Kawasaki Robot (B, BA, CP, CX, M, MC, MS, R, Y, Z). Instruction Manual (2015)

5. Installation

5.4.4 MOUNTING TOOL TO M SERIES ARM

Dimensions of Wrist End (Flange)

MD/MX series

MT400N

Pin holes

Tapped holes

㸟

CAUTION

D

Use at least one pin for assured

fixing to prevent the tool on

Positioning

the flange from moving.

hole

Positioning

hole

Specification of Mounting Bolts

Check tightening torque

Mounting bolt

Tool

Check length of engagement

Tool mounting part

(Flange)

MD400N/ MD500N

Model

MX350L/ MX420L

MT400N

MX500N/ MX700N

Tapped holes

6-M12

6-M10

D

200

160

Pin holes

2-12H7 Depth 12

2-10H7 Depth 12

Positioning hole 㻌

125H7 Depth 8.5

100H7 Depth 8

Tap depth

29 mm

12 mm

Length of

18 - 28 mm

10 - 11 mm

engagement

High tension bolt

SCM435, 10.9 Min

Tightening torque

98.07 Nm

Pin Material

S45C H *

S45CH *

NOTE* S45C thermal refining steel or equivalent in strength

5-58

5. Installation

5.4.5 MOUNTING TOOL TO MC SERIES ARM

Dimensions of Wrist End (Flange)

Pin hole

Tapped holes

D

Example of tool mounting

56h7

O-ring

Specification of Mounting Bolts

Mounting bolt

Tool

Length of

engagement

Model

MC004N

Tapped holes

4-M6

D

40

Pin hole

4H7 Depth 6

Positioning hole

56h7

Tap depth

7.5 mm

Length of engagement

5 - 7 mm

High tension bolt

SCM435, 10.9 or more

Tightening torque

12 Nm

5-59

5. Installation

5.4.6 MOUNTING TOOL TO MS SERIES ARM

Dimensions of Wrist End (Flange)

Tapped holes

Pin hole

D

Example of tool mounting

O-ring

Positioning hole

Specification of Mounting Bolts

Mounting bolt

Tool

Length of

engagement

Model

MS005N

Tapped holes

4-M6

D

40

Pin hole

6H7 Depth 12

Positioning hole

53h7

Tap depth

12 mm

Length of

7-9 mm

engagement

Tightening bolt

SUS304

Tightening torque

8.3 Nm

5-60

5. Installation

5.4.7 MOUNTING TOOL TO R SERIES ARM

Dimensions of Wrist End

Pin hole

Tapped holes

D

Positioning hole

Specification of Mounting Bolts

Mounting bolt

Tool

Length of engagement

RA10L, RA20N,

RA06L, RA10N,

RC05L, RS05L,

Model

RS10L, RS15X,

RS06L, RS10N

RS05N

RS20N

Tapped holes

4-M6

4-M5

D

40

63

31.5

Pin hole

6H7 Depth 6

5H7 Depth 8

Positioning hole

25H7 Depth 6

40H7 Depth 6

20H7 Depth 3

Tap depth

8 mm

9 mm

8 mm

Length of

6 - 7 mm

7 - 8 mm

6 - 7 mm

engagement

High tension bolt

SCM435, 10.9 min

Tightening torque

11.76 Nm

6.86 Nm

5-61

5. Installation

5.4.9 MOUNTING TOOL TO Z SERIES ARM

Dimensions of Wrist End (Flange)

ZB Series

ZD Series

Pin hole

Drill holes

Tapped holes

D

^xPositioning hole

ZH/ZT/ZX Series

Pin holes

Tapped holes

D

* Positioning hole

NOTE:

4 tapped holes marked * require no tightening.

Specification of Mounting Bolts

ZB Series

Model

ZB150S

Tapped hole

6-M10

Check tightening torque

D

125

Pin hole

2-10H7 Depth 12

Mounting bolt

Positioning hole

80H7 Depth 8

Tool

Tap depth

12 mm

Length of

Check length

Check tap depth.

10-11 mm

of engagement

engagement

Tool mounting

High tension bolt

SCM435, 10.9 min

part (flange)

Tightening torque

56.84 Nm

[ NOTE ]

The above mounting sizes are based on ISO.

If non-ISO sizes are used, insert the adapter

plate (option) prior to mounting tools.

5-64

5. Installation

ZH Series

Check flange

thickness.

Check tightening

torque.

Mounting bolt

Tool

Tool mounting part (flange)

Check tap

Check length of engagement.

depth.

Model

ZH100U

Tapped holes

6-M10

D

125

Pin holes

2-10H7 Depth 12

Positioning hole

80H7 Depth 8

Tap depth

12 mm

Length of

10 - 11 mm

engagement

High tension bolt

SCM435, 10.9 min

Tightening torque

56.84 Nm

NOTE:

4 tapped holes marked * require no tightening.

[ NOTE ]

The above mounting sizes are based on ISO. For the sizes below, insert the

adapter plate (option) prior to mounting tools.

Model

ZH100U

Tapped holes

6-M10

D

92

Pin holes

2-9H7 Depth 12

Positioning hole

55H7 Depth 12

Tap depth

16 mm

Length of

14 - 15 mm

engagement

High tension bolt

SCM435, 10.9 min

Tightening torque

56.84 Nm

5-66

5. Installation

ZT/ZX Series

Check flange

thickness.

Check tightening

torque.

Mounting bolt

Tool

Tool mounting

part (flange)

Check tap

depth.

Check length of engagement.

ZT130L, ZT130S,

ZT130U, ZT165U,

ZT200S, ZX200S,

Model

ZT200U, ZX130L,

ZX300S

ZX130S, ZX130U,

ZX165U, ZX200S

Tapped holes

6-M10

D

125

160

Pin holes

2-10H7 Depth 12

2-10H7 Depth 12

Positioning hole

80H7, Depth 8

100H7, Depth 8

Tap depth

12 mm

Length of

10 - 11 mm

engagement

High tension

SCM435,

bolt

10.9 Min

Tightening

56.84 Nm

torque

[ NOTE ]

The above mounting sizes are based on ISO. For the sizes below, insert the

adapter plate (option) prior to mounting tools.

5-67

5. Installation

ZT130L, ZT130S, ZT130U,

ZT165U, ZT200U, ZX130L,

ZT200S, ZX200S,

Model

ZX130S, ZX130U, ZX165U,

ZX300S

ZX200S

Tapped holes

6-M10

10-M10

D

92

113

Pin holes

2-9H7, Depth 12

2-10H7, Depth 17

Positioning hole

55H7, Depth 12

68H7, Depth 12

Tap depth

16 mm

17 mm

Length of

14 - 15 mm

15 - 16 mm

engagement

High tension bolt

SCM435, 10.9 Min

Tightening torque

56.84 Nm

5-68

6. Connection

6.0 CONNECTION

6.1 PRECAUTIONS FOR ROBOT CONNECTION

！

WARNING

Do not connect the external power until connections between controller and robot

are complete. Accidents, such as electric shock may occur.

！

CAUTION

1. When connecting the harnesses, be sure to use the correct harnesses. Using an

incorrect harness, or misconnecting the harness may damage connectors or cause a

break in the electrical system.

2. Use conduits, ducts, etc. to prevent people or equipment (forklift etc.) from stepping

on or riding over the signal and motor harness lines. Otherwise, an unprotected

harness may become damaged causing breaks in the electrical system.

3. Even when the harnesses are long, do not bundle them winded or bended.

Bundling the harness causes the heat to build up in the harness, resulting in

over-heat and furthermore may cause fire.

4. Separate the harnesses from any nearby high voltage lines (min. 1 m apart). Do

not bundle or run the harnesses in parallel with other power lines. Otherwise, the

noise generated from power lines will cause malfunctions.

5. Separate the motor harness from the communication and sensor cables, and

distribute the lines so they are neither bundled nor running in parallel. Moreover,

connect the communication and sensor cables using shield mesh wire that includes

twisted pair lines and connect the mesh wire to an adequate FG terminal.

Otherwise, PWM noise radiated from the robot’s motor drive lines may penetrate

into various cables, such as communication cable and cause communication errors.

6. Separate the welder secondary cable from the robot’s signal harness. Do not wire

them in the same duct.

7. The motor harness (power line) between the robot and controller will generate

PWM noise due to the PWM control driving the motors. This noise may cause

interference with signal lines. Prevent interference using these countermeasures:

(1) Separate the power and signal lines as much as possible.

(2) Use the shortest possible length for the power line.

(3) Avoid bundling, wiring in parallel the power and signal lines as much as

possible.

(4) Do not wire the power and signal line within the same duct/conduit.

(5) Set and secure a firm earth line connection for the controller.

6-1

6. Connection

6.2 CONNECTING BETWEEN CONTROLLER AND ROBOT

6.2.1 CONTROLLER SIDE

E0x controller

Signal harness (X3)

Major axis motor harness (X4)

Motor harness (X4)

Wrist axis motor harness (X5)

E01 controller

E02 controller

Signal harness (X3)

Major axis motor harness (X4)

Wrist axis motor harness (X5)

E03/E04 controller

Double stack arrangement

of controllers

！

CAUTION

1. Fix each connector securely. The robot may malfunction if connectors

loosen or detach.

2. When placing a controller on another controller, connect the separate

harnesses so that they do not block the exhaust port of the bottom

controller.

6-2

6. Connection

E4x controller

Connector for major axis

motor harness (X4)

Connector for motor

harness (X4)

Connector for wrist axis

motor harness (X5)

Connector for signal

harness (X3)

Connector for signal

harness (X3)

E40 controller

E42/E43 controllers

Connector for wrist axis

motor harness (X4-2)

Connector for major axis motor

harness (X4-1)

Connector for brake and JT7 motor

harness (X5)

Connector for signal

harness (X3)

E44 controller

！

CAUTION

1. Fix each connector securely. The robot may malfunction if connectors

loosen or detach.

2. The harness should drop straight down from the connector. Because

connectors are located at the upper part of controller, if the connected

harnesses are pulled to the controller side or rear direction, the controller

might be toppled.

6-3

6. Connection

6.3 CONNECTING PERIPHERAL CONTROL EQUIPMENT

According to application specifications, connect respective connectors in the controller shown

below with the peripheral controller or devices.

E0x controller

I/O signal inlet

Connect each connecting port

with peripheral equipment and

devices, using the I/O signal

inlet on the rear side of the

controller.

External D-I/O

Connector CN2

AVR

(Output)

Terminal block X7

Terminal block X8

Terminal block X9

External D-I/O

1VA Board

Connector CN4

(Input)

1TR Board

1TW Board

Top

See the figure on the

right for details on

connecting ports of

1VA board.

RS-232C port* USB port*

Ethernet port*

NOTE*: The left RS-232C port, the left USB port and the left Ethernet port are

connected to each port in the accessory panel for standard specification.

6-6

6. Connection

Kawasaki Robot

Instruction Manual

E4x controller

Use cable support for wiring of

24Vdc or less such as I/O, Ethernet

and fieldbus cable etc. Make sure

not to put any stress on connectors on

Cable support

each board.

Screw to connect

external I/O Cable

shield (M4)

1TR Board

1TW Board

External D-I/O

Connector CN2

(Output)

Terminal block

1TA/1VA

X7 Connector

Board

Terminal block

X8 Connector

External D-I/O

Connector CN4

(Input)

Terminal block

X9 Connector

See the figure on the right for

details on connecting ports of

1TA/1VA board.

RS-232C port*

USB port*

Ethernet port

NOTE*: The upper RS-232C port and the upper USB port are

connected to the each port in the accessory panel for

standard specification.

6-7

6. Connection

E70/E71 controllers

I/O signal inlet

Connect each

connecting port with

peripheral equipmen

and devices, using

the I/O signal inlet on

Rear

Left

the rear or the left

side of the controller.

External D-I/O

Connector CN2 (Output)

Connector CN4 (Input)

1TW Board

Terminal block X9

1TR Board

Terminal block X8

1TA/1VA

Terminal block X7

Board

AVR

Left

See the figure on the right for

details on connecting ports of

1TA/1VA board.

RS-232C port^*

USB port^*

Ethernet port

NOTE*: The left RS-232C port and the left USB port are

connected to each port in the accessory panel for

standard specification.

6-8

6. Connection

E91 controller

I/O signal inlet

Connect each connecting port

with peripheral equipment and

devices, using the I/O signal

inlet on the rear side of the

controller.

External D-I/O

Connector CN2

(Output)

AVR

Terminal block X7

Terminal block X8

Terminal block X9

1VA Board

External D-I/O

Connector CN4 (Input)

1TR Board

1TW Board

Top

See the figure on the right for

details on connecting ports of 1VA

board.

RS-232C port*

USB port*

Ethernet port

NOTE*: The left RS-232C port and the left USB port are

connected to each port in the accessory panel for

standard specification.

6-9

6. Connection

6.4 CONNECTING BETWEEN CONTROLLER AND TEACH PENDANT

1. Connect the teach pendant cable with the connector located below the operation panel.

Pull up the lever and insert the cable side connector, and then pull down the lever to lock the

connectors.

2. Hang the teach pendant and the teach pendant cable on the hook.

(No hook is provided for

E0x/E70/E71/E91 controllers.)

Teach pendant connector

E0x controller

CAUTION

！

The hook should only be used for

Hook

hanging the teach pendant or cable.

Teach pendant connector (X1)

Teach pendant connector

E70/E71/E91 controllers

E4x controller

This figure shows E70/E71 controllers.

6-10

6. Connection

6.5 CONNECTING THE EXTERNAL POWER

Strictly observe the following precautions when connecting the external power.

！

DANGER

Before beginning the connection work, confirm that the external power supply for the

controller is cut off at the source. To prevent external power from being turned ON

accidentally, tag the breaker and indicate clearly that work is in progress. Or, assign a

supervisor in front of the breaker until all the connections are complete. Connecting

components while power is supplied is extremely dangerous and may cause electric shock.

！

WARNING

1. Confirm that the connected supplying power to the controller meets specifications

shown on the rating plate. In addition, when using the transformer unit*, confirm

the connected supply power meets specifications shown on the label attached on the

side of the transformer unit and connect the voltage switching connector (X601) in

accordance with the voltage specifications. Supplying out-of-specification power

will damage electric components in the controller.

Earth the controller to prevent against electrical noise and shock.

Use dedicated earth wire (100  or less), which is equal to or larger than the

recommended power cable size (3.5 - 8.0 mm²).

Never share an earth line with workpiece to be welded or another machine (weld

machine, etc.).

In arc welding applications, connect the negative pole of the weld power supply to a

jig or directly to workpiece to be welded. Insulate the robot body and controller so

that they do not share a common earth line.

Before turning ON the external power to controller, make sure the power supply

wiring is complete and all the covers are reattached properly. Failure to do so may

cause electric shock.

NOTE* Only E0x controller

6-11

6. Connection

CAUTION

！

！ CAUTION

1. Prepare external power that meets the specifications of the controller in terms of

momentary power interruption, voltage fluctuation, power capacity, etc. If the power

is interrupted or the voltage goes out of the controller’s specified range (above/below

ratings), then the power monitoring circuit activates cutting off the power, and an error

is returned.

2. If the external power emits excessive electrical noise, set up a noise filter to reduce the

interference.

3. PWM noise from robot motor lines may cause malfunction of low noise- resistant

devices* via external power line. Confirm that there are no such devices in the

vicinity.

4. Install a separate external power switch (breaker) for the robot, independent and

unconnected to the weld machine.

5. To prevent shorting or accidental leakage on the external power switch, install an earth

leakage breaker.

(Use a time delay type with sensitivity of 100 mA or more.) Also,

use a time-delay-type earth leakage breaker with sensitivity of 100 mA or more when

using a transformer unit.

6. If there is a possibility that surge voltage such as lightning surge might be applied from

external power line, decrease the surge voltage level by mounting a surge absorber.

7. For the controller with electric power regeneration function (E03), the AC line voltage

of breaker on the secondary side may increase up to the peak value in the table below if

the power breaker supplying the AC power to the controller (NFB in the figure below)

is cut. Mind this when other equipment shares the common power from the same

breaker with the controller.

NOTE* Proximity switch directly connected with power line etc. may suffer from the

influence.

6-12

6. Connection

Power supplied to the controller

Peak value of line

Peak value of

voltage at point A

line voltage at

(400 V system)

point B (200 V

(V)

system) (V)

䐟Without transformer unit *For AC200-220V

380 V 10 ms or

less

䐠With transformer

When the power source

700 V 10 ms or

unit

setting inside the transformer

less

unit (X601 connector) is on

380 V 10 ms or

380V - 415 V side

less

When the power source

800 V 10 ms or

setting inside the transformer

less

unit (X601 connector) is on

440V - 480 V side

(Without transformer unit)

(B)200 V

E03 controller

system

NFB

AC power

(B)200 V system

(A)400 V

(With transformer unit)

Transformer unit

E03 controller

system

Transformer

NFB

AC power

6-13

6. Connection

E0x controller

Without transformer unit

Connect the external power according to the

Connect with the

following procedure.

external power

circuit breaker at

the installation

1.Turn OFF the external power for the

site.

OFF

controller.

Breaker

2.Set

CONTROLLER POWER switch on the

controller to the OFF side without fail.

Ground wire

connecting

3.Open the front cover of

screw

CONTROLLER POWER switch.

4.Feed the external power cable into the inlet

on the right or rear side of controller.

External power inlet

5.Connect the power cable to the part shown in

the right figure and the ground wire to the

art shown in the above figure.

Bar-shaped terminal

connection

Round/Y-shaped

Right side of breaker

terminal connection

Seal connector for external power inlet is provided on the right side of controller. Use the

power cable whose diameter is 16-22.

Lock nut

Cable

Controller cabinet

When inserting the power cable from the right side of controller, the stripped length of cable

sheath should be between 60 and 70 mm.

60-70 mm

y Use crimp-type terminals to connect to the breaker. When using round/Y-shaped terminal,

use the terminal for M5 screw.

6-14

6. Connection

NOTE*: If the cable diameter is more than 22, prepare a seal connector which is

appropriate for the cable diameter. The hole diameter of the plate for external

power inlet is 34.

y When inserting the external power cable from rear side, wire the cable along the route

shown in the figure below.

！

CAUTION

1. Confirm current requirements and select a power cable with

adequate capacity.

2. Do not install wire that is too small in diameter, the voltage may

drop or the cable may overheat.

Wiring route when inserting external power cable from rear side

Cable

insertion

from rear side

6-15

6. Connection

With transformer unit

1. Connection between the controller and the transformer unit

Connect the controller and the transformer unit with

dedicated power cable according to the following

Connect with the

procedure.

external power

Turn OFF the external power for the controller.

circuit breaker at

Set

CONTROLLER POWER switch on the

the installation site.

controller to the OFF side without fail.

Open the top plate and front cover of the controller,

OFF

and remove incoming plate on the rear side (upper,

without hole) and incoming plate on the side (with seal

Front cover

connector). On this occasion, mount the above

incoming plate on the rear side to the inlet on the side.

*The incoming plate on the side with seal connector is

not used.

Insert the power cable from the inlet on the rear side,

and wire it to the breaker through the wiring route

shown in the figure below.

(At this time, tighten the

Wiring route inside controller

seal connector on the rear side securely.)

*Insert wire medial to the harness guide.

Use seal connector + incoming

Mount incoming plate on

plate mounted on power cable.

rear side (without hole)

to the inlet on the side.

Incoming

Breaker

plate on rear

side (upper)

XTRFAN

connector

Right side of breaker

“XTRFAN” connector is provided at the place shown

above. Remove the jumper connector which is being

Connect here.

connected, and connect the connector of the power

cable.

(The removed jumper connector is not used.)

6. Connect the power cable to the place shown in the

Breaker

figure of the right side of breaker and the ground wire to

the place shown in the left figure.

Ground

7. Close the top plate and the front cover.

wire

connecting

6-16

screw

6. Connection

2. Connection between external power and transformer unit

Connect the external power with the transformer

Connect with the

unit according to the following procedure.

external power

1. Turn OFF the external power for the control

circuit breaker at

the installation site.

equipment.

2. Set

CONTROLLER POWER switch on the

OFF

transformer unit to the OFF side without fail.

3. Feed the external power cable into the inlet

on the rear side of transformer unit.

4. Open the power connection/setting plate, and

Rear

connect X601 power source connector in

accordance with the voltage to be used.

5. Connect external power cable to each

terminal of PE, R, S and T of TB1 terminal

block.

Power connection/

External power inlet

Setting plate

Opened in the figure below.

(A)380V-415V connector

(B)440V-480V connector

Connect X601 power source connector

bound at the place to the above (A) or (B)

in accordance with the voltage to be used.

TB1 terminal block: PE, R, S and T from the left [Terminal block type: 2006-1201/WAGO]

(1) When using naked wire

Recommended wire diameter: AWG10-AWG8

(2) When using Ferrule with insulation collar

Recommended wire diameter: AWG10

Connecting terminal length: 12 mm

*Refer to the specifications of terminal block manufacturer for details.

6-17

6. Connection

y Seal connector for external power inlet is provided on the rear side of transformer unit.

Use the power cable whose diameter is 16-22.

Lock nut

Cable

Transformer unit cabinet

y The stripped length of cable sheath of inserted power cable should be 150 mm or less.

150 mm or less

NOTE*: If the cable diameter is more than 22, prepare a seal connector which is appropriate

for the cable diameter. The hole diameter of the plate for transformer unit inlet is

34.

！

CAUTION

1. Confirm current requirements and select a power cable with

adequate capacity.

2. Do not install wire that is too small in diameter, the voltage may

drop or the cable may overheat.

3. Confirm that two fans of the transformer unit rotate properly

after connecting the transformer unit and the controller with

their power switch ON.

6-18

6. Connection

E4x controller

Connect the external power according to the

following procedure.

1. Turn OFF the external power for the

controller.

Connect with the external power circuit

2. Set

CONTROLLER POWER switch on the

breaker at the installation site.

controller door to the OFF side.

CONTROLLER POWER Switch

3. Feed the external power cable into the inlet

on the left side of controller.

Detailed procedure of fixing a cable is shown below.

y Cut a cable gland (supplied with the controller) in

accordance with the diameter of the cable.

NOTE*: If the cable diameter is more than 19,

prepare a seal connector which is

External power inlet

appropriate for the cable diameter.

The hole diameter of the plate is 34.

y Pass the cable through the cable gland.

y Tighten the screw after adjusting length of the

cable.

y Pass the cable through the inlet and tighten the lock

nut.

Cable gland

䡚

Inside

Outside

Tightening screw

Cable

9 - 12

Cutting position

11 - 14

䡚

14 - 17

(xx: diameter of cable)

17 - 19

Controller enclosure

Lock nut

！

CAUTION

1. Confirm current requirements and select a power cable with adequate

capacity.

2. Do not install wire that is too small in diameter, the voltage may drop or the

cable may overheat.

6-19

6. Connection

External

4. Attach round, crimp-type terminals on the

power

ends of the individual wires of the power

cable

Lock detent

cable. Use round insulators on each of these

Earth wire

wires to prevent contact between the crimped

part and metal.

(See left figure.)

5. Connect the external power cable to the

Breaker

breaker terminal (3 screws), and the dedicated

screw

External power cable

connection terminal

earth terminal.

cover

WARNING

！

Tighten the terminal screws securely.

Connect the earth wire to the earth terminal

Operating the robot with loose terminals

as shown below.

is very dangerous and may lead to electric

shock, robot malfunction, or breakdown

of the electrical system.

E4x controller

Earth terminal

6. Mount the external power cable connection

terminal cover.

！

DANGER

Mount the external power cable

connection terminal cover when the

wiring is complete. Failing to mount

the cover may lead to electric shock

due to accidental contact with power

line.

View A-A

Electric cable size

Crimp-type terminal size

to be used

Breaker

Earth terminal

3.5 mm²(AWG12)

R5.5-5

5.5 mm² (AWG10)

8 mm² (AWG8)

R8-5

13 mm² (AWG6)

R14-5

6-20

Kawasaki Robot (B, BA, CP, CX, M, MC, MS, R, Y, Z). Instruction Manual (2015) - page 7