Kawasaki Robot

E Series Controller

Analog Input
Manual
(Option)

Kawasaki Heavy Industries, Ltd.

90210－1251DEA
E Series Controller
Kawasaki Robot Analog Input Manual

PREFACE

This manual explains about the option boards and AS language necessary for analog input to E
series controller.

Thoroughly read and understand the contents of this and other basic manuals, including safety
manual, before proceeding with any operation.

1. This manual does not constitute a guarantee of the systems in which the robot is utilized.
Accordingly, Kawasaki is not responsible for any accidents, damages, and/or problems
relating to industrial property rights as a result of using the system.
2. It is recommended that all personnel assigned for activation of operation, teaching,
maintenance or inspection of the robot attend the necessary education/training course(s)
prepared by Kawasaki, before assuming their responsibilities.
3. Kawasaki reserves the right to change, revise, or update this manual without prior notice.
4. This manual may not, in whole or in part, be reprinted or copied without the prior written
consent of Kawasaki.
5. Store this manual with care and keep it available for use at any time. If the robot is
reinstalled or moved to a different site or sold off to a different user, attach this manual to the
robot without fail. In the event the manual is lost or damaged severely, contact Kawasaki.
All rights reserved. Copyright © 2009 Kawasaki Heavy Industries Ltd.

1
E Series Controller
Kawasaki Robot Analog Input Manual

SYMBOLS

The items that require special attention in this manual are designated with the following symbols.

Ensure proper and safe operation of the robot and prevent physical injury or property damage by
complying with the safety matters given within the boxes with these symbols.

！ DANGER

Failure to comply with indicated matters can result in

imminent injury or death.

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

！ CAUTION
Failure to comply with indicated matters may lead to
physical injury and/or mechanical damage.

[ NOTE ]

Denotes precautions regarding robot specification,

handling, teaching, operation and maintenance.

！ WARNING

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

explanations given in this manual cannot be confirmed with absolute
certainty. Should any unexplained questions or problems arise, please
contact Kawasaki Machine Systems.
2. Safety related contents described in this manual apply to each individual
work and not to all robot work. In order to perform every work in safety,
read and fully understand the safety manual, all pertinent laws, regulations
and related materials as well as all the safety explanation described in each
chapter, and prepare safety measures suitable for actual work.

2
E Series Controller
Kawasaki Robot Analog Input Manual

CONTENTS
Preface······················································································································································· 1
Symbols····················································································································································· 2

1.0 Safety················································································································································· 4

2.0 Overview··········································································································································· 5

3.0 Mounting 1TH Board······················································································································· 6

4.0 Analog Input Specification··············································································································· 7

5.0 Connecting Analog Input ················································································································· 8

5.1 1TH Board CN3 Connector Pin Allocation····················································································· 9
5.2 Voltage Input···································································································································· 10
5.3 Current Input ···································································································································· 11

6.0 Overview of 1TH Board·················································································································· 13

7.0 AS language····································································································································· 15

Appendix 1. Sample Program ··············································································································· 20

Appendix 2. Analog Input Option Errors······························································································ 21

3
E Series Controller 1. Safety
Kawasaki Robot Analog Input Manual

1.0 SAFETY

When connecting the analog input, always follow the below safety features during the operation.

！ WARNING

When connecting analog input, turn OFF the power for the controller and
external devices. Place a tag on the breaker indicating that operation is in
process or have someone watch over to avoid anyone from accidentally turning
ON the power. Conducting the operation with the power ON may result in
electrification and is very dangerous.

！ CAUTION

1. Always take proper countermeasures to avoid any noise to enter the analog
input devices. The noise may cause malfunction or damage the electric
system.
2. Always connect to the correct connector pin. Connecting to a wrong pin
results in malfunction of the electric system.
3. Do not step on or put anything on the analog input cable. Be careful so that
any person or car (forklift etc.) does not pass over the cable. The cable may
be damaged, resulting in malfunction of the electric system.
4. Avoid parallel wiring of analog input cable and power lines. The two lines
must be more than 20 cm apart (inside and outside the controller).
Especially, the electromagnetic induction from robot motor cable, power lines
of other peripheral devices and welding cables may cause noise to enter the
analog input cable and result in malfunction.
5. Use shielded cable for analog input cable.

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E Series Controller 2. Overview
Kawasaki Robot Analog Input Manual

2.0 OVERVIEW

Mounting 1TH board (analog input board) as daughter board to 1TR board in E series Controller
allows input of analog signal from external sensors, etc. The input analog signal is transformed
to digital signal, then the digital data can be used in programs such as to modify pose data, etc.
However, this data cannot be used for real time modifications such as robot path modification.

Maximum number of channel is 8 channels per one 1TH board. Two 1TH boards can be
mounted to one 1TR board. Up to 16 channels can be input when two boards are used. Input
voltage range is selected from below. Voltage range must be the same for all channels.

Minus 2.5 V - 2.5 V

Minus 5 V - 5 V
Minus 10 V - 10 V
0 V - 10 V(Standard)

Input voltage range is set via AS language. See 7.0 for details.

5
E Series Controller 3. Mounting 1TH Board
Kawasaki Robot Analog Input Manual

3.0 MOUNTING 1TH BOARD

1TH board is mounted inside the controller at the position shown in the figure below. It is
mounted inside the card rack, to the left of 1TR board and connected to connectors CN3 and CN4.
Maximum of two boards can be mounted.

[ NOTE ]
・ If any other board is connected to CN3 or CN4 on 1TR board, only one 1TH
board can be connected.
・ When connecting only one 1TH board, either CN3 or CN4 will be recognized as
channels 1 to 8.
・ When two 1TH boards are connected, CN3 side will be recognized as channel 1
to 8, CN4 side will be recognized as channel 9 to 16.

1TR Board
1TH Board

CN3 connector
on 1TR board

1THboard Analog Input

(1st board) Channel 1 - 8

CN4 connector
on 1TR board

1THboard Analog Input

(2nd board) Channel 9 - 16

Left side of 1 TR board

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E Series Controller 4. Analog Input Specification
Kawasaki Robot Analog Input Manual

4.0 ANALOG INPUT SPECIFICATION

Analog input board(1THboard)

Input Type Isolated input

Input Range Bipolar: minus 10 -10 V, minus 5-5 V, minus 2.5-2.5 V
Unipolar: 0 - 10 V
Input range is changed using AS language.
Number of
8CH
Channels
Resolution 13bits
Speed AD transformation speed 50 μs/8CH (AD updating cycle
50 μs/1CH)
Accuracy Below ±1 %
Input impedance Voltage input: 100 MΩ or more
Current input: CH7 (CH15) ⇒50 Ω
CH8 (CH16) ⇒100 Ω
CH7 (CH15), CH8 (CH16) can also be used for current
input.
See 5.3 for details.
Numbers in parenthesis show channels for second board.
Maximum rated
±13 V
voltage input

7
E Series Controller 5. Connecting Analog Input
Kawasaki Robot Analog Input Manual

5.0 CONNECTING ANALOG INPUT

Connect the analog input to the 25 pin connector (CN3) on 1TH board following the pin
allocation shown in 5.1. Draw in the cable from outside through the cable input on the
controller (see “Installation and Connection Manual).

[ NOTE ]
To avoid malfunction of analog input due to noise, use twisted pair cable or shielded
cable for analog input line and earth the cable shield through the controller casing.

Cable support

Earth the cable

shield.

Upper

Front Side

The above figure shows E2x Controller.

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E Series Controller 5. Connecting Analog Input
Kawasaki Robot Analog Input Manual

5.1 1TH BOARD CN3 CONNECTOR PIN ALLOCATION

CN3 Connector Pin Allocation (Numbers in parenthesis show channels for second board)
Pin No. Content Remarks
1 Analog Input CH1 (CH9)
14 GND CH1 (CH9)
2 Analog Input CH2 (CH10)
15 GND CH2 (CH10)
3 Analog Input CH3 (CH11)
16 GND CH3 (CH11)
4 Analog Input CH4 (CH12)
17 GND CH4 (CH12)
5 Analog Input CH5 (CH13)
18 GND CH5 (CH13)
6 Analog Input CH6 (CH14)
19 GND CH6 (CH14)
7 Analog Input CH7 (CH15)
20 GND CH7 (CH15)
8 Analog Input CH8 (CH16)
21 GND CH8 (CH16)
9 Not Used
22 Not Used
10 Not Used
23 Not Used
11 GND When using this
24 Analog power source +15 V output power outside the
12 GND controller, keep load
25 Analog power source -15 V output at or less than 5 W.

Connector Model
1TH Board CN3 DBLC-J25SAF-13L9E (JAE)

Recommended connector (opposite side) DB-25PF-N (JAE) or equivalent

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E Series Controller 5. Connecting Analog Input
Kawasaki Robot Analog Input Manual

5.2 VOLTAGE INPUT

Channels 1-6 (channel 9-14) on 1TH board is dedicated for voltage input. Channels 7, 8
(channel 15, 16) can be switched between voltage and current input.

[ NOTE ]
When using channels 7 and 8 (channel 15, 16) for voltage input, set the jumper
switch as shown below (setting for 1-2, 3-4, 5-6 side) .
Improper setting may cause damage to external devices.

CH Jumper Switch Setting

7
2 10
(15) J2
1 9

8
2 10
J3 1 9
(16)

Sample Connection
In the example below, voltage input device is connected to channel 1.

1THBoard
CN3 Voltage
Output
Channel 1 - 1 Analog InputCH1 + サ
●
+
Input
14 GND -
0V
Internal
Cable Shield
Earth to Earth to external
controller FG device FG

10
E Series Controller 5. Connecting Analog Input
Kawasaki Robot Analog Input Manual

5.3 CURRENT INPUT

Channels 7, 8 (channel 15, 16) on 1TH board can also be used for current input.

[ NOTE ]
When using channels 7 and 8 (channel 15, 16) for current input, set the jumper
switch as shown below (setting for 5-6,7-8, 9-10 side) .
Improper setting may cause damage to external devices.
Maximum Input
CH Jumper Switch Setting Current
7
2 10
J2 ±200 mA
(15) 1 9

8
2 10
J3 ±100 mA
(16) 1 9

Current input impedance is:

Channel 7 (Channel 15) = 50 Ω,
Channel 8 (Channel 16) = 100 Ω

11
 E Series Controller 5. Connecting Analog Input
Kawasaki Robot Analog Input Manual

Sample Connection 1
In the example below, current input device is connected to channel 8.

1THBoard
CN3 Current output device

Channel 8 ●
- 8 Analog input CH8 (Current input) +
+ ●

Input
100Ω OUT
○ ○

J3
21 GND CH8 -
0V ●

Internal
Cable Shield
Earth to controller FG Earth to external
device FG

Sample Connection 2
In the example below, current trance (CT) is connected to channel 7.

1THBoard
CN3 CT

Channel 7 - 7 Analog input CH7 (Current input)

Input
●
+ ● OUT
50Ω
0V ○ ○

Internal J2
24 +15 V power +

25 -15 V power -

Cable Shield
Earth to controller FG Earth to external
device FG

12
E Series Controller 6. Overview of 1TH Board
Kawasaki Robot Analog Input Manual

6.0 OVERVIEW OF 1TH BOARD

This section describes the overview of 1THboard and it settings.

CN3

LD4
LD1

LD2

LD5

LD6
LD3

LD7

TP3 J2
2 10
1 9
TP2
2 10
1 9
TP6 J3
TP4

SW1
O 1
N 2
TP5

J1
TP1 TP7

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E Series Controller 6. Overview of 1TH Board
Kawasaki Robot Analog Input Manual

Jumper Connector
Location Content Setting
J1 For debugging Not connected (Do not use)
CH7 (CH15) for switching voltage and Voltage input：1-2, 3-4, 5-6
J2 current input connected
Current input：5-6, 7-8, 9-10
connected
CH8 (CH16) for switching voltage Voltage input：1-2, 3-4, 5-6
J3 and current input connected
Current input：5-6, 7-8, 9-10
connected

LED
Location Content Status
LD1 A/D transformation status Lights after A/D initialized
LD2 - -
LD3 1THboard operation status Flickers when normal
LD4 Analog power source (-15 V) status Lights when normal
LD5 Analog power source (+15 V) status Lights when normal
LD6 Analog power source (5 V) status Lights when normal
LD7 Controller power (3.3 V) status Lights when normal

Test pin
Location Content
TP1 5 V power source
TP2 Analog +15 V
TP3 Analog -15 V
TP4 Analog 5 V
TP5 3.3 V power source
TP6 Analog GND
TP7 GND

Switch
Location Content Setting
SW1 For debugging All OFF

14
E Series Controller 7. AS Language
Kawasaki Robot Analog Input Manual

7.0 AS LANGUAGE

ADC functions (analog input functions), etc. are prepared in AS language to import the analog
input data into AS programs.

EXAMPLE

Keyword Parameter

CNTADC number of input data filter

Parameters marked with can be omitted.

Always enter a space between the keyword and the parameter.

↵ represents the Enter key in the examples.

15
E Series Controller 7. AS Language
Kawasaki Robot Analog Input Manual

Monitor Command

SET_AD_RANGE board number： input voltage range, channel group number

Function
Specifies the input voltage range for analog input channel.

Parameter
Board number
Specifies the board number (1-2)
When omitted, 1 is assumed.

Input voltage range

Sets the input voltage range (1 - 4)
1: 0 V - 10 V
2: ±5 V
3: ±10 V
4: ±2.5 V
When omitted, the current setting is assumed. Default value is 1 (0 V - 10 V).

Channel group number

Specifies channel group number (0 - 2).
All 8 channels can be set together at once for each board, or it can be set in groups of 4 channels
at a time.
0: Channel 1- 8 (Channels 9-16 when board number 2 is specified)
1: Channel 1- 4 (Channels 9-12 when board number 2 is specified)
2: Channel 5- 8 (Channels 13-16 when board number 2 is specified)
When omitted, 0 is assumed.

Explanation
Sets the input voltage range for the specified board and channels. The new setting is valid after
the controller power is turned OFF/ON. When the input voltage range is change, warning
message “(W1018) Network parameter is changed. Turn OFF & ON the control power.” appears.
[ NOTE ]
Turn OFF/ON the controller power after changing the input
voltage range.

16
E Series Controller 7. AS Language
Kawasaki Robot Analog Input Manual

Example
>set_ad_range 2 Sets the input voltage for channels 1- 8 (channel group number
0) on board number 1 to ±5 V(Input voltage range 2).
Board ID Input range The set value is displayed after input.
1(ch1-ch8), ±5 V

>set_ad_range 2:3,1 Sets the input voltage for channels 9- 12 (channel group number
1) on board number 2 to ±10 V(Input voltage range 3).
Board ID Input range The set value is displayed after input.
2(ch9-ch12), ±10 V
2(ch13-ch16), 0-10 V

Program Instruction

SET_AD_RANGE board number： input voltage range, channel group number

Function
Specifies the input voltage range for analog input channel.

Parameter
See monitor command SET_AD_RANGE. The parameter “input voltage range” may not be
omitted for program instruction.

Explanation
Sets the input voltage range for the specified board and channels. The new setting is valid after
the controller power is turned OFF/ON. When the input voltage range is change, warning
message “(W1018) Network parameter is changed. Turn OFF & ON the control power.” appears.

Example
set_ad_range 2 Sets the input voltage for channels 1- 8 (channel group number 0)
on board number 1 to ±5 V(Input voltage range 2).

set_ad_range 2:3,1 Sets the input voltage for channels 9- 12 (channel group number
1) on board number 2 to ±10 V(Input voltage range 3).

17
E Series Controller 7. AS Language
Kawasaki Robot Analog Input Manual

Real Value Function

ADC (channel number)

Function
Transforms the input analog data to digital data using A/D convertor and stores the result as real
value data.

Parameter
Channel number
Specifies the channel number. (1 - 16)

[ NOTE ]
In controllers before E series controller, this function had the format
ADC (channel number, input voltage range) and took two parameters. To keep
compatibility with the previous series, the second parameter can be specified for E
controller, although it will be ignored. Set the input voltage range via
SET_AD_RANGE command/ instruction.

Explanation
Transforms the analog data input to the specified channel to digital data within the input voltage
range set with SET_AD_RANGE command/ instruction. When using analog data input from
outside the controller, it is recommended that more than one data is read and that its average rate
is calculated.

Example
>a1=ADC (1) Conducts A/D transformation of data input to channel 1 and substitutes it
to a1. The input voltage value is stored in a1. For example, if the
input voltage range is ±5 V and the input voltage is ＋2.5 V, then 2.5 is
stored in the variable a1.
i=0
a=0
FOR i=1 TO 10
a=ADC (1) + a
END
a=a/10 Calculates the input of channel 1 from the average of the last 10 input.

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E Series Controller 7. AS Language
Kawasaki Robot Analog Input Manual

Monitor Command
Program Instruction

CNTADC number of input data filter

Function
Sets the number of ADC function input data filter. When ADC function is executed, A/D
transformation is conducted the number of filters set here and the average value is returned as the
result of the ADC function.

Parameter
Number of input data filter
Specifies the number of values from which the average value is calculated.
Settable range: 1 – 999.
When used as monitor command, omitting the parameter displays the current setting followed by
a message asking if the value is to be modified.

Example
>CNTADC 10 10 filters are set. Signal is input through channel 1,
a=ADC (1) within the range of 0-10V. (The average of 10 inputs to channel
1 is stored in variable “a”)

19
E Series Controller Appendix 1. Sample Program
Kawasaki Robot Analog Input Manual

APPENDIX 1. SAMPLE PROGRAM

The program below calculates the distance between the sensor on the robot hand and the
reference surface, and modifies the position to grab the workpiece.
First, the input voltage range is set to 0 to 10 V using monitor command.

>set_ad_range 1

× pick distance

Taught pose : org.pick

Distance sensor input value
at time of playback : rpt.height
Modified grab position : pick
Distance transformation factor :k
…

JAPPRO org, pick, 300

LAPPRO org, pick, 50

10 rpt.height=0
height=ADC (1)
TWAIT=0.001
FOR i=1 TO 10 ; Reads 10 values and adds them
height=ADC (1) ; Channel 1 (input voltage range 0 - 10 V)
IF height < 9.0 GOTO 20 ; Deletes abnormal value
height=10.0
20 rpt.height=rpt.height + height
END

IF rpt.height < 90 GOTO 30 ; Check for abnormality

TYPE "A/D transformation error"
PAUSE
GOTO 10

30 rpt.height=rpt.height/10 ; Take the average

del.pick=TRANS (0, 0, rpt.height*k, 0, 0, 0) ; Change to Tool Z direction
POINT pick=org.pick + del.pick

LMOVE pick
CLOSEI
…

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E Series Controller Appendix 2. Analog Input Option Errors
Kawasaki Robot Analog Input Manual

APPENDIX 2. ANALOG INPUT OPTION ERRORS

The following errors are exclusive to the analog input option.

E1369 Initialization error on Analog board. No. XX

Error Content
This error occurs when the initialization of analog input board has failed.

Causes
AD input initialization of the analog input board has failed at the time of controller power ON.

Countermeasures
1. Reset the error.
2. When using analog input board, turn OFF/ON the controller power. The analog input board
is re-initialized.
3. If error occurs even after the controller power is turned OFF/ON, report all error message
contents, robot model, controller model, machine number and AS software version to
Kawasaki.

E1370 Analog board No. XX is set as current input (ch XX)

Error Content
This error occurs when channels 7 and 8 (channels 15 and 16 for board number 2) are set to
current input instead of voltage input.

Causes
The jumper switches J2, J3 on the analog input board is set to current input instead of voltage
input.

Countermeasures
1. Check the current input setting (jumper switch J2, J3) on the analog input board.

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E Series Controller Appendix 2. Analog Input Option Errors
Kawasaki Robot Analog Input Manual

E1371 Analog input board is not installed.

Error Content
This error occurs when ADC function, etc. is executed when the analog input board is not
available.

Causes
Analog input board is not mounted, or the initialization of analog input board has failed and the
board cannot be used.

Countermeasures
1. Reset the error.
2. Check if analog input board is properly mounted.
3. If error occurs even if the board is properly mounted and after the controller power is turned
OFF/ON, record all error message contents, robot model, controller model and AS software
version and contact Kawasaki.

E1374 AD channel error.

Error Content
This error occurs when the channel number specified for the ADC function is out of settable
range.

Causes
The channel number specified is not with in 1- 8 when using one board, or between 1- 16 when
using two boards.

Countermeasures
1. Specify channel number 1- 8 when using one board, 1-16 when using two boards.

22
E Series Controller Appendix 2. Analog Input Option Errors
Kawasaki Robot Analog Input Manual

E1375 AD input range error.

Error Content
This error occurs when the input voltage range set via SET_AD_RANGE command/ instruction
is out of settable range.

Causes
Value set for input voltage range is other than 1- 4.

Countermeasures
1. Specify value between 1- 4 for input voltage range.

23
E Series Controller Appendix 2. Analog Input Option Errors
Kawasaki Robot Analog Input Manual

24
 Kawasaki Robot E Series Controller
ANALOG INPUT MANUAL

November 2009 : 1st Edition

Publication : KAWASAKI HEAVY INDUSTRIES, LTD.

90210-1251DEA

Copyright © 2009 KAWASAKI HEAVY INDUSTRIES, LTD. All rights reserved.