Kawasaki Robot B Series (Ver.C). Installation and Connection Manual (2017)

Applicable Robots

Applicable Robots

This manual is applicable to B Series (Ver. C) robots. Check the supporting structure of the gas

spring and the machine nameplate to know if the robot is B Series (Ver. C) or not.

B series (Ver. C) robots

Robots other than B series (Ver. C)

Gas spring shaft

Gas spring shaft

is supported on

is supported on

one side.

both sides.

“C” is written in the

Model column.

“A” or “B” is written in the Model

column.

ii

Symbols

Symbols

㻌

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

Ensure proper and safe operation of the robot and prevent physical injury or property damages by

complying with the safety matters given in the boxes with these symbols.

！

DANGER

Failure to comply with indicated matters can result in

imminent injury or death.

！

WARNING

Failure to comply with indicated matters may possibly

lead to injury or death.

！

CAUTION

Failure to comply with indicated matters may lead to

physical injury and/or mechanical damage.

[ NOTE ]

Denotes precautions regarding robot specification,

㻌

handling, teaching, operation, and maintenance.

㻌

㻌

㻌

！

WARNING

㻌

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

㻌

explanations given in this manual cannot be confirmed with absolute

㻌

certainty. Should any unexplained questions or problems arise, contact

Kawasaki.

2. Safety related contents described in this manual apply to each individual

work and not to all robot work. In order to perform every work in safety,

read and fully understand the safety manual, all pertinent laws, regulations

and related materials as well as all the safety explanation described in each

chapter, and prepare safety measures suitable for actual work.

iii

1 Precautions

1.2 Installing Environment of Robot Arm

The robot arm must be installed in a place that satisfies all the following environmental

conditions:

1.

When robot is installed on the floor, the levelness must be within 5.

2.

Be sure that the installation floor/pedestal has sufficient rigidity.

3.

Secure a flatness to prevent undue force applied to the installation section. (If sufficient

flatness is unobtainable, insert liners and adjust the flatness. Flatness of installing surface: 0.3

or less)

4.

Keep the ambient temperature during operation within the range of 0 to 45 C. (Deviation or

overload error may occur due to high viscosity of grease/oil when starting operation at low

temperatures. In this case, move the robot at low speed before regular operation.)

5.

Keep the relative humidity during operation within the range of 35 to 85%RH without dew

condensation.

6.

The robot installing place should be free from dust, dirt, oil, smoke, water, and other foreign

matters.

7.

The robot installing place should be free from flammable or corrosive liquid or gas.

8.

The robot installing place should be free from excessively strong vibration. (0.5 G or less)

9.

The robot installing place should be free from electric noise interference.

10.

The robot installing place should be sufficiently larger than the motion range of robot arm.

(1) Install safety fence so the maximum movement of fully equipped robot arm (with

tools and workpieces) does not cause interference.

(2) Minimize the number of entrance gates of the safety fence (only one is best) and

equip the entrance gate with a safety plug.

(3) Observe the requirements of ISO 10218, etc. established in each region for details of

the safety fence.

Approx.1 m㻌

A door

with safety plug㻌

Scope of robot motion

Safety fence

(Tools and workpieces are included)

Approx.1 m

Approx.1 m

Mechanical

Mechanical

stopper㻌

stopper

Approx.1 m

Approx.1 m

2

1 Precautions

1.3 Residual Risks during Work

！

WARNING

Pay attention to the hazardous places listed in the drawings below.

Hazardous places for high temperature and electric shock (BX100L, BX130X,

BX165N, BX165L, BX200L)

Hazardous place for

high temperature

Hazardous place for

electric shock

3

1 Precautions

Hazardous places for pinching (BX100L, BX130X, BX165N, BX165L, BX200L)

Hazardous place for pinching

4

2 Work Flow at Arm Installation and Connection

2

Work Flow at Arm Installation and Connection

㻌

This workflow describes only the robot arm section. For the controller, refer to “Installation and

Connection Manual” for controller.

㻌

Examination of Installation

Refer to “3. Motion Range and

Place and Motion Range

Specifications of Robot”.

Refer to “5. Installation Dimensions of

Examination and Preparation of

Base Section”, “6. Movement Reaction

Installation Surface

Acting on Installation Surface during

Operation” and “7. Installation Method”.

Refer to “4. Robot Transportation

Transportation of Robot Arm

Method”.

Refer to “5. Installation Dimensions of

Base Section”, “6. Movement Reaction

Installation of Robot Arm

Acting on Installation Surface during

Operation” and “7. Installation Method”.

Mounting of Tools

Refer to “8. Mounting of Tools”.

Refer to “Installation and Connection

Connection to Controller

Manual” for controller.

Checking of Arm Motion

Refer to “Operation Manual”.

Checking of Tool Motion

Checking of Other Functions

Refer to “Operation Manual”.

Completion of Work

5

3 Motion Range and Specifications of Robot

3

Motion Range and Specifications of Robot

3.1 Determination of Safety Fence Installation Location

Motion Range of Point P

Point P

Tool

Workpiece

L₀

L₁

L₂

The motion range of the robot is represented by the maximum area that can be covered by point P

in the figure above. Therefore, as shown in the figure below, install the safety fence outside circle

whose radius is L₀+L₁+L₂. Where; L₀ is the length from the center line of arm (point A shown

above) to the farthest point of P, L₁ is the length from point P to the farthest point of wrist flange,

tool and workpiece, and L₂ is safety margin_. For the length of L₀, refer to the drawings in the

section 3.2.

Safety fence

L₂

L₁

L₀

Location of

Location of

mechanical

mechanical

stopper

stopper

6

3 Motion Range and Specifications of Robot

3.2 Motion Range and Specifications of Robot

㻌

BX100L

Motion range

of point P

Point P

㻌

㻌

Type

Vertical Articulated Robot

㻌

Degree of

6

㻌

Freedom

㻌

JT

Motion Range

Max. Speed

1

160

105 /s

㻌

Motion Range

2

+76 to -60

130 /s

㻌

and

3

+90 to -75

130 /s

㻌

Maximum

4

210

200 /s

㻌

Speed

5

125

160 /s

6

210

300 /s

*measured condition

Max. Payload

100 kg

・ installed on the plate

JT

Torque

Moment of Inertia

rigidly fixed on the floor

Wrist Load

4

830 Nm

85 kgm²

・ 4600 mm away from JT1

Capacity

5

830 Nm

85 kgm²

center

6

441 Nm

45 kgm²

The noise level depends

Repeatability

0.06 mm

on the conditions.

Mass

890 kg

Acoustic Noise

<80 dB (A)*

7

3 Motion Range and Specifications of Robot

BX130X

Motion range

of point P

Point P

㻌

㻌

㻌

Type

Vertical Articulated Robot

㻌

Degree of

6

㻌

Freedom

JT

Motion Range

Max. Speed

㻌

1

160

105 /s

㻌

Motion Range

2

+76 to -60

90 /s

㻌

and

3

+90 to -75

130 /s

㻌

Maximum

4

210

200 /s

Speed

㻌

5

125

160 /s

㻌

*measured condition

6

210

300 /s

・ installed on the plate

㻌

Max. Payload

130 kg

rigidly fixed on the floor

㻌

JT

Torque

Moment of Inertia

・ 5000 mm away from JT1

㻌

Wrist Load

4

830 Nm

85 kgm²

center

Capacity

5

830 Nm

85 kgm²

㻌

The noise level depends

6

441 Nm

45 kgm²

on the conditions.

Repeatability

0.06 mm

Mass

920 kg

Acoustic Noise

< 80 dB (A)*

8

3 Motion Range and Specifications of Robot

BX165N㻌

Motion range

of point P

Point P

㻌

Type

Vertical Articulated Robot

Degree of

6

Freedom

JT

Motion Range

Max. Speed

1

160°

105 °/s

Motion Range

2

+76° to -60°

130 °/s

and

3

+90° to -75°

130 °/s

Maximum

4

210°

120 °/s

Speed

5

125°

160 °/s

6

210°

300 °/s

Max. Payload

165 kg

*measured condition

JT

Torque

Moment of Inertia

・installed on the plate

Wrist Load

4

930 Nm

99 kgm²

rigidly fixed on the floor

Capacity

5

930 Nm

99 kgm²

・4300 mm away from JT1

6

490 Nm

49.5 kgm²

center

Repeatability

0.06 mm

The noise level depends

Mass

875 kg

on the conditions.

Acoustic Noise

< 80 dB (A)*

9

3 Motion Range and Specifications of Robot

BX165L

Motion range

of point P

Point P

Type

Vertical Articulated Robot

Degree of

6

Freedom

JT

Motion Range

Max. Speed

1

160°

120 °/s

Motion Range

2

+76° to -60°

110 °/s

and

3

+90° to -75°

130 °/s

Maximum

4

210°

170 °/s

Speed

5

125°

170 °/s

6

210°

280 °/s

Max. Payload

165 kg

*measured condition

JT

Torque

Moment of Inertia

・installed on the plate

Wrist Load

4

952 Nm

99 kgm²

rigidly fixed on the floor

Capacity

5

952 Nm

99 kgm²

・4600 mm away from JT1

6

491 Nm

49.5 kgm²

center

Repeatability

0.06 mm

The noise level depends

Mass

890 kg

on the conditions.

Acoustic Noise

< 80 dB (A)*

10

3 Motion Range and Specifications of Robot

BX200L

Motion range

of point P

Point P

Type

Vertical Articulated Robot

Degree of

6

Freedom

JT

Motion Range

Max. Speed

1

160

105 /s

Motion Range

2

+76 to -60

90 /s

and

3

+90 to -75

100 /s

Maximum

4

210

120 /s

Speed

5

125

120 /s

6

210

200 /s

Max. Payload

200 kg

*measured condition

JT

Torque

Moment of Inertia

・ installed on the plate

Wrist Load

4

1334 Nm

199.8 kgm²

rigidly fixed on the floor

Capacity

5

1334 Nm

199.8 kgm²

・ 4600 mm away from JT1

6

588 Nm

154.9 kgm²

center

Repeatability

0.06 mm

The noise level depends

Mass

890 kg

on the conditions.

Acoustic Noise

< 80 dB (A)*

11

3 Motion Range and Specifications of Robot

3.3 Mechanical Stoppers㻌

For JT1, JT2 and JT3 of base axes, mechanical stoppers are mounted at the places shown in the

figure below. Among them, the motion range of JT1 can be changed by changing the mounting

position of stopper block of stopper member on the moving side.

However, when the motion range is changed, it is necessary to change the motion range limits to

the corresponding values by Auxiliary function 0507.

JT3 stopper section

JT3 stopper section

JT2 stopper section

JT1 stopper block

JT1 stopper section

12

3 Motion Range and Specifications of Robot

3.3.1 JT1 Stopper Block㻌

Mounting position of JT1 stopper block can be changed by angular unit of 10 degrees. In addition,

reducing the motion range is possible by mounting two stopper blocks as an option.

When mounting a stopper block:

Stopper block mounting position can only be changed within the motion range of 180 on both

plus and minus sides due to the restriction from control and harness treatment. Total motion range

of both plus and minus sides is 320.

Mounting a stopper block as shown below makes the motion range of 180 on the plus side and

140 on the minus side.

JT1 stopper block

13

3 Motion Range and Specifications of Robot

When mounting two stopper blocks:

Stopper blocks mounting positions can only be changed within the motion range of 180 on both

plus and minus sides due to the restriction from control and harness treatment. However, the total

motion range of both plus and minus sides is between 10 and 270.

Mounting stopper blocks as shown below makes the motion range of 130 on the plus side and

140 on the minus side.

Stopper block

14

4 Robot Transportation Method

㻌

Model

BX100L, BX130X, BX165L, BX200L

BX165N

Hoisting jig㻌

Wire sling x 3㻌

Hoisting jig㻌

Wire sling x 3㻌

Hoisted

up

posture㻌

㻌

㻌

JT1

0㼻

0㼻

JT2

-35㼻

-45㼻

Hoisted

JT3

-75㼻

-75㼻

up

JT4

0㼻

0㼻

posture㻌

JT5

0㼻

0㼻

JT6

0㼻

0㼻

㻌

16

4 Robot Transportation Method

Attach the hoisting jig as shown in the figure below.

Hoisting jig

Hexagon socket head bolt

M16 x 40 (3 bolts)

Tightening torque: 235 N·m㻌

17

4 Robot Transportation Method

4.2 Forklift

㻌

Attach the transportation jig for forklift to the robot arm as shown in the figure below and

transport the robot by using the jig.

！

CAUTION

1. Check if a fork of the forklift penetrates the transportation jig

sufficiently without fail.

2. When transporting robot on an inclined or rough surface, be

careful to maintain balance to prevent forklift/robot from falling.

3. Remove the transportation jig attached to the arm once the

transportation of robot is complete.

BX100L, BX130X, BX165N, BX165L, BX200L

Transportation jig for forklift

Hexagon socket head bolt

M12 x 35 (8 bolts)

Tightening torque: 98 N·m㻌

㻌

18

5 Installation Dimensions of Base Section

5

Installation Dimensions of Base Section

When installing a robot, fix the base section with high tension bolts through the bolt holes.

Model

BX100L, BX130X, BX165N, BX165L, BX200L

Dimensions for

installation

Cross-section

of installation

section

Bolt hole

8-22

8-M20

High tension

Material: SCM435

bolt

Strength class: 10.9 min.

Tightening

431 Nm

torque

Levelness

Within 5

19

6 Movement Reaction Acting on Installation Surface

during Operation

6

Movement Reaction Acting on Installation Surface during Operation

Refer to the list below for the movement reaction that acts on the installation surface during

operation. Consider these values at installation.

Model

BX100L, BX130X, BX165L, BX200L

BX165N

M

35000

33400

(Inversion Moment N·m)

T

15000

13000

(Rotating Torque N·m)

See the next chapter for M and T

20

7 Installation Method

7

Installation Method

7.1 When Installing the Base Directly on the Floor

In this case, bury steel plate (35 mm min. thickness) in the concrete floor as shown in the figure

below or fix it with anchors. Fix the steel plate firmly enough to endure the reaction forces

produced by the robot.

M

T

M20

Tightening torque:

431 N·m㻌

Steel plate

Concrete

21

8 Mounting of Tools

8

Mounting of Tools

！

WARNING

Prior to mounting tools on the robot, turn OFF the controller power switch

and the external power switch. Display signs indicating clearly “Installation

and connection in progress”, and lockout/tagout the external power switch to

prevent personnel from accidentally turning ON the power.

8.1 Dimensions of Wrist End

Pin hole

Tapped hole

In the robot arm end section, a flange is

provided on which hand, gun, or other tools

are mounted. Screw the mounting bolts into

the tapped holes on the circumference of 160

on the flange, referring to the figure on the

left. Moreover, position the tool by utilizing

the pin holes.

8.2 When passing cable/hose through Wrist Hollow Section㻌

When passing a cable/hose through the wrist

hollow section, clamp is attached on the wrist

flange as shown in the left figure. Provide a

hole of 100 on the flange of the tool side, or

use an optional adapter plate or an adaptor

bracket (option).

Outer diameter

of clamp㻌

Adaptor bracket

Clamp

Pin hole

Tapped hole

Adaptor plate

Outer diameter

of clamp㻌

Clamp㻌

22

8 Mounting of Tools

8.3 Specification of Mounting Bolt

Select mounting bolts with proper length to

secure the specified screwing depth according

Mounting bolt

to the tapped depth of tool mounting flange.

Tool parts

Use high tension mounting bolts and tighten

Screwing depth

them to the specified torque.

！

㼏㼍㼡㼠㼕㼛㼚㻌

If the screwing depth has exceeded the specified

value, the mounting bolt might bottom out, and

the tool will not be fixed securely.

Optional flange

Standard flange

(Adaptor plate)

Model

Tapped hole

6-M10

6-M10

D

160

125

Pin hole

2-10H7 Depth 12

2-10H7 Depth 14

Screw depth

19 mm

20 mm

Screwing depth

13 to 14 mm

13 to14 mm

High tension bolt

SCM435, 10.9 min

SCM435, 10.9 min

Tightening torque

56.84 Nm

56.84 Nm

Optional flange (Adaptor bracket)

Model

Tapped hole

10-M10

6-M10*

6-M10*

D

92

125

160

Pin hole

2-9H7 Depth 12

2-10H7 Depth 12

2-10H7 Depth 12

Screw depth

12 mm (through)

12 mm (through)

12 mm (through)

Screwing depth

13 to 18 mm

13 to 18 mm

13 to 18 mm

High tension bolt

SCM435, 10.9 min

SCM435, 10.9 min

SCM435, 10.9 min

Tightening torque

56.84 Nm

56.84 Nm

56.84 Nm

NOTE* No need to use the tapped holes with ☆ in the figures below.

Pin hole

Pin hole

Tapped hole

Tapped hole

23

8 Mounting of Tools

8.4 Load Capacity

Load mass applicable to robot is specified for each model and includes the mass of tool, etc.

Applicable load torque and moment of inertia around wrist axes (JT4, JT5, and JT6) are also

specified. Strictly observe the following restrictions on them.

！

CAUTION

Using the robot beyond its specified load may result in

degradation of movement performance and shortening of machine

service life. The load mass includes the tool mass such as hand,

tool changer, shock absorber, etc. If using the robot in excess of its

㻌

load capacity, first contact Kawasaki without fail.

㻌

㻌

The load torque and the moment of inertia can be calculated by the expression below:

Calculation Expression㻌

Load mass

:M䍺Mmax.(kg)

(including tools)

Load torque

:T=9.8ML(Nm)

Load moment of inertia :I =M䡡L² + I_G (kgm²)

L₆(m)

IG

L_{4 , 5}(m)

Mmax: Maximum load mass: See 3.2.

M(kg)

L: Length from axis rotation center to load

L_{4, 5} : Length from JT4(5) axis rotation

center of gravity (Unit: m) (See the figure.)

center to load center of gravity

L₆: Length from JT6 axis rotation center to load

IG: Moment of inertia around center of

gravity (Unit: kgm²)

center of gravity

If calculation of load is made by dividing the load into construction parts, such as tools and

workpieces, use the total calculation values of each part as load torque and moment of inertia.

24

8 Mounting of Tools

Regarding the load on the robot wrist section, strictly observe the following restriction:

1.

The load mass including tool mass should be less than the following value.

Model

Max. load mass

BX100L

100 kg

BX130X

130 kg

BX165N, BX165L

165 kg

BX200L

200 kg

2.

The load torque and the moment of inertia around each wrist axis (JT4, JT5, JT6) should be

within the following restriction.

！

CAUTION

Set the load data via Auxiliary function 0304 after mounting of

tools without fail. Operating robot with wrong settings may cause

vibrations in motion, degradation of movement performance and

shortening of machine service life.

BX100L

kg·m²

134.8

JT4, JT5

86.7

JT6

(830.2, 85.0)

(441.3, 45.0)

0

441.3

830.2

N·m

Load torque㻌

25

8 Mounting of Tools

BX130X

kg·m²

212.2

JT4, JT5

151.9

JT6

(830.0, 85.0)

(441.1, 45.0)

0

441.1

830.0

N·m

Load torque㻌

BX165N

kg·m²

(69.0, 285.9)

285.9

JT4, JT5

(930.0, 99.0)

JT6

(372.3, 86.7)

86.7

(490.3, 49.6)

0

490.3

930.0

N·m

Load torque㻌

26

8 Mounting of Tools

BX165L㻌

kg·m²

(478.4, 177.6)

177.6

JT4, JT5

(952, 99.0)

(423.1, 76.6)

76.6

JT6

(491.1, 49.6)

0

491.1

952

N·m

Load torque㻌

BX200L

kg·m²

(179.6, 389.9)

389.9

JT4, JT5

(266.5, 237.4)

237.4

JT6

(1333.7, 199.8)

(588.0, 159.9)

0

588.0

1333.7

N·m

Load torque㻌

27

9 Mounting External Equipment

9

Mounting External Equipment

9.1 Service Tapped Hole Positions

Service tapped holes shown in the figure below are available to mount wiring brackets and

external equipment on each part of robot arm.

！

CAUTION

Check the robot movement

very carefully and confirm that

mounted brackets and external equipment do not interfere with

peripheral equipment and robot arm itself.

BX100L, BX130X, BX165N, BX165L, BX200L

2x2-M6 Depth 12

Cross section A-A

4-M8 Depth 16

2-M8 Depth 16

4-M12 Depth 24

3-M6 Depth 12

28

9 Mounting External Equipment

9.2 Calculation of Load Caused by External Equipment

The load capacity is set for each robot model. Strictly observe the following restrictions of the

load torque and load moment of inertia on arm.

！

CAUTION

Using the robot beyond its specified load capacity may result in

degradation of movement performance and shortening of machine service

life. If the load exceeds load capacity, first contact Kawasaki without fail.

For JT2 and JT3, limit the total load torque on wrist end and arm not to exceed the maximum

allowable load torque. The load torque and the moment of inertia can be calculated by the

expression below.

Calculation Expression㻌

BX100L, BX130X, BX165N, BX165L, BX200L

L₁

L₂

L₃

LW

l₃

lW

W₃

W

Wmax : Max. allowable load [kg]

䞉JT3: W(L₃+l_w)+W₃l₃䍺W_max(L₃+L_W)

W

: Load on wrist end [kg]

䞉JT2: W(L₂+L₃+l_w)+W₃(L₂+l₃)䍺W_max(L₂+L₃+L_W)

W₃

: Total load on upper arm [kg]

lw

: Position of the center of the gravity

for load on wrist section [mm]

l₃

: Position of the center of the gravity

㻌

for total load on upper arm [mm]

㻌

29

9 Mounting External Equipment

Use data in the table below for calculation.

L₁ [mm]

L₂ [mm]

L₃ [mm]

Lw [mm]

Wmax [kg]

BX100L

200

1126

1271

847

100

BX130X

200

1126

1666

651

130

BX165N

200

854

1271

575

165

BX165L

200

1126

1271

674

165

BX200L

200

1126

1271

680

200

However, do not exceed the value below for W₃.

W(L₁+L₂+L₃+l_w)+ W₃(L₁+L₂+l₃)≤W_max(L₁+L₂+L₃+L_w)

！

CAUTION

W₃, W, l₃ and l_w are set as default in shipment. When using a

robot for the first time or when changing the load mass or the

position of the gravity center of the load, set the W₃, W, l₃ and l_w

via Auxiliary 0304 and 0404. Operating robot with wrong

settings may cause vibrations in motion, degradation of

movement performance and shortening of machine service life.

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