Kawasaki Robot Controller F Series. Installation and Connection Manual (2016) - page 3

F Series Controller

5 Arrangement of Robot Controller

Kawasaki Robot Installation and Connection Manual

Sealed specification

Double stack

arrangement of controllers

Direct the airflow avoiding the fan exhaust opening in the rear of the
controller. Foreign matter can enter from the rear of the controller and
cause failure.

CAUTION

！

0.6 to 1.9 m

Controller power

switch

200 mm or more

Airflow direction of fan

Controller power

switch

0.6 to 1.9 m

200 mm or more

Airflow direction of fan

F Series Controller

5 Arrangement of Robot Controller

Kawasaki Robot Installation and Connection Manual

5.2 Vertical Arrangement of Controller

Follow the procedure below when arranging the controllers vertically.



Precautions

•

An object cannot be placed on the top surface of the controller when the controllers are
placed vertically.



Locations

•

Arrange the controller on a flat, horizontal stand and adjust its height so that the heights of
controller power switch and operation switches from the floor are between 0.6 to 1.9 m.

•

Arrange the controller with its controller power switch facing upward.

•

Provide a clearance of 200 mm or more between the controller rear side and the wall.

Standard open specification

Controller power

switch

0.6 to 1.9 m

200 mm or more

F Series Controller

5 Arrangement of Robot Controller

Kawasaki Robot Installation and Connection Manual

Sealed specification

0.6 to 1.9 m

200 mm or more

Controller power

switch

F Series Controller

5 Arrangement of Robot Controller

Kawasaki Robot Installation and Connection Manual

5.3 Tap Position on the Side of Controller

When using the tapped holes below, be careful so that bolts do not interfere with internal
parts.
See figures below for lengths of bolts to be used. (Tapped size: M5)



F60 controller



Standard open specification

•

Sealed specification

141.2

52.5

52.5 95

95 52.5

52.5

141.2

277.5

F Series Controller

5 Arrangement of Robot Controller

Kawasaki Robot Installation and Connection Manual

E.g.) The bolt length is 15 mm or less when fixing the controller on the plate whose

thickness is 2 mm.

Side wall of

controller

Bolt length

≦

15 mm

Spot facing size (common in 8 places)

Diameter:

13 mm

Depth:

3.5 mm

Plate

F Series Controller

6 Connection Instructions

Kawasaki Robot Installation and Connection Manual

6 Connection Instructions

6.1 Connection between Controller and Robot

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

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

WARNING

！

F Series Controller

6 Connection Instructions

Kawasaki Robot Installation and Connection Manual

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.

5. Separate the motor harness from the communication and sensor

cables, and distribute the lines.
(1) Do not run the harnesses in parallel with cables.
(2) Do not bundle the harnesses.

6. Connect the communication and sensor cables using shield mesh wire

that includes twisted pair lines and connect the mesh wire properly.
Otherwise, PWM noise may penetrate into various cables, such as
communication cable and cause communication errors.

7. Separate the welder secondary cable from the robot’s signal harness.

Do not wire them in the same duct.

8. Strictly observe the following precautions so that PWM noise

generated from the motor harness (power line) does not interfere with
control signal lines.
(1)  Separate the power and signal lines.
(2)  Use the shortest length for the power line.
(3)  Do not bundle or run the harnesses in parallel with the signal line.
(4)  Do not wire the power and signal line within the same

duct/conduit.

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

！

F Series Controller

6 Connection Instructions

Kawasaki Robot Installation and Connection Manual



Connecting place

Connect the separate harnesses to their designated ports as shown below.

•

Controller side

Signal harness (X3)

Motor harness (X4)

Brake output harness (X4)

Brake output connector

Motor power

connector

(Jt2,4,6)

Motor power

connector

(Jt1,3,5)

Cable shield

*For Jt7

Bundle motor power

connector and brake

output connector.

CAUTION

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

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.

！

F Series Controller

6 Connection Instructions

Kawasaki Robot Installation and Connection Manual

To make the standard F60 open structure controller comply with the UL standard, attach the
connector covers in the rear of the controller, following the instructions below.*

※

The F60 sealed specification controller does not require the connector cover.

1. Attach the connector cover mounting metal plates to the rear of the controller.

2. Insert the connectors of the motor harnesses and power cable into the controller.
3. Attach the connector covers.

Connector cover mounting

metal plate

(XPOW connector)

Screw

Connector cover mounting

metal plate

(XMOTA/XMOTB connector)

Screw

Connector cover

(XMOTA/XMOTB)

Connector cover

(XPOW connector)

Screw

Motor harness

Power cable

F Series Controller

6 Connection Instructions

Kawasaki Robot Installation and Connection Manual

Connect the harnesses for the F60 sealed specification, following the instructions below.
1. Connect the harnesses following the procedure below.

(1) Remove the eight rear unit cover fixing screws of the sealed chassis, and remove the

cover.

(2)  Connect the harness connectors to the controller body.
(3)  Secure the harnesses to the harness seal packing in the sealed chassis rear unit body.
(4)  Attach the sealed chassis unit cover and secure it with the eight screws.

Front view of sealed chassis rear unit body

Top view of sealed chassis rear unit body

Screw

Sealed chassis rear unit

cover

Harness seal packing

Sealed chassis rear unit

body

Screw

F Series Controller

6 Connection Instructions

Kawasaki Robot Installation and Connection Manual

2. Secure each harness at the predetermined location of the harness seal packing of the

sealed chassis rear unit body as shown in the figure below.

No.

Symbol

Harness name

Specified cable

diameter

XMOT (A)

External axis (JTA) motor harness

8.1±0.5 mm

XMOT (B)

External axis (JTB) motor harness

8.1±0.5 mm

XPOW

Power cable

11.4±0.4 mm

XRLS

Brake release harness

10.3±0.8 mm

XSIG (A)

External axis (JTA) signal harness

7.3±0.2 mm

XSIG (B)

External axis (JTB) signal harness

7.3±0.2 mm

XRSIG

Arm signal harness

10.3±0.3 mm

XTP

TP cable

9.4±0.5 mm

XSW

External operation panel cable

5.6±0.4 mm

XGPIO

General I/O signal cable

8.1

0.5 mm

XMOT

Arm motor harness

19.1±0.5 mm

0.5 mm

Use for options other than those listed above

Use cables with the specified cable diameter listed.

Specification

for cables

provided by

KHI

(1) (2) (3) (4) (5) (6) (7) (8)

(10)

(9)

(12)

(11)

Harness seal

packing

Sealed chassis

rear unit body

(13)

F Series Controller

6 Connection Instructions

Kawasaki Robot Installation and Connection Manual

If there is any unused harness in the list above, fit a plastic sealing stopper provided as an
accessory into the harness seal packing for the unused harness. The sealing stoppers have
the harness codes written on them so that the right stoppers can be placed in the right
attachment points. See below for how to insert the sealing stoppers.

Sealing

stoppers

Sealing stopper (insert with

the lettering facing out from

the chassis)

Harness seal packing

Use the correct sealing

stopper

Fixing metal

plate of

packing

Harness seal

packing

F Series Controller

6 Connection Instructions

Kawasaki Robot Installation and Connection Manual

3. When securing each harness to the harness seal packing of the sealed chassis rear unit

body, be careful that the packing has not caught on the side of the cable as shown below.

Cable correctly inserted

Cable incorrectly inserted

4. When removing the harness from the harness seal packing for replacement or other

reasons after the harness has been attached in the sealed chassis rear unit body, replace
the harness seal packing with a new one, following the procedure below.

(1) Remove the four screws from the harness seal packing fixing metal plate, and replace

the harness seal packing with a new one.

Rear view of the sealed chassis rear cover

Cable

Packing

Packing is caught on the side of the cable

Fixing metal plate

of packing

Harness seal

packing

Screw

F Series Controller

6 Connection Instructions

Kawasaki Robot Installation and Connection Manual

(2) Remove the eight screws from the harness seal packing fixing metal plate of packing,

and replace the harness seal packing with a new one.

Top view of sealed chassis rear unit body

5. Secure the ferrite core on the XMOT harness in the correct position as shown the figure

below.

Top view of sealed chassis rear unit body

View A

Fixing metal plate

of packing

Harness seal

packing

Screw

Ferrite core

mounting cover

Ferrite core

Aluminum block

Screw to attach cable shield

Ferrite core

mounting cover

Screw (M3, P4 L=6

Tightening torque:

0.7 N·m)

F Series Controller

6 Connection Instructions

Kawasaki Robot Installation and Connection Manual

6. Use the positions shown below to attach the harness shield terminals to the controller.

Left view

Top view

Right view

Expanded view of sealed chassis rear unit body

Read the precautions carefully before attaching separate harnesses.
If attached incorrectly, dirt and dust, etc., could get into the controller
and cause malfunction or breakdown.

CAUTION

！

XMOT (B) shield

XMOT (A) shield

XMOT shield

Other shields

F Series Controller

6 Connection Instructions

Kawasaki Robot Installation and Connection Manual

•

Arm side

– Cable diameter

Motor harness: 18.6 to 19.6 mm, Signal harness: 10.0 to 10.6 mm

R series: 03N/05N/05L

R series: 10N/06L

R series: 07N/07L

Signal harness

Motor harness

Signal harness

Motor harness

Signal harness

Motor harness

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