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Kawasaki Robot Controller

D7x Series

Installation and
Connection Manual

Kawasaki Heavy Industries, Ltd.

902021083DEF
D7x Series Controller
Kawasaki Robot Installation and Connection Manual

PREFACE

This manual describes the installation and connection of the D7x series controller. Unless
otherwise indicated, descriptions herein apply to both specifications.

Read and understand the contents of this and safety manuals thoroughly and strictly observe all rules
for safety before proceeding with any operation. Kawasaki cannot take any responsibility for any
accidents and/or damages caused by operations that are based on only the limited part of this
manual.

This manual describes only the installation and connection of the Control Unit, the wiring, and
the external power source. Please refer to the following manuals for information on the robot
arm.
INSTALLATION AND CONNECTION =ROBOT ARM =

This Manual describes the following controller models.


D70, 71 (Europe Spec.)
D73, 74 (Japan Spec.)
D76, 77 (North America Spec.)

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, 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.
Copyright 2007 Kawasaki Heavy Industries Ltd. All rights reserved.

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D7x Series Controller
Kawasaki Robot Installation and Connection Manual

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.

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

WARNING

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


explanations given in this manual cannot be confirmed with absolute
certainty. Should any unexplained questions or problems arise, please
contact Kawasaki Machine Systems.
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.

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D7x Series Controller
Kawasaki Robot Installation and Connection Manual

CONTENTS
1.0 Safety5
1.1 Precautions during Transportation and Storage5
1.2 Installation Environments of Robot Controller 6
1.3 When Connecting the Harness7
1.4 When Connecting the External Power8
1.5 Warning Label 9

2.0 Workflow Robot Controller Installation and Connection10

3.0 Appearance and Specification of Robot Controller12


3.1 D70/73 Controller Appearance 12
3.2 D71/74 Controller Appearance 13
3.3 D76 Controller Appearance 14
3.4 D77 Controller Appearance 15
3.5 Teach Pendant Appearance16
3.6 Controller Specification16

4.0 Transportation of Robot Controller17


4.1 Crane Lifting Transportation17
4.2 Two-handed Transportation18

5.0 Arrangement of Robot Controller19

6.0 Connection Instructions21


6.1 Connection Instructions between Controller and Robot 21
6.2 Connection Instructions between Controller and Teach Pendant25

7.0 Connection of External Power 26

8.0 Connection of Peripheral Control Equipment 29


8.1 Instructions at the Connection30
8.2 Connection of DI/O General Purpose Signal 31
8.3 Connection of DI/O Hardware Dedicated Signal33
8.4 Connection of Personal Computer (Option)33
8.5 Connection of RS232C Serial Signal (Option) 33

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D7x Series Controller
Kawasaki Robot Installation and Connection Manual

8.6 Connection of Ethernet Communication Signal (Option) 33


8.7 Connection of Fieldbus (Option) 34

Appendix 1.0 Connection of Sensor Cable A-1


Appendix 1.1 Sensor Cable (Option) A-2
Appendix 1.2 Connecting Proximity and Limit Switches A-4
Appendix 1.3 Using Solenoid Signals A-5
Appendix 1.4 Using Sensor Signals A-6

Appendix 2.0 Solenoid Valve Wiring Diagram A-7

Appendix 3.0 Sensor Wiring Diagram A-9

Appendix 4.0 Protecting Sensor Line from Noise A-13

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D7x Series Controller 1. Safety
Kawasaki Robot Installation and Connection Manual

1.0 SAFETY

This chapter only describes safety precautions during installation and connection of the Controller
Unit. For all other safety matters, refer to the SAFETY MANUAL, a separate-volume.

1.1 PRECAUTIONS DURING TRANSPORTATION AND STORAGE

To transport the Kawasaki Robot Controller to its installation place, strictly observe the following
cautions while carrying out the transportation and installation work.

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

WARNING

1. When transporting a controller with a crane or a forklift, never support


the controller manually.
2. During the transportation, stay out from under the lifted controller.

CAUTION

1. Since the controller is composed of precision parts, be careful not to


apply excessive shocks or vibrations to the controller during
transportation.
2. To carry out smooth and safe installation, remove all obstacles before
installing a controller. Clear a passage for the transportation of
controller before using a crane or forklift.
3. When transporting or storing a controller:
keep the ambient temperature within the range of - 10C - 60C
keep the relative humidity within the range of 35% - 85% RH
(Non condensing)
keep free from excessively large shock and vibration.

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D7x Series Controller 1. Safety
Kawasaki Robot Installation and Connection Manual

1.2 INSTALLATION ENVIRONMENTS OF ROBOT CONTROLLER

Install the controller in a site that satisfies all the following environmental conditions:

1. Ambient temperature during operation: within 0 C - 45 C.


2. Relative humidity: 35 - 85 %RH (Non condensing)
3. Free from dust, smoke, water, oil, etc. (Controller protection grade: IP53)
(Except for controller power switch and heat sink section. See the figure below.)
IP22 IP53

4. Free from flammable and/or corrosive liquid and gas.


5. Free from excessively strong vibration.
6. Free from electrical noise interference.
(Controller external power noise: 1KV/1s or less)

CAUTION

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.

7. Place where power is supplied within specifications. (Variance +/-10 % or less)


8. Place where dedicated earthing is provided. (100 or less)
9. Outside the safety fence with margin (min. 1 m) from the motion range of robot arm (with
tools).

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D7x Series Controller 1. Safety
Kawasaki Robot Installation and Connection Manual

In addition, ensure the followings:


Enough space for easy access to the controller during maintenance
Installing an entrance gate with a safety plug to the safety fence
Referring the requirements established in each region for details of the safety fence
e.g. EN953, EN294, EN811, EN1088, ISO13852, ISO13854, and ISO/NP14120
Approx. 1 m

Motion range of robot arm


(tool included)
Approx. 1 m Mechanical Mechanical Approx. 1 m
stopper stopper

Approx. Approx. Safety fence


1m 1m
Gate with
Controller part
safety plug
1.3 WHEN CONNECTING THE HARNESS

Strictly observe the following precautions when connecting the Robot Arm with the Robot
Controller.
WARNING
Do not connect the external power until connections between the Robot Arm
and Robot Controller are completed.
Accidents may occur, such as electric shock, etc.

CAUTION
1. Be careful when connecting the harness. Be sure to use the correct harness
cable and check that the connector fittings match between the harness and
robot/controller before attempting connection. Using an incorrect harness,
or forcing 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, objects, etc.)
from stepping on or riding over the signal and motor harness lines. An
unprotected harness may become damaged causing breaks in the electrical
system.
3. Separate the harness from any nearby high voltage lines (min. 1 m apart).
Do not bundle or run the harnesses in parallel with other power lines. The
noise generated from power lines will cause malfunctions.
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D7x Series Controller 1. Safety
Kawasaki Robot Installation and Connection Manual

1.4 WHEN 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. Connect with earth wires to prevent against electrical noise and shock.
2. Use dedicated earth wire (100 or less), which is equal to or larger than the
recommended power cable size (3.5 ~ 8.0 mm2).
3. Never use a minus pole (base metal) or a common earth wire for both
controller and another machine (weld machine, etc.).
4. In arc welding applications, connect the minus pole of the weld power supply
to a jig or directly to base metal. Insulate the robot body and controller so
that they do not share a common earth line.
5. Without fail, before turning ON the external power to controller, make sure
the power supply is connected and all the covers reattached properly.
Failure to do so may cause electric shock.

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 controllers
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 a lot electrical noise, set up a noise filter to
reduce the interference.
3. Install a separate external power switch (breaker) for the robot,
independent and unconnected to the weld machine.
4. To prevent shorting or accidental leakage on the external power switch,
install a breaker with anti-leak specification. (Use a Time Delay Relay and
sensitivity of 100 mA or more.)
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D7x Series Controller 1. Safety
Kawasaki Robot Installation and Connection Manual

1.5 WARNING LABEL


WARNING
Pay attention to warning labels listed in the drawings on
this page during operation.

Controller power switch Controller power switch


Rear
Front (D70/71/73/74)

DC Power
Supply (AVR)

Controller power switch

Front (D76)

The terminals are still


live if the Controller
Power Switch is OFF.

Left

Controller power switch


9 Front (D77)
D7x Series Controller 2. Workflow - Robot Controller Installation and Connection
Kawasaki Robot Installation and Connection Manual

2.0 WORKFLOW ROBOT CONTROLLER INSTALLATION AND CONNECTION

This workflow describes only the Robot Controller. For the Mechanical Unit, refer to
INSTALLATION AND CONNECTION =Arm.

Examine installation Refer to 3.0 Appearance and


position (includes wire) and specification of Robot
environment Controller.
Prep. Work

Confirm power supply Refer to 3.0 Appearance and


voltage and power capacity specification of Robot
Controller.

Transport Robot Controller Refer to 4.0 Transportation of


Robot Controller.

Arrange and install Refer to 5.0 Arrangement of


Robot Controller Robot Controller.

Refer to 6.0 Wiring


Connect Teach Pendant
Install Work

Instructions.
and separation harness See also Installation and
Connection =Arm.

Connect ambient control Refer to 8.0 Connection of


system and equipment Peripheral Control Equipment.

Connect external power Refer to 7.0 Connection of the


External power.

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D7x Series Controller 2. Workflow - Robot Controller Installation and Connection
Kawasaki Robot Installation and Connection Manual

Turn on and confirm Note: To control power supply


Controller Power externally, see External I/O
Manual.
Robot Controller with the Robot

Turn on and confirm Note: To use external emergency


Work after connecting

Motor Power stop, see External I/O Manual.

Confirm operation of Refer to Operation manual.


robot arm and tool
(Teach Mode)

Also, confirm other, Refer to Operation manual.


various functions

Work completion

[ NOTE ]

This manual only describes installation procedures, up to the step


where external power is connected.

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D7x Series Controller 3. Appearance and Specification of Robot Controller
Kawasaki Robot Installation and Connection Manual

3.0 APPEARANCE AND SPECIFICATION OF ROBOT CONTROLLER

3.1 D70/73 CONTROLLER APPEARANCE

500 270
Operation
panel
T/P
connector

420

470
Accessory
panel
50

Connector for External power


separation harness intake port

Note) For D73, the bar and lock on controller power switch are optional.

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D7x Series Controller 3. Appearance and Specification of Robot Controller
Kawasaki Robot Installation and Connection Manual

3.2 D71/74 CONTROLLER APPEARANCE

500 36 270
Operation
panel
T/P
connector

420
520
Accessory
100 panel

Connector for External power


separation harness intake port

Note) For D74, the bar and lock on controller power switch are optional.

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D7x Series Controller 3. Appearance and Specification of Robot Controller
Kawasaki Robot Installation and Connection Manual

3.3 D76 CONTROLLER APPEARANCE

500 270
Operation
panel
T/P
connector

470
Accessory
panel

Connector for External power


separation harness intake port

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D7x Series Controller 3. Appearance and Specification of Robot Controller
Kawasaki Robot Installation and Connection Manual

3.4 D77 CONTROLLER APPEARANCE

500 307
Operation
panel

T/P
connector

520
Accessory
panel

Connector for External power


separation harness intake port

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D7x Series Controller 3. Appearance and Specification of Robot Controller
Kawasaki Robot Installation and Connection Manual

3.5 TEACH PENDANT APPEARANCE

Liquid crystal display


Emergency stop switch

Teach lock switch

3.6 CONTROLLER SPECIFICATION

Construction Self-sustaining fully closed, indirect cooling system


Mass Approx. 30 kg (without transformer)
Ambient Temperature 0 45 C
Environment Humidity 35 85 %RH (Non condensing)
Power Source AC 200-240 V (50/60 Hz) +/-10 % 1 phase
Power Capacity Refer to the table below.
Earthing Dedicated earthing (100 or less)
Length of 5 m/10 m/15 m (5 m, 15 m are options for Europe
Teach Pendant Cable spec.)
5 m/10 m/15 m (5 m, 15 m are options for Europe
Length of Separation Harness*
spec.)
Note* Harness length between Robot Arm and Controller
Reference
Power Recommended Power Cable Size Length
Model
Capacity (Including earth wire) Requirement
FS03N (D70, 73, 76) 1.5 KVA 2-2.5 mm2 or more (AWG #14 or more) Less than 200 m
FS06N/ 10N/ 10E 3 KVA 2-2.5 mm2 or more (AWG #14 or more) Less than 200 m
(D71, 74, 77)

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D7x Series Controller 4. Transportation of Robot Controller
Kawasaki Robot Installation and Connection Manual

4.0 TRANSPORTATION OF ROBOT CONTROLLER

The mass of the controller is approx. 30 kg. When transporting the controller, strictly observe
the precautions given in the sections below for whichever transport method is chosen.

4.1 CRANE LIFTING TRANSPORTATION

WARNING
1. Never support the controller manually while it is being lifted up. And,
never go under or stay too close to the controller during transport.
2. Hook the wire on the controller as shown in figure below.

CAUTION
1. Prepare wire and crane capable of
hoisting 100 kg or more.
2. Remove the teach pendant before
lifting with the wire sling.
3. Be careful as the controller may
lean when lifted up.
4. Be careful not to let the wire snag
on other equipment.

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D7x Series Controller 4. Transportation of Robot Controller
Kawasaki Robot Installation and Connection Manual

4.2 TWO-HANDED TRANSPORTATION

CAUTION
1. Remove the teach pendant before transporting.
2. Be careful not to shock the controller during transport.

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D7x Series Controller 5. Arrangement of Robot Controller
Kawasaki Robot Installation and Connection Manual

5.0 ARRANGEMENT OF ROBOT CONTROLLER

In order for the controller to maintain the proper internal temperature, the installation site must
conform to the four points below.
1. Arrange the controller on a horizontal floor.
2. Separate the right and left side and ceiling of the controller from the wall by 100 mm or more.

CAUTION
The inlet and exhaust ports for air-cooling are on the left side of D71/74/77
controller. Do not block these ports when arranging the controller.

100 mm 100 mm
or more or more

200 mm 100 mm 100 mm


or or more or more
more

Left D70/73/76 Front

100 mm 100 mm
or more Inlet port Exhaust port or more

200 mm 100 mm 100 mm


or or more or more
more

Left D71/74/77 Front


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D7x Series Controller 5. Arrangement of Robot Controller
Kawasaki Robot Installation and Connection Manual

3. The inlet and exhaust ports for air-cooling are on the rear of the controller.

CAUTION
Do not block these ports when arranging the controller. Separate
the rear of the controller from the wall by 200 mm or more.

4. Make fixing bracket(s), and fix the controller referring to the figure below.

Front Right
D70/73/76

Front Right
D71/74/77

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D7x Series Controller 6. Connection Instructions
Kawasaki Robot Installation and Connection Manual

6.0 CONNECTION INSTRUCTIONS

6.1 CONNECTION INSTRUCTIONS BETWEEN CONTROLLER AND ROBOT

WARNING
Do not connect the external power until connections between controller and robot
are completed. Accidents may occur, such as electric shock, etc.

CAUTION
1. Be careful when connecting the harness. Be sure to use the correct harness
cable and check that the connector fittings match between the harness and
robot/controller before attempting connection. Using an incorrect harness, or
forcing 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, objects, etc.)
from stepping on or riding over the signal and motor harness lines. An
unprotected harness may become damaged causing breaks in the electrical
system.
3. Separate the harness from any nearby high voltage lines (min. 1 m apart). Do
not bundle or run the harnesses in parallel with other power lines. The noise
generated from power lines will cause malfunctions.
4. 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 an adequate FG terminal. (See Appendix
4.) These measures stop PWM noise from the robots motor control from
radiating through the various cables and causing communication errors.
5. Separate the welder secondary cable from the robots signal harness. Do not
wire them in the same duct.
6. The motor harness (power line) between the robot and controller will generate
switch 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) Ground the shield of the power line securely with the FG terminal.
(5) Do not wire the power and signal line within the same duct/conduit.
(6) Set and secure a firm earth line connection for the controller.

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D7x Series Controller 6. Connection Instructions
Kawasaki Robot Installation and Connection Manual

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

1. Controller side

Connect the separation harnesses to the controller following the procedures below.
1. (For D71/74/77 only) Remove 4 screws and the plate for air-cooling fan motor power
connector, and remove the motor power (X207).
2. Remove 9 screws and the controller cover.
3. Pass the signal and motor cables through the cable intake port, and fix them to the fixing plate
with the cable clamp.
Plate for air-cooling fan
Cover
motor power connector
(D71/74/77 only)

Air-cooling fan
(D71/74/77 only)

Left and top Right

Shield part
Fix shield part
with cable clamp

Cable clamp

Cable
intake port

Cable
fixing plate
Left and top
(Cover is removed.)

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D7x Series Controller 6. Connection Instructions
Kawasaki Robot Installation and Connection Manual

4. Connect the motor and signal cables to the controller.

X701

X702

X704

X703

X506

X507

Motor cable

Signal cable

5. Reinstall the cover removed in step 2.


6. (For D71/74/77 only) Remount the air-cooling fan motor connector (X207) and the plate
removed in step 1.

CAUTION
Fix each connector securely using locking latch. The robot may
malfunctions if connectors loosen or detach.

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D7x Series Controller 6. Connection Instructions
Kawasaki Robot Installation and Connection Manual

2. Arm side

FS06N, FS10E/N/C
(C001)

X4A X3A

Motor harness Signal harness

FS03N

Lock lever

Motor harness

Signal harness

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D7x Series Controller 6. Connection Instructions
Kawasaki Robot Installation and Connection Manual

6.2 CONNECTION INSTRUCTIONS BETWEEN CONTROLLER AND TEACH


PENDANT

Connect the teach pendant cable with the connector, lower right of operation panel. Pull down
the lever and lock after pulling it up and inserting the connector.

T/P Connector (X1)

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D7x Series Controller 7. Connection of External Power
Kawasaki Robot Installation and Connection Manual

7.0 CONNECTION OF EXTERNAL POWER

DANGER

Confirm that external power supply for the controller is cut off before
starting connection process. It is extremely dangerous to connect
power terminals with the power supply turned ON and accidents may
occur, electric shock, etc. To prevent external power from being
turned ON, tag the breaker to indicate clearly that work is in progress.
Or, assign a supervisor in front of the breaker until all connections are
complete.

WARNING

1. Make sure the power supply meets the specifications listed on the
name plate on the controllers front panel. Connecting to a power
source outside specifications may damage internal components.
2. Install a dedicated earth wire (100 or less). Also, install a
separate earth wire for the weld machine, do not use a common
earth wire.

CAUTION

1. Check for fluctuations in the power supply before making any power
connections to the robot. Ensure a stable power supply, fluctuations
of +/-10 % or more will degrade the robots efficiency.
2. If there is danger of electrical noise coming through the power line
from other equipment, then be sure to place noise filters. (Noise
level: 2kv/1s or more)
3. Likewise, PWM noise coming through the power line from the robot
motors may also affect machines with low noise tolerance, resulting
in malfunction. Plan and arrange the system so that all the
peripheral equipment* can withstand the PWM noise.

Note* Beware that some devices/configurations are easily exposed to


PWM noise, e.g.: proximity switch coupled directly to power
supply, etc. (See also App. 4.)

26
D7x Series Controller 7. Connection of External Power
Kawasaki Robot Installation and Connection Manual

Connect the external power according to the


following procedure.

1. Turn OFF the external power for the


controller.
Connect with the external power 2. Set CONTROLLER POWER switch on the
circuit breaker at the installation site. controller front door to OFF.
3. Remove the controller cover. (See 6.1)
4. Pass the external power cable through the
intake port on the lower left side of the
controller.

CAUTION
1. Confirm current requirements and select a
power cable with adequate capacity. (See 3.0)
2. Do not install wire that is too small in
diameter, the voltage may drop or the cable
may overheat.

External power
intake port

Controller Power
switch

27
D7x Series Controller 7. Connection of External Power
Kawasaki Robot Installation and Connection Manual

Connect the earth wire with the earth 5. Process the end of the external power cable as
terminal as shown below. below.
Power terminal block: Strip off the cover coating
by approx.10mm.
Earth terminal: M4 Crimp-type terminal (North
America Spec.: UL listed type)
The crimp-type terminal should be crimped with
appropriate tools in accordance with
manufacturers instruction manual.
To assure the wiring, the use of ferrules is
Power terminal Push flat-head Earth terminal
block screwdriver. recommend.
Recommended model: 216-206 (WAGO, for
AWG#14)
Recommended crimping tool: 206-204 (WAGO)
(Stripped wire length: 10 mm)
6. Connect the external power cable with the breaker
terminal (2 screws), and the dedicated earth
terminal. Push the flat-head screwdriver into the
power terminal block to open the cable clamp and
pass the cable, and remove the screwdriver.

WARNING
Tighten the cables securely. Opening the
robot with loose cables is very dangerous and
may lead to electric shock, robot malfunction,
or breakdown of the electrical system.

7. Reinstall the controller cover removed in step 3.

28
D7x Series Controller 8. Connection of Peripheral Control Equipment
Kawasaki Robot Installation and Connection Manual

8.0 CONNECTION OF PERIPHERAL CONTROL EQUIPMENT

According to application or specification, connect each connector in the Controller Unit described
below with the Peripheral Control Equipment. Especially for DC (under 24V) wiring, use the
Harness support.

1KB/1RB 1KA/1RA
1NR board 1KP board board board 1GW/1HW board (Option)

External DI/O connector


CN2 (Output)
1KN/1QN board (Option)
* 1KA board only
Terminal block
X7 connector
Terminal block Ethernet port (Option)
X8 connector *Standard for 1RA board
Terminal block External DI/O connector
X9 connector CN4 (Input)

RS232C port

RS232C port
(In accessory panel)
Left

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D7x Series Controller 8. Connection of Peripheral Control Equipment
Kawasaki Robot Installation and Connection Manual

8.1 INSTRUCTIONS AT THE CONNECTION

WARNING

Turn OFF the power supply to the controller and peripheral equipment when
connecting external I/O. Prevent accidental turn ON of the power until all
connections are complete by tagging the breaker to indicate that work is in
progress or by assigning a supervisor to stand in front of the breaker. Failure
to do so is extremely dangerous and may result in electric shock or damage to
the electrical system.

CAUTION

1. Take the necessary noise countermeasures on equipment with external


I/O connections to the controller. Electrical noise that interferes with
the I/O may cause malfunction or damage to the electrical system.
2. Do not mistake pin Nos. on the connectors when connecting external I/O.
Misconnecting pins may cause breakdown of the electrical system.
3. Prevent people or equipment (forklift, objects, etc.) from stepping on or
riding over the external I/O cables. An unprotected cable may become
damaged causing breaks in the electrical system.
4. Avoid wiring the external I/O cable and the power line close together or
in parallel as much as possible. Separate the cables and lines by at least
20 cm. Electromagnetic induction from the robot motor cable, the
power lines for peripheral equipment, welding cable, etc. (either in or
outside the controller) may cause noise interference in the I/O cable and
lead to malfunction.
5. When connecting with a light load such as sequencers, we recommend
using a shield harness.
6. Fix the external I/O cable with tying bands in the harness support set on
top the Controller Unit. This protects the connector on the terminal
block from excessive force. (pulling, snagging of cable, etc.)
7. Install the protector so that external I/O cable never causes insulation
failure or disconnection at the intake port.

30
D7x Series Controller 8. Connection of Peripheral Control Equipment
Kawasaki Robot Installation and Connection Manual

8.2 CONNECTION OF DI/O GENERAL PURPOSE SIGNAL

The robot can operate synchronously with the peripheral equipment or another robot when
connecting DI/O signals to the peripheral control equipment with connectors CN2 and CN4 on
the 1GW/1HW board.

1. Pass the cable through cable intake port on the lower left of the controller.

Shield part
Fix shield part
with cable clamp

Cable clamp
Cable
intake port

Cable
fixing plate

2. Take off connectors CN2 and CN4 installed in the controller.


3. Remove the connector cover for CN2 and CN4, and wire for general purpose signal.
4. Solder the connector pin.
5. Strip off the cable coating by 2-3mm and apply solder to the wire end.
6. Solder the cable to the connector pin.
7. Cover the connector pin with the insulation tube.
[ NOTE ]
1. Use an insulation tube of heat shrinkage type, or bind the
tube ends on each line so as not to come off.
2. We recommend using AWG22-24 or equivalent for cables.

8. After wiring is complete, attach connector cover and fix securely by turning the harness clamp
screw.

31
D7x Series Controller 8. Connection of Peripheral Control Equipment
Kawasaki Robot Installation and Connection Manual

9. Insert the connector into 1GW/1HW board and fix with locking screws at both ends.
[ NOTE ]
Tighten the screw thoroughly. The connection may fail if the
screw is loose and the connector pins are exposed to above
standard stress/force.

Connector
CN2 DC-37S-N (JAE) or equivalent
CN4 DC-37P-N (JAE) or equivalent

Stripped wire
2-3 mm
Harness
Cable clamp
Cover DC19678-3 Insulation tube
(JAE) or equivalent
Locking screw
CN2 D20419-16J (JAE) or equivalent: M2.6 Connector pin
CN4 D20419-21J (JAE) or equivalent: M2.6

32
D7x Series Controller 8. Connection of Peripheral Control Equipment
Kawasaki Robot Installation and Connection Manual

8.3 CONNECTION OF DI/O HARDWARE DEDICATED SIGNAL

It is possible to construct a safety circuit using the hard circuit by connecting the external
emergency stop signal or hold signal with the terminal connector on the 1KP board. Refer to
External I/O Manual for more details about signals and their connection to each terminal block.

Terminal block connections are held in place KP board


by springs.
Push a thin flat-head screwdriver (width: 2.5
mm or less) into the hole on the right to open
spring in the left hole. Then insert the wire there XConnector
(X8 Connector)
for connection. (X9 Connector)

We recommend using AWG22-24 or equivalent for cables.


Insert driver for
(Stripped wire length: 7 mm) Connection connection
side
To assure the wiring, we recommend using ferrules;
Recommended model : 216-201 (WAGO)
Recommended crimping tool : 206-204 (WAGO)
(Stripped wire length : 9.5 mm)

8.4 CONNECTION OF PERSONAL COMPUTER (OPTION)

It is possible to use a PC as terminal for the Robot Controller, when connecting a PC loaded with
KRterm/KCwin32 software with the RS232C Port in the Accessory Panel. Refer to AS
Language Reference Manual for more details.

8.5 CONNECTION OF RS232C SERIAL SIGNAL (OPTION)

Data communication is possible between the host computer and 1KA/1RA board, when
connecting to the RS232C Port on the 1KA/1RA board with an RS232C cable. Refer to Option
Manual for details.

8.6 CONNECTION OF ETHERNET COMMUNICATION SIGNAL (OPTION)

It is possible to build an Ethernet LAN of 10baseT/100baseTX using the communication port: the
1KA board comes equipped with on the optional 1KN/1QN add-on board, the 1RA board is
equipped with as standard. Refer to the specific Option Manual because cables differ according
to application or specification.

33
D7x Series Controller 8. Connection of Peripheral Control Equipment
Kawasaki Robot Installation and Connection Manual

8.7 CONNECTION OF FIELDBUS (OPTION)

Adding the 1JF/1QK board for fieldbus (option) enables communication with peripheral devices
on the fieldbus such as DeviceNet. Refer to Option Manual for details.

34
D7x Series Controller Appendix1. Connection of
Kawasaki Robot Installation and Connection Manual Sensor Cable

APPENDIX 1.0 CONNECTION OF SENSOR CABLE

WARNING

Turn off the controller power when connecting the sensor


cable. Failure to do so is dangerous and may result in
accidental electric shock.

CAUTION

Be sure to confirm the signal name when connecting sensor


lines via faston terminals. Misconnected terminals cause
breakdowns in the electrical system in the controller.

[ NOTE ]

Ensure that the proximity and limit switches are suitable for
the robot system and compatible with its electrical specs.

A-1
D7x Series Controller Appendix1. Connection of
Kawasaki Robot Installation and Connection Manual Sensor Cable

APPENDIX 1.1 SENSOR CABLE (OPTION)

FS06/10

Faston terminal for sensor

Taking-out port for sensor cable

Prepare the terminal Sensor cable (option)


connector according Approx. 1.5 m
to application specs.

FS03N

Prepare the terminal


connector according Sensor cable (option)
to application specs. Approx. 1.5 m

Faston terminal for sensor

A-2
D7x Series Controller Appendix1. Connection of
Kawasaki Robot Installation and Connection Manual Sensor Cable

F series
Sensor cable

Sensor input signal 1 XSIG1 Blue


Black
Sensor input signal 2 XSIG2 Purple
Black
Sensor input signal 3 XSIG3 Gray
Black
Sensor input signal 4 XSIG4 Pink
Black
Brown
Black
I/O24V X24V Red
I/O24G Black
X24G

RFV-K38
(0.3Sq 6P Outside diameter : 11mm)

FS003N:
Sensor input signal 1 (SIG1) Brown
Sensor input signal 2 (SIG2) Red
Sensor input signal 3 (SIG3) Yellow
Sensor input signal 4 (SIG4) Orange
+24V Blue, Purple
+24G Green, Black, Gray, White

[ NOTE ]

1. ItIt isisalso
alsopossible
possibletoto
useuse external
external +24V
+24V power
power supply
supply for internal
for the the internal
sensor and and valve.
valve. In Inthis
thiscase,
case,remove
removejumpers
jumpers between
between 9-10,
9-10, 11-12
11-12
pins of ofX9X9connector,
connector,andand connect
connect +24V
+24V to 10topin,
10 24G
pin, to
24G to 12 pin.
12 pin.
When using an an internal
internal+24V
+24Vpowerpowersupply,
supply,short
shortbetween
between9-10,9-10,11-12
11-12
pins. (Wiring at shipment.)
2. Select aa proximity
proximitysensor,
sensor,etc.
etc.that
thatdoes
doesnot
notexceed
exceedthe
thecurrent
currentcapacity
capacity
of the built-in power supply.
Current capacity: 0.2 A or less.
(Approx. 10 mA is necessary for each channel, SIG1~4.)

A-3
D7x Series Controller Appendix1. Connection of
Kawasaki Robot Installation and Connection Manual Sensor Cable

APPENDIX 1.2 CONNECTING PROXIMITY AND LIMIT SWITCHES

It is possible to connect proximity or limit switches with a faston terminal and to download it as a
WX signal. As per below, take note that connections differ between proximity and limit
switches and these are for non-Europe controller. (Refer to page A-16 for Europe controller.)
Connecting a proximity switch
Faston/Connector Proximity switch
+24V (5) +24V
SIG1 (1) SIG
24G (6) GND

Connecting a limit switch


Faston/Connector Limit switch
SIG1 (1)
+24G (6)

Connecting a proximity and limit switch together


Faston/Connector Proximity switch
+24V (5) +24V
SIG1 (1) SIG
24G (6) GND
Limit switch
SIG2 (2)

CAUTION

1. For various reasons the sensor cable may receive noise interference from the
axis motors, due to wiring of the cables inside the arm, the type of proximity
switch being used, etc. This noise may cause the robot to malfunction.
Take the following measures to reduce noise:
(1) Connect the sensor by wiring the cable outside the robot arm.
(2) Use a proximity switch specified for high noise resistance.
(3) Take the necessary noise counter-measures.
(Refer to Appendix 4.0 Protecting Sensor Line from Noise)
2. Use twisted pair shield line when wiring the harness outside the robot arm.

A-4
D7x Series Controller Appendix1. Connection of
Kawasaki Robot Installation and Connection Manual Sensor Cable

APPENDIX 1.3 USING SOLENOID SIGNALS

When using solenoid valve signals SOL1-4 (D70/73/76), SOL1-7 (D71/74/77) via the internal
valve wiring in handling specification, they are assigned to the general purpose output signals
OUT 9-12 (D70/73/76), OUT9-15 (D71/74/77). Set them in Aux. 0605 to correspond to clamp
signals.

Signal Name Signal No.


SOL1 (SIGO1) OUT9
SOL2 (SIGO2) OUT10
D7x
SOL3 (SIGO3) OUT11
SOL4 (SIGO4) OUT12
SOL5 (SIGO5) OUT13
SOL6 (SIGO6) OUT14 D71/74/77
SOL7 (SIGO7) OUT15

CAUTION

1. To assign solenoid valve signals via internal valve wiring, select


USED/NOT USED in Aux. 0610. Refer to Operation Manual.
2. OUT9-16 cannot be used for general purpose signals once they
are set as internal wiring valve signals.

CAUTION

Set jumpers JT3 and JT4 on the 1GW/1HW board without fail as
shown below.

J3 J4
1 {{{ 1 {{{
2 {{{ 2 {{{
3 {{{ 3 {{{
4 {{{ 4 {{{
5 {{{ 5 {{{
6 {{{ 6 {{{

A B C A B C

A-5
D7x Series Controller Appendix1. Connection of
Kawasaki Robot Installation and Connection Manual Sensor Cable

APPENDIX 1.4 USING SENSOR SIGNALS

When using sensor signals SIG1-4 via the internal wiring, they are assigned to the general
purpose input signals IN13-16.

Signal Name Signal No.


Sensor signal 1 (SIG1) IN13
Sensor signal 2 (SIG2) IN14
Sensor signal 3 (SIG3) IN15
Sensor signal 4 (SIG4) IN16

CAUTION

1. To assign sensor signals via internal wiring, select USED/NOT


USED in Aux. 0610. Refer to Operation Manual.
2. IN13-16 cannot be used for general purpose signals once they
are set as internal wiring sensor signals.

CAUTION

Set jumper J5 on the 1GW/1HW board without fail as shown


below.

J5 1GW/1HW board

1 {{ {
2 {{ {
3 {{ {
4 {{ {
5 {{ {
A B C

A-6
D7x Series Controller Appendix2. Solenoid Valve
Kawasaki Robot Installation and Connection Manual Wiring Diagram

APPENDIX 2.0 SOLENOID VALVE WIRING DIAGRAM

(1) FS06/10

Controller Robot
1KP board 1NX board 1NR board
Separation
harness
P2 CN1 X703
SIGO1
A29 A26 B10
SIGO2
B30 B26 A10
SIGO3
A30 C26 B9
SIGO4
B31 A27 A9
SIGO5
A31 A28 B8
SIGO6
B32 A29 A8
SIGO7
A32 B29 B7
SIGO8
A7

I/O24V 1 1-2 for Japan/North America spec.


2
I/O24G 3 2-3 for Europe spec.

(2) FS03N

Controller Robot
1KP board 1NX board 1NR board
Separation
harness VALV1
P2 CN1 X703 X401
SIGO1 2
A29 A26 B10 41
1
SIGO2
B30 B26 A10 42 4
SIGO3
3
A30 C26 B9 43
SIGO4
B31 A27 A9 44 VALV2
2
A31 A28 B8
1
B32 A29 A8

A32 B29 B7
SIGO8
A7 39

I/O24V 1 1-2 for Japan/North America spec.


2
I/O24G 3 2-3 for Europe spec.

A-7
D7x Series Controller Appendix2. Solenoid Valve
Kawasaki Robot Installation and Connection Manual Wiring Diagram

Function Diagram for Non-Europe Specification

I/O24V SOL
I/O24V

I/O24G
1KP board

Function Diagram for Europe Specification

I/O24V
SOL

I/O24G
I/O24G
1KP board

[ NOTE ]
Be aware that solenoid driving conditions are different as shown above
between Non-Europe and Europe Specifications.

CAUTION

Select the solenoid valve with consumption current between 15 and 100 mA.
If consumption current is too small, the solenoid valve may malfunction due
to the noise. As LED for the solenoid valve motion may light slightly due
to the noise, select the type without LED for solenoid valve motion or add a
capacitor of about 4700 pF ex. Matsushita ECKANA472ME between
the solenoid valve input and the common lines.

A-8
D7x Series Controller Appendix3. Sensor Wiring Diagram
Kawasaki Robot Installation and Connection Manual

APPENDIX 3.0 SENSOR WIRING DIAGRAM

(1) FS06/10

Controller

1KB/1RB board 1NX board 1NR board


Separation
CN1 X702
harness
A12 A6

B12 B6

C12 A5

C13 B5

B27/C27 B3/B4

B28/C28 A3/A4

Robot
Separation
harness

A-9
D7x Series Controller Appendix3. Sensor Wiring Diagram
Kawasaki Robot Installation and Connection Manual

(2) FS03N

Controller

1KB/1RB board 1NX board 1NR board


Separation
CN1 X702
harness

A12 A6

B12 B6

C12 A5

C13 B5

B27/C27 B3/B4

B28/C28 A3/A4

Robot
Separation
harness X401

66

67

54

55

68

56

A-10
D7x Series Controller Appendix3. Sensor Wiring Diagram
Kawasaki Robot Installation and Connection Manual

Function Diagram for Non-Europe Specification

For a proximity switch

I/O24V* I/O24V Proximity switch


Photo coupler I/O24V

OUT
SIG1-4
I/O24G

I/O24G

For a limit switch


I/O24V*
Photo coupler

Limit switch

I/O24G

1KB/1RB board
NOTE* Confirm that Dip Switch S10on the 1KB/1RB board is set to filled circle side for 24
V supply. (See below.)

CAUTION

1. For various reasons the sensor cable may receive noise interference from the
axis motors, due to wiring of the cables inside the arm, the type of proximity
switch being used, etc. This noise may cause the robot to malfunction.
Take the following measures to reduce noise:
(1) Connect the sensor by wiring the cable outside the robot arm.
(2) Use a proximity switch specified for high noise resistance.
(3) Take the necessary noise counter-measures.
(Refer to Appendix 4.0 Protecting Sensor Line from Noise)
2. Use twisted pair shield cable when wiring the harness outside the robot arm.

A-11
D7x Series Controller Appendix3. Sensor Wiring Diagram
Kawasaki Robot Installation and Connection Manual

Function Diagram for Europe Specification

For a proximity switch

I/O24G* I/O24V Proximity switch


Photo coupler I/O24V

SIG1-4
OUT
I/O24G

I/O24G

For a limit switch


I/O24G* I/O24V
Photo coupler

Limit switch

I/O24G

1KB/1RB board

NOTE* Confirm that Dip Switch S10on the 1KB/1RB board is set to non-filled circle side
for connection to I/O 24 ground. (See below.)

CAUTION

1. For various reasons the sensor cable may receive noise interference from the
axis motors, due to wiring of the cables inside the arm, the type of proximity
switch being used, etc. This noise may cause the robot to malfunction.
Take the following measures to reduce noise:
(1) Connect the sensor by wiring the cable outside the robot arm.
(2) Use a proximity switch specified for high noise resistance.
(3) Take the necessary noise counter-measures.
(Refer to Appendix 4.0 Protecting Sensor Line from Noise)
2. Use twisted pair shield cable when wiring the harness outside the robot arm.

A-12
D7x Series Controller Appendix4. Protecting Sensor Line
Kawasaki Robot Installation and Connection Manual from Noise

APPENDIX 4.0 PROTECTING SENSOR LINE FROM NOISE

(1) Use a twisted pair shield cable for the sensor connection line. And, connect the shield jacket
with the appropriate FG terminal.

Shield jacket
Make as short as possible.

Twisted pair line Earth the shield jacket directly


by the metal harness clamp, etc.
or

Draw the shield jacket without patching via general electric wiring.
Make as short as possible. (Or, connect it with a similar wire mesh.) Fasten it to the controller
case with a screw. However, be sure to remove any insulating
material such as paints between the screw and casing/paneling when
fixing the shield jacket.

(2) Install the earth line between the noise source and AC power supply(0V side) with a capacitor.

AC sensor

AC power supply

Capacitor (Example; 0.22 F, 630 V)

Place the capacitor near the sensor to optimize the shielding. When possible, we recommend
pulling the sensor from the terminal board to reduce slack in the line.

(3) Put insulator between the sensor and installation table (metal). (Plastic, rubber, etc.)

Insulator
Sensor

Installation table (metal)

A-13
D7x Series Controller
Kawasaki Robot Installation and Connection Manual

MEMO

A-14
Kawasaki Robot Controller D7x Series
INSTALLATION AND CONNECTION MANUAL

December 2004: 1st Edition


July 2007: 6th Edition

Publication : KAWASAKI HEAVY INDUSTRIES, LTD.


ROBOT DIVISION

90202-1083DEF

Copyright 2007 KAWASAKI HEAVY INDUSTRIES, LTD. All rights reserved.