Kawasaki Robot Controller F Series. Installation and Connection Manual (2016) - page 1

Preface 

This manual describes the installation and connection of the controller. 

This manual covers the installation and wiring of the controllers and connection with external 
power. Please refer to “Operation Manual” and “External I/O Manual” for the operation of the 
controller. 

Read and understand the contents of this and “Safety Manual” thoroughly and strictly observe 
all rules for safety before proceeding with any operation. 

This manual describes only the installation and connection of the controller. For the robot 
arms, please refer to the separate manuals for them. 

This manual also describes devices equipped as an option. However, all the controllers might 
not include the devices explained here. 

1. This manual does not constitute a guarantee of the systems in which the robot is utilized.

Accordingly, Kawasaki is not responsible for any accidents, damages, and/or problems
relating to industrial property rights as a result of using the system.

2. It is recommended that all personnel assigned for activation of operation, teaching,

maintenance or inspection of the robot attend the necessary education/training course(s)
prepared by Kawasaki, before assuming their responsibilities.

3. Kawasaki reserves the right to change, revise, or update this manual without prior notice.
4. This manual may not, in whole or in part, be reprinted or copied without the prior written

consent of Kawasaki.

5. Store this manual with care and keep it available for use at any time. If the robot is

reinstalled or moved to a different site or sold off to a different user, attach this manual to
the robot without fail. In the event the manual is lost or damaged severely, contact
Kawasaki.

This manual is applicable to the following controller models. 

F60 

[

NOTE

] 

F Series Controller 

Symbols 

Kawasaki Robot    Installation and Connection Manual 

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Symbols 

The items that require special attention in this manual are designated with the following 
symbols. 
 
Ensure proper and safe operation of the robot and prevent physical injury or property damage 
by complying with the safety matters given 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. 

 

Denotes precautions regarding robot specification, handling, teaching, 
operation, and maintenance. 

[

NOTE

] 

WARNING 

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

detail explanations given in this manual cannot be confirmed with 
absolute certainty. Accordingly, it is necessary to give one’s fullest 
attention when using this manual to perform any work. Should any 
unexplained questions or problems arise, please contact Kawasaki. 

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

individual work and not to all robot work. 

3.  In order to perform every work in safety, read and fully understand 

“Safety Manual”, all pertinent laws, regulations and related materials 
as well as all the safety explanations described in each chapter, and 
prepare safety measures suitable for actual work. 

！

 

 

！

 

 

！

 

 

！

 

 

F Series Controller 

Introductory Notes 

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Introductory Notes 



 

Hardware keys and switches (button) 

F series controller provides hardware keys and switches on the operation panel and the teach 
pendant for various kinds of operations. In this manual, the names of keys and switches are 
indicated as follows. 

• 

The names of the hardware keys and switches are enclosed with a square. 

• 

The terms “key” or “switch” which should follow the relevant names are sometimes 
omitted for simpler expression. 

• 

When pressing two or more keys at the same time, the keys are indicated by “+”. 

 

Example 

ENTER: 

The hardware key “ENTER”. 

TEACH/REPEAT:  The mode switch “TEACH/REPEAT” on the operation panel 
A+MENU: 

Press MENU while pressing and holding down A. 

 
 



 

Software keys and switches 

F series controller provides software keys and switches which are displayed on the screen of 
the teach pendant for various kinds of operations depending on specifications and situations. 
In this manual, the names of keys and switches are indicated as follows. 

• 

The names of software keys and switches are enclosed by “<XXX>” parentheses. 

• 

The terms “key” or “switch” which should follow the relevant names are sometimes 
omitted for simpler expression. 

 

Example 

<ENTER>: 

“ENTER” key that appears on the teach pendant screen 

<Next Page>: 

“Next Page” key on the teach pendant screen 

 
 



 

Selection items 

Very often an item must be selected from a menu or pull-down menu on the teach pendant 
screen. In this manual, the items are indicated as follows. 

• 

The names of these menu items are enclosed in brackets [XXX]. 

• 

To select an item, move the cursor to the relevant item by the arrow keys, and press the 

↵

 

key. For detailed description, this procedure should be described every time, however, 
“select [XXX] item” will be used instead for simpler expression. 

 

Example 

[Auxiliary Function]: expresses the item “Auxiliary Function” in a menu. 

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Introductory Notes 

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

 

Abbreviation 

• 

“TP” will be used instead of “teach pendant” for simpler expression. 

• 

“F key” will be used instead of “function key” for simpler expression.

F Series Controller 

Table of Contents 

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Table of Contents 

 
Preface········································································································ i

 

Symbols ····································································································· ii

 

Introductory Notes ························································································ iii

 

1

 

Safety ······························································································· 1

 

1.1

 

Precautions during Transportation, Installation and Storage of Controller ··············· 1

 

1.2

 

Sealed Specification ·············································································· 3

 

1.3

 

Installation Environments of Controller ······················································· 4

 

1.4

 

Precautions When Connecting the Harness ··················································· 7

 

1.5

 

Precautions When Connecting the External Power ·········································· 8

 

1.6

 

Warning Labels ·················································································· 10

 

1.7

 

Battery and Fuse Use and Disposal ··························································· 13

 

1.8

 

Safety Features ··················································································· 15

 

1.9

 

Emergency Movement without Drive Power ················································ 16

 

2

 

Workflow - Robot Controller Installation and Connection ································ 20

 

3

 

Appearance and Specifications of Robot Controller ······································· 21

 

3.1

 

Controller Appearance ·········································································· 21

 

3.2

 

TP Appearance ··················································································· 23

 

3.3

 

F60 Controller Specifications ·································································· 24

 

4

 

Transportation of Robot Controller ··························································· 26

 

5

 

Arrangement of Robot Controller ····························································· 27

 

5.1

 

Horizontal Arrangement of Controller ························································ 27

 

5.2

 

Vertical Arrangement of Controller ··························································· 29

 

5.3

 

Tap Position on the Side of Controller ························································ 31

 

6

 

Connection Instructions ········································································· 33

 

6.1

 

Connection between Controller and Robot ·················································· 33

 

6.2

 

Connection between Controller and TP ······················································ 45

 

7

 

Connection of External Power ································································· 46

 

8

 

Connection of Peripheral Control Equipment ··············································· 49

 

8.1

 

Precautions When Connected ·································································· 49

 

8.2

 

Connection of General Purpose Signal ······················································· 50

 

8.3

 

Connection of Hardware Dedicated Signal ·················································· 50

 

8.4

 

Connection of Personal Computer ···························································· 51

 

8.5

 

Connection of RS-232C Serial Signal (Option) ············································· 51

 

8.6

 

Connection of Ethernet Communication Signal ············································· 51

 

8.7

 

Connection of Fieldbus (Option) ······························································ 51 

 

F Series Controller 

1 Safety 

Kawasaki Robot  Installation and Connection Manual 

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1  Safety 

This chapter only describes safety precautions during installation and connection of the 
controller. For all other safety matters, refer to the “Safety Manual”, a separate-volume. 
 
 

1.1  Precautions during Transportation, Installation and Storage of Controller 

When installing the Kawasaki Robot controller, strictly observe the following cautions while 
carrying out the transportation, installation and storage work. 

 
 

 

 

The installation shall be made by qualified installation personnel and should 
conform to all national and local codes. 

[

NOTE

] 

CAUTION 

1.  Strictly observe the following when carrying out the transportation, 

installation and storage work. The controller is composed of precision 
parts. 
When transporting or storing a controller: 
(1)  keep the ambient temperature within the range of minus 20 to 

70

°

C. (Ambient temperature during operating time: 0 to 45°C, see 

“3.3”.) 

(2)  keep the relative humidity within the range of 35 to 85% RH (Non 

condensing) 

(3)  keep free from shock and vibration. 

*See “3.3” for vibration conditions during operation. 

2.  To carry out smooth and safe installation, remove all obstacles before 

installing a controller. 

3.  Clear a passage for the transportation of controller before using a 

crane or forklift. 

！

 

 

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Kawasaki Robot  Installation and Connection Manual 

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Front view of the Controller with air filter attached 

 

Be sure to check the environmental conditions and select the chassis 
specification. 



In case of standard F60 open specification (IP20) 
No protection is provided against objects thinner than a finger, conductive 
foreign matter such as metal particles or other foreign matter that can 
become conductive in humid conditions, and water. In environments at 
contamination level 2 or lower where foreign matter such as 
non-conductive particles or dust can easily enter the controller and affect 
its functions, attach an optional air filter (see the figure below).   



In case of F60 sealed specification (IP54) 
This specification prevents dust particle penetration that may cause 
controller’s functional loss and is splash proof. In environments at 
contamination level 3 where conductive foreign matter can be generated 
and enter the controller, attach an optional sealed chassis. Even with the 
optional sealed chassis attached, avoid environments where a large amount 
of metal particles are generated and the controller is exposed directly to 
the metal particles.   
Avoid environments where oil mist is floating in the air leading to high oil 
content. 

 

CAUTION 

！

 

Air filter 

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1.2  Sealed Specification 

The F60 controller has an open structure as standard. When installing the controller in an 
environment at contamination level 3 specified by IEC60664-1, an optional sealed chassis 
must be attached. 
See the figure below for the optional sealed chassis. 
 
 

 

 
 
In the following pages, the chassis consisting of the standard F60 open structure controller 
and an optional sealed chassis is referred to as “F60 sealed specification”. Refer to the 
“Options Installation Manual” for how to install the optional sealed chassis. 
 

 

Sealed chassis front 

panel 

Standard F60 open 

specification 

Sealed chassis rear unit 

Heat sink 

Sealed chassis base unit 

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1.3  Installation Environments of Controller 

Install the controller in a site that satisfies all the following environmental conditions: 
 
1.  Ambient temperature during operation: within 0 to 45

°

C 

2.  Relative humidity: 35 to 85%RH (Non condensing) 
3.  Altitude: up to 1000 meters above mean sea level 
4.  Environmental conditions related to foreign materials 

• 

See the precautions in “1.1 Precautions during Transportation, Installation and 
Storage of Controller”. 
 
In case of standard F60 open specification 
–  Contamination level 2 or lower (no condensation)* 

※

 

The contamination level is according to IEC60664-1. 
See the figure below for the controller protection class specified by 
IEC60529. 

 

Front view 

In case of F60 sealed specification 
–  Contamination level 3 or lower (no condensation)* 

※

 

The contamination level is according to IEC60664-1. 
See the figure below for the controller protection class specified by 
IEC60529. 

 
 
 

 

Side view 

Sealed chassis front 

unit 

Standard F60 open 

structure 

Sealed chassis rear 

unit 

IP54 

IP20 

Sealed chassis rear 

unit 

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Note: 



 

Close the accessory panel cover of the sealed chassis front unit to ensure the 
sealability. 

 

Front view of F60 sealed specification   

 



 

Read the precautions for the F60 sealed specification in “6.1 Connection 
between Controller and Robot” carefully. 



 

Refer to the separate “Options Installation Manual” for the precautions for 
assembly. 

 

5.  Installation site 

• 

Free from electrical noise interference. 
Controller external power noise: 1 kV/1 µs or less 

 

• 

Free from flammable and/or corrosive liquid and gas. (e.g.: hydrogen sulfide) 

• 

Free from excessively strong vibration. 

• 

Place where power is supplied within specifications. 
Variation rate: ±10% or less 

• 

Place where dedicated grounding is provided. (100 

Ω

 or less) 

 

6.  Installation conditions of safety fence 

• 

Safety fence should be installed with margin (min. 1 m) from outside the motion 
range of robot (with tools and workpieces). 

• 

Ensure the followings when installing a safety fence. 
–  Enough space for easy access to the controller in maintenance 
–  Installing an entrance gate with a safety plug to the safety fence 

If the controller is installed near equipment that generates a lot of 
electrical noise, be sure to provide appropriate surge killers around that 
equipment. Noise producing equipment includes: induction motors, 
electromagnetic brakes, solenoids, or contact equipment, etc. 
 

CAUTION 

！

 

 

Accessory panel cover 

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Kawasaki Robot  Installation and Connection Manual 

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–  Referring the requirements established in each region for details of the safety 

fence 
(e.g. ISO 13854, 13855, 14119, and 14120) 

 

 

 

 

 

The controller shall not be located inside of the robot’s motion range/ 
work cell/safety fence. 

CAUTION 

Controller 

Motion range of robot arm 

(tool and workpiece included) 

Gate with safety plug 

Approx.1 m 

Approx.1 m 

Approx.1 m 

Approx. 

1 m 

Approx. 

1 m 

Safety fence 

Mechanical 

stopper 

Mechanical 

stopper 

！

 

 

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1.4  Precautions When Connecting the Harness 

Strictly observe the following precautions when connecting the robot with the controller. 
 

 

 

 

 

WARNING 

In order to prevent electric shock accidents, do not connect the external 
power until connections between the robot and the controller are 
complete. 

CAUTION 

1.  Do not mistake the destination of connectors when connecting the 

harnesses. Forcing to connect the harness wrongly may damage 
connectors or cause a break in the electrical system. 

2.  Prevent people or equipment (forklift etc.) from stepping on or riding 

over the harnesses. Otherwise, the harness may become damaged or 
the electrical system may break. 

3.  Separate the harnesses from any nearby high voltage lines. 

(1)  Do not run the harnesses in parallel with other power lines. 
(2)  Do not bundle the harnesses. 
(3)  Separate the harnesses for 1 m or more from any nearby high 

voltage/high current power lines. Otherwise, the noise is generated 
from power lines and will cause malfunctions. 

4.  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. 

！

 

 

！

 

 

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1.5  Precautions When Connecting the External Power 

Strictly observe the following precautions when connecting the external power. 
 

 

 

 

 

 

1.  Before connecting the external power, confirm that the external power 

supply for the controller is cut off at the source. Connecting 
components while power is supplied may cause electric shock. 

2.  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 the connection is complete. 

DANGER 

WARNING 

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

specifications shown on the rating plate. Supplying 
out-of-specification power will damage electric components in the 
controller. 

2.  Ground the controller to prevent against electrical shock and noise 

without fail. 
(1)  Dedicated ground: 

100 

Ω

 or less 

(2)  Recommended power cable size:  ground wire which is 2.0 mm

2

 or 

more (AWG #14 or more) 

3.  Never share a ground line with workpiece to be welded or another 

machine (weld machine, etc.). 

4.  Strictly observe the following precautions when conducting the arc 

welding. 
(1)  Connect the minus pole of the weld power supply to a jig or 

directly to workpiece to be welded. 

(2)  Insulate the robot body and controller so that they do not share a 

common ground line. 

5.  Before turning ON the external power to controller, make sure the 

power supply wiring is complete and all the covers are attached 
properly. Failure to do so may cause electric shock. 

！

 

 

！

 

 

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CAUTION 

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

in terms of momentary power interruption, voltage fluctuation, power 
capacity, etc. Supplying out-of-specification power is connected, the 
power monitoring circuit activates cutting off the power, and an error 
may be returned. 

2.  If the external power emits a lot of electrical noise, set up a noise filter 

to reduce the interference. 

3.  Confirm that there are no low noise-resistant devices in the vicinity 

beforehand. PWM noise generated from robot motor lines may cause 
malfunction of the devices via external power line. 

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

independent and unconnected to the other device such as weld 
machine. 

5.  To prevent shorting or accidental leakage on the external power 

switch, install a time delay type ground leakage breaker (sensitivity of 
100 mA or more.). 

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, etc. 

！

 

 

F Series Controller 

1 Safety 

Kawasaki Robot  Installation and Connection Manual 

10 

1.6  Warning Labels 

Warning labels for electric shock and high temperature are located on the controller shown 
below. 
 



 

F60 controller 



 

Standard open specification 

 

1 

 

2 

 

 

 

 

 

 

 

1 

Ceiling board 

1 

External power inlet 

1 

Cover on power/6-axis amplifier board 

(2AU/2AC board) 

2 

Regenerative resistor 

Top 

Front 

Bottom 

Rear 

1 

Controller power switch 

F Series Controller 

1 Safety 

Kawasaki Robot  Installation and Connection Manual 

11 



 

Sealed specification 

 

1 

 

2 

 

 

 

 

 

 

 

1 

Ceiling board 

1 

External power inlet 

(Rear part of standard 

open structure) 

1 

Cover on power/6-axis amplifier board 

(2AU/2AC board) 

Top 

Front 

Bottom 

Rear 

1 

Controller power switch 

1 

Upper part of sealed 

chassis rear unit