KAWASAKI ROBOT
C3✻/C4✻/C70/C80 Controller
INSTALLATION &
CONNECTION
MANUAL
KAWASAKI HEAVY INDUSTRIES, LTD.
ROBOT DIVISION
Preface
Preface
This manual is subject to change without prior notice and without our
legal responsibility.
Kawasaki pursues a policy of continuing improvement in design and
specification of the product. The right is therefore reserved to vary this
manual without prior notice.
This manual is copyrighted and all rights are reserved by Kawasaki.
This manual may not in whole or part be reproduced in any form or by
any means without prior written permission from Kawasaki.
This manual is prepared with the best care but anyway it is impossible to
exclude any misinterpretation by the user or any spelling mistakes.
In case of doubts or if the robot behavior is different from that reported in
this manual please would you get in touch with the nearest Kawasaki or
Kawasaki’s agent.
Kawasaki cannot anticipate every possible circumstance that might
involve a potential hazard. If a procedure work method or operating
technique not specifically recommended by Kawasaki is used, you must
satisfy yourself that it is safe for you and others. In this case you are
completely responsible for eventual damages on human bodies or thing.
If you discover physical defects in the manual, Kawasaki will replace the
manual at no charge during 90 days period after you purchased the
robot.
If you do not observe warnings and/or caution to be taken in the manual
as described below, it might result in the serious injuries or damages on
human bodies or robots.
Therefore you must take extreme care to observe these warnings and
caution.
All rights reserved. Copyright  2001 by KAWASAKI HEAVY INDUSTRIES, LTD.
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
i
Preface
Safety
The following symbols are present in all Kawasaki Robot documentation to signify to the user that
proper guidelines, as set forth in the text, are designed to provide pertinent information.
！ DANGER
This danger symbol identifies special warnings or
procedures which, if not strictly observed, will
result in serious injury or death.
！ WARNING
This warning symbol identifies special warnings or
procedures which, if not strictly observed, could
result in serious injury or death.
！ CAUTION
This caution symbol identifies special
instructions or procedures which, if not strictly
followed, may result in injuly.
IMPORTANT
This important symbol identifies special instructions
or produces which, if not correctly followed, could
result in serious machine damage.
NOTE:
ii
This note symbol identifies supplementary
information, or to emphasize a point or procedure,
or to give a tip for easier operation.
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
Preface
もくじ
CONTENTS
I.0. INTRODUCTION ....................................................................................................... I-3
I.1. Robot Controller....................................................................................................... I-3
I.1.1. Robot Controller Design Specifications..........................................................................................I-3
I.1.2. Controller Variations (External) and Manipulator Pairing ..............................................................I-6
I.1.3. C Controller Installation Planning................................................................................................. I-16
1.0. SAFETY .................................................................................................................. 1-3
1.1. INTRODUCTION.................................................................................................... 1-3
1.2. PERSONAL SAFETY ............................................................................................ 1-4
1.2.1. Personnel Safety Categories .................................................................................................... 1-4
1.2.1.1. Personal Safety ...................................................................................................................................1-4
1.2.1.2. Safety During Operation......................................................................................................................1-6
1.2.1.3. Safety During Programming ...............................................................................................................1-7
1.2.1.4. Safety During Inspection and Maintenance .......................................................................................1-8
1.2.2. Safety Features ........................................................................................................................... 1-9
2.0. RIGGING/LIFTING/MOVING INSTRUCTIONS ..................................................... 2-3
2.1. LIFTING C3X, C4X CONTROLLER....................................................................... 2-3
2.2. MOVING C3X, C4X CONTROLLER ON CASTERS............................................. 2-4
2.3. C70 CONTROLLER TRANSPORTATION ............................................................ 2-5
2.4. C80 CONTROLLER TRANSPORTATION ............................................................ 2-6
3.0. INSTALLATION OF ROBOT CONTROLLER ....................................................... 3-3
3.1. POSITIONING THE ROBOT CONTROLLER (C3X, C4X Controller) .............. 3-4
3.2. PERMANENT MOUNTING PROCEDURE (C3X, C4X Controller)................... 3-5
3.3. POSITIONING THE ROBOT CONTROLLER (C70 Controller)........................ 3-6
3.4. POSITIONING THE ROBOT CONTROLLER (C80 Controller)........................ 3-7
4.0. MULTI FUNCTION PANEL CONNECTIONS ........................................................ 4-3
4.1. MULTI FUNCTION PANEL CONNECTIONS ........................................................ 4-3
5.0. WIRING INSTRUCTIONS....................................................................................... 5-3
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
iii
Preface
5.1. WIRING INSTRUCTIONS FOR MAINS POWER SUPPLY ............................... 5-3
5.1.1. Connection of Mains Power ......................................................................................................... 5-3
5.1.2. Preparation and Confirmation of Incoming Power...................................................................... 5-9
5.2. WIRING INSTRUCTIONS BETWEEN CONTROLLER
AND MECHANICAL UNIT .................................................................................. 5-10
5.2.1.Harness Connections to the Mechanical Unit............................................................................ 5-10
5.2.2. Harness Connection to Controller.............................................................................................. 5-18
5.3. J,U,Z AND F-SERIES SENSOR CABLE CONNECTION (OPTIONAL).......... 5-24
5.3.1. J-Series (Handling Specification)............................................................................................... 5-24
5.3.2. UD100/150 (Handling Specification .......................................................................................... 5-26
5.3.3. ZD-Series..................................................................................................................................... 5-27
5.3.4. F-Series ....................................................................................................................................... 5-28
5.3.5. Limit and Proximity Switch Connection, J, U, Z and F-Series ................................................. 5-30
5.3.6. Sensor Wiring Diagrams ............................................................................................................ 5-32
5.3.7. Solenoid Valve Wiring Diagram (Handling Specification)........................................................ 5-39
A.0. APPENDIX ..............................................................................................................A-1
A.1. CONVERSION TABLES ........................................................................................A-3
A.1.1. Conversion from Fractional Inches to Millimeters ......................................................................A-4
A.1.2. Conversion from Millimeters to Inches........................................................................................A-5
A.1.3. Conversion from Decimal Inches to Millimeters .........................................................................A-6
A.1.4. Conversion from Foot-Pounds to Meter-Kilograms ...................................................................A-7
A.1.5. Conversion of Inch-Pounds to Inch-Ounces...............................................................................A-8
A.1.6. Conversion of Foot-Pounds to Inch-Pounds ..............................................................................A-9
A.1.7. Conversion of Inch-Pounds to Centimeter-Kilograms .............................................................A-10
A.1.8. Conversion of Foot-Pounds to Meter-Kilograms......................................................................A-11
A.1.9. Conversion of Foot-Pounds to Newton-Meters ........................................................................A-12
A.1.10. Conversion of Inch-Pounds to Newton-Meters ......................................................................A-13
A.1.11. Conversion of Inch-Ounces to Newton-Meters ......................................................................A-14
A.2. STANDARD TORQUE TABLES......................................................................... A-15
GLOSSALY ................................................................................................................... G-1
INDEX............................................................................................................................ IN-1
iv
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
INTRODUCTION
UNIT 1 SAFETY
UNIT 2 RIGGING/LIFTING/MOVING INSTRUCTIONS
UNIT 3 INSTALLATION OF ROBOT CONTROLLER
UNIT 4 MULTI FUNCTION PANEL CONNECTIONS
UNIT 5 WIRING INSTRUCTIONS
APPENDIX
GLOSSARY
INDEX
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
I-1
Introduction
I.0. INTRODUCTION .............................................................................................. I-3
I.1. Robot Controller ............................................................................................. I-3
I.1.1. Robot Controller Design Specifications .............................................................................. I-3
I.1.2. Controller Variations (External) and Manipulator Pairing ................................................... I-6
I.1.3. C Controller Installation Planning ..................................................................................... I-16
I-2
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
Introduction
I.0.
INTRODUCTION
The C Series Controller Installation manual is designed to assist the user whose primary responsibility is the
initial installation, placement, and basic electrical wiring connection of the robot controller.
This manual
provides specific information on safety, and installation procedures. It is not designated to be a programming or
operations manual, not is it designated to provide mechanical or electrical troubleshooting procedures.
I.1.
Robot Controller
The Kawasaki robot controller consists of printed circuit boards, Multi Function Panel and servo amplifiers.
I.1.1. Robot Controller Design Specifications
Control System:
32 bit RISC mainCPU
32 bit RISC CPU for Multi Function Panel
32 bit RISC servo CPU controller (one per 3 axes)
Software controlled AC servo drive system using PWM (pulse width modulation)
circuitry.
Number of Axes:
6 standard; 7th optional
Motion Control:
Teach mode-
Joint
Base
Tool
Repeat mode-
Joint move
Linear move
Circular move (optional)
Memory:
CMOS RAM
Memory Capacity:
Standard - 1024 KB (approx. 9,000 steps)
Optional - 4096 KB (approx. 36,000 steps)
Speed:
10 levels of speed for block step programs
(adjustable between 0% - 100%)
Data Editing:
Step insertion and deletion, and rewriting of auxiliary and positional data.
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
I-3
Introduction
I-4
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)
Two arm control
Program weld schedules
Servo shutdown timer
Auto Start function
I/O Signals:
32 inputs/32 outputs (C3X, C4X; 128, C70, C80; 96 maximum) including dedicated signals
RI/O (option)
Control Net (option)
Dedicated Signals:
Outputs - Motor Power ON
Error Occurrence
Automatic
CYCLE_START
Teach Mode
HOME1
HOME2
Power ON
RGSO
Ext. Program Select (RPS) Enabled
Inputs - 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
Ext. Hold (EXT_IT)
Ext. Condition Wait (EXT_WAIT)
Ext. SLOW REPEAT MODE
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
Introduction
Error Messages:
Error code messages, self-diagnosis, error logging, operation logging
Multi function panel: Dead man safety switches
VGA color LCD
Touch panel
Teach-lock function
Emergency stop switch
Pen for touch panel
PC card insertion section
Supplemental Data
Storage:
PC card
Floppy disk drive (option)
Personal computer (option)
Power Requirements: C30/31/32/33
C40/41/42/43
C70/C80
400/440/460/480/515/575 VAC
380/400/415/440/460/480 VAC
200-240 VAC
Dimensions:
C30/31/32/33
C40/41/42/43
C70
C80
W × D × H, 550 mm × 500 mm × 1150 mm
W × D × H, 550 mm × 500 mm × 1150 mm
W × D × H, 270 mm × 500 mm × 470 mm
W × D × H, 470 mm × 350 mm × 850 mm
Mass:
C30/31/32/33
C40/41/42/43
C70
C80
250 kg
250 kg
30 kg
60 kg
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
I-5
Introduction
I.1.2. Controller Variations (External) and Manipulator Pairing
C-series controllers are grouped in nine different types. The various types are paired with specific mechanical
units.
The following list indicates the correct pairing of controller and manipulator.
C30
A✼01
A✼02, A✼20
A✼12, A✼21
A✼13, A✼22
A✼14, A✼23
JS005, JC005, JW005
JS010, FS006N/L, FS010C/E/N
FA06E/N/L
FS010L, FS020C/N, FP020N
FA020N
C31
A✼01, A✼20
A✼02, A✼21
JS030/040, FS030N/L, FS045C/N
FA030L
C32
A✼01, A✼03
A✼02
A✼05
UX100/120/150, UT100/120/150
UX200/300, UT200
ZX100-300, ZT100-300
C33
A✼01
A✼02
UD100-150
ZD130
C40
A✼01
A✼02, A✼20
A✼12, A✼21
A✼13, A✼22
A✼14, A✼23
JS005, JC005, JW005
JS010, FS006N/L, FS010C/E/N
FA006E/N/L
FS010L, FS020C/N, FP020N
FA020N
C41
A✼01, A✼20
JS030/040, FS030N/L, FS045C/N
C42
A✼01
A✼02
A✼03
UX100/120/150, UT100/120/150
UX200/300
ZX130-300, ZT130-300
C43
A✼01
A✼02
UD100/150
ZD130
C70
A✼01
A✼02
FS02/03, FC02
FS02/03, FC02 Wall mounting specification
C80
A✼01, A✼02
F006N/L, FS010C/E/N
FA006E/N/L, F010N
FC006N
[ NOTE ]
There is two kinds of F-Series Robots types (A001, B002).
In this manual, we describes it in parallel in a necessary part.
I-6
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
Introduction
Mains Power Inlet
Multi Function Panel
Operation Panel
Disconnect
Switch
PC Connector
Power
Lamp
Multi Function Panel
Connector
Hour Meter
Door
Lock
550
Figure C4X Controller Frond and Left Side View
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
I-7
1150
Introduction
110
Exhaust Port
500
Figure C4X Controller Rear and Right Side View
I-8
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
Introduction
Multi Function
Panel
Disconnect
Switch
Operation
Panel
Power
Lamp
Multi Function
Panel
Hour Meter
Door Lock
Figure C3X Controller Front and Left Side View
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
I-9
Introduction
Exhaust
Port
Figure C3X Controller Rear and Right Side View
I-10
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
Introduction
Figure C70 Controller Front and Left Side View
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
I-11
Introduction
Exhaust
Port
Figure C70 Controller Rear and Right Side View
I-12
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
Introduction
350
50
43.5
470
Disconnect
Switch
Multi Function
Panel
850
User’s
Operation
Panel
Figure C80 Controller Front and Left Side View
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
I-13
Introduction
Exhaus
Figure C80 Controller Rear and Right Side View
I-14
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
Introduction
“Emergency-Stop” Switch
“TEACH LOCK” Switch
Deadman Switch
Deadman Switch
Liquid Crystal Display
Pen for Touch Panel
PC Card Port
Contrast Adjustment Volume
Figure Multi Function Panel (Type 1)
“TEACH LOCK” Switch
“Emergency-Stop” Switch
PC Card Port
Liquid Crystal Display
Deadman Switch
Deadman Switch
Figure Multi Function Panel (Type 2)
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
I-15
Introduction
I.1.3. C Controller Installation Planning
Safety
Uncrating and Unpacking Procedures
Rigging and Lifting Instructions
Installation of Robot Controller
Connection of Robot Wiring Harness
Wiring Instructions for Power Supplies
Electrical Interface Connections
NO
Available ?
Install Jumpers on Interface
of Connector
YES
Connect Wiring Interface
Refer to Manual Mechanical Maintenance Manual
I-16
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
INTRODUCTION
UNIT 1 SAFETY
UNIT 2 RIGGING/LIFTING/MOVING INSTRUCTIONS
UNIT 3 INSTALLATION OF ROBOT CONTROLLER
UNIT 4 MULTI FUNCTION PANEL CONNECTIONS
UNIT 5 WIRING INSTRUCTIONS
APPENDIX
GLOSSARY
INDEX
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
1-1
Safety
1.0. SAFETY ........................................................................................................... 1-3
1.1. INTRODUCTION .............................................................................................. 1-3
1.2. PERSONAL SAFETY....................................................................................... 1-4
1.2.1. Personnel Safety Categories .............................................................................................. 1-4
1.2.1.1. Personal Safety........................................................................................................................ 1-4
1.2.1.2. Safety During Operation .......................................................................................................... 1-6
1.2.1.3. Safety During Programming .................................................................................................... 1-7
1.2.1.4. Safety During Inspection and Maintenance ............................................................................. 1-8
1.2.2. Safety Features ................................................................................................................... 1-9
1-2
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
Safety
1.0. SAFETY
1.1. INTRODUCTION
Safety is an important consideration in the use of automated and robotic equipment in the industrial environment.
All operators, maintenance personnel, and programmers must be aware of all automated equipment, peripheral
and robotic equipment that occupies the work cell, and their associated operational and maintenance procedures.
For this reason it is recommended that all personnel who operate, maintain, and program Kawasaki robots, attend
a Kawasaki approved training course that would be pertinent to each employee’s specific job responsibilities.
The following safety sections in this text are designed to support and augment existing safety guidelines that may
be in use in your plant, and/or are provided by municipal, state, or country, but are NOT designed to supplant or
supersede any existing rules, regulations, or guidelines that may be in use. Because safety is the primary
responsibility of the user, owner, and/or employer, Kawasaki recommends that specific safety guidelines and
recommendations be adopted from groups or individuals that are professionals in safety design and
implementation.
All safety related issues and descriptions, either presented in written or oral from any representative of Kawasaki,
are intended to provide general safety precautions and procedures and, therefore, are not intended to provide all
safety measures necessary for the protection of all personnel in the work environment.
Kawasaki robots are considered safe for use in industrial environments when all safety guidelines are adhered to.
Adherence to the safety guidelines for safe robot operation and the protection of personnel and equipment is the
responsibility of the end user.
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
1-3
Safety
1.2. PERSONAL SAFETY
1.2.1. Personnel Safety Categories
Personnel safety can be described in one of four categories:
z
Personal safety
z
Safety during operation
z
Safety during programming
z
Safety during inspection and maintenance
A description of each follows in this section
1.2.1.1. Personal Safety
Safety procedures must be an integral part of operational procedures for the operator, programmer, and
maintenance person. These procedures must be followed explicitly and on a regular basis. If consistent safety
procedures are followed on a daily basis, they should become a regular part of everyday operational procedures
which are designed to protect the user. Some guidelines are presented in brief in the following section:
z
Before operating or maintaining the robot or robot controller, be sure you fully understand and comprehend
all maintenance, operating and programming procedures, and ensure that all safety related precautions are
taken and complied with before these procedures are attempted.
z
Avoid wearing loose clothing, scarves, wrist watches, rings, and jewelry when working on the controller and
robot.
It is also recommended that if ties must be worn in your shop environment, that they be the clip-on variety,
rather than tied ties.
z
Always wear safety glasses or goggles and approved safety shoes for your shop conditions. Follow all
applicable local, state, country, and plant safety specifications and procedures.
z
Know the entire work cell or area that the robot occupies.
z
Be aware of the entire work envelope of the robot and any peripheral devices.
z
Locate all emergency stop buttons or switches.
z
Avoid trap points in which personnel could become trapped between a moving device and any stationary
devices.
z
Personnel should never enter the work envelope during automatic operations.
z
Ensure that all personnel are clear of the work envelope before initiating any motion commands for the
robot.
z
Before initiating any motion commands, KNOW beforehand how the robot will perform when that
command is given.
z
Be sure that the entire work area is free of any debris, tools, fixturing, lubricants, and cleaning equipment
before operation of the robot is attempted.
1-4
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
Safety
z
If any personnel observe unsafe working conditions, report them immediately to your supervisor or plant
safety coordinator.
z
All personnel should identify by name and function all switches, indicators, and control signals that could
initiate robot motion.
z
Never defeat, render useless jumper out, or bypass any safety related device, whether mechanical or
electrical in design.
z
All safety devices approved for use in your plant must be properly installed and maintained to ensure
personnel safety.
z
NEVER attempt to stop or brake the robot during operation with your body or person.
Utilize Emergency-Stops only to stop robot motion.
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
1-5
Safety
1.2.1.2. Safety During Operation
z
During operation of the robot, identify the maximum reach of the robot in all directions, which is referred to
as the work envelope.
z
Always keep your work area clean and free of any debris which includes, but is not limited to, oil, water,
tool, fixturing, electronic test equipment, etc.
z
During operations that involve the Multi Function Panel, the only person allowed in the work envelope is the
teacher, or the person operating the Multi Function Panel.
The Multi Function Panel has provisions to
protect the operator. These safety provisions include an Emergency-Stop and deadman switch.
1-6
z
Never block the operator’s path retreat.
z
During the teach operation of the robot always have a path of retreat planned.
z
AVOID pinch points.
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
Safety
1.2.1.3. Safety During Programming
z
During operation of the robot, be sure you are able to identify the maximum reach of the robot in all
directions, which is referred to as the work envelope.
z
During teach operations the only person allowed in the work envelope is the teacher, or the person operating
the Multi Function Panel. The Multi Function Panel has provisions to protect the operator including
Emergency-Stop and deadman switch.
z
AVOID pinch points.
z
During point-to-point playback operations, be aware that the robot is only cognizant of its present location
and the next point it is requested to move to. It will execute this move with total disregard to what may lie
in its path when the move is executed.
z
Playback accuracy and speed can affect the geometry of the path coordinates. Therefore, when changing
accuracy or speed, always test run the program at a slow speed, or point-to-point mode before attempting the
continuous path operation in the repeat mode.
z
ALWAYS test run a new path program at a reduced speed, or in point-to-point mode prior to attempting a
high-speed playback operation in the repeat mode.
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
1-7
Safety
1.2.1.4. Safety During Inspection and Maintenance
Before entering the work envelope to perform either inspection or maintenance procedures, turn off three-phase
power on the disconnect and tag, and lock-out the disconnect switch.
！ WARNING
The input side (top) of the controller disconnect
may still be live when the controller disconnect is
turned OFF. If work is to be performed at the
controller disconnect switch, turn OFF the three
phase power at the source, and tag and lock-out
the source disconnect.
z
When removing an axis motor, be aware that the axis will fall if left unsupported. The brake assembly is in
the servo drive motor, therefore, the axis of the robot will be unsupported if removed.
z
When using the axis brake release switches in the controller, be aware that the axis may fall if left
unsupported.
z
Before working on pneumatic or high pressure water supplies, turn off supply pressure and purge all lines to
remove any residual pressure.
z
Assign only qualified personnel to perform all maintenance procedures.
z
Consult al available documentation before attempting any repair or service procedures.
z
Use only replacement parts approved by Kawasaki.
z
Before attempting to adjust or repair a device in the robot controller that may have yellow interlock control
circuit wires attached, locate the source of the power and remove it by disconnecting the appropriate
disconnect at its source.
z
During inspection and maintenance procedures, if your installation is equipped with safety fences and safety
plugs, remove and hold the safety plug while performing these operations
In addition, the safety
procedures outlined above should be adhered to.
1-8
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
Safety
1.2.2.Safety Features
To safeguard the user, the Kawasaki robot system is equipped with many safety features.
Some of these safety items include:
z
All Emergency-Stops are hardwired.
z
The Multi Function Panel, and operation panel are all equipped with red mushroom Emergency-Stop push
buttons.
z
Robot velocities are constantly monitored by software. Should an over-velocity condition be detected, the
robot will fault in a velocity error condition.
z
Teach velocities and check mode velocities are limited to a maximum of 250 mm/sec.
z
All robot axes have software limits.
z
All robot axes are monitored by the robot controller for velocity and deviation errors.
z
All robot axes are equipped with 24 VDC electromechanical brakes. Should the robot lose line power, the
robot arm will not drop because the brakes are engaged when power is off at the robot controller.
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
1-9
Safety
✎
1-10
MEMO
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
INTRODUCTION
UNIT 1 SAFETY
UNIT 2 RIGGING/LIFTING/MOVING INSTRUCTIONS
UNIT 3 INSTALLATION OF ROBOT CONTROLLER
UNIT 4 MULTI FUNCTION PANEL CONNECTIONS
UNIT 5 WIRING INSTRUCTIONS
APPENDIX
GLOSSARY
INDEX
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
2-1
Rigging/Lifting/Moving Instructions
2.0. RIGGING/LIFTING/MOVING INSTRUCTIONS................................................ 2-3
2.1. LIFTING C3X, C4X CONTROLLER................................................................. 2-3
2.2. MOVING C3X, C4X CONTROLLER ON CASTERS ........................................ 2-4
2.3. C70 CONTROLLER TRANSPORTATION ....................................................... 2-5
2.4. C80 CONTROLLER TRANSPORTATION ....................................................... 2-6
2-2
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
Rigging/Lifting/Moving Instructions
2.0. RIGGING/LIFTING/MOVING INSTRUCTIONS
2.1. LIFTING C3X, C4X CONTROLLER
z
The equipment used to lift the controller must have a minimum capacity of 250 kg. or 551.25 lb.
z
The lifting sling is attached to the two eye-bolts on the top of the controller.
Lifting Sling
Eye-bolts
Figure Lifting Controller
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
2-3
Rigging/Lifting/Moving Instructions
2.2. MOVING C3X, C4X CONTROLLER ON CASTERS
z
Ensure pathway is free of hazards.
z
Release brakes on two forward casters (lower front controller frame).
z
Move controller with all casters installed and contacting solid flooring.
z
Avoid movement over inclines or rough surfaces
z
Lock brakes on two forward casters when movement is complete.
！
CAUTION
Inclines greater than 15 degrees forward or
rearward will cause controller to fall over.
Inclines greater than 10 degrees to the side will
cause controller to fall over.
2-4
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
Rigging/Lifting/Moving Instructions
2.3. C70 CONTROLLER TRANSPORTATION
The mass of the controller is 30kg. Do the transportation for safety with two persons or auxiliary tools
(crane etc.)
z
Transportation with two persons
Figure Transportation with two persons
z
Lifts up by the crane
Figure Lifts up by the crane
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
2-5
Rigging/Lifting/Moving Instructions
2.4. C80 CONTROLLER TRANSPORTATION
The mass of the controller is 60kg. Do the transportation for safety with two persons or auxiliary tools
(crane etc.)
z
Transportation with two persons
Figure Transportation with two persons
z
Lifts up by the crane
Figure Lifts up by the crane
2-6
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
INTRODUCTION
UNIT 1 SAFETY
UNIT 2 RIGGING/LIFTING/MOVING INSTRUCTIONS
UNIT 3 INSTALLATION OF ROBOT CONTROLLER
UNIT 4 MULTI FUNCTION PANEL CONNECTIONS
UNIT 5 WIRING INSTRUCTIONS
APPENDIX
GLOSSARY
INDEX
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
3-1
Installation of Robot Controller
3.0. INSTALLATION OF ROBOT CONTROLLER.................................................. 3-3
3.1. POSITIONING THE ROBOT CONTROLLER (C3X, C4X Controller) .......... 3-4
3.2. PERMANENT MOUNTING PROCEDURE (C3X, C4X Controller)............... 3-5
3.3. POSITIONING THE ROBOT CONTROLLER (C70 Controller).................... 3-6
3.4. POSITIONING THE ROBOT CONTROLLER (C80 Controller).................... 3-7
3-2
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
Installation of Robot Controller
3.0. INSTALLATION OF ROBOT CONTROLLER
Prior to bolting down the robot controller and robot to the base plate, ensure that the manufacturer’s number
(numeric digits) on the mechanical unit and the serial number on the robot controller match, as illustrated in figure
below, Robot Controller and Robot Manufacturer’s Data Plates. This is very important because the factory
performs precision zeroing on each robot it manufactures and therefore, it is imperative that the corresponding
robot controller and its mechanical unit are matched as a pair.
Robot Controller Manufacture’s Data Plate
These two Serial
Numbers must match.
Robot Mechanical Unit Manufacturer’s Data Plate
Figure Robot Controller and Robot Manufacture’s Data Plates
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
3-3
Installation of Robot Controller
3.1. POSITIONING THE ROBOT CONTROLLER
(C3X, C4X Controller)
When positioning the robot controller, the installer must ensure that the robot wire harness cables are laying flat,
are not kinked or twisted, and are protected from debris and water, preferably in a wire tray or conduit as local
codes specify.
Placement of the controller is also important for controller cooling. The exhaust ports are located on the back of
the controller with the air inlets on the bottom. When installing the controller, provide a minimum of 200
millimeters between the controller’s back and right side and any wall.
Also provide a minimum of 100
millimeters from its left side and any wall. Once the robot controller has been positioned, it can be permanently
fixed using mounting bolts for attachment to anchor fixtures.
200mm
or more
100mm
or more
100mm
or more
Figure Installation Wall Clearance (C3X,C4X Controller)
3-4
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
Installation of Robot Controller
3.2. PERMANENT MOUNTING PROCEDURE
(C3X, C4X Controller)
Once the robot controller has been positioned, it can be permanently fixed to the floor surface.
Two
permanently fixed nuts are located on the lower right side in the controller cabinet. These nuts accept M12 bolts.
See figure below for location of mounting bolts holes.
Controller left side, lower
Controller right side, lower
Figure Permanent Mounting (C3X, C4X Controller)
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
3-5
Installation of Robot Controller
3.3. POSITIONING THE ROBOT CONTROLLER
(C70 Controller)
When positioning the robot controller, the installer must ensure that the robot wire harness cables are laying flat,
are not kinked or twisted, and are protected from debris and water, preferably in a wire tray or conduit as local
codes specify.
Placement of the controller is also important for controller cooling. The exhaust ports are located on the back of
the controller with the air inlets. When installing the controller, provide a minimum of 200 millimeters between
the controller’s back side and any wall. Also provide a minimum of 100 millimeters from its left side and right
side and any wall.
100mm
or more
100mm
or more
100mm
or more
100mm
or more
Figure Installation Wall Clearance (C70 Controller)
3-6
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
Installation of Robot Controller
3.4. POSITIONING THE ROBOT CONTROLLER
(C80 Controller)
When positioning the robot controller, the installer must ensure that the robot wire harness cables are laying flat,
are not kinked or twisted, and are protected from debris and water, preferably in a wire tray or conduit as local
codes specify.
Placement of the controller is also important for controller cooling. The exhaust ports are located on the back of
the controller with the air inlets. When installing the controller, provide a minimum of 200 millimeters between
the controller’s back side and any wall. Also provide a minimum of 200 millimeters from its left side and any
wall.
Figure Installation Wall Clearance (C80 Controller)
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
3-7
Installation of Robot Controller
✎
3-8
MEMO
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
INTRODUCTION
UNIT 1 SAFETY
UNIT 2 RIGGING/LIFTING/MOVING INSTRUCTIONS
UNIT 3 INSTALLATION OF ROBOT CONTROLLER
UNIT 4 MULTI FUNCTION PANEL CONNECTIONS
UNIT 5 WIRING INSTRUCTIONS
APPENDIX
GLOSSARY
INDEX
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
4-1
Multi Function Panel Connections
4.0. MULTI FUNCTION PANEL CONNECTIONS................................................... 4-3
4.1. MULTI FUNCTION PANEL CONNECTIONS................................................... 4-3
4-2
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
Multi Function Panel Connections
4.0. MULTI FUNCTION PANEL CONNECTIONS
4.1. MULTI FUNCTION PANEL CONNECTIONS
Locate and remove Multi Function Panel from packaging. Insert Multi Function Panel harness connector into
plug. The Multi Function Panel is connected to the receptacle located on the operation panel of the robot
controller. Ensure outer lock ring is rotated fully clockwise and in the locked position prior to operation of
Multi Function Panel.
Multi Function Panel
(Type 1)
Multi Function Panel
(Type 1)
Multi Function Panel
Connector
Figure Multi Function Panel Connections
(C3X, C4X Controller)
Multi Function Panel
Connector
Figure Multi Function Panel Connections
(C70 Controller)
Multi Function Panel
(Type 2)
(Option)
Multi Function Panel
Connector
Figure Multi Function Panel Connections
(C80 Controller)
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
4-3
✎
4-4
MEMO
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
INTRODUCTION
UNIT 1 SAFETY
UNIT 2 RIGGING/LIFTING/MOVING INSTRUCTIONS
UNIT 3 INSTALLATION OF ROBOT CONTROLLER
UNIT 4 MULTI FUNCTION PANEL CONNECTIONS
UNIT 5 WIRING INSTRUCTIONS
APPENDIX
GLOSSARY
INDEX
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
5-1
Wiring Instructions
5.0. WIRING INSTRUCTIONS ................................................................................ 5-3
5.1. WIRING INSTRUCTIONS FOR MAINS POWER SUPPLY.............................. 5-3
5.1.1. Connection of Mains Power ................................................................................................ 5-3
5.1.2. Preparation and Confirmation of Incoming Power ............................................................. 5-9
5.2. WIRING INSTRUCTIONS BETWEEN CONTROLLER
AND MECHANICAL UNIT.............................................................................. 5-10
5.2.1.Harness Connections to the Mechanical Unit ................................................................... 5-10
5.2.2. Harness Connection to Controller..................................................................................... 5-18
5.3. J,U,Z AND F-SERIES SENSOR CABLE CONNECTION (OPTIONAL)......... 5-24
5.3.1. J-Series (Handling Specification)...................................................................................... 5-24
5.3.2. UD100/150 (Handling Specification.................................................................................. 5-26
5.3.3. ZD-Series .......................................................................................................................... 5-27
5.3.4. F-Series ............................................................................................................................. 5-28
5.3.5. Limit and Proximity Switch Connection, J, U, Z and F-Series.......................................... 5-30
5.3.6. Sensor Wiring Diagrams................................................................................................... 5-32
5.3.7. Solenoid Valve Wiring Diagram (Handling Specification) ................................................ 5-39
5-2
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
Wiring Instructions
5.0. WIRING INSTRUCTIONS
5.1. WIRING INSTRUCTIONS
FOR MAINS POWER SUPPLY
Refer to table below for mains power supply wire specifications.
Table Wire Specifications (Primary Power)
Mode
Recommended Wire size
C30, C40
4 mm or more (#12AWG)
C31/32/33, C41/42/43
6 mm or more (#10AWG)
C70
1.5 mm or more (#16AWG)
C80
3.5 mm or more (#12AWG)
2
2
2
2
5.1.1. Connection of Mains Power
Circuit Breaker Specifications
C30/31/32/33
C40
C41/42/43
C70/C80
Amps:
15
10
16
10
Voltage:
Frequency:
600 VAC
60Hz
600 VAC
50〜60 Hz
600 VAC
50〜60 Hz
250 VAC
50〜60 Hz
Power Supply Specifications
Voltage:
C30/31/32/33
3-Phase 400/440/460/480/515/575 VAC±10%
C40/41/42/43
3-Phase 380/400/415/440/460/480 VAC±10%
C70/C80
Signal-Phase 200∼240 VAC±10%
Frequency:
50-60 Hz
KVA Rating:
C30,C40:
5 KVA
C31/32/33,C41/42/43:
10.5 KVA
C70:
1.5 KVA
C80:
3 KVA
Ground:
Less than 100 ohms, separated from welding power supply ground
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
5-3
Wiring Instructions
● C4X CONTROLLER
The 3-phase mains power should be connected to the internal circuit breaker (F1) at the left hand side of the robot
controller. This can be accomplished by the following procedure:
1. Ensure that the line side circuit breaker is in the OFF(O) position.
2. Ensure that the internal circuit breaker(F1) and disconnect switch(Q1) are in the OFF(O) position.
3. Open the controller’s door.
4. Take off the protective cover (remove the 4 screws).
5. The incoming power wire is routed into the controller.
6. Connect the individual wires to the upper terminals of the circuit breaker(F1). The circuit breaker is not
phase sensitive and power wires may be connected to any power terminal.
7. Connect the ground wire to the grounding terminal(PE). Ensure all lugs are properly.
Figure C4X Connection of Mains Power
5-4
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
Wiring Instructions
● C3X CONTROLLER
The 3-phase mains power should be connected to the internal circuit breaker (F1) at the left hand side of the robot
controller. This can be accomplished by the following procedure:
1. Ensure that the line side circuit breaker is in the OFF(O) position.
2. Ensure that the internal circuit breaker(F1) is in the OFF(O) position.
3. Open the controller’s door.
4. The incoming power wire is routed into the controller.
5. Connect the individual wires to the upper terminals of the circuit breaker(F1). The circuit breaker is not
phase sensitive and power wires may be connected to any power terminal.
6. Connect the ground wire to the grounding terminal(PE). Ensure all lugs are properly.
Figure C3X Connection of Mains Power
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
5-5
Wiring Instructions
● C70 CONTROLLER
The single-phase mains power should be connected to the internal noise filter at the left hand side of the robot
controller. This can be accomplished by the following procedure:
！
CAUTION
C70 Controller’s main switch is type which cannot
lockout. Therefore, install the disconnecting switch
which can lockout in the power supply line to the
controller so that the power supply is not improvidently
turned on when maintenance.
1. Ensure that the line side circuit breaker is in the OFF position.
2. Ensure that the internal circuit breaker is the OFF position.
3. Remove the controller top and side cover. (Remove 4 screws)
4. The incoming power wire is routed into the controller through the Cable Intaking Port, and fix the incoming
power wire to the cable fixed plate using cable clamp.
Figure C70 Connection of Mains Power
5-6
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
Wiring Instructions
5. Crimp Insulated eyelet terminals to the end of the incoming power wire.
Noise filter screw size
:M4
Grounding terminal screw size
:M4
6. Connect the incoming power wire to the terminal on the top side of the noise filter and Grounding terminal.
！
WARNING
Tighten the terminal enough (3.43Nm). It is liable
the electric shock accident, malfunction of robot
and breakdown of electrical system when using
it while having loosened.
7. Reinstall the noise filter terminal cover.
！
WARNING
Install the cover of the noise filter terminal
without fail after ending wiring. It is liable to get
an electric shock touching the terminal when you
forgets to install the cover.
8. Reinstall the controller cover.
Figure C70 Connection of Mains Power (Continued)
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
5-7
Wiring Instructions
● C80 CONTROLLER
The Singule-phase mains power should be connected to the internal circuit breaker (F1) at the left hand side of the
robot controller. This can be accomplished by the following procedure:
1. Ensure that the line side circuit breaker is in the OFF(O) position.
2. Ensure that the internal circuit breaker(F1) is in the OFF(O) position.
3. Open the controller’s door.
4. The incoming power wire is routed into the controller.
5. Connect the individual wires to the upper terminals of the circuit breaker(F1). The circuit breaker is not
phase sensitive and power wires may be connected to any power terminal.
6. Connect the ground wire to the grounding terminal(PE). Ensure all lugs are properly.
Figure C80 Connection of Mains Power
5-8
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
Wiring Instructions
5.1.2. Preparation and Confirmation of Incoming Power
Prior to setting the correct taps on the servo transformer, the incoming line voltage must be measured.
The two procedures that are described below are acceptable, however, Procedure One is the preferred method.
Procedure One
1. Obtain a voltage strip chart recorder. Monitor the incoming 3-phase voltage that will supply the robot
controller breaker (C3X, C4X Controller). Or monitor the incoming Single-phase voltage that will supply
the robot controller breaker (C70, C80 Controller). Ensure the breaker on the main disconnect is in the OFF
position.
2. Monitor this voltage for one to two days.
3. Record the highest voltage reading and the lowest voltage reading.
4. Average the highest and lowest voltage readings, and record this average value.
5. Check the existing voltage taps on the servo transformer and note the value.
6. If the value of the existing voltage taps on the servo transformer is the value as recorded in step number 4, no
change of the taps is necessary. If the servo taps do not match the value recorded in step number 4, then the
wire location will need to be changed on the taps. Refer to the label located on the transformer for correct
wire connection.
Procedure Two
Procedure Two is similar to Procedure One, however, in step 1, substitute a digital volt meter in place of the strip
chart recorder. All voltage measurements should be taken with the robot main disconnect in the OFF position.
Replace step 2 in Procedure One with: Measure the building’s incoming voltage five different times during the
controller’s operational day. Two voltage checks should be made in the morning (at different times), one at
noon, and two in the afternoon (at different times). These voltage measurements should then be averaged
together, and an average voltage found.
The voltage taps should then be set accordingly on the servo
transformer.
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
5-9
Wiring Instructions
5.2. WIRING INSTRUCTIONS BETWEEN
CONTROLLER AND MECHANICAL UNIT
5.2.1. Harness Connections to the Mechanical Unit
！
CAUTION
Do not take the locking lever with fingers, when
you release the connector. There is a possibility
you catch fingers in the lever. Push the locking
lever with the finger cushion.
Wire harness connectors are identified with labels. Push connectors X3A, X4A, X5A into sockets firmaly.
Look each connector in socket using connector’s locking lever.
Connection of Js5, JA5, JC5, JW5, Js6, Js10, JA10, JM10
Signal harness
Motor harness
Figure Mechanical Unit Harness Connections
5-10
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
Wiring Instructions
Connection of U-series
Signal harness
Major axis motor harness
Minor axis motor harness
Figure Mechanical Unit Harness Connections (Continued)
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
5-11
Wiring Instructions
Connection of Z Series
Signal harness
Major axis motor harness
Minor axis motor harness
Figure Mechanical Unit Harness Connections (Continued)
5-12
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
Wiring Instructions
Connection of Js30/40
Signal harness
Major axis motor harness
Minor axis motor harness
Figure Mechanical Unit Harness Connections (Continued)
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
5-13
Wiring Instructions
Connection of FS06N/L, FC06N, FW06N, FA06N/L/E, FS10C/N/E, FA10N
(A001)
(B002)
X4A
Motor harness
X3A
Signal harness
Motor harness
Signal harness
Figure Mechanical Unit Harness Connections (Continued)
5-14
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
Wiring Instructions
Connection of FS10L, FS20C/N, FP20N, FA20N
(A001)
(B002)
X4A
X3A
Signal harness
Motor harness
Motor harness
Signal harness
Figure Mechanical Unit Harness Connections (Continued)
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
5-15
Wiring Instructions
Connection of FS30N/L, FS45C/N, FS10X
(A001)
(B002)
X3A
X4A
X5A
Signal harness
Major axis motor harness
Minor axis motor harness
Minor axis motor harness
Major axis motor harness
Signal harness
Figure Mechanical Unit Harness Connections (Continued)
5-16
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
Wiring Instructions
Connection of FS02/03, FC02
Locking lever
Motor harness
Signal harness
Figure Mechanical Unit Harness Connections (Continued)
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
5-17
Wiring Instructions
5.2.2. Harness Connection to Controller
● C3X, C4X CONTROLLER
1. Wire harness are routed though the bottom of the controller.
2. Wire harness connectors are identified with labels. Push connectors X3, X4(,X5) into sockets firmly.
Lock each connector in socket using connector’s locking lever.
Motor harness
Signal harness
Figure C30, C40 Controller Harness Connections
5-18
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
Wiring Instructions
Minor axis motor harness
Major axis motor harness
Signal harness
Figure C31/32/33,C41/42/43 Controller Harness Connections
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
5-19
Wiring Instructions
● C70 CONTROLLER
This can be accomplished by the following procedure:
1. Remove the controller cover (Remove the 4 screws.).
2. The signal and motor harness are routed into the controller through the intaking port, and fix them to the
cable fixed plate using cable clamp.
Cable Intaking Port
Cover
Cable Fixed Plate
Shield
Fix the shield part
by cable clamp
Cable Clamp
Figure C70 Controller Harness Connections
5-20
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
Wiring Instructions
3.
Connect the motor and signal harness to the controller.
Secure the connector 1GB-CN2 and 1GB-CN6 using locking screws.
Secure the connector X001, X101, X102 and X201 using locking latch.
Signal harness
Motor harness
(1GB-CN2, 1GB-CN6, X201)
(X001, X101,X102)
Figure C70 Controller Harness Connections (Continued)
4.
Reinstall the controller cover.
！
CAUTION
~ Fix each connector surely using locking latch or locking
screws. There is a possibility of the unexpected robot
motion.
~ Connect the grounding wire to the terminal without fail.
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
5-21
Wiring Instructions
● C80 CONTROLLER
This can be accomplished by the following procedure:
1. Remove the cover provided on the controller left side lower section. (Remove the each 4 screws.).
2. The signal and motor harness are routed into the controller through the intaking port, and fix them with
screvs.
Figure C80 Controller Harness Connections
5-22
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
Wiring Instructions
3.
Connect the motor and signal harness to the controller.
Secure the connector 1GB-CN2 and 1GB-CN6 using locking screws.
Secure the connector X001, XM1, XM2 and X201 using locking latch.
Figure C80 Controller Harness Connections (Continued)
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
5-23
Wiring Instructions
5.3. J,U,Z AND F-SERIES SENSOR CABLE
CONNECTION (OPTIONAL)
The J, U, Z and F-Series can be supplied with an optional sensor cable that connects with limit or proximity
switches. The sensor cable option allows the use of four input signals. These signals can be used with limit
switches, proximity switches, or both.
The sensor cable wires are terminated with connectors for easy
termination.
The power supply (24VDC) for this sensor uses the power supply built-in the controller; supply from the outside
is unnecessary. Select the appropriate proximity sensor, etc., so the current power capacity of the built-in power
supply is not exceed. Current power capacity is 0.2A or less. SIG1-4 are approximately 10mA each.
5.3.1. J-Series (Handling Specification)
Js5/JC5/Js10: Internal wiring of the arm for sensor cable routing is illustrated in figure 5-15. The sensor cable
for Js5/JC5/Js10 is located in the fifth axis housing. The Js30 and Js40 sensor cable is located in the third axis
housing, see figure below.
Js5/JC5
Js10
Figure Js5/JC5/Js10 Sensor Cable and Faston Connector Location
5-24
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
Wiring Instructions
Js30/Js40
Faston terminals for sensor
Opening for Sensor cable
Sensor cable (option)
approx. 1.8 M.
Cable connector specified
by customer’s application
Figure Js30 and Js40 Sensor Cable and fasten Connector Location
[ NOTE ]
To prevent electrical short, insulate the ends of all sensor wires not
being used.
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
5-25
Wiring Instructions
5.3.2. UD100/150 (Handling Specification
Internal wiring of the arm for sensor cable routing is illustrated in figure below. The connector for sensor is
located on the inside surface of the access cover.
UD100/150
Cable connector specified
by customer’s application
Opening for sensor cable
Sensor cable
Connector
for sensor
Figure UD100/150 Sensor Cable Routing
[ NOTE ]
To prevent electrical short, insulate the ends of all
sensor wires not being used.
5-26
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
Wiring Instructions
5.3.3. ZD-Series
Internal wiring of the arm for sensor cable routing is illustrated in figure below. The connector for sensor is
located on the inside surface of the access cover.
ZD-Series
Wrist section (front)
Cable connector specified
by customer’s application
Wrist section (side)
Sensor cable
Connector
for sensor
Figure ZD-Series Sensor Cable Routing
[ NOTE ]
To prevent electrical short, insulate the ends of all sensor
wires not being used.
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
5-27
Wiring Instructions
5.3.4. F-Series
F-Series
(A001)
Faston terminal for sensor
Cable connector specified by
customer’s application
Opening for sensor cable
Sensor cable (option)
approx. 1.5 M.
(B002)
Connector for sensor
Cable connector specified by
customer’s application
Opening for sensor cable
Sensor cable (option)
approx. 1.5 M.
Figure F-Series Sensor Cable Routing
5-28
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
Wiring Instructions
Js02/03, FC02
Cable connector specified
by customer’s application
Sensor cable
(option)
Faston terminal for sensor
Figure FS02/03 and FC02 Sensor Cable Routing
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
5-29
Wiring Instructions
5.3.5. Limit and Proximity Switch Connection, J, U, Z and F-Series
See figure below for proper connections when connecting limit and proximity switches.
The following figure illustrates connections for single limit switches, proximity switches or the use of both.
When you connect the proximity switch:
When you connect the limit switch:
Figure Connecting Diagram for Limit and Proximity Switches
5-30
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
Wiring Instructions
When the sensor cable option is used, four of the general purpose inputs must be allocated to the sensor input
signals 1-4. The inputs that are allocated to the sensor option are Inputs 13-16. It is important to note that once
the inputs are allocated to the sensor option, they cannot be used as general purpose inputs. The following table
indicates the corresponding general purpose inputs and the sensor signal inputs.
Table Sensor Cable Input Signals
External signal
Internal signal name
Sensor signal 1(SIG1)...................................IN13
Sensor signal 2(SIG2)...................................IN14
Sensor signal 3(SIG3)...................................IN15
Sensor signal 4(SIG4)...................................IN16
The sensor signals and general purpose signals are configured with jumper 5 (J5) on the 1FR/1GW or 1HW board,
located in the controller.
[ NOTE ]
The selection of Use/Not Used is made by one set of IN13-16 which consists of a four
point unit.
Configure jumper 5 as shown in figure below.
For example, avoid
settings where 1∼3 of J5 is made A-B and/or 4∼5 is mode B-C. When selecting
Use/Not Used, all jumpers must be set to Use or all jumpers set to Not Used.
Not Used
Used
1FR/1GW board
1HW board
Figure 1FR/1GW/1HW Board Jumper Configuration for Sensor Cable Usage
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
5-31
Wiring Instructions
5.3.6. Sensor Wiring Diagrams
The following figures (on 5-32∼5-38 pages), show sensor wiring diagrams for J, U, Z and F-series mechanical
units (handling specification). The sensor wires cannot be used for JW5 mechanical units.
Js5,JC5,JW5,Js10,Js30/40,F-Series (A001):
Controller
Manipulator
1FR/1GW
1HW
Figure Js5, JC5, Js10, Js30/40, F-Series(A001) Sensor Wiring Diagram
5-32
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
Wiring Instructions
Ｆ-Series(B002) :
Controller
Manipulator
1FR/1GW
1HW
Figure Ｆ-Series (B002) Sensor Wiring Diagram
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
5-33
Wiring Instructions
Ｕ-Series :
Controller
Manipulator
1FR/1GW
1HW
Figure Ｕ-Series Sensor Wiring Diagram
5-34
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
Wiring Instructions
UD100/150 :
Controller
Robot
1FR/1GW
1HW
Figure UD100/150 Sensor Wiring Diagram
[ NOTE ]
The cable color means the following.
(1) “Blue(White)” is a white blue line with the opponent of the twist pair.
(2) “Yellow, Brown” is both lines of a yellow and brown twist pair.
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
5-35
Wiring Instructions
ZX, ZT Series :
Manipulator
Controller
1FR/1GW
1HW
Figure ZX, ZT Series Sensor Wiring Diagram
[ NOTE ]
The cable color means the following.
(1) “Blue(White)” is a white blue line with the opponent of the twist pair.
(2) “Yellow, Brown” is both lines of a yellow and brown twist pair.
5-36
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
Wiring Instructions
ZD Series :
Munipulator
Controller
1FR/1GW
1HW
Figure ZD Series Sensor Wiring Diagram
[ NOTE ]
The cable color means the following.
(1) “Blue(White)” is a white blue line with the opponent of the twist pair.
(2) “Yellow, Brown” is both lines of a yellow and brown twist pair.
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
5-37
Wiring Instructions
FS02/03 and FC02 :
Controller
Manipulator
1FR/1GW
1HW
Figure FS02/03 and FC02 Sensor Wiring Diagram
5-38
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
Wiring Instructions
5.3.7. Solenoid Valve Wiring Diagram (Handling Specification)
Js5/JC5/JW5/Js10:
Controller
Manipulator
1FR/1GW
1HW
Figure Solenoid Valve Wiring for Js5, JC5, JW5 and Js10 Robots
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
5-39
Wiring Instructions
Js30/40 :
Controller
Manipulator
1FR/1GW
1HW
Figure Solenoid Value Wiring for Js30/40 Robots
5-40
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
Wiring Instructions
U-Series :
Controller
Manipulator
1FR/1GW
1HW
Figure Solenoid Valve Wiring for U-Series Robots
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
5-41
Wiring Instructions
UD100/150 :
Controller
Manipulator
1FR/1GW
1HW
Figure Solenoid Valve Wiring for UD100/150 Robots
5-42
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
Wiring Instructions
ZX, ZT Series :
Controller
Manipulator
1FR/1GW
1HW
Figure Solenoid Valve Wiring for ZX, ZT Series Robots
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
5-43
Wiring Instructions
ZD Series :
Controller
Manipulator
1FR/1GW
1HW
Figure Solenoid Valve Wiring for ZD130 Robot
5-44
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
Wiring Instructions
FS/FC/FW-06/10/20(A001) :
Controller
Manipulator
1FR/1GW
1HW
Figure Solenoid Valve Wiring for FS/FC/FW-06/10/20(A001) Robots
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
5-45
Wiring Instructions
FS-06/10/20(B002) :
Controller
Manipulator
1FR/1GW
1HW
Figure Solenoid Valve Wiring for FS-06/10/20(B002) Robots
5-46
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
Wiring Instructions
FS30/45(A001):
Controller
Manipulator
1FR/1GW
1HW
Figure Solenoid Valve Wiring for FS30/45(A001) Robots
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
5-47
Wiring Instructions
FS30/45(B002):
Controller
Manipulator
1FR/1GW
1HW
Figure Solenoid Valve Wiring for FS30/45(B002) Robot
5-48
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
Wiring Instructions
FS02/03 and FC02:
Controller
Manipulator
1FR/1GW
1HW
Figure Solenoid Valve Wiring for FS02/03 and FC02 Robots
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
5-49
Wiring Instructions
✎
5-50
MEMO
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
INTRODUCTION
UNIT 1 SAFETY
UNIT 2 RIGGING/LIFTING/MOVING INSTRUCTIONS
UNIT 3 INSTALLATION OF ROBOT CONTROLLER
UNIT 4 MULTI FUNCTION PANEL CONNECTIONS
UNIT 5 WIRING INSTRUCTIONS
APPENDIX
GLOSSARY
INDEX
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
A-1
User Interface Connections
A.0. APPENDIX....................................................................................................... A-3
A.1. CONVERSION TABLES.................................................................................. A-3
A.1.1. Conversion from Fractional Inches to Millimeters ..............................................................A-4
A.1.2. Conversion from Millimeters to Inches ...............................................................................A-5
A.1.3. Conversion from Decimal Inches to Millimeters.................................................................A-6
A.1.4. Conversion from Foot-Pounds to Meter-Kilograms............................................................A-7
A.1.5. Conversion of Inch-Pounds to Inch-Ounces ......................................................................A-8
A.1.6. Conversion of Foot-Pounds to Inch-Pounds ......................................................................A-9
A.1.7. Conversion of Inch-Pounds to Centimeter-Kilograms......................................................A-10
A.1.8. Conversion of Foot-Pounds to Meter-Kilograms..............................................................A-11
A.1.9. Conversion of Foot-Pounds to Newton-Meters ................................................................A-12
A.1.10. Conversion of Inch-Pounds to Newton-Meters ..............................................................A-13
A.1.11. Conversion of Inch-Ounces to Newton-Meters ..............................................................A-14
A.2. STANDARD TORQUE TABLES.................................................................... A-15
A-2
KAWASAKI ROBOT C3✻/C4✻/C70C80 Controller INSTALLATION & CONNECTION MANUAL
Appendix
A.0. APPENDIX
A.1. CONVERSION TABLES
Prefixes for Units:
Units of Length:
km
×
0.6212
=
mile
× 1,000,000
m
×
3.281
=
ft
k
× 1,000
mm
×
0.03937
=
in
centi
c
× 0.01
Units of Torque:
mili
m
× 0.001
Nm
×
0.1020
=
kg-m
micro
µ
× 0.000001
Nm
×
0.7376
=
ft-Ib
Nm
×
8.851
=
in-Ib
Prefix
Symbol
mega
M
kilo
Power
Units of Mass:
Kg
×
2.205
=
Ib
kg-m
×
9.807
=
Nm
g
×
0.03527
=
oz
kg-m
×
7.233
=
ft-Ib
kg-m
×
86.80
=
in-Ib
Units of Volume:
L
×
0.2642
=
gal(US)
Units of Pressure:
L
×
0.2200
=
gal(imp)
kPa
×
0.01020
=
kg/cm
L
×
1.057
=
qt(US)
kPa
×
0.1450
=
psi
L
×
0.8799
=
qt(imp)
kPa
L
×
2.113
=
pint(US)
kg/cm
L
×
1.816
=
pint(imp)
mL
×
0.03381
=
mL
×
0.02816
mL
×
0.6102
×
0.7501
=
cmHg
2
×
98.07
=
kPa
kg/cm
2
×
14.22
=
psi
oz(USA)
cmHg
×
1.333
=
kPa
=
oz(imp)
Units of Speed:
=
cu in
km/h
0.6214
=
mpa
Units of Force:
-40
°C
×
Units of Power:
N
×
0.1020
=
kg
kW
×
1.360
=
PS
N
×
0.2248
=
lb
kW
×
1.341
=
HP
kg
×
9.807
=
N
PS
×
0.7355
=
kW
kg
×
2.205
=
lb
PS
×
0.9863
=
HP
Units of Temperature:
9(° C + 40)
− 40 =° F
5
°F
-40
2
5(° F + 40)
− 40 =° C
9
32
-20
0
-20
-17.8
20
40
0
4.4
68
60 80
20
26.7
104
100 120 140
40
60
48.9
176
160 180 200
80
71.1
220 240
100
93.3
284
°F
260 280 300 320
120
116
140
138
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
160
°C
A-3
Appendix
A.1.1. Conversion from Fractional Inches to Millimeters
1/64
1/32
3/64
inch
0.015625
0.031250
0.046875
mm
0.396875
0.793750
1.190625
33/64
17/32
35/64
inch
0.515625
0.531250
0.546875
mm
13.096875
13.493750
13.890625
1/16
0.062500
1.587500
9/16
0.562500
14.287500
5/64
3/32
7/64
0.078125
0.093750
0.109375
1.984375
2.381250
2.778125
37/64
19/32
39/64
0.578125
0.593750
0.609375
14.684375
15.081250
15.478125
1/8
0.125000
3.175000
5/8
0.625000
15.875000
9/64
5/32
11/64
0.140625
0.156250
0.171875
3.571875
3.968750
4.365625
41/64
21/32
43/64
0.640625
0.656250
0.671875
16.271875
16.668750
17.065625
3/16
0.187500
4.762500
11/16
0.687500
17.462500
13/64
7/32
15/64
0.203125
0.218750
0.234375
5.159375
5.556250
5.953125
45/64
23/32
47/64
0.703125
0.718750
0.734375
17.859375
18.256250
18.653125
1/4
0.250000
6.350000
3/4
0.75000
19.050000
17/64
9/32
19/64
0.265625
0.281250
0.296875
6.746875
7.143750
7.540625
49/64
25/32
51/64
0.765625
0.781250
0.796875
19.446875
19.843750
20.240625
5/16
0.312500
7.937500
13/16
0.812500
20.637500
21/64
11/32
23/64
0.328125
0.343750
0.329375
8.334375
8.731250
9.128125
53/64
27/32
55/64
0.828125
0.843750
0.859375
21.034375
21.431250
21.828125
3/8
0.375000
9.525000
7/8
0.875000
22.225000
25/64
13/32
27/64
0.390625
0.406250
0.421875
9.921875
10.318750
10.715625
57/64
29/32
59/64
0.890625
0.906250
0.921875
22.621875
23.018750
23.415625
7/16
0.437500
11.112500
15/16
0.937500
23.812500
29/64
15/32
31/64
0.453125
0.468750
0.484375
11.509375
11.906250
12.303125
61/64
31/32
63/64
0.953125
0.968750
0.984375
24.209375
24.606250
25.003125
1/2
0.500000
12.70000
1
1.00000
25.40000
NOTE: All Values in table are exact.
A-4
KAWASAKI ROBOT C3✻/C4✻/C70C80 Controller INSTALLATION & CONNECTION MANUAL
Appendix
A.1.2. Conversion from Millimeters to Inches
mm
1
2
3
4
5
inch
0.03937008
0.07874016
0.11811024
0.15748031
0.19685039
mm
36
37
38
39
40
inch
1.4173228
1.4566929
1.4960630
1.5354331
1.5748031
mm
71
72
73
74
75
inch
2.7952756
2.8346457
2.8740157
2.9133858
2.9527559
6
7
8
9
10
0.23422047
0.27559055
0.31496063
0.534330071
0.3937008
41
42
43
44
45
1.6141732
1.6535433
1.6929134
1.7322835
1.7716535
76
77
18
79
80
2.9921260
3.0314961
3.0708661
3.1102362
3.1496063
11
12
13
14
15
0.4330709
0.4724409
0.5118110
0.5511811
0.5905512
46
47
48
49
50
1.8110236
1.8503937
1.8897638
1.9291339
1.9685039
81
82
83
84
85
3.1889764
3.2283465
3.2677165
3.3070866
3.3464567
16
17
18
19
20
0.6299213
0.6692913
0.7086614
0.7480315
0.7874016
51
52
53
54
55
2.0078760
2.0472241
2.0866142
2.1259842
2.1653543
86
87
88
89
90
3.3855268
3.4251968
3.4645669
3.5039370
3.5433071
21
22
23
24
25
0.8267717
0.8661417
0.9055118
0.9448819
0.9842520
56
57
58
59
60
2.2047255
2.2440945
2.2834646
2.3228346
2.3622047
91
92
93
94
95
3.5826772
3.6220472
3.6614173
3.7007874
3.7401575
26
27
28
29
30
1.0236220
1.0629921
1.1023622
1.1417323
1.1811024
61
62
63
64
65
2.4015748
2.4409949
2.4803150
2.5196850
2.5590551
96
97
98
99
100
3.7795276
3.8188976
3.8582677
3.8976378
3.937008
31
32
33
34
35
1.2204724
1.2598425
1.2992126
1.3385827
1.3779528
66
67
68
69
70
2.5984252
2.6377953
2.6771654
2.7165354
2.7559055
NOTE: The inch values in this table are rounded off.
To convert mm to inches : divide 25.4 into known mm.
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
A-5
Appendix
A.1.3. Conversion from Decimal Inches to Millimeters
inch
1
2
3
4
5
25.4
50.8
76.2
101.6
127.0
mm
inch
36
37
38
39
40
mm
914.4
939.8
965.2
990.6
1016.0
inch
71
72
73
74
75
mm
1803.4
1828.8
1854.2
1879.6
1905.0
6
7
8
9
10
152.4
177.8
203.2
228.6
254.0
41
42
43
44
45
1041.4
1066.8
1092.2
1117.6
1143.0
76
77
18
79
80
1930.4
1955.8
1981.2
2006.6
2032.0
11
12
13
14
15
279.4
304.8
330.2
355.6
381.0
46
47
48
49
50
1168.4
1193.8
1219.2
1244.6
1270.0
81
82
83
84
85
2057.4
2082.2
2108.2
2133.6
2159.0
16
17
18
19
20
406.4
431.8
457.2
482.6
508.0
51
52
53
54
55
1295.4
1320.8
1346.2
1371.6
1397.0
86
87
88
89
90
2184.4
2209.8
2235.2
2260.6
2286.0
21
22
23
24
25
533.4
558.8
584.2
609.6
635.0
56
57
58
59
60
1422.4
1447.8
1473.2
1498.6
1524.0
91
92
93
94
95
2311.4
2336.8
2362.2
2387.6
2413.0
26
27
28
29
30
660.4
685.8
711.2
736.6
762.0
61
62
63
64
65
1549.4
1574.8
1600.2
1625.6
1651.0
96
97
98
99
100
2438.4
2463.8
2489.2
2514.6
2540.0
31
32
33
34
35
787.4
812.8
838.2
863.6
889.0
66
67
68
69
70
1676.4
1701.8
1727.2
1752.6
1778.0
NOTE : All valves in this table are exact.
A-6
KAWASAKI ROBOT C3✻/C4✻/C70C80 Controller INSTALLATION & CONNECTION MANUAL
Appendix
A.1.4. Conversion from Foot-Pounds to Meter-Kilograms
The chart below can be used to convert foot-pounds to meter-kilograms. The foot-pound column at the left
increases in 10 ft.-lb. increments from 0 to 110 ft.-lbs. For each additional ft-lb., read the top row of numbers.
For example, if you desire 45ft.-lbs., look to the number 40 in the left column and the number 5 in the top row.
The conversion to meter-kilograms would be 6.22 Mkgs. For your use, the conversion formula is:
FT.-LBS.X 0.1383 = METER-KILOGRAMS
ft.lb.
0
mkg
0
10
20
30
40
50
60
70
80
90
100
0
1.383
2.766
4.149
5.532
6.915
8.298
9.681
11.06
12.45
13.83
1
mkg
0.138
1.521
2.904
4.287
5.670
7.053
9.436
9.819
44.20
12.59
2
mkg
0.277
1.660
3.043
4.426
5.809
7.191
8.574
9.957
11.34
12.73
From FT.-LB. TO MKG
3
4
5
mkg
mkg
mkg
0.415
0.553
0.691
1.798
1.936
2.074
3.181
3.319
3.457
4.564
4.702
4.840
5.947
6.085
6.223
7.330
7.468
7.606
8.713
8.851
8.989
10.09
10.23
10.37
11.48
11.62
11.75
12.86
13.00
13.14
6
mkg
0.830
2.212
3.596
4.979
6.362
7.745
9.128
10.51
11.89
13.28
7
mkg
0.968
2.351
3.734
5.117
6.500
7.882
9.266
10.65
12.03
13.42
8
mkg
1.106
2.489
3.872
5.255
6.638
8.021
9.404
10.79
12.17
13.55
9
mkg
1.245
2.628
4.011
5.394
6.777
8.159
9.543
10.92
12.31
13.69
Ft.lb. X.1383 =mkg
mkg
0
ft.lb.
0
10
20
30
40
50
60
70
80
90
100
0
72.4
144.7
217.0
289.3
361.7
434.0
506.3
578.6
651.0
723.3
1
ft.lb.
7.23
79.6
151.9
224.2
296.6
368.9
441.2
513.5
585.9
658.2
2
ft.lb.
14.47
86.8
159.1
231.5
303.9
376.1
448.4
520.8
593.1
665.4
From MKG TO FT.-LB.
3
4
5
ft.lb.
ft.lb.
ft.lb.
21.70
28.93
36.17
94.0
101.3
108.5
166.4
173.6
180.8
238.7
245.9
253.2
311.0
318.3
325.5
383.3
390.6
397.8
455.7
462.9
470.1
528.0
535.2
542.5
600.3
607.6
614.8
672.7
679.9
687.1
6
ft.lb.
43.40
115.7
188.1
260.4
332.7
405.0
477.4
549.7
622.0
694.4
7
ft.lb.
50.63
123.0
195.3
267.6
340.0
412.3
484.6
556.9
629.3
701.6
8
ft.lb.
57.86
130.2
202.5
274.9
347.2
419.5
491.8
564.2
636.5
708.8
9
ft.lb.
65.10
137.4
209.8
284.1
354.4
426.7
499.1
571.4
643.7
716.1
mkg X 7.233 = ft.lb.
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
A-7
Appendix
A.1.5. Conversion of Inch-Pounds to Inch-Ounces
in.lb.
0
10
20
30
40
50
60
70
80
90
100
0
in.oz.
0
160
320
480
640
800
960
1120
1280
1440
1600
1
in.oz.
16
176
336
496
656
816
976
1236
1296
1456
2
in.oz.
32
192
352
512
672
832
992
1152
1312
1472
From IN.-LB. to IN.-OZ.
3
4
5
in.oz.
in.oz.
in.oz.
48
64
80
208
224
240
368
384
400
528
544
560
688
704
720
848
864
880
1008
1024
1040
1168
1184
1200
1328
1344
1360
1488
1504
1520
6
in.oz.
96
256
416
576
736
894
1056
1216
1376
1536
7
in.oz.
112
272
432
592
752
912
1072
1232
1392
1552
8
in.oz.
128
288
448
608
768
928
1088
1248
1408
1568
9
in.oz.
144
304
464
624
784
944
1104
1264
1424
1584
6
in.lb
.375
1.000
1.625
2.250
2.875
3.500
4.125
4.750
5.375
6.000
7
in.lb
.438
1.063
1.688
2.313
2.938
3.563
4.188
4.813
5.438
6.063
8
in.lb
.500
1.125
1.750
2.375
3.000
3.625
4.250
4.875
5.500
6.125
9
in.lb
.563
1.188
1.813
2.458
3.063
3.688
4.313
7.938
5.563
6.188
in. lb. X 16 = in.oz.
in.oz
0
in.lb
0
10
20
30
40
50
60
70
80
90
100
0
.625
1.250
1.875
2.500
3.125
3.750
4.375
5.000
5.625
6.250
1
in.lb
.063
.688
1.313
1.938
2.563
3.188
3.813
4.438
5.063
5.688
2
in.lb
.125
.750
1.375
2.000
2.625
3.250
3.875
4.500
5.125
5.750
From IN.-OZ. to IN.-LB.
3
4
5
in.lb
in.lb
in.lb
.188
.250
.313
.813
.875
.938
1.438
1.500
1.563
2.063
2.125
2.188
2.688
2.750
2.813
3.313
3.375
3.438
3.938
4.000
4.063
4.563
4.625
4.688
5.188
5.250
5.313
5.813
5.875
5.938
in.oz. ... 16 = in.lb.
A-8
KAWASAKI ROBOT C3✻/C4✻/C70C80 Controller INSTALLATION & CONNECTION MANUAL
Appendix
A.1.6. Conversion of Foot-Pounds to Inch-Pounds
ft.lb.
0
10
20
30
40
50
60
70
80
90
100
0
in.lb.
0
120
240
360
480
600
720
840
960
1080
1200
1
in.lb.
12
132
252
372
492
612
732
852
972
1092
2
in.lb.
24
144
264
384
504
624
744
864
984
1104
From FT.-LB. to IN.-LB.
3
4
5
in.lb.
in.lb.
in.lb.
36
48
60
156
168
180
276
288
300
396
408
420
516
528
540
636
648
660
756
768
780
876
888
900
996
1008
1020
1116
1128
1140
6
in.lb.
72
192
312
432
552
672
792
912
1032
1152
7
in.lb.
84
204
324
444
564
684
804
924
1044
1164
8
in.lb.
96
216
336
456
576
696
816
936
1056
1176
9
in.lb.
108
228
348
468
588
708
828
948
1068
1188
6
in.lb
.500
1.333
2.167
3.000
3.833
4.667
5.500
6.333
7.167
8.000
7
in.lb
.583
1.417
2.250
3.083
3.917
4.750
5.583
6.417
7.250
8.083
8
in.lb
.667
1.500
2.333
3.167
4.000
4.833
5.667
6.500
7.333
8.167
9
in.lb
.750
1.583
2.417
3.250
4.083
4.917
5.750
6.583
7.417
8.250
in. lb. X 12 = in.lb.
ft.lb
0
in.lb
0
10
20
30
40
50
60
70
80
90
100
0
.833
1.677
2.500
3.333
4.167
5.000
5.833
6.667
7.500
8.333
1
in.lb
.083
.917
1.750
2.583
3.417
4.250
5.083
5.917
6.750
7.583
2
in.lb
.167
1.000
1.833
2.667
3.500
4.333
5.167
6.000
6.833
7.667
From IN.-LB. to FT.-LB.
3
4
5
in.lb
in.lb
in.lb
.250
.333
.417
1.083
1.167
1.250
1.917
2.000
2.083
2.750
2.833
2.917
3.583
3.667
3.750
4.417
4.500
4.583
5.250
5.333
5.417
6.083
6.167
6.250
6.917
7.000
7.083
7.750
7.833
7.917
in.lb. ... 12 = ft.lb.
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
A-9
Appendix
A.1.7. Conversion of Inch-Pounds to Centimeter-Kilograms
in.lb.
0
10
20
30
40
50
60
70
80
90
100
0
cmkg.
0
11.52
23.04
34.56
46.09
57.61
69.13
80.65
92.17
103.7
115.2
1
cmkg.
1.152
12.67
24.19
35.71
47.23
58.75
70.27
81.79
93.32
104.9
2
cmkg.
2.304
13.83
25.35
36.87
48.39
59.90
71.42
82.94
94.49
106.1
From IN.-LB. to CMKG
3
4
5
cmkg. cmkg. cmkg.
3.456
4.608
5.760
14.97
16.13
17.28
26.49
27.65
28.80
38.02
39.17
40.32
49.54
50.69
51.85
61.06
62.21
63.37
72.57
73.73
74.89
84.05
85.21
86.41
95.66
96.83
97.93
107.2
108.3
109.5
6
cmkg.
6.912
18.43
29.96
41.47
52.99
64.51
76.03
87.58
99.08
110.7
7
cmkg.
8.064
19.59
31.07
42.62
54.14
65.66
77.18
88.75
100.2
111.8
8
cmkg.
9.217
20.74
32.26
43.77
55.29
66.81
78.33
89.91
101.4
112.9
9
cmkg.
10.36
21.89
33.41
36.60
56.45
67.96
79.49
91.00
102.6
114.1
6
in.lb
5.206
7
in.lb
6.074
8
in.lb
6.942
9
in.lb
7.809
13.883
22.560
31.237
39.914
48.591
57.268
65.945
74.622
83.299
14.751
23.428
32.105
40.782
49.459
58.136
66.813
75.490
84.167
15.619
24.296
32.973
41.650
50.327
59.004
67.681
76.358
85.035
16.486
25.163
33.840
42.517
51.194
59.871
68.548
77.225
85.902
in. lb. X 1.152 = cmkg
cmkg
0
10
20
30
40
50
60
70
80
90
100
0
in.lb
0
8.677
17.354
26.031
34.708
43.385
52.062
60.739
69.416
78.093
86.770
1
in.lb
.868
2
in.lb
1.735
9.545
18.222
26.899
35.576
44.253
52.930
61.607
70.284
78.961
10.412
19.089
27.766
36.443
45.120
53.797
62.474
71.151
79.828
From CMKG to IN.-LB.
3
4
5
in.lb
in.lb
in.lb
2.603
3.471
4.339
11.280
19.957
28.634
37.311
45.988
54.665
63.642
72.019
80.670
12.148
20.825
29.502
38.179
46.856
55.533
64.010
72.019
80.670
13.016
21.693
30.370
39.047
47.724
56.401
65.078
73.754
82.432
cmkg X 0.8677 = in.lb.
A-10
KAWASAKI ROBOT C3✻/C4✻/C70C80 Controller INSTALLATION & CONNECTION MANUAL
Appendix
A.1.8. Conversion of Foot-Pounds to Meter-Kilograms
ft.lb.
0
10
20
30
40
50
60
70
80
90
100
0
mkg.
0
1.383
2.766
4.149
5.532
6.915
8.298
9.681
11.06
12.45
13.83
1
mkg.
0.138
1.521
2.904
4.287
5.670
7.053
8.436
9.819
11.20
12.59
2
mkg.
0.277
1.660
3.043
4.426
5.809
7.191
8.574
9.957
11.34
12.73
From FT.-LB. to MKG
3
4
5
mkg.
mkg.
mkg.
0.415
0.533
0.691
1.798
1.936
2.074
3.181
3.319
3.457
4.564
4.702
4.840
5.947
6.085
6.223
7.330
7.468
7.606
8.713
8.851
8.989
10.09
10.23
10.37
11.48
11.62
11.75
12.86
13.00
13.14
6
mkg.
0.830
2.212
3.596
4.979
6.362
7.745
9.128
10.51
11.89
13.28
7
mkg.
0.968
2.351
3.734
5.117
6.500
7.883
9.266
10.65
12.03
13.42
8
mkg.
1.106
2.489
3.872
5.255
6.638
8.021
9.404
10.79
12.17
13.55
9
mkg.
1.245
2.628
4.011
5.394
6.777
8.159
9.543
10.92
12.31
13.69
6
ft.lb
43.40
115.7
188.1
260.4
332.7
405.0
477.4
549.7
622.0
694.4
7
ft.lb
50.63
123.0
195.3
267.6
340.0
412.3
484.6
556.9
629.3
701.6
8
ft.lb
57.86
130.2
202.5
274.9
347.2
419.5
491.8
564.2
636.5
708.8
9
ft.lb
65.10
137.4
209.8
284.1
354.4
426.7
499.1
571.4
643.7
716.1
ft.lb. X 1383 = mkg
mkg
0
ft.lb
0
10
20
30
40
50
60
70
80
90
100
0
72.4
114.7
217.0
289.3
361.7
434.0
506.3
578.6
651.0
723.3
1
ft.lb
7.23
79.6
151.9
224.2
296.6
368.9
441.2
513.5
585.9
658.2
2
ft.lb
14.47
86.8
159.1
231.5
303.9
376.1
448.4
520.8
593.1
665.4
From MKG to FT.-LB.
3
4
5
ft.lb
ft.lb
ft.lb
21.70
28.93
36.17
94.0
101.3
108.5
166.4
173.6
180.8
238.7
245.9
253.2
311.0
318.3
325.5
383.3
390.6
397.8
455.7
462.9
470.1
528.0
535.2
542.5
600.3
607.6
614.8
672.7
679.9
687.1
mkg X 7.233 = ft.lb.
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
A-11
Appendix
A.1.9. Conversion of Foot-Pounds to Newton-Meters
ft.lb.
0
10
20
30
40
50
60
70
80
90
100
0
Nm
0
13.56
27.11
40.67
54.22
67.78
81.33
94.89
108.45
122.00
135.66
1
Nm
1.36
14.91
28.47
42.02
55.58
69.14
82.69
2
Nm
2.71
16.27
29.83
43.48
56.94
70.49
84.05
96.25
109.80
123.36
97.60
111.16
124.72
From FT.-LB. to NM
3
4
5
Nm
Nm
Nm
4.07
5.42
6.78
17.62
18.98
20.33
29.83
32.54
33.89
43.38
46.09
47.45
56.94
59.65
61.00
70.49
73.20
74.56
84.05
86.76
88.11
97.60
111.16
124.72
100.31
113.87
127.43
101.67
115.23
128.78
6
Nm
8.13
21.69
35.25
48.80
62.36
75.91
89.47
7
Nm
9.49
23.05
36.61
50.16
63.71
77.27
90.83
8
Nm
10.84
24.40
37.97
51.51
65.07
78.62
92.18
9
Nm
12.20
25.76
39.32
52.87
66.42
79.98
93.54
103.03
116.58
130.14
104.38
117.94
131.49
105.75
119.29
132.85
107.09
120.65
134.20
6
ft.lb
4.43
11.80
19.18
26.55
33.93
41.30
48.68
56.05
63.43
70.81
7
ft.lb
5.16
12.54
19.91
27.29
34.67
42.04
49.42
56.79
64.17
71.54
8
ft.lb
5.90
13.28
20.65
28.03
35.40
42.78
50.15
57.53
64.91
72.28
9
ft.lb
6.64
14.01
21.39
28.76
36.14
43.52
50.89
58.27
65.64
73.02
ft.lb. X 1.3556 = Nm
Nm
0
ft.lb
0
10
20
30
40
50
60
70
80
90
100
0
7.38
14.75
22.13
29.50
36.88
44.25
51.63
59.00
66.38
73.76
1
ft.lb
.74
8.11
15.49
22.86
30.24
37.62
44.99
52.37
59.74
67.12
2
ft.lb
1.48
8.85
16.23
23.60
30.98
38.35
45.73
53.10
60.48
67.86
From Nm to FT.-LB.
3
4
5
ft.lb
ft.lb
ft.lb
2.21
2.95
3.69
9.59
10.33
110.6
16.96
17.70
18.44
24.34
25.08
25.81
31.72
32.45
33.19
39.09
39.83
40.57
46.47
47.20
47.94
53.84
54.58
55.32
61.22
61.96
62.69
68.59
69.33
70.07
1 Nm = 0.73756 ft.lb.
A-12
KAWASAKI ROBOT C3✻/C4✻/C70C80 Controller INSTALLATION & CONNECTION MANUAL
Appendix
A.1.10. Conversion of Inch-Pounds to Newton-Meters
in.lb.
0
Nm
0
10
20
30
40
50
60
70
80
90
100
0
1.13
2.26
3.39
4.52
5.65
6.78
7.91
9.04
10.17
11.30
1
Nm
.113
1.24
2.37
3.50
4.63
5.76
6.89
8.02
9.15
10.28
2
Nm
.226
1.36
2.49
3.62
4.75
5.88
7.01
8.14
9.27
10.40
From IN.-LB. to NM
3
4
5
Nm
Nm
Nm
.339
.452
.565
1.47
1.58
1.70
2.60
2.71
2.83
3.73
3.84
3.96
4.86
4.97
5.9
5.99
6.10
6.22
7.12
7.23
7.35
8.25
8.36
8.48
9.38
9.49
9.61
10.51
10.62
10.74
6
Nm
.678
1.81
2.94
4.07
5.20
6.33
7.46
8.59
9.72
10.85
7
Nm
.791
1.92
3.05
4.18
5.31
6.44
7.57
8.70
9.83
10.96
8
Nm
.904
2.03
3.16
4.29
5.42
6.55
7.68
8.81
9.94
11.07
9
Nm
1.02
2.15
3.28
4.41
5.54
6.67
7.80
8.93
10.06
11.19
6
in.lb
53.10
7
in.lb
61.95
8
in.lb
70.81
9
in.lb
79.66
141.61
230.12
318.62
407.13
495.64
584.15
672.65
761.16
849.67
150.46
238.98
327.48
415.98
504.49
592.10
681.50
770.01
858.52
159.31
247.82
336.33
424.83
513.34
601.85
690.35
778.86
867.37
168.16
256.67
345.18
433.68
522.19
610.70
699.20
787.21
876.22
in.lb. X .1130 = Nm
Nm
0
10
20
30
40
50
60
70
80
90
100
0
in.lb
0
88.51
177.01
265.52
354.03
442.53
531.04
619.55
708.06
796.56
885.07
1
in.lb
8.85
2
in.lb
17.70
97.36
185.86
274.38
362.88
451.36
539.89
628.40
716.91
805.41
106.21
194.72
283.22
371.73
460.24
548.74
637.25
725.76
814.26
From NM to IN.-LB.
3
4
5
in.lb
in.lb
in.lb
26.55
35.40
44.25
115.06
203.57
292.07
380.58
469.09
557.59
646.10
734.61
823.12
123.91
212.42
300.92
389.43
477.94
566.44
654.95
743.46
831.97
132.76
221.27
309.77
398.28
486.79
575.30
663.80
752.31
840.82
Nm X 8.8507 = in.lb.
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
A-13
Appendix
A.1.11. Conversion of Inch-Ounces to Newton-Meters
in.oz.
0
10
20
30
40
50
60
70
80
90
100
0
Nm
0
.071
.114
.212
.282
.353
.424
.494
.565
.635
.706
1
Nm
.007
.078
.148
.219
.289
.360
.431
.501
.572
.642
2
Nm
.014
.085
.155
.226
.297
.367
.438
.508
.579
.650
From IN.-OZ. to NM
3
4
5
Nm
Nm
Nm
.021
.028
.035
.092
.098
.106
.162
.177
.184
.232
.240
.247
.304
.312
.318
.374
.381
.388
.445
.452
.459
.515
.522
.530
.586
.593
.600
.657
.664
.671
6
Nm
.042
.113
.191
.254
.324
.395
.466
.537
.607
.678
7
Nm
.049
.120
.198
.261
.332
.402
.473
.544
.614
.685
8
Nm
.056
.127
.205
.268
.339
.409
.480
.551
.621
.692
9
Nm
.064
.134
3.28
.275
.346
.417
.487
.558
.628
.699
in.oz. X .00706 = Nm
Nm
0
10
20
30
40
50
60
70
80
90
100
0
in.oz
0
14.16
28.32
42.48
56.64
70.81
84.97
99.13
113.29
127.45
141.61
1
in.oz
1.42
15.58
29.74
43.90
58.06
72.22
86.41
2
in.oz
2.83
16.99
31.15
45.32
59.48
73.64
87.80
From NM to IN.-OZ.
3
4
5
in.oz
in.oz
in.oz
4.25
5.66
7.08
18.41
19.83
21.24
32.57
33.99
35.40
46.73
48.15
49.56
60.89
62.31
63.72
75.05
76.47
77.89
89.21
90.63
92.05
6
in.oz
8.50
22.66
36.82
50.98
65.14
79.30
93.46
7
in.oz
9.91
24.07
38.23
52.40
66.56
80.72
94.88
8
in.oz
11.33
25.49
39.65
53.81
67.97
82.13
96.30
9
in.oz
12.74
26.91
41.07
55.23
69.39
83.55
97.71
100.54
114.70
128.87
101.96
116.12
130.28
103.38
117.54
131.70
107.62
121.79
135.95
109.04
123.20
137.36
110.46
124.62
138.78
111.87
126.03
140.19
104.79
118.95
133.11
106.21
120.37
134.53
.01 Nm X 141.612 = .01 in.oz.
A-14
KAWASAKI ROBOT C3✻/C4✻/C70C80 Controller INSTALLATION & CONNECTION MANUAL
Appendix
A.2. STANDARD TORQUE TABLES
The following tables, relating tightening torque to thread diameter, 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.
Table General Fasteners Standard Torque Values
General Fasteners:
Thread dia.
Torque
(mm)
N-m
kg-m
ft-lb
5
3.4-4.9
0.35-0.50
30-43 in-lb
6
5.9-7.8
0.60-0.80
52-69 in-lb
8
14-19
1.4-1.9
10.0-13.5
10
25-39
2.6-3.5
19.0-25.0
12
44-61
4.5-6.2
33.0-45.0
14
73-98
7.4-10.0
54.0-72.0
16
115-155
11.5-16.0
83.0-115.0
18
165-225
17.0-23.0
125.0-165.0
20
225-325
23.0-33.0
165.0-240.0
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
A-15
Appendix
Table Special Material Fastener Torque Values
Torque kg-cm (ft-lb)
Cap Screw size
SCM3
S45C
SS41
M3
-
-
-
4
35(2.53)
20(1.44)
10(0.72)
5
70(5.06)
40(2.89)
20(1.44)
6
120(8.67)
70(5.06)
30(2.16)
8
300(21.69)
170(12.29)
80(5.78)
10
580(41.95)
340(24.59)
160(11.57)
12
1000(72.33)
600(43.39)
280(20.25)
14
1600(115.72
900(65.09)
420(30.37)
16
2400(173.5)
1400(101.26)
650(47.0)
18
3400(245.92)
1900(137.42)
880(63.6)
20
4400(318.25)
2700(195.29)
1300(94)
* Values in parentheses are foot-pounds (ft-lb).
MATERIAL KEY:
SS41
-Mild Steel
S45C
-Carbon Steel
SCM3
-Chrome/Moly Steel
！ CAUTION
There are many varying factors which affect
torque. The figure in the following charts are
safe figures for standard torque applications
when fastener is screwed into steel or cast iron
threads only.
A-16
KAWASAKI ROBOT C3✻/C4✻/C70C80 Controller INSTALLATION & CONNECTION MANUAL
INTRODUCTION
UNIT 1 SAFETY
UNIT 2 RIGGING/LIFTING/MOVING INSTRUCTIONS
UNIT 3 INSTALLATION OF ROBOT CONTROLLER
UNIT 4 MULTI FUNCTION PANEL CONNECTIONS
UNIT 5 WIRING INSTRUCTIONS
APPENDIX
GLOSSARY
INDEX
KAWASAKI ROBOT C3✻/C4✻/C70/A80 Controller INSTALLATION & CONNECTION MANUAL
G-1
Glossary
This glossary contains definitions of terms used by operators, programmers and maintenance personnel who work
with Kawasaki Robots. The definitions are listed in alphabetical order.
A
z
ACCELERATE
To speed up a process.
z
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).
z
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.
z
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.
z
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.
z
AIR CUT
Moving a weld gun into position but without generating an arc.
z
ALGORITHM
A finite set of well-defined rules or procedures for solving a program step-by-step.
z
ALPHANUMERIC
Pertaining to a set of symbols that contain both letters and numbers, either individually or in combination.
z
AMBIENT TEMPERATURE
The temperature of air or liquid that surrounds a device.
z
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.
z
ANALOG
A continuously changing electrical voltage signal. In robot systems, the magnitude or value of the signal
represents commanded robot axis motion.
z
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.
z
ANTI-FRICTION BEAING
A rolling element which is used to support a rotating shaft.
G-2
KAWASAKI ROBOT C3✻/C4✻/C70/A80 Controller INSTALLATION & CONNECTION MANUAL
Glossary
z
ARC SENSOR
A sensor that detects weld lines utilizing arc characteristics.
z
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.
z
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 instance, integer or character, and are
usually presented in rows and columns.
z
ARTICULATED
To join together permanently or semipermanently by means of a pivot connection for operating separate
segments as a unit.
z
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.
z
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.
z
AS LANGUAGE
Kawasaki robot language used to communicate commands and instructions from a keyboard to the CPU.
(AS: Advanced Superior, pronounced AZU)
z
ASSIGNMENT
An instruction used to express a sequence of operations, or used to assign operands to specified variables, or
symbols, or both.
z
ASYCHRONOUS
A means of data communication where the data is sent a character at a time preceded by a start bit and
followed by a stop bit. No direct timing signal links the transmitter and receiver.
z
AUXILIARY DATA
Information about a point, other than the positional data, such as speed, accuracy weld schedule and clamp
condition.
z
AXIS
A straight line about which sections of the mechanical unit rotate (e.g.,joints JT1, JT2, JT3 etc.).
KAWASAKI ROBOT C3✻/C4✻/C70/A80 Controller INSTALLATION & CONNECTION MANUAL
G-3
Glossary
B
z
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.
z
BASE COORDINATE
A fixed coordinate system having an origin at the intersection of the X, Y, and Z axes.
z
BAUD RATE
Determines the number of bits per second (bps) or characters transmitted between devices.
z
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.
z
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.
z
BIT
Acronym for binary digit, having one of two values: 0 or 1.
z
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.
z
BUFFER
A temporary memory storage area in a computer or electronic device.
z
BUG
A problem in a software or hardware element of a system.
z
BUS
The primary communication path in the controller along which internal signals are sent among processors and
memories.
C
z
CABLE CARRIER
A device which carries cables and hoses (including power sources) from a stationary location to a linear
moving device.
z
CARTESIAN COORDINATE
A location in space defined by three axes at right angles to each other, commonly labeled X, Y,Z.
z
cc
cubic centimeter.
G-4
KAWASAKI ROBOT C3✻/C4✻/C70/A80 Controller INSTALLATION & CONNECTION MANUAL
Glossary
z
CELL
A manufacturing unit consisting of two or more work stations or machines, and the material transport
mechanisms and storage buffers that interconnect them.
z
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.
z
CHARACTER
A term that describes all numbers, letters, and other symbols typically found on a computer keyboard.
z
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 analogous to reverse point and forward point operations in
other robot models.
z
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.
z
CHEMICAL ANCHOR
A threaded rod installed in a structure (e.g.,a concrete floor) and secured by epoxy, for the purpose of
securing hardware.
z
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.
z
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.
z
CODE
A set of rules for expressing information in a language that is understood and processed 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.
z
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.
z
COMMENT
Optional, non-executing remarks added to a program to explain various aspects of the program.
z
COMPILER
A system task that translates a program written in source code, into binary code that can be understood by the
processor.
z
COMPOUND TRANSFORMATION
KAWASAKI ROBOT C3✻/C4✻/C70/A80 Controller INSTALLATION & CONNECTION MANUAL
G-5
Glossary
A location in the Cartesian coordinate system that is defined relative to another Cartesian coordinate location.
z
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.
z
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.
z
CONTROL ERROR CODE
A code which identifies system problems whenever an alarm condition occurs.
z
CONTROLLED AXIS
A robot axis that is operated by electrical or hydraulic power.
z
CONTROLLER
An electronic device, with processing capabilities and software, which controls the robot actions and
functions.
z
CONVEYER TRACKING
Used to make the robot follow a part on a conveyor, without the use of a traverse axis.
z
COORDINATE
A set of numbers that locate a point in space.
z
CPU
Acronym for central processing unit.
A collection of hardware in a computer which performs all
calculations, handles I/O, and executes programmed tasks.
z
CRASH
A situation where the computer fails to operate, due to a software or hardware problem.
z
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.
z
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.
z
CURSOR
A pointer or indicator on a computer screen, that identifies the current position on the screen.
z
CYCLE
A complete path of projectory performed by the robot for a specific application.
G-6
KAWASAKI ROBOT C3✻/C4✻/C70/A80 Controller INSTALLATION & CONNECTION MANUAL
Glossary
z
CYCLOIDAL DRAIVE
A mechanical gear reduction unit that reduces the speed of the input and increase the torque capacity.
The cyclodial 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
z
DATA
A term given to information, instructions, words or symbols that are usually transmitted, processed, or stored
as a group.
z
DETENT
A part of a mechanism that locks or unlocks a movement.
z
DISCONNECT
A switch that isolates a circuit or one or more pieces of electrical apparatus after the current has been
interrupted by other means.
z
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 difference. However, if the controller detects a
condition where the difference between this mechanical value and the desired electrical position is larger than
the established value limit, the robot controller will generate a deviation error. This error is sometimes
referred to as a FOLLOWING ERROR in the robot industry.
z
DEBUG
The process by which an operator7s program is checked for mistakes and then corrected.
z
DECIMAL NUMBER
Numbers in the base-10 numbering system, which uses the numerals 0-9.
z
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.
z
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 an be dedicated.
z
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.
z
DELETE
A command which will eliminate unwanted data.
z
DELIMITER
A character which separates a group of items or a character string, from other groups, or which terminates a
task.
KAWASAKI ROBOT C3✻/C4✻/C70/A80 Controller INSTALLATION & CONNECTION MANUAL
G-7
Glossary
z
DEVICE
Any peripheral hardware connected to the processor and capable of receiving, sorting, or transmitting data.
z
DIAGNOSTICS
Function performed by the processor to identify and check for error conditions in the robot arm and
peripheral devices.
z
DIP SWITCH
DIP is an acronym for dual in-line package. A set of small switches on circuit boars that can be set for
different configurations.
z
DIRECTORY
A logical structure that organizes a group of similar files.
z
DISK
A high-speed, random-access memory device.
z
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.
z
DISK PACK
A device which is used to store additional data in a computer system, and is usually removable.
E
z
ECHO
Process in which characters that are typed on a keyboard are also displayed on the screen or are sent to the
printer.
z
EDITOR
An aid for entering information into the computer system and modifying existing text.
z
EMERGENCY STOP (E-Stop)
An immediate stop of robot motion, selected by the operator with a switch.
z
ENCODER
An electromechanical device that is connected to a shaft to produce a series of pulses that indicate the
position of the shaft.
z
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
error messages.
z
ERROR LOG
A report which contains a sequential list of system error messages.
z
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.
G-8
KAWASAKI ROBOT C3✻/C4✻/C70/A80 Controller INSTALLATION & CONNECTION MANUAL
Glossary
z
EXPRESSION
A combination of real-valued variables and functions, and mathematical and logical operators.
When
evaluated, this combination yields a numeric value.
F
z
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.
z
FIELD SIGNALS
All electrical signals that exit or enter an electrical panel.
z
FILE
A set of related records or data elements, which are stored using one name and are arranged in a structire that
can be used by a program.
z
FILESPEC
Includes the name, creation data and size of the specified file.
z
FIXED DISK
An electromagnetic mass storage device which is not removable. Hard disks have much highter storage
capacity than floppy disks.
z
FLOPPY DISK
An electromagnetic mass storage device which can be removed and exchanged.
z
FORM FEED
Process which causes a printer to advance the paper to the top of the next page.
z
FUNCTION
A formula or routine for evaluating an expression.
G
z
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.
z
GLOBAL
Refers to a function or process that affects the entire system or file.
z
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
z
HALF-DUPLEX COMMUNICATION
Data transmission between two devices, where the signal is sent in only one direction at a time.
KAWASAKI ROBOT C3✻/C4✻/C70/A80 Controller INSTALLATION & CONNECTION MANUAL
G-9
Glossary
z
HANDSHAKING PROTOCOL
Communication rules used for data transmissions between devices. Each device must recognize the same
protocol in order to communicate.
z
HANG
A term which refers to the state of a computer system that seems to be inoperative when processing should be
taking place.
z
HARDSTOP
A mechanical constraint or limit on motion.
z
HARDWARE
Physical equipment and devices such as computer hard disk, cables, printer, etc.
z
HAZARDOUS SIDE
The unsafe side of a component or panel, such as the inside of the control panel when power in applied and
functions are being performed.
z
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.
z
HOME POSITION
Refer to the starting or resting position of the robot.
z
HYBRID ENCODER
On the Kawasaki robot a hybrid encoder is used to generate positional data, and in composed of an
incremental encoder that generates incremental pulses, and an absolute encoder that generaters gray code
binary data.
I
z
ID
Abbreviation for Identification.
z
INCHING
A value that is used during the jogging process that allows the user to position the robot is small minute
increments.
z
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 alternating opaque and generated by an encoder through the use of an optical
disk with alternating 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.
z
INPUT
Transmission of an external signal into a control system.
G-10
KAWASAKI ROBOT C3✻/C4✻/C70/A80 Controller INSTALLATION & CONNECTION MANUAL
Glossary
z
INTEGRATED CIRCUIT(IC)
A combination of interconnected circuit elements which are within a continuous substrate.
z
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.
z
INTERLOCK
An arrangement where by the operation of one part or mechanism automatically brings about or prevents the
operation of another.
z
INTERPETER
A program that changes English-like commands into machine language.
An interpreter translates and
executes one command at a time.
z
INSTRUCTIONS
Discrete steps in a computer program that are commands or statements that tell a computer to do something
or identify data.
z
INTEGER
A whole number, a number without a fractional part such as 7, -318, or 19.
z
INTERFACE
The circuitry that fits between a system and a peripheral device to provide compatible coupling between the
two pieces of equipment.
z
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.
z
INTERRUPT
An external signal that halts program execution so that the computer can service the needs of some peripheral
device or subsytstem.
z
INTRINSIC SAFETY BARRIER (ISB)
An electronic device used in robot controllers to restrict current and voltage to a safe lavel.
z
INVERTER
A circuit which switches a positive signal to a negative signal, and vice versa.
z
I/O
Acronym for Input/Output. The interconnections through which the coputer and its peripheral devices
communicate.
z
IPM
Acronym for Intelligent Power Module
KAWASAKI ROBOT C3✻/C4✻/C70/A80 Controller INSTALLATION & CONNECTION MANUAL
G-11
Glossary
J
z
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.
z
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.
z
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
z
LABEL
An identifier for a program command line. To identify an instruction, memory location, or part of a
program.
z
LAN
An acronym for local area network. A group of computer terminals interconnected by cables, allowing
communication of information via the network.
z
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.
z
LIMIT SWITCH
An electrical switch positioned to be switched when a motion limit occurs, thereby deactivating the actuator
that caused the motion.
z
LINEAR MOVE
An operation where the rate an direction of relative movement of the robot arm are continuously under
computer control.
z
LINE PRINTER
A high-speed output device that prints a line at a time.
z
LINE TURN-AROUND
Changing the source of transmission in half-duplex communications.
z
LOGICAL OPERATION
Any of several operations that manipulate information according to the rules of logic (e. g., AND, OR, NOT,
and exclusive OR).
z
LM
Abbreviation for linear motion.
z
LOAD
The weight applied to the end of the robot arm.
G-12
KAWASAKI ROBOT C3✻/C4✻/C70/A80 Controller INSTALLATION & CONNECTION MANUAL
Glossary
z
LOCKOUT
Serving to prevent operation of a device or part of it.
z
LSB
Abbreviation for least significant bit.
M
z
MANIPULATOR
Another term for the mechanical portion of the robot system.
z
MACHINE LANGUAGE
A low-level computer language, usually written in binary code.
z
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.
z
MECHANICAL UNIT
robot (excluding controller)
z
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.
z
MHz
Abbreviation for magahertz. One million cycles per second.
z
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.
z
mm
Abbreviation for millimeter.
z
MNEMONIC
A term used to help the operator remember a large string of words or commands.
z
MODEM
A signal conversion device that modulates and demodulates data into an audio signal for transmission.
z
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.
z
MONITOR PROGRAM
An administrative computer program that oversees operation of a system. The AS monitor accepts user
input and initiates the appropriate response, follows instructions from user programs to direct the robot, and
performs the computations necessary to control the robot.
z
MSB
Abbreviation for most significant bit.
KAWASAKI ROBOT C3✻/C4✻/C70/A80 Controller INSTALLATION & CONNECTION MANUAL
G-13
Glossary
z
msec
Abbreviation for millisecond (0.001 seconds).
N
z
NOISE
Any unwanted disturbance within a dynamic, mechanical, or electrical system.
z
NULLED
An electrical zero state.
O
z
OCTAL NUMBER
A numeral in the base-8 numbering system, which uses the numerals 0-7.
z
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).
z
ON LINE
A state in which communication between two devices can occur.
z
OPERATING SYSTEM
A set of system tasks and commands that are entered by the operator and interpreted and performed by the
system.
z
OPEN LOOP
A control which does not use feedback to determine its output.
z
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.
z
OPTO
An optical isolator or level converter.
z
OVERFLOW
When a value or buffer exceeds a predefined limit.
z
OVERTRAVEL
An error condition that exists when the robot exceeds its normal software limit values, and then actuates an
overtravel limit switch.
z
OVERVELOCITY
When an axis exceeds a preset value for velocity.
z
OX(OUTPUT EXTERNAL)
Information transferred from the robot controller through output modules to control output devices.
G-14
KAWASAKI ROBOT C3✻/C4✻/C70/A80 Controller INSTALLATION & CONNECTION MANUAL
Glossary
KAWASAKI ROBOT C3✻/C4✻/C70/A80 Controller INSTALLATION & CONNECTION MANUAL
G-15
Glossary
P
z
PARITY
Method by which errors are detected. In this method the combined binary values of a byte are flagged as 1
or 0.
z
PARSE
To break a command string into individual elements, so it can be interpreted.
z
PASSWORD
A code, entered by the user, to permit access to protected information.
z
PAYLOAD
The maximum weight that a robot can handle satisfactorily during its normal operations and extensions.
z
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.
z
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.
z
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.
z
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.
z
PLA
Acronym for programmable logic array. Used in many servo drive circuits.
z
PLAYBACK
An operation where a taught path is run for evaluation purposes.
z
PLC
Acronym for programmable logic controller. Usually referred to as the cell module controller.
z
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.
z
POLARITY KEYS
These teach pendant or multi function panel keys allow the user to hog or slew the robot in the Joint, Base
(XYZ), or tool coordinates system.
z
PORT
The connection point of an opening or passage that is usually located outside the housing of a divice.
G-16
KAWASAKI ROBOT C3✻/C4✻/C70/A80 Controller INSTALLATION & CONNECTION MANUAL
Glossary
z
POSITIONAL DATA
The location in space of the robot manipulator.
z
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.
z
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.
z
PRECISION POINT
The play back of robot location based on the angular position of the six axes, joint angles.
z
PRINTING
A process in which characters are stamped on a surface, usually paper.
z
PROGRAM
A predefined, step-by -step of instructions that are entered into a computer so a specific process can be
performed repeatedly without re-entering all the steps. Robot paths are stored and run as part of programs.
z
PROGRAM EDIT
Modification of an existing program.
z
PROCESSOR
Generally, any hardware or software system for carrying out programs and acting on data.
z
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 referred to as pulse duration modulation (PDM), or
pulse length modulation (PLM).
R
z
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 provided.
z
REAL NUMBER
A number with a fractional part, such as 1.75 ∼ -61.89, .5, -4.00, etc.
z
REAL-TIME
The actual time during which the computer analyzes and processes data : information is usually processed as
it is received.
z
REAL VARIABLE
AS language term for a variable that has had a real value assigned to it.
z
REPEAT MODE
A mode of operation that allows the user to check positional and auxiliary information at a selscted speed
value, in a continuous or a step by step type of movement of the mechanical unit.
KAWASAKI ROBOT C3✻/C4✻/C70/A80 Controller INSTALLATION & CONNECTION MANUAL
G-17
Glossary
z
REPEATABILITY
The measurement of the closeness of agreement among repeated measurements of the same variable under
the same conditions.
z
REWRITE MODE
A mode of operation which allows the user to rewrite positional, or auxiliary data, and to insert or delete step
address locations.
z
RISC
Acronym for reduced instruction set computer.
z
ROM (read-only memory)
A memory device which is programmed at the factory and whose contents thereafter cannot be altered.
z
RS-232C
An ASCII specification for connections and communication between serial devices.
z
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
z
SAFETY PLUG
A device used with safety fencing to interlock the opening of the fence with the removal of power to the
robot.
z
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 information enters the screen from the bottom.
z
SENSOR
A device used to detect various conditions: proximity, heat, pressure, etc. An electrical signal from the
sensor can be used to communicate information to a robot program.
z
SERIAL
A method of transmitting data by which only one bit is sent or received at any one point in time.
z
SEQUENTIAL ACCESS
A method used by many computers whereby data is read in the order in which it is physically stored.
z
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.
z
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.
z
SOFTWARE
A set of written programs and instructions that are executed by a computer system.
G-18
KAWASAKI ROBOT C3✻/C4✻/C70/A80 Controller INSTALLATION & CONNECTION MANUAL
Glossary
z
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 language which can be interpreted by the computer.
z
STRING
A series of characters that have been entered in a distinct sequence that can be interpreted as a valid statement
or command.
z
STROKE
The movement in either direction of a mechanical part having a reciprocating motion. The entire distance
passed through in such movement.
z
SUBSCRIPT
A set of numbers that identifies an element of an array.
z
SUBROUTINE
A set of instructions that is run by another routine.
z
SYMBOL
A character or design that has a distinct meaning and/or is associated with something.
z
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.
z
SYSTEM DATA
Data that is specific to a individual robot. Zeroing data, upper and lower software limits, and software
switch setting are all examples of system data.
z
SYSTEM SWITCH
Software switches that are set to determine various configurations and characteristics of the robot system
performance.
T
z
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.
z
TEACH PENDANT
A hand-held, portable device used by the operator during teach and jogging operations.
z
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.
z
TOOL MODE
A mode of operation in which all motions are calculated to maintain the orientation of the tool in space.
KAWASAKI ROBOT C3✻/C4✻/C70/A80 Controller INSTALLATION & CONNECTION MANUAL
G-19
Glossary
z
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.
z
TRANSFORMER
A device to convert the current of a primary circuit into variations of voltage and current used in secondary
circuits.
z
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 location.
z
TRAP POINT
see pinch point.
z
TTL
Acronym for transistor-transistor logic.
z
TWO’s COMPLEMENT
A means of representing a negative number as one more than the binary complement of the absolute value of
the number.
z
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
z
UHF
Acronym for ultra-high frequency.
V
z
VARIABLE
The name of a memory location or stored value. A variable can refer to a scalar or an array.
z
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.
z
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.
z
VOLT
A unit of electrical potential difference and electromotive force. One volt is equivalent to the force required
to produce one amp of current through one ohm of resistance.
G-20
KAWASAKI ROBOT C3✻/C4✻/C70/A80 Controller INSTALLATION & CONNECTION MANUAL
Glossary
W
z
WORK ENVELOPE
The effective range or reach of a robot’s axes.
z
WORLD COORDINATES
A Cartesian coordinate system in which the origin points is near the base of the robot, and robot movement
can be expressed in terms of a 3-dimensional space representation of X, Y, and Z projections.
z
WRITE
In computer systems, a process in which information is output to and stored by a device or area in memory.
z
WS (WELD SCHEDURE)
Data that is stored in the weld controller and provides the specific current, clamp pressures, etc. for spot
welding applications.
z
WX (WAIT EXTERNAL)
The wait external signal is one of many inputs that are processed by the robot controller. When the robot
encounters a wait external condition, the robot will cease motion and the servo power will be removed.
Z
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 manufactures call this procedure mastering or calibration.
KAWASAKI ROBOT C3✻/C4✻/C70/A80 Controller INSTALLATION & CONNECTION MANUAL
G-21
INTRODUCTION
UNIT 1 SAFETY
UNIT 2 RIGGING/LIFTING/MOVING INSTRUCTIONS
UNIT 3 INSTALLATION OF ROBOT CONTROLLER
UNIT 4 MULTI FUNCTION PANEL CONNECTIONS
UNIT 5 WIRING INSTRUCTIONS
APPENDIX
GLOSSARY
INDEX
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
IN-1
Index
1FR/1GW Board,
5-31
1GB Board,
5-21
1HW Board.
5-31
A
AC Servo,
I-3
B
Bolt Holes,
Brakes,
3-5
2-4
C
Casters,
2-4
Circuit Breaker,
5-4, 5-5
Connecting Diagram for Limit and Proximity Switches,
Connection of Mains Power,
5-4, 5-5, 5-6
Controller Design Specifications,
Controller Variations,
I-6
Conversion Formula,
A-7
5-30
I-3
D
Data Plates,
3-3
Dedicated Signals,
Dimensions,
I-4
I-5
E
Emergency-Stops,
Error Messages,
1-9
I-5
F
F-Series Sensor Cable,
5-28
Front and Left Side View,
I-7, I-9, I-11
FS02/03 and FC02 Sensor Cable,
5-29
Function Diagram, Limit Switch,
5-30
Function Diagram, Proximity Switch,
5-30
G
General Purpose Signals,
Grounding Terminal,
IN-2
5-31
5-3, 5-4, 5-5, 5-7
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
Index
H
Harness Connections,
5-10, 5-18
I
Input Signals,
5-30
Interface Connection,
4-3
J
Js30 and Js40 Sensor Cable,
Js5/JC5.Js10 Sensor Cable,
5-25
5-24
Jumper Configuration for Sensor Cable Usage,
5-31
L
Lifting Controller,
Lifting Sling,
2-3
2-3
Lifts up by the Crane,
Limit Switches,
2-5
5-30
Line Voltage,
5-3
M
Mains Power Supply,
Mass,
5-3
I-5
Memory,
I-3
Motion Control,
I-3
Moving Controller on Casters,
Multi Function Panel,
2-4
I-15, 4-3
N
Noise Filter,
5-6, 5-7
P
Permanent Mounting Procedure,
Personal Safety,
3-5
1-4
Personnel Safety categories,
1-4
Positioning the Robot Controller,
Power Requirements,
Power Supply Specifications,
Proximity Switch,
3-4, 3-6
I-5
5-3
5-30
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
IN-3
Index
R
Rear and Right Side View,
Robot Controller,
I-8, I-10, I-12
I-3
S
Safety,
1-3
Safety During Inspection and Maintenance,
Safety During Operation,
1-6
Safety During Programming,
Safety Features,
Sensor Cable,
1-7
1-9
5-24
Sensor Cable Connection,
Sensor Signal Inputs,
Sensor Signals,
5-24
5-31
5-31
Sensor Wiring Diagrams,
5-32
Solenoid Valve Wiring Diagram,
Speed,
1-9
5-39
I-3
Switch/Breaker,
T
Torque Value,
Transformer,
A-16
5-8
Transportation with Two Persons,
2-5
U
UD100/150 Sensor Cable,
5-26
W
Wall Clearance,
3-4, 3-6
Wire harnesses,
5-10
Wire Specifications,
5-3
Wiring Instructions,
5-3
Z
ZD-Series Sensor Cable,
IN-4
5-27
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller INSTALLATION & CONNECTION MANUAL
KAWASAKI ROBOT CONTROLLER
C3✻
✻/C4✻
✻/C70/C80 Controller
INSTALLATION & CONNECTION MANUAL
October 1998 : 2nd Edition
March 2001 : 7th Edition
Publication : KAWASAKI HEAVY INDUSTRIES, LTD.
ROBOT DIVISION
90202-1031DEG
All rights reserved. Copyright  2001 KAWASAKI HEAVY INDUSTRIES, LTD.
Kawasaki Robotics
(UK) Limited
Kawasaki Robotics GmbH
Kawasaki Robotics
(USA), Inc.
Kawasaki Heavy
Industries, LTD.
Tokyo Head Office
Kawasaki Machine
Systems Korea, Ltd.
KAWASAKI HEAVY INDUSTRIES, LTD.
ROBOT DIVISION
KAWASAKI ROBOTICS CO.,
LTD.
Kawasaki Heavy
Industries, Ltd.
4-1, 2-Chome Hamamatsu-cho Minato-ku Tokyo, 105-6116 JAPAN
(World Trade Center building)
TEL 81-(0)3-3435-6908
FAX 81-(0)3-3437-9880
Kawasaki Robotics
Co., Ltd.
1-1, Kawasaki-cho Akashi, 673-8666 JAPAＮ
TEL 81-(0)78-921-1565
FAX 81-(0)78-923-0685
Kawasaki Robotics
(USA), Inc.
28059 Center Oaks Court Wixom,
Michigan, 48393 U.S.A
TEL 1-248-305-7610
FAX 1-248-305-7618
Kawasaki Robotics
(UK) Limited
Greengate, Middleton Manchester, M24 1SA
UNITED KINGDOM
TEL 44-(0)161-9565400
FAX 44-(0)161-9565404
Kawasaki Robotics
GmbH
Sperberweg29, 41468 Neuss, GERMANY
TEL 49-(0)2131-3426-0
FAX 49-(0)2131-930973
Kawasaki Machine 3FI(307), Industrial Complex Support Bidg., 637
Systems Korea, Ltd. Kojan-Dong, Namdong-Gu, Inchon, 405-310 Korea
TEL 82-32-821-6941
FAX 82-32-821-6947
Akashi Works
TEL 81-(0)78-921-1560
FAX 81-(0)78-923-6548
1-1, Kawasaki-cho Akashi, 673-8666 JAPAN
• All descriptions in this booklet subject to change for improvement without prior notice.