keypad Board
Enabling E-Stop
Device Switch
Figure 5-24 EP Teach Pendant, Functional Block Diagram
March 28, 2002 5-35


USER INTERFACES
5.5 SMALL TEACH PENDANT
The small teach pendant (TP)(Figure 5-19) provides basic teaching and manual opera-
tion capabilities for the robot. It is connected to connector X1 on the C controller door
(Figure 5-1 and 5-6), in place of the MFP.
NOTE
Program editing and system configuration cannot be
performed with the small teach pendant.
EMERGENCY
STOP Switch
TEACH/LOCK Switch
Liquid Kawasak
Crystal
Display
ARM
WRIST
2Y
3Z
1
X
1
X
Trigger Keys
3Z 2Y
TRG TRG
W A
J
REC B
T JOG
Jog Key
CL3 CL4
RST S CHK
CL1 CL2
Figure 5-25 Small Teach Pendant
5-36 March 28, 2002


USER INTERFACES
5.6 PERSONAL COMPUTER
A personal computer (PC) can be connected to the C controller for program upload or
download, program editing, and system monitoring. The PC requires the Kawasaki
KCMON or KCWIN AS Monitor interface software to communicate with the robot con-
troller.
The AS Monitor software provides the capability to control the robot system using AS
Language commands from the PC.
5.6.1 INSTALLING AS MONITOR SOFTWARE
1. Connect the PC to the C controller host communication port (X2), shown in figures
5-3 and 5-4, using an RS-232C 9-pin female-to-female null modem cable
(Figure 5-26).
2 2
C Controller 3 3 PC
5 5
Figure 5-26 RS-232C Null Modem Cable
2. Set the controller main disconnect to ON.
3. Set the TEACH LOCK switches to TEACH, and the HOLD/RUN switches to HOLD.
4. Set the PC power to ON.
5. Ensure the floppy disk containing the AS Monitor software (KCMON or KCWIN) is
write protected.
6. Insert the disk into the PC floppy drive.
March 28, 2002 5-37


USER INTERFACES
5.6.1.1 INSTALLING KCMON AS MONITOR SOFTWARE
The following procedure describes KCMON file installation using Windows 95/98:
1. From the C:\WINDOWS\START MENU\PROGRAMS directory select the

“MS-DOS Prompt” (DOS mode).
2. Verify that the KCMON installation floppy disk contains the following files in the
KCMON\DOSV directory:
• EDT.BAT
• FUTL.BAT
• INST.BAT
• KCMON.BAT
• KCMON_.EXE
• KCMONENV.DAT
3. Select the A: drive.
4. Type <INST C:\ KCMON>, press the <Enter> key.
The KCMON directory and its contents are copied from the floppy disk to the root
directory of the C: drive.
5. Confirm that the directory and its contents have been successfully copied.
6. Use the Windows System Configuration Editor to edit the CONFIG.SYS file:
• Click on the task bar “Start” button

• Select “Run...”
• Select “C:\WINDOWS\SYSTEM\Sysedit.exe”
• Select the “config.sys” file and add the following line:
“DEVICE = C:\ DOS\ANSI.SYS”
7. From the KCMON\DOSV directory type <KCMON><ENTER> to run the AS Monitor

program.
5-38 March 28, 2002


USER INTERFACES
The following procedure describes KCMON file installation using Windows 2000:
1. From the Taskbar, select Start/Programs/Accessories/Command Prompt; observe

that the Command Prompt window is displayed.
2. Verify that the KCMON installation floppy disk contains the following files in the
KCMON\DOSV directory:
• EDT.BAT
• FUTL.BAT
• INST.BAT
• KCMON.BAT
• KCMON_.EXE
• KCMONENV.DAT
3. Select the A:\KCMON\DOSV directory.
4. Type <INST C: \KCMON>, press the <Enter> key; the KCMON directory and the
files in step 2 are copied from the floppy disk to the root directory of the C:.
5. Confirm that the KCMON directory and the files in step 2 have been successfully
copied to the root directory of C:.
6. From the C:\KCMON directory, type <KCMON><Enter> to run the AS Monitor pro-
gram.
March 28, 2002 5-39


USER INTERFACES
5.6.1.2 INSTALLING KCWIN AS MONITOR SOFTWARE
The following procedure describes installation of KCWIN files to the PC hard drive using
Windows 95/98/2000:
1. Confirm that the KCWIN installation floppy disk contains the following files:
• KCWIN.EXE
• KCWIN.INI
• KCWINE.HLP
The KCWINE.HLP file provides basic help information about the KCWIN monitor
sofware.
2. Copy KCWIN.EXE to the root of C: and KCWIN.INI to the C:\WINDOWS

(Windows 95/98) or C:\WINNT (Windows 2000) directory.
3. From Windows Explorer double click on KCWIN.EXE to run the AS Monitor pro-
gram.
5.6.2 ENABLING TERMINAL OPERATION
Select AUX function 95 (AUX 95 ENVIRONMENT DATA 2) and set TERMINAL to

CONN. (connected). When the PC is connected to the C controller host communication
port (X2) (Figures 5-3 and 5-4) and the AS Monitor program is running, all functions that
are normally available from the MFP, type 2 TP, or EP MFP keyboard screen
(Figure 5-27) can be performed at the PC.
pg
! @ # $ % ^ & * ( )
1 2 3 4 5 6 7 8 9 0
Q W E R T Y U I O P
[
A S D F G H J K L ] EXIT
: “ ~ =
Z X C V B N M ; ‘ _ + BS
CTRL+N ® < > ?

® , . / _
Shift Next PG CTRL+L Space Enter
Figure 5-27 Keyboard Screen
5-40 March 28, 2002


USER INTERFACES
5.7 FLOPPY DISK DRIVE
An optional external floppy disk drive (FDD) unit (Figure 5-28) is available for the C
controller. This unit is used for saving/loading user programs and robot data to/from a
floppy disk; this is an alternative to using the flash RAM PC card.
The RS-232C serial interface cable for the unit (1HF-CN2, Table 5-4) is connected to the
C controller X2/HOST connector on the accessory panel (Figures 5-3 and 5-4). Power
for the unit is supplied by an AC cable that is connected to the 115 VAC outlet on the
accessory panel (Figure 5-3).
The three primary components of the FDD unit are the:
• AVR power supply

• FDD controller (1HF board)
• Floppy disk drive.
Table 5-4 1HF-CN2 Harness Configuration
HOST
Signal Destination Twist
Designation No. (pin) Color No.
TXD 1 2 yellow
1
GND 2 5 white
RXD 3 3 red
2
GND 4 5 blue
March 28, 2002 5-41


USER INTERFACES
1HF AVR
FDD Power
FDD Controller Supply
CN2
CP5
Jumpers
115
VAC
Input
RS-232C
Serial
Interface
Cable
AVR Power
Supply
FDD CP5
1HF FDD
Controller
Figure 5-28 Floppy Disk Drive Unit
5-42 March 28, 2002


USER INTERFACES
5.7.1 SETUP
To set up a new FDD unit for proper operation, perform the following:
1. Remove the cover to gain access to the interior of the FDD unit.
2. Set the jumpers on the 1HF board (shown in figure 5-28), according to figure 5-29.
3 2 1
G
FG
F
E
D
C
B
A
Figure 5-29 Floppy Disk Drive Jumpers
3. Set the C controller main disconnect to OFF.
4. Connect the AC power cord to the FDD unit and the 115 VAC outlet on the
accessory panel.
5. Set the C controller main disconnect to ON.
6. Using a digital multimeter, measure the voltage at CP5 on the 1HF board.
The voltage must be +5 VDC (± 0.1 V) - adjust as necessary.
7. Set the C controller main disconnect to OFF.
8. Disconnect the AC power cord.
9. Install the cover.
March 28, 2002 5-43


USER INTERFACES
5.7.2 TESTING
5.7.2.1 AS LANGUAGE COMMANDS
To test the FDD unit using AS Language commands, perform the following:
1. Obtain a floppy disk that contains a program (*.PG).
2. Connect the AC power cord to the FDD unit and the 115 VAC outlet on the
accessory panel.
3. Connect the serial interface cable to the X2/HOST connector on the accessory
panel.
4. Set the main disconnect to ON.
5. Insert the floppy disk into the FDD unit.
6. From the keyboard screen (Figure 5-27), enter the following commands:
$FDPORT 1 Assigns the FDD unit to port 1.
$FDDON
$FD_LOAD *.PG Loads the program *.PG from the disk to the 1GA
The file is loading... board system memory.
$FDFORMAT Formats the disk, all data is erased.

The format is processing...
The format is complete
$FD_SAVE/P *.PG Saves the program *.PG from the 1GA system
memory to the disk.
$FD_FDIR Displays the files and directories on the disk, con-

firm that the program *.PG has been saved to the
disk.
5-44 March 28, 2002


USER INTERFACES
7. Remove the floppy disk.
8. Set the main disconnect to OFF.
9. Disconnect the AC power cord and serial interface cable.
March 28, 2002 5-45


USER INTERFACES
5.7.2.2 AUXILIARY FUNCTION COMMANDS
To test the FDD unit using auxiliary function commands, perform the following:
1. Obtain a floppy disk that contains a program (*.PG).
2. Connect the AC power cord to the FDD unit and the 115 VAC outlet on the acces-
sory panel.
3. Connect the serial interface cable to the X2/HOST connector on the accessory
panel.
4. Set the C controller main disconnect to ON.
5. Insert the floppy disk into the FDD unit.
6. Select AUX 23-4, FDD AUX. FUNCTION - FDD CONFIG

Select FDD port “2”
Select “connection”
7. Select AUX 21, FDD -> MEMORY (FD_LOAD)

Select “1”<ENTER>
Select the program.
8. Select AUX 23-1, FDD AUX. FUNCTION - FDD FORMATTING (FD_FORMAT)

Select “1 1.44MB”<ENTER>
9. Select AUX 20, MEMORY -> FDD (FD_SAVE)

Select “2 program”<ENTER>
Press F3 (NEXT PG)
Select the progam to be saved.
10. Select AUX 22, FILE DIRECTORY (FD_FDIR)

Confirm that the program has been saved to the disk.
11. Remove the floppy disk.
12. Set the main disconnect to OFF.
13. Disconnect the AC power cord, and serial interface cable.
5-46 March 28, 2002


PRINTED CIRCUIT BOARDS
6.0 PRINTED CIRCUIT BOARDS ....................................................................... 6-2

6.1 Overview ........................................................................................................ 6-2
6.1.1 Standard C Controller .................................................................................... 6-2
6.1.2 Explosion-Proof C Controller ......................................................................... 6-8
6.2 Card Rack Circuit Boards ............................................................................ 6-14
6.2.1 1HZ Motherboard ......................................................................................... 6-14
6.2.1.1 1GA/1HA Main CPU .................................................................................... 6-18
6.2.1.2 1GS Serial Interface..................................................................................... 6-27
6.2.1.3 1GW/HW Parallel Input/Output and Analog Output ..................................... 6-29
6.2.1.4 1FS Remote Input/Output and ControlNet ................................................... 6-44
6.2.1.5 1HS Remote Input/Output and CC-Link....................................................... 6-50
6.2.1.6 1HP Power Circuit Control ........................................................................... 6-60
6.3 1HY Relay Board ......................................................................................... 6-66
6.4 Servo Amplifier Assembly ............................................................................ 6-68
6.4.1 1GB Servo CPU Board ................................................................................ 6-68
6.4.2 1GM Current Sensor Interface ..................................................................... 6-73
6.4.3 1GC/GD/1JK Power Block ........................................................................... 6-75
6.5 Explosion-Proof Unit Circuit Boards ............................................................. 6-85
6.5.1 1LU Explosion-Proof Barrier ........................................................................ 6-86
6.5.1.1 Encoder Transmit/Receive Circuit ................................................................ 6-92
6.5.1.2 Relay Interlock Circuit .................................................................................. 6-92
6.5.2 1LW Encoder Barrier.................................................................................... 6-96
6.5.2.1 Battery Replacement ................................................................................... 6-99
6.5.3 1LT E-Stop and Enabling Device Distribution ............................................ 6-100
6.5.4 Teach Pendant Barrier Unit ........................................................................ 6-103
6.6 1FG Encoder Battery Board ...................................................................... 6-106
6.7 1HG Encoder Battery Board ...................................................................... 6-109
6.8 1FT Multi Function Panel Processor .......................................................... 6-122
6.8.1 1FT Board, EP Type C Controller ............................................................... 6-125
6.9 Board A, Type 2 Teach Pendant Processor ................................................ 6-127
6.10 EP Teach Pendant ..................................................................................... 6-130
6.11 1GV Arm ID (Z-Series) .............................................................................. 6-132
6.11.1 Data Storage .............................................................................................. 6-133
6.11.2 Layout ........................................................................................................ 6-134
6.11.3 Input/Output ............................................................................................... 6-136
6.12 Printed Circuit Board Replacement............................................................ 6-137
March 28, 2002 6-1


6.0 PRINTED CIRCUIT BOARDS
6.1 OVERVIEW
6.1.1 STANDARD C CONTROLLER
For the following discussion, refer to figures 6-1 through 6-4.
The 1HZ board (motherboard) is located in the back of the card rack, and is the back-
plane that provides a point of interconnection for circuit boards and the AVR power
supply G1. Refer to section 6.2.1.
The 1GA/1HA board is the main central processing unit (CPU) board, and is located in
rightmost slot of the card rack. Refer to section 6.2.1.1.
The 1GS board is an optional industry pack (IP) serial interface board that is mounted to
the 1HA board. For the explosion-proof (EP) type C controller, the 1GS board provides
the RS-422 serial interface for the EP teach pendant. Refer to section 6.2.1.2.
The 1GW board is the parallel I/O (PI/O) board that provides 32 input and 32 output
channels, and two optional channels for analog outputs. Up to four 1GW boards can be
installed in the C controller for a total of 128 inputs and 128 outputs. Refer to section
6.2.1.3.
The 1FS board (optional) provides the capability to control remote input/output functions
using Slogic programming. It is available in two versions; remote input/output (RI/O) and
RS-485, and ControlNet. Refer to section 6.2.1.4.
The 1HS board functions as a remote device station of a Mitsubishi Control & Communi-
cation Link (CC-Link) master station general purpose programmable logic controller
(PLC). Refer to section 6.2.1.5.
6-2 March 28, 2002


Card Rack AVR

B A Power
Grounding Bar Supply
(G1)
F1
D
1HZ
C
Power Block
K1 (1GC/1GD)
C1 Servo CPU
(1GB)
F2
Relay
Chassis
K3
1HY
TB2
B A
Figure 6-1 Cabinet Interior (Front View)
March 28, 2002 6-3


The 1HP board is located in the leftmost slot of the card rack. It controls the C controller
power up sequence. It also controls distribution of +24 VDC to relays on the 1HY board;
these in turn control distribution of +24 VDC to the K1 and K2 contactors for repeat and
teach modes of operation respectively. Refer to section 6.2.1.6.
The 1HY relay board (located on the relay chassis) routes +24 VDC to the K1 and K2
contactors, and distributes 210 VAC to the K3 contactor, control power lamp, hour meter,
and cooling fans. Refer to section 6.3.
The 1GB board is the servo CPU board and is mounted to the front of the power block
assembly. The standard 1GB board is equipped with two CPUs and controls up to six
axes. The optional 1GB board is equipped with a third CPU and can control a seventh
axis and has an input for conveyor line tracking. Refer to section 6.4.1.
The 1GM current sensor interface board is a small printed circuit board mounted to the
1GB board. It converts current values detected by the current sensors (located on the
power block) to voltage levels, and then scales the voltage level for output to and pro-
cessing by the 1GB board. Refer to section 6.4.1.
The 1GC, 1GD, and 1JK boards are the primary components of the servo system power
block. The 1GC board is used for robots with payload capacities of 30 kg or more and
the 1GD board is used for robots with payload capacities less than 30 kg. Refer to
section 6.4.3.

1FS/1HS
(1FS shown)
AVR
Overtravel Limit 1GA/1HA
Power
Switch Override 1GW (1HA shown)
Supply
1HZ (G1)
1HP SLOT6 SLOT5 SLOT4 SLOT3 SLOT2 SLOT1 1GA G1
CN1
1GA/1HA Board LEDs Status
3.6V Lithium Analog Output Vcc, +5 VDC (±0.05 V) Note: Listed in order from the top to the
CN2 CN1 bottom of the board.
November 2, 2001
Batteries LD5 green LD3
red green
CN3 SW1 LD4 LD3: 1GA/1HA (green)
1HP Board LEDs Status LD3 green OFF: CPU self-test ends with an error
+12 VDC (±0.1 V) ON: CPU self-test ends without an error
LD1 (Vcc, +5 VDC) green LD2 red
LD2 CN1
LD1 green green LD2: 1GA/1HA (green)
LD2 (+12 VDC) green green AC INPUT
LD5 OFF: during AS system restart
LD101 red –12 VDC (±0.1 V)
LD3 (–12 VDC) green ON: blinks 1/sec after AS system restart
LD6 green S1 LD1
LD4 (+24 VDC) S2 red LD1: 1GA/1HA (red)
green red
LD7 OFF: normal
These LEDs are located directly behind
NOTE CN2 ON: ACFAIL or CPU error
red 1FS Board LEDs Status
Kawasak
LD8 GND
LD5, LD6, LD7, and LD8. DIP switches 1GA/S2 and 1FS/S1
DSP
DSP
are shown in their default setting. LD5 (CPU Run)
1 2 3 4 5 6 7 8
LD5 (MPWON) Blinks 1.2 sec./cycle 1HA Board Only
1 2 3 4 5 6 7 8
OFF: motor power OFF
OFF
ON: motor power ON OFF LD4 (Error) LD7: 1HA w/Ethernet Option (green)
CN3 OFF: normal
LD6 (SVCN) OFF: no LAN receive
SW1 ON: error
ON: servo control from the 1GB board ON: LAN receiving
CN5
CN4
LD7 LD3 (ControlNet Status) LD5: 1HA w/Ethernet Option (green)
LD7 (SVERR)
CN1
CN2
green ON: during ControlNet
OFF: normal OFF: LAN link not working
LD5 communication ON: LAN link working
ON: servo error from the 1GB board green
ControlNet LD2 (ControlNet Error) LD4: 1HA w/Ethernet Option (green)
LD8 (ERR) OFF: normal
OFF: normal BNC Connectors CN3 OFF: no LAN transmit
ON: error ON: LAN transmit
ON: servo control error, 1HP board LD4
green LD1 (RI/O Status) LD6: 1HA w/Ethernet Option (green)
CN4 CN2 LD6 ON: during RI/O communication OFF: no LAN collision
green ON: LAN collision
LD101 (Watch Dog Timer)
CN2 OFF: normal
ON: error
System Reset
CN1 (1GA)
CN4 CN1
CN7
CN6
CN3
CN4
+5 VDC ADJ
+12 VDC ADJ
TP1 –12 VDC ADJ

CN8 (+24 VDC)
CN9
TP1G
CN10
Figure 6-2 Card Rack

C SERIES CONTROLLER
6-5
6-6
TRANSFORMER RELAY CHASSIS SERVO AMP
210 VAC 3f X2-SA XM1-SA
POWER BLOCK MAJOR
460 VAC 60 VAC 3f MOTOR
F1 X3-SA XM2-SA
210 VAC 1f X4
115 VAC 1f
26 VAC 1f X4-SA XTH
MINOR
1GC/1GD XM3-SA
MOTOR
CN1 1HY X1-SA X5
1HZ CN1 BATTERY CN2
X5-SA XSOL
TH1
CN8
CN9
HOUR
METER
CN10 CN5
LAMP
CN1
Kawasak
AVR CN4 CARD RACK

CN6
FAN
XR2
SERVO AMP
CN7
CN9
CN13
FAN
CN10
CN12
CN11
1GA/1HA CN1
XR3 CN4 CN6
CN8
X-FORMER
CN10
FAN
SIGNAL
CN2
X3
CN3
1GW
XEPV
1GB
CN3 CN5
CN1 TB2
CN4 CN1
1HP 1GM
CN2
CN2 CN8
CN4
CN3
CONTROLLER
OPERATION BRAKE
PANEL RELEASE
X1 UNIT
DOOR
MFP
OR
TYPE 2 TP
Figure 6-3 General Interconnection Diagram

C SERIES CONTROLLER
November 2, 2001
ROBOT ARM
1HZ b'd SERVO MOTOR ASSY
TERMINAL
MOTHER BOARD JT1-7
SERIAL I/F (PERSONAL COMPUTER)
MAIN CPU RS232C
USER MEMORY EXTERNAL EQUIPMENT VALVE
SYSTEM MEMORY ENCODER BRAKE MOTOR
VME BUS LIMIT SW
LAN I/F EXTERNAL TERMINAL SENSOR
SERIAL I/F
IP I/F
RS485 EXTERNAL EQUIPMENT
A DC POWER
September 28, 2000

(+12 VDC)
1GA/1HA IP I/F
B EXTERNAL EQUIPMENT
b'd BATTERY BACKUP
CONVEYOR 1FG
ENCODER b'd DC POWER for ENCODER
ENCODER SIGNAL,
SENSOR SIGNAL,
VME BUS I/O 24Vdc, LIMIT SW,
BATTERY BACKUP
OPTIONAL BOARD BATTERY ALARM
DC POWER for
(VISION BOARD, I/O BOARD, etc.) MOTOR LINE
ENCODER BRAKE LINE
VME BUS I/O I/O SIGNAL I/F PANEL

POWER BLOCK
Kawasak
CIRCUIT
1GW
SERIAL I/F ENCODER I/F
b'd SENSOR SIGNAL, BRAKE CONTROL JT1 UNIT
RS485 RS485
I/O 24Vdc
BRAKE RELEASE SW
PWR SIGNAL,
VME BUS POWER FAILURE IPM ERROR JT2 UNIT
EXTERNAL CH 1 CPU A
DETECTION CONTROL POWER JT1, 2, 3 SERVO CONTROL,
+24 VDC
CONTROL POWER
CIRCUIT ERROR DETECTION,
EXTERNAL EMG-STOP I/F PANEL HARDWARE ERROR MANAGEMENT
JT3 UNIT
MOTOR POWER EXTERNAL HOLD
CIRCUIT SERIAL COMMUNICATION, PWM SIGNAL,
CH 1 - 3 SERVO DATA CH 2 IPM ERROR
CPU B
CH 0 COMMAND LINE JT4, 5, 6 SERVO CONTROL, JT4 UNIT
MC CONDITION, SERVO CONTROL, SERVO ERROR ERROR DETECTION
1HP
b'd PWM SIGNAL,
CH 3 IPM ERROR JT5 UNIT
SENSOR SIGNAL, I/O 24 VDC, LIMIT SW CPU C
JT7 SERVO CONTROL,
CH 0 ERROR DETECTION,
CONVEYOR ENCODER MANAGEMENT
OPERATION PANEL JT6 UNIT
MOTOR POWER ON, CYCLE START, TEACH/REPEAT,
MOTOR POWER ON, RUN/HOLD, ERROR RESET, EMG-STOP
EMG-STOP,
MC CONDITION BRAKE POWER CURRENT JT7 UNIT
1GM CURRENT FEEDBACK FEEDBACK
REMOTE,
b'd CURRENT LIMIT
ERROR
POWER FAILURE DC POWER
DETECTION RELAY
+5V, +12V, -12V 1HY CIRCUIT
b'd 1GB
DC POWER b'd
DC POWER +5V
+12V,-12V POWER UNIT

CONTROL POWER POWER CIRCUIT POWER UNIT ERROR, CONTROL CIRCUIT, THERMAL
AVR +24V
CONTROL POWER (60/210 VAC) INRUSH CURRENT CONTROL SIGNAL P-N POWER ERROR DETECTION SW
MOTOR POWER (300 VDC) CIRCUIT,
BRAKE POWER (26 VAC) INRUSH CURRENT CONTROL REGENERATE CIRCUIT REGENERATE
BATTERY RELAY RESISTOR
(3.6V) CHASSIS
1GC/1GD b'd
MOTOR POWER 300 VDC
HOUR METER,
CONTROL POWER LAMP
SERVO AMP
EMG-STOP,TRIGGER 460 VAC,

60Hz, 3-PHASE
SERIAL COMMUNICATION MFP, T/P
C CONTROLLER
Figure 6-4 C Controller and Robot Arm Circuit Board Functional Block Diagram
C SERIES CONTROLLER
6-7

6.1.2 EXPLOSION-PROOF C CONTROLLER
NOTE
The following components are located in the explosion-
proof (EP) type C controller EP unit.
For the following discussion, refer to figures 6-5 through 6-9.
The EP type C controller EP components are located in the EP unit, which is mounted
to the right side of the standard C controller cabinet. The 1LU EP barrier board is one of
the main EP unit components. It routes signals and power to/from components in the
hazardous area and pressurized containers via the intrinsically safe barrier devices.
‘Intrinsically safe’ is an industry standard terminology for electronic components that are
safe in explosive environments.
The barrier devices prevent components in the hazardous area (e.g., the painting line or
booth) from releasing enough energy, either thermal or electrical, to cause the ignition of
flammable or explosive gases. There are three types of intrinsically safe barrier devices
used in the EP type C controller:
• MTL4728+ zener barriers (ZB1–ZB3)—receive inputs from pressure switches and

flow meters and route these signals to the 1LU board relay interlock circuit (RIC).
These zener barriers also route outputs from the 1LU board to solenoid controlled
purge valves.
• MTL4728+ zener barrier (ZB4)—receives inputs from mechanical unit limit switches
and routes these signals to the 1LU board RIC.
• Encoder barrier modules (EBMs), with 1LW board—receive data from the encoders,
route data request signals to the encoders, and distribute +5 VDC to the encoders.
• ZEner BArrier (ZEBA)—EP teach pendant (TP) barrier unit that provides an
intinsically safe interface for the EP TP.
6-8 March 28, 2002


Card Rack 1GW/1HW Board

1HA Board
AVR Power Supply (G1)
1HP Board
Power Block
(1GC/1GD/IJK)
1HZ Board
Servo CPU
(1GB)
TB2
Figure 6-5 EP Type C Controller, Interior Components (Front View)
Explosion-proof protection is provided for the axis motors and other pressurized contain-
ers (e.g., the mechanical unit or peripheral devices) by an air purging and pressurizing
system. During system power up, the air in the pressurized containers is purged by
opening the purge valve and creating a flow of air through the container; the flow rate is
measured by the flow meter. If any explosive gases are present in the container, they
are discharged during this process. Following the purging process, the purge valve is
closed and the container is pressurized. By maintaining positive air pressure in the
pressurized containers, explosive gases are prevented from entering the container.
March 28, 2002 6-9


If the container air pressure drops, thereby disabling the systems ability to keep explo-
sive gases out of the pressurized container, the pressure switches signal this condition
to the EP type C controller and the controller interrupts power to components in the
hazardous area; error code ‘-2170 Internal pressure sensor error’ is generated.
Teach Pendant
ZEner BArrier (ZEBA)
TB4
E-Stop Distribution
(1LT)
Encoder AVR
Power Suppy G21
F3, F4, F5
K1 TB1
Encoder Barrier
Modules (1LW)
F2 C1 Explosion-Proof
V1 Barrier (1LU)
Zener Barriers
1HY Board Z2 (ZB1–ZB4)
K3
TB3
Figure 6-6 EP Type C Controller, Interior Components (Side View)
6-10 March 28, 2002

MFP
400/440/460/480/515/575 VAC 3f
X1
210 VAC
1LT Explosion-Proof
CN1 Teach Pendant JR2 X1A
Breaker F1 CN1 Barrier Unit
1HZ CN2 JR3
Mother AVR
Transformer CN3
Board JR4
March 28, 2002

210 VAC 3f 115 VAC 2f 26 VAC 2f 210 VAC 2f
1GS CN1 JT1~6
1LU Encoder
Breaker F4 Breaker F5 Breaker F3 Signal
1HA CN1 X2 JT1 CN1 X3
Contactor K1 CN39
Battery CN1
AC Outlet Diode Bridge Noise Filter Z2 1GW/ XSOL
CN3 CN38 JT2 CN1
Breaker F2 1HW 210 VAC 3f
24 VDC TB3 CN40
to TB3 Contactor CN10 CN8 JT3 CN1
K1 Coil
Option
JT4 CN1
CN3 CN1
Kawasak
Option
1HY Option JT5 CN1
CN5 CN6, CN7, CN10 CN8 CN2 CN9 CN4
Option
JT6 CN1
Option TB2 JT7
Hour Meter Fan Contactor Contactor Encoder
Lamp K3 K3 1HP Signal JT7
CN1 JT7 CN1 7E
Rush Prot./Discharge Circuit
(K3, C1, RS1, RS2)
Thermal
CN4
X2-SA X3-SA X5-SA X1-SA CN4
Operation
1GB Panel MTL4728+
Servo Amplifier Unit CN1 CN4
ZB1
(Power Block) CN2
5 VDC, 12V MTL4728+
CN8 CN2 ZB2
CN3
MTL4728+
ZB4
K21
Fan CN41
CN34
210 VAC AVR
TB4 CN30
G21
CN35
CN6 CN33
XTH
CN42
CN2 CN29
Brake Release
CN5 Switch
XJT
XM1-SA XM1A-SA XM2-SA XM3-SA
7M
JT3-7 Motor Power
X5
JT1, 2 Motor Power

X4
Figure 6-7 EP Type C35 Controller, Interconnection Diagram

C SERIES CONTROLLER
6-11
MFP
6-12
400/440/460/480/515/575 VAC 3f
X1
210 VAC
1LT Explosion-Proof
CN1 Teach Pendant JR2 X1A
Breaker F1 CN1 Barrier Unit
1HZ CN2 JR3
Mother AVR
Transformer CN3
Board JR4
210 VAC 3f 115 VAC 2f 26 VAC 2f 210 VAC 2f
1GS CN1 JT1~6
1LU Encoder
Breaker F4 Breaker F5 Breaker F3 Signal
1HA CN1 X2 JT1 CN1 X3
Contactor K1 CN39
Battery CN1
AC Outlet Diode Bridge Noise Filter Z2 1GW/ XSOL
CN3 CN38 JT2 CN1
Breaker F2 1HW 210 VAC 3f
24 VDC TB3 CN40
to TB3 Contactor CN10 CN8 JT3 CN1
K1 Coil
Option
JT4 CN1
CN3 CN1
Kawasak
Option
1HY Option JT5 CN1
CN5 CN6, CN7, CN10 CN8 CN2 CN9 CN4
Option
JT6 CN1
Option TB2 JT7
Hour Meter Fan Contactor Contactor Encoder
Lamp K3 K3 1HP Signal JT7
CN1 JT7 CN1 7E
Rush Prot./Discharge Circuit
(K3, C1, RS1, RS2)
Thermal
CN4
X2-SA X3-SA X5-SA X1-SA CN4
Operation
1GB Panel MTL4728+
Servo Amplifier Unit CN1 CN4
ZB1
(Power Block) CN2
5 VDC, 12V MTL4728+
CN8 CN2 ZB2
CN3
MTL4728+
ZB4
K21
Fan CN41
CN34
210 VAC AVR
TB4 CN30
G21
CN35
CN6 CN33
XTH
CN42
CN2 CN29
Brake Release
CN5 Switch
XJT
XM1-SA XM2-SA
7M
Motor Power
X4
Figure 6-8 EP Type C37 Controller, Interconnection Diagram

C SERIES CONTROLLER
March 28, 2002

Robot Arm
Explosion-Proof
Servo Motor Assembly
Teach Pendant
Joint
To Terminal PC
March 28, 2002

Cntrl LS Encoder Brake Motor
Serial I/F To external device
Mother Board Main CPU 232C
1HZ Board User Mem. To external device Trigger, Emergency Stop Flow-
Sys. Mem. Serial Communication Purge Prs.Sw meter
To external device To Ext. Equip
VME bus
Serial I/F To external device
Trigger, Emergency Stop
Serial Communication Encoder Signals
Serial I/F Serial Communication Motor
1HA Brake Signals
Board 1GS RS422 Relay Cir. Teach Pendant.
Board
Power
1LT Barrier Unit
Barrier Module
Kawasak
VME bus Option Board

Battery
(I/O board, etc.)
I/O Signal To I/L Panel Encoder Transmit/Receive Interlock

I/O
VME bus AVR Gate Circuit Circuit
Signal
1GW/1HW
Board
Explosion-Proof dedicated output signal DC24V for I/O 1LU
Motor Power ON, Cycle Start, Operation Panel

DC24V Teach/Repeat, Run/Hold, Error Reset
Emergency Stop Encoder Power
VME bus Voltage Joint Control LS
Monitor Cont. Power
External Control Power Control Signal
ON Circuit
To I/L Panel
Brake Pwr.Blk
Motor Power Serial 1/F Encoder 1/F
Emergency Stop/External Hold RS485 RS485 Control
ON Circuit
PWM IPM
Serial Communication 1-3CH Servo Related Data OCH Debug Line CPU A JT1,2,3 Servo Error
Control Error Detection
MC ON, Servo Control, Servo Error Signal Hardware Error Processing
1HP PWM IPM
Board Explosion-Proof Dedicated Input Signal, 24 VDC for I/O, Axis Control LS
CPU B JT4,5,6 Servo Error
Control Error Detection
PWM IPM
Hour Meter CPU C JT7 Servo Control Error
Error Detection
Motor power ON
Control Power On Conv. ENC Handling Crrt.
Emergency stop Feed-
MC ON
Remote Signal Relay Circuit back
Volt. Monitor Cir. Brake Power 1GM Board Power
Error Signal
1HY
Feedback Control 1GC/1GD/1JK
Control Power (DC) 1GB Board
DC Power Board
Board
Power circuit Power Unit Error Power Monitor
Controlpwr. Rush Control Signal Therm.
Regenerative
Motor pwr. Regen.
Control Circuit
Breakpwr. Rush Current Control Signal Resistor
Motor Power 300 VDC

Serial Communication
Figure 6-9 EP Type C Controller, Functional Block Diagram

C SERIES CONTROLLER
6-13

6.2 CARD RACK CIRCUIT BOARDS
6.2.1 1HZ MOTHERBOARD
The 1HZ board (Figure 6-10) is located in the back of the card rack. It is the backplane
for the standard VME chassis that provides a point of interconnection for circuit boards
and the AVR power supply G1. It distributes power from the AVR power supply to the
following components (Figure 6-10 and Table 6-1):
• +5 VDC (VCC), +12 VDC, and -12 VDC to circuit boards in the card rack.
• +5 VDC (VCC), +12 VDC, and -12 VDC to the 1GB servo CPU board.
• +12 VDC to the 1FG encoder battery board.
• +24 VDC to K1 and K2 (repeat/teach mode) contactors on the relay chassis, via the
1HY board.
Two 3.6V lithium batteries, which are mounted to the left side of the card rack chassis,
are connected to the 1HZ board at connector CN1 (Figure 6-2 and 6-10). These batter-
ies charge the super capacitor that is located on the 1GA/1HA board. The super capaci-
tor maintains the memory on the 1GA/1HA board when the controller power is OFF.
The voltage of these batteries is checked by removing the connector from CN1 and
measuring the voltage across pins 1/2 (+5 VDC) and 3/4 (GND).
Backplane connections for circuit boards are made by an upper and lower set of 96 pin
connectors, three rows of 32, that provide interfacing between circuit boards installed in
the card rack. The upper row of connectors is designated P1 and the lower row is desig-
nated P2. The rows of pins for each connector are designated A, B, and C from left to
right.
Several connectors are also provided on the left side of the board for connection to
components that are external to the card rack (Figure 6-10 and Table 6-1).
The 1GA/1HA board is always located in the rightmost position of the card rack. The
1HP board is always located in the leftmost position of the card rack.
For available positions for optional boards that are installed in slots 1 through 6, refer to
table 6-2.
1HZ board standard jumper settings are shown in tables 6-3 and 6-4.
6-14 March 28, 2002


1HP 6 5 4 3 2 1 1GA G1
CN1
RA1
RA2
RA3
R1
3A 2A 1A
1B
1B
1C
1C
1B
1B
1B
1B
1B
1B
1A
1A
1C
1C
1C
1C
1C
1C
1A
1A
1A
1A
1A
1A
C1
RA5
RA4
RA6
JP32
C2
Batteries 3B 2B 1B
4
CN2 C3
C4 4
1GB CN3 +
2
JP31
1 2
JP27
1 2
JP23
1 2
JP19
1 2
JP15
1 2
JP11
1 C5 6
1
(+5 VDC, 2 1 2 1 2 1 2 1 2 1 2 1 C6
CP2
CP4
CP3
+
CP7 CP5
A1 JP29 JP25 JP21 JP17 JP13 JP9
B1 2 1 2 1 2 1 2 1 2 1 2 1 C7
+12 VDC,
CP1
CP8
2 1 2 1 2 1 2 1 2 1 2 1
A3 B3
–12 VDC)
CP6
5
RA7
RA9
1FG
RA10
RA12
+
RA8
RA11
(+12 VDC) CP10
CP11
CP12
CP9
CP13
CP16
1
1
Signal
CP14
CP15
Harness
RA16
RA18
to 1GB
RA13
RA15
CN5
CN4
+
RA14
RA17
Jumpers for +
32B
32B
32B
32B
32B
32B
32C
32C
32A
32C
32C
32C
32C
32B
32B
32A
32A
32A
32A
32A
32C
32C
32A
32A
CP24
CP22
CP23
32 30
CP21
Optional S8 S7 S6 S5 S4 S3 S2 S1 S15
CP24
CP21
CP22
CP23
33
34
33
Limit
34
Switches
S14 S13 S9
S12 S11 S10
1B
1C
1A
1B
1C
1A
1B
1C
1A
1B
1B
1B
1C
1C
1C
1A
1A
1A
1
Jumpers for
CN7
CN6
Optional
Limit
Switches
33
33
34
34
Optional SIG 1-4

1
CN8 6 1
CN9 6
SIG 1-4 to
1GW CN3 1HZ-50
32B
CN10
32C
32A
32B
32C
32A
32B
32B
32C
32C
32A
32A
32B
32C
32A
32B
32C
32A
1HY 1 4
(+24 VDC,
+24 VDC GND)
Figure 6-10 1HZ Board Layout
NOTE
When the controller is equipped with a 1FS board, it is
located in slot 1. When the controller is equipped with a
1FS board and a 1GW board, the 1FS board is located
in slot 1 and the 1GW board in slot 2. Additional 1GW
boards, if equipped, are located in slots 2-5 (maximum
4). When the controller is equipped with 1-4 1GW
boards, without a 1FS board, they are located in slots
1-4. When the controller is equipped with an optional
1GA board in slot 1, the 1FS board and/or 1GW boards
are shifted by 1 slot.
March 28, 2002 6-15


Table 6-1 1HZ Board Connector Descriptions
Connector Description
HZ-CN1 To the 3.6V lithium batteries for 1GA board backup
HZ-CN2 DC power supply harness to the 1GB board; +5 VDC, +12 VDC, –12 VDC, GND
HZ-CN3 DC power supply to 1FG board through separate harness assembly; +12 VDC, GND
HZ-CN4 Signal harness from the 1GA board to the 1GB board
HZ-CN5, Optional overtravel limit switch and additional connections to the 1HP board.
HZ-CN6, Jumpers on these connectors complete the limit switch path. For a description
HZ-CN7 of the limit switch path see Unit 4, Alarm Circuitry.
HZ-CN8, Built-in signal (SIGIN1, SIGIN2, SIGIN3, SIGIN4) harness to 1GW board
HZ-CN9 (CN9 is optional; double arm).
HZ-CN10 DC supply (24 VDC, 24 VDC GND) harness to 1HY board.
Table 6-2 Circuit Board Positions
Position
slot slot slot slot slot slot
Board 1HP 6 5 4 3 2 1 1GA AVR
AVR X
1GA X
1GA (opt) X
1HP X
1HP (opt) X
1FS X X X
1GW X X X X X X
optional board X X X X X X
6-16 March 28, 2002


Table 6-3 1HZ Board JP1 - JP31 Settings
Signal Jumper Number Standard Setting
/IACKOUT, /IACKIN JP1, JP2, JP3, JP4, JP5, JP6, JP7 Open
/BG3OUT JP8, JP12, JP16, JP20, JP24, JP28 Open
Table 6-4 1HZ Board JP32 Settings
Do Not Connect Connect to

Jumpers
to Frame Ground Frame Ground
+5 VDC (GND) 1A-2A (Standard) 2A-3A
+24 VDC (24 G) 1B-2B 2B-3B (Standard)
March 28, 2002 6-17


6.2.1.1 1GA/1HA MAIN CPU
The 1GA/1HA board is the C controller main central processing unit (CPU) board, and is
located in the main card rack assembly in the rightmost position (Figure 6-2). It is
equipped with a 32-bit reduced instruction set computer (RISC) processor, with a clock
speed of 32 MHz (166MHz for 1HA).
The 1GA/1HA board performs the following functions:
• Stores AS software (controller operating system) and servo software in flash

memory.
• Stores user programs and system configuration data in battery backed static ran-
dom access memory (SRAM). Standard storage capacity is 1MB; an optional 4MB
capacity is also available.
• Executes user defined AS software programs.
• Controls servo position loop operations.
• Coordinate conversions.
• Path planning.
• Communication with the 1GB servo CPU board.
• Communication with the multi function panel (MFP), type 2 teach pendant (TP), or
small teach pendant (TP) via 1HP board connector CN4/P2C.
• VME bus interface communication with other circuit boards (1HP power circuit
control board, 1GW and 1FS board I/O boards).
• Industry Pack (IP) interface. Industry packs are optional circuit boards that are
mounted to the 1GA/1HA board, and provide a variety of functions (e.g., arc welding
interface, vision, and analog input).
port A: 16-bit (single size board)
port B: 16-bit (single or double size board)
• RS-232C serial communication with external equipment (e.g., personal computer).
• Monitors DC power supply voltages for abnormal +5 VDC, +12 VDC, and -12 VDC
levels.
6-18 March 28, 2002


• Checks AS software for errors when the power supply or motor power are set to
ON; hardware is monitored continuously. If an error condition clears, the error can
be reset.
An optional second 1GA board can be installed in the first optional slot (slot 1), which
provides the additional CPU, LAN coprocessor, and 10base-T interface required to
perform Ethernet communication.
When the controller power is OFF, the memory on the 1GA/1HA board is maintained by
a super capacitor, located on the 1GA/1HA board. The super capacitor is charged by
two 3.6V lithium batteries, which are mounted on the left side of the card rack and
connected to the 1GA/1HA board via CN1 on the 1HZ board. Be aware that:
• When the controller power is set to OFF, the battery lasts approximately two years,
without the optional second 1GA board installed.
• When the 1GA/1HA board is removed from the card rack, the memory is maintained
for up to 30 minutes by the super capacitor.
• When the 1GA/1HA board is installed in the card rack, it takes approximately 3
hours for the super capacitor to reach full charge.
• The life of the battery varies, depending on how often the 1GA/1HA board is re-
moved and replaced.
NOTE
Ensure that the current robot and system data is saved
to a flash RAM card or floppy disk.
Z-series robots use C controllers equipped with a 1HA board. The specifications of the
1HA board are similar to the 1GA board, except that the 1HA board has a 166 MHz
processor and Ethernet capabilities using a single 1HA board.
March 28, 2002 6-19


The following is a brief description of the functional components of the 1GA/1HA board,
refer to figure 6-11:
• CPU—Central Processing Unit — 32-bit RISC processor
• EPROM—Optional Erasable Programmable Read Only Memory
• VME I/F—Versa Module Equipment InterFace — For communication with other

circuit boards via the 1HZ board backplane connections.
• Flash Memory—AS and servo software are installed in flash memory.
• SRAM—Static Random Access Memory — System memory; user programs and

robot data
• IP I/F—Industry Pack InterFace—Optional interface circuit board (e.g., 1GS serial

I/O board, RS-422 to the 1LT board)
• RTC—Real Time Clock—32 MHz (166MHz for 1HA)
• SI/O—Serial Input/Output interface:
• RS-485 half duplex servo command (SV-CMD1–SV-CMD4) and servo debug

(SV-DBG) to the 1GB board.
• RS-485 full duplex to the MFP, type 2 TP, or small TP
• RS-232C to a personal computer
• CI/O—Complex Input/Output—Parallel I/O timer
• ASIC—Application Specific Integrated Circuit—Specially designed component for

the 1GA/1HA board
• Optional LAN Coprocessor—For EtherNet communication
• Optional 10Base-T I/F—10Base-T InterFace—For EtherNet communication
6-20 March 28, 2002


CPU
EPROM VME I/F P1

256KB a:16/24, d:16
FLASH LAN CN3

Memory Coprocessor
10BASE-T I/F
1MB/4MB
CN4
SRAM IP I/F
1MB/4MB 16BITx2
CN5
VME Bus
RS-485 SV-CMD1
Half Duplex
RTC SI/O
RS-485 SV-CMD2
Half Duplex
RS-485 SV-CMD3
Half Duplex
CI/O SI/O P2
RS-485 SV-CMD4
Half Duplex
RS-485 SV-DBG
Half Duplex
ASIC SI/O
RS-485 MFP/Type 2 TP/Small TP
Full Duplex
PC CN1
RS-232C
ASIC SI/O
HOST
RS-232C CN2
Figure 6-11 1GA/1HA Board Functional Block Diagram
For board layout information, refer to figure 6-7.
For a description of 1GA/1HA board connectors and their functions, refer to table 6-5
and 6-6.
For information about DIP switch settings, indicators, and test points, refer to figure 6-12
and tables 6-7 through 6-10.
March 28, 2002 6-21


T
E A Side IP PC
S +5 VDC CN7 Board CN9
T
LD3
+12 VDC
P LD2
CN5
O –12 VDC LD1
I CN11
(P1)
N GND
T
S SW2
SW1 1GA only
LD7
LD5
LD4
LD6
1HA w/Ethernet only
CN3
SW3
CN2
1 234
ON
CN6 CN8
Kawasak
CN4
B Side IP PC Board CN10
CN1 16-Bit Single or Double (P2)
Figure 6-12 1GA/1HA Board Layout
6-22 March 28, 2002


Table 6-5 1GA/1HA Board Connector Functions
Connector Function
CN1 PC terminal port (RS-232C ch. B), D-sub 9-pin female
CN2 Host communication port (RS-232C ch. A) D-sub 9-pin male
CN3 LAN port (10Base-T, optional)
CN4 I/O connector for B side IP PC board
CN5 I/O connector for A side IP PC board
CN6,8 System connector for B side IP PC board
CN7,9 System connector for A side IP PC board
CN10 VME bus connector (P2) for 1GB, 1FT PC board communication
CN11 VME bus connector (P1) system bus
Table 6-6 1GA/1HA Board CN1/CN2 Pin Assignments
Pin
1 2 3 4 5 6 7 8 9
– RxD TxD – GND – RTS CTS –
March 28, 2002 6-23


When power is applied to the controller, and DIP switch 2-8 (Figure 6-13 and Table 6-7)
is set to OFF, the controller powers up normally without initializing the 1GA/1HA board.
Initializing the controller deletes programs and system data from SRAM.
To display the initialization prompt [Initialize ? (Yes:1, No:0)] at start up, set DIP switch
2-8 to ON. When the controller is powered up and the initialization prompt is displayed,
the operator can select to initialize (1) or start normally (0).
NOTE
During normal operation, it is recommended that DIP
switch 2-8 is set to OFF.
Vcc, +5 VDC (±0.05 V)
LD3 (green)
+12 VDC (±0.1 V)
LD2 (green)
–12 VDC (±0.1 V)
S2 LD1 (red)
1 2 3 4 5 6 7 8
GND
DSP
OFF
SW1 System Reset (1GA)

LD7 (green)
LD5 (green)
1HA w/Ethernet
LD4 (green)
LD6 (green)
CN3
CN2
CN1
Figure 6-13 1GA/1HA Board (Front View)
6-24 March 28, 2002


Table 6-7 1GA/1HA Board Switch Settings
Normal
No. BIT Function Setting Setting Note
SW1 System reset PUSH: Reset Not normally used
VME-SYSRESET Input ON: Disable
1 ON Optional board: OFF
disable OFF: Enable
VME-SYSRESET ON: Disable
2 OFF Optional board: ON
output disable OFF: Enable
FLASH-memory write ON: Disable Set before software
3 OFF
disable OFF: Enable download
ON: EPROM
4 Boot device select OFF Do not change
OFF: FLASH-Memory
SW2
Software start
5 See table 6-6 OFF See table 6-6
condition setting
Software start
6 See table 6-6 OFF See table 6-6
condition setting
ON: Debugging port
7 RS-232C ch. A setting OFF
OFF: Host communication port
System initialization ON: Initialization screen start
8 OFF
selection OFF: Start normally
1 System setting OFF Do not change
Setting of VME bus ON: Enable
2 ON Optional board OFF
SW3 system controller OFF: Disable
3 Unused — OFF
4 Unused — OFF
Table 6-8 SW2 BIT 5 and 6 Settings
SW2
5 6 Function Note
ON ON Star t debugging monitor Not normally used
OFF ON Enable downloader star t from the MFP or type 2 TP Not normally used
ON OFF Disable downloader star t from the MFP or type 2 TP Set before software installation
OFF OFF AS system star t Normal setting
March 28, 2002 6-25


Table 6-9 1GA/1HA Board LEDs Status
No. Color Status Processor Board

OFF: No LAN receive
LD7 green 1HA w/Ethernet Option
ON: LAN receiving
OFF: No LAN collision
ON: LAN collision
OFF: LAN link not working
ON: LAN link working
OFF: No LAN transmit
ON: LAN transmit
OFF: CPU self-test ends with an error
LD3 green 1GA/1HA
ON: CPU self-test ends without an error
OFF: During AS system start
LD2 green 1GA/1HA
ON: Blinks at 1/sec after AS system start
OFF: Normal
LD1 red 1GA/1HA
ON: ACFAIL or CPU error
Table 6-10 1GA/1HA Board Test Points
No. Color Signal Value

4 yellow VCC (+5V) +5.00 VDC, ±0.05 VDC
3 yellow +12V +12.0 VDC, ±0.1 VDC
2 yellow –12V –12.0 VDC, ±0.1 VDC
1 black GND —
6-26 March 28, 2002


6.2.1.2 1GS SERIAL INTERFACE
The 1GS board (Figure 6-14) is an optional industry pack (IP) serial interface board that
is mounted to the 1HA board. For the explosion-proof (EP) type C controller, the 1GS
board provides the RS-422 serial interface for the EP teach pendant.
Specifications:
• MPU—TMP90C841AF (Toshiba)
• SRAM—32KB
• FLASH-ROM—128KB
• Dual/Port RAM—1KB
• Serial Port—RS422/485 or RS232C
• Bus I/F—Industry Pack (IP) bus I/F
• Baud rate—4800–38,400 bps
• Transmission mode RS422/RS484—full duplex (RS422)/half duplex (RS485),
baud rate 4,800–38,400 bps
• Transmission mode RS232C—5/3 lines type, baud rate 4,800–38,400 bps
The 1GS board can be connected to the 1HA CN7-9 side only (not CN6-8).
For information about 1GS board jumpers, switch settings, and connector CN1 pin
assingnments, refer to tables 6-11 through 6-13.
Figure 6-14 1GS Board Layout
March 28, 2002 6-27


Table 6-11 1GS Board Jumper Settings
Jumper Function Setting Normal

J1 RS485/RS422 selection 1-2: RS485 2-3
J2 2-3: RS422
Table 6-12 1GS Board S1 Settings
Switch Function Setting Note

1 ID cord bit 0 OF F Do not change
2 ID cord bit 1 OFF
3 System setting OF F
4 System setting OF F
Table 6-13 1GS Board CN1 Pin Assignments
Pin RS422 RS485 RS232C

1 RxD+ SD+ RxD
2 RxD- SD- CTS
3 TxD+ N.C. TxD
4 TxD- N.C. RTS
5 GND GND GND
6-28 March 28, 2002


6.2.1.3 1GW/HW PARALLEL INPUT/OUTPUT AND ANALOG OUTPUT
The 1GW/HW board is the parallel I/O board.
The difference between the 1GW and 1HW boards, is that the polarity of the inputs and
outputs is reversed (Table 6-14).
Table 6-14 1GW/HW Polarity
Board Input Output

1GW + common - common (sink)
1HW - common + common (source)
The 1GW/HW board provides 32 input and 32 output channels (Figure 6-15). There are
six available slots in the card rack for optional boards. Up to four 1GW/HW boards can
be installed, depending on the number of other optional boards installed.
The 1GW/HW board provides the capability to output signals to control solenoids and
receive input sensor signals (e.g., proximity switches).
An optional configuration of the 1GW/HW board provides two analog output channels.
For connector CN2, CN3, and CN4 pin assignments refer to table 6-15 and figure 6-16.
March 28, 2002 6-29


Transistor OUT 1-8,17-32

Output Reset C
Circuit Array C N
32 2
OUT9-16
Outputs B
J3/J4
A
Solenoid
Signals
C
P VME I/F
N
1 a:16/d:16
3
Sensor Signals
SIGIN1-SIGIN4
+24 VDC, GND
C
IN13-16
Photo B J5
Coupler C
32 A N
Inputs IN1-12, 17-32 4
Figure 6-15 1GW/HW Board Functional Block Diagram
6-30 March 28, 2002


Table 6-15 1GW/HW Board Connector Pin Assignments
CN2 CN4 CN3

Pin Signal Pin Signal Pin Signal Pin Signal Pin Signal
1 OUT1 20 OUT17 1 IN1 20 IN17 1 SOL1
2 OUT2 21 OUT18 2 IN2 21 IN18 2 SOL2
3 OUT3 22 OUT19 3 IN3 22 IN19 3 SOL3
4 OUT4 23 OUT20 4 IN4 23 IN20 4 SOL4
5 OUT5 24 OUT21 5 IN5 24 IN21 5 24VDC
6 OUT6 25 OUT22 6 IN6 25 IN22 6 24VDC
7 OUT7 26 OUT23 7 IN7 26 IN23 7 SIG1
8 OUT8 27 OUT24 8 IN8 27 IN24 8 SIG2
9 OUT9 28 OUT25 9 IN9 28 IN25 9 SOL5
10 OUT10 29 OUT26 10 IN10 29 IN26 10 SOL6
11 OUT11 30 OUT27 11 IN11 30 IN27 11 SOL7
12 OUT12 31 OUT28 12 IN12 31 IN28 12 SOL8
13 OUT13 32 OUT29 13 IN13 32 IN29 13 24G
14 OUT14 33 OUT30 14 IN14 33 IN30 14 SIG3
15 OUT15 34 OUT31 15 IN15 34 IN31 15 SIG4
16 OUT16 35 OUT32 16 IN16 35 IN32
17 N.C. 36 COM1 17 N.C. 36 N.C.
(OUT1-16)
18 VIN1 37 COM2 18 COM1 37 N.C.
(OUT1-16) (OUT17-32) (IN1-16)
19 VIN2 19 COM2
(OUT17-32) (IN17-32)
March 28, 2002 6-31


Encoder power ON1
Encoder power ON2
Air purge valve ON
NC
DC24V (input)
24G (input)
DC24V
Wiring check Internal pressure
sensor
NC
Flow meter
Figure 6-16 1GW/HW Board Connectors
6-32 March 28, 2002


For the following discussion, refer to table 6-16 and figure 6-17.
The 1GW board provides the capability to connect 32 input signals. There are two
+24 VDC power supply common connections COM-1 (CN4–18) and COM-2 (CN4–19).
Each +24 VDC power supply provides power for 16 input circuits. External input signals
are connected to ground at CN4 pins 1–16 and 20–35.
Table 6-16 1GW/HW Board Input Specifications
Number of input channels 32

Input type Photo coupler
Input voltage rating 24 VDC
Input voltage range 24 VDC ±10%
Input current rating 10 mA
Maximum input channels 100% (16 channels/common)
simultaneous
Common system 16 channels/common
sensor line - 4 channels/common
! CAUTION
Ensure the polarity of the 1GW external 24 VDC power
supply is correct (i.e., +24 VDC connected to pins
18/19). If connected incorrectly, damage to the board,
power supply, and contacts may occur.
March 28, 2002 6-33


CONTROLLER EXTERNAL
DEVICE
CN4 TB
1W ID1 1 1
PC
2.4K
16 16
680
ID16 16 16
NC 17 17
COM-1 18 18 +24 VDC
1 COM-2 +24 VDC
19 19
16 ID17 20 20
1W
PC
16 16
2.4K
680
ID32 35 35
NC 36
NC 37
17
32
1GW Board
Figure 6-17 1GW Board General Purpose Input Signals
NOTE
The terminal block (TB) in figure 6-17 is normally lo-
cated on the controller cabinet door.
6-34 March 28, 2002


The 1HW board provides the capability to connect 32 input signals. There are two
+24 VDC power supply GND common connections COM-1 (CN4–18) and COM-2
(CN4–19). Each +24 VDC power supply provides power for 16 input circuits. External
input signals are connected to +24 VDC at CN4 pins 1–16 and 20–35.
! CAUTION
Ensure the polarity of the 1HW external 24 VDC power
supply is correct (i.e., GND connected to pins 18/19). If
connected incorrectly, damage to the board, power
supply, and contacts may occur.
Controller External Device
+24V External
0V External
+24V External
0V External
Figure 6-18 1HW Board General Purpose Input Signals
March 28, 2002 6-35


The load is connected to the collector side (sink) of the 1GW board and the emitter side
(source) of the 1HW board output transistor amplifier circuits.
There are 32 available output signals from the 1GW board. The +24 VDC external
power supply provides power to the output circuitry via VIN1, for output signals
OD1–OD16; and VIN2, for output signals OD17–OD32. The two commons, OC-1 and
OC-2, provide a ground for the output circuitry for OD1–OD16 and OD17–OD32 respec-
tively.
Table 6-17 1GW/HW Board Output Specifications
Number of output channels 32

Output type Photo coupler insulated transistor array
Load voltage 24 VDC ±10%
Maximum load current 0.1 A /channel (1.6 A/common)
Maximum surge current 0.4 A /channel
Maximum output channels 100% (16 channel/common) simultaneously
Common system 16 channels/common solenoid line - 4 channels/common
6-36 March 28, 2002


! CAUTION
Ensure that surge protection is provided for all inductive
loads (i.e., relay coils, solenoids, etc.).
! CAUTION
It is recommended that the diode installed in parallel
with the load be a Hitachi V06C, or equivalent. Ensure
that proper polarity of this diode is observed. If installed
incorrectly, damage to components on the 1GW/HW
board may occur.
NOTE
The terminal block (TB) in figure 6-19 is normally
located on the controller cabinet door.
March 28, 2002 6-37


NOTE
Figure 6-19 represents the portion of the general pur-
pose output circuitry of the 1GW board for outputs OD-
1–OD-4. There is similar circuitry for the remaining 28
outputs, OD-5–OD-32.
CONTROLLER EXTERNAL
DEVICE
+24 VDC
TB
CN2
VIN-1
18 18
4700 pf
U3
ZD4
C3
PC4
1
R52
3 2 OD-1
1 1 load
PC6 12K 1/4W
4
R54
6 7 OD-2
2 2 load
PC9 12K 1/4W
5
R55
11 9 OD-3 3 load
3
PC12 12K 1/4W
12
R53
14 16 OD-4
4 4 load
8 13
12K 1/4W
ZD19
ZD17
ZD20
ZD18
OC-1 36 36
1GW Board
Figure 6-19 1GW Board External Outputs
6-38 March 28, 2002


There are 32 available output signals from the 1HW board. The +24 VDC external
power supply provides power to the output circuitry via VIN1, for output signals
OD1–OD16; and VIN2, for output signals OD17–OD32. The two commons, COM-1 and
COM-2, provide a ground for the output circuitry for OD1–OD16 and OD17–OD32
respectively.
Controller External device
+24V External
0V External
+24V External
0V External
Figure 6-20 1HW Board External Outputs
March 28, 2002 6-39


C1
A1 B1
UNI
1 2 34
±10
SW2 0-15
ON
0-10
1 DA2 U14
UNI
1 2 34
2
3
CN1 SW1 ±10
0-15
ON
0-10
4 DA1
1
20
P1
CN2
C32
A32B32
37
19
A B C A12 B12
1 24V
1 B1 A1 2 OX9
9 3 OX10
4 OX11
5
6
OX12
24G J7 U29
CN3 CN2
DA OPT I/O
J3
A B C
NO.1 NO.2
ADDRESS
SIGOUT
CN3 1
A B C
24V
CN5 2 OX13 CN6
3 OX14
96-128
65-96
33-64
4 OX15
J2
1-32
5 OX16
ADDR
15 6 24G
ESS
CN3 CN2
8 SIGOUT J4
1
2
3
4
A B C
19 B8 A8 1 24V
25-32
17-24
2 WX13
9-16
37 J1
1-8
3 WX14 A1 B1
ON OFF
A B C
4 WX15
RESET
5 WX16
CN4 CN3
SIGIN J5
1
3
2
4
ON OFF OPT
J6 RESET I/O
DA
A B C
CN4
20
1
CN1: Optional analog output

CN2: Output connector
CN3: Solenoid/sensor line
CN4: Input connector
Figure 6-21 1GW/HW Board Connector and Jumper Locations
6-40 March 28, 2002


This section provides information about 1GW/HW board component locations (Figure
6-21), jumper settings (Tables 6-18 through 6-24) and DIP switch SW1 and SW2 analog
output settings (Figure 6-22).
Table 6-18 1GW/HW Board J1 Settings
No. Function Setting Std.

A-B : Option reset
1 Reset output 1 - 8 B-C
B-C : Standard
A-B : Option reset
B-C : Standard
A-B : Option reset
B-C : Standard
A-B : Option reset
B-C : Standard
Standard Reset: The output is reset when the power supply is set to ON, or the system
is reset.
Optional Reset: The output is reset when there is no access from the bus for a fixed
time, the power supply is set to ON, or the system is reset.
I/O
No. Address Setting Note
A-B connected Addresses cannot be duplicated.
1 1 - 32
(2,3,4 open)
A-B connected
2 33 - 64
(1,3,4 open)
A-B connected
3 65 - 96
(1,2,4 open)
A-B connected
4 97 - 128
(1,2,3 open)
March 28, 2002 6-41


No. Signal Name Setting, 1GW Connector, Function Std. Note

I/O24V (for SOL1-SOL4) A–B CN3 Solenoid Because all signals share
1 B–C a common VIN or I/O24V
VIN (for outputs 9-12) B–C CN2 General purpose I/O
and COM or I/O24G, pins
A–B CN3 SOL1
2 OUT9 B–C 1-6 must be set the same
B–C CN2 General purpose I/O (i.e., A–B or B–C).
A–B CN3 SOL2
3 OUT10 B–C However, when A–B is
B–C CN2 General purpose I/O
used, these signals are
A–B CN3 SOL3 not available as general
4 OUT11 B–C
B–C CN2 General purpose I/O purpose I/O (see figure
A–B CN3 SOL4 6-9).
5 OUT12 B–C
I/O24G (for SOL1-SOL4) A–B CN3 Solenoid
6 B–C
COM (for outputs 9-12) B–C CN2 General purpose I/O
No. Signal Name Setting, 1GW Connector, Function Std. Note

I/O24V (for SOL5-SOL8) A–B CN3 Solenoid Because all signals share
1 B–C a common VIN or I/O24V
VIN (for outputs 13-16) B–C CN2 General purpose I/O
and COM or I/O24G, pins
A–B CN3 SOL5 1-6 must be set the same
2 OUT13 B–C
B–C CN2 General purpose I/O (i.e., A–B or B–C).
A–B CN3 SOL6
3 OUT14 B–C However, when A–B is
used, these signals are
A–B CN3 SOL7 not available as general
4 OUT15 B–C
B–C CN2 General purpose I/O purpose I/O (see figure
A–B CN3 SOL8 6-9).
5 OUT16 B–C
I/O24G (for SOL5-SOL8) A–B CN3 Solenoid
6 B–C
COM (for outputs 13-16) B–C CN2 General purpose I/O
6-42 March 28, 2002


Signal
No. Name Setting, 1GW Connector, Function Std. Note
B–C CN3 Sensor All signals share a
1 24V A–B common 24 VDC,
therefore pins 1–5
B–C CN3 SIGIN1 must be set the
2 WX13 A–B same way; i.e.,
A–B or B–C.
B–C CN3 SIGIN2
3 WX14 A–B
A–B CN4 General purpose I/O However, when
B–C is used,
B–C CN3 SIGIN3
4 WX15 A–B these signals are
A–B CN4 General purpose I/O not available as
B–C CN3 SIGIN4 general purpose
5 WX16 A–B I/O (see figure
A–B CN4 General purpose I/O 6-9).
No. Setting I/O Reset Std. Note

1 A–B Enabled When a watchdog timer signal is received from
B–C the 1GA board, the analog output is reset when
2 B–C Disabled the jumper is in the A–B position (enabled).
No. Address Setting Note

1 Board #1, channels 1/2 A–B Up to four 1GW board analog output channels are
available (two per board). Jumper J7 allows the
2 Board #2, channels 3/4 B–C operator to set the address of the 1GW board.
0-10V 0-15V ±10V

UNI UNI UNI
1 2 3 4
1 2 3 4
1 2 3 4
±10 ±10 ±10

0-15 0-15 0-15
ON
ON
ON
0-10 0-10 0-10

DA1 DA1 DA1
Figure 6-22 1GW/HW Board SW1 and SW2 Analog Output Settings
March 28, 2002 6-43


6.2.1.4 1FS REMOTE INPUT/OUTPUT AND CONTROLNET
The C controller provides the capability to control remote input/output (RI/O)functions

using Slogic programming with two configurations of the 1FS circuit board (refer to
figures 6-23 and 6-24). These two configurations are the:
• Remote input/output (RI/O) and RS-485
• ControlNet.
The RI/O version 1FS board can be configured as a remote rack of a programmable
logic controller (PLC) and provides serial PLC and weld timer communication.
The 1FS board is equipped with a 32-bit RISC processor running at 20 MHz and 2 MB
or 4 MB of flash memory for software and Slogic program storage.
Refer to table 6-25 for 1FS board specifications.
For information about DIP switch S1 settings, indicators and connector CN3 pin assign-
ments, refer to tables 6-26 through 6-28.
6-44 March 28, 2002


Robot CPU (1GA/1HA)

Robot Output 1 ~ 256 OX signals = Robot Output signals 1-64
Robot Input 1001 ~ 1256 WX signals = Robot Input signals 1001-1064
Robot Internal 2001 ~ 2256
1001 ~ 1256 1 ~ 256

PLC Weld
Serial Serial
Input Input
1501 ~ 1564 1601 ~ 1632
1FS Board
Allen-Bradley Weld
PLC *SLOGIC Functions Controllers
(Internal Signals) (maximum 8)
501 ~ 564 601 ~ 632

PLC Weld
Serial Serial
Output 1301~1428 301~428 Output
I/O Boards
(1GW, maximum 4,
optional)
*SLOGIC Functions (Internal Signals)
Relays: Non-Retentive 2301 ~ 2428

Relays: Retentive 2501 ~ 2516 An additional magnetic
Relays: Timers 2601 ~ 2616 relay output "SRUN" signal
Relays: Counters 2701 ~ 2716 is available. This signal
SLOGIC Status Signals 2801 ~ 2816 indicates that SLOGIC is
W/C #1 Not Connected 2801 running. It does not have
W/C #2 Communication Error 2802 a signal number.
NAC Communication Error 2803
Battery Error 2804
W/C #2 Not Connected 2805
W/C #2 Communication Error 2806
Spare 2807 ~ 2816
Message Display 2901 ~ 2964
SLOGIC messages must be named $w2901 ~ $w2964.

Refer to AS Language manual for steps to create
string variables (e.g., $w2901 = "message").
Signal for Last Weld Current 2965
Figure 6-23 1FS Board Remote Input/Output and Robot Signal Numbers
March 28, 2002 6-45


G CPU Run
R ControlNet Error
LEDs G ControlNet Status FLASH EPROM
R ControlNet Error
G RI/O Status 2 MB 128 KB
R Watch Dog Timer
DRAM VME Bus

DIP
1 MB Interface
SW P1
SRAM
MPU
4 KB
8
pin Interrupt
SIO
Controller
Timer
NAC &
PIO
BNC
C-Net
Controller P2
BNC
FLASH
64 KB
Figure 6-24 1FS Board Functional Block Diagram
6-46 March 28, 2002


Table 6-25 1FS Board Specifications
Component Specification Note

MPU 32-bit RISC CPU i960 series Working memory, no backup
80960SA20 (Intel)
20Mhz
DRAM 1 MB (pc × 256k × 16) Debug only
MB814260-70LPJ-G (FUJITSU) × 2pc Not used after download
EPROM 128 KB (64K × 16) System memory sequence
HN27C1024HCC-10 (Hitachi)× 1pc Source object
SRAM 4 KB (2k × 16) CPU main communication
common shared CPU VME bus
memory HM62256BLFP-7T × 2pc
Serial ControlNet or R I/O
I/F installed
Communication Line ControlNet 64KB FLASH memory
I/F RS-485 1 channel ControlNet
Serial R I/O, not installed when using ControlNet
Communication for 19,200 bps, half duplex
Weld Interface µPD72001 (NEC) × 1pc
System Bus VME bus interface VME Master, 1GW board
Interface Master/Slave
no system control
A:16, D:16
Hardware Interrupt ACFAIL
Watch Dog Error
VME Bus Error
H/W Timer Interrupt
NAC or ControlNet Interrupt
SIO Interrupt
Watch Dog Timer 100 ms
DIP Switch Software start condition
FLASH memory write mask
BOOT (FLASH or EPROM) boot from setting
LED CPU RUN, ERROR, NAC or
ControlNet STATUS, WDT
Board Configuration VME double height
Current/Operating Current 1.5 A

Temperature Working temperature 0-70°C
March 28, 2002 6-47

6-48
CN1 CN2 CN3 S1
C-Net BNC Connector C-Net BNC Connector R-I/O and RS485 Connector DIP Switch LD101 LD1 LD2 LD3 LD4 LD5
1 2
S1
CN4
8 CN3
CN1 CN2
ZD1 T1 ZD2 T2
C6
C5 75C140GNS
R10 R11
1FS-71 U102
1 U1 17
C-Net Hybrid-IC
Kawasak
53 U9 33
9904 HYBO 54
U12
U11
M8M
M8M
X1
FLASH
FLASH
Memory
Memory
29F400TA
29F400TA
System SW
System SW
ALS08 1 CN101 5
CPU
N80960SA
U18
6 U14 40
U19
0SC1
U13 51 7 39
M8M
M8M
FLASH
FLASH
Memory
Program
Memory
Program
RI/O ASIC
29F400TA
29F400TA
50
User S-Logic
User S-Logic
(NAC)
75 1 11
C-Net ASIC 94317761 TP102
NOTE
9904-CNA10M 17 29
31 18 28
CP33
28 U24 18 TP101
Mount for
13 U23 5 29 17 U26
Reverse Side
14 C-Net 4 HN27C1024 TP104
OSC2
FLASH ROM
39
Figure 6-25 1FS Board Layout

AM29F010 7
U104
cluded with the ControlNet configuration only.

20 30
21 29 40 6
EXO-3C TP103
OSC3
Components in figure 6-25 marked with an X are in-

P2 9 1
P1
10 CN5 2
1FS-71 L1 SM BUHIN < 9710074 >

C SERIES CONTROLLER
March 28, 2002


Table 6-26 1FS Board S1 Settings
BIT Function Setting Standard Setting

1 OFF
Normal
2 OFF
Software start condition
1 ON
System software download
2 OFF
3 FLASH memory write enable ON: Enable ON
OFF: FLASH
4 Boot device select OFF
ON: EPROM
5 Unused OFF
6 Unused OFF
7 Unused OFF
8 Local reset ON: Reset OFF
Table 6-27 1FS Board LEDs
LED Color Function Condition

Normal Error
LD5 Green CPU Run Blinks approx. 1.2sec/cycle
LD4 Red Error OFF ON
LD3 Green CNet Status ON
LD2 Red CNet Error OFF ON
LD1 Green RI/O Status ON
LD101 Red Watch Dog Timer OFF ON
Table 6-28 1FS Board CN3 Pin Assignments
Pin Signal
1 RI/O blue wire
2 RI/O clear wire
3 RI/O shield
4 Chassis ground (FG)
5 N.C.
6 RS-485 signal ground
7 RS-485 SD+
8 RS-485 SD–
March 28, 2002 6-49


6.2.1.5 1HS REMOTE INPUT/OUTPUT AND CC-LINK
The 1HS board (Figures 6-26 and 6-27) functions as a remote device station of a
Mitsubishi Control & Communication Link (CC-Link) master station general purpose
programmable logic controller (PLC). A remote device station is a station that handles
both ON/OFF and numeric data.
When a single 1HS board is installed, it must be installed in slot 1 of the card rack
(Figure 6-2). When additional I/O capacity is required, and a second 1HS board is
installed, it must be installed in slot 2.
Table 6-29 shows the function of 1HS board LEDs.
1HS Board Features
• Bit data—48/48 input/output (I/O) points (maximum), 96/96 with second

1HS board
• Word data—16/16 I/O points (maximum) for user defined signals and general purpose
I/O signals, 32/32 with second 1HS board
• CC-Link communication—bit data: 64/64 I/O points (maximum); the system area
(Table 6-30) occupies 16/16 of the 64/64 points
• 1GW board I/O
• Optional A/D D/A input/output
6-50 October 2, 2002


CN5 A/D D/A

LD1
LD5
LD2
1 2 3 4 5 6 7 8
LD6 S3 Hardware Settings
DSP
LD3 OFF
LD7
LD4 1
2
3 CN2 CC-Link
4
5
CN3 RS-422/485
CN4 RS-232C
Figure 6-26 1HS Board Layout (Front View)
Table 6-29 1HS LEDs
LED Color Function

LD1 green CC-Link Run
LD2 green CC-Link RD (read)
LD3 green CC-Link SD (send)
LD4 red CC-Link Error
LD5 red 1HS main CPU watch dog time out
LD6 red 1HS main CPU error
LD7 green 1HS main CPU run (blinking)
March 28, 2002 6-51


CN5
P1
LD1 (green)
LD5 (red) S3
1HS-71
Kawasak
LD2 (green) 1
2
3
LD6 (red) 4
5
6
LD3 (green) 7
8
LD7 (green)
LD4 (red)
CN2 1 2
CPU
CN1
9 10
CN3 DC-DC Converter
P2
CN4 7
6
S1 5
4
3
2
1
ON
8
7
S2
6
5
4
EPROM
3
2
1
ON
Figure 6-27 1HS Board Layout (Component Side)
6-52 March 28, 2002


Table 6-30 Bit Data System Area
1HS Y Master (Output) Master Y 1HS (Input)

Signal Signal
Number Signal Name Number Signal Name
RXn0 RYn0
RXn1 RYn1
RXn2 RYn2
RXn3 RYn3
Reserved Reserved
RXn4 RYn4
RXn5 RYn5
RXn6 RYn6
RXn7 RYn7
RXn8 Data link star tup request RYn8 Data link star tup complete
RXn9 Data link star tup complete RYn9 Data link star tup request
RXnA Error status RYnA Error reset request
RXnB Remote ready RYnB Not used
RXnC RYnC
Reserved Reserved
RXnD RYnD
RXnE Reserved:QnA RYnE Reserved:QnA
RXnF Reserved:QnA RYnF Reserved:QnA
1 station: n=1
2 stations: n=3
3 stations: n=5
4 stations: n=7
March 28, 2002 6-53


CC-Link Cabling and Connections
For CC-Link serial cable specifications, refer to the Mitsubishi MELSEC manual. The
1HS board CC-Link connector CN2 and it’s signal connections is shown in figure 6-28.
The CC-link twisted serial cable cross section diagram is shown in figure 6-29. A simpli-
fied CC-Link connection diagram, showing the master station and 1HS board connec-
tions, is shown in figure 6-30.
DA Data A (+)
1
2
DB Data B (-)
3 DG Data Ground
4
5 SLD Shield
FG Field Ground
Figure 6-28 1HS CN2 Connections
DA Sheath
SLD (Shielding)
Blue
White Yellow
Aluminum Tape
DB
DG
FG (Grounding Point)
Figure 6-29 CC-Link Cable Cross Section
6-54 March 28, 2002


Mitsubishi PLC
CC-Link Remote Module Remote Module
Master Module (1HS Board CN2) (1HS Board CN2)
Terminal DA DA DA Terminal
Resistor Resistor
110W DB DB DB 110W
DG DG DG
SLD SLD SLD
FG FG FG
Figure 6-30 CC-Link Simplified Wiring Diagram
March 28, 2002 6-55


1HS Board Functionality
Figure 6-31 shows the 1HS board functional block diagram. Figure 6-32 shows 1HS
board communication with the C controller 1GA/1HA main CPU board, Mitsubishi PLC,
weld controllers, and C controller 1GW parallel I/O boards. It also shows the 1HS board
internal signals.
CN5
FLASH EPROM
1MB 128KB
A/D D/A
P1
DRAM VME Bus

1MB Interface
G
R
G
R S3
G
G
R
SRAM
MPU 4KB
CN2
CC-Link
CN1
CC-Link Interrupt
MFP3 Controller
CN3
RS-422/485
D/A Timer
P2
A/D
RS-232C
CN4 7
6
S1 5
4
3
2
1
ON
8
7
6
S2 5
4
3
2
1
ON
Figure 6-31 1HS Board Functional Block Diagram
6-56 March 28, 2002


OX signals = Robot Output signals 1~64

WX signals = Robot Input signals 1001~1064
Robot CPU (1GA/1HA)

Robot Output 1~256
Robot Input 1001~1256
Bit Word
Data Data
1001~1256 1~256 D1001~D1032 D1~D32

Input
1501~1564
Bit Data
Input
Output
501~564 1HS Board 1601~1632
Mitsubishi Weld
*SLOGIC Functions RS-485
PLC Serial Controllers
(Internal Signals) (maximum 8)
CC-Link Input Output
D1501~D1516 601~632
Word
Data
D501~D516
Output
1301~1428 301~428
1GW
Parallel I/O Boards
(optional, 4 maximum)
*SLOGIC Functions (Internal Signals)
Bit Data 1GW Internal Relay Signals
Relays: Timers 3001~3064 2501: 1st 1GW 1~16

st
Relays: Non-Retentive 3065~3096 2502: 1 1GW 17~32
nd
Relays: Counters 3097~3128 2503: 2 1GW 1~16
nd
Relays: Retentive 2001~2512 2504: 2 1GW 17~32
rd
2505: 3 1GW 1~16
Word Data 2506: 3
rd
1GW 17~32
th
2507: 4 1GW 1~16
D/A Output D301~D304 2508: 4
th
1GW 17~32
A/D Input D1301~D1304
Internal Register D2001~D2064 Constant Bit
Internal Relay Signals
2510: Always OFF

2511: Always ON
Figure 6-32 1HS Board Remote Input/Output and Robot Signal Numbers
October 2, 2002 6-57


CC-Link Communication Settings
For information about 1HS board communication configuration DIP switch settings, refer
to tables 6-31 through 6-34. For the locations of 1HS board DIP switches, refer to figure
6-27.
Table 6-31 1HS Board Baud Rate Setting (S1/1–4)
Baud Rate (bps)

BIT 156 K 625 K 2.5 M 5 M 10 M
4
3 X
2 X X
1 X X
X=ON
Table 6-32 1HS Board Number of Occupied Stations Setting (S1/5–6)
Number of Occupied Stations

BIT 1 2 3 4
6 (SENYU0) X X
5 (SENYU1) X X
Data *Number of Available Signals (Input/Output)
BIT 16/16 48/48 80/80 112/112
Word 4/4 8/8 12/12 16/16
X=ON
Bits 7 and 8 are set to OFF.
*The number of available bit data input/output signals = 32n-16, where:
32 is the total number of signals

n=the number of occupied stations
16 is the number of system area signals, refer to table 6-26.
For example, if the number of occupied stations is 3, the number of available bit data
signals is:
32n - 16 = number of signals

32(3) - 16 = 80
number or signals = 80
6-58 March 28, 2002


Table 6-33 1HS Board Station Number Settings (S2)
Station Number
BIT 0 10 20 30 40 50 60 70 80 90
8 (SW80) X X
7 (SW40) X X X X
6 (SW20) X X X X
5 (SW10) X X X X X
Station Number
BIT 0 1 2 3 4 5 6 7 8 9
4 (SW8) X X
3 (SW4) X X X X
2 (SW2) X X X X
1 (SW1) X X X X X
X=ON
For example: to set the station number to 4, set bit 3 to ON.
Table 6-34 1HS Board S3 Settings
Standard
BIT Function Setting Setting
1 OFF
Normal
2 OFF
Software star t condition
1 OFF
System software download
2 ON
OFF: Disable
3 Enable write to flash memor y ON
ON: Enable
OFF: Flash
4 Boot from device select OFF
ON: EPROM
OFF: 1
5 Board address select OFF
ON: 2
OFF: No terminator
6 RS422/485 terminator OFF
ON: Terminator
7 Not used
OFF: No reset
8 Reset OFF
ON: Reset
March 28, 2002 6-59


6.2.1.6 1HP POWER CIRCUIT CONTROL
The 1HP board (Figure 6-33), which is located in the leftmost slot of the card rack
(Figure 6-2), controls the C controller power up sequence. It receives AS software
commands from the 1GA/1HA board, which control the operation of software controlled
relays on the 1HP board.
Software controlled relays control distribution of +24 VDC to relays on the 1HY board.
This, in turn, controls distribution of +24 VDC to the K1 and K2 contactors for repeat and
teach modes of operation respectively.
The 1HP board also provides safety circuits, which include emergency stop switches,
limit switches, and enabling devices. These safety circuits, and distribution of the
+24 VDC to the K1 and K2 contactors, are discussed in detail in Unit 4, Alarm Circuitry.
The 1HP board also controls relay CR1 for routing of 24 VDC to the brakes. For a
detailed discussion of brake control, refer to unit 3, Power Distribution.
Another function of the 1HP board is to provide a point of connection between the MFP,
type 2 TP, or small teach pendant and the 1GA board.
The 1GA/1HA and 1HP boards monitor the AVR power supply DC outputs. When they
detect voltages that are out of tolerance, the controller is powered down. The 1GA/1HA
board monitors the VCC (+5 VDC), +12 VDC, and -12 VDC outputs of the AVR power
supply, while the 1HP board monitors the +24 VDC output.
When a voltage is out of tolerance:
• An error signal is generated.
• This error signal is sensed by the 1HP board, generating the /DCPWR-CUT signal,
causing a relay to energize.
• When the relay is energized, its normally closed contacts open.
• The AVR power supply senses the open contacts, and shuts down the DC outputs.
An automatic error condition is repeated until the power supply voltage is within toler-
ances. For a detailed discussion of voltage monitoring and control, refer to unit 3, Power
Distribution.
Fuse F2 (User Interface)(Figure 6-33), provides circuit protection for the +24 VDC
(I/O24V) that provides power to the 1GW board for input signal circuitry (SIG1–SIG4)
and output to solenoids (SOL1–SOL8).
6-60 January 9, 2004


Safety circuit fuses F1 and F3 are discussed in Unit 4 Alarm Circuitry.
Test points TP1 (+24 VDC) and TP1G (+24 GND) provide a point to measure the
+24 VDC output of AVR power supply G1.
SW1
Overtravel
Limit Switch
Override
LD5 LD1
LD6 LD2
LD7 LD3
P1
LD8 LD4
CN1
(LOWER)
CN2
OFF
ON
(UPPER) 1
DSW1
4
4A 1A
JP2
F2 4B 1B
User
Interface
CN3
(LOWER)
CN4
(UPPER)
P2
3 2 1
JP1
6 5 4
TP1
+24V F3
Safety F1
TP1G
+24G Circuit Safety

Circuit
Kawasak 1HP-50
Figure 6-33 1HP Board Layout
March 28, 2002 6-61


In the EP type C controller, the 1HP board also receives emergency stop (EMG STOP)
and interlock inputs from the 1LU board and emergency stop (TP-EMS) and enabling
device (‘dead man switch’, DMS) inputs from the 1LT board (Figure 6-34). For more
information about EP type C controller circuit boards, refer to section 6.5.
Teach
Pendant on
External Emergency Inner Pressure Emergency
Emergency Stop on Panel Down Stop Trigger CR2
(Relay on 1LT) (Relay on 1LU) (Relay on 1LT) (Relay on 1LT) Software
Stop (Relay on
/STG-A
TEACH 1HY)
Safety Software
Fence /STG-B
REPEAT
Software CR3
/STG-A (Relay on
TEACH 1HY)
REPEAT
CR2 CR3
(Relay on (Relay on
1HY) 1HY) Magnet Contactor
K1
Figure 6-34 EP Type C Controller E-Stop Circuit
6-62 March 28, 2002


The EP type C controller 1HP board also routes 24 VDC to the 1LU board (I/O24V), via
the 1HZ/1GB boards, for the 1LU board relay interlock circuit (RIC)(Figure 6-35).
1GW/1HW Board 1HZ Board 1HP Board 1HZ Board 1GB Board 1LU Board Arm
Internal Pressure Switch
Pressure Sensor
Flow Meter Flow Meter
Wiring Check
7th Axis (Traverse)

Pressure Switch
Flow Meter
8th Axis (Traverse)

Pressure Switch
Flow Meter
Figure 6-35 EP Type C Controller, 1HP I/O24V Distribution
For information about 1HP board connectors, DIP switch (DSW1), jumper settings, and
indicators, refer to tables 6-35 through 6-39.
Table 6-35 1HP Board Connectors
Connector Destination
CN1 User interface (TB2/CJ44)
CN2 Operation panel
CN3 1HY board
CN4 MFP or type 2 TP
Table 6-36 1HP Board DSW1 Settings
Configuration BIT
1 2 3 4
Standard (1HP slot) ON ON ON OFF
Optional Board (slot 6) ON ON OFF OFF
March 28, 2002 6-63


Table 6-37 1HP Board JP1 Settings
Jumper Position
Configuration 1-2 2-3 4-5 5-6
Standard X X
Double Arm X X
NOTE
In table 6-38, ‘external axes’ are controlled by single
axis power blocks. For example, in a configuration that
includes six arm axes and two external axes, the
controller has one 1GC/GD board and two single axis
power blocks.
For low current applications (e.g., servo spot weld gun)

the controller is equipped with a seven axis 1JK/GD
board. See table 6-38 for 1HP board JP2 settings.
Table 6-38 1HP Board JP2 Settings
Arm, No. of Jumper Position

No. of External
1A-2A 2A-3A 3A-4A 1B-2B 2B-3B 3B-4B
Axes Axes
6 - X X
7 Servo Gun X X
6 1-3 X X
6 4-6 X X
7 1-3 X X
6-64 March 28, 2002


Table 6-39 1HP Board Indicators
Condition
LED Color Function Normal Error

LD1 green LD1 (V CC, +5 VDC) ON OFF
LD2 green LD2 (+12 VDC) ON OFF
LD3 green LD3 (–12 VDC) ON OFF
LD4 green LD4 (+24 VDC) ON OFF

MPWON
LD5 green OFF: motor power OFF ON when motor power is on —
ON: motor power ON
SVCN ON during 1GB board
LD6 green —
ON: servo control from the 1GB board communication
SVERR
LD7 red OFF: normal OFF ON
ON: Servo error from the 1GB board
ERR
LD8 red OFF: normal OFF ON
ON: Servo control error, 1HP board
March 28, 2002 6-65


6.3 1HY RELAY BOARD
The 1HY relay board (Figure 6-36) is mounted to the relay chassis; it performs the
following functions:
• Provides +24 VDC and ground for 1HY board relays CR2, CR3, and CR4. When
these relays are energized, contacts for these relays close and +24 VDC from the
AVR power supply (via 1HZ–CN10) is applied to the K1 or K2 contactor coils. When
the K1 or K2 contactors are energized (repeat/teach mode respectively), sets of
contacts are closed and 3-phase 210/60 VAC is applied to the power block; motor
power is now applied to the AC servo motors.
• Routes CND-K1 and CND-K2 (+24 VDC) from contactor K1 and K2 contacts to the
1HP board. These signals indicate that the contactor K1 or K2 contacts are closed.
• Distributes 210 VAC to fans, hour meter, control power lamp, and the K3 contactor
coil. In the EP type C controller, the 1HY board routes 210 VAC to the encoder
power supply G21.
• Routes +24 VDC to the brakes, refer to Unit 3, Power Distribution.
• Jumper R5 provides a means to select when the hour meter runs.
Open (standard): Hour meter runs when motor power is ON.

Short: Hour meter runs when control power is ON.
• 1HY board LEDs provide the following indications:
LD1 is ON when all EMERGENCY STOP switches are released.
LD2–LD4 are ON when motor power is ON as shown in table 6-40. When motor
power is OFF, all LEDs are OFF.
Table 6-40 1HY Board LEDs Status
Mode
LED Color Teach Repeat
LD2 green OFF ON
LD3 green ON ON
LD4 green ON OFF
6-66 March 28, 2002


210 VAC
Hour Power Card Rack Power Block EP Controller T1 CN2 NOTE
K3 Coil Encoder Power
Meter Lamp Fans Fans Supply G21 Fans 1
Motor power ON
2
Motor power OFF
not used
GND
GND
GND
GND
GND
1 CN5 5 1 CN6 3 1 CN7 3 1 CN8 3 1 CN9 3 1 CN10 3 24 VDC from V1 N
P
for brakes
CR1 E-Stop 1
A1 B1 210 VAC from TB1
1HY-31
BRK-P
BRK-P1
CR1
ON: run A2 B2 0 VAC from TB1
CN2
(GREEN)
BRK-N
OFF: E-Stop
LD1
2
Kawasak
BRK-P2
A3 B3
Ground for 210 VAC
D1
R1
3 (CN1-B1/B2)
BRK-N
CN1
A4 B4
A5 B5
CR2 +24 VDC +24 VDC G
24 VDC G for K1/K2 coils 1HZ
A6 B6
+24 VDC +24 VDC G CN10
REPEAT (G1)
(GREEN)
24 VDC
LD2
to K1/K2 coils
D2
R2
24 VDC to brakes
Relay Chassis
1GB-CN4 via K3 contacts
CR3
A1 B1
TEACH/REPEAT A2 B2 K1 coil
(GREEN)
LD3
CN3
A3 B3
D3
R3
A4 B4 K2 coil
24 VDC (CND-K1)
A5 B5
CR4 from K1 contacts
24 VDC (CND-K2)
A6 B6
from K2 contacts
TEACH
(GREEN)
LD4

D4
R4

R5
CN4
1 12
On the 1HY board

10
12
11
9
7
3
8
4
5
2
1
CND-K1
CND-K2
not used

24 VDC to CR1 coil
24 VDC to CR4 coil
GND for CR3 coil

24 VDC to CR3 coil
24 VDC to CR2 coil

17
10
18
19
1HP Board CN3

20
7
6
9
4
Figure 6-36 1HY Board Layout
March 28, 2002 6-67


6.4 SERVO AMPLIFIER ASSEMBLY
6.4.1 1GB SERVO CPU BOARD
The 1GB board (Figure 6-37 and 6-38) is the servo CPU board. The board is available
in six and eight axes configurations. Servo software is installed in the 1GA/1HA board
flash memory. When the controller is powered up, the servo software is downloaded to
the 1GB board static random access memory (SRAM).
The 1GB board performs the following functions:
• Encoder communication interface.

Standard: 6 axes
Optional: 8 axes
• Communication with the 1GA/1HA (main CPU) board.

Standard: 2 ch.
Optional: 3 ch.
• Receives commands from the 1GA/1HA board and performs current and speed
loop processing.
• Outputs pulse width modulation (PWM) signals to the 1GC/1GD board (power
block).
• Manual brake release

Standard: 6 axes
Optional: 7 axes
Manual brake release switches function when motor power is OFF.
• Control of the remote gate servo on (RGSO) signal and automatic brake release.
• Routes limit switch signals to the 1HP board.
• Detects encoder hardware and communication errors, outputs a servo unit error
signal (SVER) via the RS-485 interface to the 1HP board. The 1HP board then
controls powering down the controller.
• Controls up to 7 axes plus a conveyor, using up to three CPUs.
For information about 1GB board connectors, switch settings, indicators and test points,
refer to tables 6-41 through 6-44.
6-68 March 28, 2002


CH1
Command Line
HIC
CPU-A 1GM Current
RS-485 Overcurrent CN9
(JT1, 2, 3) I/V Conversion Feedback
Detection
Overcurrent
Error
Gate Array Encoder I/F
SRAM
A RS-485
CN2 Encoder
Encoder
Battery Alarm
MSON
SVER
Servo Control JT2, 3 PWM Signals
IPM Error
CN12
JT1 PWM Signals

IPM Error
PU Error CN13
MSON (Delay)
Brake Drive Brake

CN6
Circuit
To Manual
CN5
CH2 Brake Box
Command Line
HIC
RS-485 CPU-B 1GM Current
CN1 Overcurrent CN10
Detection
Overcurrent
Error
SRAM CN2 Encoder
B RS-485
Err-B
JT4, 5 PWM Signals

IPM Error
CN12
JT6 PWM Signals

IPM Error CN13
Motor
CN6
CH3 Thermal
Command Line
HIC
CPU-C 1GM Current
RS-485 Overcurrent CN11
(JT7, Conveyor) I/V Conversion Feedback
Detection
Overcurrent
Error
SRAM CN2
C RS-485
Err-C
CH0 Encoder
Debug Line
Conveyor CN3
RS-485
JT7 PWM Signals
IPM Error CN13
24 VDC Limit Switch I/O

CN2
Figure 6-37 1GB Board Functional Block Diagram
March 28, 2002 6-69


TP7 TP9
TP6 TP8
Front - CN8B
CN7 Back - CN8A
CN3 LEDs
No. Name
SW1
SRAM
SRAM
D26 RUN-A
D27 RUN-B
D28 RUN-C
CN1
D36 ERR-A
TP5
D37 ERR-B
CPU-C Gate
D38 ERR-C
Array
D26, D27, D28

D36, D37, D38
D39, D40, D41
CN13
D39 MSON
C D40 BRAKE
LED
D41 RGSO
SRAM
SRAM
CPU-B
TP4
CN2
Gate
CPU-A Array
B
TP3
SRAM
SRAM
CN12
Gate
Array
CN4
CN11
Test Points
CN6
No. Name
TP1 BR24G
TP2 BR24V
CN10
TP3 RUN_A
TP4 RUN_B
1GM TP5 RUN_C
TP6 GND
CN5
TP7 VCC
CN9
TP8 -12V
TP1 TP2 TP9 +12V
= Mounting Holes
Figure 6-38 1GB Board Layout
6-70 March 28, 2002


Table 6-41 1GB Board Connectors
No. Destination Function

CN1 1HZ (VME bus) Command line, debug line, servo control signal,
+24 VDC (external I/O), LS1/2, sensor input 1~4 (SIGIN1–4)
CN2 Mechanical unit Encoder signals (JT1–7), battery alarm, +24 VDC
(via signal harness) (external I/O), LS1/2, sensor input 1–4 (SIGIN1–4)
CN3 Conveyor encoder Encoder signal (conveyor)
CN4 Relay chassis +24 VDC for brakes
CN5 Manual brake release switches Brake release signal (+24 VDC)
CN6 Mechanical unit (via motor Motor brake drive signal (+24 VDC), motor thermal signal
harnesses)
CN7 — Not used
CN8A AVR power supply +5 VDC, +12 VDC, –12 VDC input
CN8B AVR power supply GND
CN9 Power block Current sensor feedback signal for ch. A1, A2, and A3
CN10 Power block Current sensor feedback signal for ch. B1, B2, and B3
CN11 Power block Current sensor feedback signal C1
CN12 Power block PWM signal and IPM error signal for ch. A2, A3, B1 and B2
CN13 Power block PWM signal and IPM error signal for ch. A1, B3, and C1
Regenerating resistor error signal
Regenerating resistor/over temperature error signal
Servo unit P-N high voltage error signal
Servo unit P-N high voltage error signal
Table 6-42 1GB Board SW1 Settings
Normal
BIT Name Function Setting Setting Note
1 UNIT-B Unit B servo control ON
2 UNIT-C Unit C servo control OFF ON for seventh axis operation
3 HPU Debug line termination ON: enable ON
4 HPU-ERR Power block error mask OFF: disable OFF ON to mask power block error
5 HPU-MC MSON termination ON
6 - - OFF not used
March 28, 2002 6-71


Table 6-43 1GB Board LEDs
No. Name Color Indication

D26 RUN-A green CPU-A normal operation
D27 RUN-B green CPU-B normal operation
D28 RUN-C green CPU-C normal operation
D36 ERR-A red Unit-A error
D37 ERR-B red Unit-B error
D38 ERR-C red Unit-C error
D39 MSON green MS ON
D40 BRAKE green Brakes released
D41 RGSO green RGSO ON
Table 6-44 1GB Board Test Points
No. Name Function

TP1 BR24G Brake power supply +24 V GND
TP2 BR24V Brake power supply +24 VDC
TP3 RUN_A CPU-A operation
TP4 RUN_B CPU-B operation
TP5 RUN_C CPU-C operation
TP6 GND Control power supply ground
TP7 VCC Control power supply VCC (+5 VDC)
TP8 –12V Control power supply –12 VDC
TP9 +12V Control power supply +12 VDC
6-72 March 28, 2002


6.4.2 1GM CURRENT SENSOR INTERFACE
The 1GM board is a small printed circuit board mounted to the 1GB board. It converts
current values detected by the current sensors (located on the power block) to voltage
levels, and then scales the voltage level for output to and processing by the 1GB board,
refer to figure 6-39.
Scaling provides the correct voltage output to the 1GB board for current values de-
tected, based on the robot model and type of motor. Because output power and motor
current vary for robot model/motor configurations, eight different 1GM boards with differ-
ent scaling factors are available, refer to table 6-45.
The voltage levels output from the 1GM board are converted to digital signals by A/D
converters on the 1GB board for processing by the 1GB board CPUs.
The 1GM board uses resistors to generate a hexadecimal identification code, refer to
figure 6-40. When the controller is powered up, the resistor code is read and compared
with the servo software to verify hardware/software compatibility. If there is a mismatch,
an error message is generated and motor power cannot be set to ON.
1GC/GD Board
1GB Board Power

OC, CL
Detector Transistor
Module
U V W
Iu VIU iIU
+- 7.5 Current
A/D Sample I/V
CPU & Hold to +5
Iv Conv. VIV Conv. iIV
Scaler Sensors
1GM Board
Servo Motor
Figure 6-39 1GM Board Functional Block Diagram
March 28, 2002 6-73


Table 6-45 1GM Board Part Numbers/ID Codes
1GM Board Part

Robot Model ID Code
No.
FC06N, FS06L, N, FS06L, N, FS10C, E, N 50999-1551 04h
FS10L, FS20C, N 50999-1731 36h
FS30L, N, FS45C, N 50999-1648 25h
UB150 50999-1646 24h
UD100/150 50999-1654 27h
UT, UX, UZ 70/100/120/150 50999-1646 24h
UT, UX, UZ 70/100/120/150 (JT7 Servo Gun) 50999-1585 07h
UX200/300 50999-1645 23h
ZD130 50999-1916 50h
ZX130L, U 50999-1645 23h
ZT165, ZX165U 50999-1645 23h
ZX200S, U, ZX300S 50999-1645 23h
1GM Board
P/N ID
ID
MSB LSB MSB LSB
0 1 0 0 0 0 0 1
4 1
Example: ID = 41 (HEX)
Figure 6-40 1GM Board Resistor Code
6-74 March 28, 2002


6.4.3 1GC/GD/1JK POWER BLOCK
The function of the 1GC (large), 1JK (large w/7th axis), and 1GD (small) power blocks is
to supply precisely controlled current to the AC servo motors, one motor per robot joint,
which produces motor rotation and mechanical unit motion.
For the following discussion, refer to figures 6-41 through 6-46 and tables 6-46 through
6-48.
The power block receives 3-phase 60/210 VAC from transformer T1, via relay K1/K2
contacts and circuit breaker F2. Relay contact K1 routes 210 VAC for the repeat mode
of operation. Relay contact K2 routes 60 VAC for the teach mode of operation. Relays
K1 and K2, and circuit breaker F2 are located on the relay chassis.
The 3-phase 60/210 VAC is supplied to the power block at connector X2-SA, and is
rectified to 86/300 VDC by the diode module. This rectified 86/300 VDC is routed back
to the relay chassis via connector X3-SA, where inrush current protection and discharge
control are performed; components for these functions include relay K3, resistors RS1
and RS2, and spark arrester Z3. Also located on the relay chassis is filter capacitor C1.
module. The filtered 86/300 VDC is routed back to the power block at X3-SA and is
supplied to the insulated gate bipolar transistors (IGBTs) located in the intelligent power
modules (IPMs), one per axis, via the P and N bus bars.
NOTE
For the large power block (1GC/1JK board), an addi-
tional filter capacitor (C1) is connected across the P and
N bus.
Hybrid integrated circuits (HICs) receive PWM signals from the 1GB board and route
them to control ICs that gate the IGBTs. When gated, the IPMs output the current that
drives the AC servo motors. The 1GC power block delivers up to 150 A of current to the
JT1, JT2, or JT3 AC servo motors, depending on the robot model, type of motion, and
load.
March 28, 2002 6-75

6-76
RS1
24 VDC
T1 SIG1 - SIG4
K3
F1 X3-SA BATTERY 1GB b'd (1GW)
N LINK
K3
F2 X2-SA P2
A1 K3
N + (XHZ-CN5,6,7:
L1 H1 R1 K1 A1 B1 Z3
460 210 N C1 DUMMY (XHZ-CN9:
L2 H2 S1 K1 B1 Power B2 XHZ-CN1 XHZ-CN4 XHZ-CN8
VAC VAC P CONNECTOR) OPTION)
L3 H3 T1 K1 A2 A2 RS2 K3
Block P
B2 A3
N 21 22
R2 K2 B3
60
S2 K2
PE VAC 1 2 4 3 X1-SA
PE T2 K2 K3
13 14
TB1 K3
(Ground) XG1-CN1
5
1
F3 (5 A) 6 AVR (G1)
Z2 2
1 2 7
210 X30 1 3 3
TB1-1 8
VAC Y10 2 4 4
F4 (3 A) 9
AC OUTLET 5
1 2 TB1-3 10
115 X10
VAC Y10 LINK
TB1-4
F5 (12 A)
1HZ b'd
1 2
Kawasak
26 X20
VAC Y20 XHZ-CN10
LINK
TB1-2
XHY-CN8 1
1
2
3
2
XHY-CN1 XHY-CN6 120
(3PC) 3
B6 1
C/F 4
A6 2 FAN
B5 3
A5
B1 XHY-CN9
B2 1
A3 2
B3 3 XHZ-CN2 XHZ-CN3
1 2 3 4 5 A1 B1 A2 B2 A3 B3
A4
V1 B4 XHY-CN7 XR2 120
P
GND
GND
BRK-P
A1 1
+5 VDC
N BRK-N P.B.
-12 VDC
ENCODER HARNESS
+12 VDC
A2 2 FAN
3
XHY-CN10 XR3 120

1
TRANS.
2 FAN
3
XHY-CN5
5 POWER LAMP
4 L1
1HY b'd 3 2 HOUR METER

OPERATION PANEL HM
2 1
1
XHY-CN3
K1
XHY-CN4 A5 +24 VDC
13 14
B5 CND-K1
+24 VDC K2
1HP b'd A6
13 14
B6 CND-K2
A1
DOOR B1 K2
K1ON 21 22
A2 A1(+)
K1 A2(-)
B2 +24 VDC G 1 2 3 4 5 XGB-
CN8
A3
B3 K1
K2ON 21 22
A4 A1(+)
K2 A2(-)
B4 +24 VDC G
XGB-
XHY-CN2 K3 CN4
1 1
1GB b'd
43 44
GROUND of AC OUTLET 3 3
31 32
2 2
K3
Figure 6-41 Relay Chassis Schematic Diagram

C SERIES CONTROLLER
March 28, 2002

Large Power Block (1GC Board)
R IPM JT1
Inrush
P4 Protection P IGBT IGBT IGBT
and Servo Motor
S Diode
210 VAC Discharge U
Module Control Control Control CD
Circuit IC IC IC
T N (Not located on the N
Power Block)
Uø CD
March 28, 2002

Vø Wø
MSON MS Drive IGBT IGBT IGBT
V W
MS Operation
Confirmation Control Control Control
IC IC IC
P1 B
Voltage Additional Regenerative Regenerative H20/M21
Error Signal Monitoring Resistor Unit Resistor Encoder
P-N (Not located on the Power Block) Thermal +15 VDC
Regeneration Switch
Signal
Kawasak
Resistor Thermal Error

+12 VDC
PWM HIC
IPM ERR
Current Feedback
Encoder Signal
IPM JT2~7
To IGBT IGBT IGBT
1GB Servo Motor
Board
IC IC IC
Uø CD
Vø Wø
IGBT IGBT IGBT
V W

IC IC IC
H20/M21
+15 VDC Encoder
+12 VDC
PWM HIC
IPM ERR
Current Feedback
Encoder Signal
Figure 6-42 1GC/JK Board Functional Block Diagram

C SERIES CONTROLLER
6-77
Small Power Block (1GD Board)
6-78
R
Inrush IPM JT1
and Servo Motor
S Diode
210 VAC Discharge U
Circuit IC IC IC
Power Block)
Uø CD
Vø Wø
V W
MS Operation
IC IC IC
B P1
Voltage Regeneration
Error Signal Monitoring Signal Regenerative Regenerative H20/M21
P-N Drive Circuit Resistor Encoder
Thermal +15 VDC
Restor Thermal Error
Switch
Kawasak
+24 VDC Fan

+12 VDC
PWM HIC
IPM ERR
Current Feedback
Encoder Signal
IPM JT2~7
To IGBT IGBT IGBT
1GB Servo Motor
Board
IC IC IC
Uø CD
Vø Wø
IGBT IGBT IGBT
V W

IC IC IC
H20/M21
+15 VDC Encoder
+12 VDC
PWM HIC
IPM ERR
Current Feedback
Encoder Signal
Figure 6-43 1GD Board Functional Block Diagram

C SERIES CONTROLLER
March 28, 2002


R S T CN12 CN21
CN11
Diode Module CN10
CN20 GB-CN1
+
P P1
Bus B
CN7
N
Bars
U CSU
W
CSV 6
C16 HIC3 HIC6
1
V CN6
V
CN1
IPM1 IPM6 W
CSV
CSU U C53 6
1 C11
C
N
W 9 U CSU
CSV 5
2 HIC2 HIC5
V CN5
CN2 V
IPM2 IPM5 CSV
U W
CSU C52 5
2 C6
W N U CSU
P 4
CSV
3 HIC1 HIC4
V CN4
CN3 C V
N
IPM3 8 IPM4 CSV
CSU U C50 W 4
3
FG
GB-CN9 GB-CN10
Intelligent Power Module (IPM)
CSU/CSV - Current Sensor (U/V phase)
Figure 6-44 1GC/JK Board
March 28, 2002 6-79


Table 6-46 1GC/JK Connectors
Connector Signal Destination
CN1 JT1 - Current feedback from current sensor
JT2 - Current feedback from current sensor, current sensor

CN2 1GB-CN9
disconnect signal

CN5 1GB-CN10
disconnect signal

CN7 1GB-CN11
disconnect signal
CN8 JT2, 3, 4, 5 (1GB Channels A2, A3, B1, B2) PWM, IPM error 1GB-CN12
JT1, 6, 7 (1GB Channels A1, B3, C1) PWM, IPM error, regeneration
CN9 overtime, P-N overvoltage, P-N low voltage, regenerative resistor 1GB-CN13
overheat
CN10 MS ON signal (to K3 contactor) MS Coil
CN11 Regenerative resistor thermal switch Thermal Switch
CN12 MS condition signal (from K3 contactor) K3 Spare Contact
CN20 JT7 motor (U, V, W) SV-M4
Additional regenerative resistor unit, additional regenerative resistor Install jumper plug
unit thermal switch and heat sink thermal switch, regenerative resistor when controller
CN21
thermal switch and, controller thermal switch thermal is not
used
6-80 March 28, 2002


GB-CN11
Diode Module
R
CN
G CN CN CN
S 27
7 10 12
+ CN
T CN11 26
N
P
IPM1 IPM6
CS CS
CN
HIC 28 C
CN HIC CN
N
CN 20 25 CN
9
1 6
CS CS
IPM2 IPM5
CS CS
CN HIC HIC CN
CN 21 24 CN
2 5
CS CS
CS
IPM3 C IPM4 CS
N
8
CN HIC HIC CN
CN 22 23 CN
3 4
CS CS
GB-CN9 GB-CN10
CS - Current Sensor
IPM - Intelligent Power Module
HIC - Hybrid Integrated Circuit
Figure 6-45 1GD Board
March 28, 2002 6-81


Table 6-47 1GD Connectors

CN2 1GB-CN9
disconnect signal

CN5 1GB-CN10
disconnect signal

CN7 1GB-CN11
disconnect signal
overheat
CN11 Regenerative resistor thermal switch Thermal Switch
CN12 MS condition signal (from K3 contactor) MS Spare Contact
CN20 JT1 motor (U, V, W)

SV-M1
CN27 Regenerative resistor Resistor
CN28 24 VDC for regenerative resistor fan Fan
6-82 March 28, 2002


X3-SA X4-SA X1-SA X5-SA
X2-SA XM1-SA XM2-SA XM3-SA
Figure 6-46 Power Block Connector Locations
March 28, 2002 6-83


Table 6-48 Power Block Connectors

MS ON signal to K3 contactor; MS condition
X1-SA K3 coil, K3 spare contact
signal from K3 contactor
X2-SA 210/60 VAC, 3-phase servo power Circuit protector F2
K3 contactor, capacitor C1, inrush
X3-SA 300/86 VDC servo power
resistor RS1, discharge resistor RS2
X4-SA 300/86 VDC servo power Spare
1GJ board (additional regenerative
Control signal to additional regenerative
X5-SA resistor unit driver board); controller
resistor unit; controller thermal sensing circuit
thermal switch
XM1-SA JT1 servo motor power - U, V, W Connector X4
XM2-SA JT2, 3 servo motor power - U, V, W Connector X4
XM3-SA JT4, 5, 6, 7 servo motor power - U, V, W Connector X5
6-84 March 28, 2002


6.5 EXPLOSION-PROOF UNIT CIRCUIT BOARDS
The explosion-proof (EP) unit is a cabinet that is mounted to the right side of the stan-
dard C controller cabinet (Figure 6-47). All EP type C controller EP circuit boards and
other components are located in the EP unit. The EP unit provides all intrinsically safe
components that are required to provide safe spray painting, sealing, and other EP
operations.
TB4 1LT Board
ZEner BArrier
(ZEBA) Encoder AVR
Unit Power Suppy G21
ZEBA Board
Encoder Barrier Modules

with 1LW Boards
1LU Board
Zener Barriers
(ZB1–ZB4)
TB3
Figure 6-47 EP Type C Controller (Right Side, Cover Removed), EP Unit
March 28, 2002 6-85


6.5.1 1LU EXPLOSION-PROOF BARRIER
! WARNING
When replacing the 1LU board, ensure that connection
to TB1/TB2 is made. Connection to earth ground is
necessary for proper intrinsically safe operation. Failure
to proplerly ground the 1LU board can result in an ex-
plosion or fire in the hazardous area.
The 1LU explosion-proof (EP) barrier board (Figure 6-48 and 6-49) is located in and
mounted to the rear wall of the EP unit. The 1LU board is one of the main EP type
C controller EP components. The 1LU board, in conjunction with the encoder barrier
modules (EBMs, mounted to connectors on the 1LU board), provides the 1GB/encoder
interfaces. The EBMs, with 1LW boards, provide the intrinsically safe portion of the
1GB/encoder interface and the encoder transmit/receive (ET/R) circuit (located on the
1LU board) controls data routing. In addition to encoder data, the 1LU board routes
+6 VDC from the encoder AVR power supply G21 to the EBMs. The EBMs regulate the
+6 VDC to +5 VDC for the encoder logic circuits. The 1LU board also provides +5 VDC
(vcc) to the 1LW board for the non-intrinsically safe portion of the 1LW board isolation
circuit.
The 1LU board also includes the relay interlock circuit (RIC). The RIC, in conjunction
with zener barriers ZB1–ZB4, provides the interface for pressure switches, flow meters,
purge valve solenoids, and limit switches. The zener barriers provide the intrinsically
safe portion of the interface. The RIC also controls +24 VDC to the brakes and motor
thermal (MTH) switch circuit, and interlock and emergency stop (E-stop) signals to the
1HP board and K21 relay. The K21 relay controls power to the encoder AVR power
supply G21.
6-86 March 28, 2002


Encoder
Power Supply LEDs Barrier
Test Points Module
(w/1LW board)
Relay
Interlock
Circuit
(RIC)
LEDs
Zener Barriers
(ZB1–ZB4)
To Earth Ground Bar E1
Figure 6-48 1LU Board Layout
March 28, 2002 6-87


There are many LED indicators on the 1LU board (Figures 6-48 and 6-49, and Table
6-49), that provide very useful information about the operation of various functional
components on the 1LU board. There are two groups of LEDs; the RIC and the power
supply LEDs.
Table 6-49 1LU Board LEDs
LED Label Color Indication

1 PSL1 Yellow Pressure switch for container 1 is ON. ON during normal operation, OFF
when pressure drops.
2 FLS1 Yellow Flow meter for container 1 is ON. ON during power ON purging phase,
OFF during normal operation.
7 LS1 Yellow Limit switch LS1 is ON.
8 LS2 Yellow Limit switch LS2 is ON.
9 ENC_ON1 Yellow Encoder power ON 1 signal (ENC_ON1) from 1HA board is ON.
10 ENC_ON2 Yellow Encoder power ON 2 signal (ENC_ON2) from 1HA boardi s ON.
11 INTERLOCK Green Air purge is completed and encoder power is ON.
12 SOL_ON Green Purge valve solenoid signal (SOL_ON) from 1HA board is ON.
13 Venc Green +6 VDC encoder power is ON.
14 DC24V Green +24 VDC for relay interlock circuit (RIC) is ON.
15 DC12V Green +12 VDC for 12V-5V DC/DC conver ter is ON. The DC/DC conver ter
provides 5V logic power for the encoder transmit/receive (ET/R) circuit.
The RIC LEDs (1–12) indicate the operation of the following:
• PSL1/2/3—pressure switches
• FLS1/2/3—flow meter switches
• LS1/2—limit switches
• ENC_ON1/2—encoder power ON signal from the 1HA board
• SOL_ON—Solenoid power ON signal from the 1HA board
The power supply LEDs (13–15) indicate the status of the following:
• DC24V — +24 VDC to the RIC

• DC12V — +12 VDC to the DC/DC converter, which supplies +5 VDC for the
ET/R logic circuits
• Venc — +6 VDC encoder power supply
6-88 March 28, 2002

1 LED
1LU Board
vcc
RXD/TXD/TXEN
EBAT I/O24V TP6 14 CN
vcc BATER
TP7 1
1LW JT1 Encoder
TB1 +6 VDC CN
TB2
Encoder 2
vcc
JT1-7 1GB Data Request/Encoder Data Transmit/Receive RXD/TXD/TXEN
March 28, 2002

1GB Board CN
29 TP2 (ET/R) BATER
CN
TP1 +5 VDC
3
12 VDC JT2 Encoder
+12 VDC Circuit +6 VDC
1LW
GND vcc CN
15 4
12V-5V
TP3
DC/DC
PSL/FLS/LS GND
Converter
vcc
RXD/TXD/TXEN
JT8-10 1GB Data Request/Encoder Data BATER
CN
CN 19
EBAT 1LW JT10 Encoder
32 +6 VDC CN
TP4 20
TP5
Kawasak
6 VDC +6 VDC
GND Venc I/O24V
Encoder +6 VDC CN 13
AVR Power 30 PSL1/FLS1 1 2 Pressure Switch
Supply G21 SOL1
CN ZB1 Flow Meter
21 Purge Valve
1HA Board PSL2/FLS2 3 4 Pressure Switch

SOL2
CN ZB2 Flow Meter
22
Purge Valve
1HZ Board
PSL3/FLS3 5 6 Pressure Switch
SOL3
CN ZB3 Flow Meter
SOL ON CN ENC ON1/2 9 10 SOL ON 12 23
1GW/HW Board ENC ON1/2 Purge Valve
38
LS1/LS2 7 8 CN ZB4 Limit Switches
JT1-7 +24V Brakes 24
CN JT1 Brake
33 MTH
Relay +24V Brakes CN

1GB Board 34
Interlock JT6 Brake

CN JT8-10 +24V Brakes
Circuit
37 Motor
(RIC) MTHP (24 VDC) CN Thermal Switch
42 JT 1–6
Air purge complete/ MTH
11 encoder power ON
CN EMG STOP
JT7 Brake
39 +24V Brakes CN
1HP Board 35 Motor
CN INTERLOCK Thermal Switch
JT 7
43
MTH JT8 Brake
CN ENC PWR ON
K21 41
+24V Brakes
TB3 CN JT10 Brake
CN INTERLOCK MTHN 36
210 VAC 3f 40
to AVR G21 Motor
Thermal Switch
JT 8–10
Figure 6-49 1LU Board Functional Block Diagram

C SERIES CONTROLLER
6-89

Table 6-50 1LU Board Connectors
Connector Destination Description

CN1–CN19 Encoder • Encoder transmit/receive data (TXD/RXD)
(odd) Barrier • 1GB encoder data requests
Modules • Encoder positional data (TXEN) to the 1GB board
(EBMs) • Battery alarm signal (BATER) from the encoders
CN2–CN20 1LW board +6 VDC to the 1LW voltage regulator for +5 VDC encoder logic power
(even)
CN21 ZB1 Pressurized container 1
• Pressure switch (PSL1) input
• Flow meter (FLS1) input
• Solenoid (SOL1) output output to the purge valve
• Solenoid (SOL2) output to the purge valve
• Solenoid (SOL3) output to the purge valve
CN24 ZB4 Limit switch inputs (LS1/LS2) from the mechanical unit
CN25–CN28 Jumpers • Pressure switch jumpers
• Limit switch jumpers
• Flow meter jumpers
CN29 1GB board • 1GB data requests to the JT1–7 encoders
• Encoder data, JT1–7
• Encoder battery error signals (EBAT)(JT1–7)
• +24 VDC to the RIC
• +12 VDC to the 12V-5V DC conver ter (+5V vcc logic power)
• Pressure switch, flow meter, and limit switch status from the RIC
CN30 Encoder +6 VDC to encoders
AVR power
suppy G21
CN32 1GB board • JT8–10 encoder data
• Battery error signals (EBAT)(JT8–10)
CN33 1GB board • +24 VDC to JT1–7 brakes
• Motor thermal (MTH) switch signal from axis motors to 1GB
CN34 Brakes +24 VDC to JT1–6 brakes
CN35 JT7 brakes/ +24 VDC to JT7 brake, JT7 motor thermal (MTH) switch input
motor
thermal
switch
CN36 JT8–10 +24 VDC to JT8–10 brakes
brakes
CN37 1GB board +24 VDC to JT8–10 brakes
CN38 1HA via • Encoder power ON (ENC ON1/2) from 1HA to RIC
XSOL • Solenoid ON (SOL ON) from 1HA to purge valve solenoids
connector,
1GW/1HW,
and 1HZ
CN39 1HP board Emergency stop (EMG STOP) signal from RIC, output to 1HP when
pressurized container air pressure drops
CN40 TB3 210 VAC 3φ interlock
CN41 K21 Encoder power ON (ENC PWR ON) from RIC to relay K21. K21 controls
210 VAC 3φ power to encoder AVR power supply G21.
CN42 Motor JT1–6 motor thermal (MTH) switch input
thermal
switch
CN43 1HP board INTERLOCK signal from RIC to 1HP board. Output to 1HP when
pressurized container air pressure is nominal and encoder power is ON.
CN44 not used Non-explosion-proof
• pressure switch
• flow switch
• purge valve solenoid
TB1, TB2 Ground bar Class A ear th ground
6-90 March 28, 2002


1LU test points (TPs) provide convenient access to several power supply test points,
refer to figures 6-48 and 6-49, and table 6-51 below.
Table 6-51 1LU Board Test Points
Test
Point Description
TP1 +12 VDC to 12V-5V DC/DC conver ter
+5 VDC output of 12V-5V DC/DC conver ter, vcc for 1LU board ET/R
TP2 logic circuits and the non-intrinsically safe por tion of the 1LW board
isolation circuit
TP3 GND for +12 and +5 VDC (TP1/TP2)
+6 VDC, Venc encoder power to the 1LW voltage regulator for
TP4
+5 VDC encoder logic power
TP5 GND for Venc (TP4)
TP6 +24 VDC, I/O24V to RIC
TP7 GND for I/O24V (TP6), ear th ground TB1/TB2
Jumper J1 (Figures 6-48 and 6-50) allows selection of 1LU board connection to either a
1GW (all set to A-B) or 1HW (all set to B-C) board.
A B C
1
2
3
4
5
6
7
Figure 6-50 Jumper J1, 1GW/HW Selection
March 28, 2002 6-91


For the following discussion, refer to figure 6-49 and table 6-50.
6.5.1.1 ENCODER TRANSMIT/RECEIVE CIRCUIT
The 1GB servo CPU board requests rotational position, speed, and direction data from
the encoders via the 1LU board encoder transmit/receive (ET/R) circuit and EBMs; when
requested, this data (TXEN) is transmitted to the 1GB board, via the EBMs and 1LU
board ET/R circuit. The EBMs contain the 1LW board, and are mounted to 1LU board
connectors CN1–CN20, and provide an intrinsically safe interface.
The 1LU board receives battery error signals (BATER) from the EBM 1LW board low
voltage detection circuit (LVDC, detects low encoder backup battery voltage), and routes
them to the 1GB board via 1LU connector CN29 (JT1–7) and CN32 (JT8–10). The 1LU
board also distributes +6 VDC from the encoder AVR power supply G21 to the 1LW
voltage regulator for + 5 VDC encoder logic power. The 1LU board supports up to 3
pressurized containers (i.e., one mechanical unit container and two peripheral axis
containers) for a total of 10 axes.
6.5.1.2 RELAY INTERLOCK CIRCUIT
The 1LU board relay interlock circuit (RIC) is a safety circuit that monitors mechanical
unit and other pressurized container air pressure and flow meters, and limit switches.
Depending on the status of these devices, the RIC outputs signals to the 1GB and 1HP
boards, and the K21 relay, to control power distribution to components in the pressur-
ized containers.
6-92 March 28, 2002


Pressure Drop
One of the primary functions of the 1LU board is to interrupt power to the hazardous
area components if, during normal operation, there is a drop in pressurized container
internal air pressure. If the internal air pressure drops, due to the loss of supplied air or
an air leak, the pressurized container loses it’s ability to keep explosive gases out of the
container. If the internal pressure drops, the pressure switches open, RIC relays are de-
energized, and the RIC interrupts power to components in the hazardous area.
If a pressure switch opens due to an air pressure drop, the RIC interrupts power to the
following components:
• Relay K21, which controls power to the encoder AVR power supply; +6 VDC (Venc) to
the 1LW board voltage regulators (+5 VDC [VendH] to the encoders)
• +24 VDC to the brakes, the brakes engage
• +24 VDC to the motor thermal (MTH) circuit—the MTH switches are daisy chained
(i.e., connected in series) between connectors CN35/36/42.
• 1HP E-stop circuit
• 1HP internal pressure interlock circuit
Power ON Cycle
At power up, the C controller goes through a power ON cycle. Part of the power ON
cycle is a purge phase that removes explosive gases from the pressurized container in
preparation for EP robot operation. By supplying fresh compressed air to the container
and opening the purge valve, a flow of air through the container is created. This flow of
air removes explosive gas from the container and replaces it with fresh air. Once the
purging phase is completed, the purge valve is closed and the container is pressurized.
By maintaining a positive pressure inside the container, explosive gases are prevented
from entering the container.
There are three power ON cycle phases;
• Supplied air check

• Purging
• Pressurizing
1. Supplied air check—at power ON, the EP type C controller determines if com-
pressed air is currently being supplied to the pressurized container. At power ON,
pressure switches are open and the yellow PSL1/2/3 LEDs (1, 3, and 5) are extin-
guished. During this phase, the purge valve is closed and the internal pressure
increases and is monitored by the pressure switches. When the pressure increases
to the nominal value, the pressure switches close, the yellow pressure LEDs
PSL1/2/3 illuminate, and the supplied air check phase is complete.
March 28, 2002 6-93


If the pressure does not reach the nominal value in the specified time during this
phase, the pressure switches remain open, the error ‘-2172 Internal pressure low.’ is
generated, the yellow PSL1/2/3 LEDs (1, 3, and 5) do not illuminate, and the sup-
plied air check phase and power ON cycle is terminated.
If the pressure reaches and then drops below the nominal value during this phase,
the pressure switches open, the error ‘-2172 Internal pressure low.’ is generated, the
yellow PSL1/2/3 LEDs (1, 3, and 5) extinguish, and the supplied air check phase
and power ON cycle is terminated.
2. Purging—upon completion of the supplied air check phase, the 1HA board outputs
the SOL_ON signal to the 1LU board; the green SOL_ON LED (12) illuminates. The
RIC receives this signal and distributes +24 VDC to the purge valve solenoids.
When energized, the solenoids open the purge valves and allow air to flow through
the pressurized containers.
When the purge valves open, the container pressure drops, the pressure switches
open, and the yellow PSL1/2/3 LEDs (1, 3, and 5) extinguish. During the purging
phase, the air flow rate through the pressurized containers is monitored by the flow
meters. When the air flow rate reaches its nominal value, the flow rate switches
close and the yellow FLS1/2/3 LEDs (2, 4, and 6) illuminate.
When the purging phase is complete, the following occur:
a. SOL_OFF signal from the 1HA board

b. green SOL_ON LED (12) extinguishes
c. purge valve solenoids de-energize
d. purge valves close
e. as the pressure increases, the air flow rate decreases and the flow rate
switches open
f. yellow FLS1/2/3 LEDs (2, 4, and 6) extinguish
If, during the purging phase, there is insufficient air flow to purge the containers, the
flow meter switches remain open and the purging phase and power ON cycle is not
completed; the error ‘-2171 Lacks of air flux.’ is generated.
Or, if the air flow drops below the nominal value, the flow meter switches open, and
the purging phase and power ON cycle is not completed; the error ‘-2171 Lacks of
air flux.’ is generated.
6-94 March 28, 2002


3. Pressurizing—upon completion of the purging phase, the pressure in the container

increases. When the pressure is nominal, the pressure switches close, the yellow
PSL1/2/3 LEDs (1, 3, and 5) illuminate, and the green INTERLOCK LED (11) illumi-
nates. LED 11 indicates that the air purging and pressurizing phases are complete
and encoder power is ON. The EP type C controller is now ready for operation.
If the pressure does not reach the nominal value within the specified time, the error
‘-2170 Internal pressure sensor error.’ is generated.
March 28, 2002 6-95


6.5.2 1LW ENCODER BARRIER
The 1LW boards are located in the encoder barrier modules (EBMs)(Figure 6-51). The
EP type C controller supports up to 10 encoders, using 10 EBMs. Each EBM is
mounted to a pair of connectors on the 1LU board (Figure 6-48). The The 1LW boards
provide the intrinsically safe interfaces for the encoders.
CN3
Battery
LED1
LED2
CN2
CN1
CN4
Figure 6-51 Encoder Barrier Module (EBM)
Data circuit electrical isolation is provided by the isolation circuit photo-couplers.

+5 VDC (vcc) for the non-intrinsically safe side of the isolation circuit is supplied from the
1LU board. The 1LU board also supplies unregulated + 6 VDC (Venc) to the 1LW
board voltage regulator, via relays K1/K2. The +6 VDC is regulated to +5 VDC for the
intrinsically safe side of the isolation circuit (5VH) and encoder logic circuits (VencH).
Intrinsically safe isoloation for the +5 VDC power supply (5VH and VencH) is provided by
relays K1/K2.
Encoder data requests from the 1GB board, via the 1LU board, are routed to the encod-
ers via the 1LW board isolation circuit and transmit/recieve signal distribution circuit; the
encoder data (TXEN) is transmitted back to the 1LU/1GB board, via the 1LW board
transmit/recieve signal distribution circuit and isolation circuit.
6-96 March 28, 2002


1 LED
Encoder Barrier Module
1LW Board Isolation

VCC
Circuit
Photo-coupler VCC 5VH
Intrinsically Safe
RXD
CN CN TXDEN
1 2 BATER VCC EN-P
5VH Transmit/Receive
EN-N
TXD Signal CN Encoder
VencH
Distribution 1
GNDH
Circuit
VCC 5VH
1LU
Board
VCC 5VH
Low Voltage
Detection 1 CN Battery
3
Circuit
Venc
5VH
CN CN K1/K2 +5 VDC
2 4 Voltage
GNDenc 2
Regulator
Figure 6-52 1LW Board Functional Block Diagram
March 28, 2002 6-97


! CAUTION
With controller power OFF, encoder barrier module bat-
tery life is approximately three years.
NOTE
Because the EP type C controller encoder backup bat-
teries are not located on the mechanical unit (i.e., on
the 1FG/HG board using the standard C controller),
when the EP type C controller separate harnesses are
disconnected, encoder data is not maintained.
The EBMs contain a battery that provides +3.6 VDC to the encoders, to maintain en-
coder data when the EP type C controller power is OFF. If the battery voltage drops to
3.3 VDC or less, the 1LW board low voltage detection circuit sends a signal (BATER) to
the 1HA board, LED1 illuminates (Figure 6-52 and Table 6-53), and the error ‘-1511
Encoder battery voltage low [Servo (*)]’ is generated. When an EBM battery low voltage
condition exists, it is recommended that when replacing a battery that all EBM batteries
be replaced at this.
Table 6-52 1LW Board Connectors

CN1 Encoder • +5 VDC (VencH) to the encoder
• 1GB encoder data requests to the encoder
• Encoder transmit/receive data to/from the encoder
• Encoder rotational position data (TXEN) from the encoder
CN2 1LU Board • +5 VDC power supply (vcc) from 1LU board for non-intrinsically safe side of
the 1LW board isolation circuit
• Encoder data requests from the 1GB board
• Encoder transmit/receive data from/to the 1GB board
• Battery error signal (BATER) to the 1GB board
CN3 Batter y +3.6 VDC encoder backup battery
CN4 1LU Board Unregulated + 6 VDC (Venc) to 1LW board voltage regulator
6-98 March 28, 2002


Table 6-53 1LW Board LEDs

1 LOW BATTERY Red Backup battery voltage has dropped to +3.3 VDC or less
2 POWER Green +5 VDC (5VH) output from the voltage regulator for the intrinsically safe
side of the 1LW board isolation circuit
6.5.2.1 BATTERY REPLACEMENT
This section describes the EBM battery replacement procedure, refer to figure 6-47 and
6-51.
NOTE
Batteries have a life-span of one and a half years with
controller power turned OFF and should be replaced ev-
ery five years regardless of their condition and use.
NOTE
Before replacing an EBM battery, record the encoder
value. When replacing a battery, it is recommended that
all batteries be replaced.
1. Record the encoder value

2. Set the controller power to OFF
3. Remove the EP unit cover
4. Remove the EBM battery cover
5. Disconnect the battery connector
6. Replace the battery
7. Connect the battery connector
8. Replace the EBM battery cover
9. Replace the EP unit cover
10. Set the controller power to ON
11. Verify that the encoder value has not changed
12. Verify that 1LW board LED2 is illuminated and LED1 is extinguished
January 10, 2007 6-99


6.5.3 1LT E-STOP AND ENABLING DEVICE DISTRIBUTION
The 1LT board (Figures 6-53) is located in the EP unit and is mounted to the ZEner
BArrier (ZEBA) unit (Figure 6-47). The 1LT board relay distribution circuit (RDC) routes
emergency stop (E-stop) and enabling device switch status from the TP to the 1HP
board. It also routes EP teach pendant (TP) transmit and receive data to/from the 1HA
board, via the 1GS board.
Figure 6-53 1LT Board Layout
+12 VDC (12V_INT) is supplied from 1HP CN4 to 1LT CN1. 12V_INT is supplied to the
EP TP via 1LT CN2 and the ZEBA.
Normally, +12 VDC (12VA) for the RDC is supplied from the 1HP board (+12V/12V_INT)
to 1LT CN1. When external +24 VDC (EXT24V) is supplied from TB2 to 1LT CN1 and
the 24V-12V DC-DC converter, the +12 VDC output of the converter is applied to relay
CR12; CR12 switches from contacts 4-3 to 4-5. This switches the RDC power supply
from internal (12V_INT) to external (12V EXT).
6-100 March 28, 2002


1 LED
1LT Board
12V_INT
TXD/RXD
1HA 1GS ZEBA TP
12VA
TP-EMS/DMS TP-EMS/DMS
1HP CN
EXT-EMS 2
12V_INT TP1
CN +12V 12VA
1
R2 CR12
3 4
1
TB2 12G TP2 5
EXT24V 12V EXT

Relay
24V-12V
EXT24G
DC-DC TP3 R1
CR12 Distribution
Converter 2
12VA
Circuit
Operation (RDC)
OP-EMS
Panel
E-Stop Switch
HP1 CN OP-EMS
3
OP-EMS
HP2
Figure 6-54 1LT Board Functional Block Diagram
The 1LT board distributes EP TP RS-422, full duplex, serial transmit data (TXD, switch
status) from the EP TP to the 1HA board, via the 1GS serial communication board. The
1LT board also distributes EP TP receive data (RXD, LCD display data) to the EP TP via
the ZEBA.
The 1LT board receives EP TP emergency stop (EMS) and enabling device (DMS, ‘dead
man switch’) inputs via the ZEBA. These inputs are routed to the RDC. The
TP-EMS/DMS outputs from the RDC are routed to the 1HP board. The ZEBA provides
the intrinsically safe EP TP interface.
Another function of the 1LT board is to route the operation panel E-stop switch status
(OP-EMS) to the 1HP board(s). The RDC also routes an external emergency stop
signal (EXT-EMS) to TB2.
March 28, 2002 6-101


Table 6-54 1LT Board Connectors

1GS Board Serial RS-422 TXD data (switch status) to and RXD data (display data)
from the 1GS board
CN1
1HP Board +12 VDC (12V_INT) from the 1HP board
TB2 External +24 VDC (EXT24V) from TB2
ZEBA Serial RS-422 TXD data (switch status) from and RXD data (display
CN2
data) to the ZEBA/EP TP
Operation Panel Operation panel E-stop switch status (OP-EMS) to the 1HP board(s)
CN3
1HP Board(s)
Table 6-55 1LT Board LEDs

1 12V (INT) Green Internal +12 VDC (+12V) supplied from the 1HP board
2 12V (EXT) Green External +24 VDC supplied from TB2, conver ted to +12 VDC by the 1LT board
DC-DC conver ter
Table 6-56 1LT Board Test Points
Test
Point Description
TP1 Internal +12 VDC (12V_INT) from 1HP board
+12 VDC (12V EXT), from external +24 VDC supply/TB2/1LT DC-DC
TP2
conver ter
TP3 GND
6-102 March 28, 2002


6.5.4 TEACH PENDANT BARRIER UNIT
The ZEner BArrier (ZEBA) board is mounted in the ZEBA unit (Figure 6-55). It provides
the intrinsically safe interface for the explosion-proof (EP) teach pendant (TP). Intrinsic
safety for the TP is provided by zener barrier circuits and fuses (Figure 6-56); if the TP
load for a particular circuit exceeds specifications, the fuse blows.
ZEBA Board
Earth Terminal
Earth Terminals
Figure 6-55 ZEBA Unit
March 28, 2002 6-103


! WARNING
If a ZEBA board fuse blows, the entire ZEBA board
must be replaced. When replacing the ZEBA board, en-
sure that connection to the earth ground terminals E1
and E3 is properly made. If the connections to earth
ground E1 and E3 are not made correctly, the ZEBA
board does not function correctly, and a fire or an explo-
sion can occur in the hazardous area.
! WARNING
Do not modify the ZEBA board in any way. Modifying
the ZEBA board may cause the board to function incor-
rectly, and a fire or an explosion to occur in the hazard-
ous area.
6-104 March 28, 2002


ZEBA Board
Fuse
Power Supply
Zener Barrier
Fuse
Transmit/Receive Signals
Zener Barrier
Fuse
E-Stop Type 1
Zener Barrier
Fuse
Enabling Device Type 1
1LT Board Zener Barrier
TP
Fuse
E-Stop Type 2
Zener Barrier
Fuse
Enabling Device Type 2
Zener Barrier
Figure 6-56 ZEBA Board Functional Block Diagram
Table 6-57 ZEBA Board Connectors

XJR2 TP • TP power supply to TP
• Transmit/receive data
• Type 1 E-stop and enabling device from TP
XJR3 Type 2 E-stop
XJR4 Type 2 enabling device
XLT-CN2 1LT Board • TP power supply to TP

• Transmit/receive data
• Type 1 E-stop and enabling device from TP
• Type 2 E-stop
• Type 2 enabling device
March 28, 2002 6-105


6.6 1FG ENCODER BATTERY BOARD
The 1FG board (Figure 6-57) is located in the base of the U-series and Z-series me-
chanical units, and is accessible by removing the robot cable connection panel.
The 1FG board:
• Converts +12 VDC from the controller to +5 VDC for encoder logic power.
• Provides +3.6 VDC battery power for the encoders, maintaining encoder data when
the controller is off or the mechanical unit is disconnected from the controller.
• Monitors battery voltage between TP4 and TPG (see figure 6-57 and table 6-59).
NOTE
Refer to table 6-58 for a description of the 1FG board connectors and their functions.
Refer to figures 6-59 through 6-62 for 1FG interconnection diagrams.
Battery Replacement:
1. Set the controller main disconnect to OFF and lock it out.
2. Remove the robot cable connection panel.
3. Disconnect 1FG-CN10.
4. Disconnect the band that secures the batteries to the board.
5. Remove the batteries.
6. Install the new batteries in the holder.
7. Secure the batteries to the board with the band.
8. Connect 1FG-CN10.
6-106 January 10, 2007


9. Replace the robot cable connection panel.
10. Remove the lock out and set the controller main disconnect to ON.
NOTE
The encoder assembly contains a capacitor that main-
tains memory power for approximately 30 minutes. In
order to maintain the encoder data when replacing the
1FG batteries or disconnecting the encoder from the
1FG board, the batteries must be replaced or the en-
coder reconnected within the 30 minute period.
CN13
Battery
Battery
CN12
TPG TP1 TP2
CN8
CN11
GND +12 VDC +5 VDC
CN10
TP4 TPG2 TP5
BAT +24 +24

VDC VDC
CN7
CN9
GND
TP3
CN1 CN2 CN3 CN4 CN5 CN6
Figure 6-57 1FG Board Layout
January 10, 2007 6-107


Table 6-58 1FG Board Connectors
Connector Function
CN1 JT1 encoder data in, +5 VDC to JT1 encoder
controller interface; encoder data, limit switch,
battery status, external I/O signals (SIG1–SIG4),
CN8
external +24 VDC power supply,
+12 VDC from controller
external I/O signals (SIG1–SIG4),
CN9
external +24 VDC power supply
CN10 connection to battery
CN11 limit switch input from mechanical unit
Table 6-59 1FG Board Test Points
No. Name Function

TP1 +12 VDC +12 VDC from controller
TP2 +5 VDC +5 VDC power supply for encoders
TP3 +5 VDC/BAT +5 VDC controller ON/BAT controller OFF
TP4 BAT + Battery voltage
TP5 +24 VDC External +24 VDC power supply
TPG GND +5 VDC, +12 VDC, and battery ground
TPG2 +24 VDC GND External +24 VDC power supply ground
6-108 March 28, 2002


6.7 1HG ENCODER BATTERY BOARD
The1HG board (Figure 6-58) is located in the base of the F-series mechanical units, and
is accessible by removing the robot cable connection panel.
The 1HG board:
• Converts +12 VDC from the controller to +5 VDC for encoder logic power.
• Provides +3.6 VDC battery power for the encoders, maintaining encoder data when
the controller is off or the mechanical unit is disconnected from the controller.
• Monitors battery voltage between TP4 and TPG (Figure 6-58 and table 6-61).
NOTE
Refer to table 6-60 for a description of the 1HG board connectors and their functions.
Refer to figures 6-63 through 6-69 for 1HG interconnection diagrams.
Battery Replacement:
2. Remove the robot cable connection panel.
3. Disconnect 1HG-CN3.
4. Cut the wire tie bands that secures the batteries to the board.
5. Remove the batteries.
6. Install the new batteries in the holder.
7. Secure the batteries to the board with new wire tie bands.
8. Connect 1HG-CN3.
January 10, 2007 6-109


9. Replace the robot cable connection panel.
10. Remove the lock out and set the controller main disconnect to ON.
TP4
CN3
TP3
DC to DC TP2
CN4
TP1 TP5
Converter
Batteries
CN1 CN2
Figure 6-58 1HG Board Layout
Table 6-60 1HG Board Connectors
Connector Function
CN1 +12 VDC, +12 VDC GND, JT7 encoder data out, battery alarm
CN2 JT7 encoder data in, +5VDC to JT7 encoder
CN3 Connection to battery (3.6 VDC)
CN4 +5 VDC to JT1 - JT6 encoders
Table 6-61 1HG Board Test Points
No. Name Function

TP1 +12 VDC +12 VDC from controller
TP2 +5 VDC +5 VDC power supply for encoders
TP3 +5 VDC/BAT +5 VDC controller ON/BAT controller OFF
TP4 BAT + Battery voltage
TP5 GND +5 VDC, +12 VDC, and battery ground
6-110 January 10, 2007

March 28, 2002
Kawasak
Figure 6-59 UX/UT Machine Harness Interconnection Diagram

C SERIES CONTROLLER
6-111
6-112
Kawasak
Figure 6-60 UZ Machine Harness Interconnection Diagram

C SERIES CONTROLLER
March 28, 2002

March 28, 2002
Kawasak
Figure 6-61 ZD130 Machine Harness Interconnection Diagram

C SERIES CONTROLLER
6-113
6-114
Kawasak
Figure 6-62 ZT/ZX165 Machine Harness Interconnection Diagram

C SERIES CONTROLLER
March 28, 2002

March 28, 2002
Kawasak
Figure 6-63 FS06L Machine Harness Interconnection Diagram

C SERIES CONTROLLER
6-115
6-116
Kawasak
Figure 6-64 FS06N/FS10C Machine Harness Interconnection Diagram

C SERIES CONTROLLER
March 28, 2002

March 28, 2002
Kawasak
Figure 6-65 FS10E/N Machine Harness Interconnection Diagram

C SERIES CONTROLLER
6-117
6-118
Kawasak
Figure 6-66 FS10L Machine Harness Interconnection Diagram

C SERIES CONTROLLER
March 28, 2002

March 28, 2002
Kawasak
Figure 6-67 FS20C Machine Harness Interconnection Diagram

C SERIES CONTROLLER
6-119
6-120
Kawasak
Figure 6-68 FP20N/FS20N Machine Harness Interconnection Diagram

C SERIES CONTROLLER
March 28, 2002

March 28, 2002
Kawasak
Figure 6-69 FS30L,N/FS45C,N Machine Harness Interconnection Diagram

C SERIES CONTROLLER
6-121

6.8 1FT MULTI FUNCTION PANEL PROCESSOR
To 1HP Board CN4

(Serial Communication
to 1GA/HA Board)
To Board A CN1
TEACH LOCK Switch

2-Position ON OFF 2-Position

Enabling Device TEACH LOCK Enabling Device
LCD/Touch Panel
Touch Panel Pen
Contrast Adjustment
PC Card Slot (JM8)
Figure 6-70 Multi Function Panel
The multi function panel (MFP) 1FT board is the display and touch panel processor
board. It contains a 32-bit RISC CPU, 4MB of flash memory, and 1MB of RAM.
The MFP communicates with the controller 1GA/HA board via an RS-485 full duplex
serial interface (through the 1HP board); connection to the 1FT board is at CN1. There
is also an optional RS-232C serial interface for troubleshooting with a PC; connection to
the 1FT board is at CN2.
The 1FT board receives AS software (controller operating system) display information
and routes video data to the 1FU board (video board) for display on the liquid crystal
display (LCD). The 1FT board also receives touch panel input for routing to the 1GA/HA
board for processing.
6-122 March 28, 2002


The 1FT board also receives inputs from the following switches and controls, located on
the MFP:
• 2-position enabling devices (left and right)
DIP switch SW1, located next to the PC card slot, enables MFP software to be loaded
from the PC card to the 1FT flash memory, refer to table 6-62.

EMERGENCY
Backlight STOP
Contrast
CN CN Switch
Adjustment
Power
2 1
Supply
CN7 CN4 CN8
CN CN
LCD 1FU 20 7
CN
PC
22 Controller
Board CN CN
1 RS-485
21
1FT Board
CN Debug
CN 2 RS-232C
42
J1 CN JM8
41
Touch Panel CN3
J2 Flash RAM
PC Card
Deadman TEACH Deadman
Switch LOCK Switch
(left) Switch (right)
Figure 6-71 Multi Function Panel Functional Block Diagram
March 28, 2002 6-123


Table 6-62 MFP, 1FT Board SW1 Settings
Setting
Note
1 2 Function
OFF OFF Normal
Enables writing MFP software from the flash
ON OFF
card to the 1FT board flash memory
ON ON Enables system start up from the 1FT EPROM Not used
6-124 March 28, 2002


6.8.1 1FT BOARD, EP TYPE C CONTROLLER
The EP type C controller multi function panel (MFP)(Figure 6-72) is a modified MFP
(refer to section 6.8). It is primarily used as a display device to view various monitor and
status screens. The EP MFP is also used to display and set auxiliary functions, set up
the software interface panel, and enter AS language commands via the keyboard
screen. It is not intrinsically safe and is not used in the hazardous area; the short cable
prevents it from reaching and being used in the hazardous area. The EP MFP does not
include emergency stop (E-stop), enabling device, or TEACH LOCK switches, and is not
used to teach programs. It includes the flash random access memory (RAM) PC card
slot for software downloading and data storage.
For additional information about using the EP type C controller MFP, refer to the C
Series Controller EP Type Operations and Programming Manual.
To 1HP Board CN4

(Serial Communication to 1HA Board)
To FT Board CN1
LCD/Touch Panel
Touch Panel Pen
Contrast Adjustment
PC Card Slot (JM8)
Figure 6-72 EP Type C Controller, MFP
March 28, 2002 6-125


Backlight Contrast
CN CN Adjust
Power
2 1
Supply
CN7 CN4 CN8
CN CN
LCD
Display 1FU 20 5
CN
PC
22
Board CN CN
21 1
1FT Board
CN Debug
CN 2 RS232C
42
J1 CN JM8
41
Touch Panel CN3
Earth
J2 (fixed to the upper
left LCD frame)
T/P
Figure 6-73 EP Type C Controller, MFP Block Diagram
6-126 March 28, 2002


6.9 BOARD A, TYPE 2 TEACH PENDANT PROCESSOR
A VIEW A B
Emergency Stop
Switch
ON OFF
Teach Lock Switch

T.LOCK
Brightness
Control
Liquid Crystal
Display/
Touch Panel PC Card Slot
ENA SHIFT SPEED CNT
1 4
— —
X Rx
2 5
— —
Y Ry CHECK
3
—
6
—
Enabling
Z Rz
Device
Soft Key Keypad
CL1 CL2
REC
To Board A CN1
To 1HP Board CN4

(Serial Communication
to 1GA/HA Board)
Figure 6-74 Type 2 Teach Pendant
March 28, 2002 6-127


The type 2 TP board A is the display and touch panel processor board. It contains a
32-bit RISC CPU, 4MB of flash memory, and 1MB of RAM.
The type 2 TP communicates with the controller 1GA/HA board via an RS-485 full du-
plex serial interface (through the 1HP board); connection to board A is at CN1. There is
also an optional RS-232C serial interface for troubleshooting with a PC; connection to
board A is at CN2.
Board A receives AS software (controller operating system) display information and

routes video data to the video board for display on the liquid crystal display (LCD).
Board A also receives touch panel and soft key keypad input for routing to the 1GA/HA
board for processing.
Type 2 Teach Pendant
Backlight
CN CN
Power Emergency Contrast
2 1 Stop Adjustment
Suppy Switch
Flexible
Circuit Board
CN7 CN4 CN8
CN20
Video
LCD CN6
Board
CN22 CN Controller
1 RS-485
Board A
CN
42 CN Debug
2 RS-485
CN
J1 41
Touch Panel
J2 JM8
CN3 CN5 CN9
T. LOCK
Switch Flash RAM
3-Position 3-Position PC Card
Enabling Enabling
Device Device
(Left) (Right) CN11 CN12
Board B
Soft Key Keypad/LEDs
Figure 6-75 Type 2 Teach Pendant Functional Block Diagram
6-128 March 28, 2002


Board A also receives inputs from the following switches and controls, located on the
type 2 TP:
• 3-position enabling devices (left and right)
DIP switch SW1, located next to the PC card slot, enables type 2 TP software to be
loaded from the PC card to the Board A flash memory, refer to table 6-63.
Table 6-63 Type 2 TP, 1FT Board SW1 Settings
Setting
1 2 Function Note
OFF OFF Normal
Enables writing type 2 TP software from the flash card to the board A flash
ON OFF
memor y
ON ON Enables system star t up from the board A EPROM Not used
March 28, 2002 6-129


6.10 EP TEACH PENDANT
The explosion-proof (EP) teach pendant (TP)(Figure 6-76) is the intrinsically safe device
that is used to jog the robot and teach programs. It includes the emergency stop
(E-stop), enabling device, and teach lock switches.
LCD
Keypad
Buzzer
Enabling Devices
Rear View
Figure 6-76 EP Teach Pendant
6-130 March 28, 2002


Components:
• Keypad—44 keys, 14 LEDs, Keypad sheets are available in Japanese or in English

• Liquid crystal display (LCD)—STN reflection model, black and white, 34 × 127
characters (64 × 240 dpi)
• Safety switches—safety-duplicated E-stop and enabling device switches are hard
wired. The ANSI 3-position enabling device switch is used during teaching to acti-
vate servo motor power. It is ON at the mid point and OFF when pressed forcefully.
• RS-422 serial interface—the EP TP 8-bit CPU communicates with the EP type C
controller 1HA CPU via the RS-422 interface.
• Buzzer
EP Teach Pendant
CPU Board
RS-422 serial data to/from CPU

ZEBA
Keypad Board
Enabling E-Stop
Device Switch
Figure 6-77 EP Teach Pendant Functional Block Diagram
March 28, 2002 6-131


6.11 1GV ARM ID (Z-SERIES)
The 1GV arm ID board is installed in the robot arm ID board box (Figure 6-78). The arm
ID board stores robot model information, maintenance log information, and I/O signal
settings. Functions and settings of the arm ID board are accessed from the controller.
For information on the arm ID board functions refer to the C Series Controller Opera-
tions and Programming Manual.
The functions and settings of the arm ID board include:
• entries to the maintenance log

• display of the maintenance log
• deletion of maintenance log entries
• settings of I/O signals to the robot arm
Arm ID Board Box
Figure 6-78 Robot Arm ID Board Location
6-132 March 28, 2002


6.11.1 DATA STORAGE
Robot specifications, zeroing data, and maintenance log entries are stored in flash
memory. Data is transfered by serial communications through the 1HP board
(Figure 6-79).
Two input channels are available for sensor signals ID1 and ID2.
Controller
1HP Board
Robot
1GB Board
VME
Bus Û Arm ID board box
1FG
Serial Serial 1GV Board
communication CN1 CN8 communication CN2 CN1
Sensor input Sensor input
+24 VDC CN2 CN9 +24 VDC
Sensor input
The 1HP board used to communicate with the 1GV board is PN 50999-1859.
The following jumper settings are used for the 1HP board.
1 4 1 4 1 4
JP1 2 5 JP3 2 5 JP4 2 5
3 6 3 6 3 6
Figure 6-79 1GV Board Interconnection
January 9, 2004 6-133


6.11.2 LAYOUT
Figure 6-80 shows the 1GV board layout and tables 6-64 and 6-65 show the connector
pin assignments.
CN2
CN5
CN3
CN4
LD1 LD2
CPU
CN1
Figure 6-80 1GV Board Layout
Table 6-64 1GV-CN1 Pin Assignment
Pin Function
1 I/O Common
2 ID1
3 ID2
4 +24 VDC (1 A max.)
5 +24 VDCG
6 SIG3 (Sensor input)
7 SIG4 (Sensor input)
6-134 March 28, 2002


Table 6-65 1GV-CN2 Pin Assignment
Pin Function
1 Serial communication line +
2 Serial communicaiton line -
3 +5 VDC Power
4 GND
5 +24 VDC
6 +24 VDCG
7 SIG3
8 SIG4
9 Not used
CN3 is for future I/O expansion.
CN4 and CN5 are not used.
LD1 - Green:
ON during normal operaton, OFF during an error condition.
LD2 - Red:
OFF during normal operation, ON during an error condition.
March 28, 2002 6-135


6.11.3 INPUT/OUTPUT
Two methods for I/O are available.
If SIG3 and SIG4 (inside machine sensor inputs) are used, a 1GW board is required
(1GV-CN1-6 and 7).
If ID1 and ID2 are used, serial communication to the 1HP board is utilized (Figure 6-81)
(1GV-CN1-2 and 3).
ID1,2 Input circuit (+) common
Robot External
+24 VDC +24 VDC
CN1-2,3 or
(ID1,2)
CN1-1
Photo coupler
TLP181 (Toshiba) or equivalent
0V
ID1,2 Input circuit (-) common
Robot External
+24 VDC
CN1-1
CN1-2,3
(ID1,2)
Photo coupler
TLP181 (Toshiba) or equivalent or
0V 0V
Figure 6-81 1GV Board I/O Connections
6-136 March 28, 2002


6.12 PRINTED CIRCUIT BOARD REPLACEMENT
! CAUTION
Components on the printed circuit boards (PCBs) are
electostatic discharge (ESD) sensitive. Use care when
handling PCBs - hold them by the edges and avoid
contact with components and edge connectors. When
working on a PCB, place it on an antistatic mat and use
a wrist strap. When storing a PCB, place it in an anti-
static bag, wrap the bag in bubble wrap, and place the
wrapped PCB in a suitable box.
To replace a printed circuit board, perform steps 1-14 below:
2. Before replacing the power block, ensure that capacitor C1 on the power block is
discharged (refer to unit 7, Servo System). Dissipate static charges on your body
by touching a grounded object inside the controller (e.g., the card rack).
3. Note the orientation of cables that are connected to the board for reference.
4. Disconnect the cables.
5. Remove the retaining screws that secure the PCB to the card rack, or to the power
block (1GB board).
6. Remove the circuit board.
7. Ensure the part number of the replacement board is identical to the defective board.
Set all jumpers and DIP switches on the replacement board to match the settings
on the defective board.
For 1GM board replacement, ensure that the part number and ID code is correct for
the robot model.
March 28, 2002 6-137


8. Place the defective board in an antistatic bag, wrap the bag in bubble wrap, and
place the wrapped board in a suitable box.
9. Install the new board. When installing boards in the card rack, ensure that the plugs
on the circuit board are aligned with the sockets on the backplane (1HZ board),
before seating the board firmly into the slot.
10. Tighten the retaining screws; do not overtighten the screws.
11. Connect the cables to the board.
12. Remove the lock-out and set the controller main disconnect to ON.
13. Verify proper operation of the controller.
14. Complete a Kawasaki Repair Parts Report and forward the defective board to:

Attn.: Customer Service Department
28059 Center Oaks Court
Wixom, MI 48393
6-138 March 28, 2002


SERVO SYSTEM
7.0 SERVO SYSTEM ........................................................................................... 7-2

7.1 Introduction .................................................................................................... 7-2
7.2 1GB Servo Board ........................................................................................... 7-4
7.2.1 1GM Current Sensor Interface Board .......................................................... 7-10
7.3 Servo Power Block ....................................................................................... 7-12
7.3.1 Servo Power Unit ......................................................................................... 7-20
7.3.2 Servo Amplifier Section................................................................................ 7-22
7.3.3 Servo Power Block Replacement ................................................................. 7-25
7.4 AC Servo Motor Assembly ........................................................................... 7-27
7.4.1 Permanent Magnet Rotor ............................................................................. 7-28
7.4.2 Stator Windings ............................................................................................ 7-29
7.4.3 24 VDC Brake Assembly .............................................................................. 7-31
7.4.4 Servo Motor Part Numbers .......................................................................... 7-33
7.4.5 Motor Specifications..................................................................................... 7-34
7.4.6 Motor Model Number Designation ............................................................... 7-36
7.4.7 Servo Motor Replacement ........................................................................... 7-38
7.5 H20/M21 and H32KT/M30KT Encoder Assemblies ..................................... 7-44
7.5.1 Handling Instructions for the Encoder .......................................................... 7-48
7.5.2 H20 Encoder Replacement Procedures ...................................................... 7-49
January 9, 2004 7-1


SERVO SYSTEM
7.0 SERVO SYSTEM
7.1 INTRODUCTION
The C controller digital servo system is the primary motion producing component in the
robot system. The servo system generates command voltages to drive the brushless
AC servo motors in the system, and also monitors each axis for speed, motor direction,
shaft angle sensing, and position. The methods by which this is accomplished are
discussed in detail in the following sections.
Since the servo drive system is the primary motion producing component for the robot, it
is essential for the electrical maintenance person to comprehend this system com-
pletely, so that proper diagnostic methods are followed during troubleshooting and
maintenance procedures. Troubleshooting the servo system is simplified due to the fact
that many components in the servo system incorporate easily accessible test points,
LED indicators, and error messages for fault diagnostics purposes.
! WARNING
Voltages in the servo system in many cases exceed 200
volts. When making any voltage checks, exercise
extreme caution and follow all established electrical
safety procedures and guidelines. When replacing any
components in the robot controller, place the disconnect
in the OFF position and lock it, and if necessary turn
OFF the supply voltage to the controller at the source.
Figure 7-1 is a simplified block diagram showing the relationship of the circuits in the
C controller digital servo system. The servo system consists of these four major compo-
nents:
• 1GB servo CPU board
• Servo power block
• Brushless permanent-magnet AC servo motor assembly
• Hybrid encoder assembly
7-2 March 28, 2002


SERVO SYSTEM
The 1GB servo CPU board processes and controls the position, velocity, and current for
each robot axis. It receives positional and velocity data from each encoder and motor
current data from the power block. Its on-board reduced instruction set computer
(RISC) processors and gate arrays process the data and generate pulse width modula-
tion (PWM) signals that are sent to the power block to gate the intelligent power mod-
ules (IPMs).
The servo power block is mounted inside of the controller. It receives 60/210 VAC from
the T1 transformer to supply the diode module. The 86/300 VDC output of the diode
module is distributed to the IPMs. When the IPMs are gated by the PWM signals from
the 1GB board, current is supplied to the stator windings of the servo motors.
The C controller can control up to six servo motors in a standard configuration, and up
to seven servo motors with optional hardware. These motors are classified as AC syn-
chronous permanent magnet brushless motors.
The hybrid encoder assembly is an optical and magnetic rotary device mounted to the
motor and driven by the motor shaft. The encoder is responsible for generating and
sending positional, directional, and motor velocity feedback data to the 1GB board.
CONTROLLER SECTION ROBOT SECTION

300 VDC
From 1GB AC
1GA/1HA DIGITAL PWM POWER BRUSHLESS
BLOCK ENCODER
SERVO SERVO H20/M21
BOARD IPM MOTOR
INVERTER H32KT/M30KT
1GM
CURRENT
SENSOR
INTERFACE CURRENT
FEEDBACK
POSITION / VELOCITY FEEDBACK
Figure 7-1 Servo System Simplified Block Diagram
March 28, 2002 7-3


SERVO SYSTEM
7.2 1GB SERVO BOARD
Figures 7-2 and 7-3 illustrate the 1GB board and its main functions. The 1GB board is
available in two versions; six axes (standard) and 8 axes (optional). 1GB board architec-
ture consists of an A block, B block, and C block. Each block controls up to three axes.
The A block controls joints 1, 2, 3 and the B block controls joints 4, 5, 6. The optional C
block controls joint 7 and can process data from a conveyor mounted encoder to provide
line tracking capability.
TP7 TP9
TP6 TP8
Front - CN8B
CN7 Back - CN8A
CN3 LEDs
No. Name
SW1
SRAM
SRAM
D26 RUN-A
D27 RUN-B
D28 RUN-C
CN1
D36 ERR-A
TP5
D37 ERR-B
CPU-C Gate
D38 ERR-C
Array
D26, D27, D28

D36, D37, D38
D39, D40, D41
CN13
D39 MSON
C LED D40 BRAKE
D41 RGSO
SRAM
SRAM
CPU-B
TP4
CN2
Gate
CPU-A Array
B
TP3
SRAM
SRAM
CN12
Gate
Array
CN4
A
CN11
Test Points
CN6
No. Name
TP1 BR24G
TP2 BR24V
CN10
TP3 RUN_A
TP4 RUN_B
1GM TP5 RUN_C
TP6 GND
CN5
TP7 VCC
CN9
TP8 -12V
TP1 TP2 TP9 +12V
= Mounting Holes
Figure 7-2 1GB Board Layout
7-4 April 13, 2000


SERVO SYSTEM
CH1
Command Line
HIC
CPU-A 1GM Current
RS485 Overcurrent CN9
Detection
Overcurrent
Error
SRAM
A RS485
CN2 Encoder
Encoder
Battery Alarm
MSON
SVER
Servo Control JT2, 3 PWM Signals
IPM Error
CN12
JT1 PWM Signals

IPM Error
PU Error CN13
MSON (Delay)
Brake Drive Brake

CN6
Circuit
To Manual
CN5
CH2 Brake Box
Command Line
HIC
RS485 CPU-B 1GM Current
CN1 Overcurrent CN10
Detection
Overcurrent
Error
SRAM CN2 Encoder
B RS485
Err-B
JT4, 5 PWM Signals

IPM Error
CN12
JT6 PWM Signals

IPM Error CN13
Motor
CN6
CH3 Thermal
Command Line
HIC
CPU-C 1GM Current
RS485 Overcurrent CN11
(JT7, Conveyor) I/V Conversion Feedback
Detection
Overcurrent
Error
SRAM CN2
C RS485
Err-C
CH0 Encoder
Debug Line
Conveyor CN3
RS485
JT7 PWM Signals

IPM Error CN13
DC24V Limit Switch I/O

CN2
Figure 7-3 1GB Board Block Diagram
April 13, 2000 7-5


SERVO SYSTEM
The standard 1GB board is equipped with two RISC processors; one for the A block and
one for the B block. The optional 1GB board is equipped with a third RISC processor for
the C block.
Table 7-1 indicates the central processing unit (CPU) channel that controls each axis.
Table 7-1 1GB Board Channels
1GB CPU Channels

CPU Unit CPU Channel Axis
1 JT1
A 2 JT2
3 JT3
1 JT4
B 2 JT5
3 JT6
1 JT7
C
2 Conveyor
Each RISC processor executes a software algorithm to control the position, velocity, and
current amplifiers (Figure 7-4) for a maximum of three axes.
The RISC processor receives commanded positional data from the 1GA/1HA board,
current input signals from the power block, and position, speed, and commutation data
from the encoder, to produce a current command signal.
The current command signal amplitude increases and decreases to fulfill motor load
demands, and changes polarity to control motor rotational direction.
The RISC processor then calculates the motor phase data, by combining the current
command signal with current sensor and encoder data, in a technique called d-q axis
coordinate transformation. The d-q axis coordinate transformation monitors the rota-
tional magnetic field inside of the motor to determine the stator current in any given
position. The outputs of the d-q to 3-phase conversion are 3-phase velocity command
signals that are sent to the PWM generator in the gate array.
7-6 September 28, 2000

1GA/1HA
Board 1GB Board Power Block
SH RISC CPU Servo Software GATE-ARRAY
March 28, 2002

KId PU1
VUCMD
IdCMD PU2
=0 d-q to PV1
3- VVCMD PWM Dead Time Photo
KP KV KIq Buffer PV3
Phase Generator Generator Coupler
PCMD VCMD IqCMD Conv. PW1
VWCMD PW2
Position Velocity Phase CL PWM

Id Iq Shut
Kawasak
Power
Calculate Calculate Calculate 3-Phase Error Block Base Amp
Position Velocity Phase to d-q Error Error Information Protection Errors
Data Data Data Conv. Operation
Logics DCOC, 12V
100V, HV
Iu Iv Iw OC
Calculate
M-Code to Binary W-Phase OC, CL Power
Convert Current Detector Transistor
Module
U V W
Iu VIU iIU
Sample ± 7.5
I/V Current
A/D to +5
Iv Conv. & Hold VIV Conv. iIV
Scaler Sensors
SERVO SYSTEM
Encoder I/F Logics Servo Motor

TxD RS-485
Encoder Absolute Data (M-Code) Request Signal Generator Line
and Rotation Data RxD Driver,
Serial to Parallel Converter
Receiver
Figure 7-4 1GB Board Function Diagram

Encoder Serial
Communication
Data Line H20/M21
H32KT/M30KT
Encoder
C SERIES CONTROLLER
7-7

SERVO SYSTEM
The PWM generator receives the 3-phase velocity command signals from the RISC
processors, to determine the PWM pulse widths. The pulses generated by this circuit
vary in width, to meet both motor commutation and load demands.
To apply direct current to a brushless AC servo motor, pulse widths are adjusted propor-
tionally to the amplitude of a sine wave. The sine wave calculations are handled by the
servo software before the velocity command signals are sent to the PWM generator.
Figure 7-5 shows a sine wave being sampled by a triangle wave, with the resulting pulse
train emulating the sine wave. The PWM pulse trains that are sent to the IPMs are
generated in a similar manner to accommodate commutation requirements. Motor load
demands are then fulfilled by proportionally increasing or decreasing the pulse widths.
Figure 7-6 compares the PWM pulse train in a single phase of the servo motor to a sine
wave.
PWM Signal
Figure 7-5 PWM - Sine Wave Comparison
7-8 April 13, 2000


SERVO SYSTEM
Figure 7-6 Motor PWM Signal
A gate array resides in each block of the 1GB board. The basic function of the gate
array is to generate the PWM signals, and to process IPM errors and encoder data. In
addition, the A block gate array also processes encoder battery errors, power unit er-
rors, and controls the power unit capacitor charging cycle with the MSON signal.
The servo software for the 1GB board resides in flash memory on the 1GA/1HA board.
When the controller is powered-up, the servo software is downloaded to the SRAM on
the 1GB board. The kernel part of the servo software resides in the ROM of the 1GB
CPU and is common to all robot models. Therefore, software is not a consideration
when replacing the 1GB board.
Other functions handled by the 1GB board include:
• Control of the remote gate servo on (RGSO) signal and automatic brake release.
• Manual brake release functions. The manual brake release switches (located inside
of the controller) do not function when motor power is turned on. Brake line discon-
nect or short circuit detection are not performed.
• Relaying the overtravel limit switch signal to the 1HP board.
• Sending the servo unit error (SVER) signal to the 1HP board.
• Various error detection and error processing functions shown in table 7-2.
September 28, 2000 7-9


SERVO SYSTEM
Table 7-2 1GB Board Error Detection
Error Detection Level Error Code 1GB Block

Feed back from the current sensor exceeds
Amp Overcurrent -1401 A, B, C
144% of the maximum motor current
Servo CPU- x 1GB board CPU has stopped. "x" indicates

-1300 A, B, C
Watch Dog Error which CPU has stopped
Servo Unit +12 VDC: +10.7 VDC or less

-1563 A
12 VDC Error –12 VDC: –10.3 VDC or more
Current Sensor Defective connection in the current sensor

-1561 A, B, C
Disconnect harness
Motor thermal switch has opened due to high

Motor Overheat or
motor temperature, or a motor power harness -1501 B
Harness Disconnect
is disconnected
7.2.1 1GM CURRENT SENSOR INTERFACE BOARD
The 1GM board is mounted directly to the 1GB board. The 1GM board is responsible for
current to voltage conversion and for scaling the sensor output level based on robot
model. Motor current is measured by current sensors located on the power block.
The 1GM board converts this current to voltage, and scales the voltage according to the
motor type. Because the output power and motor current vary with each type of motor,
every robot model may require a different 1GM board with different scaling factors.
The 1GM board utilizes resistors to generate an identification code. The resistor code is
in a hexadecimal format, and is read as shown in figure 7-7.
When the controller is powered up, the resistor code is read and compared to a servo
software code to verify hardware/software compatibility. If a mismatch exists, an error is
generated, and motor power cannot be turned on.
Table 7-3 lists the 1GM boards for the various robot models.
7-10 April 13, 2000


SERVO SYSTEM
1GM Board
P/N ID
ID
MSB LSB MSB LSB
0 1 0 0 0 0 0 1
4 1
Example: ID = 41 (HEX)
Figure 7-7 1GM Board Identification Resistor Code
Table 7-3 1GM Board Part Numbers
1GM Board Part

Robot Model ID Code
No.
FC06N, FS06L, N, FS06L, N, FS10C, E, N 50999-1551 04h
FS10L, FS20C, N 50999-1731 36h
FS30L, N, FS45C, N 50999-1648 25h
UB150 50999-1646 24h
UD100/150 50999-1654 27h
UT, UX, UZ 70/100/120/150 50999-1646 24h
UT, UX, UZ 70/100/120/150 (JT7 Servo Gun) 50999-1585 07h
UX200/300 50999-1645 23h
ZD130 50999-1916 50h
ZX130L, U 50999-1645 23h
ZT165, ZX165U 50999-1645 23h
ZX200S, U, ZX300S 50999-1645 23h
September 28, 2000 7-11


SERVO SYSTEM
7.3 SERVO POWER BLOCK
The servo power block (figure 7-8) is the central component of the servo system. Com-
prised of the power unit and amplifier, its primary function is to condition line power and
control current flow through the servo motor stator windings.
The standard power block is available in three versions - the 1GC (large type), 1JK
(large w/7th axis), and the 1GD (small type) power block. Robots with payload capacities
of 30 kg or more utilize the 1GC/1JK large power block, and robots with payload capaci-
ties lower than 30 kg utilize the 1GD small power block. The 1GD power block is avail-
able in six and seven axes configurations, as shown in table 7-4.
The 1GC and 1GD printed circuit boards are shown in figures 7-9 and 7-10, with con-
nector descriptions given in tables 7-5, 7-7, and 7-8.
The servo power block also incorporates various protective functions that are monitored
by the 1GB board. The errors that can be generated by the power block are shown in
table 7-6.
Table 7-4 Power Block Models
Power Block Robot Model
F*06N
F*06L
F*10N
F*10E
F*10C
F*20N F*10L
F*20L F*30
6 Axes 7 Axes KF121 F*45 U-Series Z-Series KE610
1GC 50607-1082 50607-1083 X X X
1GC 50607-1082 - X
1JK - X
1GD 50607-1084 50607-1085 X
7-12 March 28, 2002


SERVO SYSTEM
Figure 7-8 Servo Power Block
March 26, 1999 7-13


SERVO SYSTEM
Table 7-5 Power Block Connectors
Power Block Connectors

MSON signal to K3 contactor; MS

X1-SA K3 coil, K3 spare contact
condition signal from K3 contactor
X2-SA 210/60 VAC, 3-phase servo power Circuit protector F2
K3 contactor, capacitor C1, inrush

X3-SA 300/86 VDC servo power
resistor RS1, discharge resistor RS2
X4-SA 300/86 VDC servo power Spare
Control signal to additional regenerative 1GJ board (additional regenerative

X5-SA resistor unit; controller thermal sensing resistor unit driver board); controller
circuit thermal switch
XM1-SA JT1 servo motor power - U, V, W Connector X4
XM2-SA JT2, 3 servo motor power - U, V, W Connector X4
XM3-SA JT4, 5, 6, 7 servo motor power - U, V, W Connector X5
7-14 April 13, 2000


SERVO SYSTEM
Table 7-6 Power Block Errors
Error 1GB
Error Detection Level
Code Block
IPM detected one of the following errors:
• Overcurrent
P/B IPM Error • Short circuit -1559 A, B, C
• Overheat
• Low control voltage.
Regeneration continues for six seconds or more, or

Regenerative Power
the connection between the 1GB board CN13 and -1567 A
Over Time
1GC/1GD-CN9 is abnormal.
The power block (1GC/1GD) or additional regenerative

resistor unit (1GJ) temperature is 140° C, or
the additional regenerative resistor unit heat sink
Regenerative Resistor temperature is 90° C.
-1570 A
Overheat or Disconnect
Also check the connections between:
1GB-CN13 and 1GC/1GD-CN11
1GC-CN21 and 1GJ Thermal
The voltage across P-N is 60 VDC or less,

when motor power is ON.
Voltage of P-N is Low -1568 A
The voltage across P-N is 410 VDC or more,

when motor power is ON.
Voltage of P-N is High -1569 A
April 13, 2000 7-15


SERVO SYSTEM
R S T CN12 CN21
CN11
Diode Module CN10
CN20 GB-CN1
+
P P1
Bus B
CN7
N
Bars
U CSU
W
CSV 6
C16 HIC3 HIC6
1
V CN6
V
CN1
IPM1 IPM6 W
CSV
CSU U C53 6
1 C11
C
N
W 9 U CSU
CSV 5
2 HIC2 HIC5
V CN5
CN2 V
IPM2 IPM5 CSV
U W
CSU C52 5
2 C6
W N U CSU
P 4
CSV
3 HIC1 HIC4
V CN4
CN3 C V
N
IPM3 8 IPM4 CSV
CSU U C50 W 4
3
FG
GB-CN9 GB-CN10
Intelligent Power Module (IPM)
CSU/CSV - Current Sensor (U/V phase)
Figure 7-9 1GC Printed Circuit Board
7-16 March 26, 1999


SERVO SYSTEM
Table 7-7 1GC Connectors
1GC Signal Destination

Connector
JT2 - Current feedback from current sensor, current sensor disconnect

CN2 1GB-CN9
signal

CN5 1GB-CN10
signal

CN7 1GB-CN11
signal
overheat
Thermal
CN11 Regenerative resistor thermal switch
Switch
K3 Spare
CN12 MS condition signal (from K3 contactor)
Contact
Install jumper
Additional regenerative resistor unit, additional regenerative resistor plug when
CN21 unit thermal switch and heat sink thermal switch, regenerative resistor controller
thermal switch and, controller thermal switch thermal is not
used
April 13, 2000 7-17


SERVO SYSTEM
GB-CN11
Diode Module
R
CN
G CN CN CN
S 27
7 10 12
+ CN
T CN11 26
N
P
IPM1 IPM6
CS CS
CN
HIC 28 C
CN HIC CN
N
CN 20 25 CN
9
1 6
CS CS
IPM2 IPM5
CS CS
CN HIC HIC CN
CN 21 24 CN
2 5
CS CS
CS
IPM3 C IPM4 CS
N
8
CN HIC HIC CN
CN 22 23 CN
3 4
CS CS
GB-CN9 GB-CN10
CS - Current Sensor
IPM - Intelligent Power Module
HIC - Hybrid Integrated Circuit
Figure 7-10 1GD Printed Circuit Board
7-18 March 26, 1999


SERVO SYSTEM
Table 7-8 1GD Connectors
1GD Signal Destination

Connector

CN2 1GB-CN9
signal

CN5 1GB-CN10
signal

CN7 1GB-CN11
signal
overheat
Thermal
CN11 Regenerative resistor thermal switch
Switch
MS Spare
CN12 MS condition signal (from K3 contactor)
Contact

SV-M1
CN27 Regenerative resistor Resistor
CN28 24 VDC for regenerative resistor fan Fan
April 13, 2000 7-19


SERVO SYSTEM
7.3.1 SERVO POWER UNIT
The servo power unit rectifies AC power through a 3-phase diode module for use by the
servo motors. The DC power is then filtered by capacitor C1 (400 V, 6800 µF) before it
continues to the IPMs.
Controllers utilizing the large power block use two C1 capacitors; one mounted to the
inside of the controller cabinet and the second (400 V, 1000 µF) mounted inside of the
power block. Controllers utilizing the small power block use a single C1 capacitor
mounted inside of the controller cabinet.
To prevent inrush damage to the capacitor, the charge rate is regulated by resistor RS1.
After a predetermined charging interval, the 1GB board signals the power block with the
MSON signal, to energize contactor K3 and disconnect resistor RS1. An auxiliary K3
contact closes at that time to verify the contactor is operating and prevent powering the
servo motors through the resistor. 300 VDC is now available to the IPMs.
When motor power is turned off, contactor K3 is de-energized, connecting resistor RS2
across the DC bus, to discharge capacitor C1.
! WARNING
Before working on the power block, verify that the P-N
voltage is 0 VDC by checking across pins A1 and B1 on
power block connector X3-SA. The capacitors begin
discharging when motor power is turned off and require
approximately one minute to reach 0 VDC. Do not
remove connector X3-SA until the P-N voltage is 0 VDC.
Power Block
X3-SA
A3 A2 A1
B3 B2 B1
7-20 April 13, 2000


SERVO SYSTEM
During servo motor deceleration, regenerative voltage levels are controlled to protect the
IPMs from overvoltage damage. This is done by connecting regenerative resistors,
located on the back of the power block, across the DC bus.
The 1GC power block may have an optional second regenerative resistor unit, con-
nected at connector X5-SA, to further control regenerative voltages resulting from ex-
treme loads. The regenerative resistors are connected to the DC bus when the voltage
reaches 390 VDC. The resistors are disconnected when the voltage drops to 365 VDC
on the 1GD power block, and 355 VDC on the 1GC power block.
The 1GC power block uses the brake terminal of the JT1 IPM to control the regenerative
resistors. The 1GD power block uses a field-effect transistor (FET) to control the regen-
erative resistors.
A function diagram of the 1GC and 1GD power blocks is shown in figures 7-11 and
7-12.
April 13, 2000 7-21


SERVO SYSTEM
7.3.2 SERVO AMPLIFIER SECTION
Hybrid integrated circuits (HICs) in the amplifier section receive PWM signals from the
1GB board. The PWM signals are then sent to the IPMs to control current flow through
the servo motor stator windings. One IPM is used for each robot axis. The IPMs incor-
porate overcurrent, short circuit, overheat (self resetting), and low control voltage protec-
tion.
Table 7-9 describes the IPM errors.
Current detection modules are used to provide motor load information to the 1GB board.
Two modules are used for each robot axis. One module reads the U-phase current and
the second module reads the V-phase current. The 1GB board calculates the W-phase
current based on the feedback of the U- and V-phases.
A function diagram of the 1GC and 1GD power blocks is shown in figures 7-11 and
7-12.
Table 7-9 Intelligent Power Module Errors
IPM Errors
Error Item 1GC Power Block 1GD Power Block Notes
IPM Rating Error Level IPM Rating Error Level
JT1~3 150A 210A o-p 30A 39A o-p Min.
JT4~6 50A 65A o-p 15A 18A o-p

Over Current
IPM Output JT7 30A 39A o-p 30A 39A o-p
Trip Level
JT1 IPM
Brake Circuit 65A o-p ------ ------
Brake
JT1~3 150A 420A o-p 30A 80A o-p Typ.
JT4~6 50A 132A o-p 15A 39A o-p

Short Circuit
IPM Output JT7 30A 80A o-p 30A 80A o-p
Trip Level
JT1 IPM
Brake Circuit 132A o-p ------ ------
Brake
110° C 110° C
Over Temp. IPM Base Plate Temp. ------ ------
or more or more
Under IPM Power Supply +12.5 VDC +12.5 VDC

------ ------
Voltage +15 VDC or less or less
7-22 April 13, 2000

Large Power Block (1GC Board)
R IPM JT1
Inrush
and Servo Motor
S Diode
210 VAC Discharge U
Circuit IC IC IC
April 13, 2000

Power Block)
Uø CD
Vø Wø
V W
MS Operation
IC IC IC
P1 B
Voltage Additional Regenerative Regenerative H20/M21
Error Signal Monitoring Resistor Unit Resistor Encoder
P-N (Not located on the Power Block) Thermal +15 VDC
Kawasak
Regeneration Switch
Signal
Resistor Thermal Error

+12 VDC
PWM HIC
IPM ERR
Current Feedback
Encoder Signal
IPM JT2~7
To IGBT IGBT IGBT
1GB Servo Motor
Board
SERVO SYSTEM

IC IC IC
Uø CD
Vø Wø
IGBT IGBT IGBT
V W
IC IC IC
Figure 7-11 1GC Power Block Function Diagram

H20/M21
+15 VDC Encoder
+12 VDC
PWM HIC
IPM ERR
Current Feedback
Encoder Signal
C SERIES CONTROLLER
7-23
Small Power Block (1GD Board)
7-24
R
Inrush IPM JT1
and Servo Motor
S Diode
210 VAC Discharge U
Circuit IC IC IC
Power Block)
Uø CD
Vø Wø
V W
MS Operation
IC IC IC
B P1
Voltage Regeneration
Error Signal Monitoring Signal Regenerative Regenerative H20/M21
P-N Drive Circuit Resistor Encoder
Kawasak
Thermal +15 VDC

Restor Thermal Error
Switch
+24 VDC Fan
+12 VDC
PWM HIC
IPM ERR
Current Feedback
Encoder Signal
IPM JT2~7
To IGBT IGBT IGBT
1GB Servo Motor
SERVO SYSTEM
Board
IC IC IC
Uø CD
Vø Wø
IGBT IGBT IGBT
V W
IC IC IC
Figure 7-12 1GD Power Block Function Diagram

H20/M21
+15 VDC Encoder
+12 VDC
PWM HIC
IPM ERR
Current Feedback
Encoder Signal
C SERIES CONTROLLER
April 13, 2000


SERVO SYSTEM
7.3.3 SERVO POWER BLOCK REPLACEMENT
To replace the servo power block follow the steps below.
! WARNING
Before working on the power block, verify that the P-N
voltage is 0 VDC by checking across pins A1 and B1 on
power block connector X3-SA. The capacitors begin
discharging when motor power is turned off and require
approximately one minute to reach 0 VDC. Do not
remove connector X3-SA until the P-N voltage is 0 VDC.
Power Block
X3-SA
A3 A2 A1
B3 B2 B1
1. Power down the controller.
2. Check that the P-N voltage is 0 VDC as described above.
3. Note the orientation of all power block and 1GB servo board cables and connectors.
4. Disconnect the cables from the power block and 1GB servo board.
5. Remove the six M3.5 x 120 mm screws from the power block (Figure 7-13), and
remove the power block from the controller.
6. Inspect the regenerative resistor and heat sink cooling fans for dirt accumulation or
damage. Clean and replace the fans as necessary.
7. Reinstall the power block with the six M3.5 x 120 mm screws, and tighten securely.
8. Reconnect the cables to the power block and 1GB servo board.
April 13, 2000 7-25


SERVO SYSTEM
M3.5 x 120 Screws
Figure 7-13 Power Block Mounting Screws
7-26 March 26, 1999


SERVO SYSTEM
7.4 AC SERVO MOTOR ASSEMBLY
The servo motors used with the C controller are classified as brushless, AC synchro-
nous, permanent-magnet servo motors, and are referred to as AC servo motors in this
section for convenience. The motor sizes vary depending upon the type of robot used.
They are manufactured by Sanyo Denki, Matsushita, and Kawasaki; and are described
in the sections that follow.
The AC servo motor is the primary motion producing device of the servo drive system. It
is designed with permanently lubricated shaft ball bearings, and contains no brushes,
eliminating brush maintenance, arcing, and excessive heat generation.
The motor receives the pulsed electrical drive signals from the power block IPMs, and
provides position and velocity feedback signals to the 1GB servo board through the
integral hybrid encoder mounted at the end.
The AC servo motor is composed of the following subassemblies, as illustrated in figure

7-14:
• Permanent magnet rotor
• Stator windings
• 24 VDC brake assembly
• Case
A complete discussion on each major subassembly follows.
April 13, 2000 7-27


SERVO SYSTEM
7.4.1 PERMANENT MAGNET ROTOR
The rotors are of the rotational-magnetic-field type, with permanent magnets bonded to
the rotor shaft. The rotor contains 8 or 6 salient-pole circular shaped permanent-mag-
nets made of rare-earth cobalt (re-Co) or Neodymium-iron (Ne-Fe) material.
The rotor is supported at either end by sealed bearings, which are pre-lubricated for
their service life. Mounted at one end of the rotor are the electromechanical brake and
encoder assemblies.
The other end of the rotor shaft is the power output end, which has a woodruff key for
proper alignment with the power input gear.
Surrounding the rotor are the stator windings.
BRAKE DISC
THERMOSTAT
STATOR
WINDING
ENCODER
STATOR
PERMANENT
MAGNET
ROTOR
SEAL
BRAKE COIL
BALL BEARING
Figure 7-14 Motor Cross-Sectional View
7-28 March 28, 2002


SERVO SYSTEM
7.4.2 STATOR WINDINGS
The stator windings surround the rotor and receive the 3-phase electrical drive signals
(U, V, W) supplied from the power modules. The stator windings are composed of lami-
nated segments which have 3-phase copper windings wound between the laminations.
These stator windings are configured into a wye, or a star configuration.
Refer to figure 7-15 for the following discussion.
The rotor of the servo motor is composed of a 6 to 8-pole permanent magnet structure.
The field windings surround the rotor, and two phases at a time are supplied with electri-
cal current.
The letter X indicates current flow away from the viewer and the dot (•) indicates current
flow toward the viewer. The windings marked with an X indicates a magnetic field of
south and a dot (•) indicates a magnetic field of north. Since opposite magnetic polari-
ties attract and like polarities repel, this arrangement causes the motor to rotate.
Some motors are equipped with a thermostat. The overheat thermostat is attached
directly to the windings, and opens at 130° C (266° F) to detect a motor overheat condi-
tion. The thermostat automatically resets after the temperature of the windings has
cooled down sufficiently.
April 13, 2000 7-29


SERVO SYSTEM
1 2 3
W U W U W U
V V V V V V
U W U W U W
S S
S
N N
W U W U W U
N N
N N
V V V V V V
S S
S S
U W U W U W
S S
N N N
W U W U W U
V V V V V V
U W U W U W
4 5 6
W U W U W U
V V V V V V
U W U W U W
N N N
S S
W U W U W U
S S
S S
V V V V V V
N N
N N
U W U W U W
N N
S S S
W U W U W U
V V V V V V
U W U W U W
Indicates current flow toward viewer
Indicates current flow away from viewer
1 2 3 4 5 6
Iu
Iv
Iw
Figure 7-15 Principles of Motor Rotation
7-30 March 26, 1999


SERVO SYSTEM
7.4.3 24 VDC BRAKE ASSEMBLY
All servo motors are equipped with a 24 VDC electromechanical brake assembly. These
brakes are engaged when an emergency stop occurs, a hold condition occurs, or upon
completion of a program. Sequence control for actuation and de-actuation of the brake
is controlled by the 1GB board.
The 1GB board generates the RGSO signal to energize the servo motors, and the
/BRK_REQ signal to disengage the brakes. Before releasing the brakes, the RGSO
signal energizes the servo motors to maintain the axes positions. The brake release
signal is then applied to solid state relays on the 1GB board, which in turn apply 24
VDC to the brake coils, releasing the brakes.
When the brake coils are electrically de-energized, the brake disks are mechanically
engaged by a series of coil springs acting upon a pressure plate.
Each brake assembly is equipped with one nonmetallic brake disc sandwiched between
a fixed plate and a pressure plate in the brake housing (Figure 7-16). The brake disc is
attached directly to the rotor shaft of the servo motor with a square metal coupling. The
brake housing is attached to the stationary motor housing.
Pressure
Plate
Brake 24 VDC
Spring Disk Fixed to coil
Plate
Coil
A
Keyway
A
A - A' Cross Section
Figure 7-16 Brake Assembly
April 13, 2000 7-31


SERVO SYSTEM
The timing sequence in which the brake operates, is illustrated in figure 7-17 and de-
scribed below.
1. The RGSO signal turns ON and applies power to the servo motors.
2. A small digital current command signal is sent to apply sufficient current to the
servo motors to maintain the axes positions.
3. The /BRK_REQ signal is sent to energize the brake coils and disengage the brakes.
4. The current command signal is then increased and motor rotation ramps up to the
commanded velocity, maintains velocity, and finally ramps down to a stopped condi-
tion.
The current command signal is reduced to the level of maintaining the axes position, the
brake coil is de-energized and the brakes engage. Finally, the servo power is removed
when the RGSO signal turns OFF.
Motor Motor
Rotation Rotation
Speed Speed
0 0
4
/BRK_REQ /BRK_REQ
(OFF) (ON) (OFF)
3
Digital CMD Digital CMD

Signal Signal
0 0
2
RGSO RGSO
(OFF) (ON) (OFF)
1
Electromechanical Delay time Electromechanical

delay time to allow to allow delay time to allow
brake to motor to brake to engage
disengage decelerate
completely
Figure 7-17 Brake Sequence Timing Chart
7-32 April 13, 2000


SERVO SYSTEM
7.4.4 SERVO MOTOR PART NUMBERS
Table 7-10 F-Series Servo Motors
Joint No.
RatingMotor FS06L
Assembly Motor FS06N FS10E FS10L FS30N
Part No. Model No. Rating FS10C FS10N FS20N FS20C FS30L FS45C FS45N
50601-1121 P80B22450RCX2A 4.2 kW 1,2 1,2 1,2
50601-1123 P60B13150HCX23 2.1 kW 1,2 1,2
50601-1125 P60B13200LCX23 3.1 kW 3 3 3
50601-1136 P50B05010DCX20 100 W 4,5,6 4,5,6
50601-1138 P50B07050DCX20 475 W 3 3 4,5,6 4,5,6 4,5,6
50601-1139 P60B13100HCX25 1.0 kW 1,2 1,2 3 3
50601-1143 P50B05020DCX21 200 W 4,5,6 4,5,6
Table 7-11 U-Series Servo Motors
Joint No.
UX70
Motor UT100 UX100 UZ100
Assembly Motor UT120 UX120 UX200 UZ120
Part No. Model No. Rating UB150 UT150 UX150 UX300 UZ150
50601-1121 P80B22450RCX2A 4.2 kW 1,2,3 1,2,3 1,2,3 1,2,3 1,2,3
50601-1122 MFM50202V 5.0 kW 1,2,3 1,2,3 1,2,3 1,2,3
50601-1123 P60B13150HCX23 2.1 kW 4,5,6,7 4,5,6,7 4,5,6,7 4,5,6,7
50601-1124 MDM25202V 2.5 kW 4,5,6,7 4,5,6,7 7 4,5,6,7
50601-1125 P60B13200LCX23 3.1 kW 4,5,6
50601-1126 MDM31202V 3.1 kW 4,5,6
September 28, 2000 7-33


SERVO SYSTEM
Table 7-12 Z-Series Servo Motor
Motor Joint No.

Assembly Motor
Part No. Model No. Rating ZX, ZT
50601-1148 P80B22450LCX2A 4.2 kW 1,2,3
50601-1146 P60B13200LCX2C 2.1 kW 4,5,6,7
7.4.5 MOTOR SPECIFICATIONS
Table 7-13 Motor Specifications
Cont.
Torque @
Max. Max. Max. Cont. Max. Stall Max. Cont.
Output Speed Torque Torque Max. Armature Max. Armature
Motor Power N-m N-m N-m Speed Current Current Resistance Weight
Model No. (Watt) (kg-cm) (kg-cm) (kg-cm) (RPM) (Amp) (Amp) (Ohm) (Kg)
7.84 11.76 17.35
MDM25202V 2500 3000 12 30 0.17 12.8
(80.0) (120.0) (177.0)
9.8 12.25 26.46
MDM31202V 3100 3000 16.25 50 0.1 14.4
(100.0) (120.0) (270.0)
19.6 38.22 68.60
MFM50202V 5000 2700 33.2 90 0.034 28.8
(200.0) (390.0) (700.0)
0.32 0.35 0.98
P50B04010DCXS9 100 5000 1.2 5.1 7 0.96
(3.25) (3.6) (10.0)
1.27 1.37 3.92
P50B07040DCXS9 400 5000 3.1 14.1 1.65 2.56
(13.0) (14.0) (40.0)
3.19 3.92 11.76
P50B08100VCXS9 1000 4000 5.6 26.9 0.73 5.7
(32.5) (40.0) (120.0)
6.66 7.84 16.17
P60B13150HCX23 2100 3000 9.5 31 0.27 11
(68.0) (80.0) (165.0)
9.80 11.76 26.46
P60B13200LCX23 3100 3000 14.8 52.3 0.15 13.2
(100.0) (120.0) (270.0)
9.80 11.8 26.5
P60B13200LCX2C 2100 3000 14.8 37 0.15 13.2
(100.0) (120.3) (270.2)
16.66 32.34 63.70
P80B22450RCX2A 4200 2730 33 97.6 0.043 30.6
(170.0) (330.0) (650.0)
16.7 32.3 63.70
P80B22450LCX2A 4200 2400 35 72 0.035 30.6
(170.2) (329.3) (650.0)
Kilowatt to horsepower conversion: 1 kW = 1.34 HP
Example: 4.2 kW x 1.34 = 5.63HP
7-34 September 28, 2000


SERVO SYSTEM
Table 7-14 Motor Brake Specifications
Motor Static Excitation Excitation

Model No. Friction Voltage Current
Torque (Volt) (Amp)
N.M
(Kg.CM)
11.76
MDM25202V DC24 +/- 10% 0.79
(120.0)
11.76
MDM31202V DC24 +/- 10% 0.79
(120.0)
32.34
MFM50202V DC24 +/- 10% 0.88
(330.0)
0.32
P50B04010DCXS9 DC24 +/- 10% 0.26
(3.25)
0.98
P50B07040DCXS9 DC24 +/- 10% 0.3
(10.0)
2.94
P50B08100VCXS9 DC24 +/- 10% 0.33
(30.0)
8.82
P60B13150HCX23 DC24 +/- 10% 0.86
(90.0)
11.96
P60B13200LCX23 DC24 +/- 10% 1.00
(122.0)
32.34
P80B22450RCX2A DC24 +/- 10% 1.60
(330.0)
September 28, 2000 7-35


SERVO SYSTEM
7.4.6 MOTOR MODEL NUMBER DESIGNATION
65 BM 040 H B R S A R1
Revision No.
Encoder Type A : Standard
B : High Resolution
Specification
Sensor R : With Encoder
X : No Brake
B : With Brake
RPM H: 3600 RPM

Maximum Continuous Torque
Brushless Motor
BL Series Amplifier Number
Figure 7-18 Sanyo Denki Minor Axes Motor Model Number Designations
68 BM 220 L B A 20 R1
Revision No.
Design Number
Sensor A :With Encoder
X : Without Encoder
X : No Brake
B : With Brake
RPM H :3000 RPM
L : 2730 RPM
Maximum Continuous Torque
Brushless Motor
BL Series Amplifier Number
Figure 7-19 Sanyo Denki Major Axes Motor Model Number Designations
7-36 April 13, 2000


SERVO SYSTEM
MRM 21 2 0 1 H
Manufacturer's Specification
Design Revision
Without Encoder
Power Source 1 : 100V
2 : 200V
Z : 100/200V
Output Power 21 : 2.1KW
3A : 30W
5A : 50W
8A : 80W
AC Servo Motor Series
MRM : Large Motor
MSM : Small Motor
Figure 7-20 Matsushita Minor Axes Motor Model Number Designations
MFA 420 F Y O B S
Manufacturer's Specification
With Brake
Without Encoder
Type
Type of Packaging
Output 420 : 4.2KW

360 : 3.6KW
AC Servo Motor Series
Figure 7-21 Matsushita Major Axes Motor Model Number Designations
April 13, 2000 7-37


SERVO SYSTEM
7.4.7 SERVO MOTOR REPLACEMENT
! WARNING
Unsupported axes will fall when the servo motor is re-
moved. Position the axis on a hard stop, or support the
axis with a suitable lifting device before removing the
servo motor.
1. Turn the robot controller main disconnect OFF, and tag and lockout the controller.
2. Remove the four M4 X 25 mm screws from the encoder cover and the four M5 X 30
mm screws in the motor power and brake connector box shown in figure 7-22.
3. Disconnect the motor power, motor brake, and encoder electrical connectors from
the servo motor and encoder (see figure 7-23 to separate the encoder connectors).
Note the direction and routing of these connectors for correct servo motor installa-
tion.
M4 X 30 mm Screws
and Washers
Motor Power and Brake

Connector Box
Servo Motor
H20 Encoder
Nylon Washers
M4 X 25 mm Screws
Figure 7-22 Encoder and Motor Power/Brake Connection Boxes
7-38 March 26, 1999


SERVO SYSTEM
Connector Key
Push Downward
Rubber Packing
Pull out with fingers
Figure 7-23 Encoder Connector Separation
4. Remove the four M12 X 30 mm screws (figure 7-24, U-series and 7-25, Z-series)
that attach the servo motor to the reduction unit and remove the servo motor and
gear from the reduction unit.
M12 X 30 mm Screw
Servo Motor
Gear Assembly
Washer
Gear Assembly Mounting Screw
Figure 7-24 Servo Motor/Gear Assembly, U-Series
January 9, 2004 7-39


SERVO SYSTEM
M12 X 30 mm Screw
Servo Motor
M5 X 12 mm Screw
Flywheel
Ring
Spur Gear
End Plate
Fastener Seal
M10 X 45 mm Screw
Figure 7-25 Servo Motor/Gear Assembly, Z-Series (JT1 Shown)
7-40 January 9, 2004


SERVO SYSTEM
5. Install jig ROD onto the flats of the gear assembly as shown in figure 7-26.
6. Loosen the gear assembly mounting screw to provide approximately a 5 mm gap

between the head of the screw and the end of the gear assembly.
7. Attach a gear puller to jig ROD and the gear assembly mounting screw to release
the gear assembly from the motor shaft.
Jig, ROD
5 mm Gap
Gear Puller
Figure 7-26 Gear Assembly Removal
January 9, 2004 7-41


SERVO SYSTEM
8. U-Series:
Apply a lubricant containing MoS2 (Molybdenum Disulfide) to the shaft of the servo
motor.
Z-Series:
Apply a thin coating of Daphne Eponex No.3 to the shaft of the servo motor.
9. U-Series:
Install the gear assembly onto the motor shaft with the washer and gear assembly
mounting screw. Tighten the gear assembly mounting screw to 580 kg-cm (41.95 ft-
lb) to seat the gear assembly onto the motor shaft.
Z-Series:
Install the gear assembly onto the motor shaft. If reusing existing parts the end
plate is installed with Loctite® 515® sealant and is installed with the gear assembly.
If new parts are used the end plate is not installed at this time. Install the steel plate
tool and the gear assembly mounting screw (Figure 7-27). Tighten the gear assem-
bly mounting screw to 580 kg-cm (41.95 ft-lb) to seat the gear assembly onto the
motor shaft.
NOTE
The steel plate tool is used as a pusher to install the
gear assembly (Z-series) and prevent motor rotation
during the initial torque procedure.
Steel Plate Tool
M12 X 30 mm Screw
Servo Motor
Gear Assembly
Figure 7-27 Servo Motor Gear Assembly Installation, Z-Series
7-42 January 9, 2004


SERVO SYSTEM
10. U-Series:
Remove the gear assembly mounting screw and washer from the gear assembly.
Clean both parts with a suitable cleaner. Apply Loctite® 242® threadlocker to the
mounting screw threads and Three Bond® No. 1212 sealant to both sides of the
washer (Three Bond sealant for JT1 only). Reinstall the gear assembly mounting
screw and washer onto the gear assembly and tighten to 175 kg-cm (151.89 in-lb).
Z-Series:
Remove the gear assembly mounting screw and steel plate tool from the gear
assembly. Clean the mounting screw with a suitable cleaner. Apply Loctite® 242®
threadlocker to the mounting screw threads. For new parts apply Loctite® 515®
sealant to the end plate gear assembly mating surface. Install the end plate (new
parts), fastener seal and gear assembly mounting screw onto the gear assembly
and tighten to 175 kg-cm (151.89 in-lb).
11. Install the servo motor into the reduction unit with the motor power and encoder
connectors facing the correct direction.
12. Fasten the servo motor to the reduction unit with the four M12 X 30 mm screws
and tighten to 1000 kg-cm (72.33 ft-lb).
13. Reattach the motor power and encoder electrical connectors to the servo motor and
encoder.
14. Install the encoder cover with the four M4 X 25 mm screws and seal washers.
Tighten the screws to 8 kg-cm (6.94 in-lb).
! CAUTION
Do not over tighten the cover screws in the following
step - damage to the seal washers results.
15. Install the motor power and brake connector box cover with the four M5 X 30 mm
screws and seal washers. Tighten the screws to 30 kg-cm (26.04 in-lb).
16. Perform the zeroing procedure. Refer to unit 8.
January 9, 2004 7-43


SERVO SYSTEM
7.5 H20/M21 AND H32KT/M30KT ENCODER ASSEMBLIES
Robots utilizing the C controller are equipped with the model H20 or M21 hybrid en-
coder. The H20 encoder is used on the F-series 10/20/30/45 robots, all U-series, and all
Z-series robots. The M21 encoder is used on the F-series 6/10/20 robots.
Internally, the H20 and M21 encoders are the same. The difference lies in the method
used to mount the encoder to the servo motor. This difference allows H20 encoders to
be replaced by the user, while the M21 encoder and motor assembly must be returned
to Kawasaki Robotics (USA), Inc., for repair.
Robot systems using the explosion-proof (EP) type C controller use the H32KT or
M30KT encoder. The H32KT is used for large motors and the M30KT is used for small
motors. The H32KT can be removed from the motor assembly; the M30KT is integral to
the motor assembly and cannot be removed.
Encoder specifications are shown in table 7-15.
Table 7-15 Encoder Specifications
Electrical Specification Optical Encoder Magnetic Encoder

Type Optical Disk Magnetic Incremental
Power 5 VDC ± 0.25 V 3.6 VDC or more
25 µA - H20
Current Consumption 180 mA
30 µA - M21
Resolution 213 (8,192) Revolutions 1 / Revolution
Response 6,000 RPM
Countable Rotations 216 (65,536) Revolutions
Operating Temperature -20° – +80° C (-4° – +176° F)
Storage Temperature -20° – +80° C (-4° – +176° F)
Humidity 95% RH or less, no dew condensation
Vibration 10G, 3,000 Hz or less
Impact 100G, 6 ms or less
Miscellaneous Dustproof, water and oil resistant
7-44 January 9, 2004


SERVO SYSTEM
The function of the encoder is to sense motor shaft movement and timing for commuta-
tion. The data generated by the encoder determines the absolute position, speed,
direction of rotation, and alignment of the rotor magnets with the stator poles. The
encoder sends 48 bits of data via half duplex serial communications to the 1GB board,
at a baud rate of 1 MB/sec.
This data is sent after receiving a request signal from the 1GB board, and includes the
following:
• 13 bit M-pattern data, providing 8,192 bits of data per revolution, used to indicate
the position of the motor shaft within 360°.
• 15 bit binary data, used to indicate the number of motor shaft revolutions in both
directions, to a maximum of ±32,768 revolutions.
• 2 bit magnetic incremental encoder used to feed the rotation counter.
• 3 bit encoder alarm data.
January 9, 2004 7-45


SERVO SYSTEM
The encoder assembly is comprised of an optical encoder and a magnetic encoder, as

shown in figure 7-28. The optical encoder uses an LED and photo-receivers on oppo-
site sides of a metal disk to generate data. The metal disk has a proprietary pattern of
slots that act as a shutter between the LED and photo-receivers. The disk provides
incremental A and B pulses in addition to the M-pattern absolute data. Calibration upon
power up is not required, as the absolute data provides this information.
The magnetic encoder uses a series of magnets and magnetic reluctance (MR) sensors
to generate the incremental A and B pulses that provide data to the rotation counter.
The rotation count together with the absolute count provide absolute position sensing
anywhere within the robots work envelope.
The rotation count is stored in a volatile memory inside of the encoder. Batteries on the
1FG board, located in the base of the robot, maintain the rotation counter memory when
controller power is turned off. A minimum of +3.3 VDC is required for the rotation
counter circuitry to operate.
If the encoder becomes disconnected from 1FG board, battery power is no longer
applied to the rotation counter memory. To prevent immediate memory loss, a super
capacitor in the encoder provides approximately 30 minutes of power to the rotation
counter circuitry. During this 30 minute time period, the rotation count updates if an axis
is moved, e.g., external brake release, etc. After the 30 minute time period has elapsed,
the axis must be re-zeroed.
To determine commutation sensing (CS), the encoder must be adjusted to a specific

starting point. This factory adjustment is performed by rotating the encoder until the
zero point of the U-phase regenerative voltage, and the midpoint of the Z-phase
encoder pulse, are aligned. From this point, the servo system relies on encoder data
and servo software to generate a PWM signal that emulates a sine wave.
The factory CS adjustment procedure also stamps an index mark on the heat insulator
located between the encoder and motor. Whenever an encoder is replaced, the CS
index marks on the encoder and motor must be aligned to maintain the proper commu-
tation sensing.
7-46 January 9, 2004


SERVO SYSTEM
Main Circuit Board
ASIC-2
Rotation Power Supply

Amplifier Circuit
Backup & Normal
Counter
Operation
Capacitor Voltage
MR Monitor
Sensor LED Normal Operation
Only Operational State
Switch
ASIC-1
Disk Incremental
Rotor Magnet Data Vcc
Initial 0V
Value
SD
Amp Absolute
Data /SD
Sensor
Circuit Board Control Signals
Error Detect
Communication Communication
Circuit - RS-485
Figure 7-28 Encoder Block Diagram
Power for the encoder is sent from the controller to the 1FG board. The 12 VDC pro-
vided by the controller is converted to 5 VDC by the 1FG board before being applied to
the encoder. Operational states of the encoder are determined by voltage levels as
indicated below.
• 5.0 VDC - normal operation of the encoder.
• 3.3 VDC or more - backup operation of the encoder. Only the rotation counter
circuitry is functional.
• 3.0 VDC or less - all operation stops and the affected axes must be re-zeroed.
The encoder is capable of generating three alarm signals as shown in table 7-16. Each
of these signals displays an error message on the multi function panel, and robot opera-
tion stops.
January 9, 2004 7-47


SERVO SYSTEM
Table 7-16 Encoder Errors
Encoder Errors
Error Error Code & Message Description
Unable to determine absolute data at

BUSY -1553 Encoder initialize error
control power on.
Incremental counter data and

ABSALM -1556 ABS-track error
absolute data do not match.
Incremental A and B pulses are

INPALM -1557 INC-pulse error
abnormal.
7.5.1 HANDLING INSTRUCTIONS FOR THE ENCODER
• Because the encoder is a precision optical device, handle it with care. Exposing the
encoder to excessive mechanical shock such as dropping may seriously damage
the encoder assembly.
• An excessive load to the encoder shaft may decrease the life and may deteriorate
the accuracy of the encoder. Avoid excessive load to the shaft (refer to the specifi-
cations).
• Do not exceed the temperature range listed in the specifications.
• The encoder should not be exposed to water, grease, or excessive dust.
• Do not open the encoder case for any reason.
• When encoder repair is required, return it to Kawasaki Robotics (USA), Inc..
7-48 January 9, 2004


SERVO SYSTEM
7.5.2 H20 ENCODER REPLACEMENT PROCEDURES
1. Turn the robot controller main disconnect OFF, and tag and lockout the controller.
2. Remove the encoder cover from the encoder by removing the four M4 X 25 mm
screws and nylon washers, as shown in figure 7-29.
Nylon Washers
M4 X 25 mm Screws
Servo Motor
H20 Encoder
Figure 7-29 Encoder Cover Removal
3. Disconnect the electrical connector from the encoder and remove the rubber pack-
ing from the encoder housing as shown in figure 7-30.
Connector Key
Push downward
Rubber Packing
Pull out with fingers
Figure 7-30 Encoder Connector Removal
January 9, 2004 7-49


SERVO SYSTEM
4. Remove the four M4 X 25 mm screws that attach the encoder housing to the servo
motor and the M4 X 22 mm stainless screw with the special washer from the center
of the encoder housing (Figure 7-31). If necessary, use small tweezers to retrieve
the washer.
Special washer
M4 X 22 mm stainless screw
M4 X 25 mm screws
Figure 7-31 Encoder Mounting Screw Removal
5. Install an M6 X 50 mm 100% threaded jack screw into the center of the encoder to
separate the encoder coupling from the servo motor shaft, and remove the encoder.
6. Remove the gasket from the mounting flange of the old encoder, and install onto the
flange of the new encoder.
7. To install the new encoder, align the slot in the encoder coupling with the pin in the
motor shaft, as shown in figure 7-32.
Servo Motor Encoder
Encoder coupling
Pin Slot
Figure 7-32 Encoder Coupling
7-50 January 9, 2004


SERVO SYSTEM
8. Fasten the encoder coupling to the servo motor shaft with the M4 X 22 mm stain-
less screw coated with Loctite 242, and the special washer. Tighten the M4 X 22
mm screw to 20 kg-cm (23 in lb).
9. Install the four M4 X 25 mm screws coated with Loctite 242 into the encoder hous-
ing but do not tighten the screws at this time.
10. Rotate the encoder housing to align the match mark on the encoder housing with
the match mark on the servo motor (Figure 7-33), and tighten the four M4 X 25 mm
screws to 20 kg-cm (17.36 in-lb).
Align match marks
Figure 7-33 Encoder Match Marks
11. Reinstall the rubber packing and reattach the wire harness electrical connector to
the encoder.
12. Reinstall the encoder cover with the four M4 X 25 mm screws and nylon washers
and tighten to 8 kg-cm (6.94 in-lb).
13. Perform the zeroing procedure. Refer to unit 8, Zeroing.
January 9, 2004 7-51


ZEROING
8.0 ZEROING....................................................................................................... 8-2

8.1 Zeroing Checks .............................................................................................. 8-2
8.2 Simple Zeroing ............................................................................................... 8-4
8.2.1 Zeroing Scale Locations ................................................................................ 8-5
8.2.2 Simple Zeroing Using AS Language Keyboard Commands .......................... 8-8
8.2.3 Simple Zeroing Using AUX Functions 140 and 41 ....................................... 8-13
8.3 Precision Zeroing ......................................................................................... 8-17
8.3.1 Inclinometer Zero Adjustment ...................................................................... 8-17
8.3.2 Attachment of UX- and UZ-Series Zeroing Jigs ........................................... 8-22
8.3.3 Attachment of UT-Series Zeroing Jigs ......................................................... 8-27
8.3.4 Attachment of F-Series Zeroing Jigs............................................................ 8-32
8.3.5 Precision Zeroing Using AS Language Keyboard Commands .................... 8-37
8.3.6 Precision Zeroing Using AUX Functions 140 and 41 ................................... 8-40


ZEROING
8.0 ZEROING
The robot motor/encoder zero points are adjusted, and zero scribe marks aligned, prior
to shipment from the factory. While the robot does not need periodic re-zeroing, certain
repair or replacement procedures require robot re-zeroing after they are performed. For
a list of procedures that require simple zeroing, refer to section 8.1.2
8.1 ZEROING CHECKS
If the robot arm interferes with the workpiece, or indications of alignment problems exist,
check the robot zeroing using the following procedure:
! WARNING
The following robot operation should only be performed
by personnel with thorough training and understanding
of robot operations and programming.
1. If the robot HOME position is defined as 0.0 degrees on all joints, the AS Language
command DO HOME can be entered on the keyboard screen to drive the robot
joints to the zero encoder position. For additional information about defining and
using the HOME command, refer to the C Controller AS Language Manual
(MRPCCONTO118E).
As an alternate method, to drive the robot joints to the zero encoder position, use
the AS Language precision point function #PPOINT. Enter the following
command on the keyboard screen:
DO JMOVE #PPOINT(0,0,0,0,0,0)
For additional information about AS Language commands and functions, refer to the
C Controller AS Language Manual (MRPCCONTO118E).
2. Check the alignment of the zero scribe marks. If the scribe marks are not properly
aligned, it is necessary to perform the zeroing procedure. Also, check the zero
scribe plates to ensure that they are not loose, nor misaligned.
8-2 April 13, 2000


ZEROING
Use the following guidelines to determine when simple zeroing or precision zeroing
should be used.
Simple zeroing is performed after any of the following:
• Servo motor or encoder replacement
• Reduction unit replacement
• Wrist replacement
• 1GA/1HA board replacement
• System initialization
• Upgrading the AS software
Precision zeroing is performed when any of the following conditions exist:
• Robot is overhauled
• Zeroing scales are misaligned, damaged, or the original position of the scales is
disturbed in any manner
• Positional data for the robot is provided by an off-line robot simulation/programming

system, such as the Kawasaki ROSET®


ZEROING
8.2 SIMPLE ZEROING
Simple zeroing is performed using the axes scale marks, shown in section 8.2.1, to
position the mechanical unit. After the mechanical unit is in the zero position, the
encoder rotation count is updated and the resulting encoder position registered using
auxiliary functions or AS Language commands.
Simple zeroing is performed when any of the following procedures is completed:
• Servo motor or encoder replacement
• Reduction unit replacement
• Wrist replacement
• 1GA/1HA board replacement
• System initialization
• Upgrading the AS software
There are two methods to perform simple zeroing:
• Simple Zeroing Using AS Language Keyboard Commands (section 8.2.2).
• Simple Zeroing Using AUX Function 140 and 41 (section 8.2.3)


ZEROING
8.2.1 ZEROING SCALE LOCATIONS
JT6
JT5
JT4
JT3
JT2
JT1
Figure 8-1 F-Series Zeroing Scale Locations


ZEROING
JT3
JT2
JT1
JT4
JT5
JT6
Figure 8-2 UT-Series Zeroing Scale Locations
JT3
JT6
JT4 JT5
JT2
JT1
Figure 8-3 UX- and UZ-Series Zeroing Scale Locations


ZEROING
Figure 8-4 ZX-Series Zeroing Scale Locations


ZEROING
8.2.2 SIMPLE ZEROING USING AS LANGUAGE KEYBOARD COMMANDS
This procedure utilizes AS Language keyboard commands to complete the simple

zeroing procedure. When the robot is in the critical position (zero mechanical position),
the AS Language ZZERO command is used to reset the encoder rotation count and
register the encoder absolute count, within the controller’s memory.
When the rotation count is reset, the current value of the rotation counter is sent to the
controller to update the value stored in the controller’s memory. Once the rotation count
is updated, the absolute count is determined. The absolute count, based on the rotation
count and the shaft angle of the encoder, is also stored in the controller’s memory to
indicate the mechanical zero position of each joint.
To use the ZZERO command, type the command on the keyboard screen followed by an
integer:
>ZZERO (integer) <RETURN>


ZEROING
When the ZZERO command is used to reset the encoder rotation count, the integer
ranges from 100 to 107:
• Entering 100 resets all of the rotation counts.
• Entering 101 through 107 resets the individual rotation counts

(i.e., 101 resets the JT1 rotation count, 102 resets the JT2 rotation count, etc.).
When the ZZERO command is used to register the encoder absolute count, the integer
ranges from 0 to 7:
• Entering 0 registers the encoder absolute count for all joints.
• Entering while 1 through 7 registers the encoder absolute count for the individual
joints.
When the ZZERO command is used to view or manually enter the robots zeroing data,
the integer is not used. Without an integer the zeroing data is viewed and changed by
entering new values through the keyboard screen.
NOTE
The robot axes can be zeroed individually but may
require other axes to be positioned at specific angles.
Refer to tables 8-1 and 8-2 to determine which axes
must be positioned prior to zeroing.
ZZERO AS Language Command Procedures
1. Jog all axes to be zeroed, until the zero scribe marks are aligned as shown in
figures 8-1 through 8-3 (a metal ruler can be used as an aid to align the zero
scribe marks).
When zeroing axes individually, refer to tables 8-1 and 8-2 to determine which
axes need to be positioned at zero before other axes are zeroed.
For example, when zeroing joint 6 (T-axis) of a U-series robot, checking table
8-1 shows that joints 4 and 5 (S and B axes) must also be zeroed. Adjust the
axes in the following order: JT4 - JT5 - JT6 (S - B - T).

Table 8-1 Additional Axes to be Zeroed (U/Z-Series) Table 8-2 Additional Axes to be Zeroed (F-Series)
8-10
F-Series
AXES TO BE ZEROED
JT1 JT2 JT3 JT4 JT5 JT6

(R) (O) (D) (S) (B) (T)
JT1
(R) X X X X X
Kawasak
JT2
(O) X X X X X
JT3
(D) X X X X X
JT4
X X X X X
ZEROING
(S)
JT5
(B) X X X X O
ADDITIONAL AXES TO BE ZEROED
JT6
(T) X X X X X
KEY: X = Positioning At Zero Not Required

O = Must Be Positioned At Zero
C SERIES CONTROLLER
September 28, 2000


ZEROING
2. Reset the encoder rotation count with the ZZERO command, as shown in
figure 8-5. To reset the encoder rotation count of all axes simultaneously, type:
>ZZERO 100 <RETURN>
To reset the encoder rotation count of an individual axis, type:
>ZZERO 101–107 <RETURN>
Entering 101 resets the encoder rotation count for JT1, 102 resets JT2, etc.
When prompted for the current angle, enter 0 degrees if the joint is in the critical
position. If the joint is not in the critical position, enter the actual position in
degrees, relative to the critical position.
1) To reset the rotation counts of all joints, type the command “ZZERO 100” and
press the RETURN key.
ZZERO 100
**Encoder rotation counter reset (all joints)**
Are you sure? (Enter 1 to execute) 1
Setting complete
2) To reset the rotation count for a specific joint, type the command “ZZERO 101”
for example, and press the RETURN key.
ZZERO 101
**Encoder rotation. counter reset (1th axis)**
Current angle (deg, mm)? 0
Setting complete
Figure 8-5 AS Language Rotation Counter Reset Example
3. Register the encoder absolute count with the ZZERO command as shown in figure
8-6. To register the encoder absolute count of all robot axes simultaneously, type:
>ZZERO 0 <RETURN>
To register the encoder absolute count of an individual robot axis, type:
Entering 1 registers the absolute count of JT1, entering 2 registers JT2, etc.
September 28, 2000 8-11


ZEROING
When prompted for the current angle, enter 0 degrees if the individual joint is in the
critical position. If the joint is not in the critical position, enter the actual position of
the joint in degrees relative to the critical position.
1) To display or manually change the zeroing data for all joints, type the command “ZZERO”
and press the RETURN key.
ZZERO
Set data 268435710 268440360 268414070 268435970 268443125 268432333
Current 268435604 268441202 268414065 268435982 268443131 268432329
Change? (if not, Press RETURN only.)
OFFSET
0 135 65,105 4,129 0 42
Change (if not, Press RETURN only.)
2) To register the zeroing data for all joints, type the command “ZZERO 0” and press the
RETURN key.
ZZERO 0
Set data 268435710 268440360 268414070 268435970 268443125 268432333
Current 268435604 268441202 268414065 268435982 268443131 268432329
Set current value of all joints as zeroing data? (Enter 1 to set.) 1
Setting Complete
3) To register the zeroing data for a specific joint, type the command “ZZERO 2”, for example,
ZZERO 2
Encoder value? (Current = 268440360. Enter 1 to set current value) 1
Zeroing value = 268440360 (268419072 - 268451840) OK? (Enter 0 to change)
Setting complete
Figure 8-6 ZZERO AS Language Command Example
4. Operate the robot in Check mode to verify the point locations of a previously taught
program playback correctly.
8-12 September 28, 2000


ZEROING
8.2.3 SIMPLE ZEROING USING AUX FUNCTIONS 140 AND 41
This procedure utilizes AUX Function 140, Encoder Rotation Counter Reset, and AUX
Function 41, Zeroing, to complete the simple zeroing procedure. When the robot is in
the critical position (zero mechanical position), AUX Function 140, resets the encoder
rotation count, and AUX Function 41 registers the encoder absolute count within the
controller’s memory.
controller to update the offset value that is stored in the controller’s memory. Once the
rotation count has been updated, the absolute count is determined. The absolute count,
based on the rotation count and the shaft angle of the encoder, is also stored in the
controller’s memory to indicate the mechanical zero position of each joint.
NOTE
The robot axes can be zeroed individually but may
require other axes to be positioned at specific angles.
Refer to tables 8-3 and 8-4 to determine which axes
must be positioned prior to zeroing.
AUX Function 140 and AUX Function 41 Procedures
1. Jog all axes which are to be zeroed, until the zero scribe marks are aligned as
shown in figures 8-1 through 8-3 (a metal ruler can be used as an aid to align the
zero scribe marks).
When zeroing individual axes, refer to tables 8-3 and 8-4 to determine which axes
need to be positioned at zero before other axes can be zeroed. For example, when
zeroing joint 6 (T-axis) of a U-series robot, table 8-3 shows that joints 4 and 5 (S
and B axes) must also be zeroed. Adjust the axes in the following order:
JT4 - JT5 - JT6 (S - B - T).
September 28, 2000 8-13

Table 8-3 Additional Axes to be Zeroed (U/Z-Series) Table 8-4 Additional Axes to be Zeroed (F-Series)
8-14
F-Series
AXES TO BE ZEROED

(R) (O) (D) (S) (B) (T)
JT1
(R) X X X X X
Kawasak
JT2
(O) X X X X X
JT3
(D) X X X X X
JT4
X X X X X
ZEROING
(S)
JT5
(B) X X X X O
JT6
(T) X X X X X

C SERIES CONTROLLER
September 28, 2000


ZEROING
2. Reset the encoder rotation count with the AUX Function 140 shown in figure 8-7.
Enter the joint number to be zeroed at the JOINT NO. prompt. Enter 0 to reset the
encoder rotation counts for all joints or 1–7 to reset the rotation count for an indi-
vidual joint.
Enter the rotation angle of the joint at the SET DEGREE prompt. Enter 0 degrees if
the joint or joints are in the critical position. If a joint is not in the critical position,
enter the actual position in degrees relative to the critical position.
NOTE
Simultaneous zeroing of all axes can only be performed
when all axes are in the critical position. If an axis can-
not be moved to the critical position, it must be zeroed
individually.
When all of the information has been entered, press RETURN, and answer the
prompt:
>Are you Sure ? (F1-YES, F4-NO.)
AUX 140 ENCODER ROT.COUNTER RESET

SETTING CURRENT
JT1 268422562 268422562
JT2 268437254 268437254
JT3 268421269 268421269
JT4 268433264 268433264
JT5 268427274 268427274
JT6 268428465 268428465
JOINT NO. = 0
(0 = reset all joint)
SET DEGREE = 0 deg
F1 F2 F3 F4
PRE DATA
Figure 8-7 AUX Function 140, Encoder Rotation Counter Reset
September 28, 2000 8-15


ZEROING
3. Register the encoder absolute count with AUX Function 41 shown in figure 8-8.
Enter the joint number to be zeroed at the JOINT NO. prompt. Enter 0 to register
the absolute counts for all joints or 1–7 to register the absolute count for an indi-
vidual joint.
NOTE
when all axes are in the critical position. If an axis
cannot be moved to the critical position, it must be
zeroed individually.
When all of the information is entered, press RETURN and answer the prompt:
>Replace all set values with current position. Are you sure ? (F1-YES, F4-NO.)
AUX 41 ZEROING
SETTING CURRENT
JT1 268422562 268422562
JT2 268437254 268437254
JT3 268421269 268421269
JT4 268433264 268433264
JT5 268427274 268427274
JT6 268428465 268428465
JOINT NO. = 0
(0 = all joint)
SET DEGREE = 0 deg
F1 F2 F3 F4
PRE DATA
Figure 8-8 AUX Function 41, Zeroing
4. Operate the robot in check mode to verify the point locations of a previously taught
8-16 September 28, 2000


ZEROING
8.3 PRECISION ZEROING
Precision zeroing is performed prior to robot shipment from the factory. A precision
inclinometer is used to position the robot during the precision zeroing procedure.
Precision zeroing is performed when any of the following conditions exist:
1. The robot is overhauled
2. The zeroing scales have been mechanically misaligned, damaged, or the original
position of the scales is disturbed in any manner
3. The taught positional data for the robot is provided by an off-line robot simulation/
programming system such as the Kawasaki ROSET®, or other off-line systems
NOTE
A Niigata Seiki®, small-type, 1/100 digital level inclinom-
eter, model DL-S1 is recommended.
8.3.1 INCLINOMETER ZERO ADJUSTMENT
In the procedures that follow, a Niigata Seiki® Digital Level Gauge DL-S1-S1V Digital
Inclinometer is utilized. Prior to performing the procedures/adjustments in this section,
the operator must be familiar with the information that follows.
! CAUTION
The Niigata Seiki® Digital Level Gauge DL-S1-S1V Digi-
tal Inclinometer is a precision instrument. It must not be
exposed to any mechanical shock generated by drop-
ping, or other types of mishandling.
September 28, 2000 8-17


ZEROING
1. Digital Level Gauge DL-S1-S1V Digital Inclinometer Specifications:
Range: ± 9.99 mm/m
Minimum Value: 0.01 mm/m (0.00039 inch/39.37 inches)
Temperature: 0–40° C (32–104° F)
Accuracy: ± 1.3% rdg at 17–23° C (62.6–73.4° F)

± 3.0% rdg at 0–4° C (32–39.2° F)
Repeatability: Less than ± 0.01 mm/m (±0.00039 inch/39.37 inches)
Dimension (HxWxL): 104 mm x 78 mm x 159 mm (4.09 in. x 3.07 in. x 6.26 in.)
Length of Base: 150 mm (5.90 in.)
Weight: 1.0 kg (2.2 lb)
Power: 1 x 006P Battery (9 V),

Optional 100 VAC Adapter
Life of Battery: Manganese Battery—Approximately 25 hours

Alkaline Battery—Approximately 50 hours
8-18 September 28, 2000


ZEROING
8 1
POWER DATA 0-ADJUST

6 ON HOLD
+
-
OFF RUN
4
5
2 3
1. Indication Panel (Digital)

2. Power Switch
3. RUN/HOLD Switch
4. Zero Adjustment Volume
5. AC Adapter Jack
6. Knob for Battery Case
7. Battery Case Cover
8. Bubble Level Gauge
Figure 8-9 Digital Inclinometer Description Drawing
September 28, 2000 8-19


ZEROING
ZERO ADJUST VOLUME
Position "A" Position "B"
CALIBRATION
REQUIRED
CALIBRATED
OVER OVER
OVER RANGE
Figure 8-10 Zero Adjustment/Ranges
2. The digital inclinometer is equipped with a zero adjustment knob used to zero the
inclinometer. This adjustment is necessary to accommodate for variations in robot
base to floor inclinations, and must be performed prior to any measurements of
actual robot axes inclinations. The inclinometer has a total range of ±10.00
mm/meter (Figure 8-10).
3. Completely remove any paint, rust, weld spatter, etc. from the zero datum plane with
an oil stone. Install a battery in the inclinometer, turn it on, and allow it to warm-up
for 20 minutes, prior to use.
4. Ensure no foreign material is on either the mating surface of the inclinometer, nor
the datum reference plane, then set the inclinometer on the datum reference plane.
5. Set the DATA RUN/HOLD switch to RUN.
6. Note the value of position A on the inclinometer shown in figure 8-9, Zero
Adjustment/Ranges. For example, “7.00”.
7. Mark the location of the inclinometer on the datum plane with a pencil.
8-20 September 28, 2000


ZEROING
8. Set the DATA RUN/HOLD switch to HOLD, rotate the digital inclinometer 180°, and
position it on the marks made in the previous step.
9. Set the DATA RUN/HOLD switch to RUN, and note the value of position B on the
inclinometer, shown in figure 8-9, Zero Adjustment/Ranges. For example, “-5.00”.
10. Add the two values together, and divide by two:
Example
Position A + Position B 7.00 + (-5.00)
2 =X = 1
2
Add quotient "X" to the value of position A and the value of position B:
Example
Position A + (X * -1) = Z 7.00 + (1 * -1) = 6.00
Position B + (X * -1) = Z -5.00 + (1 * -1) = -6.00
Adjust the inclinometer zero adjust volume to the value "Z", so when the inclinom-
eter is rotated in the next step, the two readings are the same but of opposite sign
values. In the example above, the inclinometer is adjusted to -6.00.
11. Set the DATA RUN/HOLD switch to HOLD.
12. Rotate the digital inclinometer 180°, and set the DATA RUN/HOLD switch to RUN.
Note the new reading. If the two numbers match and are of opposite signs, the
procedure is complete. In the example shown, the inclinometer should now read
6.00. If the two numbers do not match, repeat steps 6–12 again.
NOTE
Place the inclinometer on the datum plane in the same
direction as the axis being zeroed. This ensures the in-
clinometer is zeroed in the correct direction prior to ze-
roing a robot axis.
September 28, 2000 8-21


ZEROING
8.3.2 ATTACHMENT OF UX- AND UZ-SERIES ZEROING JIGS
1. Completely remove any paint, rust, weld spatter, etc., from the zeroing jig attaching
plane with an oil stone (or similar method).
2. Attach the zeroing jigs as shown in figure 8-11 through figure 8-16.
NOTE
The robot axes can be zeroed individually, but may re-
quire other axes to be positioned at specific angles. Re-
fer to table 8-5 to determine which axes must be posi-
tioned prior to zeroing.
3. In teach mode, jog the robot until the inclinometer reads an inclination of zero as
established in the section 8.3.1. The inclinometer angle is read in millimeters per
meter. The axis must be adjusted to within ± 0.01 mm/meter of the calibrated value.
4. Complete the precision zeroing procedure by performing one of the procedures

below:
• Precision Zeroing Using AS Language Keyboard Commands (section 8.3.5)
• Precision Zeroing Using AUX Function 140 and 41 (section 8.3.6)
8-22 September 28, 2000


ZEROING
Table 8-5 Additional Axes to be Zeroed (U/Z-Series )
September 28, 2000 8-23


ZEROING
Inclinometer
Position
Datum
Plane
Figure 8-11 Location of UX and UZ Datum Plane
Inclinometer
Position
Inclinometer
Calibration
Direction of Position
Movement
Zeroing
Jig no. 1
Figure 8-12 Zeroing of UX and UZ O-Axis (JT2)
8-24 November 2, 2001


ZEROING
Inclinometer
Position
Direction of
Movement
Inclinometer
Calibration
Position
Zeroing
Jig no. 2
Figure 8-13 Zeroing of UX and UZ D-Axis (JT3)
Direction of
Movement
Inclinometer
Calibration
Position
Inclinometer
Position
Figure 8-14 Zeroing of UX and UZ S-Axis (JT4)
November 2, 2001 8-25


ZEROING
Direction of
Movement
Inclinometer
Calibration
Position
Inclinometer
Zeroing
Position
Jig no. 1
Figure 8-15 Zeroing of UX and UZ B-Axis (JT5)
Inclinometer
Position
Direction of
Movement Inclinometer
Calibration
Position
Zeroing
Jig no. 1
Figure 8-16 Zeroing of UX and UZ T-Axis (JT6)
8-26 November 2, 2001


ZEROING
8.3.3 ATTACHMENT OF UT-SERIES ZEROING JIGS
NOTE
The robot axes can be zeroed individually but may re-
fer to table 8-6 to determine which axes must be posi-
tioned prior to zeroing.
3. In teach mode, jog the robot until the inclinometer reads an inclination of zero, as

below:
September 28, 2000 8-27


ZEROING
Table 8-6 Additional Axes to be Zeroed (U-Series )
U-Series
AXES TO BE ZEROED

(R) (O) (D) (S) (B) (T)
JT1
(R) X X X X X
JT2
(O) X O O O O
JT3
(D) X X O O O
JT4
(S) X X X O O
JT5
(B) X X X X O
JT6
(T) X X X X X

Inclinometer
Datum Plane
Figure 8-17 Location of UT Datum Plane
8-28 September 28, 2000


ZEROING
Inclinometer
Calibration
Direction of Movement Position
Zeroing Jig 3
Inclinometer
Position
Figure 8-18 Zeroing of UT O-Axis (JT2)
Inclinometer Calibration
Position
Direction of
Movement Inclinometer
Position
Zeroing Jig 3
Figure 8-19 Zeroing of UT D-Axis (JT3)
September 28, 2000 8-29


ZEROING
Direction of
Movement
Position
Inclinometer
Position
Figure 8-20 Zeroing of UT S-Axis (JT4)
Direction of
Movement
Position
Inclinometer
Position
Zeroing Jig 1
Figure 8-21 Zeroing of UT B-Axis (JT5)
8-30 September 28, 2000


ZEROING
Direction of
Position
Movement
Inclinometer
Position
Zeroing Jig 1
Figure 8-22 Zeroing of UT T-Axis (JT6)
September 28, 2000 8-31


ZEROING
8.3.4 ATTACHMENT OF F-SERIES ZEROING JIGS
NOTE
The robot axes can be zeroed individually but may re-
fer to tables 8-7 and 8-8 to determine which axes must
be positioned prior to zeroing.
3. In teach mode, jog the robot until the inclinometer reads an inclination of zero as

below:
8-32 September 28, 2000

Table 8-7 Additional Axes to be Zeroed (Fx06/10/20) Table 8-8 Additional Axes to be Zeroed (FS30/45)
Fx06/10/20 Accurate Zeroing FS30/45 Accurate Zeroing
AXES TO BE ZEROED AXES TO BE ZEROED
JT1 JT2 JT3 JT4 JT5 JT6 JT1 JT2 JT3 JT4 JT5 JT6
September 28, 2000

(R) (O) (D) (S) (B) (T) (R) (O) (D) (S) (B) (T)
JT1 JT1
(R) X X X X X (R) X X X X X
Kawasak
JT2 JT2
(O) X O O O O (O) X O O O O
JT3 JT3
(D) X X -90° O -90° (D) X X -90° O -90°
ZEROING
JT4 JT4
(S) X X O O O (S) X X +90° O O
JT5 JT5
(B) X X X +90° O (B) X X X +90° O

JT6 JT6
(T) X X X X X (T) X X X X X
KEY: X = Positioning At Zero Not Required KEY: X = Positioning At Zero Not Required
O = Must Be Positioned At Zero O = Must Be Positioned At Zero
C SERIES CONTROLLER
8-33

ZEROING
Direction of
Movement
– +
Inclinometer
Zeroing
jig no. 2
Figure 8-23 Zeroing of F-Series O-Axis (JT2)
Direction of
Movement
– +
Inclinometer
Zeroing
Jig no. 3
Figure 8-24 Zeroing of FS06/10/20 D-Axis (JT3)
8-34 September 28, 2000


ZEROING
Direction of
Movement
– +
Zeroing Inclinometer
Jig no. 2
JT4
Rotated
to +90°
Figure 8-25 Zeroing of FS30/45 D-Axis (JT3)
Direction of
Movement
JT3 – +
Rotated
to –90°
JT5
Rotated
to +90°
Figure 8-26 Zeroing of F-Series S-Axis (JT4)
September 28, 2000 8-35


ZEROING
Direction of
Movement
+ –
Inclinometer
Zeroing
jig no. 2
Figure 8-27 Zeroing of F-Series B-Axis (JT5)
Direction of
Movement
JT3
Rotated – +
to –90°
Zeroing
Jig No. 4
Figure 8-28 Zeroing of F-Series T-Axis (JT6)
8-36 September 28, 2000


ZEROING
8.3.5 PRECISION ZEROING USING AS LANGUAGE KEYBOARD COMMANDS
This procedure utilizes AS Language keyboard commands to complete the precision

zeroing procedure. When the robot is in the critical position (zero mechanical position),
the AS Language ZZERO command is used to reset the encoder rotation count and
register the encoder absolute count, within the controller’s memory.
controller to update the value that is stored in the controller’s memory. Once the rotation
count is been updated, the absolute count is determined. The absolute count, based on
the rotation count and the shaft angle of the encoder, is also be stored in the controller’s
memory, to indicate the mechanical zero position of each joint.
To use the ZZERO command, type the command on the keyboard screen followed by an
integer:
>ZZERO (integer) <RETURN>
When the ZZERO command is used to reset the encoder rotation count, the integer
ranges from 100 to 107:
• Entering 100 resets all of the rotation counts.
• Entering 101 through 107 resets the individual rotation counts

(i.e., 101 resets the JT1 rotation count, 102 resets the JT2 rotation count, etc.).
When the ZZERO command is used to register the encoder absolute count, the integer
ranges from 0 to 7:
• Entering 0 registers the encoder absolute count for all joints.
• Entering while 1 through 7 registers the encoder absolute count for the individual
joints.
When the ZZERO command is used to view or manually enter the robots zeroing data,
the integer is not used. Without an integer the zeroing data is viewed and changed by
entering new values through the keyboard screen.
September 28, 2000 8-37


ZEROING
ZZERO AS Language Command Procedures
1. Jog the robot axes to the critical position as determined in sections 8.3.2 through
8.3.4.
2. Reset the encoder rotation count with the ZZERO command as shown in
figure 8-29. To reset the encoder rotation count of all axes simultaneously, type:
>ZZERO 100 <RETURN>
To reset the encoder rotation count of an individual axis, type:
Entering 101 resets the encoder rotation count for JT1, 102 resets JT2, etc.
When prompted for the current angle, enter 0 degrees if the joint is in the critical
position. If the joint is not in the critical position, enter the actual position in
degrees, relative to the critical position.
1) To reset the rotation counts of all joints, type the command “ZZERO 100” and
press the RETURN key.
ZZERO 100
**Encoder rotation counter reset (all joints)**
Setting complete
2) To reset the rotation count for a specific joint, type the command “ZZERO 101”
for example, and press the RETURN key.
ZZERO 101
**Encoder rotation. counter reset (1th axis)**
Setting complete
Figure 8-29 AS Language Rotation Counter Reset Example
3. Register the robot zeroing data with the ZZERO command, as shown in figure 8-30.
To register the zeroing data of all robot axes simultaneously, type:
>ZZERO 0 <RETURN>
8-38 September 28, 2000


ZEROING
To register the zeroing data of an individual robot axis, type:
Entering 1 registers the zeroing data of JT1, 2 registers the zeroing data of JT2, etc.
When prompted for the current angle, enter 0 degrees if the individual joint is in the
critical position. If the joint is not in the critical position, enter the actual position of
the joint in degrees relative to the critical position.
1) To display or manually change the zeroing data for all joints, type the command “ZZERO”
ZZERO
Set data 268435710 268440360 268414070 268435970 268443125 268432333
Current 268435604 268441202 268414065 268435982 268443131 268432329
Change? (if not, Press RETURN only.)
OFFSET
0 135 65,105 4,129 0 42
Change (if not, Press RETURN only.)
2) To register the zeroing data for all joints, type the command “ZZERO 0” and press the
RETURN key.
ZZERO 0
Set data 268435710 268440360 268414070 268435970 268443125 268432333
Current 268435604 268441202 268414065 268435982 268443131 268432329
Set current value of all joints as zeroing data? (Enter 1 to set.) 1
Setting Complete
3) To register the zeroing data for a specific joint, type the command “ZZERO 2”, for example,
ZZERO 2
Encoder value? (Current = 268440360. Enter 1 to set current value) 1
Zeroing value = 268440360 (268419072 - 268451840) OK? (Enter 0 to change)
Setting complete
Figure 8-30 AS Language ZZERO Command Example
4. Operate the robot in check mode to verify the point locations of a previously taught
September 28, 2000 8-39


ZEROING
8.3.6 PRECISION ZEROING USING AUX FUNCTIONS 140 AND 41
This procedure utilizes AUX Function 140, Encoder Rotation Counter Reset and AUX
Function 41, Zeroing, to complete the simple zeroing procedure. When the robot is in
the critical position (zero mechanical position), AUX Function 140, resets the encoder
rotation count, and AUX Function 41 registers the encoder absolute count within the
controller’s memory.
controller to update the value stored in the controller’s memory. Once the rotation count
is updated, the absolute value is determined. This absolute value, based on the rotation
count and the shaft angle of the encoder, is also be stored in the controller’s memory to
indicate the mechanical zero position of each joint.
1. Jog the robot axes to the critical position as determined in sections 8.3.2 through
8.3.4.
2. Reset the encoder rotation count with the AUX Function 140, shown in figure 8-31.
AUX 140 ENCODER ROT.COUNTER RESET

SETTING CURRENT
JT1 268422562 268422562
JT2 268437254 268437254
JT3 268421269 268421269
JT4 268433264 268433264
JT5 268427274 268427274
JT6 268428465 268428465
JOINT NO. = 0
(0 = reset all joint)
SET DEGREE = 0 deg
F1 F2 F3 F4
PRE DATA
Figure 8-31 AUX Function 140, Encoder Rotation Counter Reset
Enter the joint number to be zeroed at the JOINT NO. prompt. Enter 0 to reset the
encoder rotation counts for all joints or 1–7 to reset the rotation count for an indi-
vidual joint.
8-40 September 28, 2000


ZEROING
NOTE
individually.
enter the actual position in degrees relative to the critical position. When all of the
information has been entered, press RETURN, and answer the prompt:
>Are you sure ? (F1-YES, F4-NO.)
3. Register the encoder absolute count with AUX Function 41, shown in figure 8-32.
Enter the joint number to be zeroed at the JOINT NO. prompt. Enter 0 to register
the absolute counts for all joints or 1–7 to register the absolute count for an indi-
vidual joint.
AUX 41 ZEROING
SETTING CURRENT
JT1 268422562 268422562
JT2 268437254 268437254
JT3 268421269 268421269
JT4 268433264 268433264
JT5 268427274 268427274
JT6 268428465 268428465
JOINT NO. = 0
(0 = all joint)
SET DEGREE = 0 deg
F1 F2 F3 F4
PRE DATA
Figure 8-32 AUX Function 41, Zeroing
September 28, 2000 8-41


ZEROING
NOTE
individually.
When all of the information has been entered press RETURN, and answer the
prompt:
>Replace all set values with current position.

Are you sure ? (F1-YES, F4-NO.)
4. Operate the robot in check mode to verify that the point locations of a previously
taught program playback correctly.
8-42 September 28, 2000


ERROR CODES/TROUBLESHOOTING
9.0 ERROR CODES/TROUBLESHOOTING ....................................................... 9-2

9.1 Error Recovery ............................................................................................... 9-2
9.2 Error Codes ................................................................................................... 9-5
May 21, 2003 9-1


9.0 ERROR CODES/TROUBLESHOOTING
This unit provides error recovery flowcharts, error code information, and error code
troubleshooting flow charts. In addition, typical causes and remedies for the errors are
also provided.
9.1 ERROR RECOVERY
Figure 10-1 shows troubleshooting processes that may be helpful if the controller be-
comes unresponsive to commands or an error code has been encountered that cannot
be cleared. Troubleshooting should begin with confirmation of basic integrity of the
system: ensure that the power supply is on and meeting supply requirements, all cables
are correctly attached, all circuit boards are properly installed and fully seated, all pe-
ripheral equipment is wired correctly, software is properly configured, etc.
9-2 March 28, 2002


Figure 9-1 Troubleshooting Process
March 28, 2002 9-3


Continued from previous pg
Create Error or “locked” Reset Run program

backup information condition cleared system settings not and continue
files and initialize the set to defaults after to monitor
system initialization
Error still present
Remove the
1GA board from the
rack and allow RAM
memory to deplete
Reinstall Error clears and robot

1GA board, Run program
runs normally
initialize the and continue
system, zero to monitor
Begin electrical
troubleshooting and repair if
qualified; call service
technician for further
assistance
Figure 9-2 Troubleshooting Process (cont’d)
9-4 March 28, 2002


9.2 ERROR CODES

This unit provides information about the error codes that are displayed on the multi
function panel or other user interfaces that provide display screen information. The error
codes are listed in numerical order by code number with the message that is displayed
with the associated code. An expanded explanation of the message is provided along
with possible methods to clear or prevent the specific error. Troubleshooting information
is preceded by a ⇒ symbol.
NOTE
All error codes not preceded by a minus sign (-) are for
C35/C37 controllers only. These error codes are desig-
nated by an asterisk (*).
*ERROR CODE 50 Acknowledgment error.
This error occurs when the main CPU board (1HA board) does not respond to the com-
mand requested by the explosion-proof teach pendant.
Main causes include:

1. Disconnection, short-circuit, or defective harness in the communication line between
the explosion-proof teach pendant and the controller.
2. Defective barrier unit for the explosion-proof teach pendant.
3. Defective explosion-proof teach pendant.
4. Defective communication board (1GS board) for the explosion-proof teach pendant.
5. Defective 1LT board.
6. Malfunction due to noise, etc.
⇒ Check for disconnection or short-circuit in the communication line between the explo-
sion-proof teach pendant an the controller, and repair or replace as necessary.
⇒ Replace the barrier unit for the teach pendant.
⇒ Replace the explosion-proof teach pendant.
⇒ Replace defective 1GS board.
⇒ Replace defective 1LT board.
⇒ Repair source of line noise or shield line noise.
_____________________________________________________________________
*This error code is for C35/C37 controllers only. Error code with the minus sign (-) follows.
March 28, 2002 9-5


ERROR CODE -50 Warning! Cannot move along straight line in this
configuration.
Joint speed may exceed maximum, joints 4 and 6 aligned.
⇒ Change angle of joint 5, slow the speed, change to joint mode.

_____________________________________________________________________
ERROR CODE -57 Set low speed because of exceeding joint max. speed in
check.
When joint speed is checked with commanded speed, the difference exceeds accept-
able range.
⇒ Slow the speed.

_____________________________________________________________________
*ERROR CODE 81, 82, 83 Receive data error.
This error occurs when the serial communication control IC in the explosion-proof teach
pendant detects an overrun error (81), framing error (82), or parity error (83).

sion-proof teach pendant and the controller, and repair or replace as necessary.
_____________________________________________________________________
9-6 March 28, 2002


ERROR CODE -100 Matrix Calculation Error.
The vector element of the matrix cannot be operated because of 0.
⇒ Change and recalculate value.

_____________________________________________________________________
ERROR CODE -101 Turn off motor power.
Motor power cannot turn on according to command and instruction.
⇒ Turn motor power OFF and execute command and instruction.

_____________________________________________________________________
ERROR CODE -102 Application is changed. Turn OFF & ON the control power.
The robot configuration was changed from spot welding/material handling to a paint/
sealant application using AUX 907.
⇒ Turn controller power OFF then ON.

_____________________________________________________________________
ERROR CODE -103 There is no external axis.
External axis equipment is not installed and cannot operate.
⇒ Enable option or contact customer service to install desired option.

_____________________________________________________________________
ERROR CODE -104 Illegal positioner type.
Equipment is not installed and cannot operate.

_____________________________________________________________________
ERROR CODE -105 Cannot change data because user data exist.
Data cannot be overwritten.
⇒ Delete current data and replace with new data.

_____________________________________________________________________
March 28, 2002 9-7


ERROR CODE -106 Graphic area error.
Unable to display data in designated display area.
⇒ Select different display area.

_____________________________________________________________________
ERROR CODE -107 Option is OFF.
Selected option is OFF or is not installed.

_____________________________________________________________________
ERROR CODE -200 Cannot execute a program because motor power is OFF.
Program will not start because motor power is not on.
⇒ Turn motor power ON.

_____________________________________________________________________
*ERROR CODE 201 Receive error (STX).
This error occurs when a start code (STX) is not detected in the data transmitted to the
explosion-proof teach pendant from the controller.

_____________________________________________________________________
9-8 March 28, 2002


ERROR CODE -201 Cannot execute a program in TEACH mode.

(ERROR CODE 201 see sec. 10.3)
Programs cannot run when in the teach mode of operation.
⇒ Ensure that the controller is in the REPEAT mode of operation.

_____________________________________________________________________
*ERROR CODE 202 Receive error (ETC).
This error occurs when an end code (ETC) is not detected in the data transmitted to the

_____________________________________________________________________
ERROR CODE -202 Cannot execute a program because teach lock is ON.
(ERROR CODE 202 see sec. 10.3)
Programs cannot be run with the teach lock in the ON position.
⇒ Turn the TEACH LOCK switch to OFF and execute the program again in repeat
mode.
_____________________________________________________________________
March 28, 2002 9-9


*ERROR CODE 203 Receive error (BCC).
This error is displayed when an error occurs in BCC check for the data transmitted to the

_____________________________________________________________________
ERROR CODE -207 Turn to HOLD at HOLD/RUN sw.
Occurs when an attempt to perform DO, STEP, MSTEP, CONTINUE, or EXECUTE

commands is made with the RUN/HOLD switch in the RUN position. Only applies if the
CHECK HOLD system switch is ON.
⇒ Turn the RUN/HOLD switch to HOLD position.

_____________________________________________________________________
ERROR CODE -208 Teach pendant is not connected.
Hardwired switches for teach pendant and multi function panel must be jumpered and
equipment configuration identified in environmental data functions.
⇒ Install teach pendant or configure system accordingly.

_____________________________________________________________________
9-10 March 28, 2002


ERROR CODE -211 Cannot edit a program because the TEACH LOCK switch
is ON.
Programs cannot be edited if the TEACH LOCK switch is ON.
⇒ Turn TEACH LOCK switch OFF.

_____________________________________________________________________
ERROR CODE -212 Cannot execute because executed by other device.
Occurs when the operator attempts to execute the same command from the KCWIN
terminal and the multi function panel or type 2 teach pendant at the same time.
⇒ Cannot execute commands from two devices at the same time.

_____________________________________________________________________
ERROR CODE -213 Cannot execute a program because of EXT-IT.
External hold signal and or external hold reset signal not received.
⇒ Check dedicated input signals in AUX 111 match signals programed from the PLC in
the Slogic program.
⇒ If the external hold signal is not needed, change the signal setting in AUX 111 from
set to reset.
_____________________________________________________________________
ERROR CODE -300 Program is already running.
Occurs when an attempt is made to edit or execute a program that is currently running.
⇒ Stop the robot control program prior to editing or checking.

_____________________________________________________________________
ERROR CODE -301 Robot control program is already running.
Occurs when an attempt is made to execute a DO, TOOL, or BASE command when a
robot control program is running.
⇒ Wait for the robot control program to complete execution.

⇒ Stop the robot control program.
_____________________________________________________________________
March 28, 2002 9-11


ERROR CODE -302 Can’t continue. Use EXEC.
The CONTINUE command is not permitted because of program selection status.
⇒ Use the EXECUTE command to start program.

_____________________________________________________________________
ERROR CODE -303 Robot is moving now.
Displayed if any of the following commands are entered while a program is running:
EXECUTE, CONTINUE, TOOL, BASE, DO. SYSINIT or CYCLE START.
⇒ Stop the program or confirm the operation to be performed.

_____________________________________________________________________
ERROR CODE -304 Cannot execute because in error now. Reset error.
Occurs when attempt is made to start robot motion if an error has not been cleared.
⇒ Clear any errors and re-enter the command.

_____________________________________________________________________
ERROR CODE -306 Cannot execute with DO command.
Displayed when the DO command is entered with an instruction that is not of acceptable
format.
⇒ Execute the instruction from within a program or use acceptable instruction format for
DO command.
_____________________________________________________________________
ERROR CODE -308 PC program is running.
Occurs when a PC program is running and instructions are entered that are not allowed.
⇒ Stop the PC program and enter the command.

_____________________________________________________________________
ERROR CODE -314 Cannot execute because the program is already used.
Occurs when a program being edited is selected to run by a CALL, ON, ONI or PC
program instruction.
⇒ Stop editing the program or stop the program that is calling the program being edited.
_____________________________________________________________________
9-12 March 28, 2002


ERROR CODE -316 Waiting weld completion.
Displayed when a command to change the step is entered while a welding sequence is
in progress.
⇒ Wait until after the weld sequence is completed or force a weld complete condition.
_____________________________________________________________________
ERROR CODE -317 Position offset error at last E-stop JTxx.
The error message is generated when an E-stop is applied and the position of the robot
is not within a range of the commanded position. The error deviation range is specified
in AUX 42.
⇒ Before the error is reset, operators must be aware of the robot’s position within the
work envelope.
_____________________________________________________________________
ERROR CODE -318 Waiting retract or extend pos. input signal.
One of the following operations were attempted when the robot was processing a spot
weld sequence (waiting for the Retract/Extend signal after the weld complete signal had
been received).
1. Cycle start (including EXECUTE, CONTINUE command).
2. Program selection or step change.
3. Record.
⇒ Input the Retract/Extend detection signal to the robot or press the WX key and wait
override key on the multi function panel.
_____________________________________________________________________
ERROR CODE -319 Spot sequence is running.
Step change, program change, or program execution were attempted while the spot
weld sequence was executing (after Retract/Extend input signal and weld complete
signal have been received). For example, the robot is executing move delay time after
weld complete.
⇒ Perform step change, program registration or program execution after the spot weld-
ing sequence.
_____________________________________________________________________
March 28, 2002 9-13


ERROR CODE -320 Cannot operate because teach pendant in operation.
You cannot perform functions on the personal computer while the multi function panel is
in use.
⇒ Perform functions on the PC after the multi function panel has completed operation.
_____________________________________________________________________
ERROR CODE -324 Cannot execute with MC instruction.
MC instruction could not be carried out.
⇒ Use instruction which can be executed by MC instruction.

_____________________________________________________________________
ERROR CODE -325 Cannot execute the instruction in robot program.
Command and instruction cannot be used or executed.
⇒ Rewrite the command or instruction.

_____________________________________________________________________
ERROR CODE -326 Cannot delete because used by another command.
Cannot COPY, DELETE or XFER command because current step is being executed.
⇒ Perform DELETE commands after execution ends.

_____________________________________________________________________
ERROR CODE -327 Used in programs.
The variable used with the program was deleted.
⇒ Confirm the deleted variable.

_____________________________________________________________________
ERROR CODE -328 Used in editor.
When the program was used in the editor, the program was deleted.
_____________________________________________________________________
9-14 March 28, 2002


ERROR CODE -329 KILL or PCKILL to delete program.
Occurs when an attempt to delete a program is made and that program is still on the
stack (selected).
⇒ Select another program or KILL/PC KILL the program, then delete.

_____________________________________________________________________
ERROR CODE -330 Cannot paste.
Occurs when the operator is executing the paste function and no data is stored in the
paste buffer or the step(s) cannot be overwritten.
⇒ Check paste operation and the destination steps.

_____________________________________________________________________
ERROR CODE -350 Illegal input data.
Input data from AS Language monitor command is improper for the instruction.
⇒ Enter data that is within acceptable range.

_____________________________________________________________________
ERROR CODE -351 Too many arguments.
Input data from AS Language editor commands exceeds the number of user specified
items allowed by the format.
⇒ Verify input data and format of command.

_____________________________________________________________________
ERROR CODE -353 Input data is too big.
Data entered for the POINT or HERE commands exceeds the allowable range.

_____________________________________________________________________
ERROR CODE -360 Illegal WHERE parameter.
Occurs if data entered with the WHERE command is not an integer between 1 and 6.
⇒ Ensure that data is within acceptable range.

_____________________________________________________________________
March 28, 2002 9-15


ERROR CODE -361 Illegal PC number.
Unused
_____________________________________________________________________
ERROR CODE -365 Illegal robot number.
Unused
_____________________________________________________________________
ERROR CODE -367 Illegal priority.
Priority level designation is wrong.
⇒ Input a correct priority level.

_____________________________________________________________________
ERROR CODE -368 Invalid coordinate value.
Upper limit value is less than value of lower limit.
⇒ Input the correct upper limit coordinates.

_____________________________________________________________________
ERROR CODE -371 External axis type and gun data mismatch.
The servo gun setting does not correspond to the type of external axis (set in AUX 160)
and type of gun (set in AUX 114). This error is detected when motion begins for a step
with a clamp signal set.
⇒ Confirm that the external axis and gun type data settings are correct.
ERROR CODE -400 Syntax error.
Occurs when an AS Language command is entered that does not follow the correct
format or contains typing or spelling errors.
⇒ Correct format or spelling of command/instruction.

_____________________________________________________________________
9-16 March 28, 2002


ERROR CODE -401 Invalid statement.
Occurs when an AS Language command is entered that has typing errors, incorrect
spelling or is in the wrong format.
⇒ Correct the input data spelling or format.

_____________________________________________________________________
ERROR CODE -402 Ambiguous statement.
Displayed when an abbreviation is entered incorrectly or has missing letters.
⇒ Enter the correct abbreviation or entire command.

_____________________________________________________________________
ERROR CODE -403 Cannot use this command or instruction here.
Displayed because a program or monitor command was entered that could not be
executed while a program is running.
⇒ Stop program execution or wait for completion.

_____________________________________________________________________
ERROR CODE -404 Cannot execute with DO command.
A program instruction that is not acceptable to use with the DO command was entered.
⇒ Place the desired instruction within a program or choose an acceptable instruction for
use with a DO command at the monitor prompt.
_____________________________________________________________________
ERROR CODE -405 Statement cannot be executed.
Occurs when the AS Language instruction entered was not acceptable for the mode of
operation. For example: a monitor command was entered in the editor mode.
⇒ Use instructions and commands that are compatible with the input mode.
_____________________________________________________________________
March 28, 2002 9-17


ERROR CODE -406 Not a program instruction.
An instruction was entered into a program that is not a valid program instruction, i.e., a
monitor command, editor command, etc.
⇒ Refer to the AS Language Manual for proper use of AS Language commands.

_____________________________________________________________________
ERROR CODE -407 Too many arguments.
Input data from AS Language editor commands exceeds the number of user specified
items allowed by the format.
⇒ Verify input data and format of command.

_____________________________________________________________________
ERROR CODE -408 Missing argument.
Displayed when a DO command is not followed by an acceptable program instruction.
⇒ Correct the input and re-enter.

_____________________________________________________________________
ERROR CODE -410 Illegal expression.
A real number expression must be present for processing DECOMPOSE command(s).

Also displayed when incorrect numerical information is entered with arguments.
⇒ Ensure correct format and numerical expressions are entered.

_____________________________________________________________________
ERROR CODE -411 Illegal function.
Occurs when functions are used to assign values to variables but the data is incompat-
ible. For example: assigning XYZ coordinate data to precision points.
⇒ Ensure function is compatible with variables.

_____________________________________________________________________
ERROR CODE -412 Illegal argument of function.
Occurs when function and argument are not in correct format.
⇒ Use correct format for functions and arguments.

_____________________________________________________________________
9-18 March 28, 2002


ERROR CODE -413 Invalid variable (or program) name.
Displayed when illegal variable or program name is entered from the editor or monitor
modes. For example: JM ##a (to many precision symbols) or CALL #a (not an accept-
able program name).
⇒ Define program names and variables correctly.

_____________________________________________________________________
ERROR CODE -414 Illegal variable type.
Displayed when illegal variable is entered from editor or monitor modes.

For example: b = #a + b (combining location and real variables using an arithmetic
operator).
⇒ Use compatible variable type for commands or instructions.

_____________________________________________________________________
ERROR CODE -415 Illegal array index.
Displayed when an attempt is made to use a variable that has previously been defined
as an array. May also occur if the order of an array is reversed when editing or entering
monitor commands.
⇒ Enter the correct array variable information.

_____________________________________________________________________
ERROR CODE -416 Missing parenthesis.
Occurs when parentheses are not entered as a pair, containing both a left and right
parenthesis.
⇒ Enter parentheses in left and right pairs.

_____________________________________________________________________
ERROR CODE -417 Expected to be a binary operator.
A non-binary operator has been entered where a command expected a binary operator.
⇒ Input a binary operator.

_____________________________________________________________________
March 28, 2002 9-19


ERROR CODE -418 Illegal constant.
A variable, or a non constant is used where a constant or integer should be used in a

monitor command.
Example: WHERE a (Should be WHERE 1 … WHERE 6)
⇒ Use the proper constant or integer with the command. See the C Series Controller
AS Language Reference Manual for more information.
_____________________________________________________________________
ERROR CODE -419 Illegal qualifier.
Displayed when monitor commands are followed by unexpected qualifiers. For example:
LIST W (expected characters would include P, L, and R for program, location, and real
variables; “W” causes error).
⇒ Use only acceptable qualifiers.

_____________________________________________________________________
ERROR CODE -420 Invalid label.
Occurs in the editor mode when a GOTO instruction is combined with a reserved char-
acter. For example: GOTO #a (“#” is a reserved character).
⇒ Do not use reserved characters in label identification.

_____________________________________________________________________
ERROR CODE -421 Invalid name.
Displayed when an unidentified program, file, variable, etc., is used in a command.
⇒ Use only names that have been defined.

_____________________________________________________________________
ERROR CODE -422 Missing expected character.
Occurs when commands or instructions are entered with an incorrect format. For ex-
ample: TOOL a=b (TOOL a would be correct, “=b” causes error).
⇒ Use correct format for commands and instructions.

_____________________________________________________________________
9-20 March 28, 2002


ERROR CODE -423 Illegal switch name.
Displayed when a system switch is incorrectly identified. For example: SWITCH light
(there is no system switch named “light”).
⇒ Use only available switch names.

_____________________________________________________________________
ERROR CODE -424 Ambiguous switch name.
Displayed when a switch name has been entered that is not available for the software
version that is operating in the controller.
⇒ Use only system switches that are compatible with the software version that is operat-
ing.
_____________________________________________________________________
ERROR CODE -425 Illegal format qualifier.
Occurs when the TYPE or PRINT command is not used with an acceptable format
portion of the instruction.
⇒ Use only specified format instructions with TYPE and PRINT commands.
_____________________________________________________________________
ERROR CODE -426 Duplicate statement label.
A specific program label name can only be used once per program. Error is displayed if
the same label name is entered a second time in the same program.
⇒ Use label names only once per program.

_____________________________________________________________________
ERROR CODE -430 Cannot define as array.
A non-array variable with the same name as the array variable that was attempted to be
created, already exists.
⇒ Use a different name for the new variable. Refer to the AS Language Manual for
proper use of AS Language commands.
_____________________________________________________________________
March 28, 2002 9-21


ERROR CODE -431 Dimension exceeds 3.
Attempted to create an array variable with more than 3 dimensions.

_____________________________________________________________________
ERROR CODE -432 Different dimensional array exist.
An array variable with same name but a different number of dimensions already exists.
⇒ Change the name of the new variable or provide the same number of dimensions as
the existing variable. Refer to the AS Language Manual for proper use of AS Lan-
guage commands.
_____________________________________________________________________
ERROR CODE -433 Array variable exist.
Attempted to create a non-array variable with the same name as an existing array vari-
able.
⇒ Confirm array variable exists. Select new name for non-array variable or select array
variable.
_____________________________________________________________________
ERROR CODE -434 Non array variable exist.
Attempted to create an array variable with the same name as an existing non-array
variable.
⇒ Confirm non-array variable exists. Select new name for array variable or select non-
array variable.
_____________________________________________________________________
ERROR CODE -435 Array variable expected.
A non-array variable exists with the same name as the array variable that was specified
for the decompose instruction.
⇒ Select a new name for the array variable that was specified for the decompose in-
struction.
_____________________________________________________________________
9-22 March 28, 2002


ERROR CODE -440 Local variable expected.
A subroutine call to a program with a local variable found a program with the same
name but without a local variable.

_____________________________________________________________________
ERROR CODE -441 Unexpected suffix.
No data was provided in the brackets of an array variable.

_____________________________________________________________________
ERROR CODE -442 Mismatch of arguments at subroutine call.
The order of the local variable in the called program and the order of the local variable in
the actual program are different.
⇒ Check the order of the local variable in the actual program and modify the subroutine
call accordingly. Refer to the AS Language Manual for proper use of AS Language
commands.
_____________________________________________________________________
ERROR CODE -443 Mismatch of argument type at subroutine call.
The type of argument, i.e. location variable, real variable, is different than the argument
in the origin program.
⇒ Correct the type of the argument in the called program or origin program.
_____________________________________________________________________
ERROR CODE -450 Control structure error.
Displayed when an illegal program control flow structure is evaluated.
⇒ Use correct syntax and components in control flow structures.

_____________________________________________________________________
March 28, 2002 9-23


ERROR CODE -451 Step:xxx Wrong END statement.
Occurs when an illegal END statement is entered during editing.

_____________________________________________________________________
ERROR CODE -452 Step:xxx Extra END statement.
Occurs when an extra END statement is present and there is no corresponding struc-
ture.
⇒ Use correct syntax and components in control flow structures, check structure of
END statements.
_____________________________________________________________________
ERROR CODE -453 Step:xxx Cannot terminate DO with END.
This error is displayed when the control flow structure DO….UNTIL is entered with an
END statement .

_____________________________________________________________________
ERROR CODE -454 Step:xxx No VALUE statement after CASE.
Occurs when the control flow structure CASE OF….END is entered without a value to
evaluate.

_____________________________________________________________________
ERROR CODE -455 Step:xxx Preceding IF missing.
Displayed when control flow structure does not contain the correct structure for
IF…THEN… ELSE…END commands.

_____________________________________________________________________
9-24 March 28, 2002


ERROR CODE -456 Step:xxx Preceding CASE missing.
CASE…of… VALUE…ANY…END commands.

_____________________________________________________________________
ERROR CODE -457 Step:xxx Preceding DO missing.
DO…UNTIL.

_____________________________________________________________________
ERROR CODE -458 Step:xxx Can’t find END of xxx.
Occurs when control flow structure that requires an END statement does not contain the
necessary END.

_____________________________________________________________________
ERROR CODE -459 Step:xxx Too many control structures.
Occurs when 11 layers of control flow structure are exceeded.
⇒ Limit control flow structure to 11 layers.

_____________________________________________________________________
ERROR CODE -460 Variable (or program) already exists.
Displayed when a variable is entered that is already part of the system memory. For
example: a location named “weld1” is entered when a program named “weld1” is already
in the memory.
⇒ Do not use variable names for more than one item.

_____________________________________________________________________
March 28, 2002 9-25


ERROR CODE -461 Variable of different type already exists.
Displayed when a variable is entered that is already part of the system memory. For
example: a location named “weld1” is entered when a program named “weld1” is already
in the memory.
⇒ Do not use variable names for more than one item.

_____________________________________________________________________
ERROR CODE -464 Internal buffer over.
Attempted to solve a complex mathematical equation in a program.
⇒ Rewrite to reduce the complexity of the operations required to solve the equation.
_____________________________________________________________________
ERROR CODE -465 Undefined Variable (or program).
Attempt call a subroutine or process a variable that does not exist.
⇒ Verify the variable or program exists.

_____________________________________________________________________
ERROR CODE -466 Illegal clock value.
Time or date was entered in the wrong format.
⇒ Re-enter the values correctly; time - military, date - yy/mm/dd.

_____________________________________________________________________
ERROR CODE -470 Expect “=”.
The argument is missing the necessary “=”.
⇒ Check the argument and correct it.

_____________________________________________________________________
ERROR CODE -471 Expect “)”.
The argument is missing the necessary “)”.

_____________________________________________________________________
9-26 March 28, 2002


ERROR CODE -472 Expect “]”.
The argument is missing the necessary “]”.

_____________________________________________________________________
ERROR CODE -473 “Expect “TO”.
The argument is missing the necessary “TO”.

_____________________________________________________________________
ERROR CODE -474 “Expect “BY”.
The argument is missing the necessary “BY”.

_____________________________________________________________________
ERROR CODE -475 Expect “:”.
The argument is missing the necessary “:”.

_____________________________________________________________________
ERROR CODE -476 “Expect ”ON/OFF”.
An instruction other than ON/OFF was used with a SYSTEM SWITCH.
⇒ Check the ON/OFF status SYSTEM SWITCH and input it correctly.

_____________________________________________________________________
ERROR CODE -490 Program name not specified.
Displayed when no program is on the stack and the EDIT command is entered without
specifying a program name.
⇒ Identify the name of the program to be edited.

_____________________________________________________________________
March 28, 2002 9-27


ERROR CODE -494 Program is interlocked by another procedure.
Attempt to edit a running program was made.
⇒ Stop program execution before editing the program.

_____________________________________________________________________
ERROR CODE -499 Invalid statement.
Occurs when the program is executed and instructions are encountered that cannot be
processed as AS Language commands.
⇒ Use correct syntax and components for AS Language commands.

_____________________________________________________________________
ERROR CODE -507 Communication error.
When a vision system is incorporated and the transmission of data is interrupted (trans-
mission line problem or stoppage of the program) this error will be displayed.
_____________________________________________________________________
ERROR CODE -514 Device is not ready.
Unused
_____________________________________________________________________
ERROR CODE -523 Illegal file name.
Unused
_____________________________________________________________________
ERROR CODE -525 File already exists.
Occurs when the operator executes the rename command and the designated file name
already exists.
⇒ Change file name or delete existing file.

_____________________________________________________________________
ERROR CODE -543 Data read error.
Unused
_____________________________________________________________________
9-28 March 28, 2002


ERROR CODE -545 Record inhibited. Set ”record accept” and operate again.
Displayed when an attempt is made to enter data, but RECORD INHIBIT in auxiliary
function 71 is set to inhibit.
⇒ Change the setting of the RECORD INHIBIT in AUX 71.

_____________________________________________________________________
ERROR CODE -548 Program change inhibited. Set ”program change accept”
and operate again.
Displayed when an attempt is made to enter data, but PROGRAM CHANGE INHIBIT in
auxiliary function 71 is set to inhibit.
⇒ Change the setting of the PROGRAM CHANGE INHIBIT in AUX 71.

_____________________________________________________________________
ERROR CODE -551 Cannot open the file.
Unused
_____________________________________________________________________
ERROR CODE -565 RI/O board is not installed.
1FS board is not installed.
⇒ Ensure the 1FS board is properly installed and operational.

_____________________________________________________________________
ERROR CODE -580 Retry error.
Occurs when there is a problem with the communication link between the controller and
a host communication PC.
⇒ Check the integrity of the controller and host PC link.

_____________________________________________________________________
ERROR CODE -581 Stop of process.
(Option: Host communication I correspondence.)

Refer to the host communication manual for details.
_____________________________________________________________________
March 28, 2002 9-29


ERROR CODE -583 Receive not data after receive request.

_____________________________________________________________________
ERROR CODE -584 Too long receive data (MAX=255 character).

_____________________________________________________________________
ERROR CODE -585 Abnormal data (EOT) received in communicating.

_____________________________________________________________________
ERROR CODE -586 Time out.

_____________________________________________________________________
ERROR CODE -591 Illegal device number.
Two types of selections are possible for the serial port. This error occurs when port
numbers other than the sensor port are specified.

_____________________________________________________________________
ERROR CODE -596 Cannot attach terminal.
The prompt instruction was executed by two or more programs at the same time.
⇒ Do not execute the prompt instruction from two or more programs at the same time.
_____________________________________________________________________
9-30 March 28, 2002


ERROR CODE -597 Cannot attach communication port.
The RECEIVE instruction and the SEND instruction were executed by two or more
programs at the same time.
⇒ Do not execute these instructions from two or more programs at the same time.
_____________________________________________________________________
ERROR CODE -598 Cannot execute on this terminal.
Attempt was made to execute a command that cannot be used at that terminal. Some
commands can only be used at the multi function panel and some only at the PC.
⇒ Use the above command from the proper terminal.

_____________________________________________________________________
ERROR CODE -599 Waiting input data for PROMPT. Connect input device.
The input device specified by the prompt command, i.e., PC or MFP, was not connected.
⇒ Verify that the specified device is connected.

_____________________________________________________________________
ERROR CODE -600 Motor power OFF. Displayed whenever an emergency

stop is encountered.
⇒ Reset emergency stop button and reapply motor power.

_____________________________________________________________________
ERROR CODE -605 PLC communication error.
Allen-Bradley (RI/O) PLC communication error between the 1FS board node adapter
chip (NAC) and the Allen-Bradley PLC.
Occurs when the PLC is not in run mode, the NAC configuration is incorrect, or connec-
tion is lost with the PLC.
⇒ Ensure the PLC is in run mode.

⇒ Ensure the NAC configuration is correct.
⇒ Ensure the PLC connection is established.
_____________________________________________________________________
March 28, 2002 9-31


ERROR CODE -606 Weld controller #%d not connected.
Occurs when the 1FS board RI/O function is not able to communicate normally with a
welder. When the START sequence is executed there is no response from the welder.
⇒ Ensure the welder connection is established.

⇒ Ensure the welder is operational.
_____________________________________________________________________
ERROR CODE -607 Weld controller #%d no response.
welder. When the NORMAL sequence is executed there is no response from the
welder.

⇒ Ensure the welder and related peripherals are operational.
_____________________________________________________________________
ERROR CODE -608 Weld controller #%d response error.
welder. The data received form the welder or the protocol is incorrect.

⇒ Ensure the welder communication protocol is correct.
⇒ Ensure the welder and related peripherals are operational.
_____________________________________________________________________
ERROR CODE -610 Weld completion time over.
Occurs when a weld complete signal is not received in a specified time period.
⇒ Override the wait condition, ensure that weld complete signal specifications are
correctly identified, check the operation of the weld gun or controller.
_____________________________________________________________________
ERROR CODE -611 Illegal extend (retract) output signal.
Occurs when the output signals for the extend and retract operation of a spot welding
application are not properly set.
⇒ Check the setting in AUX 114.

_____________________________________________________________________
9-32 March 28, 2002


ERROR CODE -612 Weld fault input.
Displayed when the controller receives a weld fault signal.
⇒ Check operation of welding equipment, ensure signal numbers are correctly set.
_____________________________________________________________________
ERROR CODE -613 Retract pos. monitor error.
Occurs when the input signal for the retract operation of a spot welding application is not
received.
⇒ Check the operation of welding equipment, check the signal number setting in AUX
114-10.
_____________________________________________________________________
ERROR CODE -614 Extend pos. monitor error.
Occurs when the input signal for the extend operation of a spot welding application is
not received.
⇒ Check the operation of welding equipment, check the signal number setting in AUX
114-10.
_____________________________________________________________________
ERROR CODE -615 Weld completion signal is already inputted.
Displayed when the weld complete signal has been received before the weld initiate
output has not been issued.
⇒ Check operation of welding equipment, check the signal number setting in AUX 114-
11.
_____________________________________________________________________
ERROR CODE -616 Gun retract position mismatch.
In the check mode, retractable gun output signals are monitored and compared to open/
close data for a specific step. If the data does not compare, an error is displayed.
⇒ Check settings in clamp conditions, check operation of gun with clamp key.
_____________________________________________________________________
March 28, 2002 9-33


ERROR CODE -631 Cannot achieve desired pressure.
The gun does not obtain the set closing pressure within 5 seconds after the gun starts
closing.
1. Tip wear measurement is not executed.

2. Incorrect taught point (closing pressure is not defined for the recorded position).
3. Closing pressure is set too high.
⇒ Perform the tip wear measurement.

⇒ Reteach the point.
⇒ Decrease the closing pressure.
_____________________________________________________________________
ERROR CODE -632 Gun chip[tip] stick.
Indicates that the tips are stuck. More power is required to open the gun, following a
weld, than the stuck detection value, set in AUX 114-41, WELDING DETECTION(0:NO
CHK) [kgf].
If the stuck detection value is set below the power level required for normal operation,
the gun cannot operate properly and the error is set.
⇒ If the gun is stuck, release it manually.

⇒ If the gun is not stuck, verify that the stuck detection value (AUX 114-41, WELDING
DETECTION(0:NO CHK) [kgf]) is set correctly. This setting may need to be in-
creased.
_____________________________________________________________________
ERROR CODE -633 Copper plate abrasion over the limit. step=*.
The copper backing plate wear exceeds the copper plate wear limit (AUX 114-12). The
error is detected when the gun executes a weld.
⇒ Replace the copper backing plate.

_____________________________________________________________________
ERROR CODE -634 Not dedicated encoder and brake power off signal.
The gun separation accept signal is not received during a gun change.
⇒ From AUX 111 Dedicated Input Signal, set the gun separation accept signal number
(encoder brake power supply OFF control signal).
_____________________________________________________________________
9-34 March 28, 2002


ERROR CODE -641 Now servo gun is disconnected or a different gun.
The robot executes a step when a gun is not attached to the tool changer or the gun
number in the tool changer is different than the gun number for the program step.
⇒ Execute the step in manual mode or manually install the correct gun. In the teach or
check mode, verify connection of the gun by pressing the connect/separate button.
⇒ If the correct gun is attached to the tool changer, confirm that the gun signal number
(AUX 114-41, GUN CONNECTION SIGNAL) is correct. From the MONITOR (INPUT
SIGNAL) screen, confirm that the signal number is received.
⇒ Inspect the connectivity from the gun to the 1FG board.
⇒ Temporarily set the gun connect signal number (AUX 114-41, GUN CONNECTION
SIGNAL) to 0 (when the gun connect number is set to 0, the error is not detected);
ensure that the correct gun is in the tool changer. Repair the gun connection and set
the gun connect signal number as soon as possible.
_____________________________________________________________________
ERROR CODE -642 Calibration is not completed.
The controller terminates the calibration operation after a gun change.
⇒ Reset the error and perform a manual gun change.

_____________________________________________________________________
ERROR CODE -643 Measure of chip abrasion (stage 1) was not executed.
When the tip wear measurement program stage 2 (reference plate) is attempted, without
first performing stage 1.
⇒ Execute tip wear measurement program stage 1 prior to executing stage 2.

_____________________________________________________________________
ERROR CODE -644 Work sensing signal (gun_chip[tip] touch sig) is not estab-
lished.
A workpiece thickness measurement is attempted, when the gun tip touch signal (set in
AUX 114-41) has not been received.
⇒ Set the gun tip touch signal number (AUX 114-41).

_____________________________________________________________________
March 28, 2002 9-35


ERROR CODE -645 Cannot weld because of abnormal thickness.
The thickness of the workpiece is out of tolerance.
Probable causes:
1. Defective workpiece.
2. Incorrect positioning of the workpiece
3. A gap between the two panels being welded.
4. Current tip wear (AUX 114-41) and actual tip wear are different.
⇒ Inspect the workpiece. Measure the thickness and positioning; replace workpiece
and/or correct abnormal positioning.
⇒ Execute the tip wear measurement program. Manually measure the tip wear; com-
pare these measurements to the current tip wear data (AUX 114-41).
_____________________________________________________________________
ERROR CODE -646 Servo welding gun mechanical parameter is not estab-
lished.
When connecting a new gun, the mechanical parameters are not defined.
⇒ Define the parameters in AUX 114-12 SPOT WELD GUN DEFINITION and AUX114-
42 SERVO WELDING MECHANICAL PARA.
_____________________________________________________________________
ERROR CODE -653 Illegal DOUBLE OX output.
When Double type signals are used, if either output in the pair is turned ON, the other
turns OFF. An instruction to turn both outputs ON or turn both outputs OFF (OX=+1,2 or
OX=-1,2) causes this error.
⇒ Modify using the teaching screen.

_____________________________________________________________________
ERROR CODE -654 Cannot use DOUBLE OX.
When Double type signals are used, if either output in the pair is turned ON, the other
turns OFF. An instruction (BITS, PULSE, DELSIG, etc.) to change the state of either
output causes this error to occur.
⇒ Modify using the teaching screen.

_____________________________________________________________________
9-36 March 28, 2002


ERROR CODE -660 Gun chip abrasion over the limit.
The maximum tip wear limit (AUX 114-41 MAX ABRASION MOVING/FIXED[mm]) is
exceeded.
⇒ Replace the tips.

_____________________________________________________________________
ERROR CODE -662 Start point position error for circle.
The robot was stopped after it began executing a circular motion and moved 4 mm or
more away from its calculated path (jogging or brake slippage, etc.). Attempting to
continue execution of the path from this position will result in this error.
⇒ Move the robot closer to the calculated path or restart the program a step prior to the
circular path.
_____________________________________________________________________
ERROR CODE -671 Cannot execute in check back mode.
The program reached an instruction which cannot be executed in check back mode.
⇒ Execute after selecting a step that can be checked backward. If possible, check
forward.
_____________________________________________________________________
ERROR CODE -672 Cannot execute in ONE program.
The instructions specified in the ONE program area not valid for this type of program.
⇒ Refer to the AS Language manual for proper use of the AS Language commands.
_____________________________________________________________________
ERROR CODE -673 Angle between JT2 and JT3 is out of range at start loca-
tion.
Movement from the current position to the start location position would cause JT2 and
JT3 to move beyond their limits.
⇒ Modify the position of the start location of the program.

_____________________________________________________________________
March 28, 2002 9-37


ERROR CODE -674 Angle between JT2 and JT3 is out of range at end loca-
tion.
Movement from the current position to the end location position would cause JT2 and
JT3 to move beyond their limits.
⇒ Modify the position of the end location of the program.

_____________________________________________________________________
ERROR CODE -675 Terminal is not connected.
A PRINT, TYPE, or PROMPT command is specified for display on a PC that is not

connected.
⇒ Verify the PC connections or modify the commands for display on the MFP.
_____________________________________________________________________
ERROR CODE -676 Cannot input /output to multi function panel.
A PRINT, TYPE, or PROMPT command is specified for display on the MFP, although no
MFP connection is present.
⇒ Verify the MFP connections or modify the commands for display on the PC.
_____________________________________________________________________
ERROR CODE -691 Cannot change two or more guns at the same step.
The operator attempts to execute a step with more than one gun change.
⇒ Edit the program so that there is only one gun change per step.
_____________________________________________________________________
9-38 March 28, 2002


ERROR CODE -692 Gun is connected other.
The tool changer attempts to connect to a gun that is already connected to another tool
changer or is missing.
⇒ Select a different gun or disconnect the gun from the other tool changer.
NOTE
The following are conventional robot errors; however,
when they occur for the servo gun axis, the following ad-
ditional causes are possible.
_____________________________________________________________________
ERROR CODE -700 No free memory.
No free memory is available to teach or edit programs.
⇒ Delete unused programs and variables, or, expand system memory to maintain the
required capacity.
_____________________________________________________________________
ERROR CODE -800 Program does not exist.
No program is on the stack at the time of cycle start or execution command (without a
program being specified).
⇒ Identify program to be executed.

_____________________________________________________________________
ERROR CODE -801 No program step. The step specified for execution does
not exist.
⇒ Select valid step numbers for execution.

_____________________________________________________________________
ERROR CODE -802 Nonexistent label.
Occurs when executing the GOTO command and the destination label is not defined.
⇒ Ensure valid labels are used within the program.

_____________________________________________________________________
March 28, 2002 9-39


ERROR CODE -803 Undefined variable. Variable data for a specific argument
in a command is not defined.
⇒ Ensure variables are properly defined.

_____________________________________________________________________
ERROR CODE -804 Undefined location data.
The location variable for the BASE, TOOL or POINT command is not specified. Also, a
named position in a program is not defined in system memory.
⇒ Define all locations identified in programs.

_____________________________________________________________________
ERROR CODE -805 Undefined string variable. String variables that are evalu-
ated by ASC and LEN functions are not defined.
⇒ Define the string variables to be evaluated or correct the name of the string variable
used for evaluation.
_____________________________________________________________________
ERROR CODE -807 Undefined program or label.
The program name or label associated with an ON or ONI command does not exist.
⇒ Define the program or label used with the ON or ONI command.

_____________________________________________________________________
ERROR CODE -808 Illegal value. The numeric value entered exceeds the
upper or lower limits of the acceptable range.

_____________________________________________________________________
ERROR CODE -809 Undefined array suffix.
Attempt to process an array variable with undefined suffixes, i.e., attempting to process
A=B[C,D,E], but C, D, E have no values.
⇒ Rewrite the program to define the array suffix before attempting to process the array.
_____________________________________________________________________
9-40 March 28, 2002


ERROR CODE -810 Divided by zero.
Occurs when the system encounters a mathematical evaluation that involves division by
“0”. Typically associated with the FRAME function and circular interpolation.
⇒ Check data source for calculations.

_____________________________________________________________________
ERROR CODE -811 Floating point overflow.
Occurs when the system encounters a numeric floating point overflow in using arith-
metic (+, -, *, /)or logical (AND, OR, etc.) operators. This also occurs when converting a
numeric argument to an integer value.
⇒ Correct the program. Integer values with full precision ranges are from -16,777,216
to 16,777,216. For more information refer to the C Series Controller AS Language
Reference Manual.
_____________________________________________________________________
ERROR CODE -812 Character string is too long.
Character strings associated with arithmetic or comparative operators or the LEN func-
tion are too long.
⇒ Correct the program.

_____________________________________________________________________
ERROR CODE -813 Illegal exponential operation.
Numeric values that have exponents must be positive in value.
⇒ Correct equations in program.

_____________________________________________________________________
ERROR CODE -814 Expression too complicated.
A numeric calculation too complex to be evaluated was encountered.
⇒ Simplify mathematical equations.

_____________________________________________________________________
March 28, 2002 9-41


ERROR CODE -815 No expressions to evaluate.
The type of data in an argument is incompatible with the operation being performed.
⇒ Correct the program to evaluate compatible expressions.

_____________________________________________________________________
ERROR CODE -816 Unexpected error while evaluating expression.
Occurs when the system is evaluating the argument in an expression and the data of
the argument is found to be incompatible or missing.
⇒ Correct the program so that data is compatible with arguments and expressions.
_____________________________________________________________________
ERROR CODE -817 SQRT parameter is negative.
In the argument of a SQRT function, a negative number was entered for evaluation.
⇒ Do not enter negative numbers for evaluation by the SQRT function.

_____________________________________________________________________
ERROR CODE -820 Illegal array index.
Occurs when the array subscript number exceeds the acceptable range from 0 to 9999.
⇒ Ensure the range of array subscripts is acceptable.

_____________________________________________________________________
ERROR CODE -821 Illegal argument value.
Displayed when the parameter specified for an command or instruction is illegal. For
example: TOOL 2112 (after the TOOL command a defined transformation location or null
is expected, 2112 causes error).
⇒ Use correct argument values.

_____________________________________________________________________
ERROR CODE -822 Illegal joint number.
The joint numbered entered does not exist or is in the wrong format.
⇒ Retype the command using the correct format.

_____________________________________________________________________
9-42 March 28, 2002


ERROR CODE -823 Illegal signal number.
This is displayed when the SIG or BITS command is used and the specified signal
number is beyond the range permitted by the system configuration.
⇒ Use acceptable signal numbers for system configuration.

_____________________________________________________________________
ERROR CODE -824 Illegal timer number.
Displayed when a timer was specified that was not within the acceptable range of be-
tween 1 and 10.
⇒ Specify timers in the range between 1 and 10.

_____________________________________________________________________
When the RUNMASK, SIGNAL, BITS, PULSE, or SWAIT commands are used with a
signal number that exceeds the range permitted by system configuration, this error is
displayed.
⇒ Check signal number specified in instruction and ensure it is within system configura-
tion.
_____________________________________________________________________
ERROR CODE -826 Illegal clamp number.
Displayed when the clamp number entered exceeds the maximum permitted by system
configuration.
⇒ Use only clamp numbers that are supported by system configuration.

_____________________________________________________________________
ERROR CODE -827 Illegal time value.
Displayed when a negative number is entered as part of a DELAY or TIMER command.
⇒ Correct the time setting to a positive number.

_____________________________________________________________________
March 28, 2002 9-43


ERROR CODE -828 No value set.
Occurs when an instruction like the BITS command is evaluated and there is no corre-
sponding value set.
⇒ Correct program code to evaluate existing values.

_____________________________________________________________________
This error is displayed when the RUNMASK, SIGNAL, BITS, PULSE, or SWAIT com-
mands are used with a signal number that exceeds the range permitted by system
configuration.
⇒ Check signal number specified in the instruction and ensure it is within system con-
figuration.
_____________________________________________________________________
ERROR CODE -832 Illegal time input data.
Occurs when erroneous data has been entered in the setting of the TIME and DATE
function. For example: a date of Feb. 30.
⇒ Input time and date information correctly, mm/dd/yy.

_____________________________________________________________________
ERROR CODE -834 Program name already exists.
When using the RENAME command a new program name must be specified. If an
existing name is used to rename a program this error will be displayed.
⇒ Specify unused program names when renaming programs.

_____________________________________________________________________
ERROR CODE -835 Can’t KILL because the program is running.
Displayed when an attempt was made to KILL a program that was in the process of
executing.
⇒ Stop program execution with HOLD or ABORT commands before program is re-
moved from the stack with a KILL command.
_____________________________________________________________________
9-44 March 28, 2002


ERROR CODE -837 Cannot use dedicated signal.
Occurs when a previously dedicated signal was used as a general purpose signal.
⇒ Use signals that have not been dedicated for general functions.
_____________________________________________________________________
ERROR CODE -838 Not RPS mode.
Occurs when the required input signals are not dedicated at the time an attempt to run
an externally selected program is made.
⇒ If RPS is to be used the necessary signals must be dedicated.

_____________________________________________________________________
ERROR CODE -839 Cannot use negative number. Displayed when a negative
number has been used in conjunction with the PULSE or
ACCURACY commands.
⇒ Use only positive numbers in the acceptable range for the PULSE and ACCURACY
commands.
_____________________________________________________________________
ERROR CODE -840 Too many subroutines.
Occurs when more than 20 subroutines are nested with EXTCALL or CALL instructions.
⇒ Do not exceed 20 nested subroutines.

_____________________________________________________________________
ERROR CODE -842 Nonexistent subroutine. Displayed when the program

identified by a CALL, ON, or ONI does not exist.
⇒ Select only existing programs to be run as subroutines.

_____________________________________________________________________
ERROR CODE -846 No program exist.
Pertinent program does not exist in DIRECTORY and LIST commands.
⇒ Correct program or make program.

_____________________________________________________________________
March 28, 2002 9-45


ERROR CODE -850 Out of absolute lower limit.
Displayed when an attempt has been made to set the software lower limits of robot
travel to a value that is too low.
⇒ Set lower software travel limits to an acceptable range.

_____________________________________________________________________
ERROR CODE -851 Out of absolute upper limit.
Displayed when an attempt has been made to set the software upper limits of robot
travel to a value that is too high.
⇒ Set upper software travel limits to an acceptable range.

_____________________________________________________________________
ERROR CODE -852 Out of user lower limit.
Displayed when an attempt has been made to set the software lower limits of robot
travel to a value that is too low.
⇒ Set lower software travel limits to an acceptable range.

_____________________________________________________________________
ERROR CODE -853 Out of user upper limit.
Displayed when an attempt has been made to set the software upper limits of robot
travel to a value that is too high.
⇒ Set upper software travel limits to an acceptable range.

_____________________________________________________________________
ERROR CODE -854 Current position of jt x is out of range.

Current position of jt x is out of limit.
Out of motion limit!! Current JT x
Current position of the relative joint exceeds the upper or lower limit of motion range.
In repeat or check mode, the joint value of the current robot position exceeds the motion
range set under ‘software limit’.
⇒ Check and reset the ‘software limit’.

⇒ Correct the taught point or position data.
_____________________________________________________________________
9-46 March 28, 2002


ERROR CODE -855 Motion start location of jt-x is out of range.
Prior to beginning a program or motion to a step, the software has calculated the loca-
tion to be outside of the allowable upper or lower software limits.
⇒ Correct location to within working envelope or expand software limits to accept loca-
tion.
_____________________________________________________________________
ERROR CODE -856 Motion and location of jt-x is out of range.
While executing a motion to a step, the software has calculated the location destination
of the specific joint number to be outside of the allowable upper or lower software limits.
tion.
_____________________________________________________________________
ERROR CODE -857 Destination is out of range.
While executing a motion to a step, the software has calculated the location destination
of all joints to be outside of the allowable upper or lower software limits.
tion.
_____________________________________________________________________
ERROR CODE -858 Illegal configuration for linear motion.
System software has determined that the start and end points of a linear move will
cause the robot to exceed the acceptable motion parameters.
⇒ Change motion interpolation to a joint move; move location to avoid configuration.

_____________________________________________________________________
ERROR CODE -871 Illegal joint number.
Occurs when the DRIVE command is used and specifies a joint number that is not part
of the robot configuration.
⇒ Confirm robot configuration before using the DRIVE command.

_____________________________________________________________________
March 28, 2002 9-47


ERROR CODE -872 Cannot execute motion instruction in PC program.
A PC program cannot contain instructions that initiate robot motion. If a motion instruc-
tion is encountered in a PC program this error will be displayed.
⇒ Correct the PC program by removing motion instructions.

_____________________________________________________________________
ERROR CODE -873 Illegal auxiliary data number.
The value selected for auxiliary data (speed, timer, tool etc.) exceeds allowable range.
⇒ Correct the value of auxiliary data.

_____________________________________________________________________
ERROR CODE -874 No circular location.
Program circular motion instructions must have C1 moves followed by either a C1 or C2

move.
⇒ Correct program instructions.

_____________________________________________________________________
ERROR CODE -875 No C1MOVE(CIR1) ins.
Program circular motion instructions must have C2 moves preceded by a C1 move.

_____________________________________________________________________
ERROR CODE -876 Cannot create circle.
Circular interpolation moves cannot be processed because the points identified are too
narrow or are on a straight path.

_____________________________________________________________________
ERROR CODE -877 Cannot execute, because of sealing type.
Occurs when a command for a sealing application is evaluated by a controller that is not
configured for sealing applications.
⇒ Correct program instructions to match software configuration.

_____________________________________________________________________
9-48 March 28, 2002


ERROR CODE -879 Cannot execute, because of not sealing type.
Occurs when a GUNON, GUNOFF, GUNONTIME or GUNOFFTIME command for a

sealing application is evaluated by a controller that is not configured for sealing applica-
tions.
⇒ Correct program instructions to match software configuration.

_____________________________________________________________________
ERROR CODE -896 Option is not set up, can’t execute.
⇒ Contact customer service for option specifications after confirming the purchase
specification.
_____________________________________________________________________
ERROR CODE -900 Arc failure.
The signal (current detection: WCR) that indicates the robot is executing the weld did not
return from the welder for 1 sec. or more after welding started.
⇒ Check for insulating debris that prevents welding.

⇒ Confirm that adequate supply of wire is available.
⇒ Confirm that wire is not stuck to the welding tip.
_____________________________________________________________________
ERROR CODE -901 Wire stuck.
The wire is stuck to the base metal at the weld end.
⇒ Cut the wire.

⇒ Change weld conditions if problem occurs frequently.
_____________________________________________________________________
ERROR CODE -902 Electric pole stuck.
⇒ Contact KRI Customer Service.

_____________________________________________________________________
ERROR CODE -909 Watch-Dog Error RS485 Special Communication Board.

_____________________________________________________________________
March 28, 2002 9-49


ERROR CODE -910 Work not detected (Touch sensing)
Occurs when touch sensing does not detect the workpiece within the range of touch
sensing distance set in system data or no workpiece is present. The robot stops and
error -910 is generated.
⇒ Reset the workpiece in the proper position.

⇒ Increase the range of touch sensing distance in system data.
_____________________________________________________________________
ERROR CODE -911 Undefined sensing direction. (Touch sensing)
Occurs when the step proceeding the WORK_DETECT instruction is not an air_cut
point. The robot stops and error -911 is generated.
⇒ Insert an air_cut point in the program before the WORK_DETECT instruction.

⇒ When using step select to chose the start step, select the air_cut point before the
WORK_DETECT instruction in the program
_____________________________________________________________________
ERROR CODE -912 Insufficient sensing points. (Touch sensing)
Occurs when two point sensing is set up and the following point is other than an air_cut
point. The robot stops and error -912 is generated.
Example:
1. AC JOINT SPEED9 ACCU4 TIMER0 MOTHER_RESET
2. AC LINEAR SPEED9 ACCU4 TIMER0 MOTHER_WORK2 (error occurs at this step)
3. WS LINEAR SPEED9 TIMER0
Step two sets 2 point sensing and step three is a weld start point instead of an air_cut
point.
⇒ Add the required air_cut sensing points.
Example:
2. AC LINEAR SPEED9 ACCU4 TIMER0 MOTHER_WORK2
3. AC JOINT SPEED9 ACCU4 TIMER0
_____________________________________________________________________
9-50 March 28, 2002


ERROR CODE -913 Mother or daughter work does not exist. (Touch sensing)
Occurs when a previous work instruction is not completed before another work instruc-
tion is executed. The robot stops and error -913 is generated.
Example:
2. AC LINEAR SPEED9 ACCU4 TIMER0 DAUGHTER_WORK2 (error occurs at this
step)
⇒ Add the required steps in the program to complete the first work instruction before
another work instruction is executed.
Example:
_____________________________________________________________________
ERROR CODE -914 Number of sensing points exceeded. (Touch sensing)
Occurs when a work instruction is completed and another work instruction is executed
without a reset instruction. The robot stops and error -914 is generated.
Example:
3. AC LINEAR SPEED9 ACCU4 TIMER0
5. WE LINEAR WELD_COND0
7. WS LINEAR SPEED9 ACCU4 TIMER0 MOTHER_WORK1 (error occurs at this step)
⇒ Add a reset instruction before the next work instruction.
Example:
6. AC LINEAR SPEED9 ACCU4 TIMER0 MOTHER_RESET
7. WS LINEAR SPEED9 ACCU4 TIMER0 MOTHER_WORK1
_____________________________________________________________________
March 28, 2002 9-51


ERROR CODE -915 Illegal work appointment. (Touch sensing)
Occurs when a previous work instruction is not completed before another work instruc-
tion is executed. The robot stops and error -915 is generated.
Example:
4. AC LINEAR SPEED9 ACCU4 TIMER0 MOTHER_WORK1 (error occurs at this step)
⇒ Add the required steps in the program to complete the first work instruction before
another work instruction is executed.
Example:
_____________________________________________________________________
ERROR CODE -916 Illegal sensing points appointment. (Touch sensing)
Occurs when points are taught in incorrect order.
Example:
points should be taught in order A1, B1, A2, B2, A3, B3.
Occurs when the distance between two points taught on the same check plane is 20
mm or less or the angle between the sensing direction for a check plane and for the
other check plane is out of the 30 to 150 degrees range.
⇒ Reteach points to comply with parameters described above .

_____________________________________________________________________
ERROR CODE -917 Wire check failed. (Touch sensing)
Occurs when:
The position of a taught point is recorded too far from the workpiece.
The weld wire was not sent due to the welding unit power off.
⇒ Reteach point at the correct distance.

⇒ Check the welding machine for power and press CYCLE START to manually feed
wire for five seconds.
_____________________________________________________________________
9-52 March 28, 2002


ERROR CODE -919 No RS485 Special Communication board.

_____________________________________________________________________
ERROR CODE -920 Illegal welding condition number.

_____________________________________________________________________
ERROR CODE -921 Weld data not set up.

_____________________________________________________________________
ERROR CODE -922 Weld data out of range.

_____________________________________________________________________
ERROR CODE -934 No weld data base.

_____________________________________________________________________
ERROR CODE -935 Cannot change condition.

_____________________________________________________________________
ERROR CODE -951 No RTPM board. (RTPM)
Occurs when the software option for RTPM is installed but the hardware (1FH board) is
not installed.
Occurs when the software and hardware (1FH board) are installed but controller power
is not cycled OFF and ON after RTPM option is set-up.
⇒ Ensure the 1FH board is properly installed.

⇒ Reseat board and connectors.
⇒ Perform RTPM option set-up procedure and cycle controller power OFF and ON.
_____________________________________________________________________
March 28, 2002 9-53


ERROR CODE -960 To many taught points for RTPM. (RTPM)
Occurs when the number of taught points between the weld start point and the weld end
point exceeds 127 points
⇒ Reteach program points not to exceed 127 points.

_____________________________________________________________________
ERROR CODE -961 RTPM arc sensor error. (RTPM)

_____________________________________________________________________
ERROR CODE -962 Out of RTPM tracking value. (RTPM)
Occurs when the detection value exceeds the error check value set in RTPM.
⇒ Ensure the weld start point is taught in the welding groove.

⇒ Confirm proper welder operation.
⇒ Ensure the RTPM function is activated.
_____________________________________________________________________
ERROR CODE -963 Out of RTPM tracking capacity. (RTPM)
Occurs when the threshold setting in AUX 31 RTPM Errors, exceeds the number of
times setting (also set in AUX 131 RTPM Errors).
Example:
If the threshold is set a 9 mm and the number of times is set at 30, the error occurs after
30 weave cycles and the path has deviated more than 9 mm from the original welding
path.
⇒ Ensure the welding start point is taught in the grove. Starting outside the grove will
cause this error.
⇒ Execute a weld without the RTPM function, to ensure the welding power supply is
operation properly.
⇒ Improve fixturing and/or part to minimize the required correction.
⇒ Verify the linearization table is correct by comparing the current reading indicated on
the welding power supply to the current value set in the weld condition number in
AUX 28.
⇒ Increase the out of tracking capacity values (threshold and number of times). This
allows the robot to deviate further from the planned path and could cause the robot to
collide with peripherals or the workpiece.
_____________________________________________________________________
9-54 March 28, 2002


ERROR CODE -964 RTPM current deviation error. (RTPM)
Occurs when actual current exceeds commanded current for a time period that exceeds
the current deviation error time-out value while using RTPM.
⇒ Set controller power to OFF and reseat the 1FH board and the 1FH board connec-
tors.
⇒ Ensure the weld start point is taught in the welding grove.
⇒ Ensure the welding unit power is ON and in proper operating condition.
⇒ Ensure the RTPM function is activated.
⇒ Ensure the welding unit metered current during a continuous bead is the same a the
⇒ commanded current.
_____________________________________________________________________
ERROR CODE -990 No welding interface board.
The welding interface board was not detected at control power on.
⇒ Turn control power off and confirm that the weld interface board is mounted.
⇒ Confirm that the weld interface board is not loose. Insert the board firmly.
_____________________________________________________________________
ERROR CODE -999 No welding interface board.
The welding interface board was not detected at control power on.
⇒ Turn control power off and confirm that the weld interface board is mounted.
⇒ Confirm that the weld interface board is not loose. Insert the board firmly.
_____________________________________________________________________
March 28, 2002 9-55


ERROR CODE -1003 Data base error.
The program storage area of the system memory has been damaged and is not linking
data correctly.
⇒ Turn on the 1GA board switch SW2-8 to initialize the memory, do not use AUX100 or
SYSINIT command. Reload the teach data.
⇒ Check that system is properly isolated from electrical noise.
⇒ Check the memory backup battery. Replace if necessary.
⇒ Replace the 1GA board if the error re-occurs.
_____________________________________________________________________
ERROR CODE -1012 Command position of jt-x has suddenly changed.
Spot welding and material handling

In the repeat mode, the commanded position of the joint identified has exceeded 1.3
times the maximum arm speed. In the check mode, the commanded position of the joint
identified has exceeded 200 mm/sec.
⇒ Check for singularity condition during robot motion and reteach to correct.
⇒ Check for loose or defective servo system encoders, harnesses, and circuit boards.
Servo welding gun

Occurs when corrections for deflection cause movement of the robot to exceed the
range of motion of one or more axes. This condition is not limited to the gun axis; any
axis, including the gun axis, can cause this error.
⇒ Change the posture of the robot.

⇒ Decrease the speed in the step.
⇒ Reduce the amount of the deflection correction in the step by using AS Language
SGREFLEX command.
⇒ Reteach the point and change the configuration of the posture of the robot if needed.
_____________________________________________________________________
9-56 March 28, 2002


ERROR CODE -1014 Commanded position of jt-x is out range.

The commanded position for the joint identified has exceeded the software limits. Con-
dition is monitored in both the check and repeat modes.
⇒ Correct taught positions to avoid the software limits.

⇒ Adjust the software limits to provide the necessary work envelope.
Servo welding gun

If a taught point is near a servo gun or arm axis range of motion limit, the combination of
tip wear and deflection correction can prevent the robot from reaching the taught point.
⇒ Do not teach points that are near axes range of motion limits.
_____________________________________________________________________
ERROR CODE -1017 Angle between JT2 and JT3 is out of range.
The commanded position for JT2 and JT3 cannot be reached due to the nature of the
mechanical links that exist between these points for the U-series, EH, and ES robots.
This error does not apply to JS-series robots. The main cause of this error is that the
taught positions, including positions through which the robot moves, are bad.
⇒ Change the taught positions.

_____________________________________________________________________
ERROR CODE -1019 Check sum error of system data.
The check sum of the system data of the AS software was changed when the system
information such as model number, number of axis, and option setting, was downloaded.
When the error occurs in situations other than downloading, the error is caused by
defective memory back-up, defective 1GA board, or memory error from noise.
⇒ Use AUX 78 Clear Check Sum Error or CHSUM command to reset the data. When
the error cannot be reset using the check sum commands, the command with the
abnormality is shown. Rewrite the command and use CHSUM or Aux 78 to clear the
error.
⇒ Check the memory backup battery. Replace if necessary.
⇒ Replace the 1GA board if the error re-occurs.
_____________________________________________________________________
March 28, 2002 9-57


ERROR CODE -1022 RAM battery low voltage <board name>.
When control power is applied or motor power is turned on, a voltage check is per-
formed on the batteries that maintain SRAM memory when power is off. This message
is displayed when a voltage of 2.5 VDC or less is detected (normal is 3.6 VDC).
⇒ Back up system and program data, check and replace batteries as required.
⇒ Check batteries for defective connections. Repair the defective connection.
⇒ Defective battery voltage monitoring circuit. Replace the circuit board.
_____________________________________________________________________
ERROR CODE -1025 AS Flash memory sum check error.
A check sum error of AS system data in flash memory on 1GA board occurred when the
power was turned on. The check sum data is created when the FCHK command is
executed and is recorded in flash memory during download. Main causes of the error
are:
1. When the AS system was downloaded, the FCHK command was not executed.
2. The addressing of the FCHK command was wrong.
3. The flash memory and 1GA board are defective.
4. The system data in the flash memory is damaged.
⇒ Confirm the content of the command as_load.cmd file in the IC card if error occurs
immediately after downloading the AS system. Download system again. If error
continues after download, exchange the 1GA board.
_____________________________________________________________________
ERROR CODE -1026 Servo Flash memory sum check error.
A check sum error of the servo system in flash memory on 1GA board occurred when
the power was turned on. The check sum data is created when the FCHK command is
executed and is recorded in flash memory during download. Main causes of the error
are:
1. When the servo system was downloaded, the FCHK command was not executed.
2. The addressing of the FCHK command was wrong.
3. The flash memory and 1GA board are defective.
4. The system data in flash memory is damaged.
⇒ If the error occurs immediately after download, confirm the content of as_load.cmd in
the PC card and download again. If the error persists, change the 1GA board.
_____________________________________________________________________
9-58 March 28, 2002


ERROR CODE -1051 Cannot execute in this robot arm.
Unused
_____________________________________________________________________
ERROR CODE -1100 CPU Error (Code = ****).
The 1GA board CPU has stopped (detected with the AS software). This error is caused
by defective AS or servo software, defective hardware, or noise related malfunction.
⇒ With a PC connected enter “$save/flt filename” to save the fault data, and send to
KHI.
⇒ Confirm which board the error occurred on by referring to the message that appears
on the PC. This error does not appear on the multi function panel or the small teach
pendant.
I/O BUS ERROR: error in the address of the 1FR or 1GW board.
PSB BUS ERROR: error with the 1FP or 1HP power sequence board.
VME BUS ERROR: error in the address of the boards that use the VME bus.
⇒ If the initialization prompt appears, answer “no”, then reload software. If the error
returns, initialize the system and reload software. If the multi function panel or PC are
not functional, system initialization cannot be performed.
⇒ If this error occurs during certain specific operations it may indicate a defect in the AS
system.
⇒ Replace the 1GA board if the error cannot be reproduced or cleared.
_____________________________________________________________________
March 28, 2002 9-59


ERROR CODE -1101 Main CPU BUS error.
On the 1GA board, a bus error (in the VME bus line, data processing was not able to be
done normally) has occurred (detected with the AS software). This error is caused by
defective AS or servo software, defective 1GA board, or noise related malfunction.
⇒ With PC connected enter “$save/flt filename” to save the fault data, and send to KHI.
pendant.
system.
_____________________________________________________________________
ERROR CODE -1102 VME BUS error.
This error occurs when the CPU does not receive a response from one of the I/O bus
devices within a specific time. This error is caused by defective AS or servo software,
defective 1GA board, or noise related malfunction.
⇒ With a PC connected enter “$save/flt filename” to save the fault data, and send to
KHI.
pendant.
system.
_____________________________________________________________________
9-60 March 28, 2002


ERROR CODE -1200 Encoder board is not installed.
Unused
_____________________________________________________________________
ERROR CODE -1201 Power sequence board is not installed.
The first address of the No.1 power sequence board (1FP/1HP board) cannot be read
when control power is turned ON. Main causes for this error include:
1. The power sequence board (1FP/1HP board) is not installed in the correct card slot.
2. Jumper or dip switch settings of the power sequence board are incorrect.
3. Defect in the power sequence board.
⇒ Ensure the 1FP/1HP board DSW1 setting is configured as power sequence board
No. 1 and is installed in the 1FP/1HP card rack slot. Check and replace the board if
necessary.
_____________________________________________________________________
ERROR CODE -1202 No2 power sequence board is not installed.
The first address of the No.2 power sequence board (1FP/1HP board) cannot be read
when the control power is turned ON. Main causes for this error include:
1. The power sequence board (1FP/1HP board) is not installed in the correct card slot.
2. Jumper or dip switch settings of the power sequence board are incorrect.
⇒ Ensure the 1FP/1HP board DSW1 setting is configured as power sequence board
No. 2 and is installed in the 1FP/1HP card rack slot. Check and replace the board if
necessary.
_____________________________________________________________________
March 28, 2002 9-61


ERROR CODE -1203 No x-M I/O board is not installed.
Cannot read the first addresses of I/O boards (1FR/1GW board, etc.) based on the
number of signals that have been set with DO (output point), or DI (input point) of the
ZSIGSPEC command, when the control power supply is turned on. This error is not
used when a 1FS board is installed. Main causes include:
1. Incorrect value set with the ZSIGSPEC command.
2. Error in board address of I/O board (1FR/1GW board, etc.).
3. Defect of I/O board (1FR/1GW board, etc.).
⇒ Set the correct number of signals with the ZSIGSPEC command. I/O cards are
typically mounted in the card rack from right to left in ascending order. Because of
VME buss communication, this is not critical. The robot can run without I/O boards.
The maximum number of signals in the software set with the ZIGSPEC command is
DO, DI=256, INT=512, but DO and DI are restricted by hardware and other options.
⇒ Set board address jumpers correctly.
⇒ Replace the 1FR/1GW board.
_____________________________________________________________________
ERROR CODE -1204 Option SIO port is not installed.
The 1GA board sets more than seven axes at control power ON, but the IC (SIO) for
serial communications for command line 3 and 4CH communication with the servo
board is not installed. This error typically does not occur because SIO is installed on
standard 1GA boards but may not be on the prototype boards. Main causes of this error
include more than seven axes set with a prototype board with SIO not mounted or a
defect in the 1GA board.
⇒ Replace the 1GA board.

_____________________________________________________________________
9-62 March 28, 2002


ERROR CODE -1205 Power sequence board any error.
An error signal, not classified through the error summary, is generated by the 1FP/1HP
board and not recognized by the AS software. Main causes include:
1. The error detection function of the power sequence board does not correspond to
the error processing function of the AS software.
3. Defect in the 1GB board.
4. Defect in the wiring between the 1FP/1HP board and the 1GB board.
(XGB-CN1 ↔ XHZ-CN4)
⇒ Replace the power sequence board.

⇒ Repair/Replace the 1FP/1HP board to the 1GB board wiring harness.
⇒ Install the correct version of the AS software.
_____________________________________________________________________
ERROR CODE -1206 Built-in sequence board is not installed.
Installation of the built-in sequencer board is checked when the control power supply is
turned ON. This error occurs when the built-in sequencer board is not installed.
⇒ Install the built-in sequencer board.

_____________________________________________________________________
ERROR CODE -1208 RI/O board is not installed.
This error occurs when the control power supply is turned on and the first address of the
RI/O board is not read (1GW, 1FS etc.).
1. The RI/O board is not installed.
2. Defect in the RI/O board.
⇒ Ensure the RI/O board installed.

⇒ Replace the RI/O board.
_____________________________________________________________________
March 28, 2002 9-63


ERROR CODE -1209 RI/O board initialize error.
This error occurs when the control power supply is turned on and the RI/O board does
not successfully initialize (1FS board).
1. Incorrect dip switch settings on the RI/O.
2. Defect in the RI/O board software.
⇒ Set dip switch correctly on RI/O board.

⇒ Reinstall the RI/O board software.
_____________________________________________________________________
ERROR CODE -1220, -1221, -1222 See table below.
(-1220) No response from the arm ID board.

Possible damaged arm ID board or power sequence board.
(-1221) Arm ID board error (code xxx).

Possible damaged arm ID board or power sequence board.
(-1222) Power sequence board error (code xxx).

Possible damaged power sequence board.
Code Description -1220 -1221 -1222

NA No response from the arm ID board x
4AH Arm ID board data is not normal or is corrupt x
4FH Writing error to arm ID board memory1 x
C1H Communication check sum error2 x x
C5H Communication protocol error2 x x
C6H Communication response time-out error2 x
C7H Communication character string time-out error2 x
F1H ROM check sum error (at board star t-up)3 x
F2H Abnormal RAM (at board star t-up)3 x
F4H Abnormal SRAM (at board star t-up)3 x
F5H Abnormal DRAM (at board star t-up)3 x
FFH Other errors x x
1
Cannot write to arm ID board memory. Replace arm ID board.
2
Damaged or disconnected communication cable.
3
Cycle controller power ON and OFF. If error does not clear further diagnosis is needed
(possible damaged arm ID board or power sequence board).
_____________________________________________________________________
9-64 October 2, 2002

ERROR CODE -1247 Axis setting data incorrect.
The command channel line for the external axis was incorrectly set using AUX 901,
External Axis Set.
⇒ Input the correct value.

_____________________________________________________________________
ERROR CODE -1248 Number of Axis Changed! SYSINI.
The number of axis assigned to the robot has changed.
⇒ Change the number of axes and initialize the system.

_____________________________________________________________________
ERROR CODE -1249 Servo parameter Changed! Control power turn OFF & ON.
Servo parameters in system data changed during LOAD.
⇒ Turn control power supply OFF and ON.

_____________________________________________________________________
October 2, 2002 9-65


ERROR CODE -1250 Servo board (X) Initialize error.
The servo software was not successfully loaded from the FLASH memory on the 1GA
board to the servo board when control power was turned ON. The contents of (X) is an
alphanumeric code as indicated below:
A 0 7
7: Servo program download error

6: Servo parameter download error
4: Trap error (Servo software initialization error)
CPU channel of servo board

1. Defect in the 1GB servo board.
2. Defect of the harness between power sequence board and servo board.
3. Error in mother board jumper setting.
4. The servo software is not in the flash memory on the 1GA board.
(XGB-CN1↔XHZ-CN4)
5. Malfunction caused by noise, etc.
6. Servo software and AS software versions incompatible.
7. Versions of ROM in servo software and servo board not compatible.
⇒ Replace the 1GA, servo board, and each harness.

⇒ Confirm the servo software and the servo board monitor ROM version and install the
corresponding servo software again. Confirmation of the version can be confirmed by
AUX 90, Software Version Display, or ID command.
_____________________________________________________________________
9-66 October 2, 2002


ERROR CODE -1251 Servo board (X) communication error.
Communications in the command line of each CPU of the servo board (1GB board)
failed twice consecutively. The command line always communicates every 4 msec.
When each CPU of the servo board stops, this error might be detected. Main causes
include:
Relay to Power Sequence

CH To Communication
Board (1FP/1HP PC Board)
A First 1GB PC Board A Unit Master
B First 1GB PC Board B Unit Master
First 1GB PC Board C Unit
or
C Second 1GB P Board A Unit Slave
or
One Axis Amplifier
Second 1GB P Board B Unit
D or Slave
One Axis Amplifier
1. Defect in the 1GA board.

3. Defect in each communication harness.
4. Encoder defect if JT3 (A) or JT4 (B) are displayed.
5. Noise malfunction.
6. Mismatch of AS and servo software
7. Improper setting of AUX 928; servo type 2.
⇒ Ensure software versions are correct.

⇒ Ensure AUX 928 setting is correct.
⇒ Replace the 1GA, servo board, and each harness.
_____________________________________________________________________
October 2, 2002 9-67


ERROR CODE -1252(A), -1253(B), -1254(C), -1255(D)
Servo board (x) hardware error code = xxxx.
A hardware error was detected by the 1GB board with no corresponding error in the AS
software. The internal error code number that the AS software detected is displayed in
xxxx. The unit name of the servo board displayed at x in the error message corresponds
to the CH column in the table below.

CH To Communication
or
or
One Axis Amplifier
D or Slave
One Axis Amplifier
Main causes of this problem include the following abnormalities:

1. Defect in the servo software.
3. Defect in the harness between servo board and power sequence board.
4. Defect of the servo board.
5. Versions of servo and AS software incompatible.
6. Malfunction in the servo or AS software.
⇒ Install upgraded versions of servo and AS software.

⇒ Replace the 1GA board, the servo board, and each harness.
⇒ When this error occurs, contact KRI to report the details.
_____________________________________________________________________
9-68 October 2, 2002


ERROR CODE -1256(A), -1257(B), -1258(C), -1259(D)
Servo board (x) software error code = xxxx.
A hardware error was detected by the 1GB board with no corresponding error in the AS
software. The internal error code number that the AS software detected is displayed in
xxxx. The unit name of the servo board displayed at x in the error message corresponds
to the CH column in the table below.

CH To Communication
or
or
One Axis Amplifier
D or Slave
One Axis Amplifier
Main causes of this problem include the following abnormalities:

1. Defect in the servo software.
4. Defect of the servo board.
⇒ Install upgraded versions of servo and AS software.

⇒ When this error occurs, contact KRI to report the details.
_____________________________________________________________________
October 2, 2002 9-69


ERROR CODE -1260 Option changed! SYSINI.
Unused
_____________________________________________________________________
ERROR CODE -1261 Servo board (x) parameter setting error.
After a setting was changed with AUX 976 servo parameter, the data sent to the servo
board was different than the data received two or more times. The unit name of the
servo board displayed at x in the error message corresponds to the CH column in the
table below.

CH To Communication
or
or
One Axis Amplifier
D or Slave
One Axis Amplifier
Main causes of this error include:

1. Defect in the 1GA board.
2. Defect in the servo board.
3. Defect of each communication harness.
5. Malfunction by noise.
⇒ Replace the 1GA board, the servo board and each harness.
⇒ Install correct versions of AS and servo software.
⇒ If error cannot be reset, reset data with AUX 976.
⇒ If error cannot be reset, cycle control power.
_____________________________________________________________________
9-70 October 2, 2002


ERROR CODE -1262 EXT AXIS cutting error.
Occurs when a gun disconnect is not normally completed.
⇒ Check for errors on the 1HP and 1GB boards.

⇒ Check the wiring harness between the 1HP and 1GB boards.
ERROR CODE -1263 EXT AXIS connecting error (CODE ).
Occurs when the gun axis connection is not normally completed.
Code 0: No answer from the servo welding gun.

Code 11: Terminated normally.
Code 80: Channel No. is erroneous or erroneous code.
Code 81: Inexecutable due to RGSO is unkown.
Code 101: Pressure applying force limit value is not yet selected in negative section.
Code 102: Pressure applying force limit value is not yet selected in positive section.
Code 103: Pressure applying force limit value is not yet selected in both sections.
Code 200: Scope of movement restoration after calibration is not terminated.
According to the code number displayed following the error message, perform the
following:
Code 0:This error occurs when the servo software does not respond. It may be caused
by failure of the 1HP or 1GB board or the harness between the boards.
Code 200: After connecting the gun, if the gun cannot be operated within a specified
time this error is displayed.
If the gun fully opens once and the error is generated:
⇒ Verify that the servo gun’s upper and lower limits are correctly set.
⇒ Use the gun brake release switch, release the gun’s brake. Manually move the gun
to check for mechanical binding.
If the gun cannot be moved and the error is generated:
⇒ The pressure setting may not be enough to move the gun.

From the Spot service : Servo welding gun pressure adjustment function, calibrate
the clamping pressure.
⇒ Check the gun for proper mechanical functioning. Check the brake.
October 2, 2002 9-71


ERROR CODE -1267 1JS board is not installed
1JS board is not installed for interface with an incremental-type conveyor encoder.
1. 1JS board not installed.
2. Defective 1JS board
3. Defective 1GW board to which the 1JS board is installed.
⇒ Replace the 1JS board.

⇒ Replace the 1JS board and the 1GW board.
_____________________________________________________________________
ERROR CODE -1300 Servo CPU-(x) watch dog error.
The watch dog circuit on the 1GB board has detected a software problem. This is
caused by a defective servo board or a problem with the servo software. The unit name
of the servo board displayed at x in the error message corresponds to the CH column in
the table below.

CH To Communication
or
or
One Axis Amplifier
D or Slave
One Axis Amplifier
⇒ Replace the servo board.

_____________________________________________________________________
9-72 October 2, 2002


ERROR CODE -1306 Servo board command error.
Servo software has returned the error code to the AS software. Main causes include:
4. Defect of the servo board or the 1GA board.
⇒ Install correct versions of servo and AS software.

_____________________________________________________________________
ERROR CODE -1308 Motor power off.
Occurs when software turns motor power on (K1 or K2 contactors on) but there is no
signal feedback (MCON) indicating motor power is on. Main causes include:
1. Defect in the power sequence board (1FP/1HP board).
2. Defect in the relay board (1FY/1HY board).
3. Malfunction in the error detection circuit and error processing of each board.
4. Auxiliary contact of magnet contactor (K1, K2) for motor power is defective.
5. Malfunction with the servo software or the AS software.
6. Defect in the harnesses between XHY-CN3 and KI/K2.
⇒ Replace the power sequence board.

⇒ Replace the relay board.
⇒ Replace the magnetic contactor.
⇒ Repair or replace the harnesses between XHY-CN3 and K1/K2.
_____________________________________________________________________
ERROR CODE -1333 Monitor ID of servo board mismatch!
The monitor ROM software version of each unit on the 1GB board is different, caused by
a defect of the 1GB board.
⇒ Replace the 1GB board.

_____________________________________________________________________
October 2, 2002 9-73


ERROR CODE -1334 Servo control line error.
Brake open command is not returned within 2 seconds when the servo control on
(SVCN) signal is sent from the AS software to the servo board (1GB) through the EPLD
register of the power sequence board (1FP/1HP). Main causes include:
1. Defect in the 1FP/1HP power sequence board.
3. Incorrect 1GB board dip switch settings.
4. Defect in the harness between the two boards. (XGB-CN1↔XHZ-CN4)
5. Defect in the harness between the 1GC/1GD power block and K3 contactor.
(X1SA↔MS, X1-SA↔XGC/XGD-CN10/CN12)
6. Defect in the harness between the 1GB servo board and the 1GC power block.
(XGB-CN12↔XGC/XGD-CN8, XGB-CN13↔XGC/XGD-CN9)
7. Defect in the 1GC/1GD power block.
⇒ Repair or Replace harnesses as needed.

⇒ Exchange the power sequence board and the servo board, etc.
⇒ Check 1GB board dip switch settings.
_____________________________________________________________________
ERROR CODE -1336 Safety gate circuit open.
The safety gate branch of the safety circuit is open due to a missing safety plug or
defective circuit.
⇒ Reinsert the safety plug.

⇒ Repair open circuit.
⇒ Replace the power sequence board (1FP/1HP).
_____________________________________________________________________
ERROR CODE -1337 Two MC lines are not consistent.
A problem has been detected with the MC lines controlling the K1/K2 contactors, due to
an open safety circuit, loose connectors or defects of the 1HP, 1HY, or 1HZ boards.
⇒ Check the safety circuit.

⇒ Check connections to the 1HP, 1HY, and 1HZ boards.
⇒ Replace the 1HP, 1HY, or 1HZ boards as necessary.
_____________________________________________________________________
9-74 October 2, 2002


ERROR CODE -1338 K1 and/or K2 works wrong.
Feedback from the auxiliary contacts of the K1/K2 contactors was not received within a
fixed time, when the contactor was energized. Main causes are safety circuit failures,
K1/K2 auxiliary contact fault (welded, etc.), loose connectors or defects of the 1HP, 1HY,
or 1HZ boards.
(XHP-CN3↔XHY-CN4↔1HY↔XHY-CN3↔K1/K2)
⇒ Check the safety circuit.

⇒ Check connections to the 1HP, 1HY, and 1HZ boards.
⇒ Replace the 1HP, 1HY, or 1HZ boards as necessary.
_____________________________________________________________________
ERROR CODE -1401 Amp over current jt x-M.
The feedback current from a current sensor in the power block exceeded 144% of the
maximum instantaneous motor current rating. This error can be caused by the following
abnormalities:
1. Short in the U, V, W from the power block to motor and ground wire.
(power block↔X4/X5↔robot)
2. Defect in the motor.
3. Defect in the power block.
4. Defect in the servo board (1GB board, etc.)
⇒ Check the connection for the U, V, W and ground line to the power block. Replace the
separation harness if necessary.
⇒ Replace the motor, 1GB board, or power block.
_____________________________________________________________________
ERROR CODE -1407 AMP power unit error.
General servo system error. This error indicates that a servo system error has occurred.
Main causes include a defect in the connection of the harness between the power
sequence board and the servo board.
⇒ Check the servo error codes that follow this error for additional information. Check
the harness connections between the 1HP board and 1GB board. Replace the 1HP
board.
_____________________________________________________________________
October 2, 2002 9-75


ERROR CODE -1413 Regenerative resistor overheat or disconnect.
Unused
_____________________________________________________________________
ERROR CODE -1420 Current detector type (x) mismatch!
When the control power supply is turned ON, the ID code data of the 1GM board and
the AS software installed on the 1GB board do not correspond. The unit name of the
servo board displayed at x in the error message corresponds to the CH column in the
table below.

CH To Communication
or
or
One Axis Amplifier
D or Slave
One Axis Amplifier

1. 1GM board is not suitable for the AS software (robot model).
2. The AS software does not correspond to the 1GM board.
⇒ Install the 1GB board equipped with 1GM board.

⇒ Load the robot system data when this error occurs immediately after initializing.
⇒ Re-initialize and reload the robot/system data if this error occurred immediately after
loading the data.
_____________________________________________________________________
9-76 October 2, 2002


ERROR CODE -1500 Motor overload jt-x.

The current feedback from the power block exceeded maximum continuous ratings
longer than the time allowed. Main causes include:
Mechanical -
1. The robot arm has contacted an external item hindering movement.
2. The harness is caught in the robot arm.
3. The decelerator, the gear, or the bearing are damaged.
4. Gear decelerator backlash is too narrow.
5. Payload weight exceeds robot specifications for capacity.
6. Robot motion pattern exceeds ratings of the motor.
7. Motor brake is not released.
Electrical-
1. Motor power line U, V, and W phase are disconnected.
(1GC↔power block↔X4/X5↔robot)
2. The brake line is disconnected or brake drive circuit is damaged.
(T1↔TB1↔V1↔XHY-CN1↔1HY↔XHY-CN2↔XGB-CN14↔1GB↔
XGB-CN6↔X5↔robot)
3. The power block is damaged.
4. Defect in the 1HY board.
6. Malfunction of the motor.
⇒ Check the decelerator, etc. for mechanical failure. Replace as necessary.

⇒ Re-teach the robot motion as necessary.
⇒ Check the harness and servo unit for electrical malfunctions and replace if necessary.
Servo welding gun

1. Clamping pressure time is excessive.
2. Distance between weld points is short; the motor does not have time to cool suffi-
ciently between welds.
3. Clamping pressure setting exceeds the servo gun motor power capacity.
⇒ If the weld points are close to each other, set a time delay. This provides a cool-down
period for the servo gun motor.
⇒ Set the clamping force lower (see servo gun manufacturer’s specifications).
_____________________________________________________________________
October 2, 2002 9-77


ERROR CODE -1501 Overheat or motor harness is disconnected (x).
Motor thermal circuit is open due to motor overheat or harness problem. Not all robot
models utilize thermal switches in the motors. The unit name of the servo board dis-
played at x in the error message corresponds to the CH column in the table below.

CH To Communication
or
or
One Axis Amplifier
D or Slave
One Axis Amplifier

1. Disconnected thermal line.
(1GB↔XGB-CN6↔XTH↔X4↔robot)
2. Defective connection in the separation harness.
4. When the thermal is built-in:
The robot rated weight capacity is exceeded.
The ambient temperature exceeds limits for use.
Constant execution of abrupt high speed direction changes.
Defect robot cooling fan or cooling air purge system.
Servo system holding the robot arm in high load position for extended periods.
Defect in the thermal switch.
⇒ When the thermal switch opens, error cannot be reset until cooling is complete.
⇒ Confirm continuity of thermal line.
⇒ Replace the harness or servo board as necessary.
⇒ Use the auto servo off function, AUX 91, to prevent the servo system holding a high
load arm position for extended periods.
_____________________________________________________________________
9-78 October 2, 2002


ERROR CODE -1503 Speed error jt-x.
Joint speed (motor speed) calculated using encoder values exceeds a regulated value.
In the Repeat mode: the regulated value is joint speed (motor speed) multiplied by 1.2.
In the Teach/Check modes: the regulated value is 250 mm/sec. multiplied 1.5, at the
equivalent radius position for a rotating joint or actual command value speed for joints
during a linear move.
This error is caused by the following abnormalities:

1. Disconnected motor power line U, V, and/or W phase, or defective power block.
2. Wiring error in motor power line and/or encoder line.
3. Disconnected encoder signal line, short circuit in encoder or encoder wiring, and/or
defective main body of the encoder.
4. Robot motion program causes a singularity.
5. Defect in the 1GB servo board and/or 1GB power block.
6. Moment of inertia exceeded the motor torque.
⇒ Check for disconnection, short circuit, and proper wiring. Replace the harness and
encoder if necessary.
⇒ Replace the servo unit.
⇒ Rewrite program teach data such as speed and position in the case of singularity
motion.
_____________________________________________________________________
October 2, 2002 9-79


ERROR CODE -1504 Position envelope error jt-x.

The difference between the current value from the encoder and the command value in
the AS software exceeded a regulated value which varies by robot model. Main causes
include singularity motion or the following abnormalities:
Mechanical -
1. The robot arm has contacted an external item hindering movement.
2. The harness is caught in the robot arm.
3. The decelerator, the gear, or the bearing are damaged.
4. Gear decelerator backlash is too narrow.
5. Payload weight exceeds robot specifications for capacity.
6. Robot motion pattern exceeds ratings of the motor.
7. Motor brake is not released.
Electrical-
1. Motor power line U, V, and W phase are disconnected.
(1GC↔power block↔X4/X5↔robot)
2. The brake line is disconnected or brake drive circuit is damaged.
(T1↔TB1↔V1↔XHY-CN1↔1HY↔XHY-CN2↔XGB-CN14↔1GB↔
XGB-CN6↔X5↔robot)
3. The power block is damaged.
5. Malfunction of the motor.
⇒ Check the decelerator, etc. for mechanical failure. Replace as necessary.

⇒ Re-teach robot motion as necessary.
⇒ Check the harness and servo unit for electrical malfunctions and replace if neces-
sary.
⇒ Correct the teach data in case of singularity motion.
Servo welding gun

The thickness of the workpiece at the weld point is greater than the thickness when the
point was taught. The thickness difference needed to set this error is approximately
10mm, depending on the gun type.
⇒ Inspect the workpiece; replace it if necessary.

⇒ Preform the software gun disconnect and connect procedure.
_____________________________________________________________________
9-80 May 21, 2003


ERROR CODE -1505 Velocity envelope error jt-x.
The robot’s current velocity is unable to keep up with the velocity command signal.
⇒ Refer to Error Code -1504: Position envelope error jt-x

_____________________________________________________________________
ERROR CODE -1506 Commanded speed error jt-x.
Unused.
_____________________________________________________________________
ERROR CODE -1507 Commanded acceleration error jt-x.
This error occurs when the amount of change of the positional command value sent to
the 1GB board from the 1GA/1HA board exceeds the value range.

⇒ Replace the 1HA board or 1GA and 1HZ (motherboard).
⇒ Reload software for the 1GB board and/or 1GA/1HA board.
Servo welding gun

After the cause of the error is corrected.
⇒ Perform the software gun disconnect and connect procedure.

_____________________________________________________________________
ERROR CODE -1510 Encoder harness broken jt-x.
The encoder signal is lost.

1. The machine signal or separate signal harness is damaged.
2. The +12 VDC or +5 VDC supply is not present at the 1FG board.
3. Defective 1GB or 1FG board
⇒ Replace damaged machine signal or separate signal harness.

⇒ Repair cause of +12 VDC or +5 VDC supply not present at the 1FG board.
⇒ Replace defective 1GB or 1FG board.
_____________________________________________________________________
May 21, 2003 9-81


ERROR CODE -1511 Encoder battery voltage low [Servo (A)].
Voltage of the encoder back up battery on the 1FG board decreased to 3.2 volts, or the
encoder battery alarm signal (BAL_AL) was disconnected. This error is only detected at
control power on or motor power on. This is caused by the following:
1. Discharged batteries.
2. Defective encoder battery board (1FG board).
3. Defective encoder.
4. Short in the harness from the encoder battery backup board to the encoder.
5. Battery discharge.
6. Defective servo board (1GB board).
This error is reported by servo board unit A.
⇒ Exchange the battery. There is a possibility that internal encoder data may be lost.
Check the robot zeroing.
⇒ Check each harness for short circuit.
⇒ Replace the encoder, the servo board, or the encoder battery backup board, if neces-
sary.
_____________________________________________________________________
ERROR CODE -1513 Encoder rotation data abnormal jt-x.
Occurs when there is a difference between the rotation data in the serial encoder data
and the calculated rotation data by incremental technique.
⇒ Check connections at encoder, 1FG board, and separation harness.

⇒ Check for noise and shield integrity.
⇒ Check connections, jumpers, and switches on 1GB board.
⇒ Check for continuity in the machine harness and separation harness.
⇒ Replace 1FG board.
⇒ Replace the encoder.
For additional information on error code -1513, see section 9.3.

_____________________________________________________________________
9-82 May 21, 2003


ERROR CODE -1516 Encoder data abnormal jt-x.
When control power is switched ON, the current encoder value is compared to the
stored encoder value when the power was turned OFF. If the difference is more than the
value set by AUX 43 Encoder Error Range, or the ENCCHK_DATA command, this error
occurs. Normal occurrence is due to the following:
1. Back up battery failure due to disconnection or discharged battery.
2. Control power was turned off during robot motion by an abnormal power supply, etc.,
causing the robot to stop in a position other than the last position memorized by the
AS software.
3. Motor replacement/encoder replacement.
4. Robot arm or motor operated by force when control power was off.
5. Robot was initialized.
⇒ Data may have been lost due to backup battery. See error -1511. Exchange the
battery. There is a possibility that internal encoder data may be lost. Check the robot
zeroing.
⇒ Check each harness for short circuit.
⇒ Replace the encoder, the servo board or the encoder battery backup board if neces-
sary.
_____________________________________________________________________
ERROR CODE -1517 Cannot read initial data encoder jt-x.

Immediately after control power on, steady encoder data was not able to be read. This
error is caused by a disconnected encoder signal line or a short circuit, or a defect in the
main body of the encoder.
⇒ Check for disconnection or short circuit for encoder signal line.

⇒ Replace the encoder.
⇒ Replace the servo board (1GB board).
Servo welding gun

If the gun is in the software disconnect state, the encoder data is abnormal, or the gun
is not connected (un-chucked), this error is displayed.
If the gun is disconnected from the tool changer, without performing a software discon-
nect, this error is displayed.
⇒ Inspect the gun axis encoder harness for damage and repair or replace as necessary.
⇒ Replace the gun axis encoder.
⇒ Perform the software gun disconnect and connect procedure and cycle the controller
power (OFF/ON).
_____________________________________________________________________
May 21, 2003 9-83


ERROR CODE -1518 Miscount of encoder data jt*.
This error occurs when the encoder data at controller power-up is different than the
encoder data when the controller powered down. If an axis is moved while the controller
power is OFF this error occurs. Defective encoder.
⇒ Replace encoder.
Servo welding gun

The servo gun or tool changer harness is defective.
⇒ Clean tool changer contacts.

⇒ Inspect the servo gun and tool changer harnesses; replace if necessary.
_____________________________________________________________________
ERROR CODE -1521 Mismatch ABS and INC encoder of jt-x.
Occurs when there is a large difference between the value in the serial encoder data
and the data calculated by incremental technique.
⇒ Replace encoder, replace 1GB board.


_____________________________________________________________________
ERROR CODE -1524 Encoder line error of jt-x.
Not used.
_____________________________________________________________________
9-84 May 21, 2003


ERROR CODE -1550 Encoder initialize error jt-x.
The encoder is not able to fix the absolute position at control power on. The scanning of
absolute data is begun immediately after a shift from the state of non-operation or back-
up operation to normal encoder operation. BUSY=1 is output until the absolute position
has been determined.
⇒ In the case of a conveyor encoder, ensure power-up speed is below 300 RPM.
⇒ Check connections at encoder, 1FG board, jumpers, and switches on 1GB board.
⇒ Replace encoder, replace 1GB board, replace 1FG board.

_____________________________________________________________________
ERROR CODE -1553 Encoder response error jt-x.

Occurs when the encoder does not respond to data request signal from the 1GB board.

⇒ Check for noise malfunction and shield integrity.
Servo welding gun

The servo gun or tool changer harness is defective.
⇒ Clean tool changer contacts.

⇒ Inspect the servo gun and tool changer harnesses; replace if necessary.

_____________________________________________________________________
May 21, 2003 9-85


ERROR CODE -1554 Encoder communication error jt-x.
Occurs when the encoder serial data is not correctly transmitted according to communi-
cation protocol.


_____________________________________________________________________
ERROR CODE -1555 Encoder data conversion error jt-x.
Occurs when the M-code data from the encoder has an error pattern.

⇒ Check connections, jumpers and switches on 1GB board.

_____________________________________________________________________
ERROR CODE -1556 Encoder ABS-track error jt-x.
The absolute data and the incremental data in the encoder are different. ABSALM=1 is
output from the encoder when this error occurs.

⇒ Check connections, jumpers and switches on 1GB board.

_____________________________________________________________________
9-86 May 21, 2003


ERROR CODE -1557 Encoder INC-pulse error jt-x.
Occurs when the encoder A and B incremental pulses are abnormal. The encoder
INALM bit sent with the serial data=1.


_____________________________________________________________________
ERROR CODE -1558 Encoder MR-sensor error jt-x.
The state of the MR sensor in the encoder does not match with JT ENCODER in one
rotation.
⇒ Replace the encoder harness.

_____________________________________________________________________
ERROR CODE -1559 Power module error jt-x.
An error signal from the IPM module in the power block was detected. This error may be
caused by:
1. Short-circuit of the motor power line U, V, and W phase.
2. Defect in the power block.
4. Defective cooling fan in the servo unit.
5. Defect in the harness between the servo board and the power blocks.
(XGB-CN12↔XGC/XGD-CN8, XGB-CN13↔XGC/XGD-CN9)
⇒ Check for short circuit in the motor harness and replace if necessary.
⇒ Replace the servo unit.
⇒ Refer to the “Quick Reference Troubleshooting Guide” for additional information.
_____________________________________________________________________
February 8, 2005 9-87


ERROR CODE -1561 Current sensor disconnect [Servo (x)].
The current sensor cable between the servo board and the power blocks is not con-
nected. The x indicates the servo board unit reporting the error. Check the following
harnesses as indicated below.
Unit A - 1GB-CN9↔power block CN1, CN2 CN3.

Unit B - 1GB-CN10↔power block CN4, CN5, CN6.
Unit C - 1GB-CN11↔power block CN7.
This error may be caused by a defect in the 1GB board.
⇒ Check connection and continuity in the current sensor cable between the 1GB board
and the power block. (XGB-CN9↔XGB-CN10)
⇒ Replace the 1GB board if necessary.
_____________________________________________________________________
ERROR CODE -1563 Servo unit 12V DC error [Servo (A)].
The +/-12V supply to the 1GB board is below specified limits of +10.75V and -10.4V.
This error may be caused by a defect in the harness between the 1GB board (XGB-
CN8), the mother board (XHZ-CN2) and the AVR, or a defect in the 1GB board. This
error is reported by servo board unit A.
⇒ Check the voltage and replace the 1GB board and the AVR as necessary.
_____________________________________________________________________
ERROR CODE -1567 Regenerative resistor error [Servo (A)].
Current was sent to regenerative resistors for six or more consecutive seconds. Main
causes include:
1. Abrupt direction changes at high speed.
2. Burned out resistors or defective power block.
3. Defect in the servo board (1GB board).
4. Defective connection or harness between the servo board and the power block
(1GB-CN13 ⇔ power block CN9).
5. Defect in the optional second regenerative resistance unit (when used).
⇒ Avoid abrupt high speed direction changes. Change accuracy, speed, add points.
⇒ Install optional second regenerative resistance unit.
_____________________________________________________________________
9-88 May 21, 2003


ERROR CODE -1568 Servo unit P-N low voltage [Servo (A)].
The voltage between P-N supplied to the power block is 60VDC or less at servo on.
1. Defect of K1, K2, K3.
2. Defect in the relay board (1FY/1HY board).
3. Defect in the power sequence board (1FP/1HP board).
4. Defect in the power unit.
6. Defect in the motor power circuit (diode bridge, K3, etc).
7. Defect in Circuit breaker F2 or F2 is in the OFF position.
8. Defect in the harness between the operation unit and the servo units or the connec-
tions.
⇒ Check the motor power circuit and the equipment, replace as necessary.
⇒ Check the power sequence board, the relay board ,and the servo unit, and replace as
necessary.
_____________________________________________________________________
ERROR CODE -1569 Servo unit P-N- high voltage [Servo (A)].
The voltage between P-N supplied to the power block exceeded 410 VDC. This error is
caused by:
1. Defect in regenerative resistance control circuit, overheat failure of regenerative
resistance unit, defect in the voltage monitoring circuit, or defect in the power block.
2. Defect of servo board (1GB board)
3. Defect in the regenerative resistance unit.
4. Defect in the servo board (1GB board).
5. High inertia loads due to tool weight or program data.
⇒ Reteach program steps to eliminate sudden high speed direction changes (dynamic
shock).
⇒ Replace the servo unit and the regenerative unit.
⇒ Add the second regenerative resistor unit.
_____________________________________________________________________
May 21, 2003 9-89


ERROR CODE -1570 Regenerative resistor over-heat [Servo (A)] or controller

hot.
The thermal switch for the power block regenerative resistor unit, or the optional regen-
erative resistor unit reached 140° C (284°F), or the heat sink thermal switch reached
90°C (194°F), or the controller cabinet thermal switch reached 70° C (158° F). This
error is reported by servo board unit A.
⇒ Defective cooling fans.

⇒ Insufficient clearance for air circulation.
⇒ Power block connecter X5-SA disconnected, or defect in the wiring harness to the
controller cabinet thermal switch, or to the optional regenerative resistor unit.
⇒ High inertia loads.
⇒ High ambient controller temperature.
⇒ Defective power block.
⇒ Defective regenerating resistor unit.
⇒ Defective 1GB board.
⇒ Defect in the following harnesses: 1GB-CN13↔power block CN9,
1GC-CN21↔optional regenerative resistor unit.
_____________________________________________________________________
ERROR CODE -1600 Uncoincidence error jt-x.
During the execution of a program, all joints must reach total coincidence within a given
accuracy and time (approx. 5 seconds) This error occurs if the difference between the
designated value and current value exceeds the established accuracy. Typical causes
are listed below.
Mechanical-
1. Damaged bearings.
2. Insufficient gear backlash.
3. Motor brake not released.
4. Arm movement restricted by harnesses or peripheral devices.
Electrical-
1. Defective servo board (1GB board).
2. Defective power block.
3. Disconnected motor power or brake lines.
4. Defective encoder or encoder harness.
Program data-
1. Wrist positions at the beginning and end of a path that utilize the same XYZ coordi-
nate.
⇒ Repair mechanical or electrical failures.

⇒ Check interference from external devices.
⇒ Modify taught wrist positions as required.
_____________________________________________________________________
9-90 May 21, 2003

ERROR CODE -1601 Limit switch of joint-x is ON.
This error occurs when the software can specify the axis that has caused the over travel
condition. If the joint number cannot be specified, ERROR CODE 1602 Limit switch is
broken, is displayed. Main causes include:
1. Software limits are set incorrectly.
2. Axis was moved using the manual brake release and the limit switch was turned ON.
3. The limit switch was turned ON by overshoot from inertia.
⇒ Check and exchange the harness and the limit switch.

⇒ Set the software limits to an appropriate value.
⇒ Change the installation angle of the axis restriction limit switch to an appropriate
value.
⇒ Replace the power sequence board if necessary.
_____________________________________________________________________
ERROR CODE -1602 Limit switch signal line is broken.
This error occurs when the software cannot specify the axis that has caused the over
travel condition. If the joint number can be identified, the “ERROR CODE 1601 Limit
switch of jt-x is ON.”
⇒ Set the software limits to an appropriate value.

⇒ Change the installation angle of the axis restriction limit switch to an appropriate
value.
⇒ Check harness and limit switch and replace as necessary.
⇒ Check the power sequence board and replace if necessary.
_____________________________________________________________________
ERROR CODE -1610 Torch is interfered.
The limit switch for torch interference detection has been tripped.
⇒ Move the robot away from the interference to close the limit switch. Inspect the torch
for damage.
⇒ Determine the cause of the interference before continuing operation.
_____________________________________________________________________
May 21, 2003 9-91


ERROR CODE -1735 GROUP is not primed.
The GROUP instruction is not programmed before a motion instruction, with external
axis system.
⇒ This error occurs if the program is interrupted after a GROUP instruction and before
the motion commands pertaining to the GROUP instruction are complete. When
restarting the program prime the program before the GROUP instruction.
⇒ In check mode, if the GROUP instruction is used, start checking before the GROUP
instruction.
_____________________________________________________________________
ERROR CODE -1800 AC primary power off.
This error occurs when there is an instantaneous decrease in the primary power to the
AVR for control power supply (AC130-145V or less for 20-30 msec from 0 phase). The
main causes for this error are:
1. NFB for the control power supply was turned OFF.
2. AC200/220V supplied to AVR for the control power supply caused the instantaneous
decrease.
3. Defective AVR for control power supply.
4. Defective NFB for control power supply or NFB tripped.
5. Defect in the primary power supply.
6. Defective power sequence board.
7. Defect in the relay board.
⇒ It is normal for this error to occur when NFB for control power supply is turned OFF.
⇒ Check power supply circuit in AVR for the control power supply and NFB.
⇒ Confirm that primary power is supplied according to specifications.
_____________________________________________________________________
9-92 May 21, 2003


ERROR CODE -1801 24VDC power source is low.
24VDC to the power sequence board has dropped below 21.6V. Main causes include
the following abnormalities:
1. Defect in the AVR for control power supply.
3. Defect in the relay board.
4. Short circuit in the motor power on circuitry, the EMERGENCY STOP switch and axis
restriction limit switch circuits.
5. Short in machine valve and sensor circuits.
⇒ Check the power supply, machine valve, and the sensor circuits for short circuits.
⇒ Check the AVR, the power sequence board, and the relay board and replace as
necessary.
_____________________________________________________________________
ERROR CODE -1802 Primary power source is high.
Voltage level of the AVR for the control power supply was too high (AC2667-277V or
more for 1-2 sec.). The main causes of this error include a defect in the AVR, the power
sequence board, the relay board or the power supply circuit.
⇒ Verify the power supply to the controller are within ratings.

⇒ Check power supply circuit to the AVR.
⇒ Confirm the supply power is within specifications.
⇒ Confirm transformer tap settings are correct.
_____________________________________________________________________
ERROR CODE -1803 Primary power source is low.
Voltage level of the AVR for the control power supply was too low (AC150-158V or less
for 1-2 sec.). The main causes of this error include an instantaneous drop in the power
supply; a defect in the AVR or NFB, the power sequence board, the relay board or the
power supply circuit.
⇒ Verify the power supply to the controller is within ratings.

⇒ Check the AVR and NFB.
⇒ Confirm supply power is within specifications.
⇒ Confirm transformer tap settings are correct.
_____________________________________________________________________
May 21, 2003 9-93


ERROR CODE -1804 5 VDC or ± 12 VDC is abnormal.
5 VDC or +/-12 VDC supplied to the 1GA board is out of specifications.

+5 VDC: less than +4.85 VDC - more than +5.45 VDC
+12 VDC: +10.75 VDC or less
-12 VDC: -10.4 VDC or more
1. Defective DC power supply.
2. Defective 1GA board.
3. Power supply contacts in the mother board are bad.
4. Defective MFP, small teach pendant, or harness.
5. Defective servo board or power block.
6. Defective 1FG board.
7. Short in the harness between the servo unit and the 1FG board.
8. Short in the optional circuit boards, i.e., vision, etc.
9. Insufficient DC power supply capacity to support optional boards.
⇒ Replace the AVR and each board for the control power supply.
⇒ Check for short circuits in the MFP, the operation panel, and separation harness and
replace as necessary.
_____________________________________________________________________
ERROR CODE -1805 Memory is locked because of AC_FAIL.
The memory was accessed during the controller shut down due to a power supply
abnormality (ACFAIL).
⇒ Cycle the controller power OFF and ON.

_____________________________________________________________________
ERROR CODE -1915 GUN TIP CHANGE OVER THE LIMIT.
This error occurs when the tip wear measurement exceeds the permitted value set in
AUX 114-48.
⇒ Ensure the tip wear measurement is executed after the welding tips are replaced.
⇒ Ensure the permitted value in AUX 114-48 is correct.
_____________________________________________________________________
9-94 May 21, 2003


ERROR CODE -2100 Explosion-proof TP is not connected.
A communication board (1GS board) for the explosion-proof teach pendant is not in-
stalled on the main CPU board (1HA board).

1. 1GS board not installed.
2. Defective 1GS board.
3. Defective 1HA board.
⇒ If not installed, install a 1GS board to the 1HA board.

⇒ Replace the 1GS board (if installed).
⇒ Replace the 1HA board.
_____________________________________________________________________
ERROR CODE -2170 Internal pressure sensor error.
This error occurs when inner pressure drops after purging cycle is complete.

Mechanical:
1. The air hose is disconnected.
2. The air supply is stopped.
3. The pressure inside the pressurized enclosure drops due to air leakage.
4. Defective pressure switch.
Electrical:
1. The signal wiring for the pressure switch is disconnected.
2. A harness connector for circuit boards is disconnected.
3. Defective I/O board (1GW board).
4. Defective power sequence board (1HP board).
5. Defective back plane board for inner pressure barrier (1LU board).
6. Defective MTL barrier ZB1, ZB2, ZB3 (MTL4728+).
⇒ Repair cause of pressure leak in pressurized enclosure.

⇒ Repair disconnected and or lose connectors.
⇒ Replace harnesses or connectors as necessary.
⇒ Replace defective board(s) (1GW, 1HP, 1LU board).
_____________________________________________________________________
May 21, 2003 9-95


ERROR CODE -2171 Lacks of air flux.
This error occurs when the flow rate switch is turned OFF due to insufficient flow rate
(the flow rate switch monitors flow rate during purging).

Mechanical:
4. Defective flow rate switch.
5. Defective purging valve.
6. Defective purging electromagnetic valve (solenoid valve).
Electrical:
1. The flow rate switch is disconnected.
⇒ Repair air hose disconnected.

⇒ Replace defective flow rate switch, purging valve, or purging solenoid valve.
_____________________________________________________________________
9-96 May 21, 2003


ERROR CODE -2172 Internal pressure low.
This error occurs when the inner pressure drops during purging.

Mechanical:
4. Defective pressure switch.
Electrical:
1. The pressure switch is disconnected.
⇒ Repair air hose disconnected.

⇒ Replace defective pressure switch.
_____________________________________________________________________
May 21, 2003 9-97


ERROR CODE -2173 Illegal barrier unit setting.
This error occurs when the jumper pin (JP1) for selecting I/O base board on the back
plane board (1LU board) for the inner pressure barrier is set incorrectly.

1. The jumper pin JP1 is set incorrectly on the back plane board (1LU board) for the
inner pressure barrier.
2. A harness connector for circuit boards is disconnected (CN3 on the 1GW board).
5. Defective 1GB board.
⇒ Repair jumper set incorrectly (set JP1 on the 1LU board correctly, all set at B-C with
1GW board installed).
⇒ Replace defective board(s) (1GW, 1HP, 1GB, 1LU board).
_____________________________________________________________________
ERROR CODE -2174 Communication board to explosion-proof teach pendant

watch-dog error.
This error occurs when the CPU on the communication board (1GS board) for the explo-
sion-proof teach pendant is suspended.

1. Defective communication board (1GS board).
2. Defective main CPU board (1HA board).

⇒ Replace defective 1HA board.
_____________________________________________________________________
9-98 May 21, 2003


9.3 TROUBLESHOOTING FLOWCHARTS
The following flowcharts are arranged in the numerical order of the error code. Refer
also to the corresponding error code information in section 9.2 during troubleshooting
procedures.
May 21, 2003 9-99


Error 1513
Does this
error occur just Follow
Yes troubleshooting
after resetting error
1553, 1554, or flowchart for each
1555? error
No
Replace encoder
Yes
Does No
problem still END
exist?
Yes
Replace 1GB board
Does
No
problem still END
exist?
Yes
Check connections at the

encoder connector
Check connections on the

1FG board
Check connections in the

separation harness
Check connections, jumpers, and

switches on the 1GB board
Figure 9-3 Error 1513 Flowchart (1)
9-100 May 21, 2003


Does No
problem still END
exist?
Yes
Check inside
machine harness
and separation
harness
Does No
problem still END
exist?
Yes
Replace 1FG board
Does No
problem still END
exist?
Yes
Service call
May 21, 2003 9-101


Error 1521
Does this
error occur just Follow
Yes troubleshooting
after resetting error
1553, 1554, or flowchart for each
1555? error
No
No
Replace encoder END
Yes
Does
problem still
exist?
Yes
Replace 1GB board
Does
No
problem still END
exist?
Yes

encoder connector

1FG board

separation harness

9-102 May 21, 2003


Does No
problem still END
exist?
Yes
Check inside
machine harness
and separation
harness
Does No
problem still END
exist?
Yes
Replace 1FG board
Does No
problem still END
exist?
Yes
Service call
May 21, 2003 9-103


Error 1550
Does the
Reduce conveyor
encoder revolve over
Yes encoder revolution
300 RPM?
speed under 300
(Case of conveyor
RPM at power-up
encoder)
No END
encoder connector

1FG board

separation harness

Does No
problem still END
exist?
Yes
Replace encoder
Does No
problem still END
exist?
Yes
9-104 May 21, 2003


Replace 1GB board
Does No
problem still END
exist?
Yes
Replace 1FG board
Does No
problem still END
exist?
Yes
Check machine
harness and
separation harness
Does No
problem still END
exist?
Yes
Service call
May 21, 2003 9-105


Error 1553
Retry robot
Can you reset Yes program execution
the error? or manual
operation carefully
No
Check connections at the Yes Does the error

encoder connector reoccur?
No
1FG board
END

separation harness

Check and repair or replace servo weld

gun encoder harness as necessary
Does No
problem still END
exist?
Yes
Replace encoder
Does No
problem still END
exist?
Yes
9-106 May 21, 2003


Replace 1GB board
Does No
problem still END
exist?
Yes
Check machine
harness and
separation harness
Does No
problem still END
exist?
Yes
Replace 1FG board
Does No
problem still END
exist?
Yes
Service call
May 21, 2003 9-107


Error 1554
Retry robot
operation carefully
No
Check connections at the Yes Does the error

encoder connector reoccur?
No
1FG board
END

separation harness

Does No
problem still END
exist?
Yes
Replace encoder
Does No
problem still END
exist?
Yes
9-108 May 21, 2003


Replace 1GB board
Does No
problem still END
exist?
Yes
Check machine
harness and
separation harness
Does No
problem still END
exist?
Yes
Replace 1FG board
Does No
problem still END
exist?
Yes
Service call
May 21, 2003 9-109


Error 1555
Retry robot
operation carefully
No
Replace encoder Yes Does the error

reoccur?
Yes
No
Does No
problem still END
exist?
Yes
Replace 1GB board
Does
No
problem still END
exist?
Yes

encoder connector

1FG board

separation harness

9-110 May 21, 2003


Does No
problem still END
exist?
Yes
Check inside
machine harness
and separation
harness
Does No
problem still END
exist?
Yes
Replace 1FG board
Does No
problem still END
exist?
Yes
Service call
May 21, 2003 9-111


Error 1556
Replace encoder
Does No
problem still END
exist?
Yes
Replace 1GB board
Does
No
problem still END
exist?
Yes
encoder connector

1FG board

separation harness

Does
No
problem still END
exist?
Yes
9-112 May 21, 2003


Check inside
machine harness
and separation
harness
Does No
problem still END
exist?
Yes
Replace 1FG board
Does No
problem still END
exist?
Yes
Service call
May 21, 2003 9-113


Error 1557
Replace encoder
Does No
problem still END
exist?
Yes
Replace 1GB board
Does
No
problem still END
exist?
Yes
encoder connector

1FG board

separation harness

Does
No
problem still END
exist?
Yes
9-114 May 21, 2003


Does No
problem still END
exist?
Yes
Check inside
machine harness
and separation
harness
Does No
problem still END
exist?
Yes
Replace 1FG board
Does No
problem still END
exist?
Yes
Service call
May 21, 2003 9-115


APPENDIX
A.0 APPENDIX .................................................................................................... A-2

A.1 Setting of Tool Dimensions............................................................................. A-2
A.2 Conversion Tables .......................................................................................... A-5
A.2.1 Conversion from Fractional Inches to Millimeters .......................................... A-6
A.2.2 Conversion from Millimeters to Inches ........................................................... A-7
A.2.3 Conversion from Inches to Millimeters ........................................................... A-8
A.2.4 How to Use Conversion Tables ...................................................................... A-9
A.2.5 Conversion of Inch-Pounds to/from Inch-Ounces ........................................ A-10
A.2.6 Conversion of Foot-Pounds to/from Inch-Pounds ........................................ A-11
A.2.7 Conversion of Inch-Pounds to/from Kilogram-Centimeters .......................... A-12
A.2.8 Conversion of Foot-Pounds to/from Kilogram-Meters .................................. A-13
A.2.9 Conversion of Foot-Pounds to/from Newton-Meters .................................... A-14
A.2.10 Conversion of Inch-Pounds to/from Newton-Meters .................................... A-15
A.2.11 Conversion of Kilogram-Meters to/from Newton-Meters .............................. A-16
A.3 Standard Torque Tables ............................................................................... A-17
A.4 Joint 1 - Axis Control .................................................................................... A-21
A.4.1 UX100/120/150 Robot Model ...................................................................... A-21
A.5 Charts and Forms for Checks and Lubrication ............................................ A-23
A.6 TB2 Dedicated Signal Pin Assignments ...................................................... A-25
A.7 Interface Panels ........................................................................................... A-26
A.7.1 Material Handling Interface Panel (Option) .................................................. A-26
A.7.2 Spot Welding Interface Panel (Option) ......................................................... A-27
A.8 Special Tools ................................................................................................ A-28
January 9, 2004 A-1


APPENDIX
A.0 APPENDIX
A.1 SETTING OF TOOL DIMENSIONS
AUX Function 48 - Tool Dimensions, shown in figure A-1, allows the user to set and
store tool dimensions and coordinate system orientation parameters for one to nine
different end effectors.
Changes in the X, Y, and Z directions are in millimeters, with a range of ±10,000 mm,
measured in tenths of a millimeter (0.1 mm).
Changes in the O, A, and T tool coordinate rotation angles are measured in degrees,
with a range of ±180°, measured in tenths of a degree (0.1°).
AUX 48 TOOL DIMENSIONS

TOOL 1
X DIRECTION 0.0mm
Y DIRECTION 0.0mm
Z DIRECTION 0.0mm
O ROTATION 0.0deg
A ROTATION 0.0deg
T ROTATION 0.0deg
WEIGHT OF LOAD 120.0kg
X POSITION OF LOAD 0.0mm
Y POSITION OF LOAD 0.0mm
Z POSITION OF LOAD 0.0mm
F1 F2 F3 F4
PRE DATA NEXT PG
Figure A-1 AUX Function 48 - Tool Dimensions
A-2 April 13, 2000


APPENDIX
The base and tool coordinate systems shown in figure A-2 show the standard orienta-
tion and origin of each coordinate system. The tool coordinate system is rotated,
through system software, from the base coordinate orientation by using the O, A, and T
angles of 90°, 90°, and -90° respectively.
For this reason, the robot location is shown as having O, A, and T angles of 90°, 90°,
and –90° when the wrist is in a straight or zero position, and the tool dimension is setup
with O, A, and T angles of 0°, 0°, and 0°.
The tool coordinate system is rotated into other orientations by defining the proper O, A,
and T angles. Typically this is done so that the "Z" tool coordinate axis is aligned in the
direction of the tool.
X
Y
Tool Coordinate System
X, Y, Z, O, A, T = 0, 0, 0, 0, 0, 0
Y
Base Coordinate System
X, Y, Z, O, A, T = 0, 0, 0, 0, 0, 0
Figure A-2 Robot Coordinate Systems
April 13, 2000 A-3


APPENDIX
Figure A-3 shows the rotation of the tool coordinate system in its standard orientation
from the base coordinate system orientation, with the values O = 90°, A = 90°, and T = -
90°. This standard orientation is displayed as O = 0°, A = 0°, and T = 0° on the tool
dimension setup screens (AUX function 48).
To properly specify the OAT angles, the tool coordinate system axes must be rotated in
the correct order, beginning with the O angle, then the A angle, and finally the T angle.
O - Turning angle around the Z-axis

A - Turning angle around the Y-axis after O has been specified
T - Turning angle around the Z-axis after O and A have been specified.
1 Defining O=90 2 Defining A=90 3 Defining T=-90
Z Z
Y Y
+ -
+
+
-
Y X Z
-
X
X
O - Defined A - Defined T - Defined

Z
Y Y
X Z Z
X
X Y
Figure A-3 Orientation of XYZ and OAT
A-4 April 13, 2000


APPENDIX
A.2 CONVERSION TABLES
Table A-1 Common Conversion Factors

Prefixes for Units: Units of Length:
Prefix Symbol Power m x 3.281 = feet
mega M x 1,000,000 m x 39.37 = inches
kilo k x 1,000 mm x 0.03937 = inches
centi c x 0.01 inch x 25.40 = mm
milli c x 0.01 km x 0.6214 = miles
micro µ x 0.000001
Units of Torque:
Units of Mass: N-m x 0.1020 = kg-m
kg x 2.205 = lb N-m x 0.7375 = ft-lb
g x 0.03527 = oz. (US) N-m x 8.851 = in-lb
kg-m x 9.807 = N-m

Units of Volume:
kg-m x 7.233 = ft-lb
l x 0.2642 = gal. (US)
kg-m x 86.80 = in-lb
l x 0.2200 = gal. (Imp.)
l x 1.057 = qt. (US) Units of Pressure:

l x 0.8799 = qt. (Imp.) kPa x 0.01020 = kg/cm²
l x 2.113 = pint (US) kPa x 0.1450 = PSI
l x 1.816 = pint (Imp.) kPa x 0.7501 = cm-Hg
ml x 0.03381 = oz. (US) kg/cm2 x 98.07 = kPa

2
ml x 0.02816 = oz. (Imp.) kg/cm x 14.22 = PSI
ml x 0.06102 = cu. in. cm-Hg x 1.333 = kPA
Units of Force: Units of Power:

N x 0.1020 = kg kW x 1.360 = PS
N x 0.2248 = lb kW x 1.341 = HP
kg x 9.807 = N PS x 0.7355 = kW
kg x 2.205 = lb PS x 0.9863 = HP
Units of Temperature:
9 x (°C) 5 x (°F – 32)
+ 32 = °F = °C
5 9
°F °F
-4 32 68 104 176 212 248 284
-40 -20 0 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320
-40 -20 0 20 40 60 80 100 120 140 160

-17.8 4.4 26.7 48.9 71.1 93.3 115.6 137.8
°C °C
April 13, 2000 A-5


APPENDIX
A.2.1 CONVERSION FROM FRACTIONAL INCHES TO MILLIMETERS
Table A-2 Conversion from Fractional Inches to Millimeters
Inch mm Inch mm Inch mm

1/64 0.015625 0.396875 25/64 0.390625 9.921875 49/64 0.765625 19.446875
1/32 0.031250 0.793750 13/32 0.406250 10.318750 25/32 0.781250 19.843750
3/64 0.468750 1.190625 27/64 0.412875 10.715625 51/64 0.793875 20.240625
1/16 0.062500 1.587500 7/16 0.437500 11.112500 13/16 0.812500 20.637500
5/64 0.078125 1.984375 29/64 0.453125 11.509375 53/64 0.828125 21.034375

3/32 0.093750 2.381250 15/32 0.468750 11.906250 27/32 0.843750 21.431250
7/64 0.109375 2.778125 31/64 0.484375 12.303125 55/64 0.859375 21.828125
1/8 0.125000 3.175000 1/2 0.500000 12.700000 7/8 0.875000 22.225000
9/64 0.140625 3.571875 33/64 0.515625 13.096875 57/64 0.890625 22.621875

5/32 0.156250 3.968750 17/32 0.531250 13.493750 29/32 0.906250 23.018750
11/64 0.171875 4.365625 35/64 0.546875 13.890625 59/64 0.921875 23.415625
3/16 0.187500 4.762500 9/16 0.562500 14.287500 15/16 0.937500 23.812500
13/64 0.203125 5.159375 37/64 0.578125 14.684375 61/64 0.953125 24.209375

7/32 0.281750 5.556250 19/32 0.593750 15.081250 31/32 0.968750 24.606250
15/64 0.234375 5.953125 39/64 0.609375 15.478125 63/64 0.984375 25.003125
1/4 0.250000 6.350000 5/8 0.625000 15.875000 1 1.000000 25.400000
17/64 0.265625 6.746875 41/64 0.640625 16.271875

9/32 0.218250 7.143750 21/32 0.656250 16.668750
19/64 0.296875 7.540625 43/64 0.671875 17.065625
5/16 0.312500 7.937500 11/16 0.687500 17.462500
21/64 0.328125 8.334375 45/64 0.703125 17.859375

11/32 0.343750 8.731250 23/32 0.718750 18.256250
23/64 0.359375 9.128125 47/64 0.734375 18.653125
3/8 0.375000 9.525000 3/4 0.750000 19.050000
Note: All values are exact.
A-6 April 13, 2000


APPENDIX
A.2.2 CONVERSION FROM MILLIMETERS TO INCHES
Table A-3 Conversion from Millimeters to Inches
mm Inch mm Inch mm Inch mm Inch

1 0.0394 26 1.0236 51 2.0079 76 2.9921
2 0.0787 27 1.0630 52 2.0472 77 3.0315
3 0.1181 28 1.1024 53 2.0866 78 3.0709
4 0.1575 29 1.1417 54 2.1260 79 3.1102
5 0.1969 30 1.1811 55 2.1654 80 3.1496
6 0.2362 31 1.2205 56 2.2047 81 3.1890

7 0.2756 32 1.2598 57 2.2441 82 3.2283
8 0.3150 33 1.2992 58 2.2835 83 3.2677
9 0.3543 34 1.3386 59 2.3228 84 3.3071
10 0.3937 35 1.3780 60 2.3622 85 3.3465
11 0.4331 36 1.4173 61 2.4016 86 3.3858

12 0.4724 37 1.4567 62 2.4409 87 3.4252
13 0.5118 38 1.4961 63 2.4803 88 3.4646
14 0.5512 39 1.5354 64 2.5197 89 3.5039
15 0.5906 40 1.5748 65 2.5591 90 3.5433
16 0.6299 41 1.6142 66 2.5984 91 3.5827

17 0.6693 42 1.6535 67 2.6378 92 3.6220
18 0.7087 43 1.6929 68 2.6772 93 3.6614
19 0.7480 44 1.7323 69 2.7165 94 3.7008
20 0.7874 45 1.7717 70 2.7559 95 3.7402
21 0.8268 46 1.8110 71 2.7953 96 3.7795

22 0.8661 47 1.8504 72 2.8346 97 3.8189
23 0.9055 48 1.8898 73 2.8740 98 3.8583
24 0.9449 49 1.9291 74 2.9134 99 3.8976
25 0.9843 50 1.9685 75 2.9528 100 3.9370
Note: Inch values are rounded off.
April 13, 2000 A-7


APPENDIX
A.2.3 CONVERSION FROM INCHES TO MILLIMETERS
Table A-4 Conversion from Inches to Millimeters
Inches mm Inches mm Inches mm Inches mm

1 25.4 26 660.4 51 1295.4 76 1930.4
2 50.8 27 685.8 52 1320.8 77 1955.8
3 76.2 28 711.2 53 1346.2 78 1981.2
4 101.6 29 736.6 54 1371.6 79 2006.6
5 127.0 30 762.0 55 1397.0 80 2032.0
6 152.4 31 787.4 56 1422.4 81 2057.4

7 177.8 32 812.8 57 1447.8 82 2082.8
8 203.2 33 838.2 58 1473.2 83 2108.2
9 228.6 34 863.6 59 1498.6 84 2133.6
10 254.0 35 889.0 60 1524.0 85 2159.0
11 279.4 36 914.4 61 1549.4 86 2184.4

12 304.8 37 939.8 62 1574.8 87 2209.8
13 330.2 38 965.2 63 1600.2 88 2235.2
14 355.6 39 990.6 64 1625.6 89 2260.6
15 381.0 40 1016.0 65 1651.0 90 2286.0
16 406.4 41 1041.4 66 1676.4 91 2311.4

17 431.8 42 1066.8 67 1707.8 92 2336.8
18 457.2 43 1092.2 68 1727.2 93 2362.2
19 482.6 44 1117.6 69 1752.6 94 2387.6
20 508.0 45 1143.0 70 1778.0 95 2413.0
21 533.4 46 1168.4 71 1803.4 96 2438.4

22 558.8 47 1193.8 72 1828.8 97 2463.8
23 584.2 48 1219.2 73 1854.2 98 2489.2
24 609.6 49 1244.6 74 1879.6 99 2514.6
25 635.0 50 1270.0 75 1905.0 100 2540.0
Note: Millimeter values are rounded off.
A-8 April 13, 2000


APPENDIX
A.2.4 HOW TO USE CONVERSION TABLES
The chart below is used to convert foot-pounds (ft-lb) to kilogram-meters (kg-m). The ft-
lb column at the left increases in 10 ft-lb increments from 0 to 110 ft-lb. For each addi-
tional ft-lb, read the top row of numbers.
For example, to convert 45 ft-lb to kg-m, look for the number 40 in the left column, and
the number 5 in the top row. The conversion factor from ft-lb to kg-m is 6.224.
The conversion formula used is: kg-m = ft-lb x 0.1383.
Table A-5 Sample Conversion (from ft-lb to kg-m)
FOOT-POUNDS TO KILOGRAM-METERS
0 1 2 3 4 5 6 7 8 9
ft-lb kg-m kg-m kg-m kg-m kg-m kg-m kg-m kg-m kg-m kg-m
0 0.000 0.138 0.277 0.415 0.553 0.692 0.830 0.968 1.106 1.245
10 1.383 1.521 1.660 1.798 1.936 2.075 2.213 2.351 2.489 2.628
20 2.766 2.904 3.043 3.181 3.319 3.458 3.596 3.734 3.872 4.011
30 4.149 4.287 4.426 4.564 4.702 4.841 4.979 5.117 5.255 5.394
40 5.532 5.670 5.809 5.947 6.085 6.224 6.362 6.500 6.638 6.777
50 6.915 7.053 7.192 7.330 7.468 7.607 7.745 7.883 8.021 8.160
60 8.298 8.436 8.575 8.713 8.851 8.990 9.128 9.266 9.404 9.543
70 9.681 9.819 9.958 10.096 10.234 10.373 10.511 10.649 10.787 10.926
80 11.064 11.202 11.341 11.479 11.617 11.756 11.894 12.032 12.170 12.309
90 12.447 12.585 12.724 12.862 13.000 13.139 13.277 13.415 13.553 13.692
100 13.830 13.968 14.107 14.245 14.383 14.522 14.660 14.798 14.936 15.075
110 15.213 15.351 15.490 15.628 15.766 15.905 16.043 16.181 16.319 16.458
kg-m = ft-lb x 0.1383
April 13, 2000 A-9


APPENDIX
A.2.5 CONVERSION OF INCH-POUNDS TO/FROM INCH-OUNCES
Table A-6 Conversion from Inch-Pounds to Inch-Ounces
INCH-POUNDS TO INCH-OUNCES
0 1 2 3 4 5 6 7 8 9
in-lb in-oz in-oz in-oz in-oz in-oz in-oz in-oz in-oz in-oz in-oz
0 0 16 32 48 64 80 96 112 128 144
10 160 176 192 208 224 240 256 272 288 304
20 320 336 352 368 384 400 416 432 448 464
30 480 496 512 528 544 560 576 592 608 624
40 640 656 672 688 704 720 736 752 768 784
50 800 816 832 848 864 880 896 912 928 944
60 960 976 992 1008 1024 1040 1056 1072 1088 1104
70 1120 1136 1152 1168 1184 1200 1216 1232 1248 1264
80 1280 1296 1312 1328 1344 1360 1376 1392 1408 1424
90 1440 1456 1472 1488 1504 1520 1536 1552 1568 1584
100 1600
in-oz = in-lb x 16
Table A-7 Conversion from Inch-Ounces to Inch-Pounds
INCH-OUNCES TO INCH-POUNDS
0 1 2 3 4 5 6 7 8 9
in-oz in-lb in-lb in-lb in-lb in-lb in-lb in-lb in-lb in-lb in-lb
0 0.000 0.063 0.125 0.188 0.250 0.313 0.375 0.438 0.500 0.563
10 0.625 0.688 0.750 0.813 0.875 0.938 1.000 1.063 1.125 1.188
20 1.250 1.313 1.375 1.438 1.500 1.563 1.625 1.688 1.750 1.813
30 1.875 1.938 2.000 2.063 2.125 2.188 2.250 2.313 2.375 2.438
40 2.500 2.563 2.625 2.688 2.750 2.813 2.875 2.938 3.000 3.063
50 3.125 3.188 3.250 3.313 3.375 3.438 3.500 3.563 3.625 3.688
60 3.750 3.813 3.875 3.938 4.000 4.063 4.125 4.188 4.250 4.313
70 4.375 4.438 4.500 4.563 4.625 4.688 4.750 4.813 4.875 4.938
80 5.000 5.063 5.125 5.188 5.250 5.313 5.375 5.438 5.500 5.563
90 5.625 5.688 5.750 5.813 5.875 5.938 6.000 6.063 6.125 6.188
100 6.250
in-lb = in-oz ÷ 16
A-10 April 13, 2000


APPENDIX
A.2.6 CONVERSION OF FOOT-POUNDS TO/FROM INCH-POUNDS
Table A-8 Conversion from Foot-Pounds to Inch-Pounds
FOOT-POUNDS TO INCH-POUNDS
0 1 2 3 4 5 6 7 8 9
ft-lb in-lb in-lb in-lb in-lb in-lb in-lb in-lb in-lb in-lb in-lb
0 0 12 24 36 48 60 72 84 96 108
10 120 132 144 156 168 180 192 204 216 228
20 240 252 264 276 288 300 312 324 336 348
30 360 372 384 396 408 420 432 444 456 468
40 480 492 504 516 528 540 552 564 576 588
50 600 612 624 636 648 660 672 684 696 708
60 720 732 744 756 768 780 792 804 816 828
70 840 852 864 876 888 900 912 924 936 948
80 960 972 984 996 1008 1020 1032 1044 1056 1068
90 1080 1092 1104 1116 1128 1140 1152 1164 1176 1188
100 1200
in-lb = ft-lb x 12
Table A-9 Conversion from Inch-Pounds to Foot-Pounds
INCH-POUNDS TO FOOT-POUNDS
0 1 2 3 4 5 6 7 8 9
in-lb ft-lb ft-lb ft-lb ft-lb ft-lb ft-lb ft-lb ft-lb ft-lb ft-lb
0 0.000 0.083 0.167 0.250 0.333 0.417 0.500 0.583 0.667 0.750
10 0.833 0.917 1.000 1.083 1.167 1.250 1.333 1.417 1.500 1.583
20 1.667 1.750 1.833 1.917 2.000 2.083 2.167 2.250 2.333 2.417
30 2.500 2.583 2.667 2.750 2.833 2.917 3.000 3.083 3.167 3.250
40 3.333 3.417 3.500 3.583 3.667 3.750 3.833 3.917 4.000 4.083
50 4.167 4.250 4.333 4.417 4.500 4.583 4.667 4.750 4.833 4.917
60 5.000 5.083 5.167 5.250 5.333 5.417 5.500 5.583 5.667 5.750
70 5.833 5.917 6.000 6.083 6.167 6.250 6.333 6.417 6.500 6.583
80 6.667 6.750 6.833 6.917 7.000 7.083 7.167 7.250 7.333 7.417
90 7.500 7.583 7.667 7.750 7.833 7.917 8.000 8.083 8.167 8.250
100 8.333
ft-lb = in-lb ÷ 12
April 13, 2000 A-11


APPENDIX
A.2.7 CONVERSION OF INCH-POUNDS TO/FROM KILOGRAM-CENTIMETERS
Table A-10 Conversion from Inch-Pounds to Kilogram-Centimeters
INCH-POUNDS TO KILOGRAM-CENTIMETERS
0 1 2 3 4 5 6 7 8 9
in-lb kg-cm kg-cm kg-cm kg-cm kg-cm kg-cm kg-cm kg-cm kg-cm kg-cm
0 0.00 1.15 2.30 3.46 4.61 5.76 6.91 8.07 9.22 10.37
10 11.52 12.67 13.83 14.98 16.13 17.28 18.43 19.59 20.74 21.89
20 23.04 24.20 25.35 26.50 27.65 28.80 29.96 31.11 32.26 33.41
30 34.57 35.72 36.87 38.02 39.17 40.33 41.48 42.63 43.78 44.93
40 46.09 47.24 48.39 49.54 50.70 51.85 53.00 54.15 55.30 56.46
50 57.61 58.76 59.91 61.07 62.22 63.37 64.52 65.67 66.83 67.98
60 69.13 70.28 71.43 72.59 73.74 74.89 76.04 77.20 78.35 79.50
70 80.65 81.80 82.96 84.11 85.26 86.41 87.56 88.72 89.87 91.02
80 92.17 93.33 94.48 95.63 96.78 97.93 99.09 100.24 101.39 102.54
90 103.70 104.85 106.00 107.15 108.30 109.46 110.61 111.76 112.91 114.06
100 115.22
kg-cm = in-lb x 1.1520
Table A-11 Conversion from Kilogram-Centimeters to Inch-Pounds
KILOGRAM-CENTIMETERS TO INCH-POUNDS
0 1 2 3 4 5 6 7 8 9
kg-cm in-lb in-lb in-lb in-lb in-lb in-lb in-lb in-lb in-lb in-lb
0 0.00 0.87 1.74 2.60 3.47 4.34 5.21 6.08 6.94 7.81
10 8.68 9.55 10.42 11.28 12.15 13.02 13.89 14.75 15.62 16.49
20 17.36 18.23 19.09 19.96 20.83 21.70 22.57 23.43 24.30 25.17
30 26.04 26.91 27.77 28.64 29.51 30.38 31.25 32.11 32.98 33.85
40 34.72 35.59 36.45 37.32 38.19 39.06 39.92 40.79 41.66 42.53
50 43.40 44.26 45.13 46.00 46.87 47.74 48.60 49.47 50.34 51.21
60 52.08 52.94 53.81 54.68 55.55 56.42 57.28 58.15 59.02 59.89
70 60.75 61.62 62.49 63.36 64.23 65.09 65.96 66.83 67.70 68.57
80 69.43 70.30 71.17 72.04 72.91 73.77 74.64 75.51 76.38 77.25
90 78.11 78.98 79.85 80.72 81.59 82.45 83.32 84.19 85.06 85.92
100 86.79
in-lb = kg-cm x 0.8679
A-12 April 13, 2000


APPENDIX
A.2.8 CONVERSION OF FOOT-POUNDS TO/FROM KILOGRAM-METERS
Table A-12 Conversion from Foot-Pounds to Kilogram-Meters
FOOT-POUNDS TO KILOGRAM-METERS
0 1 2 3 4 5 6 7 8 9
ft-lb kg-m kg-m kg-m kg-m kg-m kg-m kg-m kg-m kg-m kg-m
0 0.00 0.14 0.28 0.41 0.55 0.69 0.83 0.97 1.11 1.24
10 1.38 1.52 1.66 1.80 1.94 2.07 2.21 2.35 2.49 2.63
20 2.77 2.90 3.04 3.18 3.32 3.46 3.60 3.73 3.87 4.01
30 4.15 4.29 4.43 4.56 4.70 4.84 4.98 5.12 5.26 5.39
40 5.53 5.67 5.81 5.95 6.09 6.22 6.36 6.50 6.64 6.78
50 6.92 7.05 7.19 7.33 7.47 7.61 7.74 7.88 8.02 8.16
60 8.30 8.44 8.57 8.71 8.85 8.99 9.13 9.27 9.40 9.54
70 9.68 9.82 9.96 10.10 10.23 10.37 10.51 10.65 10.79 10.93
80 11.06 11.20 11.34 11.48 11.62 11.76 11.89 12.03 12.17 12.31
90 12.45 12.59 12.72 12.86 13.00 13.14 13.28 13.42 13.55 13.69
100 13.83
kg-m = ft-lb x 0.1383
Table A-13 Conversion from Kilogram-Meters to Foot-Pounds
KILOGRAM-METERS TO FOOT-POUNDS
0 1 2 3 4 5 6 7 8 9
kg-m ft-lb ft-lb ft-lb ft-lb ft-lb ft-lb ft-lb ft-lb ft-lb ft-lb
0 0.0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.3 390.6 397.8 405.0 412.3 419.5 426.7
60 434.0 441.2 448.4 455.7 462.9 470.1 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3
ft-lb = kg-m x 7.2330
April 13, 2000 A-13


APPENDIX
A.2.9 CONVERSION OF FOOT-POUNDS TO/FROM NEWTON-METERS
Table A-14 Conversion from Foot-Pounds to Newton-Meters
FOOT-POUNDS TO NEWTON-METERS
0 1 2 3 4 5 6 7 8 9
N-m ft-lb ft-lb ft-lb ft-lb ft-lb ft-lb ft-lb ft-lb ft-lb ft-lb
0 0.00 1.36 2.71 4.07 5.42 6.78 8.14 9.49 10.85 12.20
10 13.56 14.92 16.27 17.63 18.98 20.34 21.70 23.05 24.41 25.76
20 27.12 28.48 29.83 31.19 32.54 33.90 35.26 36.61 37.97 39.32
30 40.68 42.04 43.39 44.75 46.10 47.46 48.82 50.17 51.53 52.88
40 54.24 55.60 56.95 58.31 59.66 61.02 62.38 63.73 65.09 66.44
50 67.80 69.16 70.51 71.87 73.22 74.58 75.94 77.29 78.65 80.00
60 81.36 82.72 84.07 85.43 86.78 88.14 89.50 90.85 92.21 93.56
70 94.92 96.28 97.63 98.99 100.34 101.70 103.06 104.41 105.77 107.12
80 108.48 109.84 111.19 112.55 113.90 115.26 116.62 117.97 119.33 120.68
90 122.04 123.40 124.75 126.11 127.46 128.82 130.18 131.53 132.89 134.24
100 135.60
N-m = ft-lb x 1.3560
Table A-15 Conversion from Newton-Meters to Foot-Pounds
NEWTON-METERS TO FOOT-POUNDS
0 1 2 3 4 5 6 7 8 9
0 0.00 0.74 1.47 2.21 2.95 3.69 4.42 5.16 5.90 6.64
10 7.37 8.11 8.85 9.59 10.32 11.06 11.80 12.54 13.27 14.01
20 14.75 15.49 16.22 16.96 17.70 18.44 19.17 19.91 20.65 21.39
30 22.12 22.86 23.60 24.34 25.07 25.81 26.55 27.29 28.02 28.76
40 29.50 30.24 30.97 31.71 32.45 33.19 33.92 34.66 35.40 36.14
50 36.87 37.61 38.35 39.09 39.82 40.56 41.30 42.04 42.77 43.51
60 44.25 44.99 45.72 46.46 47.20 47.93 48.67 49.41 50.15 50.88
70 51.62 52.36 53.10 53.83 54.57 55.31 56.05 56.78 57.52 58.26
80 59.00 59.73 60.47 61.21 61.95 62.68 63.42 64.16 64.90 65.63
90 66.37 67.11 67.85 68.58 69.32 70.06 70.80 71.53 72.27 73.01
100 73.75
ft-lb = N-m x 0.7375
A-14 April 13, 2000


APPENDIX
A.2.10 CONVERSION OF INCH-POUNDS TO/FROM NEWTON-METERS
Table A-16 Conversion from Inch-Pounds to Newton-Meters
INCHES-POUNDS TO NEWTON-METERS
0 1 2 3 4 5 6 7 8 9
in-lb N-m N-m N-m N-m N-m N-m N-m N-m N-m N-m
0 0.00 0.11 0.23 0.34 0.45 0.57 0.68 0.79 0.90 1.02
10 1.13 1.24 1.36 1.47 1.58 1.70 1.81 1.92 2.03 2.15
20 2.26 2.37 2.49 2.60 2.71 2.83 2.94 3.05 3.16 3.28
30 3.39 3.50 3.62 3.73 3.84 3.96 4.07 4.18 4.29 4.41
40 4.52 4.63 4.75 4.86 4.97 5.09 5.20 5.31 5.42 5.54
50 5.65 5.76 5.88 5.99 6.10 6.22 6.33 6.44 6.55 6.67
60 6.78 6.89 7.01 7.12 7.23 7.35 7.46 7.57 7.68 7.80
70 7.91 8.02 8.14 8.25 8.36 8.48 8.59 8.70 8.81 8.93
80 9.04 9.15 9.27 9.38 9.49 9.61 9.72 9.83 9.94 10.06
90 10.17 10.28 10.40 10.51 10.62 10.74 10.85 10.96 11.07 11.19
100 11.30
N-m = in-lb x 0.1130
Table A-17 Conversion from Newton-Meters to Inch-Pounds
NEWTON-METERS TO INCH-POUNDS
0 1 2 3 4 5 6 7 8 9
in-lb N-m N-m N-m N-m N-m N-m N-m N-m N-m N-m
0 0.00 8.85 17.70 26.55 35.40 44.25 53.10 61.95 70.80 79.65
10 88.50 97.34 106.19 115.04 123.89 132.74 141.59 150.44 159.29 168.14
20 176.99 185.84 194.69 203.54 212.39 221.24 230.09 238.94 247.79 256.64
30 265.49 274.34 283.18 292.03 300.88 309.73 318.58 327.43 336.28 345.13
40 353.98 362.83 371.68 380.53 389.38 398.23 407.08 415.93 424.78 433.63
50 442.48 451.33 460.18 469.02 477.87 486.72 495.57 504.42 513.27 522.12
60 530.97 539.82 548.67 557.52 566.37 575.22 584.07 592.92 601.77 610.62
70 619.47 628.32 637.17 646.01 654.86 663.71 672.56 681.41 690.26 699.11
80 707.96 716.81 725.66 734.51 743.36 752.21 761.06 769.91 778.76 787.61
90 796.46 805.31 814.16 823.01 831.85 840.70 849.55 858.40 867.25 876.10
100 884.95
in-lb = N-m x 8.8495
April 13, 2000 A-15


APPENDIX
A.2.11 CONVERSION OF KILOGRAM-METERS TO/FROM NEWTON-METERS
Table A-18 Conversion from Kilogram-Meters to Newton-Meters
KILOGRAM-METERS TO NEWTON-METERS
0 1 2 3 4 5 6 7 8 9
kg-m N-m N-m N-m N-m N-m N-m N-m N-m N-m N-m
0 0.00 9.81 19.61 29.42 39.23 49.03 58.84 68.65 78.45 88.26
10 98.07 107.87 117.68 127.49 137.29 147.10 156.91 166.71 176.52 186.33
20 196.13 205.94 215.75 225.55 235.36 245.17 254.97 264.78 274.59 284.39
30 294.20 304.00 313.81 323.62 333.42 343.23 353.04 362.84 372.65 382.46
40 392.26 402.07 411.88 421.68 431.49 441.30 451.10 460.91 470.72 480.52
50 490.33 500.14 509.94 519.75 529.56 539.36 549.17 558.98 568.78 578.59
60 588.40 598.20 608.01 617.82 627.62 637.43 647.24 657.04 666.85 676.66
70 686.46 696.27 706.08 715.88 725.69 735.50 745.30 755.11 764.92 774.72
80 784.53 794.34 804.14 813.95 823.76 833.56 843.37 853.18 862.98 872.79
90 882.59 892.40 902.21 912.01 921.82 931.63 941.43 951.24 961.05 970.85
100 980.66
N-m = kg-m x 9.8066
Table A-19 Conversion from Newton-Meters to Kilogram-Meters
NEWTON-METERS TO KILOGRAM-METERS
0 1 2 3 4 5 6 7 8 9
0 0.000 0.102 0.204 0.306 0.408 0.511 0.612 0.714 0.816 0.918
10 1.020 1.122 1.224 1.326 1.428 1.530 1.632 1.734 1.835 1.937
20 2.039 2.141 2.243 2.345 2.447 2.549 2.651 2.753 2.855 2.957
30 3.059 3.161 3.263 3.365 3.467 3.569 3.671 3.773 3.875 3.977
40 4.079 4.181 4.283 4.385 4.487 4.589 4.691 4.793 4.895 4.997
50 5.099 5.201 5.303 5.405 5.506 5.608 5.710 5.812 5.914 6.016
60 6.118 6.220 6.322 6.424 6.526 6.628 6.730 6.832 6.934 7.036
70 7.138 7.240 7.342 7.444 7.546 7.648 7.750 7.852 7.954 8.056
80 8.158 8.260 8.362 8.464 8.566 8.668 8.770 8.872 8.974 9.076
90 9.177 9.279 9.381 9.483 9.585 9.687 9.789 9.891 9.993 10.095
100 10.197
kg-m = N-m x 0.10197
A-16 April 13, 2000


APPENDIX
A.3 STANDARD TORQUE TABLES
These tables relate tightening torque to thread diameter and list the basic torque for
bolts and nuts. Use the tables only for bolts and nuts which do not require a specific
torque value, and which are being screwed into steel or cast iron. If screws are inserted
in aluminum or aluminum alloys, torque must be reduced. All values are for use with dry,
solvent-cleaned threads.
! CAUTION
There are many varying factors which affect torque.
The figures in the following charts are safe figures for
standard torque applications only; e.g., when fasteners
are screwed into steel or cast iron threads only.
Table A-20 General Fasteners Standard Torque Values
Thread Torque
Diameter
(mm) N-m kg-m ft-lb
30.1–43.4
5 3.4–4.9 0.35–0.50
in-lb
52.2–69.0
6 5.9–7.8 0.60–0.80
in-lb
8 14.0–19.0 1.43–1.94 10.0–13.5
10 25.0–39.0 2.55–3.98 19.0–25.0
12 44.0–61.0 4.49–6.22 32.4–45.0
14 73.0–98.0 7.44–10.0 53.8–72.3
16 115–155 11.5–16.0 84.8–115
18 165–225 17.0–23.0 125–165
20 225–325 23.0–33.0 165–240
April 13, 2000 A-17


APPENDIX
Table A-21 Special Material Fastener Torque Values
Cap Torque kg-cm (ft-lb)

Screw
Size SCM3 S45C SS41
M3 — — —
35 20 10
4
(2.53) (1.44) (0.72)
70 40 20
5
(5.06) (2.89) (1.44)
120 70 30
6
(8.67) (5.06) (2.17)
300 170 80
8
(21.69) (12.29) (5.78)
580 340 160
10
(41.95) (24.59) (11.57)
1,000 600 280
12
(72.33) (43.39) (20.25)
1,600 900 420
14
(115.72) (65.09) (30.38)
2,400 1,400 650
16
(173.59) (101.26) (47.01)
3,400 1,900 880
18
(245.91) (137.42) (63.65)
4,400 2,700 1,300
20
(318.24) (195.28) (94.03)
Material Key:
SS41 – Mild Steel
S45C – Carbon Steel
SCM3 – Chrome-Moly Steel
A-18 April 13, 2000


APPENDIX
Table A-22 Torque Values
FASTENER
SAE SAE SAE SAE SOCKET HEAD SOCKET HEAD MACHINE SCREW
TYPE
1 OR 2 5 7 8 CAP SCREW SET SCREW YELLOW BRASS
MIN. TENSILE
74,000 PSI 120,000 PS1 133,000 PSI 150,000 PSI 160,000 PSI 212,000 PSI 60,000 PSI
STRENGTH
MEDIUM CARBON
ALLOY STEEL,
MED. CARBON MEDIUM CARBON 63% COPPER
QUENCHED AND HIGH CARBON HIGH CARBON
LOW OR MEDIUM STEEL, ALLOY STEEL, (Cu)
MATERIAL TEMPERED, CASE HARDENED CASE HARDENED
CARBON STEEL QUENCHED AND QUENCHED AND 37% ZINC
ROLL THREADED STEEL STEEL
TEMPERED TEMPERED (Zn)
AFTER HEAT
TREATMENT
BODY SIZE
OR
TORQUE VALUE
OUTSIDE
DIAMETER
All values are foot pounds unless noted by * indicating inch pounds
OF
FASTENER
3 2*
4 3.3*
5 4.4*
6 9* 6.4*
8 16* 8*
10 30* 16*
1/4 6 10 13 14 16 70* 20*
5/16 12 19 25 29 33 140* 65*
3/8 20 33 44 47 54 18 110*
7/16 32 54 71 78 84 29 17
1/2 47 78 110 119 125 43 27
9/16 69 114 154 169 180 63 37
5/8 96 154 215 230 250 100 49
3/4 155 257 360 380 400 146 78
7/8 206 382 570 600 640 104
1 310 587 840 900 970 160
1 1/8 480 794 1325 1430 1520 215
1 1/4 675 1105 1825 1975 2130 325
1 3/8 900 1500 2500 2650 2850 400
1 1/2 1100 1775 3000 3200 3450
1 5/8 1470 2425 4000 4400 4700
1 3/4 1900 3150 5300 5650 6100
1 7/8 2360 4200 7000 7600 8200
2 2750 4550 7500 8200 8800
2 1/4 3450 6550 11000 12000 13000
2 1/2 4400 7175 15000 17000 18000
2 3/4 7350 13000 21000 23000 24000
3 9500 16000 27000 29000 31000
NOTE: In the above chart there is no distinction between the torque figures for fine or
coarse threads. The torque figures for a finely threaded fastener as compared to a
coarsely threaded fastener of the same diameter, may be slightly higher, but hardly
worth mentioning.
April 23, 2001 A-19


APPENDIX
Table A-23 Metric Tap Drill Sizes
Decimal Nearest
Tap Size Drill Size Equivalent Fraction
M3 x .50 39 0.0995 3/32
M3 x .60 3/32 0.0938 3/32
M4 x .70 30 0.129 1/8
M4 x .75 1/8 0.125 1/8
M5 x .80 19 0.166 11/64
M5 x .90 20 0.161 5/32
M6 x 1.00 9 0.196 13/64
M7 x 1.00 15/64 0.234 15/64
M8 x 1.00 J 0.277 9/32
M8 x 1.25 17/64 0.266 17/64
M9 x 1.00 5/16 0.313 5/16
M9 x 1.25 5/16 0.313 5/16
M10 x 1.25 11/32 0.344 11/32
M10 x 1.50 R 0.339 11/32
M11 x 1.50 3/8 0.375 3/8
M12 x 1.50 13/32 0.406 13/32
M12 x 1.75 13/32 0.406 13/32
1/8 - 28BSP 21/64 0.328 21/64
A-20 April 13, 2000


APPENDIX
A.4 JOINT 1 - AXIS CONTROL
A.4.1 UX100/120/150 ROBOT MODEL
The operating angle of Joint 1 can be restricted according to the peripheral conditions
of the robot. As illustrated in figure A-4, the operating angle can be changed in incre-
ments of 10° by shifting the position of the limit switch bracket and the mechanical
stopper.
ROBOT ARM FORWARD
10 10
LEFT SIDE 20 20 RIGHT SIDE
OPERATING 30 30 OPERATING
ANGLE ANGLE
40 40
50 50
60 60
70 70
80 80
90 90
100 100
110 110
120 120
130 130
140 140
150 150
160 160
170 180 170
AVAILABLE OPERATING ANGLE

LEFT SIDE RIGHT SIDE
0 0
180 180
Figure A-4 UX100/120/150 Joint 1 - Axis Operating Angle
April 13, 2000 A-21


APPENDIX
Use the following procedure to change the R-axis (JT1) operating angle:
1. Set the desired operating angle by using AUX Function 51, SOFTWARE LIMIT,
shown in figure A-5 below.
2. Jog the R-axis (JT1) to the software limit set in step 1.
3. Install the mechanical stopper block into the robot base next to the fixed stopper
block underneath the arm base. Tighten the M6 X 10 mm mounting bolts to 70
kg-cm (104.04 in-lb).
4. Attach the limit switch bracket onto the base next to the stopper block.
5. Adjust the limit switch bracket so that the position of the limit switch is half way
between the actuation point and trip point as shown in figure A-6.
AUX 51 SOFTWARE LIMIT AUX 51 SOFTWARE LIMIT

UPPER LOWER
SET ABLE UPPER SETTING F3 SET ABLE LOWER SETTING
ð ð
JT1 180.000deg 45.000deg NEXT PG JT1 -180.000deg -45.000deg
JT2 70.000deg 70.000deg JT2 -65.000deg -65.000deg
F1 F2 F3 F4 F1 F2 F3 F4
PRE DATA NEXT PG PRE DATA PREV. PG
Figure A-5 AUX Function 51, Software Limit
A-22 April 23, 2001


APPENDIX
Motion of Robot
Overtravel Limit Switch Trip Dog
O.T.
Limit
Switch Overtravel Limit Switch Actuation Point
Software Limit - should be centered

between the overtravel limit switch
actuation point and trip point
Overtravel Limit Switch Trip Point
Mechanical Hard Stop
Motor Power ON
Motor Power OFF
Figure A-6 Overtravel Limit Switch Adjustment
A.5 CHARTS AND FORMS FOR CHECKS AND LUBRICATION
The following pages contain forms that can be used in conjunction with the required
preventative maintenance procedures for the Kawasaki robot systems. As each mainte-
nance procedure is performed, the item is checked off and initialed, and the form is
placed in a file to provide a maintenance record for the robot. The preventive mainte-
nance forms in this section may be removed from the manual and photo copied as
required.
April 13, 2000 A-23


APPENDIX
Robot model:
Mechanical unit serial number:
Robot line number:
Location of line
Type of robot application:
Date of checks:
Person performing checks:
DAILY CHECKS Check when Initial when

Performed Performed
1. Cables
Check the electrical harnesses for rubbing, chafing, or abrasion

against the mechanical unit. Also check for kinks, twists, or irregu-
lar bends in the electrical harness. Check rubber hoses and air
lines for defects. Check all electrical harnesses of the major axes
motors and encoders for defects and interference with robot fixtures
and supports.
2. Robot Damage
Check the robot for obvious mechanical damage caused by interfer-

ence with fixturing etc. Inspect carefully the wrist and D, S, B, and
T axes servo motors and encoders. Check covers on the robot for
mounting integrity and any damage caused by interference.
3. Robot Motion
Does each axis move smoothly? Does any axis make abnormal
noise or vibration? Does the robot overshoot taught point loca-
tions? Do the servo motors generate an abnormal amount of heat?
Normal surface temperature should be lower than 80° C (176° F).
4. Positioning Accuracy
Compare the new position with the original position. When the
robot stops, check for repeatibility.
Signature:
Date:
Hour Meter Reading:
A-24 April 23, 2001


APPENDIX
A.6 TB2 DEDICATED SIGNAL PIN ASSIGNMENTS
1HP-CN1 TB2
EXT CONTROL POWER-P EXT 24 VDC 24 VDC INPUT
1 1 EXT CONTROL
EXT CONTROL POWER-N EXT 24 VDC G POWER ON/OFF
2 2 (SHORT STANDARD)
REMOTE-P
3 3
REMOTE-N
4 4
INTERNAL-EMG1-P
5 5
EMG1-P
6 6
INT EMG1-N
7 7 EXT E-STOP
24 VDC EMG1-N CONNECTION
8 8
INT EMG2-P
relay 9 9
EMG2-P
10 10
INT EMG2-N
relay 11 11
EMG2-N
12 12
SAFETY FENCE1-P
13 15
SAFETY FENCE1-N
14 16 SAFETY FENCE INPUT
(REPEAT MODE ONLY,
SAFETY FENCE2-P
SAFETY FENCE2-N
16 18
EXT HOLD-P
17 19 EXT HOLD INPUT
(REPEAT MODE ONLY,
EXT HOLD-N
21 21
22 22 (NOT USED)
23 23
24 24
25 EXT TRG1-P 25
26 EXT TRG1-N 26 EXT TRIGGER INPUT
(TEACH MODE ONLY,
27 EXT TRG2-P 27 STOP WHEN OPEN)
EXT TRG2-N
28 28
EXT MOTOR POWER -P
29 29 EXTERNAL
MOTOR POWER ON
EXT MOTOR POWER -N
30 30 (WHEN CLOSED)
TEACH SW-P
35 31 INT TEACH SW OUTPUT
TEACH SW-N (CLOSED IN TEACH MODE)
36 32
INT 24 VDC
37 33 INT 24 VDC OUTPUT
INT 24 VDC G
38 34 I/O 24 VDC INPUT
I/O 24 VDC
39 35 INT 24 VDC G OUTPUT
I/O 24 VDC G
40 36 I/O 24 VDC G INPUT
Figure A-7 1HP to TB2 Connections
March 28, 2002 A-25


APPENDIX
A.7 INTERFACE PANELS
A.7.1 MATERIAL HANDLING INTERFACE PANEL (OPTION)
AUTO MAINT. RUN EXTERNAL

INTLK POS. HOLD
HOLD RESET HOLD ON
G
SS1 PL1
KS2
ROBOT
BYPASS
AUTO LINE
INTLK BYPASS
KS3
TEACH
EMERGENCY STOP
OFF ON
KS1
PB1
FCM2
CR4
CR3
CR2
CR5
CR1
IN
17-32
* IF USED
Figure A-8 Material Handling Interface Panel (Option)
A-26 April 13, 2000


APPENDIX
A.7.2 SPOT WELDING INTERFACE PANEL (OPTION)
AUTO MAINT. RUN MANUAL EXTERNAL

INTLK POS. HOLD WELD / PURGE
HOLD RESET HOLD ON
B G
SS1 PB2 PL1
KS2
NO
WELD WELD
ROBOT
BYPASS
AUTO LINE
SS2
INTLK BYPASS
KS3
TEACH
EMERGENCY STOP
OFF ON
KS1
PB1
FCM2
CR4
CR3
CR2
CR5
CR1
IN
17-32
* IF USED
Figure A-9 Spot Welding Interface Panel (Option)
April 23, 2001 A-27

C SERIES CONTROLLER
Kawasak

APPENDIX
A.8 SPECIAL TOOLS
M12 X 120 mm Screw (2 pc)

Jig, ROD (2 pc)
Jig, Pipe U (2 pc)
M12 Nuts (2 pc)
Figure A-10 Jig ROD Assembly, U-Series
55 +0.3
-0.6 mm
17.3 mm Ø
SGP10A
NOTE:
1. Chamfer all sharp edges.
2. Unichrome plated.
Figure A-11 Jig, Pipe U, U-Series
A-28 January 9, 2004


APPENDIX
115.00 mm
12.50 90.00 mm 22 mm
22 mm
12
.5
11.00 mm 2-14 Dia
Drill
NOTE:
1. Chamfer all edges
2. Unichrome plated
Figure A-12 Jig, ROD, U-Series
January 9, 2004 A-29

C SERIES CONTROLLER
Kawasak

APPENDIX
M12 X 120 mm Screw (2 pc)

Jig, ROD (2 pc)
Jig, Pipe U (2 pc)
M12 Nuts (2 pc)
Figure A-13 Jig ROD Assembly, Z-Series
54.85 ± 0.45 mm
17.3 mm Ø
SGP10A
NOTE:
1. Chamfer all sharp edges.
2. Unichrome plated.
Figure A-14 Jig ROD, Pipe U, Z-Series
A-30 January 9, 2004


APPENDIX
120.0 mm
14 mm Æ 11.0 mm 98.0 mm 11.0 mm

12
.5
11.0 mm 3.5 mm
22.0 mm 15.0 mm 22.0 mm
3.5 mm
20.0 mm
20.0 mm 60.0 mm
10.0 mm 10.0 mm
22.0 mm
NOTE:
1. Chamfer all edges
2. Unichrome plated
Figure A-15 Jig ROD, Z-Series
January 9, 2004 A-31

A-32
187.3 mm (7 3/8 in)
25.4 mm
(1 in)
Kawasak
(1 in)
25.4 mm
Æ10 mm (.39 in)
(2 in)
50.8 mm
APPENDIX
146 mm (5 3/4 in)
Figure A-16 Steel Plate Tool, Z-Series

4.76 mm (3/16 in)
C SERIES CONTROLLER
January 9, 2004

GLOSSARY
GLOSSARY ................................................................................................................ G-2
November 30, 1998 G-1


GLOSSARY
This glossary contains definitions of terms used by operators, programmers, and main-
tenance personnel who work with Kawasaki robots. The definitions are listed in alpha-
betical order.
A
• ACCELERATE
To speed up a process.
• ACCURACY
A measure of the difference between the commanded robot arm position and the
actual position. Also identifies how well an indicated value conforms to a true value
(i.e., an actual or accepted standard value).
• ACRONYM
A term made up of the initial letters of words in a set phrase. For example, LED is an
acronym for light emitting diode.
• ADDRESS
A number that identifies a specific location in the computer’s or processor’s memory.
Means of identifying a location or data in a control system.
• ADDRESSING
Computer operations store data in specific memory locations or addresses. The
largest memory location determines the amount of data that can be stored. The
larger the number, the larger the possible program.
• AIR CUT
Moving a weld gun into position but without generating an arc.
• ALGORITHM
A finite set of well-defined rules or procedures for solving a problem step-by-step.
• ALPHANUMERIC
Pertaining to a set of symbols that contain both letters and numbers, either individu-
ally or in combination.
• AMBIENT TEMPERATURE
The temperature of air or liquid that surrounds a device.
• AMPERE (AMP)
A unit of electrical current flow that is equivalent to one (1) coulomb per second.
One (1) volt across one (1) ohm of resistance causes a current flow that is equivalent
to one (1) amp.
G-2 November 30, 1998


GLOSSARY
• ANALOG
A continuously changing electrical voltage signal. In robot systems, the magnitude
or value of the signal represents commanded robot axis motion.
• ANALOG DATA
Information that is represented by a characteristic of the value or magnitude of an
electrical signal, such as the amplitude, phase, or frequency of the voltage, the
amplitude or duration of a pulse, the angular position of a shaft, or the pressure of a
fluid number.
• ANTI-FRICTION BEARING
A rolling element which is used to support a rotating shaft.
• ARC SENSOR
A sensor that detects weld lines utilizing arc characteristics.
• ARGUMENT
A value applied to a procedure; data used by a function or other command. For
instance, in the AS command JMOVE flange, 2. The variable, flange, and the clamp
number 2 are the arguments of the function JMOVE.
• ARRAY
An ordered set of addresses or their values. Elements of an array can be referenced
individually or collectively. Array elements all have the same type of data, for in-
stance, integer or character, and are usually presented in rows and columns.
• ARTICULATED
To join together permanently or semi-permanently by means of a pivot connection for
operating separate segments as a unit.
• ARTICULATED ROBOT
A robot arm which contains at least two consecutive revolute joints, acting around
parallel axes, resembling human arm motion. The work envelope is formed by partial
cylinders or spheres. The two basic types of articulated robots, vertical and
horizontal, are sometimes called anthropomorphic because of the resemblance to
the motions of the human arm.
• ASCII
An acronym for American Standard Code for Information Interchange. This standard
8-bit code is used by many devices, such as keyboards and printers.
• AS LANGUAGE
Kawasaki robot language used to communicate commands and instructions from a
keyboard to the CPU.


GLOSSARY
• ASSIGNMENT
An instruction used to express a sequence of operations, or used to assign operands
to specified variables, or symbols, or both.
• ASYNCHRONOUS
A means of data communication where the data is sent a character at a time pre-
ceded by a start bit and followed by a stop bit. No direct timing signal links the trans-
mitter and receiver.
• AUXILIARY DATA
Information about a point, other than the positional data, such as speed, accuracy,
weld schedule and clamp condition.
• AXIS
A straight line about which sections of the mechanical unit rotate (e.g., joints JT1,
JT2, JT3 etc.).
B
• BACKLASH
The clearance, slack, or play between adjacent gears, or the jar or reaction often
caused by such clearance when the parts are suddenly put in action or are in
irregular action.
• BASE COORDINATE
A fixed coordinate system having an origin at the intersection of the X, Y, and Z axes.
• BAUD RATE
Determines the number of bits per second (bps) or characters transmitted between
devices.
• BCD
An acronym for binary coded decimal. The BCD 8-4-2-1 code expresses each
decimal digit by its own 4-bit binary equivalent. The 8-4-2-1 code is identical to
binary through the decimal number 9. Above the decimal number 9 each decimal
digit is represented by its own 4-bit binary equivalent. For example, using the 8-4-2-
1 binary-coded system, the number 10 is interpreted as 0001 0000.
• BINARY CODE
A system in which characters are represented by a group of binary digits, that have
the value of either 0 or 1, true or false, on or off.
• BIT
Acronym for binary digit, having one of two values: 0 or 1.


GLOSSARY
• BOOT
The method by which computers are brought from a non-operating to an operating
state. During this sequence, the computer memory is usually reset. This is often
performed to restart the computer after a crash, to bring it on-line.
• BUFFER
A temporary memory storage area in a computer or electronic device.
• BUG
A problem in a software or hardware element of a system.
• BUS
The primary communication path in the controller along which internal signals are
sent among processors and memories.
C
• CABLE CARRIER
A device which carries cables and hoses (including power sources) from a stationary
location to a linear moving device.
• CARTESIAN COORDINATE
A location in space defined by three axes at right angles to each other, commonly
labeled X, Y, Z.
• cc
cubic centimeter
• CELL
A manufacturing unit consisting of two or more work stations or machines, and the
material transport mechanisms and storage buffers that interconnect them.
• CENTER OF GRAVITY
The point at which the entire weight of a body may be considered as concentrated,
so that if supported at this point the body would remain in equilibrium in any position.
• CHARACTER
A term that describes all numbers, letters, and other symbols typically found on a
computer keyboard.
• CHECK MODE
A procedure that allows the user to check positional data and auxiliary data while in
the teach mode with the Kawasaki robot . This procedure is in many ways analo-
gous to reverse point and forward point operations in other robot models.


GLOSSARY
• CHECKSUM
A method by which the contents of data or a transmission are verified to be accurate.
This method ‘sums’ all the characters and translates them into a number which is
appended to the data.
• CHEMICAL ANCHOR
A threaded rod installed in a structure (e.g., a concrete floor) and secured by epoxy,
for the purpose of securing hardware.
• CIRCULAR INTERPOLATION
A path taken by the robot that connects at least three points with an arching motion.
The CPU will calculate a path that places the taught points on a section of a circle.
• CLOSED-LOOP SYSTEM
A system in which a command value is output and a feedback value is returned. The
resulting error, the difference between the command and the feedback, is used to
correct the signal. In a robot system, the command signal is output by the controller,
causing the robot arm to move, and the feedback signal is produced by the encoder,
which reads the current position of the arm.
• CODE
A set of rules for expressing information in a language that is understood and pro-
cessed by a control system.
Also, a term for instructions in a computer program. Code performs a process, and
data is the information that is processed.
• COMMAND
An analog signal, or group of signals or pulses, which cause a specified function to
be performed. An instruction or request in a computer program that performs a
particular action. Commands that are needed to run the operating system are called
a command language.
• COMMENT
Optional, non-executing remarks added to a program to explain various aspects of
the program.
• COMPILER
A system task that translates a program written in source code, into binary code that
can be understood by the processor.
• COMPOUND TRANSFORMATION
A location in the Cartesian coordinate system that is defined relative to another
Cartesian coordinate location.


GLOSSARY
• CONTIGUOUS FILE
A file that is stored in continuously adjacent areas of memory, in contrast to a file
which is scattered to make more efficient use of disk space.
• CONTINUOUS PATH CONTROL

A type of robot control in which the robot moves according to a replay of closely
spaced points programmed on a constant time base during teaching.
• CONTROL ERROR CODE

A code which identifies system problems whenever an alarm condition occurs.
• CONTROLLED AXIS
A robot axis that is operated by electrical or hydraulic power.
• CONTROLLER
An electronic device, with processing capabilities and software, which controls the
robot actions and functions.
• CONVEYER TRACKING
Used to make the robot follow a part on a conveyor, without the use of a traverse
axis.
• COORDINATE
A set of numbers that locate a point in space.
• CPU
Acronym for central processing unit. A collection of hardware in a computer which
performs all calculations, handles I/O, and executes programmed tasks.
• CRASH
A situation where the computer fails to operate, due to a software or hardware prob-
lem.
• CRT
An acronym for cathode ray tube. A CRT is a charge storage tube in which the
information is written by means of the cathode ray beam.
• CURRENT LOOP
A circuit in which a portion of the output is returned to modify the control circuit
output. This circuit may be used as a limiting device, for safety protection.
• CURSOR
A pointer or indicator on a computer screen, that identifies the current position on the
screen.


GLOSSARY
• CYCLE
A complete path of projectory performed by the robot for a specific application.
• CYCLOIDAL DRIVE
A mechanical gear reduction unit that reduces the speed of the input and increases
the torque capacity. The cycloidal unit consists of an internal arrangement of discs
and pins that are driven by an eccentric drive cam. This type of gear reduction offers
low gear train backlash and the capability to achieve high reduction ratios from a
single contained unit.
D
• DATA
A term given to information, instructions, words or symbols that are usually transmit-
ted, processed, or stored as a group.
• DETENT
A part of a mechanism that locks or unlocks a movement.
• DISCONNECT
A switch that isolates a circuit or one or more pieces of electrical apparatus after the
current has been interrupted by other means.
• DEVIATION ERROR
In all mechanical devices, the actual position of the mechanical unit will lag behind
the electrical command of the controller. An allowable limit is assigned for this differ-
ence. However, if the controller detects a condition where the difference between
this mechanical value and the desired electrical position is larger than the estab-
lished value limit, the robot controller will generate a deviation error. This error is
sometimes referred to as a FOLLOWING ERROR in the robot industry.
• DEBUG
The process by which an operator’s program is checked for mistakes and then cor-
rected.
• DECIMAL NUMBER
Numbers in the base-10 numbering system, which uses the numerals 0 - 9.
• DEDICATED
A term used to describe a system resource, such as an I/O device or terminal, which
is used for only one purpose, or assigned a single function.


GLOSSARY
• DEDICATED SIGNAL
A term used to describe a signal which is used for only one purpose, or assigned a
single function. Both inputs and outputs can be dedicated.
• DEFAULT
A value or operation that is automatically entered by the system, if the operator does
not specify one. Typically, the default is the standard or expected response.
• DELETE
A command which will eliminate unwanted data.
• DELIMITER
A character which separates a group of items or a character string, from other
groups, or which terminates a task.
• DEVICE
Any peripheral hardware connected to the processor and capable of receiving,
sorting, or transmitting data.
• DIAGNOSTICS
Function performed by the processor to identify and check for error conditions in the
robot arm and peripheral devices.
• DIP SWITCH
DIP is an acronym for dual in-line package. A set of small switches on circuit boards
that can be set for different configurations.
• DIRECTORY
A logical structure that organizes a group of similar files.
• DISK
A high-speed, random-access memory device.
• DISK-BASED SYSTEM
System in which programs and files are stored on the hard disk and are read into
memory when requested by the user.
• DISK PACK
A device which is used to store additional data in a computer system, and is usually
removable.


GLOSSARY
E
• ECHO
Process in which characters that are typed on a keyboard are also displayed on the
screen or are sent to the printer.
• EDITOR
An aid for entering information into the computer system and modifying existing text.
• EMERGENCY STOP (E-Stop)

An immediate stop of robot motion, selected by the operator with a switch.
• ENCODER
An electromechanical device that is connected to a shaft to produce a series of
pulses that indicate the position of the shaft.
• EPROM
Acronym for erasable programmable read-only memory. The contents of this
memory (computer chip) are retained, even when power to the system is turned off.
Usually stores executive programs and critical system variables.
• ERROR LOG
A report which contains a sequential list of system error messages.
• ERROR MESSAGE
Messages displayed on the plasma screen of the robot controller, when the action
requested by the operator could not be completed. Error messages can occur when
components malfunction or if an incorrect command is typed by the operator.
• EXPRESSION
A combination of real-valued variables and functions, and mathematical and logical
operators. When evaluated, this combination yields a numeric value.
F
• FEEDBACK
The transmission of a signal from a measuring device (e.g., encoder, transducer) to
the device which issued the command signal within a closed-loop system. See
CLOSED-LOOP SYSTEM.
• FIELD SIGNALS
All electrical signals that exit or enter an electrical panel.


GLOSSARY
• FILE
A set of related records or data elements, which are stored using one name and are
arranged in a structure that can be used by a program.
• FILESPEC
Includes the name, creation date and size of the specified file.
• FIXED DISK
An electromagnetic mass storage device which is not removable. Hard disks have
much higher storage capacity than floppy disks.
• FLOPPY DISK
An electromagnetic mass storage device which can be removed and exchanged.
• FORM FEED
Process which causes a printer to advance the paper to the top of the next page.
• FUNCTION
A formula or routine for evaluating an expression.
G
• GAIN
A proportional increase in power or signal value relative to a control signal. The
ratios of voltage, power, or current as related to a reference or control signal input.
• GLOBAL
Refers to a function or process that affects the entire system or file.
• GRAY CODE
A positional binary number notation in which any two numbers whose difference is
one are represented by expressions that are the same except in one place or column
and differ by only one unit in that place or column.
H
• HALF-DUPLEX COMMUNICATION
Data transmission between two devices, where the signal is sent in only one direc-
tion at a time.
• HANDSHAKING PROTOCOL
Communication rules used for data transmissions between devices. Each device
must recognize the same protocol in order to communicate.


GLOSSARY
• HANG
A term which refers to the state of a computer system that seems to be inoperative
when processing should be taking place.
• HARDSTOP
A mechanical constraint or limit on motion.
• HARDWARE
Physical equipment and devices such as computer hard disk, cables, printer, etc.
• HAZARDOUS SIDE
The unsafe side of a component or panel, such as the inside of the control panel
when power is applied and functions are being performed.
• HOLD
When an external or an internal input is available for a hold condition, the robot will
stop its motion and servo drive power will be removed from the robot. When an
external hold reset is performed, the servo drive power will be energized.
• HOME POSITION
Refers to the starting or resting position of the robot.
• HYBRID ENCODER
On the Kawasaki robot a hybrid encoder is used to generate positional data, and is
composed of an incremental encoder that generates incremental pulses, and an
absolute encoder that generates gray code binary data.
I
• ID
Abbreviation for Identification.
• INCHING
A value that is used during the jogging process that allows the user to position the
robot in small minute increments.
• INCREMENTAL CODE
A digital closed loop feedback code that provides digital feedback pulses to the robot
controller for the purpose of providing positional information. These incremental
pulses are generated by an encoder through the use of an optical disk with alternat-
ing opaque and transparent bars or lines around the periphery of the disk. On one
side of the disk a light source is mounted, and on the opposite side a phototransistor
When the disk rotates, the phototransistor is alternately forced into saturation and
cutoff, producing the digital signal.


GLOSSARY
• INPUT
Transmission of an external signal into a control system.
• INTEGRATED CIRCUIT (IC)

A combination of interconnected circuit elements which are within a continuous
substrate.
• INTERACTIVE SYSTEM
System where the user and the operating system communicate directly; the user
through the keyboard, and the operating system via the display screen.
• INTERLOCK
An arrangement whereby the operation of one part or mechanism automatically
brings about or prevents the operation of another.
• INTERPRETER
A program that changes English-like commands into machine language. An inter-
preter translates and executes one command at a time.
• INSTRUCTIONS
Discrete steps in a computer program that are commands or statements that tell a
computer to do something or identify data.
• INTEGER
A whole number, a number without a fractional part such as 7, -318, or 19.
• INTERFACE
The circuitry that fits between a system and a peripheral device to provide compat-
ible coupling between the two pieces of equipment.
• INTERPOLATION
The mathematical process that the CPU utilizes to plot a path for the robot to travel
from one position to another. A mathematical process that evaluates a number of
dependent and independent variables for the purpose of comparison and prediction.
• INTERRUPT
An external signal that halts program execution so that the computer can service the
needs of some peripheral device or subsystem.
• INTRINSIC SAFETY BARRIER (ISB)

An electronic device used in robot controllers to restrict current and voltage to a safe
level.


GLOSSARY
• INVERTER
A circuit which switches a positive signal to a negative signal, and vice versa.
• I/O
Acronym for Input/Output. The interconnections through which the computer and its
peripheral devices communicate.
• IPM
Acronym for Intelligent Power Module
J
• JOG
A term used to describe the process in which the user moves the mechanical unit
through interaction with the robot controller and the teach pendant. Sometimes
referred to as slewing.
• JOINT
1. A term used to describe the individual axes of a robot.
2. A term used to describe the jogging process in which the robot is jogged one axis
at a time.
• JOINT MOVE
A mode of operation in which the robot moves from one point to the next with an
arching path. All axes motors (required for the move) begin and end their rotation at
the same time. The tool center point does not follow a linear path to reach the taught
position.
L
• LABEL
An identifier for a program command line. To identify an instruction, memory loca-
tion, or part of a program.
• LAN
An acronym for local area network. A group of computer terminals interconnected by
cables, allowing communication of information via the network.
• LCD
An acronym for liquid crystal display. This type of display is made of material whose
reflectance or transmittance of light changes when an electric field is applied.


GLOSSARY
• LIMIT SWITCH
An electrical switch positioned to be switched when a motion limit occurs, thereby
deactivating the actuator that caused the motion.
• LINEAR MOVE
An operation where the rate and direction of relative movement of the robot arm are
continuously under computer control.
• LINE PRINTER
A high-speed output device that prints a line at a time.
• LINE TURN-AROUND
Changing the source of transmission in half-duplex communications.
• LOGICAL OPERATION
Any of several operations that manipulate information according to the rules of logic
(e.g., AND, OR, NOT, and exclusive OR).
• LM
Abbreviation for linear motion.
• LOAD
The weight applied to the end of the robot arm.
• LOCKOUT
Serving to prevent operation of a device or part of it.
• LSB
Abbreviation for least significant bit.
M
• MANIPULATOR
Another term for the mechanical portion of the robot system.
• MACHINE LANGUAGE
A low-level computer language, usually written in binary code.
• MASS-STORAGE DEVICE
An input/output device that retains data input to it. Examples include: hard disk
drives, magnetic tapes, floppy diskettes, and disk packs.
• MECHANICAL UNIT
robot (excluding controller)


GLOSSARY
• MEMORY
An area of the computer which stores data, either permanently or temporarily. When
a program is requested, it is first loaded into memory so it can be accessed quickly
by the processor.
• MHz
Abbreviation for megahertz. One million cycles per second.
• MIRROR IMAGE
A process which converts the positive and negative values of a taught path from a
right-handed robot to a left-handed robot, or vice versa. The actions of the opposing
robots are then coordinated and synchronized.
• mm
Abbreviation for millimeter.
• MNEMONIC
A term used to help the operator remember a large string of words or commands.
• MODEM
A signal conversion device that modulates and demodulates data into an audio
signal for transmission.
• MOMENT OF INERTIA
Used to calculate end of arm tooling and handling weights. The sum of the products
formed by multiplying the mass of the load by the square of the distance from the
tool mounting flange.
• MONITOR PROGRAM
An administrative computer program that oversees operation of a system. The AS
monitor accepts user input and initiates the appropriate response, follows instruc-
tions from user programs to direct the robot, and performs the computations neces-
sary to control the robot.
• MSB
Abbreviation for most significant bit.
• msec
Abbreviation for millisecond (0.001 seconds).


GLOSSARY
N
• NOISE
Any unwanted disturbance within a dynamic, mechanical, or electrical system.
• NULLED
An electrical zero state.
O
• OCTAL NUMBER
A numeral in the base-8 numbering system, which uses the numerals 0 - 7.
• OFF LINE
A state in which communications between two devices cannot occur (e.g., between a
printer and a computer, if the printer is off line).
• ON LINE
A state in which communication between two devices can occur.
• OPERATING SYSTEM
A set of system tasks and commands that are entered by the operator and inter-
preted and performed by the system.
• OPEN LOOP
A control which does not use feedback to determine its output.
• OPERATOR
Any mathematical action or function. The arithmetic operators are: add, subtract,
multiply, divide, modulo, and exponentiate. The relational operators are: greater
than, less than, equal to, and their combinations. The logical operators are: AND,
OR, exclusive OR, negate. The binary logical operators are AND, OR, exclusive OR,
ones complement.
• OPTO
An optical isolator or level converter.
• OVERFLOW
When a value or buffer exceeds a predefined limit.


GLOSSARY
• OVERTRAVEL
An error condition that exists when the robot exceeds its normal software limit val-
ues, and then actuates an overtravel limit switch.
• OVERVELOCITY
When an axis exceeds a preset value for velocity.
• OX (OUTPUT EXTERNAL)
Information transferred from the robot controller through output modules to control
output devices.
P
• PARITY
Method by which errors are detected. In this method the combined binary values of
a byte are flagged as 1 or 0.
• PARSE
To break a command string into individual elements, so it can be interpreted.
• PASSWORD
A code, entered by the user, to permit access to protected information.
• PAYLOAD
The maximum weight that a robot can handle satisfactorily during its normal
operations and extensions.
• PC PROGRAM
PC is an acronym for process control. A PC program cannot contain any step that
causes robot motion. PC programs are used to evaluate logic and variables and
execute program CALL and GOTO commands
• PERIPHERAL DEVICE
Hardware equipment which is external to the CPU, but that transmits and/or receives
I/O from the processor. Examples include: printer, CRT screen, or disk.
• PHASE
The angular relationship between current and voltage in alternating current circuits.
In a waveform or period function, the fraction of the period that has elapsed, as
measured from a reference point. Phase angle is determined by multiplying the
phase by 360 degrees.


GLOSSARY
• PINCH POINT
Any point where it is possible for a part of the body to be injured between the moving
or stationary parts of a robot and the moving or stationary parts of associated
equipment, or between the material and moving parts of the robot or associated
equipment.
• PLA
Acronym for programmable logic array. Used in many servo drive circuits.
• PLAYBACK
An operation where a taught path is run for evaluation purposes.
• PLC
Acronym for programmable logic controller. Usually referred to as the cell module
controller.
• POINT-TO-POINT
A robot motion control in which the robot can be programmed by a user to move
from one position to the next. The intermediate paths between these points cannot
be specified.
• POLARITY KEYS
These teach pendant or multi function panel keys allow the user to jog or slew the
robot in the Joint, Base (XYZ), or Tool coordinates system.
• PORT
The connection point of an opening or passage that is usually located outside the
housing of a device.
• POSITIONAL DATA
The location in space of the robot manipulator.
• POUNCE POSITION
A positional location at a point near the workpiece, clear of the transfer mechanism
and part, from which the robot is ready to begin production.
• PRINTED CIRCUIT
An assembly of electronic elements that provide a complete path of electrical current
through conductive material deposited between terminals on an insulated surface.
• PRECISION POINT
The play back of robot location based on the angular position of the six axes, joint
angles


GLOSSARY
• PRINTING
A process in which characters are stamped on a surface, usually paper.
• PROGRAM
A predefined, step-by-step set of instructions that are entered into a computer so a
specific process can be performed repeatedly without reentering all the steps. Robot
paths are stored and run as part of programs.
• PROGRAM EDIT
Modification of an existing program.
• PROCESSOR
Generally, any hardware or software system for carrying out programs and acting on
data.
• PULSE WIDTH MODULATION (PWM)

A modulation process in which the instantaneous sampling of the modulating wave is
caused to modulate the duration of the pulse. This type of modulation is also re-
ferred to as pulse duration modulation (PDM), or pulse length modulation (PLM).
R
• RAM
Acronym for random access memory. An area used by the CPU for processing and
temporarily loading programs so they can be accessed quickly. The contents of
RAM are lost when the computer is powered down, unless battery backup is pro-
vided.
• REAL NUMBER
A number with a fractional part, such as 1.75, -31.89, .5, -4.00, etc.
• REAL-TIME
The actual time during which the computer analyzes and processes data: informa-
tion is usually processed as it is received.
• REAL VARIABLE
AS language term for a variable that has had a real value assigned to it.
• REPEAT MODE
A mode of operation that allows the user to check positional and auxiliary informa-
tion at a selected speed value, in a continuous or a step by step type of movement of
the mechanical unit.


GLOSSARY
• REPEATABILITY
The measurement of the closeness of agreement among repeated measurements of
the same variable under the same conditions.
• REWRITE MODE
A mode of operation which allows the user to rewrite positional, or auxiliary data,
and to insert or delete step address locations.
• RISC
Acronym for reduced instruction set computer.
• ROM (read-only memory)
A memory device which is programmed at the factory and whose contents thereafter
cannot be altered.
• RS-232C
An ASCII specification for connections and communication between serial devices.
• RUN
A mode of operation that allows the user to select servo motor power to provide drive
energy to the robot, allowing it to perform such modes of operation as teach, check,
repeat, and rewrite.
S
• SAFETY PLUG
A device used with safety fencing to interlock the opening of the fence with the
removal of power to the robot.
• SCROLL
When more information exists than can be displayed on one screen, the operator
can move up and down through the data to view it. When data is scrolled to the
screen, the information previously viewed moves up off the screen, and new informa-
tion enters the screen from the bottom.
• SENSOR
A device used to detect various conditions: proximity, heat, pressure, etc. An electri-
cal signal from the sensor can be used to communicate information to a robot pro-
gram.
• SERIAL
A method of transmitting data by which only one bit is sent or received at any one


GLOSSARY
point in time.
• SEQUENTIAL ACCESS
A method used by many computers whereby data is read in the order in which it is
physically stored.
• SINGULARITY POSITION
When the robot is processing a linear or circular move and two or more joints are in
alignment. The CPU can not process the ambiguity of a singularity configuration and
an error is generated.
• SOFTWARE LIMITS
Programmed values that are included in a program at the point before a mechanical
device hits an overtravel limit switch or a hard limit.
• SOFTWARE
A set of written programs and instructions that are executed by a computer system.
• SOURCE CODE
A program that contains the actual software instructions entered by the user, in
contrast to object code which is source code that has been translated into a lan-
guage which can be interpreted by the computer.
• STRING
A series of characters that have been entered in a distinct sequence that can be
interpreted as a valid statement or command.
• STROKE
The movement in either direction of a mechanical part having a reciprocating motion.
The entire distance passed through in such a movement.
• SUBSCRIPT
A set of numbers that identifies an element of an array.
• SUBROUTINE
A set of instructions that is run by another routine.
• SYMBOL
A character or design that has a distinct meaning and/or is associated with some-
thing.
• SYNTAX
The proper way in which commands and phrases should be typed in order to be
understood by the control system. If the operator incorrectly types a command (i.e.,
misspelled or invalid characters), a syntax error message will be displayed.


GLOSSARY
• SYSTEM DATA
Data that is specific to a individual robot. Zeroing data, upper and lower software
limits, and software switch settings are all examples of system data.
• SYSTEM SWITCH
Software switches that are set to determine various configurations and characteris-
tics of the robot system performance.
T
• TEACH MODE
A mode selected on the operator panel, during which robot arm axes positions can
be taught by the operator and are recorded by the robot.
• TEACH PENDANT
A hand-held, portable device used by the operator during teach and jogging opera-
tions.
• TOOL COORDINATES
A Cartesian coordinate system in which the origin point is at the face plate of the
robot and the orientation of the tool can be expressed in terms of a 3-dimensional
space representation of X, Y, and Z projections.
• TOOL MODE
A mode of operation in which all motions are calculated to maintain the orientation of
the tool in space.
• TORQUE
Something which produces or tends to produce rotation or torsion and whose
effectiveness is measured by the product of the force and the perpendicular distance
from the line of action of the force to the axis of rotation.
• TRANSFORMER
A device to convert the current of a primary circuit into variations of voltage and
current used in secondary circuits.
• TRANSFORMATION
A mathematical description of a location that defines the position and orientation of
the location without regard for the configuration of the robot when it is at that loca-
tion.


GLOSSARY
• TRAP POINT
see pinch point
• TTL
Acronym for transistor-transistor logic.
• TWO’S COMPLEMENT
A means of representing a negative number as one more than the binary comple-
ment of the absolute value of the number.
• TRIANGULAR WAVEFORM
A waveform that has the shape of a triangle and is used in determining sampling
values for servo drive circuits that utilize pulse width modulation.
U
• UHF
Acronym for ultra-high frequency.
V
• VARIABLE
The name of a memory location or stored value. A variable can refer to a scalar or
an array.
• VELOCITY COMMAND
This analog signal is directly proportional to motor speed, and provides the initial
signal that is processed by the servo drive system to drive a servo motor.
• VELOCITY ERROR
When the robot controller detects an axis that has exceeded a preset value for
velocity, the robot controller will E-stop the robot.
• VOLT
A unit of electrical potential difference and electromotive force. One volt is equiva-
lent to the force required to produce one amp of current through one ohm of resis-
tance.


GLOSSARY
• WORK ENVELOPE
The effective range or reach of a robot’s axes.
• WORLD COORDINATES
A Cartesian coordinate system in which the origin point is near the base of the robot,
and robot movement can be expressed in terms of a 3-dimensional space represen-
tation of X, Y, and Z projections.
• WRITE
In computer systems, a process in which information is output to and stored by a
device or area in memory.
• WS (WELD SCHEDULE)
Data that is stored in the weld controller and provides the specific current, clamp
pressures, etc. for spot welding applications.
• WX (WAIT EXTERNAL)
The wait external signal is one of many inputs that are processed by the robot con-
troller. When the robot encounters a wait external condition, the robot will cease
motion and the servo power will be removed.
Z
• ZEROING
This procedure provides the robot controller with encoder data that is referenced
from a known mechanical position (zeroing witness marks, in simple zeroing, or
inclinometer values in precision zeroing) and then establishes an encoder value for
this known position. Two methods can be used, simple and precision zeroing. Some
robot manufacturers call this procedure mastering or calibration.


INDEX
INDEX ......................................................................................................................IN-2
March 28, 2002 IN-1


INDEX
Symbols
+12V, 6-100
+24VFAIL Signal, 3-25, 4-21
/ACFAIL Signal, 3-25, 4-21
/DCPWR-CUT Signal, 3-23, 3-25, 6-60
_acfail_vme Signal, 3-25
_dcfail Signal, 3-25
10base-T Interface, 6-19
115 VAC Utility Outlet, 3-12, 5-7
12V_INT, 6-100
12VA, 6-100
1FG Board, 3-18, 6-14, 6-106, 6-109
Connectors, 6-108
Test Points, 6-108
1FS Board, I-11, 1-21, 6-2, 6-18, 6-44
RISC Processor, 6-44
1FT Board, 5-24, 5-26
Flash Memory, 5-26
1FU Board, 5-24
1GA Board, 6-18, 6-19, 6-56
1GA/1HA Board, 1-20, 1-22, 4-6, 4-16, 5-7, 5-24, 5-26, 6-2, 6-18, 6-19, 6-21, 6-24, 6-60, 6-68
Connectors, 6-23
Functional Block Diagram, 6-21
Layout, 6-22
LEDs, 6-26
Replacement, 8-3
Switch Settings, 6-25
Test Points, 6-26
1GA/HA
Central Processing Unit (CPU), 6-18
1GB Board, 1-22, 1-25, 3-18, 3-27, 4-17, 6-4, 6-14, 6-63, 6-68, 6-73, 6-75, 6-86, 6-92, 6-96, 7-3, 7-
4
SRAM Memory, 1-22, 6-68
Test Points, 6-72
1GC Board, 1-22, 4-18, 4-20, 6-4, 6-64, 6-68, 6-75
Connectors, 6-80, 7-17
1GD Board, 1-22, 4-18, 4-20, 6-4, 6-68, 6-75
1GM Board, 1-22, 6-4, 6-73, 7-10
1GS Board, 6-2, 6-20, 6-27, 6-100, 6-101
Baud Rate, 6-27
1GV Board, 6-132, 6-133
I/O, 6-136
Layout, 6-134
LEDs, 6-135
1GV-CN1 Pin Assignment, 6-134
1GV-CN2 Pin Assignment, 6-135
1GW Board, I-11, 1-21, 3-49, 6-18, 6-29, 6-36, 6-50, 6-56, 6-91
Analog Output Settings, 6-43
Connectors, 6-40
External Outputs, 6-38
General Purpose Input Signals, 6-34
IN-2 March 28, 2002


INDEX
Jumper Settings, 6-42, 6-43

Jumpers, 6-40
Output Specifications, 6-36
Parallel I/O (PI/O), 1-21
1GW/HW Board
Polarity, 6-29
1HA Board, 5-32, 6-56, 6-94, 6-100, 6-101
1HA CPU, 6-131
1HG Board, 6-109
Connectors, 6-110
Layout, 6-110
Test Points, 6-110
1HP Board, 1-21, 1-22, 3-15, 3-25, 4-2, 4-3, 4-6, 4-16, 5-7, 6-4, 6-18, 6-60, 6-63, 6-66, 6-86, 6-
92, 6-93, 6-100, A-25
1HS Board, 1-21, 6-2, 6-50, 6-51, 6-52, 6-56, 6-57, 6-58
Baud Rate, 6-58
DIP Switches, 6-58
LEDs, 6-51
Robot Signal Numbers, 6-57
Station Number, 6-59
1HW Board, 6-29, 6-35, 6-36, 6-91
Analog Output Settings, 6-43
Connectors, 6-40
Connectors Jumpers, 6-40
External Outputs, 6-39
General Purpose Input Signals, 6-35
Jumper Settings, 6-42, 6-43
Output Specifications, 6-36
1HY Board, 1-21, 1-22, 3-12, 3-14, 3-15, 3-18, 3-27, 4-2, 4-3, 4-12, 6-14, 6-60, 6-66
1HZ Board, 1-20, 6-14, 6-15, 6-16, 6-19, 6-20, 6-63
JP1 - JP31, 6-17
JP32, 6-17
1HZ Motherboard, 3-18
1JK Board, 6-4, 6-75
1LT Board, 6-20, 6-62, 6-100, 6-101
Connectors, 6-102
Layout, 6-100
LEDs, 6-102
Test Points, 6-102
1LU Board, 6-8, 6-62, 6-63, 6-86, 6-87, 6-89, 6-92, 6-93, 6-94, 6-96
Connectors, 6-90
J1, 6-91
LEDs, 6-88
Test Points, 6-91
1LW Board, 6-8, 6-86, 6-92, 6-93, 6-96, 6-97
Connectors, 6-98
LED1, 6-99
LED2, 6-99
LEDs, 6-99
Voltage Regulator, 6-92, 6-93
March 28, 2002 IN-3


INDEX
A
A Harness, 3-46
A/D, 6-50
Absolute Count, 8-8, 8-13, 8-37, 8-40
AC Ripple, 1-22, 6-75
AC Servo Motors, 1-22, 6-75
Accessory Cover, 3-27
Accessory Panel, 5-7
Accuracy, 2-11
F-Series, I-10
KE610, I-10
KF121, I-10
UT-Series, I-10
UX-Series, I-10
UZ-Series, I-10
Z-Series, I-10
ACER Signal, 4-21
Air Pressure, 6-10, 6-93
Air Pressure Meter, 6-92
Air Purging/Pressurizing System, 6-9
American National Standards Institute (ANSI), 2-6
ANSI, 2-6
ANSI.SYS File, 5-38
AS Language, 5-37
#PPOINT Command, 8-2
HOME Command, 8-2
ZZERO Command, 8-8, 8-38
AS Monitor, 5-37, 5-38, 5-39, 5-40
AS System Software, 1-20, 4-3, 4-4, 5-24, 5-26, 5-28, 5-32, 6-18, 6-19
Auto Voltage Regulator (AVR), 3-20
AUX 41, 8-4, 8-13, 8-40
AUX 51, 4-12
AUX 95 (Environment DATA 2), 5-40
AUX 140, 8-4, 8-13, 8-40
AUX 48, A-2, A-4
AUX 51 SOFTWARE LIMIT, A-22
AVR Power Supply, I-9
AVR Power Supply (G1), 1-20, 3-12, 3-14, 3-18, 3-25, 3-27, 6-14, 6-60, 6-61
Axes
B-Axis, I-2
D-Axis, I-2
O-Axis, I-2
R-Axis, I-2
S-Axis, I-2
S-axis, I-2
T-Axis, I-2
V-Axis, I-2
B
B Harness, 3-46
B-Axis, I-2
Barrier Device, 6-8
IN-4 March 28, 2002


INDEX
Base (World) Coordinate System, I-3

Base (World) Coordinates, I-10
Base Coordinate System, A-3, A-4
BATER, 6-92
Batteries
Encoder Board
Replacement, 6-106, 6-109
Lithium, 3-18
Battery, 6-98
Battery Error, 6-92
Battery Replacement, 6-99
Baud Rate, 1GS Board, 6-27
Bit Data, 6-50
System Area, 6-53
Board A, 5-31, 5-32
Brake Assembly, 2-12, 7-31
Brake Control, 3-27
Brake Release Switches, 4-4, 4-13
Brake Sequence Timing, 7-32
Brakes, 1-21, 2-13, 3-12, 3-17, 4-12, 4-20, 5-14, 6-60, 6-66, 6-86, 6-93
Bridge Rectifier, 3-12
Brightness Control, 1-10, 5-29
Bus Bars, 1-22, 6-75
Buzzer, 5-33, 6-131
C
C Controller, Explosion-Proof, 6-8
C Controller Versions
Explosion-proof (EP), 1-3
New Production, 1-3
Original Production, 1-3
C1, 1-22, 6-75
C1 Capacitor, 3-12, 3-14, 3-28, 6-75, 7-20
C35 Controller, 6-11
C37 Controller, 6-12
C3x Controller
Design Specifications, I-10
Power Requirements, I-14
Software Features, I-11
Special Features, I-12
Capacitors
C1, 3-14
Card Rack, I-9, 1-20, 3-14, 3-18, 3-20, 3-25, 3-27, 6-4, 6-14, 6-50, 6-60
Caution Symbol, 2-8
CC-Link, 1-21, 6-2, 6-50, 6-54, 6-55, 6-58
Cable, 6-54
Central Processing Unit (CPU), 6-20
Check Mode, 2-13
Circuit Breakers, 3-12
F1, 6-61
F1 (Main), 3-2, 3-27, 3-36, 3-37
F2, 3-12, 3-28, 6-60
March 28, 2002 IN-5


INDEX
F3, 3-12, 3-14, 3-27, 6-61

F4, 3-12, 3-27
F5, 3-12
Circuits
LS1P/LS1N, 4-5
LS2P/LS2N, 4-5
Overtravel, 4-12
Thermal, 4-18
CJ44, 4-2
CMOS RAM, I-10
Commutation, 7-45, 7-46
Compressed Air, 6-93
Conditions
E-Stop, 5-13, 5-15
CONFIG.SYS File, 5-38
Connector CJ44, 4-6, 4-11
Connectors
1FG-CN10, 6-106, 6-109
1FS-CN3, 6-44
1GA-CN1, 6-23
1GA-CN2, 6-23
1GA-CN3, 6-23
1GA-CN4, 6-23
1GA-CN5, 6-23
1GA-CN6, 6-23
1GA-CN7, 6-23
1GA-CN8, 6-23
1GA-CN9, 6-23
1GA-CN10, 6-23
1GA-CN11, 6-23
1GB-CN1, 6-71
1GB-CN2, 6-71
1GB-CN3, 6-71
1GB-CN4, 3-27, 6-71
1GB-CN5, 6-71
1GB-CN6, 6-71
1GB-CN7, 6-71
1GB-CN8A, 6-71
1GB-CN8B, 6-71
1GB-CN9, 6-71
1GB-CN10, 6-71
1GB-CN11, 6-71
1GB-CN12, 6-71
1GB-CN13, 6-71
1HP-CN1, 6-63
1HP-CN2, 6-63
1HP-CN3, 6-63
1HP-CN4, 6-63
1HS-CN2, 6-54
1HZ-CN1, 6-16, 6-19
1HZ-CN2, 6-16
1HZ-CN3, 6-16
1HZ-CN4, 6-16
IN-6 January 9, 2004


INDEX
1HZ-CN5, 6-16
1HZ-CN6, 6-16
1HZ-CN7, 6-16
1HZ-CN8, 6-16
1HZ-CN9, 6-16
1HZ-CN10, 6-16, 6-66
Faston, 3-49
Molex, 3-42, 3-44
X1-SA, 6-84
X2-SA, 6-75, 6-84
X3-SA, 6-75, 6-84
X4-SA, 6-84
X5-SA, 4-18, 6-84
XM1-SA, 6-84
XM2-SA, 6-84
XM3-SA, 6-84
Connectors, 1GW/HW Board, 6-32
Contactors
K1, 1-21, 3-12, 3-14, 3-18, 6-4, 6-14, 6-60, 6-66, 6-75
K2, 1-21, 3-12, 3-14, 3-18, 6-4, 6-14, 6-60, 6-66, 6-75
K3, 3-12, 3-14
Continuous Path, 2-11
Contrast (MFP), 1-8, 5-23
Control & Communication Link (CC-Link), 1-21, 6-2, 6-50
Control IC, 1-22, 6-75
Controller Thermal Circuit, 4-18
ControlNet, 1-21, 6-44
Coordinate System, A-2
Coordinate Systems, I-3, I-11, A-3
CR1 Relay, 4-3, 4-4
CR12, 6-100
CR2 Relay, 4-3, 4-4, 4-5, 4-12
CR3 Relay, 4-3, 4-4, 4-5, 4-12
CR4 Relay, 4-3, 4-4, 4-5, 4-12
Current Detect Modules, 1-27
Current Sensors, 1-22, 6-4, 6-73
Cycle Start, 1-14
CYCLE START Switch, 5-2, 5-15, 5-16, 5-17, 5-20
D
D-Axis, I-2
d-q Axis Coordinate Transformation, 7-6
D/A, 6-50
Data Editing, I-11
DC-DC Converter, 6-100
Dedicated Input Signals, I-12
Dedicated Signals
Inputs, I-12
Outputs, I-12
Deviation Error, 2-13
Digital Command Signal, 1-25
Dimensions, I-14
March 28, 2002 IN-7


INDEX
Diode Module, 1-22, 3-28, 6-75

Discharge Control, 1-22, 6-75
Discharge Resistor, 3-14
Disconnect, Main, 3-2
DMS, 6-101
Dogs, 4-13
DOS Prompt, 5-38
E
E-Stop, 5-33
Circuit, 6-93
Signal, 6-86
Switch, 6-60, 6-100, 6-101, 6-130, 6-131
E-Stop Condition, 5-13, 5-15
E-Stop Switch, 1-12, 1-21, 4-5, 4-6, 5-2, 5-7, 5-12, 5-14, 5-19, 5-23, 5-26, 5-29
E-stop Switch, 2-9, 2-10, 2-11, 2-13
E1, 6-104
E3, 6-104
Earth Ground, 6-86, 6-104
EBM, 6-86, 6-92, 6-96
Battery, 6-98, 6-99
EDT.BAT, 5-38, 5-39
Electro-Magnetic Interference (EMI), 3-14
EMERGENCY STOP Switch, 4-3, 4-4
Emergency Stop Switch, 1-9, 1-10
EMS, 6-101
Enabling Device, 1-10, 1-12, 1-21, 2-11, 5-23, 5-29, 5-33, 6-60, 6-62, 6-100, 6-101, 6-130, 6-131
Enabling Devices, 1-8, 4-3
Encoder, 1-25, 6-8, 6-93, 6-96, 6-98, 7-44
AVR Power Supply, 6-93
AVR Power Supply (G21), 6-86
AVR Power Supply G21, 6-66, 6-86, 6-92
H20, 7-44
H32KT, 7-44
Interface, 6-86
M21, 7-44
M30KT, 7-44
Transmit/Receive (ET/R) Circuit, 6-86, 6-92
Encoder Barrier Module (EBM), 6-8, 6-86, 6-96, 6-98
Encoder Board, 6-106, 6-109
Battery Replacement, 6-106, 6-109
Encoder Errors, 7-48
Encoder Feedback, 3-42, 3-44
Encoder Replacement, 7-49
End Effector, A-2
Environment DATA 2, AUX 95, 5-40
EP MFP, 5-40
EP Teach Pendant, 1-12, 5-2, 5-14, 5-33, 5-34, 6-8, 6-100, 6-101, 6-103, 6-130, 6-131
EP Type C Controller, I-9, 3-2, 3-6, 3-7, 3-8, 3-10, 3-11, 3-28, 3-46, 5-4, 6-10, 6-66, 6-85, 6-98, 7-
44
E-Stop Circuit, 6-62
IN-8 January 9, 2004


INDEX
MFP, 6-125, 6-126

Multi Function Panel, 5-27
Power Distribution, 3-31
EP Type C controller, 6-27, 6-62, 6-63, 6-86
EP Type MFP, 1-9
EP Unit, 3-2, 6-8, 6-85, 6-86, 6-99, 6-100
ERROR, 5-13, 5-19, 5-20
Error -1501, 4-17
Error -1601, 4-12
Error -1602, 4-12
Error Codes/Troubleshooting, 9-2
Error Conditions, 5-2
ERROR Lamp, 1-14
Error Messages, I-11, I-12
Error Recovery, 9-2
ERROR RESET Switch, 4-12, 5-13, 5-15, 5-16, 5-17
ET/R Circuit, 6-86, 6-92
EtherNet, 6-19
Explosion Proof Unit, I-9
Explosion-Proof (EP), 6-2
Explosion-Proof (EP) C Controller, 6-8
Explosion-Proof (EP) Type TP, 1-7
Explosion-proof (EP) Type TP, I-9
Explosion-Proof (EP) Unit, 6-85
Explosion-Proof Teach Pendant, 1-12, 5-33
Circuit Boards, 6-85
Explosive Gas, 6-8, 6-9, 6-10, 6-93
EXT-EMS, 6-101
EXT24V, 6-100
External Axis, 6-64
External Hold, 4-6, 4-16, 5-13, 5-15
External Hold Signal, 4-16
External Hold Switches, 4-3
External Input Signals
Number of Inputs, 6-33, 6-35
External Output Signals
Number of Outputs, 6-36, 6-39
External Signals, 4-6
External Trigger, 4-6
F
F1, 3-27, 3-36, 3-37, 6-61
F1 Fuse, 4-4
F2, 3-12, 3-28, 6-60, 6-75
F3, 3-12, 3-14, 3-27, 6-61
F3 Fuse, 4-4
F4, 3-12, 3-27
F5, 3-12
Fans, 1-22, 3-12, 3-14, 3-15, 3-27, 6-66
FC06N, 2-14
Features, 1-2
March 28, 2002 IN-9


INDEX
Flammable Gas, 6-8

Flash Memory, 1-8, 1-20, 1-21, 1-22, 5-23, 5-26, 6-18, 6-20, 6-44, 6-68
Flash RAM, 5-28, 5-29, 5-31
Flash RAM PC Card, 5-28
Flash Random Access Memory (RAM), 1-10
Floppy Disk Drive, 1-7, 5-2, 5-39, 5-40
Floppy Disk Drive (FDD), 1-17
Flow Meter, 6-8, 6-9, 6-86, 6-92, 6-94
Flow Rate Switch, 6-94
FLS LED, 6-94
FP20N, 2-15
FS02N, 2-16
FS03N, 2-16
FS06 Robot
Zeroing, 8-33
FS06L, 2-17
FS06N, 2-14
FS10 Robot
Zeroing, 8-33
FS10C, 2-14
FS10E, 2-18
FS10L, 2-19
FS10N, 2-20
FS20 Robot
Zeroing, 8-33
FS20C, 2-21
FS20N, 2-22
FS30 Robot
Zeroing, 8-33
FS30L, 2-23
FS30N, 2-24
FS45 Robot
Zeroing, 8-33
FS45C, 2-24
FS45N, 2-25
Full Duplex, 6-27
Fuse, 6-103
Fuses
F1, 4-4
F3, 4-4
FUTL.BAT, 5-38, 5-39
FW06N, 2-14
G
G1 (AVR), 3-12, 3-20
Gas, Explosive, 6-8, 6-9, 6-10, 6-93
Gas, Flammable, 6-8
Gate Array, 7-3, 7-6, 7-9
Goggles, 2-9
Ground Wire, I-14
IN-10 March 28, 2002


INDEX
H
Hard Hat, 2-9
Hardstop, 2-13
Hazardous Area, 6-8, 6-10, 6-86, 6-93, 6-104
Hexadecimal Identification Code, 6-73
High-Speed Playback, 2-11
Hold, 1-14
Hold State, 5-2
HOLD/RUN Switch, 5-13, 5-15, 5-16, 5-37
Host Communication Port, 5-37, 5-40
Hour Meter, 1-22, 3-12, 3-14, 3-15, 3-27, 6-66
Hybrid Encoder, 1-27
Hybrid Integrated Circuit (HIC), 1-22, 6-75
I
I/O Signals, I-12
I/O24V Signal, 6-60
Identification Code, 7-10
Inclinometer, 8-17
Inductive Load, 6-37
Industry Pack (IP), 1-20, 6-2, 6-18, 6-27
Initialization, 5-13, 6-24
Inrush Current Protection, 1-22, 6-75
Inrush Resistor RS2, 3-14
INST.BAT, 5-38, 5-39
Insulated Gate Bipolar Pransistors (IGBTs), 1-22
Insulated Gate Bipolar Transistors (IGBTs), 3-28, 6-75
Intelligent Power Module (IPM), 1-22
Intelligent Power Modules (IPMs), 3-28, 6-75, 7-3, 7-21, 7-22
Interface Panel, I-9, 1-16, A-26
Interface Panel, Optional, 2-13
Interfaces
Industry pack (IP), 1-20, 6-18
Interlock Control Circuit, 2-12
INTERLOCK LED, 6-95
Interlock Signal, 6-86
Intrinsic Safety, 5-33, 6-85, 6-86, 6-92, 6-96, 6-101, 6-103, 6-130
Intrinsically Safe, 6-8
Isolation Circuit, 6-86, 6-96
J
J1, 6-91
JM8, 5-26
JT1
Operating Angle, A-21, A-22
K
K1 Contactor, 1-21, 3-12, 3-14, 3-18, 3-28, 4-4, 4-5, 4-12, 6-4, 6-14, 6-60, 6-66, 6-75
K1/K2 Relays, 6-96
K2 Contactor, 1-21, 3-12, 3-14, 3-18, 3-28, 4-4, 4-5, 4-12, 6-4, 6-14, 6-60, 6-66, 6-75
K21 Relay, 6-86, 6-92, 6-93
March 28, 2002 IN-11


INDEX
K3 Contactor, 1-22, 3-12, 3-14, 3-15, 3-27, 6-66, 6-75

KCMON, 5-37, 5-38, 5-39
KCMON Interface Software, 1-16
KCMON.BAT, 5-38, 5-39
KCMON\DOSV, 5-38
KCMON_.EXE, 5-38, 5-39
KCMONENV.DAT, 5-38, 5-39
KCWIN, 5-37, 5-40
KCWIN Interface Software, 1-16
KCWIN.EXE, 5-40
KCWIN.INI, 5-40
KE610, I-10, 2-26, 3-46
Machine Harness, 3-48
Separate Harness, 3-46, 3-48
KE610 Mechanical Unit, 1-4
Keyboard Screen, 5-40
Keypad, 1-10, 1-12, 5-29, 5-31, 5-33, 6-131
KF121, 2-27, 3-46
Machine Harness, 3-47
Separate Harness, 3-46, 3-47
L
Lamp
ERROR, 1-14
LCD
Display Data, 6-101
Limit Switch, 1-21, 2-13, 6-8, 6-60, 6-86, 6-92, A-22
Limit Switch Bracket, A-21, A-22
Limit Switches, I-12, 3-49
Liquid Crystal Display (LCD), 1-8, 1-10, 5-23, 5-24, 5-29, 5-32, 5-33, 6-131
Load, 6-36
Lock Out, 2-12
Low Voltage Detection Circuit, 6-92
LS1P/LS1N Circuit, 4-5
Lubrication, A-23
LVDC, 6-92
M
Main Disconnect, I-9, 2-12, 3-2, 5-17
Maintenance Log, 6-132
Major Axes, I-2
Master Station, 1-21, 6-2, 6-50
Material Handling, A-26
Mechanical Stopper, A-21, A-22
Mechanical Unit, 1-28
Mechanical Unit Drive Mechanisms, 1-28
MELSEC, 6-54
Memory
Flash, 1-8, 1-21, 1-22, 5-23, 5-26, 5-28, 6-20, 6-44, 6-68
SRAM, 1-20, 1-22, 6-18, 6-20, 6-24, 6-68
Supplemental, I-13
Memory Capacity, I-10
IN-12 March 28, 2002


INDEX
MFP, 6-20, 6-60

EP Type C Controller, 6-125, 6-126
MFP, EP Type, 1-9
Mine Safety and Health Administration (MSHA), 2-6
Minor Axes, I-2
Mitsubishi, 1-21, 6-2, 6-50, 6-54, 6-56
Molex Connectors, 3-42, 3-44
Motor Harness A, 3-32, 3-42, 3-44
Motor Harness B, 3-32, 3-44
Motor Power, 1-14, 4-6, 4-12, 4-16
MOTOR POWER Switch, 5-2, 5-13, 5-15, 5-17, 5-20
Motor Replacement, 7-38
Motor Specifications, 7-34
Motor Thermal (MTH), 6-93
Motor Thermal (MTH) Switch Circuit, 6-86
Motor Thermal Signal, 4-17
Motors
AC Servo, 5-13, 5-14, 5-15
MSHA, 2-6, 2-9
MSON Signal, 7-20
MTH Switch, 6-93
Multi Function Panel, 2-13, 5-2
EP Type C Controller, 5-27
Multi Function Panel (MFP), I-9, I-13, 1-7, 1-8, 1-9, 1-20, 1-21, 4-2, 4-5, 4-12, 4-17, 5-2, 5-14, 5-
23, 5-26, 5-28, 5-36, 5-40, 6-18
N
NIOSH, 2-6, 2-9
Noise Filters
Z2, 3-12
Null Modem Cable, 5-37
O
O-Axis, I-2
OAT, A-2, A-3, A-4
Operation Panel, I-9, 1-7, 1-14, 2-13, 3-12, 4-2, 4-12, 5-2, 5-6, 5-7, 5-8, 5-9, 5-10, 6-101
EP Type C Controller, 5-6
Standard C Controller, 5-5
Orientation, A-3
OSHA, 2-6, 2-9
Output Amplifier Circuit, 6-36
Overheat, 7-29
Overtravel Circuit, 4-12
Overtravel Limit Switches, 3-42, 3-44, 4-3, 4-5, 4-12
P
P-N Voltage, 4-20
P-N Voltage Detection Circuit, 4-20
Parallel I/O, 6-29
Parallel I/O (PI/O), 6-2
Parts, Replacement, 2-12
Payload, 4-17
March 28, 2002 IN-13


INDEX
PC, 5-2
PC Card, 1-7, 1-13
PC Card Slot, 5-26
PC Files
ANSI.SYS, 5-38
CONFIG.SYS, 5-38
EDT.BAT, 5-38, 5-39
FUTL.BAT, 5-38, 5-39
INST.BAT, 5-38, 5-39
KCMON.BAT, 5-38, 5-39
KCMON_.EXE, 5-38, 5-39
KCMONENV.DAT, 5-38, 5-39
KCWIN.EXE, 5-40
KCWIN.INI, 5-40
Peripheral Device, 2-9
Personal Computer (PC), 5-2, 5-32, 5-37
Personal Safety, 2-9
Phase
Pressurizing, 6-93, 6-95
Purging, 6-93, 6-94
Supplied Air Check, 6-93
PLC, 6-2, 6-44, 6-50, 6-56
Pneumatic, 2-12
Point-to-Point Mode, 2-11
Polarity, 6-29, 6-33, 6-35
Power Block, 1-22, 1-25, 1-26, 3-12, 4-3, 4-4, 4-5, 6-66, 6-75, 7-12
1GC, 7-12
1GD, 7-12
1JK, 7-12
Connectors, 7-14
Diode Module, 1-22, 6-75
Replacement, 7-25
Single Axis, 6-64
Power Cable, I-9
Power Lamp, 3-12, 3-14, 3-15, 3-27
Power ON Cycle, 6-93
Power, Primary, 3-27
Power Supply
AVR, 3-20
Power Unit, 1-26
Pressure, Air, 6-93
Pressure Drop, 6-93
Pressure Switch, 6-8, 6-10, 6-86, 6-93, 6-94, 6-95
Pressurized Container, 6-8, 6-9, 6-10, 6-92, 6-93, 6-94
Pressurizing, 6-9
Pressurizing Phase, 6-93, 6-95
Preventative Maintenance, A-23
Printed Circuit Boards, I-9
Replacement, 6-137
Programmable Logic Controller (PLC), 1-21, 6-2, 6-44, 6-50
Prompt
DOS, 5-38
Proximity Switch, 3-49
IN-14 March 28, 2002


INDEX
PSL LED, 6-93, 6-94, 6-95

Pulse Width Modulation (PWM), 1-22, 1-25, 6-68, 6-75
Purge, 6-9
Purge Phase, 6-93
Purge Valve, 6-8, 6-9, 6-86, 6-93, 6-94
Purging Phase, 6-93, 6-94
PWM Generator, 7-6, 7-8
R
R-Axis, I-2
Radio Frequency Interference (RFI), 3-14
RDC, 6-100, 6-101
RDC Power Supply, 6-100
Regenerative Resistors, 4-18
Regenerative Voltage, 7-21
Relay Board, 3-12
Relay Chassis, I-9, 1-22, 3-12, 3-15, 3-18, 3-28, 6-14, 6-66, 6-75
Relay Distribution Circuit (RDC), 6-100
Relay Interlock Circuit (RIC), 6-8, 6-63, 6-86, 6-92
Relays
CR1, 4-3, 4-4
CR2, 4-3, 4-4, 4-5, 4-12
CR3, 4-3, 4-4, 4-5, 4-12
CR4, 4-3, 4-4, 4-5, 4-12
RY2, 4-3, 4-4
RY3, 4-3, 4-4
RY4, 4-3, 4-4
Remote Device Station, 1-21, 6-2, 6-50
Remote Gate Servo On (RGSO) Signal, 6-68
Remote I/O (RI/O), 1-21, 6-44
Remote Input/Output, 6-50
Repeat Mode, 1-21, 2-11, 3-14, 3-28, 4-5, 4-16, 5-2, 5-13, 5-15, 5-16, 6-4, 6-14, 6-60, 6-66, 6-75
Replacement Parts, 2-12
Replacement Procedures
Switches/Lamps, 5-17
Resistors
Coding, 7-10, 7-11
Regenerative, 4-18, 7-21
RS1, 3-12, 3-14, 6-75
RS2, 3-12, 3-14, 6-75
Restricted Space, 2-9, 2-11, 2-14
Retreat Path, 2-11
RIC, 6-93
RISC Processor, I-10, 6-18, 6-44, 7-3
Robot Controller Versions, I-9
Robot Specifications, I-4, I-5, I-6, I-7, I-8
Rocker Arm, 4-13
Rotation Count, 8-4, 8-8, 8-13, 8-37, 8-40
Rotor, Permanent Magnet, 7-28
RS-232C, 1-20, 5-7, 5-24, 5-32, 5-37, 6-18
RS-422, 5-33, 6-2, 6-20, 6-27, 6-101, 6-131
RS-485, 1-21, 5-24, 5-32, 6-20, 6-44
March 28, 2002 IN-15


INDEX
RS1 Resistor, 3-12, 3-14, 6-75, 7-20

RS2 Resistor, 3-12, 3-14, 6-75
Run State, 5-2
RXD, 6-101
RY2 Relay, 4-3, 4-4, 4-5
RY3 Relay, 4-3, 4-4, 4-5
RY4 Relay, 4-3, 4-4, 4-5
S
S-Axis, I-2
S-axis, I-2
Safeguarded Space, 2-2, 2-9, 2-10, 2-11, 2-12
Safety
Intrinsic, 6-86
Safety Categories, 2-9
Safety Coordinator, 2-10
Safety Device, 2-10
Safety During Inspection and Maintenance, 2-12
Safety During Operation, 2-11
Safety During Programming, 2-11
Safety Features, 2-13
Safety Fence, 2-12, 4-6
Switches, 4-3
Safety Glasses, 2-9
Safety Plug, 2-12
Safety Shoes, 2-9
Scaling, 6-73
Sealing, 6-85
Sensor Cable, 3-49
F-Series Robots, 3-49
Sensor Wiring Diagrams, 3-50
Separate Harness, 3-32
KE610, 3-46
KF121, 3-46
Separate Harnesses, I-9
Servo Amplifier, 1-26, 3-28, 7-22
Servo Amplifiers, I-9
Servo Drive Motor, 2-12
Servo Motor, 1-25
Servo Motors, 4-17, 7-2, 7-27
Part Numbers, 7-33
Servo Power Block, 7-12
Replacement, 7-25
Servo Power Unit, 7-20
Servo Software, 1-22, 1-25, 5-26, 5-28, 6-68, 7-9, 7-10
Servo Spot Weld Gun, 6-64
Servo Unit Error Signal (SVER), 6-68
Signal Cable, 3-42, 3-44
Signals
+24VFAIL, 3-25, 4-21
/ACFAIL, 3-25, 4-21
/DCPWR-CUT, 3-23, 3-25, 6-60
IN-16 March 28, 2002


INDEX
_acfail_vme, 3-25
_dcfail, 3-25
ACER, 4-21
CND-K1, 1-22, 6-66
CND-K2, 1-22, 6-66
External Hold, 4-16
I/O24V, 6-60
Motor Thermal, 4-17
MSON, 7-20
Remote Gate Servo On (RGSO), 6-68
Servo Unit Error Signal (SVER), 6-68
Sine Wave, 7-8
Single Axis Power Block, 6-64
Sink, 6-36
Slogic, 1-21, 6-44
Small Teach Pendant, I-9, I-13, 1-7, 1-13, 1-20, 1-21, 2-13, 5-2, 5-14, 5-36, 6-60
Small Teach Pendant (TP), 6-18
Small TP, 6-20
Soft Key, 5-29, 5-32
Soft Keys, 1-10, 1-12
Software Interface, 1-17
Software Interface Panel, 1-7
Software Limit, 2-13, A-22
Software Limits, 4-12
SOL_OFF Signal, 6-94
SOL_ON LED, 6-94
SOL_ON Signal, 6-94
Source, 6-36
Spark Arrester, 3-12
Spark Arresters
Z3, 6-75
Special Tools, A-28
Specifications, 7-34
Speed, I-11, 2-11
Spot Welding, A-27
Spray Painting, 6-85
SRAM Memory, 1-20, 1-22, 6-18, 6-20, 6-24, 6-68
SRAM PC Card Slot, 5-23
Stator Windings, 7-29
Stopper Block, A-22
Strip Chart Recorder
Voltage, 3-40
Super Capacitor, 6-19
Supplied Air Check Phase, 6-93
Surge Protection, 6-37
SW1, 5-26
Switch
E-Stop, 1-10, 1-21
E-stop, 1-12
Limit, 1-21
T.LOCK, 1-10
TEACH LOCK, 1-8
Switches
January 9, 2004 IN-17


INDEX
1HP Override, 4-12

CYCLE START, 5-15
E-Stop, 4-4
EMERGENCY STOP, 4-3, 5-12
Emergency Stop, 5-29
ERROR RESET, 4-12
External Hold, 4-3
Limit, I-12
Main Disconnect, 5-13
MOTOR POWER, 5-2, 5-13, 5-15, 5-17, 5-20
Overtravel Limit, 4-3
Safety Fence, 4-3
TEACH/REPEAT, 4-5, 5-7, 5-12, 5-15, 5-19
Thermal, 4-18
System Area, 6-50
T
T-Axis, I-2
T1, 3-11
Tag Out, 2-12
Tap/Drill Size, A-20
TB1, 3-12, 3-14, 3-27
TB2, 4-2, 4-6, 6-100, 6-101, A-25
TEACH LOCK Switch, 5-23, 5-26, 5-29, 5-37
Teach Lock Switch, 6-130
Teach Mode, 1-21, 2-13, 3-14, 3-28, 4-5, 4-16, 5-2, 5-13, 5-15, 5-16, 6-4, 6-14, 6-60, 6-66, 6-75
Teach Pendant, 2-11, 2-13
EP, 6-130, 6-131
Teach Pendant (TP)
EP, 6-130
Teach Pendant (TP), EP, 6-100
Teach Pendant, EP, 6-2
TEACH/REPEAT Switch, 4-3, 4-5, 5-7, 5-12, 5-15, 5-19
TERMINAL, 5-40
Thermal Sensors
Motor, 3-42, 3-44
Thermal Switches, 4-17, 4-18
Tool Coordinate System, I-3, A-3, A-4
Tool Coordinates, I-10
Tool Dimension, A-3
Tool Dimensions, A-2
Torque, A-17, A-19
Touch Panel, 1-10, 5-24, 5-29, 5-31, 5-32
TP-DMS, 6-101
TP-EMS, 6-101
Transformer, I-9
Transformer T1, 3-11, 3-27, 6-75
Taps, 3-40, 3-41
Trap Point, 2-11, 2-9
Troubleshooting Flowcharts, 9-99
TXD, 6-101
TXEN, 6-92, 6-96
IN-18 March 28, 2002


INDEX
Type 2 Teach Pendant, 5-2, 5-14, 5-29, 5-30, 5-31, 5-40

Type 2 Teach Pendant (TP), I-9, 1-7, 1-11, 1-20, 4-2, 5-2, 6-18
Type 2 TP, 1-21, 4-5, 4-12, 6-20, 6-60
U
UB150, 2-28
User Interfaces, 1-7
UT 200, 2-29
UT-Series Robots
Zeroing, 8-28
UT100, 2-29
UT150, 2-29
Utility Outlet, 115 VAC, 3-12, 5-7
UX-Series Robots
Zeroing, 8-23
UX100, 2-31
UX120, 2-31
UX150, 2-31
UX200, 2-32
UX300, 2-33
UX70, 2-30
UZ-Series Robots
Zeroing, 8-23
UZ100, 2-34
UZ120, 2-34
UZ150, 2-34
V
V-Axis, I-2
V1 Bridge Rectifier, 3-12, 3-27
V1A, 3-46
V1B, 3-46
V2A, 3-46
V2B, 3-46
V3A, 3-46
V3B, 3-46
V4A, 3-46
V4B, 3-46
Valve, Purge, 6-9
Velocity Error, 2-13
Video Board, 5-32
VME Bus, 1-20, 6-18
VME Interface, 6-20
Voltage Monitoring, 4-21
Voltage Regulator, 6-96
Voltmeter
Digital, 3-41
W
Warning Symbol, 2-8
Water, High Pressure, 2-12
March 28, 2002 IN-19


INDEX
Weight, I-14
Weld Controller, 6-56
Weld Timer, 1-21, 6-44
Communication, 1-21
Windows 2000, 5-39
Windows 95/98, 5-38
Windows 95/98/2000, 5-40
Word Data, 6-50
X
X1, 5-36
X1-CN1, 5-25, 5-32
X2, 5-7, 5-40
X3, 3-42, 3-44
X3A, 3-42, 3-44
X4, 3-42, 3-44
X4A, 3-42, 3-44
X5, 3-44
X5A, 3-44
XGA-CN1, 5-7
XHP-CN2, 5-7
XR-SW1, 5-7
XYZ, A-4
XYZ Direction, A-2
Z
Z Axis, A-3
Z-Series Overtravel Limit Switch Circuit, 4-15
Z2 Noise Filter, 3-12, 3-27
Z3 Spark Arrester, 3-12, 6-75
ZD130, 2-35
ZD130 Machine Harness Interconnection diagram, 6-113
ZD165, 2-36
ZEBA, 6-8, 6-100, 6-101, 6-104
Fuse, 6-103, 6-104
ZEBA Board, 6-103, 6-105
Connectors, 6-105
ZEBA Unit, 6-103
Zener Barrier, 6-8, 6-86, 6-103
Zero Position, A-3
Zeroing, 4-13, 8-2
FS06 Robot, 8-33
FS10 Robot, 8-33
FS20 Robot, 8-33
FS30 Robot, 8-33
FS45 Robot, 8-33
Precision, 8-17, 8-37, 8-40
Simple, 8-4, 8-8, 8-13
UT-Series Robots, 8-10
UX-Series Robots, 8-10
IN-20 March 28, 2002


INDEX
UZ-Series Robots, 8-10

Zeroing jigs
ZT130, 2-37
ZT165, 2-38
ZT200, 2-39
ZX130L, 2-40
ZX130U, 2-41
ZX165U, 2-42
ZX200S, 2-43
ZX200U, 2-44
ZX300S, 2-45
ZZERO Command, 8-8, 8-38
March 28, 2002 IN-21

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COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY

All Rights Reserved.

Copyright © 2007, Kawasaki Robotics (USA), Inc.

KAWASAKI ROBOTICS (USA), INC. TRAINING

Training courses covering operation, programming, electrical maintenance, and me-

For additional information contact:

Kawasaki Robotics (USA), Inc.

COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY

I.0 INTRODUCTION ............................................................................................ I-2

March 28, 2002 I-1

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I.1 MECHANICAL UNIT

• JT1 (R-axis) rotary; rotation of the base

• JT4 (S-axis) swivel; sets orientation of JT5 for pitch/yaw motion

KE610 minor axes:

• JT4 (S-axis) swivel; sets orientation of JT5 for pitch/yaw motion

Auxiliary axis (optional):

• JT7 (V-axis) traverse; linear positioning of the mechanical unit

I-2 March 28, 2002

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I.1.1 MECHANICAL UNIT DESIGN SPECIFICATIONS

March 28, 2002 I-3

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Table I-1 Robot Specifications

ROBOT MODEL FC06N FS06L FS06N FW06N FS10C FS10E FS10L

Number of Axes 6 (7)* 6 (7)* 6 (7)* 6 (7)* 6 (7)* 6 (7)* 6 (7)*

JT1 240°/sec 200°/sec 240°/sec 240°/sec 200°/sec 200°/sec 160°/sec

JT2 200°/sec 140°/sec 200°/sec 200°/sec 140°/sec 140°/sec 140°/sec

JT3 250°/sec 200°/sec 250°/sec 250°/sec 200°/sec 200°/sec 160°/sec

JT6 720°/sec 600°/sec 720°/sec 720°/sec 600°/sec 600°/sec 500°/sec

JT2 +140°/-105° +140°/-105° +140°/-105° +140°/-105° +140°/-105° +140°/-105° +140°/-105°

JT3 +295°/-225° +295°/-225° +295°/-225° +295°/-225° +295°/-225° +295°/-225° +295°/-225°

JT6 ±360° ±360° ±360° ±360° ±360° ±360° ±360°

I-4 March 28, 2002

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Table I-1 Robot Specifications (Continued)

JT1 160°/sec 160°/sec 160°/sec 160°/sec 160°/sec 160°/sec 145°/sec 220°/sec

JT2 140°/sec 140°/sec 140°/sec 140°/sec 140°/sec 140°/sec 135°/sec 120°/sec

JT3 160°/sec 160°/sec 160°/sec 160°/sec 160°/sec 160°/sec 135°/sec 240°/sec

JT6 500°/sec 500°/sec 340°/sec 340°/sec 340°/sec 340°/sec 550°/sec 720°/sec

JT2 +140°/-105° +140°/-105° +140°/-105° +140°/-105° +140°/-105° +140°/-105° +60°/-110° ±180°

JT3 +295°/-225° +295°/-225° +295°/-225° +295°/-225° +295°/-225° +295°/-225° +90°/-80° ±480°

JT6 ±360° ±360° ±360° ±360° ±360° ±360° ±210° ±720°

March 28, 2002 I-5

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Table I-1 Robot Specifications (Continued)

JT1 120°/sec 120°/sec 100°/sec 120°/sec 120°/sec 120°/sec 100°/sec 100°/sec

JT2 100°/sec 100°/sec 90°/sec 120°/sec 120°/sec 120°/sec 100°/sec 90°/sec

JT3 120°/sec 120°/sec 100°/sec 120°/sec 120°/sec 120°/sec 100°/sec 90°/sec

JT6 240°/sec 240°/sec 200°/sec 200°/sec 240°/sec 240°/sec 200°/sec 200°/sec

JT2 +55°/-80° +55°/-80° +55°/-80° +70°/-65° +70°/-65° +70°/-65° +70°/-65° +70°/-65°

JT3 +95°/-105° +95°/-105° +95°/-105° +90°/-119° +90°/-119° +90°/-119° +90°/-119° +90°/-119°

JT6 ±360° ±360° ±360° ±360° ±360° ±360° ±360° ±360°

I-6 March 28, 2002

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Table I-1 Robot Specifications (Continued)

ROBOT MODEL UX300 UZ100 UZ120 UZ150 ZT130S ZT130U ZT165U

Number of Axes 6 (7)* 6 (7)* 6 (7)* 6 (7)* 6 (7)* 6 (7)* 6 (7)*

JT1 100°/sec 120°/sec 120°/sec 100°/sec 130°/sec 105°/sec 105°/sec

JT2 80°/sec 100°/sec 100°/sec 100°/sec 130°/sec 105°/sec 105°/sec

JT3 68°/sec 110°/sec 110°/sec 100°/sec 130°/sec 105°/sec 105°/sec

JT6 135°/sec 240°/sec 240°/sec 200°/sec 280°/sec 230°/sec 210°/sec

JT2 +70°/-60° +70°/-75° +70°/-75° +70°/-75° +60°/-75° +60°/-75° +60°/-75°

JT3 +90°/-126° +283°/-105° +283°/-105° +283°/-105° +165°/-95° +165°/-95° +165°/-95°