Kawasak

C SERIES CONTROLLER
INSTALLATION MANUAL
MPICCON38E

Kawasak
Kawasaki Robotics (USA), Inc.
This publication contains proprietary information of Kawasaki Robotics (USA), Inc. and
is furnished solely for customer use only. No other uses are authorized or permitted
without the express written permission of Kawasaki Robotics (USA), Inc. The contents
of this manual cannot be reproduced, nor transmitted by any means, e.g., mechanical,
electrical, photocopy, facsimile, or electronic data media, without the express written
permission of Kawasaki Robotics (USA), Inc.

All Rights Reserved.

Copyright © 1999, Kawasaki Robotics (USA), Inc.

Wixom, Michigan 48393

The descriptions and specifications in this manual were in effect when it was submitted
for publishing. Kawasaki Robotics (USA), Inc. reserves the right to change or discon-
tinue specific robot models and associated hardware and software, designs, descrip-
tions, specifications, or performance parameters at any time and without notice, without
incurring any obligation whatsoever.

This manual presents information specific to the robot model listed on the title page of
this document. Before performing maintenance, operation, or programming proce-
dures, all personnel are recommended to attend an approved Kawasaki Robotics
(USA), Inc. training course.

KAWASAKI ROBOTICS (USA), INC. TRAINING

Training is available from Kawasaki Robotics (USA), Inc. on courses covering operation,
programming, electrical maintenance and mechanical maintenance. These courses are
conducted both on-site at the customer’s location, or at our training facility in Wixom,
Michigan.

For additional information contact:

Kawasaki Robotics (USA), Inc.

Training and Documentation Dept.
28059 Center Oaks Court
Wixom, Michigan 48393
 C SERIES CONTROLLER
Kawasak INSTALLATION MANUAL

REVISION HISTORY

Revision Release
Description of Change Initials
Number Date

0 6/21/99 Initial PDF release, based on rev. 1 of print copy KR

 Kawasak C SERIES CONTROLLER
INSTALLATION MANUAL

INTRODUCTION

I.0 INTRODUCTION ................................................................................................ I-2

I.1 Mechanical Unit .................................................................................................. I-2
I.1.1 Mechanical Unit Design Specifications .............................................................. I-3
I.2 Robot Controller ............................................................................................... I-10
I.2.1 Robot Controller Design Specifications ............................................................ I-11
1.2.2 C Controller Installation Planning ..................................................................... I-17

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 Kawasak C SERIES CONTROLLER
INSTALLATION MANUAL

INTRODUCTION

I.0 INTRODUCTION

The C Controller Installation manual is designed to assist the user whose primary re-
sponsibility is to program and operate the robot on a daily basis. This manual provides
specific information on safety, basic operation, programming path and auxiliary data,
setting the Auxiliary Data screens, and error information.

I.1 MECHANICAL UNIT

The Kawasaki F and U-series AC servo driven industrial robots are articulated coordi-
nate-type robots designed for many applications in the industrial environment. The
robot with its AC servo closed-loop drive system, is built with high rigidity. This design
allows it to perform tasks that require high accuracy, speed, and wrist load capacities,
while achieving significant energy reduction through the use of high efficiency brushless
AC servo motors.

The mechanical unit has six or seven axes depending upon the configuration of the
robot.

The major axes are:

• JT1 (R-axis) rotary; rotation of the base

• JT2 (O-axis) out and in; rotation of the lower arm
• JT3 (D-axis) down and up; rotation of the upper arm

The minor axes are:

• JT4 (S-axis) swivel; sets orientation of JT5 for pitch/yaw motion

• JT5 (B-axis) bend; provides pitch/yaw wrist motion
• JT6 (T-axis) twist; provides rotation of the tool only

The auxiliary axis, if so equipped is:

• JT7 (V-axis) traverse; linear positioning of the mechanical unit

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 Kawasak C SERIES CONTROLLER
INSTALLATION MANUAL

INTRODUCTION

The Kawasaki robot system supports Cartesian coordinate motion which includes:

• Base (World) coordinates

• Tool coordinates

These coordinate systems can be used when manually operating the robot in the teach
mode and with various program instructions for shifting program positional data, defin-
ing tool center points, and recording positional data.

Kawasaki robot systems use the left-hand-rule to determine the orientation of the base
or tool coordinate system.

I.1.1 MECHANICAL UNIT DESIGN SPECIFICATIONS

Table I-1 provides the design specifications for the mechanical units that utilize the C
controller.

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 Kawasak C SERIES CONTROLLER
INSTALLATION MANUAL

INTRODUCTION

Table I-1 Robot Specifications

ROBOT MODEL FA06E FA06L FA06 FC06N FS06L FS06

Number of Axes 6 (7)* 6 (7)* 6 (7)* 6 (7)* 6 (7)* 6 (7)*

JT1 200°/sec 200°/sec 240°/sec 240°/sec 200°/sec 240°/sec

JT2 140°/sec 140°/sec 200°/sec 200°/sec 140°/sec 200°/sec

JT3 200°/sec 200°/sec 250°/sec 250°/sec 200°/sec 250°/sec

Maximu JT4 360°/sec 430°/sec 430°/sec 430°/sec 360°/sec 430°/sec
Velocity
JT5 360°/sec 430°/sec 430°/sec 430°/sec 360°/sec 430°/sec

JT6 600°/sec 600°/sec 720°/sec 720°/sec 600°/sec 720°/sec

1,200 mm/sec 1,200 mm/sec 1,200 mm/sec 1,200 mm/sec 1,200 mm/sec 1,200 mm/sec
JT7
(47.24 (47.24 (47.24 (47.24 (47.24 (47.24
Maximum Linear 9,200 mm/sec 8,250 mm/sec 8,000 mm/sec 8,000 mm/sec 9,200 mm/sec 8,000 mm/sec
Tool Tip Speed (362.2 (324.8 (314.9 (314.9 (362.2 (314.9
JT1 ±160° ±160° ±160° ±160° ±160° ±160°

JT2 +140°/-105° +140°/-105° +140°/-105° +140°/-105° +140°/-105° +140°/-105°

JT3 +295°/-225° +295°/-225° +295°/-225° +295°/-225° +295°/-225° +295°/-225°

Work
Envelope JT4 ±270° ±270° ±270° ±270° ±270° ±270°
(Stroke)
JT5 ±145° ±145° ±145° ±145° ±145° ±145°

JT6 ±360° ±360° ±360° ±360° ±360° ±360°

Custom Custom Custom Custom Custom Custom
JT7
Lengths Lengths Lengths Lengths Lengths Lengths
Max. Payload (lbs. 6 (13 6 (13 6 (13 6 (13 6 (13 6 (13

JT4 12 N m (8.8 12 N m (8.8 12 N m (8.8 12 N m (8.8 12 N m (8.8 12 N m (8.8

Wrist Rated
Torque JT5 12 N m (8.8 12 N m (8.8 12 N m (8.8 12 N m (8.8 12 N m (8.8 12 N m (8.8
(ft. lbs.)
JT6 6 N m (4.4) 6 N m (4.4) 6 N m (4.4) 6 N m (4.4) 6 N m (4.4) 6 N m (4.4)
0.24 kg m s 2 0.24 kg m s 2 0.24 kg m s 2 0.24 kg m s 2 0.24 kg m s 2 0.24 kg m s 2
JT4
(1.72 ) (1.72 ) (1.72 ) (1.72 ) (1.72 ) (1.72 )
Wrist Rated
0.24 kg m s 2 0.24 kg m s 2 0.24 kg m s 2 0.24 kg m s 2 0.24 kg m s 2 0.24 kg m s 2
Moment of JT5
(1.72 (1.72 (1.72 (1.72 (1.72 (1.72
Inertia
0.07 kg m s 2 0.07 kg m s 2 0.07 kg m s 2 0.07 kg m s 2 0.07 kg m s 2 0.07 kg m s 2
JT6
(0.51 (0.51 (0.51 (0.51 (0.51 (0.51
Repeatability (in. ±0.1 (0.004 ±0.1 (0.004 ±0.05 (0.002 ±0.05 (0.002 ±0.1 (0.004 ±0.05 (0.002

JT1 1.0 kw (1.34 1.0 kw (1.34 1.0 kw (1.34 1.0 kw (1.34 1.0 kw (1.34 1.0 kw (1.34

JT2 1.0 kw (1.34 1.0 kw (1.34 1.0 kw (1.34 1.0 kw (1.34 1.0 kw (1.34 1.0 kw (1.34

JT3 475 w (0.64) 475 w (0.64 475 w (0.64 475 w (0.64 475 w (0.64 475 w (0.64
Drive
JT4 100 w (0.13 100 w (0.13 100 w (0.13 100 w (0.13 100 w (0.13 100 w (0.13
Source (hp
JT5 100 w (0.13 100 w (0.13 100 w (0.13 100 w (0.13 100 w (0.13 100 w (0.13

JT6 100 w (0.13 100 w (0.13 100 w (0.13 100 w (0.13 100 w (0.13 100 w (0.13

JT7 2.5 kw (3.35 2.5 kw (3.35 2.5 kw (3.35 2.5 kw (3.35 2.5 kw (3.35 2.5 kw (3.35
Weigh 6
125 kg (276 115 kg (254 110 kg (243 110 kg (243 125 kg (276 110 kg (243
(lbs.) Axes

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 Kawasak C SERIES CONTROLLER
INSTALLATION MANUAL

INTRODUCTION

Table I-1 Robot Specifications (Continued)

ROBOT MODEL FW06 FS10 FS10E FS10L FA20 FS20

Number of Axes 6 (7)* 6 (7)* 6 (7)* 6 (7)* 6 (7)* 6 (7)*

JT1 240°/sec 200°/sec 200°/sec 160°/sec 160°/sec 160°/sec

JT2 200°/sec 140°/sec 140°/sec 140°/sec 140°/sec 140°/sec

JT3 250°/sec 200°/sec 200°/sec 160°/sec 160°/sec 160°/sec

Maximum JT4 430°/sec 360°/sec 360°/sec 330°/sec 330°/sec 330°/sec
Velocity
JT5 430°/sec 360°/sec 360°/sec 330°/sec 330°/sec 330°/sec

JT6 720°/sec 600°/sec 600°/sec 500°/sec 500°/sec 500°/sec

1,200 mm/sec 1,200 mm/sec 1,200 mm/sec 1200 mm/sec 1200 mm/sec 1200 mm/sec
JT7
(47.24 (47.24 (47.24 (47.24 (47.24 (47.24
Maximum Linear 8,000 mm/sec 6,200 mm/sec 8,800 mm/sec 9,400 mm/sec 8,500 mm/sec 6,900 mm/sec
Tool Tip Speed (314.9) (244 (346.4) (370 (334.6) (271.6)
JT1 ±160° ±160° ±160° ±160° ±160° ±160°

JT2 +140°/-105° +140°/-105° +140°/-105° +140°/-105° +140°/-105° +140°/-105°

JT3 +295°/-225° +295°/-225° +295°/-225° +295°/-225° +295°/-225° +295°/-225°

Work
Envelope JT4 ±270° ±270° ±270° ±270° ±270° ±270°
(Stroke)
JT5 ±145° ±145° ±145° ±145° ±145° ±145°

JT6 ±360° ±360° ±360° ±360° ±360° ±360°

Custom Custom Custom Custom Custom Custom
JT7
Lengths Lengths Lengths Lengths Lengths Lengths
Max. Payload (lbs.) 6 (13 10 (22 10 (22 10 (22 20 (44 20 (44
21.5 N m 21.5 N m 21.5 N m 39.3 N m 39.3 N m
JT4 12 N m (8.8
(15.8) (15.8) (15.8) (28.9) (28.9)
Wrist Rated
21.5 N m 21.5 N m 21.5 N m 39.3 N m 39.3 N m
Torque JT5 12 N m (8.8
(15.8) (15.8) (15.8) (28.9) (28.9)
(ft. lbs.)
19.6 N m 19.6 N m
JT6 6 N m (4.4) 9.8 N m (7.2) 9.8 N m (7.2) 9.8 N m (7.2)
(14.4) (14.4)
0.24 kg m s2 0.63 kg m s 2 0.63 kg m s 2 0.63 kg m s 2 0.88 kg m s 2 0.88 kg m s 2
JT4
(1.72 ) (4.56 (4.56 (4.56 (6.37 (6.37
Wrist Rated
0.24 kg m s 2 0.63 kg m s 2 0.63 kg m s 2 0.63 kg m s 2 0.88 kg m s 2 0.88 kg m s 2
Moment of JT5
(1.72 (4.56 (4.56 (4.56 (6.37 (6.37
Inertia
0.07 kg m s 2 0.15 kg m s 2 0.15 kg m s 2 0.15 kg m s 2 0.25 kg m s 2 0.25 kg m s 2
JT6
(0.51 (1.08 ) (1.08 ) (1.08 ) (1.81 ) (1.81 )
Repeatability (in.) ±0.05 (0.002 ±0.05 (0.002 ±0.1 (0.004 ±0.1 (0.004 ±0.1 (0.004 ±0.1 (0.004

JT1 1.0 kw (1.34 1.0 kw (1.34 1.0 kw (1.34 2.1 kw (2.82 2.1 kw (2.82 2.1 kw (2.82

JT2 1.0 kw (1.34 1.0 kw (1.34 1.0 kw (1.34 2.1 kw (2.52 2.1 kw (2.52 2.1 kw (2.52

JT3 475 w (0.64 475 w (0.64 475 w (0.64 1.0 kw (1.34 1.0 kw (1.34 1.0 kw (1.34
Drive
JT4 100 w (0.13 100 w (0.13 100 w (0.13 200 w (0.27 200 w (0.27 200 w (0.27
Source (hp)
JT5 100 w (0.13 100 w (0.13 100 w (0.13 200 w (0.27 200 w (0.27 200 w (0.27

JT6 100 w (0.13 100 w (0.13 100 w (0.13 200 w (0.27 200 w (0.27 200 w (0.27

JT7 2.5 kw (3.35 2.5 kw (3.35 2.5 kw (3.35 2.5 kw (3.35 2.5 kw (3.35 2.5 kw (3.35
Weight 6
110 kg (243 110 kg (243 120 kg (265 220 kg (485 210 kg (463 205 kg (452
(lbs.) Axes

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 Kawasak C SERIES CONTROLLER
INSTALLATION MANUAL

INTRODUCTION

Table I-1 Robot Specifications (Continued)

ROBOT MODEL FS20N FS30L FS30N FS45C FS45N

Number of Axes 6 (7)* 6 (7)* 6 (7)* 6 (7)* 6 (7)*

JT1 160°/sec 160°/sec 160°/sec 160°/sec 160°/sec

JT2 140°/sec 140°/sec 140°/sec 140°/sec 140°/sec

JT3 160°/sec 160°/sec 160°/sec 160°/sec 160°/sec

Maximum JT4 330°/sec 240°/sec 240°/sec 240°/sec 240°/sec
Velocity
JT5 330°/sec 240°/sec 240°/sec 240°/sec 240°/sec

JT6 500°/sec 340°/sec 340°/sec 340°/sec 340°/sec

1200 mm/sec 1200 mm/sec 1200 mm/sec 1200 mm/sec 1200 mm/sec
JT7
(47.24 (47.24 (47.24 (47.24 (47.24
Maximum Linear 8,500 mm/sec 11,100 mm/sec 8,900 mm/sec 8,900 mm/sec 9,700 mm/sec
Tool Tip Speed (334.6) (437) (350.3) (350.3) (381.8)
JT1 ±160° ±160° ±160° ±160° ±160°

JT2 +140°/-105° +140°/-105° +140°/-105° +140°/-105° +140°/-105°

JT3 +295°/-225° +295°/-225° +295°/-225° +295°/-225° +295°/-225°

Work
Envelope JT4 ±270° ±270° ±270° ±270° ±270°
(Stroke
JT5 ±145° ±130° ±130° ±130° ±130°

JT6 ±360° ±360° ±360° ±360° ±360°

Custom Custom Custom Custom Custom
JT7
Lengths Lengths Lengths Lengths Lengths
Max. Payload (lbs.) 20 (44 30 (66 30 (66 45 (99 45 (99
39.3 N m 176.4 N m 176.4 N m 176.4 N m 176.4 N m
JT4
(28.9) (130.1) (130.1) (130.1) (130.1)
Wrist Rated
39.3 N m 176.4 N m 176.4 N m 176.4 N m 176.4 N m
Torque JT5
(28.9) (130.1) (130.1) (130.1) (130.1)
(ft. lbs.)
19.6 N m 98.0 N m 98.0 N m 98.0 N m 98.0 N m
JT6
(14.4) (72.2) (72.2) (72.2) (72.2)
0.88 kg m s 2 7.2 kg m s2 7.2 kg m s 2 10.8 kg m s2 10.8 kg m s2
JT4
(6.37) (52.08 (52.08 (78.12 (78.12
Wrist Rated
0.88 kg m s 2 7.2 kg m s2 7.2 kg m s 2 10.8 kg m s2 10.8 kg m s2
Moment of JT5
(6.37) (52.08 (52.08 (78.12 (78.12
Inertia
0.25 kg m s 2 3.3 kg m s2 3.3 kg m s 2 5.0 kg m s 2 5.0 kg m s 2
JT6
(1.81 ) (23.87 ) (23.87 ) (36.17 ) (36.17 )
Repeatability (in.) ±0.1 (0.004) ±0.15 (0.006 ±0.15 (0.006 ±0.15 (0.006 ±0.15 (0.006

JT1 2.1 kw (2.82) 4.2 kw (5.63) 4.2 kw (5.63) 4.2 kw (5.63) 4.2 kw (5.63)

JT2 2.1 kw (2.82) 4.2 kw (5.63) 4.2 kw (5.63) 4.2 kw (5.63) 4.2 kw (5.63)

JT3 1.0 kw (1.34) 3.1 kw (4.16) 3.1 kw (4.16) 3.1 kw (4.16) 3.1 kw (4.16)
Drive
JT4 200 w (0.27) 475 w (0.64) 475 w (0.64) 475 w (0.64) 475 w (0.64)
Source (hp
JT5 200 w (0.27) 475 w (0.64) 475 w (0.64) 475 w (0.64) 475 w (0.64)

JT6 200 w (0.27) 475 w (0.64) 475 w (0.64) 475 w (0.64) 475 w (0.64)

JT7 2.5 kw (3.35) 2.5 kw (3.35) 2.5 kw (3.35) 2.5 kw (3.35) 2.5 kw (3.35)
Weigh 6
210 kg (463 580 kg (1279) 540 kg (1191) 540 kg (1191) 550 kg (1213)
(lbs.) Axes

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 Kawasak C SERIES CONTROLLER
INSTALLATION MANUAL

INTRODUCTION

Table I-1 Robot Specifications (Continued)

ROBOT MODEL UT100 UT120 UT150 UX70 UX100

Number of Axes 6 (7)* 6 (7)* 6 (7)* 6 (7)* 6 (7)*

JT1 120°/sec 120°/sec 100°/sec 120°/sec 120°/sec

JT2 100°/sec 100°/sec 90°/sec 120°/sec 120°/sec

JT3 120°/sec 120°/sec 100°/sec 120°/sec 120°/sec

Maximum JT4 150°/sec 150°/sec 125°/sec 150°/sec 150°/sec
Velocity
JT5 150°/sec 150°/sec 125°/sec 150°/sec 150°/sec

JT6 240°/sec 240°/sec 200°/sec 200°/sec 240°/sec

1000 mm/sec 1000 mm/sec 1000 mm/sec 1000 mm/sec 1000 mm/sec
JT7
(39.37) (39.37) (39.37) (39.37) (39.37)
Maximum Linear 2400 mm/sec 2400 mm/sec 2400 mm/sec 2400 mm/sec 2400 mm/sec
Tool Tip Speed (94.49) (94.49) (94.49) (94.49) (94.49)
JT1 ±180° ±180° ±180° ±180° ±180°

JT2 +55°/-80° +55°/-80° +55°/-80° +70°/-65° +70°/-65°

JT3 +95°/-105° +95°/-105° +95°/-105° +90°/-119° +90°/-119°

Work
Envelope JT4 ±280° ±280° ±280° ±280° ±280°
(Stroke)
JT5 ±125° ±125° ±125° ±125° ±125°

JT6 ±360° ±360° ±360° ±360° ±360°

Custom Custom Custom Custom Custom
JT7 Lengths Lengths Lengths Lengths Lengths
Max. Payload (lbs.) 100 (220) 120 (264) 150 (330) 70 (154) 100 (220)

JT4 539 N m (398) 686 N m (506) 833 N m (615) 490 N m (362) 539 N m (398)
Wrist Rated
Torque JT5 539 N m (398) 686 N m (506) 833 N m (615) 490 N m (362) 539 N m (398)
(ft. lbs.)
JT6 343 N m (253) 392 N m (289) 441 N m (325) 294 N m (217) 343 N m (253)
4.0 kg m s 2 5.0 kg m s 2 7.3 kg m s 2 5.0 kg m s 2 4.0 kg m s 2
JT4
(28.92) (36.15) (52.78) (36.15) (28.92)
Wrist Rated
4.5 kg m s 2 5.5 kg m s 2 7.3 kg m s 2 5.5 kg m s 2 4.5 kg m s 2
Moment of JT5
(32.54) (39.77) (52.78) (39.77) (32.54)
Inertia
2.5 kg m s 2 2.8 kg m s 2 3.2 kg m s 2 2.8 kg m s 2 2.5 kg m s 2
JT6
(18.08) (20.24) (23.14) (20.24) (18.08)
Repeatability (in.) ±0.5mm (0.20) ±0.5mm (0.20) ±0.5mm (0.20) ±0.5mm (0.20) ±0.5mm (0.20)

JT1 5.0 kw (6.7) 5.0 kw (6.7) 5.0 kw (6.7) 5.0 kw (6.7) 5.0 kw (6.7)

JT2 5.0 kw (6.7) 5.0 kw (6.7) 5.0 kw (6.7) 5.0 kw (6.7) 5.0 kw (6.7)

JT3 5.0 kw (6.7) 5.0 kw (6.7) 5.0 kw (6.7) 5.0 kw (6.7) 5.0 kw (6.7)
Drive
JT4 2.5 kw (3.35) 2.5 kw (3.35) 2.5 kw (3.35) 2.5 kw (3.35) 2.5 kw (3.35)
Source (hp)
JT5 2.5 kw (3.35) 2.5 kw (3.35) 2.5 kw (3.35) 2.5 kw (3.35) 2.5 kw (3.35)

JT6 2.5 kw (3.35) 2.5 kw (3.35) 2.5 kw (3.35) 2.5 kw (3.35) 2.5 kw (3.35)

JT7 2.5 kw (3.35) 2.5 kw (3.35) 2.5 kw (3.35) 2.5 kw (3.35) 2.5 kw (3.35)
Weight 6 1500 kg 1500 kg 1500 kg 1430 kg 1400 kg
(lbs.) Axes (3300) (3300) (3300) (3150) (3080)

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INTRODUCTION

Table I-1 Robot Specifications (Continued)

ROBOT MODEL UX120 UX150 UX200 UX300 UZ100 UZ120

Number of Axes 6 (7)* 6 (7)* 6 (7)* 6 (7)* 6 (7)* 6 (7)*

JT1 120°/sec 100°/sec 100°/sec 100°/sec 120°/sec 120°/sec

JT2 120°/sec 100°/sec 90°/sec 80°/sec 100°/sec 100°/sec

JT3 120°/sec 100°/sec 90°/sec 68°/sec 110°/sec 110°/sec

Maximum JT4 150°/sec 125°/sec 120°/sec 80°/sec 150°/sec 150°/sec
Velocity
JT5 150°/sec 125°/sec 110°/sec 70°/sec 150°/sec 150°/sec

JT6 240°/sec 200°/sec 200°/sec 135°/sec 240°/sec 240°/sec

1000 mm/sec 1000 mm/sec 1000 mm/sec 1000 mm/sec 1000 mm/sec 1000 mm/sec
JT7
(39.37) (39.37) (39.37) (39.37) (39.37) (39.37)
Maximum Linear 2400 mm/sec 2400 mm/sec 2400 mm/sec 2400 mm/sec 2400 mm/sec 2400 mm/sec
Tool Tip Speed (94.49) (94.49) (94.49) (94.49) (94.49) (94.49)
JT1 ±180° ±180° ±180° ±180° ±180° ±180°

JT2 +70°/-65° +70°/-65° +70°/-65° +70°/-60° +70°/-75° +70°/-75°

JT3 +90°/-119° +90°/-119° +90°/-119° +90°/-126° +283°/-105° +283°/-105°

Work
Envelope JT4 ±280° ±280° ±280° ±280° ±280° ±280°
(Stroke)
JT5 ±125° ±125° ±125° ±120° ±125° ±125°

JT6 ±360° ±360° ±360° ±360° ±360° ±360°

JT7 Custom Custom Custom Custom Custom Custom

Lengths Lengths Lengths Lengths Lengths Lengths
Max. Payload (lbs.) 120 (264 150 (330 200 (440 300 (660 100 (220 120 (264
1176 N m 1626 N m
JT4 686 N m (506) 833 N m (615) 539 N m (398) 686 N m (506)
(868) (1201)
Wrist Rated
Torque 1176 N m 1626 N m
JT5 686 N m (506) 833 N m (615) 539 N m (398) 686 N m (506)
(ft. lbs.) (868) (1201)
JT6 392 N m (289) 441 N m (325) 686 N m (506) 715 N m (528) 343 N m (253) 392 N m (289)
5.0 kg m s2 7.3 kg m s2 12.7 kg m s 2 13.7 kg m s 2 5.2 kg m s2 6.3 kg m s2
JT4
(36.15) (52.78) (91.82) (99.05) (37.56) (45.55)
Wrist Rated
5.5 kg m s2 7.3 kg m s2 12.7 kg m s 2 13.7 kg m s 2 5.2 kg m s2 6.3 kg m s2
Moment of JT5
(39.77) (52.78) (91.82) (99.05) (37.56) (45.55)
Inertia
2.8 kg m s 2 3.2 kg m s2 7.9 kg m s 2 7.4 kg m s2 2.8 kg m s2 3.0 kg m s 2
JT6
(20.24) (23.14) (57.12) (53.50) (20.24) (21.69)
Repeatability (in.) ±0.5mm (0.20) ±0.5mm (0.20) ±0.5mm (0.20) ±0.5mm (0.20) ±0.3mm (0.12) ±0.3mm (0.12)

JT1 5.0 kw (6.7) 5.0 kw (6.7) 5.0 kw (6.7) 5.0 kw (6.7) 5.0 kw (6.7) 5.0 kw (6.7)

JT2 5.0 kw (6.7) 5.0 kw (6.7) 5.0 kw (6.7) 5.0 kw (6.7) 5.0 kw (6.7) 5.0 kw (6.7)

JT3 5.0 kw (6.7) 5.0 kw (6.7) 5.0 kw (6.7) 5.0 kw (6.7) 5.0 kw (6.7) 5.0 kw (6.7)
Drive
JT4 2.5 kw (3.35) 2.5 kw (3.35) 2.5 kw (3.35) 2.5 kw (3.35) 2.5 kw (3.35) 2.5 kw (3.35)
Source (hp)
JT5 2.5 kw (3.35) 2.5 kw (3.35) 2.5 kw (3.35) 2.5 kw (3.35) 2.5 kw (3.35) 2.5 kw (3.35)

JT6 2.5 kw (3.35) 2.5 kw (3.35) 2.5 kw (3.35) 2.5 kw (3.35) 2.5 kw (3.35) 2.5 kw (3.35)

JT7 2.5 kw (3.35) 2.5 kw (3.35) 2.5 kw (3.35) 2.5 kw (3.35) 2.5 kw (3.35) 2.5 kw (3.35)
Weight 6 1400 kg 1500 kg 1550 kg 1700 kg 1400 kg 1400 kg
(lbs.) Axes (3080) (3300) (3410) (3740) (3080) (3080)

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Table I-1 Robot Specifications (Continued)

ROBOT MODEL UZ150

Number of Axes 6 (7)*

JT1 100°/sec

JT2 100°/sec

JT3 100°/sec
Maximum JT4 125°/sec
Velocity
JT5 125°/sec

JT6 200°/sec
1000 mm/sec
JT7
(39.37
Maximum Linear 2400 mm/sec
Tool Tip Speed (94.49
JT1 ±180°

JT2 +70°/-75°

JT3 +283°/-105°
Work
Envelope JT4 ±280°
(Stroke
JT5 ±125°

JT6 ±360°

JT7 Custom
Lengths
Max. Payload (lbs.) 150 (330

JT4 833 N m (615

Wrist Rated
Torque JT5 833 N m (615
(ft. lbs.)
JT6 441 N m (325
7.3 kg m s 2
JT4
(52.78
Wrist Rated
7.3 kg m s 2
Moment of JT5
(52.78
Inertia
3.2 kg m s 2
JT6
(23.14
Repeatability (in.) ±0.3mm (0.12

JT1 5.0 kw (6.7)

JT2 5.0 kw (6.7)

JT3 5.0 kw (6.7)

Drive
JT4 2.5 kw (3.35
Source (hp)
JT5 2.5 kw (3.35

JT6 2.5 kw (3.35

JT7 2.5 kw (3.35

Weight 6 1400 kg
(lbs.) Axes (3080

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I.2 ROBOT CONTROLLER

The Kawasaki C controller consists of printed circuit boards, multi function panel or
small teach pendant, optional interface panel, and servo amplifiers. The controller is
available in three versions; standard, North American, and European. Table I-2 lists the
controller type (Cxx) and revision code (A00x) for the various robot models.

Table I-2 Robot Controller Versions

C Controller Model & Revision Code

Standard N. American European
Robot Model Specification Specification Specification

EE10 C43 A001

FA06E C11, C50 C30 C40

FA06L C11, C50 C30 C40

FA06N C11, C50 C30 C40

FA20N C11, C50 C30 C40

FC06N C11, C50 C30 C40

FS06L C11, C50 C30 C40

FS06N C11, C50 C30 C40

FS10C C11, C50 C30 C40

FS10E C11, C50 C30 C40

FS10L C11, C50 C30 C40

FS20C C11, C50 C30 C40

FS20N C11, C50 C30 C40

FS30L C20, C51 C31 C41

FS30N C20, C51 C31 C41

FS45C C20, C51 C31 C41

FS45N C20, C51 C31 C41

FW06N C20, C51 C31 C41

UD C22

UT/UX/UZ
C21 C32 A001 C42 A001
100~150

UX200~300 C21 C32 A002 C42 A002

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I.2.1 ROBOT CONTROLLER DESIGN SPECIFICATIONS

Control System: 32 bit RISC main CPU

32 bit RISC CPU for multi function panel unit
32 bit RISC servo CPU controller (one per 3 axes)
Software controlled AC servo drive system using PWM
(pulse width modulation) circuitry.

Number of Axes: 6 standard; 7th optional

Motion Control: Teach mode - Joint

Base
Tool

Repeat mode - Joint move

Linear move
Circular move (optional)
FLIN move (optional)

Memory: CMOS RAM

Memory Capacity: Standard - 1024 KB (approx. 4,000 steps)

Optional - 4096 KB (approx. 34,000 steps)

Accuracy: Four levels of accuracy for block step programs

F-series
Adjustable between 0.1 mm - 5,000 mm

UT/UX-series
Adjustable between 0.5 mm - 5,000 mm

UZ-series
Adjustable between 0.3 mm - 5,000 mm

Speed: 10 levels of speed for block step programs

(adjustable between 0% - 100%)

Data Editing: Step insertion and deletion, and rewriting of auxiliary and
positional data.

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Software Features: Continuous path motion control - CP ON/OFF

Time delays
Coordinate modification
Process control programs (3)
Peripheral equipment control
Interrupt signal control
Error interrupt control
Input of real, string, and integer variables
Local variables
Subroutine calls with arguments (maximum stack = 20)
Program weld schedules
Servo shutdown timer
Auto start function

I/O Signals: 1GW I/O board 32 inputs/32 outputs (128 maximum)

(including dedicated signals)
Robot internal 256

1FS RI/O board (option)

Robot I/O 256 I/O (including dedicated signals)
Robot internal 256
A-B PLC 64 I/O
Weld controller 32 I/O
Non-retentive 128
Retentive 16
Timers 16
Counters 16
Message display 64
Slogic status 16

Control Net (option)

Dedicated Signals: Outputs - Motor power ON

Error occurrence
Automatic
CYCLE_START
Teach mode
HOME1
HOME2
Power ON
RGSO
External program select (RPS) enabled

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Dedicated Signals: Inputs - External motor power ON,

External error reset
External cycle start
External program select start (JUMP)
JUMP_ON
JUMP_OFF
JUMP_ST
External program select start (RPS)
RPS_ON
RPS_ST
Number of RPS code signal
First signal number of RPS code
Program reset
External Hold (EXT_IT)
External condition wait (EXT_WAIT)
External slow repeat mode

Error Messages: Error code messages, self-diagnosis, error logging, opera-

tion logging

Special Features: Program check mode

Adjustable hard stops - F-series JT1, JT2, JT3
U-series JT1
Terminal box on robot arm (optional)
Robot application interface panel (optional)
Overtravel limit switch - JT1 (JT2, JT3 option)
Power lockout
Ethernet (option)

Multi Function Panel: Deadman safety switches

8 inch color LCD
Touch panel
Teach-lock function
Emergency stop switch
Pen for touch panel
PC card insertion section

Small Teach Pendant: Deadman safety switches

(option) Teach-lock function
Emergency stop switch
Membrane switch keypad
Alphanumeric LCD

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Supplemental
Data Storage: PC SRAM Memory Card, 2 or 4 MB, PCMCIA 2.1 Slot
Floppy disk drive (option)
Personal computer (option)

Power Requirements: Standard Spec.: 3-phase 200/220 VAC

N. American Spec.: 3-phase 400/440/460/480/515/575 VAC

European Spec.: 3-phase 380/400/415/440/460/480 VAC

Tolerance: +/- 10%

Frequency: 50/60 Hz

Rated Load: 10.5 kVA

Ground: less than 100 ohm ground line sepa

rated from welder power ground

Dimensions: Standard Spec.: W x D x H, 460.8mm x 430mm x

1240mm (inches: 18.1 x 16.9 x 48.8)

N. American Spec.: WxDxH, 550mm x 500mm x 1150mm

(inches: 21.7 x 19.7 x 45.3)

European Spec.: WxDxH, 550mm x 500mm x 1150mm

(inches: 21.7 x 19.7 x 45.3)

Weight: Standard Spec.: approx. 80 kg (176 lbs)

N. American Spec.: 250 kg (550 lbs)

European Spec.: 250 kg (550 lbs)

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“EMERGENCY STOP” switch “TEACH LOCK” switch

ON OFF

TEACH LOC
K
“Trigger” switch “Trigger” switch

Liquid Crystal Display

Pen only for touch panel

PC card insertion cover Contrast adjustment volume

Figure I-1 Multi Function Panel (All C-Series Controllers)

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INTRODUCTION

“TEACH LOCK” switch “EMERGENCY STOP” switch

Liquid crystal display

Trigger key
Jog key

Figure I-2 Small Teach Pendant (All C-Series Controllers)

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INTRODUCTION

1.2.2 C CONTROLLER INSTALLATION PLANNING

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SAFETY

1.0 SAFETY ............................................................................................................ 1-2

1.1 Introduction ....................................................................................................... 1-2
1.2 Safety Conventions and Symbology .................................................................. 1-3
1.2.1 Warning/Caution Symbols ................................................................................. 1-3
1.3 Safety Categories .............................................................................................. 1-4
1.3.1 Personal Safety ................................................................................................. 1-4
1.3.2 Safety During Operation .................................................................................... 1-6
1.3.3 Safety During Programming .............................................................................. 1-7
1.3.4 Safety During Inspection and Maintenance....................................................... 1-8
1.4 Safety Features ................................................................................................. 1-9
1.5 Work Envelope Drawings ................................................................................ 1-10

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SAFETY

1.0 SAFETY

1.1 INTRODUCTION

Safety is an important consideration in the use of automated and robotic equipment in

the industrial environment. All operators, maintenance personnel, and programmers
must be aware of all automated equipment, peripheral and robotic equipment that
occupies the work cell, and their associated operational and maintenance procedures.
For this reason it is recommended that all personnel who operate, maintain, and pro-
gram Kawasaki robots, attend a Kawasaki approved training course that would be perti-
nent to each employee’s specific job responsibilities.

The following safety sections in this text are designed to support and augment existing
safety guidelines that may be in use in your plant, and/or are provided by municipal,
state, or federal governments, but are NOT designed to supplant or supersede any
existing rules, regulations, or guidelines that may be in use. Because safety is the
primary responsibility of the user, owner, and/or employer, Kawasaki recommends that
specific safety guidelines and recommendations be adopted from groups or individuals
that are professionals in safety design and implementation.

Two recommended sources for national and federal safety laws and regulations include:

1. OCCUPATIONAL SAFETY AND HEALTH STANDARDS, available from the Depart-

ment of Labor, Washington, D.C.

2. AMERICAN NATIONAL STANDARD FOR INDUSTRIAL ROBOTS AND ROBOT

SYSTEMS-SAFETY REQUIREMENTS (ANSI/RIA R15.06-1992), available from the
American National Standards Institute, Inc. 1430 Broadway, New York, New York 10018

All safety related issues and descriptions, either presented in written or oral form from
any representative of Kawasaki Robotics (USA), Inc., are intended to provide general
safety precautions and procedures and, therefore, are not intended to provide all safety
measures necessary for the protection of all personnel in the work environment.

Kawasaki robots are considered safe for use in industrial environments when all safety
guidelines are adhered to. Adherence to the safety guidelines for safe robot operation
and the protection of personnel and equipment is the responsibility of the end user.

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1.2 SAFETY CONVENTIONS AND SYMBOLOGY

1.2.1 WARNING/CAUTION SYMBOLS

The following symbol is present in all Kawasaki Robotics (USA), Inc. documentation to
signify to the user that proper guidelines, as set forth in the text, are designed to provide
pertinent information for the protection of personnel:

! WARNING
This warning symbology is used in all Kawasaki Robot-
ics (USA), Inc. documentation to identify processes or
procedures, that if not followed properly, may result in
serious injury or death to personnel.

The following symbol is present in all Kawasaki Robotics (USA), Inc. documentation to
signify to the user that proper guidelines as set forth, are designed to provide pertinent
information for the protection of robotic related equipment:

! CAUTION
This caution symbology is used in all Kawasaki Robot-
ics (USA), Inc. documentation to identify processes or
procedures, that if not followed properly, may result in
damage to robotic or peripheral equipment.

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1.3 SAFETY CATEGORIES

Personnel safety can be described in one of four categories:

• Personal safety

• Safety during operation

• Safety during programming

• Safety during inspection and maintenance

A description of each follows in this section.

1.3.1 PERSONAL SAFETY

Safety procedures must be an integral part of operational procedures for the operator,
programmer, and maintenance person. These procedures must be followed explicitly
and on a regular basis. If consistent safety procedures are followed on a daily basis,
they should become a regular part of everyday operational procedures which are de-
signed to protect the user. Some guidelines are presented in brief in the following
section:

• Before operating or maintaining the robot or robot controller, be sure you fully un-
derstand and comprehend all maintenance, operating, and programming proce-
dures, and ensure that all safety related precautions are taken and complied with
before these procedures are attempted.

• Avoid wearing loose clothing, scarves, wrist watches, rings, and jewelry when
working on the controller and robot. It is also recommended that if ties must be
worn in your shop environment that they be the clip-on variety rather than tied ties.

• Always wear safety glasses or goggles and approved safety shoes for your shop
conditions. Follow all applicable OSHA, NIOSHA, MHSA, local, state, federal, and
plant safety specifications and procedures.

• Know the entire work cell or area that the robot occupies.

• Be aware of the entire work envelope of the robot and any peripheral devices.

• Locate all emergency stop buttons or switches.

• Avoid trap points in which personnel could become trapped between a moving
device and any stationary devices.

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• Personnel should never enter the work envelope during automatic operations.

• Ensure that all personnel are clear of the work envelope before initiating any motion
commands for the robot.

• Before initiating any motion commands, KNOW beforehand how the robot will per-
form when that command is given.

• Be sure that the entire work area is free of any debris, tools, fixturing, lubricants,
and cleaning equipment before operation of the robot is attempted.

• If any personnel observe unsafe working conditions, report them immediately to

your supervisor or plant safety coordinator.

• All personnel should identify by name and function all switches, indicators, and
control signals that could initiate robot motion.

• Never defeat, render useless, jumper out, or bypass any safety related device,
whether mechanical or electrical in design.

• All safety devices approved for use in your plant must be properly installed and
maintained to ensure personnel safety.

• NEVER attempt to stop or brake the robot during operation with your body or per-
son.

• Utilize E-stops to stop robot motion in emergency situations only.

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SAFETY

1.3.2 SAFETY DURING OPERATION

• During operation of the robot, identify the maximum reach of the robot in all direc-
tions, which is referred to as the work envelope.

• Always keep your work area clean and free of any debris which includes, but is not
limited to, oil, water, tool, fixturing, electronic test equipment, etc.

• During operations that involve the teach pendant, the only person allowed in the
work envelope is the teacher, or the person operating the teach pendant. The teach
pendant has provisions to protect the operator. These safety provisions include an
E-stop, trigger switch, and deadman switch.

• Never block the operator’s path of retreat.

• During the teach operation of the robot always have a path of retreat planned.

• AVOID pinch points.

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1.3.3 SAFETY DURING PROGRAMMING

• During operation of the robot, be sure you are able to identify the maximum reach
of the robot in all directions, which is referred to as the work envelope.

• During teach operations the only person allowed in the work envelope is the
teacher, or the person operating the teach pendant. The teach pendant has provi-
sions to protect the operator including E-stop, trigger switch, and deadman switch.

• AVOID pinch points.

• During point-to-point playback operations, be aware that the robot is only cognizant
of its present location and the next point it is requested to move to. It will execute
this move with total disregard to what may lie in its path when the move is executed.

• Playback accuracy and speed can affect the geometry of the path coordinates.
Therefore, when changing accuracy or speed, always test run the program at a slow
speed or point-to-point mode before attempting the continuous path operation in the
repeat mode.

• ALWAYS test run a new path program at a reduced speed or in point-to-point mode
prior to attempting a high-speed playback operation in the repeat mode.

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1.3.4 SAFETY DURING INSPECTION AND MAINTENANCE

Before entering the work envelope to perform either inspection or maintenance proce-
dures, turn off three-phase power on the disconnect and tag and lockout the disconnect
switch.

! WARNING
The input side (top) of the controller disconnect may still
be live when the controller disconnect is turned OFF. If
work is to be performed at the controller disconnect
switch, turn OFF the three-phase power at the source,
and tag and lockout the source disconnect.

• When removing an axis motor, be aware that the axis will fall if left unsupported.
The brake assembly is in the servo drive motor, therefore, the axis of the robot will
be unsupported if removed.

• When using the axis brake release switches in the controller, be aware that the axis
may fall if left unsupported.

• Before working on pneumatic or high pressure water supplies, turn off supply pres-
sure and purge all lines to remove any residual pressure.

• Assign only qualified personnel to perform all maintenance procedures.

• Consult all available documentation before attempting any repair or service proce-
dures.

• Use only replacement parts approved by Kawasaki Robotics (USA), Inc.

• Before attempting to adjust or repair a device in the robot controller that may have
yellow interlock control circuit wires attached, locate the source of the power and
remove it by disconnecting the appropriate disconnect at its source.

• During inspection and maintenance procedures, if your installation is equipped with

safety fences and safety plugs, remove and hold the safety plug while performing
these operations. In addition, the safety procedures outlined above should be
adhered to.

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SAFETY

1.4 SAFETY FEATURES

To safeguard the user, the Kawasaki robot system is equipped with many safety fea-
tures. Some of these safety items include:

• All E-stops are hard-wired.

• The MFP, small teach pendant, and operation panel are equipped with red mush-
room-type detented E-stop push buttons. If an optional interface panel is installed,
the E-stop from the operation panel is relocated to the optional interface panel.

• Robot velocities are constantly monitored by software. Should an over-velocity

condition be detected, the robot will fault in a velocity error condition.

• Teach velocities and check mode velocities are limited to a maximum of 250 mm/
sec (9.84 in/sec).

• JT1 is equipped with overtravel limit switches (JT2, JT3 are optional).

• All robot axes have software limits.

• All U and F-series mechanical units have overtravel hardstops on the JT1, JT2,
JT3, and JT5 axes.

• All robot axes are monitored by the robot controller for velocity and deviation errors.

• All robot axes are equipped with 24 VDC electromechanical brakes. Should the
robot lose line power, the robot arm will not drop because the brakes are engaged
when power is off at the robot controller.

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1.5 WORK ENVELOPE DRAWINGS
Figure 1-1 FA06L Work Envelope
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SAFETY
Figure 1-2 FA06N Work Envelope
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Figure 1-3 FS06L Work Envelope
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Figure 1-4 FS06N, FS10C Work Envelope
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Figure 1-5 FS10E Work Envelope
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SAFETY
Figure 1-6 FS10L Work Envelope
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Figure 1-7 FS10N Work Envelope
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Figure 1-8 FA20N Work Envelope
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Figure 1-9 FP20N Work Envelope
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SAFETY
Figure 1-10 FS20C Work Envelope
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Figure 1-11 FS20N Work Envelope
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SAFETY
Figure 1-12 FS30L Work Envelope
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Figure 1-13 FS30N, FS45C Work Envelope
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Figure 1-14 FS45N Work Envelope
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Figure 1-15 UT-Series Work Envelope
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SAFETY
Figure 1-16 UX70 Work Envelope
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Figure 1-17 UX100/120/150 Work Envelope
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Figure 1-18 UX200 Work Envelope
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Figure 1-19 UX300 Work Envelope
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Figure 1-20 UZ100/200/150 Work Envelope
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UNCRATING AND UNPACKING PROCEDURES

2.0 UNCRATING AND UNPACKING PROCEDURES ............................................. 2-2

2.1 Kawasaki Robotics Standard Packing ............................................................... 2-2
2.1.1 Robot Controller with Robot Standard Packing ................................................. 2-2
2.1.2 Controller Standard Packing .............................................................................. 2-3
2.2 Robot Controller Uncrating and Unpacking Procedures .................................... 2-4
2.2.1 Standard Packaging .......................................................................................... 2-4
2.2.2 Modified Packaging ........................................................................................... 2-5

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UNCRATING AND UNPACKING PROCEDURES

2.0 UNCRATING AND UNPACKING PROCEDURES

C-series controllers are shipped seperate from the mechanical unit in a wooden con-
tainer from the factory. Prior to starting the unpacking procedure, retain all shipping
invoices and other documentation shipped with the robot controller.

2.1 KAWASAKI ROBOTICS STANDARD PACKING

2.1.1 ROBOT CONTROLLER WITH ROBOT STANDARD PACKING

The controller is braced on the skid with wooden beams, and the entire controller is
covered with plasticized/aluminized foil to protect it from moisture, dust, and humidity.

Figure 2-1 Kawasaki Robot C Controller With Robot Standard Packing

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UNCRATING AND UNPACKING PROCEDURES

2.1.2 CONTROLLER STANDARD PACKING

The controller is braced in the container with wooden supports on the bottom and sides.
The upper portion of the container is packed with bubble wrap sheets and corrugated
paper. See figure 2-2, Kawasaki C Controller Standard Packing.

Figure 2-2 Kawasaki C Controller Standard Packing

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UNCRATING AND UNPACKING PROCEDURES

2.2 ROBOT CONTROLLER UNCRATING AND UNPACKING PROCEDURES

! WARNING
Extreme care should be used in the removal of the top
and sides of the crate. Contact between nails and
power saws should be avoided, as injury could result
from unexpected saw movements.

2.2.1 STANDARD PACKAGING

1. Prior to unpacking the robot controller, use a pry bar to partially open an upper
corner of the container, see figure 2-3, Location of Inspection Opening. Use a flash
light to observe the placement of the controller in the container. Note the location of
the supports and packing material.

Open Here

Figure 2-3 Location of Inspection Opening

2. Check the distance between robot controller and the top and sides of packaging
container prior to performing the following steps.

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UNCRATING AND UNPACKING PROCEDURES

3. Pry the front of container loose and place aside.

4. Remove the top of container and place aside.

5. Remove remaining sides and discard all scrap material.

6. Ensure controller is in a stable position prior to lifting the controller off the remaining
portion of shipping container.

2.2.2 MODIFIED PACKAGING

1. Prior to unpacking the robot controller, inspect the position of the controller on the
pallet. It is secured to the pallet with plastic straps in the upright position. Ensure the
controller is in a stable position prior to removal of the plastic straps. Cut the plastic
strapping and remove foil covering (not shown). Figure 2-5 illustrates the modified
shipping pallet.

The controller can be lifted with an overhead crane, high/low, or movable crane.

2. Lift the controller from its pallet and place in desired location. Refer to unit 3,
Rigging/Lifting/Moving for lifting procedures.

Figure 2-4 Modified Controller Shipping Pallet

April 26, 1999 2-5

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INSTALLATION MANUAL

RIGGING/LIFTING/MOVING INSTRUCTIONS

3.0 RIGGING/LIFTING/MOVING INSTRUCTIONS ................................................. 3-2

3.1 Lifting the C30 Controller ................................................................................... 3-2
3.2 Moving Controller on Casters............................................................................. 3-3

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INSTALLATION MANUAL

RIGGING/LIFTING/MOVING INSTRUCTIONS

3.0 RIGGING/LIFTING/MOVING INSTRUCTIONS

3.1 LIFTING THE C30 CONTROLLER

• The equipment used to lift the controller must have a minimum capacity of 250kg.
or 551.25 lb.

• The lifting sling is attached to the two eye-bolts on the top of the controller.

Lifting Sling

Lifting fixture

Shipping pallet

Figure 3-1 Lifting C30 Type Controllers

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INSTALLATION MANUAL

RIGGING/LIFTING/MOVING INSTRUCTIONS

3.2 MOVING CONTROLLER ON CASTERS

• Ensure pathway is free of hazards.

• Release brakes on two forward casters (lower front controller frame).

• Move controller with all casters installed and contacting solid flooring.

• Avoid movement over inclines or rough surfaces.

• Lock brakes on two forward casters when movement is complete.

! CAUTION
Inclines greater than 15 degrees forward or rearward
will cause controller to fall over. Inclines greater than 10
degrees to the side will cause controller to fall over.

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INSTALLATION MANUAL

INSTALLATION OF ROBOT CONTROLLER

4.0 INSTALLATION OF ROBOT CONTROLLER ...................................................... 4-2

4.1 Positioning Robot Controller ................................................................................. 4-3
4.2 C30 Controller Permanent Mounting Procedure .................................................. 4-4

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 Kawasak C SERIES CONTROLLER
INSTALLATION MANUAL

INSTALLATION OF ROBOT CONTROLLER

4.0 INSTALLATION OF ROBOT CONTROLLER

Prior to bolting down the robot controller and robot to the base plate, ensure that the
manufacturer’s number (numeric digits) on the mechanical unit and the serial number on
the robot controller match, as illustrated in figure 4-1, Robot Controller and Robot
Manufacturer’s Data Plates. This is very important because the factory performs preci-
sion zeroing on each robot it manufactures and therefore, it is imperative that the corre-
sponding robot controller and its mechanical unit are matched as a pair.

Kawasaki Robot
Model: UX120FC32. Supply Voltage AC460 V
Phase 3
Dwg. No.
Frequency 60 Hz
Mfg. No. L2076
Full-load Current 14 A
Mfd. in 1999 Interrupting Capacity 14 KA
Largest Load 14 A
MFD. BY
KAWASAKI MOTORS MANUFACTURING CORP., U.S.A.
LINCOLN NEBRASKA

Robot Controller Manufacturer's Data Plate

THESE TWO MFG.

NUMBERS
MUST MATCH

Kawasaki Robot
Type UX120FC32.

Mfg. No. L2076 R0S1S

KAWASAKI
HEAVY INDUSTRIES, LTD.

ROBOT DIVISION MADE IN JAPAN

Robot Mechanical Unit Manufacturer's Data Plate

Figure 4-1 Robot Controller and Robot Manufacturer’s Data Plates

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INSTALLATION MANUAL

INSTALLATION OF ROBOT CONTROLLER

4.1 POSITIONING ROBOT CONTROLLER

When positioning the robot controller, the installer must ensure that the robot wire har-
ness cables are laying flat, are not kinked or twisted, and are protected from debris and
water, preferably in a wire tray or conduit as local codes specify.

Placement of the controller is also important for controller cooling. The exhaust ports are
located on the back of the controller with the air inlets on the bottom. When installing the
controller, provide a minimum of 200 millimeters between the controller’s back and right
side and any wall. Also provide a minimum of 100 millimeters from its left side and any
wall. Once the robot controller has been positioned, it can be permanently fixed using
mounting bolts (M8) for attachment to anchor fixtures.

Figure 4-2 Installation Wall Clearance

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 Kawasak C SERIES CONTROLLER
INSTALLATION MANUAL

INSTALLATION OF ROBOT CONTROLLER

4.2 C30 CONTROLLER PERMANENT MOUNTING PROCEDURE

Once the robot controller has been positioned, it can be permanently fixed to the floor
surface. Two permanently fixed nuts are located on the lower right side in the controller
cabinet. These nuts accept M12 bolts having a 1.75 mm thread pitch. See figure 4-3 for
location of mounting bolt holes.

Controller right side, low

Bolt hole locations

Figure 4-3 C30 Controller Mounting

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INSTALLATION MANUAL

USER INTERFACE CONNECTIONS

5.0 USER INTERFACE CONNECTIONS ................................................................... 5-2

5.1 User Interface Connections C30 Controller ......................................................... 5-2

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USER INTERFACE CONNECTIONS

5.0 USER INTERFACE CONNECTIONS

5.1 USER INTERFACE CONNECTIONS C30 CONTROLLER

Locate and remove interface from packaging. Insert interface wire harness connector
into plug. The multi function panel or small teach pendant is connected to the receptacle
located on the switch panel of the robot controller. Ensure outer lock ring is rotated fully
clockwise and in the locked position prior to operation of interface. See figure 5-1, Inter-
face Connections C30 Controllers.

Figure 5-1 Interface Connections C30 Controllers

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INSTALLATION MANUAL

WIRING INSTRUCTIONS

6.0 WIRING INSTRUCTIONS ................................................................................. 6-2

6.1 Wiring Instructions for Power Supply ................................................................. 6-2
6.1.1 Connection of Primary Power, C30 Type Controller .......................................... 6-2
6.1.2 Preparation and Confirmation of Incoming Power ............................................. 6-3
6.2 Wiring Instructions Between Controller and Mechanical Unit ........................... 6-4
6.2.1 Harness Connections To the Mechanical Unit ................................................... 6-4
6.3 C30 Controller ................................................................................................... 6-6
6.4 UD100 Sensor Cable Connection (Optional) .................................................... 6-7
6.4.1 UD100 (Handling Specifications) ...................................................................... 6-8
6.4.2 Limit and Proximity Switch Connections UD100 and F Series .......................... 6-9
6.4.3 Sensor Wiring Diagrams ................................................................................. 6-11
6.4.4 Solenoid Valve Wiring Diagram (Handling Specification) ................................ 6-12

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WIRING INSTRUCTIONS

6.0 WIRING INSTRUCTIONS

6.1 WIRING INSTRUCTIONS FOR POWER SUPPLY

Refer to table 6-1 for primary power supply wire specifications.

Table 6-1 Wire Specifications (Primary Power)

Model Power Supply Capacity Recommended Harness size

U-Series 10KVA 8.0mm2 or more (#8AWG)
UD-Series 10KVA 8.0mm2 or more (#8AWG)
FS/FA06, 20, & FS10 5KVA 3.5mm2 or more(#12AWG)
FS30 & 45 10KVA 8.0mm2 or more (#8AWG)

6.1.1 CONNECTION OF PRIMARY POWER, C30 TYPE CONTROLLER

1. Ensure that the circuit breaker is in the OFF position.

2. The incoming power wire is routed into the controller.

3. Connect the individual wires to the upper terminals of the circuit breaker. The circuit
breaker is not phase sensitive and power wires may be connected to any power
terminal.

4. Connect the ground wire to the grounding terminal on the circuit breaker. Ensure all
lugs are properly tightened. See figure 6-1, Connection of Primary Power C30
Type Controllers.

Figure 6-1 Connection of Primary Power C30 Type Controllers

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WIRING INSTRUCTIONS

6.1.2 PREPARATION AND CONFIRMATION OF INCOMING POWER

Prior to setting the correct taps on the servo transformer, the incoming line voltage must
be measured. The two procedures that are described below are acceptable, however,
Procedure One is the preferred method.

Procedure One

1. Obtain a voltage strip chart recorder. Monitor the incoming 3-phase voltage that will
supply the robot controller breaker. Ensure the breaker on the main disconnect is in
the OFF position.

2. Monitor this voltage for one to two days.

3. Record the highest voltage reading and the lowest voltage reading.

4. Average the highest and lowest voltage readings, and record this average value.

5. Check the existing voltage taps on the servo transformer and note the value.

6. If the value of the existing voltage taps on the servo transformer is the value as
recorded in step number 4, no change of the taps is necessary. If the servo taps do
not match the value recorded in step number 4, then the wire location will need to
be changed on the taps. Refer to the label located on the transformer for correct
wire connection.

Procedure Two

Procedure Two is similar to Procedure One, however, in step 1, substitute a digital volt
meter in place of the strip chart recorder. All voltage measurements should be taken
with the robot main disconnect in the OFF position. Replace step 2 in Procedure One
with: Measure the building’s incoming voltage five different times during the controller’s
operational day. Two voltage checks should be made in the morning (at different times),
one at noon, and two in the afternoon (at different times). These voltage measurements
should then be averaged together, and an average voltage found. The voltage taps
should then be set accordingly on the servo transformer.

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INSTALLATION MANUAL

WIRING INSTRUCTIONS

6.2 WIRING INSTRUCTIONS BETWEEN CONTROLLER AND MECHANICAL UNIT

6.2.1 HARNESS CONNECTIONS TO THE MECHANICAL UNIT

When installing wire harnesses to the mechanical unit, the following procedure is used:

1. Remove connector cover at robot base for U-series manipulators.

2. Connect Amphenol connectors as shown in figure 6-2, or 6-3, and tighten collars.

3. Connect ground straps to connector box.

4. Install connector cover if connecting a U-series manipulator.

Connection of U-Series Robots

Robot base
(view from
the rear)

CN1 CN3

Major axis motor harness CN2 Groun

Minor axis motor harness
Signal h rness a

Figure 6-2 Mechanical Unit Harness Connections

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WIRING INSTRUCTIONS

Figure 6-3 Mechanical Unit Harness Connections (Continued)

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WIRING INSTRUCTIONS

6.3 C30 CONTROLLER

1. Wire harnesses are routed through the bottom of the controller.

2. Wire harness connectors are identified with labels. Push connectors CN1, CN2,
CN3 into sockets firmly. Lock each connector in socket using connector’s locking
lever, see figure 6-4, C30 Robot to Controller Harness Connections.

Figure 6-4 C30 Robot to Controller Harness Connections

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WIRING INSTRUCTIONS

6.4 UD100 SENSOR CABLE CONNECTION (OPTIONAL)

The UD100 can be supplied with an optional sensor cable that connects with limit or
proximity switches. The sensor cable option allows the use of four input signals. These
signals can be used with limit switches, proximity switches, or both. Table 6-2 shows the
wire colors for signals 1 through 4, ground, and the 24VDC power source for proximity
switches. The sensor cable wires are terminated with Faston connectors for easy termi-
nation. All sensor wires are contained within cable assembly. Outside cable diameter is
8.6 mm.

Table 6-2 Sensor Cable Termination

Sensor input signal 1...........................................SIG 1, Brown

Sensor input signal 2...........................................SIG 2, Red
Sensor input signal 3...........................................SIG 3, Yellow
Sensor input signal 4...........................................SIG 4, Orange
Power supply for proximity sensor (24VDC)+24V, Blue and Purple
GROUND COMMON for proximity sensor, 24G, Green, Black, Ash
and White

The power supply (24VDC) for this sensor uses the power supply built-in the controller;
supply from the outside is unecessary. Select the appropriate proximity sensor, etc., so
the current power capacity of the built-in power supply is not exceeded. Currect power
capacity is 0.2A or less. SIG 1 through 4 are approximately 10mA each.

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WIRING INSTRUCTIONS

6.4.1 UD100 (HANDLING SPECIFICATIONS)

Internal wiring of the arm for sensor cable routing is illustrated in figure 6-5. The termi-
nal board for Faston connectors is located on the inside surface of the access cover.

Cable connector specifie

customer’s applicatio

Figure 6-5 UD100 Sensor Cable Routing

NOTE

To prevent electrical short, insulate the ends of all sen-

sor wires not being used.

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WIRING INSTRUCTIONS

6.4.2 LIMIT AND PROXIMITY SWITCH CONNECTIONS UD100 AND F SERIES

See figure 6-6 for proper connections when connecting limit and proximity switches.
Figure 6-6 illustrates connections for single limit switches, proximity switches or the use
of both.

When you connect the proximity switch:

Faston Proximity switch

+24V (5) +24V

SIG1 (1) SIG
24G (6) GND

When you connect the limit switch:

Faston Limit switch

SIG1 (1) ¡ ¡
+24G (6)

When connecting both the proximity switch and the limit switch:

Faston Proximity switch

+24V (5) +24V

SIG1 (1) SIG
24G (6) GND
Limit switch

SIG2 (2) ¡ ¡

Figure 6-6 Connecting Diagram for Limit and Proximity Switches

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WIRING INSTRUCTIONS

When the sensor cable option is used, four of the general purpose inputs must be
allocated to the sensor input signals 1-4. The inputs that are allocated to the sensor
option are Inputs 13-16. It is important to note that once the inputs are allocated to the
sensor option, they cannot be used as general purpose inputs. Table 6-3 indicates the
corresponding general purpose inputs and the sensor signal inputs.

Table 6-3 Sensor Cable Input Signals

External signal Internal signal name

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

The sensor signals and general purpose signals are configured with jumper 5 (J5) on
the 1GW board, located in the controller. The location of the jumpers is dependent upon
the number of signals selected.

NOTE

The selection of Use/Not Used is made by one set of

IN13-16 which consists of a four point unit. Configure
jumper 5 as shown in figure 6-7. For example, avoid
settings where 1~3 of J5 is made A-B and/or 4~5 is
made B-C. When selecting Use/Not Used, all jumpers
must be set to Use or all jumpers set to Not Used.

1GW board
Not used Used
J5 J5 Power suppl
for intern a
COM1..... 1 !! ! 1 ! !! ...... sensor.(+24V)
!! ! ! !!
IN13 ........ 2 2 ...... IN13
J3
IN14 ........ 3 !! ! 3 ! !! ...... IN14
IN15 ........ 4 !! ! 4 ! !! ...... IN15 J4
IN16 ........ 5 !! ! 5 ! !! ...... IN16 J5
A B C A B C

Figure 6-7 1GW Board Jumper Configuration for Sensor Cable Usage

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WIRING INSTRUCTIONS

6.4.3 SENSOR WIRING DIAGRAMS

Figure 6-8 shows a sensor wiring diagram for UD-series mechanical units.

UD100:

Controller

1GW board 1GB board Separation harness

Robot

Separation Harness

Figure 6-8 UD100 Sensor Wiring Diagram

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WIRING INSTRUCTIONS

+24V
Photo coupler
Limit switch
SG1-4
24G

+24V Proximity switch

Photo coupler 24V

SG1-4 OUT

24G

OV

Figure 6-9 Function Diagram, Proximity Switch for UD100 Robots

6.4.4 SOLENOID VALVE WIRING DIAGRAM (HANDLING SPECIFICATION)

UD100:

Controller Robot

Separation
harness

Figure 6-11 Solenoid Valve Wiring for UD100 Robots

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WIRING INSTRUCTIONS

+24V
SOL

1FR board Manipulator

Figure 6-12 Solenoid Valve Wiring for F Series and UD100 Robots

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INSTALLATION MANUAL

ELECTRICAL INTERFACE CONNECTIONS

7.0 ELECTRICAL INTERFACE CONNECTIONS .................................................... 7-2

7.1 External I/O Signal Connections ....................................................................... 7-2
7.1.1 Dedicated Signals .............................................................................................. 7-2
7.1.2 Hardware Dedicated Signals ............................................................................. 7-2
7.1.3 Teach/Repeat Switch Output ............................................................................. 7-2
7.1.4 Emergency Stop Switch Output ........................................................................ 7-2
7.1.5 External Control Power On/Off ......................................................................... 7-3
7.1.6 External Motor Power On .................................................................................. 7-3
7.1.7 External Motor Power Off.................................................................................. 7-3
7.1.8 External Hold ..................................................................................................... 7-3
7.2 External I/O Signal Connections C30 Series Controller .................................... 7-4
7.2.1 Hardware Dedicated Signals ............................................................................. 7-4
7.2.2 External Control Power ..................................................................................... 7-4
7.2.3 External Motor Power On .................................................................................. 7-6
7.2.4 External Emergency Stop ................................................................................. 7-8
7.2.5 External Hold ................................................................................................... 7-10
7.2.6 External Teach/Repeat Output ........................................................................ 7-12
7.2.7 Safety Fence Input .......................................................................................... 7-13
7.2.8 External Trigger Input ...................................................................................... 7-15
7.3 1GW General Purpose Input/Output Signals .................................................. 7-20
7.3.1 1GW Input Signals .......................................................................................... 7-20
7.3.2 1GW Output Signals ....................................................................................... 7-21
7.4 Hardware Configuration of Dedicated Signals ................................................. 7-22
7.4.1 Hardware Connection of Dedicated Signals .................................................... 7-22
7.4.2 Teach/Repeat Switch Output and Emergency Stop ........................................ 7-22
7.4.3 External Control Power On/Off ....................................................................... 7-23
7.4.4 External Motor Power On (Used) .................................................................... 7-25
7.4.5 External Motor Power On (Not Used) ............................................................. 7-26
7.4.6 External Motor Power Off (Used) .................................................................... 7-26
7.4.7 External Motor Power OFf (Not Used) ............................................................ 7-27
7.4.8 External Hold ................................................................................................... 7-28

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ELECTRICAL INTERFACE CONNECTIONS

7.0 ELECTRICAL INTERFACE CONNECTIONS

This section describes external I/O hardware signal configurations for N. American
controllers.

The C-series controller is capable of interfacing with external equipment, including

programmable logic controllers (PLCs), and weld controllers. The N. American control-
ler is configured with thirty-two inputs and thirty-two outputs. The I/O circuit board for
the N. American C controller is the 1GW board. Additional I/O boards can be added to
increase the total number of inputs and outputs to 128 each.

7.1 EXTERNAL I/O SIGNAL CONNECTIONS

7.1.1 DEDICATED SIGNALS

Dedicated signals are those used by the controller for specific functions. These func-
tions are typically not changeable by the user. Dedicated signals are configured as part
of the software or hardware. When dedicated signals are assigned using the software,
the number of general purpose signals available decreases. Hardware dedicated sig-
nals have no effect on general purpose signals.

7.1.2 HARDWARE DEDICATED SIGNALS

The teach/repeat and emergency stop signals are hardware dedicated output signals.
External control power ON/OFF, external motor power ON, external motor power OFF,
and external HOLD are four dedicated input signals that may be used as hardware
dedicated signals. The 1HP circuit board, part of the controller’s power circuit, is config-
ured to make use of these signals. These signals are described in the following sub-
sections.

7.1.3 TEACH/REPEAT SWITCH OUTPUT

This is an output signal from the operations panel switch indicating the condition of the
contacts, open or closed, for TEACH mode.

7.1.4 EMERGENCY STOP SWITCH OUTPUT

This is a contact output signal from the multi function panel, operations panel, or the
small teach pendant.

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ELECTRICAL INTERFACE CONNECTIONS

7.1.5 EXTERNAL CONTROL POWER ON/OFF

This input signal provides a means to turn controller power on and off externally. The
controller’s main disconnect switch must be in the ON position to make use of this
signal.

! WARNING
The external control power ON input signal could be-
come high while performing maintenance. Ensure
power supply to controller is OFF prior to performing
maintenance.

7.1.6 EXTERNAL MOTOR POWER ON

This input signal is used to apply sevo motor power. When the controller receives the
signal, motor power comes on within 0.3 ~ 0.5 seconds. The signal is released by an
emergency stop, external motor power OFF, etc.

NOTE

External motor power ON is also a software dedicated

signal.

7.1.7 EXTERNAL MOTOR POWER OFF

This input signal is used to turn off control power externally. When this signal is set to
open, controller power is not available.

7.1.8 EXTERNAL HOLD

This input signal is used to temporarily halt the repeat mode of robot operation. Upon
recognition of this signal, robot motion is stopped using deceleration and then the
brakes are applied to hold the robot arm.

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ELECTRICAL INTERFACE CONNECTIONS

7.2 EXTERNAL I/O SIGNAL CONNECTIONS C30 SERIES CONTROLLER

This section describes external I/O hardware, general purpose and software dedicated
signal configurations. C30 controllers are built to N. American specifications.

7.2.1 HARDWARE DEDICATED SIGNALS

When using hardware dedicated signals, ensure connections are made according to the
information provided in the following sections.

7.2.2 EXTERNAL CONTROL POWER

! CAUTION
Ensure that connection to CN1 pins 1 and 2 is not re-
versed; damage to diode D28 can occur.

Figure 7-1 External Control Power

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ELECTRICAL INTERFACE CONNECTIONS

NOTE

The external relay must meet the following specifica-

tions:

Contact Power Capacity: 24 VDC > 0.1 A

Coil: 24 VDC , 10mA +/- 20%
Power Supply: 24 VDC +/- 10%
Wiring: AWG 22~24

There is a cycle wait time of 2~3 seconds from OFF to

ON for relay RY2 on the 1HP board.

CN1 TB2
CN3-23
1 1

RY5 RY5 D28 Do not connect

2 2

3 3

Jumper

4 4

1HP board

Figure 7-2 External Control Power Disabled

NOTE

The controller can be shipped with TB2 or CJ44. When

shipped with TB2, 3/4 is jumpered at TB2. When
shipped with CJ44, 3/4 is jumpered at CN1. Both are
applicable to non-use of external control power. To use
external control power capability, ensure the jumper is
removed and connection of the external device to TB2
or CN1 is configured as shown in figure 7-1.

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ELECTRICAL INTERFACE CONNECTIONS

7.2.3 EXTERNAL MOTOR POWER ON

External motor power ON is an external signal used to set the controller motor power to
ON, and performs the same function as the MOTOR POWER ON switch on the opera-
tion panel.

! WARNING
Do not wire pins 9 and 10 as a normally closed circuit.
Motor power will come on immediately following the cor-
rection of an emergency stop.

Figure 7-3 External Motor Power ON

NOTE

Applications using CJ44 do not use pins 29 and 30.

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ELECTRICAL INTERFACE CONNECTIONS

NOTE

The external switch or relay must meet the following

specifications:

Contact Power Capacity: 24 VDC > 0.1 A

Wiring: AWG 22~24

Photo Coupler PC22 is rated at 24 VDC,

10 mA +/-20%.

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ELECTRICAL INTERFACE CONNECTIONS

7.2.4 EXTERNAL EMERGENCY STOP

External emergency stop is an input signal from an external device that interrupts motor
power. It performs the same function as the EMERGENCY STOP switch on the opera-
tion panel

Figure 7-4 External Emergency Stop (E-Stop)

NOTE

External switches must meet the following specifica-

tions:

Contact Power Capacity: 24 VDC > 0.1 A

Wiring: AWG 22~24

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ELECTRICAL INTERFACE CONNECTIONS

CN1 TB2
CN2-5
5 5
F1 RY2 jumper
0.3A 5 4
+24 VDC 9 6

6 7
CN4-12 R73
PC14 10 8
2.4K
R47 7 9
680 D20 jumper
11 10

8 11
CN2-7
12 12

SW1
CN2-12
6 5

CN4-14
RY2
9 8

1HP Board

Figure 7-5 External Emergency Stop (E-Stop) Disabled

NOTE

When the controller is shipped, motor power cannot be

turned on because TB2-5/6 and TB2-9/10 or CN1-5/6
and CN1-9/10 on CJ44 applications are not jumpered.
These jumpers must be installed before operating the
robot.

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ELECTRICAL INTERFACE CONNECTIONS

7.2.5 EXTERNAL HOLD

External hold is an external input signal that stops the robot temporarily and is effective
only when the controller is in the repeat mode.

Figure 7-6 External Hold

NOTE

The external switch or relay contact must meet the fol-

lowing specifications:

Contact Power Capacity: 24 VDC > 0.1 A

Coil: 24 VDC , 10mA +/- 20%
Power Supply: 24 VDC +/- 10%
Wiring: AWG 22~24

When the switch or relay contact (between TB2-19/20

or between CJ44-3/4) opens, the robot is in the hold
mode.

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ELECTRICAL INTERFACE CONNECTIONS

Figure 7-7 External Hold Not Used

NOTE

When the controller is shipped, the robot is in the hold

mode because pins CN3-7/8 are not jumpered. Prior to
operating the robot, the jumper must be installed.

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ELECTRICAL INTERFACE CONNECTIONS

7.2.6 EXTERNAL TEACH/REPEAT OUTPUT

The external teach/repeat output is provided via TB2-31/32.

CONTROLLER EXTERNAL DEVICE

repeat teach
CN1 TB2
CN2

19 35 31

Teach: closed
Repeat: open

20 36 32

1HP Board

Figure 7-8 External Teach/Repeat Output

NOTE

The load should not exceed the switch contact specifi-

cation.

Contact specification: 24 VDC, < 0.1A.

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ELECTRICAL INTERFACE CONNECTIONS

7.2.7 SAFETY FENCE INPUT

The safety fence input signal interrupts motor power and performs the same function as
the external emergency stop (E-stop) signal.

! WARNING
Functional operation of the safety fence switch is ex-
tremely important for the safety of personnel. Ensure
that a mechanical switch is used; semiconductor type
switches should not be used, because they are less reli-
able.

CONTROLLER EXTERNAL
DEVICE

CN1 TB2
CN2-14 safety fence
13 15

R75
PC17 14 16
+24 VDC
2.4K
R50 safety fence
680 D23 15 17

16 18

CN1-24

CN2-17
1HP Board

Figure 7-9 Safety Fence Switches

NOTE

For CJ44 applications, pins 13/14 and 15/16 will be

jumpered at CN1.

April 26, 1999 7-13

 Kawasak C SERIES CONTROLLER
INSTALLATION MANUAL

ELECTRICAL INTERFACE CONNECTIONS

CN1 TB2
CN2-14
13 15
jumper
R75
PC17 14 16
+24 VDC
2.4K
R50
680 D23 15 17
jumper
16 18

CN1-24

CN2-17

1HP Board

Figure 7-10 Safety Fence Switches Not Used

NOTE

When the controller is shipped, the jumpers for TB2-15/

16 and TB2-17/18 are not installed; motor power cannot
be set to ON. These jumpers must be installed prior to
operating the controller. For CJ44 applications, the
jumpers for CN1-13/14 and CN1-15/16 must be in-
stalled to gain motor power.

7-14 April 26, 1999

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INSTALLATION MANUAL

ELECTRICAL INTERFACE CONNECTIONS

7.2.8 EXTERNAL TRIGGER INPUT

The external trigger input signal interrupts motor power, and performs the same func-
tion as the EMERGENCY STOP (E-stop) switch on the operation panel.

! WARNING
Functional operation of the external trigger switch is ex-
tremely important for the safety of personnel. Ensure
that a mechanical switch is used; semiconductor type
switches should not be used because they are less reli-
able.

April 26, 1999 7-15

7-16

CONTROLLER EXTERNAL
DEVICE
TB2
CN1
CN4-16
25 25

Kawasak
R79
PC20
2.4K
+24 VDC R53
680 D26

ELECTRICAL INTERFACE CONNECTIONS

CN3-5 D6 RY4
5 4 26 26

R57 R80
2.4K P21
2.4K
PC8 R54
680 D27

R41
680 D14

CN3-7 RY4
9 8 27 27
+24 VDC
R69
PC10
2.4K
R43
680 D16

C SERIES CONTROLLER
INSTALLATION MANUAL
CN4-17
28 28
April 26, 1999

1HP Board

Figure 7-11 External Trigger Input

 Kawasak C SERIES CONTROLLER
INSTALLATION MANUAL

ELECTRICAL INTERFACE CONNECTIONS

NOTE

The external switch or relay contact must meet the fol-

lowing specifications:

Contact Power Capacity: 24 VDC > 0.1 A

Coil: 24 VDC , 10mA +/- 20%
Power Supply: 24 VDC +/- 10%
Wiring: AWG 22~24

NOTE

For CJ44 applications pins 25/26 and 27/28 will be

jumpered at CN1.

NOTE

The terminal block (TB) in figure 7-11 is located on the

controller cabinet door.

April 26, 1999 7-17

7-18

TB2
CN1
CN4-16
25 25

R79

Kawasak
PC20
2.4K
+24 VDC R53
680 D26
jumper

ELECTRICAL INTERFACE CONNECTIONS

CN3-5 D6 RY4
5 4
26 26

R57 R80
2.4K P21
2.4K
PC8 R54
680 D27

R41
680 D14

CN3-7 RY4
9 8 27 27
+24 VDC
R69
PC10
2.4K
R43
680 D16
jumper

C SERIES CONTROLLER
INSTALLATION MANUAL
CN4-17
April 26, 1999

28 28

1HP Board

Figure 7-12 External Trigger Input Not Used

 Kawasak C SERIES CONTROLLER
INSTALLATION MANUAL

ELECTRICAL INTERFACE CONNECTIONS

NOTE

The terminal block (TB) in figure 7-12 is located on the

controller cabinet door.

NOTE

For CJ44 applications pins 25/26 and 27/28 will be

jumpered at CN1.

April 26, 1999 7-19

 Kawasak C SERIES CONTROLLER
INSTALLATION MANUAL

ELECTRICAL INTERFACE CONNECTIONS

7.3 1GW GENERAL PURPOSE INPUT/OUTPUT SIGNALS

All general purpose I/O signals are processed with the 1GW board. The 1GW board is
configured to handle 32 inputs and 32 outputs. These signals can be assigned freely by
the user to interface the robot with external equipment. The number of general purpose
signals available is dependent upon total I/O, less the number of software assigned
dedicated signals. General purpose signals may be assigned only once, which de-
creases the available number of assignable signals.

7.3.1 1GW INPUT SIGNALS

The 32 points available are two groups of 16, inputs 1-16 and inputs 17 - 32. They
share positive (+) commons, COM1 and COM2 respectively.

Input specifications:

Input method .................... Photo coupler input

Input voltage ..................... DC24V +/- 10%
Input current ..................... 10mA +/- 20%
Connection ....................... 37 pin D-sub connector

ROBOT EXTERNAL

DC +24V

+ COM1,2

IN-1-16,17-32

Photo coupler
Or
TLP181 (TOSHIBA) or Equivalent

0V 0V

Figure 7-13 Input Signal Circuit

7-20 April 26, 1999

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ELECTRICAL INTERFACE CONNECTIONS

7.3.2 1GW OUTPUT SIGNALS

The 32 points available are two groups of 16, inputs 1-16 and inputs 17 - 32. They
share negative (-) commons, COM1 and COM2 respectively.

Output specifications:

Output method .......................... Transistor output

Voltage....................................... DC24V +/- 10%
Max. continuous load current .... 0.1A or less
Connection ................................ 37 pin D-sub connector

ROBOT EXTERNAL

Figure 7-14 Output Signal Circuit

NOTE

Install electrical spike protection in the output load cir-

cuit. Observe polarity carefully to prevent damage to
the robot output circuit. The diode installed in the load
circuit should conform to the specifications of Hitachi
Ltd. V60C. All output loads should share a single power
supply.

April 26, 1999 7-21

 Kawasak C SERIES CONTROLLER
INSTALLATION MANUAL

ELECTRICAL INTERFACE CONNECTIONS

7.4 HARDWARE CONFIGURATION OF DEDICATED SIGNALS

Hardware connections of external I/O are different from software connections of exter-
nal I/O.

7.4.1 HARDWARE CONNECTION OF DEDICATED SIGNALS

7.4.2 TEACH/REPEAT SWITCH OUTPUT AND EMERGENCY STOP

Contact specification: DC 24V

0.1A or less
Wire specification: AWG 22~24

ROBOT EXTERNAL

Multi Function Panel or Sm. Teach Pendant

(1HP Board)

Figure 7-15 Teach/Repeat and E-Stop Connections

7-22 April 26, 1999

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INSTALLATION MANUAL

ELECTRICAL INTERFACE CONNECTIONS

7.4.3 EXTERNAL CONTROL POWER ON/OFF

When using this signal, connect pins 1~4 on the 1HP board as shown in figure 7-16.

Contact specifications for External Control Power ON/OFF:

Power capacity: DC24V 0.1A or more (coil spec.: DC24V, 10mA +/- 20%)
Power supply: DC24V +/- 10%
Wiring: AWG22~24

NOTE

Wait 3 seconds before turning controller power ON

after power has been turned OFF.

! CAUTION
Do not reverse polarity on pins 1 and 2 of the CN3 con-
nector. Damage to the diode on the 1FP board will re-
sult.

ROBOT EXTERNAL

CN3 +24V

Relay 1 1

2 2

3 3
Do not connect
4 4

Contact close : Control power ON

Contact open : Control power OFF

(1HP Board)

Figure 7-16 External Control Power ON/OFF (Used)

April 26, 1999 7-23

 Kawasak C SERIES CONTROLLER
INSTALLATION MANUAL

ELECTRICAL INTERFACE CONNECTIONS

When the external control power ON/OFF signal is not used, jumper pins 3 and 4 to-
gether, see figure below:

ROBOT EXTERNAL

CN3

Relay 1 1
Do not connect
2 2

3 3
Pins 3 and 4 are
connected together
4 4

(1HP Board)

Figure 7-17 External Control Power ON/OFF (Not Used)

NOTE

The controller is shipped with the “not used” configura-

tion. Pins 3 and 4 are connected together. The jumper
wire between pins 3 and 4 must be removed if a dedi-
cated signal is to be used.

7-24 April 26, 1999

 Kawasak C SERIES CONTROLLER
INSTALLATION MANUAL

ELECTRICAL INTERFACE CONNECTIONS

7.4.4 EXTERNAL MOTOR POWER ON (USED)

When using the external motor power on input signal, connect the switch or relay con-
tact between pins 9 and 10 of the CN3 connector. The input signal must remain on for
at least 0.3 ~ 0.5 seconds to be recognized.

Contact power capacity: DC24V, 0.2A or more

Photo coupler current: DC24V 10mA +/- 20%
Wiring: AWG 22~24

ROBOT EXTERNAL

CN3

Switch or Relay contact

DC24V 9 9

Photo Coupler
10 10

(1HP Board)

Figure 7-18 External Motor Power On (Used)

! WARNING
If external motor power ON (contact closed) is applied
when the controller EMERGENCY STOP switch is
pressed, robot motion will resume when the switch is re-
leased.

April 26, 1999 7-25

 Kawasak C SERIES CONTROLLER
INSTALLATION MANUAL

ELECTRICAL INTERFACE CONNECTIONS

7.4.5 EXTERNAL MOTOR POWER ON (NOT USED)

When the external motor power ON dedicated signal is not used, do not use pins 9 and
10 of the CN3 connector for any other purpose.

NOTE

The controller is shipped with the “not used” configura-

tion.

7.4.6 EXTERNAL MOTOR POWER OFF (USED)

Connect the switch or relay contact between pins 5 and 6 of the CN3 connector. When
this input signal is used as an emergency stop signal, use dry contacts only. Semicon-
ductor type relays will not guarantee the interception of motor power.

Contact specifications for External Motor Power OFF:

Contact power capacity: DC24V, 0.1A or more

Coil specification: DC24V 10mA +/- 20%
Wiring: AWG 22~24

ROBOT EXTERNAL

External EMERGENCY STOP switch

Safety fence door switch

DC24V ... 5 5

Relay 6 6

(1HP Board)

Figure 7-19 External Motor Power Off (Used)

7-26 April 26, 1999

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INSTALLATION MANUAL

ELECTRICAL INTERFACE CONNECTIONS

7.4.7 EXTERNAL MOTOR POWER OFF (NOT USED)

When the input signal is not used, pins 5 and 6 of the CN3 connector must be con-
nected together; otherwise, motor power is unavailable.

NOTE

The controller is shipped with pins 5 and 6 of the CN3

connector not connected. Motor power is unavailable
until connection is made.

ROBOT EXTERNAL

DC24V ... 5 5

Relay 6 6

(1HP Board)

Figure 7-20 External Motor Power Off (Not Used)

April 26, 1999 7-27

 Kawasak C SERIES CONTROLLER
INSTALLATION MANUAL

ELECTRICAL INTERFACE CONNECTIONS

7.4.8 EXTERNAL HOLD

When the external hold signal is used, the switch or relay is wired in the normally closed
condition. When the switch or relay contact opens, the robot motion halts. Connect the
switch or the relay contact between pins 7 and 8 of the CN3 connector on the 1HP
circuit board.

Contact power capacity: DC24V, 0.1A or more

Coil specifications: DC24V 10mA +/- 20%
Power supply: DC24V +/- 10%
Wiring: AWG 22~24

ROBOT EXTERNAL

CN3
Switch or Relay contact
DC24V 7 7

Relay 8 8

(1HP Board)

Figure 7-21 External Hold (Used)

7-28 April 26, 1999

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ELECTRICAL INTERFACE CONNECTIONS

When the external hold signal is not used, pins 7 and 8 of the CN3 connector must be
connected together.

NOTE

The controller is shipped with pins 7 and 8 not con-

nected and the robot controller is in the hold state. Wire
the controller for either the “used” or “not used” condi-
tion prior to attempting robot operation.

ROBOT EXTERNAL

CN3

DC24V 7 7

Relay 8 8

(1HP Board)

Figure 7-22 External Hold (Not Used)

April 26, 1999 7-29

 Kawasak C SERIES CONTROLLER
INSTALLATION MANUAL

MECHANICAL UNIT INSTALLATION INSTRUCTIONS

MECHANICAL UNIT INSTALLATION I

8.0 MECHANICAL UNIT INSTALLATION INSTRUCTIONS .................................. 8-2
8.1 Uncrating, Unpacking, and Positioning Procedures ......................................... 8-2
8.2 Kawasaki Heavy Industries Standard Packing ................................................. 8-2
8.2.1 Mechanical Unit Standard Packing .................................................................. 8-2
8.3 Uncrating, Unpacking, and Positioning Procedures ......................................... 8-3
8.3.1 Mechanical Unit Uncrating and Unpacking Procedures ................................... 8-3
8.3.2 Lifting Mechanical Unit from Shipping Container ............................................. 8-4
8.4 Rigging and Lifting Instructions ........................................................................ 8-6
8.4.1 Rigging and Lifting Instructions for Mechanical Units ...................................... 8-6
8.4.1.1 Rigging and Lifting Instructions for U and F-Series Mechanical Units ............. 8-6
8.5 Robot Base Plate Installation U-Series Robots ............................................... 8-7
8.5.1 Base Plate Installation Dimensions U-Series Robots ...................................... 8-8
8.5.2 Installation Methods U-Series Robots ............................................................. 8-9
8.5.3 Operational Loading U-Series Robots ........................................................... 8-11
8.6 Robot Base Plate Installation F-Series Robots .............................................. 8-12
8.6.1 Base Plate Installation Dimensions F-Series Robots ..................................... 8-13
8.6.2 Installation Methods F-Series Robots ............................................................ 8-14
8.7 Mounting of Tools for U and F-Series Robots ................................................ 8-16
8.8 Positioning of the Mechanical Unit ................................................................. 8-17
8.8.1 Positioning of the Robot with Controller ......................................................... 8-17
8.8.1.2 Enabling the Jogging Procedure .................................................................... 8-17
8.8.2 Positioning the Mechanical Unit with Brake Release Switches ...................... 8-18

April 26, 1999 8-1

 Kawasak C SERIES CONTROLLER
INSTALLATION MANUAL

MECHANICAL UNIT INSTALLATION INSTRUCTIONS

8.0 MECHANICAL UNIT INSTALLATION INSTRUCTIONS

8.1 UNCRATING, UNPACKING, AND POSITIONING PROCEDURES

The mechanical unit and robot controller are shipped from the factory in separate
wooden containers. Prior to beginning the unpacking procedure, retain all shipping
invoices and other documentation shipped with the robot and controller.

8.2 KAWASAKI HEAVY INDUSTRIES STANDARD PACKING

8.2.1 MECHANICAL UNIT STANDARD PACKING

The mechanical unit is shipped on a wooden skid, see figure 8-1, KHI Mechanical Unit
Standard Packing. The robot has a protective plasticized/aluminized foil to protect it
from water, dust, and humidity. The robot is secured to the skid by bolt and nut combi-
nations. The sides of the shipping container are secured to the bottom and top by
nailing. The teach pendant, and robot harness cables are contained in a box that is
mounted toward one end of the shipping container.

Figure 8-1 KHI Mechanical Unit Standard Packing

8-2 April 26, 1999

 Kawasak C SERIES CONTROLLER
INSTALLATION MANUAL

MECHANICAL UNIT INSTALLATION INSTRUCTIONS

8.3 UNCRATING, UNPACKING, AND POSITIONING PROCEDURES

8.3.1 MECHANICAL UNIT UNCRATING AND UNPACKING PROCEDURES

1. Remove the supports surrounding the end of the manipulator arm which secures it
to the inside of the packing container. A pry bar or wood saw may be used for this.

NOTE

Support position will vary with each manipulator.

2. Using a wood saw, cut the vertical side and corner boards near the bottom of the
container. See figure 8-2, Cut Line for Mechanical Unit Shipping Container.

Figure 8-2 Cut Line for Mechanical Unit Shipping Container

3. Lift the upper portion of container away from the mechanical unit with an overhead
crane or similar lifting device.

4. Remove the plasticized/aluminized foil covering the mechanical unit.

5. Remove the four nuts from the bolts securing the robot to the skid. Remove four
bolts using a drift punch and hammer.

March 31, 1998 8-3

 Kawasak C SERIES CONTROLLER
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MECHANICAL UNIT INSTALLATION INSTRUCTIONS

8.3.2 LIFTING MECHANICAL UNIT FROM SHIPPING CONTAINER

Remove the robot from the skid using a forklift or heavy equipment lifting device. Refer
to figures 8-3, Forklift Pockets and 8-4, Mounting Position of Optional Fork Pockets
when using a forklift. See figure 8-5, U-Series Sling Load or figure 8-6, F-Series SLing
Load when using an overhead lifting device. Sling loading requires the installation of eye
bolts for sling attachment. For detailed instructions, refer to section 8.4.1.1, Rigging and
Lifting Instructions for F and U-Series Mechanical Units

65mm
2.56 in
190mm 820mm
7.480 i 32.28 in n

Thrust tines o u

Figure 8-3 Forklift Pockets

Foklift Jig

Figure 8-4 Mounting Position of Optional Fork Pockets

NOTE

Maximum weight capacity of forklift fixturing (pockets) is

2,100 Kg./4,620 Lb.

8-4 April 26, 1999

 Kawasak C SERIES CONTROLLER
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MECHANICAL UNIT INSTALLATION INSTRUCTIONS

Lifting eye bolts

Figure 8-5 Sling Load of U-Series Robots

Belt for arm sling

Figure 8-6 Sling Load of F-Series Robots

After the robot has been removed from the packing crate, remove the small box from
the crate which contains the teach pendant and multi function panel, and the robot
wiring harness cables.

April 26, 1999 8-5

 Kawasak C SERIES CONTROLLER
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MECHANICAL UNIT INSTALLATION INSTRUCTIONS

! CAUTION
Make sure that joint 2 (O-axis) is far enough forward to
avoid interference with the lifting mechanisms of the
forklift. Maximum capacity of the forklift pockets is
2,100 kg (4,620 lb.). Excess weight must be removed
prior to lifting the robot.

8.4 RIGGING AND LIFTING INSTRUCTIONS

8.4.1 RIGGING AND LIFTING INSTRUCTIONS FOR MECHANICAL UNITS

The mechanical unit (manipulator) can be lifted with an overhead crane, or movable
crane. A forklift can also be used if precautions are taken to ensure that the electrical
connectors at the back of the robot are not damaged during lifting operations, and tip
hazards are taken into consideration during transportation. The lifting mechanism must
be capable of lifting 1,550kg./3,418lb., which is the weight of the heaviest manipulator.

8.4.1.1 RIGGING AND LIFTING INSTRUCTIONS FOR U AND F-SERIES

MECHANICAL UNITS

Method 1

Figures 8-5 and 8-6, Sling Loading, demonstrate the positioning of the robot if an over-
head hoist is used to transport the mechanical unit. A nylon sling, cable, or similar
device can be used to lift the mechanical unit when attached to the lifting eye bolts or
robot arm. If this method is used, position joint 2 (O-axis) either in the negative or
positive position so that the robot base is kept parallel to the floor. If the robot is not
correctly positioned, interference with the motor harness could result. Variations of this
method will occur depending on the manipulator type, be sure to keep the robot base
parallel to the floor.

Method 2

Transporting the mechanical unit with a forklift is performed either with a sling attached
to the robot and around the lifting forks, or by using the optional lifting fixturing, shown in
figure 8-3, Forklift Pockets, and figure 8-4, Mounting Position of Optional Fork Pockets.
Greater stability afforded by the use of fork pockets, is the preferred method.

The joint 2 (O-axis) should be positioned in the neutral position, or positioned so the
robot does not contact any part of the forklift lifting mechanism.

8-6 April 26, 1999

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MECHANICAL UNIT INSTALLATION INSTRUCTIONS

8.5 ROBOT BASE PLATE INSTALLATION U-SERIES ROBOTS

When mounting the robot base plate to floor, it is recommended that M20 chemical
anchors be used. If chemical anchors cannot be used, the robot base plate should be
anchored to the floor with eight M20 anchor bolts. The robot base plate must be at
least 32 mm/1.259 inches thick. Bolt thread engagement must be at least 25.4 mm/1
inch into the robot base plate for proper attachment. Figure 8-7 illustrates the robot and
base plate installation requirements. Figure 8-8 illustrates base plate mounting dimen-
sions.

Tighten M20 Bolts To

4400 kg cm (318.25 ft lbs)

Max. Pullout Load

(Including Tightening Torque)
1300 kgf (2866 lbs) Robot Base

M20 Bolt Engagement

25 mm Min.
Into Base Plate

Thickness Of Base Plate

32 mm Min.
Depth Into Concrete
200 mm Min. Thickness Of Concrete
Do Not Break Through 230 mm Min.

Cut M20 Bolt

At 45 Degree Angle
When Using Chemical Anchor

Figure 8-7 Robot Base Plate Installation Requirements

April 26, 1999 8-7

 Kawasak C SERIES CONTROLLER
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MECHANICAL UNIT INSTALLATION INSTRUCTIONS

8.5.1 BASE PLATE INSTALLATION DIMENSIONS U-SERIES ROBOTS

Figure 8-8 illustrates the robot base plate mounting dimensions and figure 8-9 illustrates
the robot base flange bolt hole depth.

350mm 350mm

100mm

250mm

Center of 250mm
Rotation

100mm
8-20 mm holes

100mm 250mm 250mm 100mm

Minimum Plate Thickness: 32 mm

Figure 8-8 Robot Base Plate Mounting Dimensions

16mm

Figure 8-9 Robot Base Flange Bolt Hole Depth

8-8 March 31, 1998

 Kawasak C SERIES CONTROLLER
INSTALLATION MANUAL

MECHANICAL UNIT INSTALLATION INSTRUCTIONS

8.5.2 INSTALLATION METHODS U-SERIES ROBOTS

Figures 8-10 to 8-12 illustrate different types of installation and specifications for U-
series robots.

Figure 8-10 Installation of Base-to-Steel Plate on Concrete Floor

Table 8-1 U-Series Robot Base-to-Steel Plate Mounting Specifications

Thickness of High Tension Depth of

Model
Steel Plate Bolt High Tension Bolt

UZ100 / UZ120

UZ150 / UX100

UX120 / UX150

UX200 32mm min. 8 - M20 25mm min.

UT100 / UT120

UT150

UD100 / UD150

Figure 8-11 Installation of Base-to-Concrete Floor

April 26, 1999 8-9

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MECHANICAL UNIT INSTALLATION INSTRUCTIONS

Table 8-2 U-Series Robot Base-to-Concrete Floor Mounting Specifications

Chemical Thickness Max. Pulling Out Load

Model Driving Depth
Anchor of Concrete (Including Tightening Torque)

UZ100 / UZ120

UZ150 / UX100

UX120 / UX150
127400N
UX200 M20 200mm min. 230mm min.
(1300kgf)
UT100 / UT120

UT150

UD100 / UD150

200 mm Min.
200 mm Min.

32mm Min. Installing Block

Thickness
8 - M20 High Tension Bolts

Figure 8-12 Installing Block Utilization

8-10 April 26, 1999

 Kawasak C SERIES CONTROLLER
INSTALLATION MANUAL

MECHANICAL UNIT INSTALLATION INSTRUCTIONS

8.5.3 OPERATIONAL LOADING U-SERIES ROBOTS

Figure 8-13, Robot Bolt Tension and Hold Down Torques, illustrates the load encoun-
tered during normal operation of the robot. In addition, the robot base plate bolt tension
load is also given.

Max. Load Applied

In Up/Down Direction
2,200 kgf m (15,910 ft lbs)

Max. Load Applied In Repeated Continuous Tension Per Bolt

Side To Side Rotating Direction When 8 Bolts Are Used For Installation:
2,000 kgf m (14,464 ft lbs) 1,600 kg

Figure 8-13 Robot Bolt Tension and Hold Down Torques

April 26, 1999 8-11

 Kawasak C SERIES CONTROLLER
INSTALLATION MANUAL

MECHANICAL UNIT INSTALLATION INSTRUCTIONS

8.6 ROBOT BASE PLATE INSTALLATION F-SERIES ROBOTS

When mounting the robot base plate to floor, it is recommended that M12 or M18
chemical anchors be used, depending upon the robot model number. If chemical an-
chors cannot be used, the robot base plate should be anchored to the floor with eight
(8) M12 or M18 anchor bolts depending upon the robot model number. The robot base
plate must be at least 32mm/1.259 inches thick. Bolt thread engagement must be at
least 25mm into the robot base plate for proper attachment. Figure 8-14 illustrates the
robot and base plate installation requirements.

Figure 8-14 Robot Base Plate Installation Requirements

8-12 April 26, 1999

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MECHANICAL UNIT INSTALLATION INSTRUCTIONS

8.6.1 BASE PLATE INSTALLATION DIMENSIONS F-SERIES ROBOTS

F-series robots can be installed in a few different manners. The robot base plate can be
mounted to a stand and the stand can be mounted to a steel plate. The robot base
plate can be mounted directly to a steel plate. The steel plate can be mounted to a
concrete floor or can be recessed in a concrete floor. Figure 8-15 shows mounting
dimensions for F-series robots.

Figure 8-15 Robot and Base Plate Mounting Dimensions

April 26, 1999 8-13

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MECHANICAL UNIT INSTALLATION INSTRUCTIONS

8.6.2 INSTALLATION METHODS F-SERIES ROBOTS

Figures 8-16 through 8-18 illustrate three primary types of installation and specifications
for F-series robots.

Figure 8-16 Base Installation to Steel Plate in Concrete Floor

8-14 April 26, 1999

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MECHANICAL UNIT INSTALLATION INSTRUCTIONS

Figure 8-17 Base-to-Stand-to-Steel Plate in Concrete Floor

Figure 8-18 Base-to-Stand-to-Steel Plate on Concrete Floor

April 26, 1999 8-15

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MECHANICAL UNIT INSTALLATION INSTRUCTIONS

8.7 MOUNTING OF TOOLS FOR U AND F-SERIES ROBOTS

Bolt length for tool attachment to the tool mounting flange is determined by the depth of
the tapped holes in the mounting flange and tool design. Bolts used for tool attachment
must be high tension bolts grade 10.9 or higher, SCM435 material. Figure 8-19 is an
example of a U-series robot tool mounting flange. Use table 8-3, Flange Dimensions for
specific robot models.

Figure 8-19 Tool Flange

Table 8-3 Flange Dimensions

Hole Centerline Tapped Holes Center Hole

Robot Model Pin Holes
Diameter Dia. / Depth Diameter

UX and UZ Series,
92 6 @ 10/18 2- φ 9H7 55
Except UX200

UD100 150 8 @ 11/through N/A 104

FS06N, FS06L
25H7
FA06N, FA06L 40 4-M6 @ 6-7 mm φ 6H7 Deep 6
Deep 6
FS10C, FS10N

25H7
FC06N, FW06N 40 4-M6 @ 6-7 mm φ 6H7 Deep 6
Deep 7

FS20C, FS20N 40H7

63 4-M6 @ 6-7 mm φ 6H7 Deep 6
FA20N, FS10L Deep 6

FS30N, FS30L 50H7

80 6-M8 @ 8-14 mm φ 8H7 Deep 8
FS45C, FS45N Deep 6

8-16 April 26, 1999

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MECHANICAL UNIT INSTALLATION INSTRUCTIONS

8.8 POSITIONING OF THE MECHANICAL UNIT

8.8.1 POSITIONING OF THE ROBOT WITH CONTROLLER

Connect the controller and power supply to the robot. Once the wiring and cabling
connections are completed, the following procedure is used to jog the robot in the joint
mode of operation:

1. First, ensure all personnel are clear of the robot work envelope and all safety
precautions are taken.

2. Place the two-position HOLD/RUN switch in the HOLD position.

3. Place the two-position TEACH/REPEAT switch in the TEACH position.

4. Place teach lock switch in the ON position.

5. Turn main disconnect to the ON position. The CONTROL POWER indicator lamp
will illuminate.

6. Remove the small teach pendant or multi function panel from its holder and check
the LCD display for error conditions. Errors must be cleared to obtain motor power.

7. Place two-position HOLD/RUN switch in RUN position. The MOTOR POWER INDI-
CATOR will not illuminate because a trigger key is not depressed and the MOTOR
POWER ON switch has not been pressed.

8. Press a trigger key. Then press the controller’s MOTOR POWER ON switch. The
MOTOR POWER INDICATOR lamp will illuminate.

9. Ensure teach mode is selected. Press the COORDINATE key until the JOINT
coordinate system for jogging operations has been selected.

10. Kawasaki manipulators have three speeds available for jogging operations. The
jogging speed is selected by toggling the MAN.SPEED key.

11. Follow the instructions on the next page to enable the jogging procedure.

8.8.1.2 ENABLING THE JOGGING PROCEDURE

Press the jog key and a trigger key, then press the desired axis joint 1, joint 2, joint 3,
joint 4, joint 5, joint 6, joint 7 (R,O,D,S,B,T, or V auxiliary axis) direction key to move the
robot either left, right, back, forward, or down and up. Figure 8-20, C Controller Small
Teach Pendant, illustrates the keys that are used in the jogging process.

April 26, 1999 8-17

 Kawasak C SERIES CONTROLLER
INSTALLATION MANUAL

MECHANICAL UNIT INSTALLATION INSTRUCTIONS

For additional information on the small teach pendant and multi function panel, consult
the Kawasaki Robotics (USA), Inc. publication C Controller Operations and Program-
ming Reference Manual.

EMERGENCY
STOP Switc
TEACH LOCK Switc

Liquid
Crystal
Display

Trigger Key

Jog Key

Figure 8-20 C Controller Small Teach Pendant

8.8.2 POSITIONING THE MECHANICAL UNIT WITH BRAKE RELEASE SWITCHES

Connect the controller power supply to the robot. Connect the brake release switches
cable to connector CN5 on the 1GB board. Once wiring and cabling connections are
completed, the following procedure is used to release the brakes on the mechanical
unit.

! WARNING
Unsupported axes may fall when the brake release
switch is pressed. Axes that are overhung, particularly
joint 2 and joint 3 (O-axis, D-axis), will fall the fastest
depending on robot position, weight of the end-of-arm
tooling, and wrist axis position.

8-18 April 26, 1999

 Kawasak C SERIES CONTROLLER
INSTALLATION MANUAL

MECHANICAL UNIT INSTALLATION INSTRUCTIONS

ON OFF

TEACH LOCK

EMERGENCY STOP

ERROR MOTOR POWER

ERROR RESET CYCLE START

TEACH REPEAT HOLD RUN

HOST

MFP
AC115V 1A

Figure 8-21 N. American C Controller

• Place two-position HOLD/RUN switch in HOLD position.

• Turn main disconnect to the ON position. The CONTROL POWER indicator lamp
will illuminate.

• Select the joint to be positioned. Press and hold the corresponding brake release
switch.

• Manually move the desired joint to its new position.

• Release brake switch.

• Continue with procedure one joint at a time, until desired robot position is achieved.

April 26, 1999 8-19

 Kawasak C SERIES CONTROLLER
INSTALLATION MANUAL

APPENDIX

A.0 APPENDIX ...................................................................................................... A-2

A.1 Conversion Tables............................................................................................ A-2
A1.1 Conversion from Fractional Inches to Millimeters ............................................ A-3
A.1.2 Conversion from Millimeters to Inches ............................................................ A-4
A.1.3 Conversion from Decimal Inches to Millimeters............................................... A-5
A.1.4 Conversion from Foot-Pounds to Meter-Kilograms .......................................... A-6
A.1.5 Conversion of Inch-Pounds from/to Inch-Ounces ............................................ A-7
A.1.6 Conversion of Foot-Pounds from/to Inch-Pounds ............................................ A-8
A.1.7 Conversion of Inch-Pounds from/to Centimeter-Kilograms .............................. A-9
A.1.8 Conversion of Foot-Pounds from/to Meter-Kilograms .................................... A-10
A.1.9 Conversion of Foot-Pounds from/to Newton-Meters ...................................... A-11
A.1.10 Conversion of Inch-Pounds from/to Newton-Meters ...................................... A-12
A.1.11 Conversion of Meter-Kilograms from/to Newton-Meters ................................ A-13
A.2 Standard Torque Tables ................................................................................. A-14

April 26, 1999 A-1

 Kawasak C SERIES CONTROLLER
INSTALLATION MANUAL

APPENDIX

A.0 APPENDIX

A.1 CONVERSION TABLES

Table A-1 Standard Conversions

Prefixes for Units:

Units of Length:
Prefix Symbol Power km x 0.6212 = mile
mega M x 1,000,000 m x 3.281 = ft
kilo k x 1,000 mm x 0.03937 = in
centi c x 0.01
Units of Torque:
mili m x 0.001
Nm x 0.1020 = kg-m
micro µ x 0.000001
Nm x 0.7376 = ft-lb
Units of Mass: Nm x 8.851 = in-lb
kg x 2.205 = lb
kg-m x 9.807 = Nm
g x 0.03527 oz
kg-m x 7.233 = ft-lb

Units of Volume: kg-m x 86.80 in-lb

L x 0.2642 = gal (US)
L x 0.2200 = gal (imp) Units of Pressure:
2
L x 1.057 = qt (US) kPa x 0.01020 = kg/cm

L x 0.8799 = qt (imp) kPa x 0.1450 = psi

L x 2.113 = pint US) kPa x 0.7501 = cmHg

kg/cm 2 x 98.07 = kPa
L x 1.816 = pint (imp)
2
mL x 0.03381 = oz (USA) kg/cm x 14.22 = psi

mL x 0.02816 = oz (imp) cmHg x 1.333 kPa

mL x 0.06102 = cu in
Units of Speed:
Units of Force:
N x 0.1020 = kg km/h x 0.6214 = mph

N x 0.2248 = lb
Units of Power:
kg x 9.807 = N
kW x 1.360 = PS
kg x 2.205 = lb
kW x 1.341 = HP
Units of Temperature: PS x 0.7355 = kW
9 (˚C + 40) 5 (˚F + 40) PS x 0.9863 = HP
40 = ˚F 40 = ˚C
5 9

˚F ˚F
32 68 104 176 284
-40 -20 0 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320

-40 -20 0 20 40 60 80 100 120 140 160

-17.8 4.4 26.7 48.9 71.1 93.3 116 138 ˚C
˚C

A-2 April 26, 1999

 Kawasak C SERIES CONTROLLER
INSTALLATION MANUAL

APPENDIX

A1.1 CONVERSION FROM FRACTIONAL INCHES TO MILLIMETERS

Table A-2 Conversion from Fractional Inches to Millimeters

Inch mm Inch mm
1/64 0.015625 0.396875 33/64 0.515625 13.096875
1/32 0.031250 0.793750 17/32 0.531250 13.493750
3/64 0.046875 1.190625 35/64 0.546875 13.890625

1/16 0.062500 1.587500 9/16 0.562500 14.287500

5/64 0.078125 1.984375 37/64 0.0578125 14.684375

3/32 0.093750 2.381250 19/32 0.593750 15.081250
7/64 0.109375 2.778125 39/64 0.609375 15.478125

1/8 0.125000 3.175000 5/8 0.625000 15.875000

9/64 0.140625 3.571875 41/64 0.640625 16.271875

5/32 0.156250 3.968750 21/32 0.656250 16.668750
11/64 0.171875 4.365625 43/64 0.671875 17.065625

3/16 0.187500 4.762500 11/16 0.687500 17.462500

13/64 0.203125 5.159375 45/64 0.703125 17.859375

7/32 0.281750 5.556250 23/32 0.718750 18.256250
15/64 0.234375 5.953125 47/64 0.734375 18.653125

1/4 0.250000 6.350000 3/4 0.750000 19.050000

17/64 0.265625 6.746875 49/64 0.765625 19.446875

9/32 0.218250 7.143750 25/32 0.781250 19.843750
19/64 0.296875 7.540625 51/64 0.796875 20.240625

5/16 0.312500 7.937500 13/16 0.812500 20.637500

21/64 0.328125 8.334375 53/64 0.828125 21.034375

11/32 0.343750 8.731250 27/32 0.843750 21.431250
23/64 0.359375 9.128125 55/64 0.859375 21.828125

3/8 0.375000 9.525000 7/8 0.875000 22.225000

25/64 0.390625 9.921875 57/64 0.890625 22.621875

13/32 0.406250 10.318750 29/32 0.906250 23.018750
27/64 0.412875 10.715625 59/64 0.921875 23.415625

7/16 0.437500 11.112500 15/16 0.937500 23.812500

29/64 0.453125 11.509375 61/64 0.953125 24.209375

15/32 0.468750 11.906250 31/32 0.968750 24.606250
31/64 0.484375 12.303125 63/64 0.984375 25.003125

1/2 0.500000 12.700000 1 1.000000 25.400000

Note: All values are exact

April 26, 1999 A-3

 Kawasak C SERIES CONTROLLER
INSTALLATION MANUAL

APPENDIX

A.1.2 CONVERSION FROM MILLIMETERS TO INCHES

Table A-3 Conversion from Millimeters to Inches

mm Inch mm Inch mm Inch

1 0.03937008 36 1.4173228 71 2.7952756
2 0.07874016 37 1.4566929 72 2.8346457
3 0.11811024 38 1.4960630 73 2.8740157
4 0.15748031 39 1.5354331 74 2.9133858
5 0.19685039 40 1.5748031 75 2.9527559

6 0.23622047 41 1.6141732 76 2.9921260

7 0.27559055 42 1.6535433 77 3.0314961
8 0.31496063 43 1.6929134 78 3.0708661
9 0.53433071 44 1.7322835 79 3.1102362
10 0.3937008 45 1.7716535 80 3.1496063

11 0.4330709 46 1.8110236 81 3.1889764

12 0.4724409 47 1.8503937 82 3.2283465
13 0.5118110 48 1.8897638 83 3.2677165
14 0.5511811 49 1.9291339 84 3.3070866
15 0.5905512 50 1.9685039 85 3.3464567

16 0.6299213 51 2.0078740 86 3.3855268

17 0.6692913 52 2.0472241 87 3.4251968
18 0.7086614 53 2.0866142 88 3.4645669
19 0.7480315 54 2.1259842 89 3.5039370
20 0.7874016 55 2.1653543 90 3.5433071

21 0.8267717 56 2.2047244 91 3.5826772

22 0.8661417 57 2.2440945 92 3.6220472
23 0.9055118 58 2.2834646 93 3.6614173
24 0.9448819 59 2.3228346 94 3.7007874
25 0.9842520 60 2.3622047 95 3.7401575

26 1.0236220 61 2.4015748 96 3.7795276

27 1.0629921 62 2.4409949 97 3.8188976
28 1.1023622 63 2.4803150 98 3.8582677
29 1.1417323 64 2.5196850 99 3.8976378
30 1.1811024 65 2.5590551 100 3.937008

31 1.2204724 66 2.5984252
32 1.2598425 67 2.6377953
33 1.2992126 68 2.6771654
34 1.3385827 69 2.7165354
35 1.3779528 70 2.7559055
Note: inch values are rounded off.

To convert mm to inches: divide 25.4 into known mm.

A-4 April 26, 1999

 Kawasak C SERIES CONTROLLER
INSTALLATION MANUAL

APPENDIX

A.1.3 CONVERSION FROM DECIMAL INCHES TO MILLIMETERS

Table A-4 Conversion from Decimal Inches to Millimeters

mm Inch mm Inch mm Inch
1 25.4 36 914.4 71 1803.4
2 50.8 37 939.8 72 1828.8
3 76.2 38 965.2 73 1854.2
4 101.6 39 990.6 74 1879.6
5 127.0 40 1016.0 75 1905.0

6 152.4 41 1041.4 76 1930.4

7 177.8 42 1066.8 77 1955.8
8 203.2 43 1092.2 78 1981.2
9 228.6 44 1117.6 79 2006.6
10 254.0 45 1143.0 80 2032.0

11 279.4 46 1168.4 81 2057.4

12 304.8 47 1193.8 82 2082.8
13 330.2 48 1219.2 83 2108.2
14 355.6 49 1244.6 84 2133.6
15 381.0 50 1270.0 85 2159.0

16 406.4 51 1295.4 86 2184.4

17 431.8 52 1320.8 87 2209.8
18 457.2 53 1346.2 88 2235.2
19 482.6 54 1371.6 89 2260.6
20 508.0 55 1397.0 90 2286.0

21 533.4 56 1422.4 91 2311.4

22 558.8 57 1447.8 92 2336.8
23 584.2 58 1473.2 93 2362.2
24 609.6 59 1498.6 94 2387.6
25 635.0 60 1524.0 95 2413.0

26 660.4 61 1549.4 96 2438.4

27 685.8 62 1574.8 97 2463.8
28 711.2 63 1600.2 98 2489.2
29 736.6 64 1625.6 99 2514.6
30 762.0 65 1651.0 100 2540.0

31 787.4 66 1676.4
32 812.8 67 1701.8
33 838.2 68 1727.2
34 863.6 69 1752.6
35 889.0 70 1778.0
Note: inch values are rounded off.

April 26, 1999 A-5

 Kawasak C SERIES CONTROLLER
INSTALLATION MANUAL

APPENDIX

A.1.4 CONVERSION FROM FOOT-POUNDS TO METER-KILOGRAMS

The chart below can be used to convert foot-pounds to meter-kilograms. The foot-
pound column at the left increases in 10 ft.-lb. increments from 0 to 110 ft.-lbs. For each
additional ft.-lb., read the top row of numbers. For example, If you desire 45 ft. lbs., you
would look to the number 40 in the left column and the number 5 in the top row. The
conversion to meter-kilograms would be 6.22 Mkgs.
The conversion formula is: FT.-LBS. X 0.1383 = METER-KILOGRAMS.

Table A-5 Conversion from Foot-Pounds to Meter-Kilograms

FROM FOOT-POUNDS TO METER-KILOGRAMS

Ft. 0 1 2 3 4 5 6 7 8 9
Lbs. Mkgs Mkgs Mkgs Mkgs Mkgs Mkgs. Mkgs. Mkgs Mkgs Mkgs.

0 0 .14 .28 .42 .55 .69 .83 .97 1.11 1.25

10 1.38 1.52 1.66 1.80 1.94 2.07 2.21 2.35 2.49 2.63

20 2.77 2.90 3.04 3.18 3.32 3.46 3.60 3.73 3.87 4.01

30 4.15 4.29 4.43 4.58 4.70 4.84 4.98 5.12 5.26 5.39

40 5.53 5.67 5.81 5.95 6.09 6.22 6.36 6.50 6.64 6.78

50 6.92 7.05 7.19 7.33 7.47 7.61 7.75 7.88 8.02 8.16

60 8.30 8.44 8.57 8.71 8.85 8.90 9.13 9.27 9.40 9.54

70 9.68 9.82 9.96 10.09 10.23 10.37 10.51 10.65 10.79 10.92

80 11.01 11.20 11.34 11.48 11.62 11.75 11.89 12.03 12.17 12.31

90 12.45 12.59 12.73 12.86 13.00 13.14 13.26 13.42 13.55 13.69

100 13.83 13.97 14.11 14.25 14.38 14.52 14.66 14.80 14.94 15.08

110 15.21 15.35 15.49 15.63 15.76 15.90 16.04 16.18 16.32 16.46

A-6 April 26, 1999

 Kawasak C SERIES CONTROLLER
INSTALLATION MANUAL

APPENDIX

A.1.5 CONVERSION OF INCH-POUNDS FROM/TO INCH-OUNCES

Table A-6 Conversion from Inch-Pounds to Inch-Ounces

FROM IN.-LB. TO IN.-OZ.

0 1 2 3 4 5 6 7 8 9
in. lb.
in.oz. in.oz. in.oz. in.oz. in.oz. in.oz. in.oz. in.oz. in.oz. in.oz.

0 0 16 32 48 64 80 96 112 128 144

10 160 176 192 208 224 240 256 272 288 304

20 320 336 352 368 384 400 416 432 448 464

30 480 496 512 528 544 560 576 592 608 624

40 640 656 672 688 704 720 736 752 768 784

50 800 816 832 848 864 880 896 912 928 944

60 960 976 992 1008 1024 1040 1056 1072 1088 1104

70 1120 1236 1152 1168 1184 1200 1216 1232 1248 1264

80 1280 1296 1312 1328 1344 1360 1376 1392 1408 1424

90 1440 1456 1472 1488 1504 1520 1536 1552 1568 1584

100 1600

in.lb. x 16 = in.oz.

Table A-7 Conversion from Inch-Ounces to Inch-Pounds

FROM IN.-OZ. TO IN-.LB.

0 1 2 3 4 5 6 7 8 9
in. oz.
in.lb. in.lb. in.lb. in.lb. in.lb. in.lb. in.lb. in.lb. in.lb. in.lb.

0 0 .063 .125 .188 .250 .313 .375 .438 .500 .563

10 .625 .688 .750 .813 .875 .938 1.000 1.063 1.125 1.188

20 1.250 1.313 1.375 1.438 1.500 1.563 1.625 1.688 1.750 1.813

30 1.875 1.938 2.000 2.063 2.125 2.188 2.250 2.313 2.375 2.458

40 2.500 2.563 2.625 2.688 2.750 2.813 2.875 2.938 3.000 3.063

50 3.125 3.188 3.250 3.313 3.375 3.438 3.500 3.563 3.625 3.688

60 3.750 3.813 3.875 3.938 4.000 4.063 4.125 4.188 4.250 4.313

70 4.375 4.438 4.500 4.563 4.625 4.688 4.750 4.813 4.875 4.938

80 5.000 5.063 5.125 5.188 5.250 5.313 5.375 5.438 5.500 5.563

90 5.625 5.688 5.750 5.813 5.875 5.938 6.000 6.063 6.125 6.188

100 6.250

in.oz. ÷ 16 = in.lb.

April 26, 1999 A-7

 Kawasak C SERIES CONTROLLER
INSTALLATION MANUAL

APPENDIX

A.1.6 CONVERSION OF FOOT-POUNDS FROM/TO INCH-POUNDS

Table A-8 Conversion from Foot-Pounds to Inch-Pounds

FROM FT.-LB. TO IN.-LB.

0 1 2 3 4 5 6 7 8 9
ft. lb.
in.lb. in.lb. in.lb. in.lb. in.lb. in.lb. in.lb. in.lb. in.lb. in.lb.

0 0 12 24 36 48 60 72 84 96 108

10 120 132 144 156 168 180 192 204 216 228

20 240 252 264 276 288 300 312 324 336 348

30 360 372 384 396 408 420 432 444 456 468

40 480 492 504 516 528 540 552 564 576 588

50 600 612 624 636 648 660 672 684 696 708

60 720 732 744 756 768 780 792 804 816 828

70 840 852 864 876 888 900 912 924 936 948

80 960 972 984 996 1008 1020 1032 1044 1056 1068

90 1080 1092 1104 1116 1128 1140 1152 1164 1176 1188

100 1200

ft. lb. X 12 = in. lb

Table A-9 Conversion from Inch-Pounds to Foot-Pounds

FROM IN.-LB. TO FT.-LB.

0 1 2 3 4 5 6 7 8 9
in. lb.
ft. lb. ft. lb. ft. lb. ft. lb. ft. lb. ft. lb. ft. lb. ft. lb. ft. lb. ft. lb.

0 0 12 24 36 48 60 72 84 96 108

10 120 132 144 156 168 180 192 204 216 228

20 240 252 264 276 288 300 312 324 336 348

30 360 372 384 396 408 420 432 444 456 468

40 480 492 504 516 528 540 552 564 576 588

50 600 612 624 636 648 680 672 684 696 708

60 720 732 744 756 768 780 792 804 816 828

70 840 852 864 876 888 900 912 924 936 948

80 960 972 984 996 1008 1020 1032 1044 1056 1068

90 1080 1092 1104 1116 1128 1140 1152 1164 1176 1188

100 1200

in. lb. : 12= ft.lb.

A-8 April 26, 1999

 Kawasak C SERIES CONTROLLER
INSTALLATION MANUAL

APPENDIX

A.1.7 CONVERSION OF INCH-POUNDS FROM/TO CENTIMETER-KILOGRAMS

Table A-10 Conversion from Inch-Pounds to Centimeter-Kilograms

FROM IN.-LB. TO CMKG

0 1 2 3 4 5 6 7 8 9
in. lb.
cmkg cmkg. cmkg cmkg cmkg cmkg cmkg cmkg cmkg cmkg

0 0 1.152 2.304 3.456 4.608 5.760 6.912 8.064 9.217 10.36

10 11.52 12.67 13.83 14.97 16.13 17.28 18.43 19.59 20.74 21.89

20 23.04 24.19 25.35 26.49 27.65 28.80 29.96 31.07 32.26 33.41

30 34.56 35.71 36.87 38.02 39.17 40.32 41.47 42.62 43.77 36.60

40 46.09 47.23 48.39 49.54 50.69 51.85 52.99 54.14 55.29 56.45

50 57.61 58.75 59.90 61.06 62.21 63.37 64.51 65.66 66.81 67.96

60 69.13 70.27 71.42 72.57 73.73 74.89 76.03 77.18 78.33 79.49

70 80.65 81.79 82.94 84.05 85.21 86.41 87.58 88.75 89.91 91.00

80 92.17 93.32 94.49 95.66 96.83 97.93 99.08 100.2 101.4 102.6

90 103.7 104.9 106.1 107.20 108.3 109.50 110.70 111.8 112.9 114.1

100 115.2 116.35 117.5 118.66 119.80 120.96 122.11 123.26 124.42 125.56

in. lb. X 1.152 = cmkg

Table A-11 Conversion from Centimeter-Kilograms to Inch-Pounds

FROM CMKG TO IN.-LB.

0 1 2 3 4 5 6 7 8 9
cmkg
in. lb. in. lb. in. lb. in. lb. in. lb. in. lb. in. lb. in. lb. in. lb. in. lb.

0 0 .868 1.735 2.603 3.471 4.339 5.206 6.074 6.942 7.809

10 8.677 9.545 10.412 11.280 12.148 13.016 13.883 14.751 15.619 16.486

20 17.354 18.222 19.089 19.957 20.825 21.693 22.560 23.428 24.296 25.163

30 26.031 26.899 27.766 28.634 29.502 30.370 31.237 32.105 32.973 33.840

40 34.708 35.576 36.443 37.311 38.179 39.047 39.914 40.782 41.650 42.517

50 43.385 44.253 45.120 45.988 46.856 47.724 48.591 49.459 50.327 51.194

60 52.062 52.930 53.797 54.665 55.533 56.401 57.268 58.136 59.004 59.871

70 60.739 61.607 62.474 63.342 64.010 65.078 65.945 66.813 67.681 68.548

80 69.416 70.284 71.151 72.019 72.019 73.754 74.622 75.490 76.358 77.225

90 78.093 78.961 79.828 80.670 80.670 82.432 83.299 84.167 85.035 85.902

100 86.77 87.638 88.505 89.373 90.241 91.109 91.976 92.844 93.712 94.579

cmkg X 0.8677 = in. lb.

April 26, 1999 A-9

 Kawasak C SERIES CONTROLLER
INSTALLATION MANUAL

APPENDIX

A.1.8 CONVERSION OF FOOT-POUNDS FROM/TO METER-KILOGRAMS

Table A-12 Conversion from Foot-Pounds to Meter-Kilograms

FROM FT.-LB. TO MKG

0 1 2 3 4 5 6 7 8 9
ft. lb.
mkg mkg mkg mkg mkg mkg mkg mkg mkg mkg

0 0 0.138 0.277 0.415 0.553 0.691 0.830 0.968 1.106 1.245

10 1.383 1.521 1.660 1.798 1.936 2.074 2.212 2.351 2.489 2.628

20 2.766 2.904 3.043 3.181 3.319 3.457 3.596 3.734 3.872 4.011

30 4.149 4.287 4.426 4.564 4.702 4.840 4.979 5.117 5.255 5.394

40 5.532 5.670 5.809 5.947 6.085 6.223 6.362 6.500 6.638 6.777

50 6.915 7.053 7.191 7.330 7.468 7.606 7.745 7.883 8.021 8.159

60 8.298 8.436 8.574 8.713 8.851 8.989 9.128 9.266 9.404 9.543

70 9.681 9.819 9.957 10.09 10.23 10.37 10.51 10.65 10.79 10.92

80 11.06 11.20 11.34 11.48 11.62 11.75 11.89 12.03 12.17 12.31

90 12.45 12.59 12.73 12.86 13.00 13.14 13.28 13.42 13.55 13.69

100 13.83

ft. lb. X .1383 = mkg

Table A-13 Conversion from Meter-Kilograms to Foot-Pounds

FROM MKG TO FT. LB.

0 1 2 3 4 5 6 7 8 9
mkg
ft. lb. ft. lb. ft. lb. ft. lb. ft. lb. ft. lb. ft. lb. ft. lb. ft. lb. ft. lb.

0 0 7.23 14.47 21.7 28.93 36.17 43.40 50.63 57.86 65.10

10 72.4 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4

20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8

30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 284.1

40 289.3 296.6 303.9 311.0 318.3 325.5 332.7 340.0 347.2 354.4

50 361.7 368.9 376.1 383.3 390.6 397.8 405.0 412.3 419.5 426.7

60 434.0 441.2 448.4 455.7 462.9 470.1 477.4 484.6 491.8 499.1

70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4

80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7

90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1

100 723.3

mkg. X 7.233 = ft.lb.

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APPENDIX

A.1.9 CONVERSION OF FOOT-POUNDS FROM/TO NEWTON-METERS

Table A-14 Conversion from Foot-Pounds to Newton-Meters

FROM FT.-LB. TO NM

0 1 2 3 4 5 6 7 8 9
ft. lb.
Nm Nm Nm Nm Nm. Nm Nm Nm Nm Nm

0 0 1.36 2.71 4.07 5.42 6.78 8.13 9.49 10.84 12.20

10 13.56 14.91 16.27 17.62 18.98 20.33 21.69 23.05 24.40 25.76

20 27.11 28.47 29.82 31.18 32.54 33.89 35.25 36.61 37.97 39.32

30 40.67 42.02 43.48 43.38 46.09 47.45 48.80 50.16 51.51 52.87

40 54.22 55.58 56.94 56.94 59.65 61.00 62.36 63.71 65.07 66.42

50 67.78 69.14 70.49 70.49 73.20 74.56 75.91 77.27 78.62 79.98

60 81.33 82.69 84.05 84.05 86.76 88.11 89.47 90.83 92.18 93.54

70 94.89 96.25 97.60 97.60 100.31 101.67 103.03 104.38 105.74 107.09

80 108.45 109.80 111.16 112.51 113.87 115.23 116.58 117.94 119.29 120.65

90 122.00 123.36 124.72 126.07 127.43 128.78 130.14 131.49 132.85 134.20

100 135.66

ft. lb. X 1.3556 = Nm

Table A-15 Conversion from Newton-Meters to Foot-Pounds

FROM NM TO FT.-LB.

0 1 2 3 4 5 6 7 8 9
Nm
ft. lb. ft. lb. ft. lb. ft. lb. ft. lb. ft. lb. ft. lb. ft. lb. ft. lb. ft. lb.

0 0 .74 1.48 2.21 2.95 3.69 4.43 5.16 5.90 6.64

10 7.38 8.11 8.85 9.59 10.33 11.06 11.80 12.54 13.28 14.01

20 14.75 15.49 16.23 16.96 17.70 18.44 19.18 19.91 20.65 21.39

30 22.13 22.86 23.60 24.34 25.08 25.81 26.55 27.29 28.03 28.76

40 29.50 30.24 30.98 31.72 32.45 33.19 33.93 34.67 35.40 36.14

50 36.88 37.62 38.35 39.09 39.83 40.57 41.30 42.04 42.78 43.52

60 44.25 44.99 45.73 46.47 47.20 47.94 48.68 49.42 50.15 50.89

70 51.63 52.37 53.10 53.84 54.58 55.32 56.05 56.79 57.53 58.27

80 59.00 59.74 60.48 61.22 61.96 62.69 63.43 64.17 64.19 65.64

90 66.38 67.12 67.86 68.59 69.33 70.07 70.81 71.54 72.28 73.02

100 73.76

1 Nm =0.73756 ft.lb.

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APPENDIX

A.1.10 CONVERSION OF INCH-POUNDS FROM/TO NEWTON-METERS

Table A-16 Conversion from Inch-Pounds to Newton-Meters

FROM IN.LB. TO NM

0 1 2 3 4 5 6 7 8 9
in.lb.
Nm Nm Nm Nm Nm. Nm Nm Nm Nm Nm

0 0 .113 .226 .339 .452 .565 .678 .791 .904 1.02

10 1.13 1.24 1.36 1.47 1.58 1.70 1.81 1.92 2.03 2.15

20 2.26 2.37 2.49 2.60 2.71 2.83 2.94 3.05 3.16 3.28

30 3.39 3.50 3.62 3.73 3.84 3.96 4.07 4.18 4.29 4.41

40 4.52 4.63 4.75 4.86 4.97 5.09 5.20 5.31 5.42 5.54

50 5.65 5.76 5.88 5.99 6.10 6.22 6.33 6.44 6.55 6.67

60 6.78 6.89 7.01 7.12 7.23 7.35 7.46 7.57 7.68 7.80

70 7.91 8.02 8.14 8.25 8.36 8.48 8.59 8.70 8.81 8.93

80 9.04 9.15 9.27 9.38 9.49 9.61 9.72 9.83 9.94 10.06

90 10.17 10.28 10.40 10.51 10.62 10.74 10.85 10.96 11.07 11.19

100 11.30

in. lb. X .1130 = Nm

Table A-17 Conversion from Newton-Meters to Inch-Pounds

FROM NM TO IN-.LB.

0 1 2 3 4 5 6 7 8 9
Nm
in.lb. in.lb. in.lb. in.lb. in.lb. in.lb. in.lb. in.lb. in.lb. in.lb.

0 0 8.85 17.70 26.55 35.40 44.25 53.10 61.95 70.81 79.66

10 88.51 97.36 106.21 115.06 123.91 132.76 141.61 150.46 159.31 168.16

20 177.01 185.86 194.72 203.57 212.42 221.27 230.12 238.98 247.82 256.67

30 265.52 274.38 283.22 292.07 300.92 309.77 318.62 327.48 336.33 345.18

40 354.03 362.88 371.73 380.58 389.43 398.28 407.13 415.98 424.83 433.68

50 442.53 451.36 460.24 469.09 477.94 486.79 495.64 504.49 513.34 522.19

60 531.04 539.89 548.74 557.59 566.44 575.30 584.15 592.10 601.85 610.70

70 619.55 628.40 637.25 646.10 654.95 663.80 672.65 681.50 690.35 699.20

80 708.06 716.91 725.76 734.61 743.46 752.31 761.16 770.01 778.86 787.21

90 796.56 805.41 814.26 823.12 831.97 840.82 849.67 858.52 867.37 876.22

100 885.07

NM X 8.8507= in.lb.

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APPENDIX

A.1.11 CONVERSION OF METER-KILOGRAMS FROM/TO NEWTON-METERS

Table A-18 Conversion from Meter-Kilograms to Newton-Meters

FROM MKG TO NM

0 1 2 3 4 5 6 7 8 9
mkg
Nm Nm Nm Nm Nm. Nm Nm Nm Nm Nm

0 0 9.81 19.61 29.42 39.23 49.03 58.84 68.65 78.45 88.26

10 98.07 107.87 117.68 127.49 137.30 147.10 156.90 166.71 176.52 186.33

20 196.13 205.94 215.75 225.55 235.36 245.17 254.98 264.78 274.59 284.40

30 294.20 304.00 313.81 323.62 333.43 343.23 353.04 362.85 372.65 382.46

40 392.27 402.07 411.88 421.69 431.49 441.30 451.11 460.91 470.72 480.53

50 490.33 500.14 509.95 519.75 529.56 529.37 549.17 558.98 568.79 578.60

60 588.40 598.21 608.01 617.82 627.63 637.43 647.24 657.05 666.86 676.66

70 686.47 696.27 706.08 715.89 725.70 735.50 745.30 755.11 764.92 774.73

80 784.53 794.34 804.15 813.95 823.76 833.57 843.37 853.18 862.99 872.79

90 882.60 892.41 902.21 912.02 921.83 931.63 941.44 951.25 961.05 970.86

100 980.67

mkg (or kpm) = 9.80665 Nm

Table A-19 Conversion from Newton-Meters to Meter-Kilograms

FROM NM TO MKG

0 1 2 3 4 5 6 7 8 9
Nm
mkg mkg mkg mkg mkg mkg mkg mkg mkg mkg

0 0 .102 .204 .306 .408 .510 .611 .714 .816 .918

10 1.020 1.122 1.224 1.326 1.428 1.530 1.632 1.733 1.835 1.937

20 2.039 2.141 2.243 2.345 2.447 2.549 2.651 2.753 2.855 2.957

30 3.059 3.161 3.263 3.365 3.467 3.569 3.569 3.773 3.875 3.977

40 4.079 4.181 4.383 4.385 4.487 4.589 4.589 4.793 4.895 4.997

50 5.099 5.200 5.302 5.404 5.506 5.608 5.608 5.812 5.914 6.016

60 6.118 6.220 6.322 6.424 6.526 6.628 6.628 6.832 6.934 7.036

70 7.138 7.240 7.342 7.444 7.546 7.648 7.648 7.852 7.954 8.056

80 8.158 8.260 8.362 8.464 8.565 8.667 8.667 8.871 8.973 9.075

90 9.177 9.279 9.381 9.483 9.585 9.687 9.687 9.891 9.993 10.095

100 10.197

Nm X .10197 = mkg (or kpm)

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APPENDIX

A.2 STANDARD TORQUE TABLES

These tables relate tightening torque to thread diameter and list the basic torque for
bolts and nuts. Use the tables only for bolts and nuts which do not require a specific
torque value, and which are being screwed into steel or cast iron. If screws are inserted
in aluminum or aluminum alloys, torque must be reduced. All values are for use with
dry, solvent-cleaned threads.

Table A-20 General Fasteners Standard Torque Values

Thread Torque
Diameter (mm) N-m kg-m ft-lb
5 3.4 - 4.9 0.35 - 0.50 30 - 43 in-lb
6 5.9 - 7.8 0.60 - 0.80 52 - 69 in-lb
8 14 - 19 1.4 - 1.9 10.0 - 13.5
10 25 - 39 2.6 - 3.5 19.0 - 25
12 44 - 61 4.5 - 6.2 33 - 45
14 73 - 98 7.4 - 10.0 54 - 72
16 115 - 155 11.5 - 16.0 83 - 115
18 165 - 225 17.0 - 23 125 - 165
20 225 - 325 23 - 33 165 - 240

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APPENDIX

Table A-21 Special Material Fastener Torque Values

Cap Screw Torque kg-cm (ft-lb)

Size SCM3 S45C SS41

M3 - - -

4 35 (2.53) 20 (1.44) 10 (0.72)

5 70 (5.06) 40 (2.89) 20 (1.44)

6 120 (8.67) 70 (5.06) 30 (2.16)

8 300 (21.69) 170 (12.29) 80 (5.78)

10 580 (41.95) 340 (24.59) 160 (11.57)

12 1000 (72.35) 600 (43.39) 280 (20.25)

14 1600 (115.72) 900 (65.09) 420 (30.37)

16 2400 (173.5) 1400 (101.26) 650 (47.0)

18 3400 (245.92) 1900 (137.42) 880 (63.6)

20 4400 (318.25) 2700 (195.29) 1300 (94)

* Values in parentheses are foot-pounds (ft-lb)

Material Key:

SS41 - Mild Steel

S45C - Carbon Steel
SCM3 - Chrome/Moly Steel

! CAUTION
There are many varying factors which affect torque.
The figures in the following charts are safe figures for
standard torque applications only; when fasteners are
screwed into steel or cast iron threads only.

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APPENDIX

Table A-22 Torque Values

FASTENER

SAE SAE SAE SAE SOCKET HEAD SOCKET HEAD MACHINE SCREW
TYPE
1 OR 2 5 7 8 CAP SCREW SET SCREW YELLOW BRASS
MIN. TENSILE
74,000 PSI 120,000 PS1 133,000 PSI 150,000 PSI 160,000 PSI 212,000 PSI 60,000 PSI
STRENGTH
MEDIUM CARBON
ALLOY STEEL,
MED. CARBON MEDIUM CARBON 63% COPPER
QUENCHED AND HIGH CARBON HIGH CARBON
LOW OR MEDIUM STEEL, ALLOY STEEL, (Cu)
MATERIAL TEMPERED, CASE HARDENED CASE HARDENED
CARBON STEEL QUENCHED AND QUENCHED AND 37% ZINC
ROLL THREADED STEEL STEEL
TEMPERED TEMPERED (Zn)
AFTER HEAT
TREATMENT
BODY SIZE
OR
TORQUE VALUE
OUTSIDE
DIAMETER
All values are foot pounds unless noted by * indicating inch pounds
OF
FASTENER
3 2*
4 3.3*
5 4.4*
6 9* 6.4*
8 16* 8*
10 30* 16*
1/4 6 10 13 14 16 70* 20*
5/16 12 19 25 29 33 140* 65*
3/8 20 33 44 47 54 18 110*
7/16 32 54 71 78 84 29 17
1/2 47 78 110 119 125 43 27
9/16 69 114 154 169 180 63 37
5/8 96 154 215 230 250 100 49
3/4 155 257 360 380 400 146 78
7/8 206 382 570 600 640 104
1 310 587 840 900 970 160
1 1/8 480 794 1325 1430 1520 215
1 1/4 675 1105 1825 1975 2130 325
1 3/8 900 1500 2500 2650 2850 400
1 1/2 1100 1775 3000 3200 3450
1 5/8 1470 2425 4000 4400 4700
1 3/4 1900 3150 5300 5650 6100
1 7/8 2360 4200 7000 7600 8200
2 2750 4550 7500 8200 8800
2 1/4 3450 6550 11000 12000 13000
2 1/2 4400 7175 15000 17000 18000
2 3/4 7350 13000 21000 23000 24000
3 9500 16000 27000 29000 31000

NOTE: In the above chart there is no distinction between the torque figures for fine or
coarse threads. The torque figures for a finely threaded fastener as compared to a
coarsely threaded fastener of the same diameter, may be slightly higher, but hardly
worth mentioning.

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GLOSSARY

GLOSSARY ............................................................................................................... G-2

April 26, 1999 G-1

 Kawasak C SERIES CONTROLLER
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GLOSSARY

This glossary contains definitions of terms used by operators, programmers, and main-
tenance personnel who work with Kawasaki Robots. The definitions are listed in alpha-
betical order.

A
• ACCELERATE
To speed up a process.

• ACCURACY
A measure of the difference between the commanded robot arm position and the
actual position. Also identifies how well an indicated value conforms to a true value
(i.e., an actual or accepted standard value).

• ACRONYM
A term made up of the initial letters of words in a set phrase. For example, LED is
an acronym for light emitting diode.

• ADDRESS
A number that identifies a specific location in the computer’s or processor’s memory.
Means of identifying a location or data in a control system.

• ADDRESSING
Computer operations store data in specific memory locations or addresses. The
largest memory location determines the amount of data that can be stored. The
larger the number, the larger the possible program.

• AIR CUT
Moving a weld gun into position but without generating an arc.

• ALGORITHM
A finite set of well-defined rules or procedures for solving a problem step-by-step.

• ALPHANUMERIC
Pertaining to a set of symbols that contain both letters and numbers, either individu-
ally or in combination.

• AMBIENT TEMPERATURE
The temperature of air or liquid that surrounds a device.

• AMPERE (AMP)
A unit of electrical current flow that is equivalent to one (1) coulomb per second.
One (1) volt across one (1) ohm of resistance causes a current flow that is equiva-
lent to one (1) amp.

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GLOSSARY

• ANALOG
A continuously changing electrical voltage signal. In robot systems, the magnitude
or value of the signal represents commanded robot axis motion.

• ANALOG DATA
Information that is represented by a characteristic of the value or magnitude of an
electrical signal, such as the amplitude, phase, or frequency of the voltage, the
amplitude or duration of a pulse, the angular position of a shaft, or the pressure of a
fluid number.

• ANTI-FRICTION BEARING
A rolling element which is used to support a rotating shaft.

• ARC SENSOR
A sensor that detects weld lines utilizing arc characteristics.

• ARGUMENT
A value applied to a procedure; data used by a function or other command. For
instance, in the AS command JMOVE flange, 2. The variable, flange, and the clamp
number 2 are the arguments of the function JMOVE.

• ARRAY
An ordered set of addresses or their values. Elements of an array can be referenced
individually or collectively. Array elements all have the same type of data, for in-
stance, integer or character, and are usually presented in rows and columns.

• ARTICULATED
To join together permanently or semipermanently by means of a pivot connection for
operating separate segments as a unit.

• ARTICULATED ROBOT
A robot arm which contains at least two consecutive revolute joints, acting around
parallel axes, resembling human arm motion. The work envelope is formed by
partial cylinders or spheres. The two basic types of articulated robots, vertical and
horizontal, are sometimes called anthropomorphic because of the resemblance to
the motions of the human arm.

• ASCII
An acronym for American Standard Code for Information Interchange. This standard
8-bit code is used by many devices, such as keyboards and printers.

• AS LANGUAGE
Kawasaki robot language used to communicate commands and instructions from a
keyboard to the CPU. (AS : Advanced Superior, pronounced AZU)

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GLOSSARY

• ASSIGNMENT
An instruction used to express a sequence of operations, or used to assign oper-
ands to specified variables, or symbols, or both.

• ASYNCHRONOUS
A means of data communication where the data is sent a character at a time pre-
ceded by a start bit and followed by a stop bit. No direct timing signal links the
transmitter and receiver.

• AUXILIARY DATA
Information about a point, other than the positional data, such as speed, accuracy,
weld schedule and clamp condition.

• AXIS
A straight line about which sections of the mechanical unit rotate (e.g., joints JT1,
JT2, JT3 etc.).

B
• BACKLASH
The clearance, slack, or play between adjacent gears, or the jar or reaction often
caused by such clearance when the parts are suddenly put in action or are in
irregular action.

• BASE COORDINATE
A fixed coordinate system having an origin at the intersection of the X, Y, and Z axes.

• BAUD RATE
Determines the number of bits per second (bps) or characters transmitted between
devices.

• BCD
An acronym for binary coded decimal. The BCD 8-4-2-1 code expresses each
decimal digit by its own 4-bit binary equivalent. The 8-4-2-1 code is identical to
binary through the decimal number 9. Above the decimal number 9 each decimal
digit is represented by its own 4-bit binary equivalent. For example, using the 8-4-2-
1 binary-coded system, the number 10 is interpreted as 0001 0000.

• BINARY CODE
A system in which characters are represented by a group of binary digits, that have
the value of either 0 or 1, true or false, on or off.

• BIT
Acronym for binary digit, having one of two values: 0 or 1.

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GLOSSARY

• BOOT
The method by which computers are brought from a non-operating to an operating
state. During this sequence, the computer memory is usually reset. This is often
performed to restart the computer after a crash, to bring it on-line.

• BUFFER
A temporary memory storage area in a computer or electronic device.

• BUG
A problem in a software or hardware element of a system.

• BUS
The primary communication path in the controller along which internal signals are
sent among processors and memories.

C
• CABLE CARRIER
A device which carries cables and hoses (including power sources) from a stationary
location to a linear moving device.

• CARTESIAN COORDINATE
A location in space defined by three axes at right angles to each other, commonly
labeled X, Y, Z.

• cc
cubic centimeter

• CELL
A manufacturing unit consisting of two or more work stations or machines, and the
material transport mechanisms and storage buffers that interconnect them.

• CENTER OF GRAVITY
The point at which the entire weight of a body may be considered as concentrated,
so that if supported at this point the body would remain in equilibrium in any position.

• CHARACTER
A term that describes all numbers, letters, and other symbols typically found on a
computer keyboard.

• CHECK MODE
A procedure that allows the user to check positional data and auxiliary data while in
the teach mode with the Kawasaki robot . This procedure is in many ways analo-
gous to reverse point and forward point operations in other robot models.

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GLOSSARY

• CHECKSUM
A method by which the contents of data or a transmission are verified to be accurate.
This method ‘sums’ all the characters and translates them into a number which is
appended to the data.

• CHEMICAL ANCHOR
A threaded rod installed in a structure (e.g., a concrete floor) and secured by epoxy,
for the purpose of securing hardware.

• CIRCULAR INTERPOLATION
A path taken by the robot that connects at least three points with an arching motion.
The CPU will calculate a path that places the taught points on a section of a circle.

• CLOSED-LOOP SYSTEM
A system in which a command value is output and a feedback value is returned. The
resulting error, the difference between the command and the feedback, is used to
correct the signal. In a robot system, the command signal is output by the controller,
causing the robot arm to move, and the feedback signal is produced by the encoder,
which reads the current position of the arm.

• CODE
A set of rules for expressing information in a language that is understood and pro-
cessed by a control system.

Also, a term for instructions in a computer program. Code performs a process, and
data is the information that is processed.

• COMMAND
An analog signal, or group of signals or pulses, which cause a specified function to
be performed. An instruction or request in a computer program that performs a
particular action. Commands that are needed to run the operating system are called
a command language.

• COMMENT
Optional, non-executing remarks added to a program to explain various aspects of
the program.

• COMPILER
A system task that translates a program written in source code, into binary code that
can be understood by the processor.

• COMPOUND TRANSFORMATION
A location in the Cartesian coordinate system that is defined relative to another
Cartesian coordinate location.

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GLOSSARY

• CONTIGUOUS FILE
A file that is stored in continuously adjacent areas of memory, in contrast to a file
which is scattered to make more efficient use of disk space.

• CONTINUOUS PATH CONTROL

A type of robot control in which the robot moves according to a replay of closely
spaced points programmed on a constant time base during teaching.

• CONTROL ERROR CODE

A code which identifies system problems whenever an alarm condition occurs.

• CONTROLLED AXIS
A robot axis that is operated by electrical or hydraulic power.

• CONTROLLER
An electronic device, with processing capabilities and software, which controls the
robot actions and functions.

• CONVEYER TRACKING
Used to make the robot follow a part on a conveyor, without the use of a traverse
axis.

• COORDINATE
A set of numbers that locate a point in space.

• CPU
Acronym for central processing unit. A collection of hardware in a computer which
performs all calculations, handles I/O, and executes programmed tasks.

• CRASH
A situation where the computer fails to operate, due to a software or hardware prob-
lem.

• CRT
An acronym for cathode ray tube. A CRT is a charge storage tube in which the
information is written by means of the cathode ray beam.

• CURRENT LOOP
A circuit in which a portion of the output is returned to modify the control circuit
output. This circuit may be used as a limiting device, for safety protection.

• CURSOR
A pointer or indicator on a computer screen, that identifies the current position on
the screen.

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GLOSSARY

• CYCLE
A complete path of projectory performed by the robot for a specific application.

• CYCLOIDAL DRIVE
A mechanical gear reduction unit that reduces the speed of the input and increases
the torque capacity. The cycloidal unit consists of an internal arrangement of discs
and pins that are driven by an eccentric drive cam. This type of gear reduction offers
low gear train backlash and the capability to achieve high reduction ratios from a
single contained unit.

D
• DATA
A term given to information, instructions, words or symbols that are usually transmit-
ted, processed, or stored as a group.

• DETENT
A part of a mechanism that locks or unlocks a movement.

• DISCONNECT
A switch that isolates a circuit or one or more pieces of electrical apparatus after the
current has been interrupted by other means.

• DEVIATION ERROR
In all mechanical devices, the actual position of the mechanical unit will lag behind
the electrical command of the controller. An allowable limit is assigned for this differ-
ence. However, if the controller detects a condition where the difference between
this mechanical value and the desired electrical position is larger than the estab-
lished value limit, the robot controller will generate a deviation error. This error is
sometimes referred to as a FOLLOWING ERROR in the robot industry.

• DEBUG
The process by which an operator’s program is checked for mistakes and then cor-
rected.

• DECIMAL NUMBER
Numbers in the base-10 numbering system, which uses the numerals 0 - 9.

• DEDICATED
A term used to describe a system resource, such as an I/O device or terminal, which
is used for only one purpose, or assigned a single function.

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GLOSSARY

• DEDICATED SIGNAL
A term used to describe a signal which is used for only one purpose, or assigned a
single function. Both inputs and outputs can be dedicated.

• DEFAULT
A value or operation that is automatically entered by the system, if the operator does
not specify one. Typically, the default is the standard or expected response.

• DELETE
A command which will eliminate unwanted data.

• DELIMITER
A character which separates a group of items or a character string, from other
groups, or which terminates a task.

• DEVICE
Any peripheral hardware connected to the processor and capable of receiving,
sorting, or transmitting data.

• DIAGNOSTICS
Function performed by the processor to identify and check for error conditions in the
robot arm and peripheral devices.

• DIP SWITCH
DIP is an acronym for dual in-line package. A set of small switches on circuit boards
that can be set for different configurations.

• DIRECTORY
A logical structure that organizes a group of similar files.

• DISK
A high-speed, random-access memory device.

• DISK-BASED SYSTEM
System in which programs and files are stored on the hard disk and are read into
memory when requested by the user.

• DISK PACK
A device which is used to store additional data in a computer system, and is usually
removable.

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GLOSSARY

E
• ECHO
Process in which characters that are typed on a keyboard are also displayed on the
screen or are sent to the printer.

• EDITOR
An aid for entering information into the computer system and modifying existing text.

• EMERGENCY STOP (E-Stop)

An immediate stop of robot motion, selected by the operator with a switch.

• ENCODER
An electromechanical device that is connected to a shaft to produce a series of
pulses that indicate the position of the shaft.

• EPROM
Acronym for erasable programmable read-only memory. The contents of this
memory (computer chip) are retained, even when power to the system is turned off.
Usually stores executive programs and critical system variables.

• ERROR LOG
A report which contains a sequential list of system error messages.

• ERROR MESSAGE
Messages displayed on the plasma screen of the robot controller, when the action
requested by the operator could not be completed. Error messages can occur
when components malfunction or if an incorrect command is typed by the operator.

• EXPRESSION
A combination of real-valued variables and functions, and mathematical and logical
operators. When evaluated, this combination yields a numeric value.

F
• FEEDBACK
The transmission of a signal from a measuring device (e.g., encoder, transducer) to
the device which issued the command signal within a closed-loop system. See
CLOSED-LOOP SYSTEM.

• FIELD SIGNALS
All electrical signals that exit or enter an electrical panel.

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GLOSSARY

• FILE
A set of related records or data elements, which are stored using one name and are
arranged in a structure that can be used by a program.

• FILESPEC
Includes the name, creation date and size of the specified file.

• FIXED DISK
An electromagnetic mass storage device which is not removable. Hard disks have
much higher storage capacity than floppy disks.

• FLOPPY DISK
An electromagnetic mass storage device which can be removed and exchanged.

• FORM FEED
Process which causes a printer to advance the paper to the top of the next page.

• FUNCTION
A formula or routine for evaluating an expression.

G
• GAIN
A proportional increase in power or signal value relative to a control signal. The
ratios of voltage, power, or current as related to a reference or control signal input.

• GLOBAL
Refers to a function or process that affects the entire system or file.

• GRAY CODE
A positional binary number notation in which any two numbers whose difference is
one are represented by expressions that are the same except in one place or col-
umn and differ by only one unit in that place or column.

H
• HALF-DUPLEX COMMUNICATION
Data transmission between two devices, where the signal is sent in only one direc-
tion at a time.

• HANDSHAKING PROTOCOL
Communication rules used for data transmissions between devices. Each device
must recognize the same protocol in order to communicate.

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GLOSSARY

• HANG
A term which refers to the state of a computer system that seems to be inoperative
when processing should be taking place.

• HARDSTOP
A mechanical constraint or limit on motion.

• HARDWARE
Physical equipment and devices such as computer hard disk, cables, printer, etc.

• HAZARDOUS SIDE
The unsafe side of a component or panel, such as the inside of the control panel
when power is applied and functions are being performed.

• HOLD
When an external or an internal input is available for a hold condition, the robot will
stop its motion and servo drive power will be removed from the robot. When an
external hold reset is performed, the servo drive power will be energized.

• HOME POSITION
Refers to the starting or resting position of the robot.

• HYBRID ENCODER
On the Kawasaki robot a hybrid encoder is used to generate positional data, and is
composed of an incremental encoder that generates incremental pulses, and an
absolute encoder that generates gray code binary data.

I
• ID
Abbreviation for Identification.

• INCHING
A value that is used during the jogging process that allows the user to position the
robot in small minute increments.

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GLOSSARY

• INCREMENTAL CODE
A digital closed loop feedback code that provides digital feedback pulses to the robot
controller for the purpose of providing positional information. These incremental
pulses are generated by an encoder through the use of an optical disk with alternat-
ing opaque and transparent bars or lines around the periphery of the disk. On one
side of the disk a light source is mounted, and on the opposite side a phototransistor.
When the disk rotates, the phototransistor is alternately forced into saturation and
cutoff, producing the digital signal.

• INPUT
Transmission of an external signal into a control system.

• INTEGRATED CIRCUIT (IC)

A combination of interconnected circuit elements which are within a continuous
substrate.

• INTERACTIVE SYSTEM
System where the user and the operating system communicate directly; the user
through the keyboard, and the operating system via the display screen.

• INTERLOCK
An arrangement whereby the operation of one part or mechanism automatically
brings about or prevents the operation of another.

• INTERPRETER
A program that changes English-like commands into machine language. An inter-
preter translates and executes one command at a time.

• INSTRUCTIONS
Discrete steps in a computer program that are commands or statements that tell a
computer to do something or identify data.

• INTEGER
A whole number, a number without a fractional part such as 7, -318, or 19.

• INTERFACE
The circuitry that fits between a system and a peripheral device to provide compat-
ible coupling between the two pieces of equipment.

• INTERPOLATION
The mathematical process that the CPU utilizes to plot a path for the robot to travel
from one position to another. A mathematical process that evaluates a number of
dependent and independent variables for the purpose of comparison and prediction.

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GLOSSARY

• INTERRUPT
An external signal that halts program execution so that the computer can service the
needs of some peripheral device or subsystem.

• INTRINSIC SAFETY BARRIER (ISB)

An electronic device used in robot controllers to restrict current and voltage to a safe
level.

• INVERTER
A circuit which switches a positive signal to a negative signal, and vice versa.

• I/O
Acronym for Input/Output. The interconnections through which the computer and its
peripheral devices communicate.

• IPM
Acronym for Intelligent Power Module

J
• JOG
A term used to describe the process in which the user moves the mechanical unit
through interaction with the robot controller and the teach pendant. Sometimes
referred to as slewing.

• JOINT
1. A term used to describe the individual axes of a robot.
2. A term used to describe the jogging process in which the robot is jogged one axis
at a time.

• JOINT MOVE
A mode of operation in which the robot moves from one point to the next with an
arching path. All axes motors (required for the move) begin and end their rotation at
the same time. The tool center point does not follow a linear path to reach the taught
position.

L
• LABEL
An identifier for a program command line. To identify an instruction, memory loca-
tion, or part of a program.

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GLOSSARY

• LAN
An acronym for local area network. A group of computer terminals interconnected
by cables, allowing communication of information via the network.

• LCD
An acronym for liquid crystal display. This type of display is made of material whose
reflectance or transmittance of light changes when an electric field is applied.

• LIMIT SWITCH
An electrical switch positioned to be switched when a motion limit occurs, thereby
deactivating the actuator that caused the motion.

• LINEAR MOVE
An operation where the rate and direction of relative movement of the robot arm are
continuously under computer control.

• LINE PRINTER
A high-speed output device that prints a line at a time.

• LINE TURN-AROUND
Changing the source of transmission in half-duplex communications.

• LOGICAL OPERATION
Any of several operations that manipulate information according to the rules of logic
(e.g., AND, OR, NOT, and exclusive OR).

• LM
Abbreviation for linear motion.

• LOAD
The weight applied to the end of the robot arm.

• LOCKOUT
Serving to prevent operation of a device or part of it.

• LSB
Abbreviation for least significant bit.

M
• MANIPULATOR
Another term for the mechanical portion of the robot system.

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GLOSSARY

• MACHINE LANGUAGE
A low-level computer language, usually written in binary code.

• MASS-STORAGE DEVICE
An input/output device that retains data input to it. Examples include: hard disk
drives, magnetic tapes, floppy diskettes, and disk packs.

• MECHANICAL UNIT
robot (excluding controller)

• MEMORY
An area of the computer which stores data, either permanently or temporarily. When
a program is requested, it is first loaded into memory so it can be accessed quickly
by the processor.

• MHz
Abbreviation for megahertz. One million cycles per second.

• MIRROR IMAGE
A process which converts the positive and negative values of a taught path from a
right-handed robot to a left-handed robot, or vice versa. The actions of the opposing
robots are then coordinated and synchronized.

• mm
Abbreviation for millimeter.

• MNEMONIC
A term used to help the operator remember a large string of words or commands.

• MODEM
A signal conversion device that modulates and demodulates data into an audio
signal for transmission.

• MOMENT OF INERTIA
Used to calculate end of arm tooling and handling weights. The sum of the products
formed by multiplying the mass of the load by the square of the distance from the
tool mounting flange.

• MONITOR PROGRAM
An administrative computer program that oversees operation of a system. The AS
monitor accepts user input and initiates the appropriate response, follows instruc-
tions from user programs to direct the robot, and performs the computations neces-
sary to control the robot.

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GLOSSARY

• MSB
Abbreviation for most significant bit.

• msec
Abbreviation for millisecond (0.001 seconds).

N
• NOISE
Any unwanted disturbance within a dynamic, mechanical, or electrical system.

• NULLED
An electrical zero state.

O
• OCTAL NUMBER
A numeral in the base-8 numbering system, which uses the numerals 0 - 7.

• OFF LINE
A state in which communications between two devices cannot occur (e.g., between a
printer and a computer, if the printer is off line).

• ON LINE
A state in which communication between two devices can occur.

• OPERATING SYSTEM
A set of system tasks and commands that are entered by the operator and inter-
preted and performed by the system.

• OPEN LOOP
A control which does not use feedback to determine its output.

• OPERATOR
Any mathematical action or function. The arithmetic operators are: add, subtract,
multiply, divide, modulo, and exponentiate. The relational operators are: greater
than, less than, equal to, and their combinations. The logical operators are: AND,
OR, exclusive OR, negate. The binary logical operators are AND, OR, exclusive OR,
ones complement.

• OPTO
An optical isolator or level converter.

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GLOSSARY

• OVERFLOW
When a value or buffer exceeds a predefined limit.

• OVERTRAVEL
An error condition that exists when the robot exceeds its normal software limit val-
ues, and then actuates an overtravel limit switch.

• OVERVELOCITY
When an axis exceeds a preset value for velocity.

• OX (OUTPUT EXTERNAL)
Information transferred from the robot controller through output modules to control
output devices.

P
• PARITY
Method by which errors are detected. In this method the combined binary values of
a byte are flagged as 1 or 0.

• PARSE
To break a command string into individual elements, so it can be interpreted.

• PASSWORD
A code, entered by the user, to permit access to protected information.

• PAYLOAD
The maximum weight that a robot can handle satisfactorily during its normal
operations and extensions.

• PC PROGRAM
PC is an acronym for process control. A PC program cannot contain any step that
causes robot motion. PC programs are used to evaluate logic and variables and
execute program CALL and GOTO commands

• PERIPHERAL DEVICE
Hardware equipment which is external to the CPU, but that transmits and/or receives
I/O from the processor. Examples include: printer, CRT screen, or disk.

• PHASE
The angular relationship between current and voltage in alternating current circuits.
In a waveform or period function, the fraction of the period that has elapsed, as
measured from a reference point. Phase angle is determined by multiplying the
phase by 360 degrees.

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GLOSSARY

• PINCH POINT
Any point where it is possible for a part of the body to be injured between the moving
or stationary parts of a robot and the moving or stationary parts of associated
equipment, or between the material and moving parts of the robot or associated
equipment.

• PLA
Acronym for programmable logic array. Used in many servo drive circuits.

• PLAYBACK
An operation where a taught path is run for evaluation purposes.

• PLC
Acronym for programmable logic controller. Usually referred to as the cell module
controller.

• POINT-TO-POINT
A robot motion control in which the robot can be programmed by a user to move
from one postion to the next. The intermediate paths between these points cannot
be specified.

• POLARITY KEYS
These teach pendant or multi function panel keys allow the user to jog or slew the
robot in the Joint, Base (XYZ), or Tool coordinates system.

• PORT
The connection point of an opening or passage that is usually located outside the
housing of a device.

• POSITIONAL DATA
The location in space of the robot manipulator.

• POUNCE POSITION
A positional location at a point near the workpiece, clear of the transfer mechanism
and part, from which the robot is ready to begin production.

• PRINTED CIRCUIT
An assembly of electronic elements that provide a complete path of electrical current
through conductive material deposited between terminals on an insulated surface.

• PRECISION POINT
The play back of robot location based on the angular position of the six axes, joint
angles

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GLOSSARY

• PRINTING
A process in which characters are stamped on a surface, usually paper.

• PROGRAM
A predefined, step-by-step set of instructions that are entered into a computer so a
specific process can be performed repeatedly without re-entering all the steps.
Robot paths are stored and run as part of programs.

• PROGRAM EDIT
Modification of an existing program.

• PROCESSOR
Generally, any hardware or software system for carrying out programs and acting on
data.

• PULSE WIDTH MODULATION (PWM)

A modulation process in which the instantaneous sampling of the modulating wave is
caused to modulate the duration of the pulse. This type of modulation is also re-
ferred to as pulse duration modulation (PDM), or pulse length modulation (PLM).

R
• RAM
Acronym for random access memory. An area used by the CPU for processing and
temporarily loading programs so they can be accessed quickly. The contents of
RAM are lost when the computer is powered down, unless battery backup is pro-
vided.

• REAL NUMBER
A number with a fractional part, such as 1.75, -31.89, .5, -4.00, etc.

• REAL-TIME
The actual time during which the computer analyzes and processes data: informa-
tion is usually processed as it is received.

• REAL VARIABLE
AS language term for a variable that has had a real value assigned to it.

• REPEAT MODE
A mode of operation that allows the user to check positional and auxiliary informa-
tion at a selected speed value, in a continuous or a step by step type of movement of
the mechanical unit.

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GLOSSARY

• REPEATABILITY
The measurement of the closeness of agreement among repeated measurements of
the same variable under the same conditions.

• REWRITE MODE
A mode of operation which allows the user to rewrite positional, or auxiliary data,
and to insert or delete step address locations.

• RISC
Acronym for reduced instruction set computer.

• ROM (read-only memory)

A memory device which is programmed at the factory and whose contents thereafter
cannot be altered.

• RS-232C
An ASCII specification for connections and communication between serial devices.

• RUN
A mode of operation that allows the user to select servo motor power to provide
drive energy to the robot, allowing it to perform such modes of operation as teach,
check, repeat, and rewrite.

S
• SAFETY PLUG
A device used with safety fencing to interlock the opening of the fence with the
removal of power to the robot.

• SCROLL
When more information exists than can be displayed on one screen, the operator
can move up and down through the data to view it. When data is scrolled to the
screen, the information previously viewed moves up off the screen, and new informa-
tion enters the screen from the bottom.

• SENSOR
A device used to detect various conditions: proximity, heat, pressure, etc. An electri-
cal signal from the sensor can be used to communicate information to a robot pro-
gram.

• SERIAL
A method of transmitting data by which only one bit is sent or received at any one
point in time.

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GLOSSARY

• SEQUENTIAL ACCESS
A method used by many computers whereby data is read in the order in which it is
physically stored.

• SINGULARITY POSITION
When the robot is processing a linear or circular move and two or more joints are in
alignment. The CPU can not process the ambiguity of a singularity configuration and
an error is generated.

• SOFTWARE LIMITS
Programmed values that are included in a program at the point before a mechanical
device hits an overtravel limit switch or a hard limit.

• SOFTWARE
A set of written programs and instructions that are executed by a computer system.

• SOURCE CODE
A program that contains the actual software instructions entered by the user, in
contrast to object code which is source code that has been translated into a lan-
guage which can be interpreted by the computer.

• STRING
A series of characters that have been entered in a distinct sequence that can be
interpreted as a valid statement or command.

• STROKE
The movement in either direction of a mechanical part having a reciprocating motion.
The entire distance passed through in such a movement.

• SUBSCRIPT
A set of numbers that identifies an element of an array.

• SUBROUTINE
A set of instructions that is run by another routine.

• SYMBOL
A character or design that has a distinct meaning and/or is associated with some-
thing.

• SYNTAX
The proper way in which commands and phrases should be typed in order to be
understood by the control system. If the operator incorrectly types a command (i.e.,
misspelled or invalid characters), a syntax error message will be displayed.

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GLOSSARY

• SYSTEM DATA
Data that is specific to a individual robot. Zeroing data, upper and lower software
limits, and software switch settings are all examples of system data.

• SYSTEM SWITCH
Software switches that are set to determine various configurations and characteris-
tics of the robot system performance.

T
• TEACH MODE
A mode selected on the operator panel, during which robot arm axes positions can
be taught by the operator and are recorded by the robot.

• TEACH PENDANT
A hand-held, portable device used by the operator during teach and jogging opera-
tions.

• TOOL COORDINATES
A Cartesian coordinate system in which the origin point is at the face plate of the
robot and the orientation of the tool can be expressed in terms of a 3-dimensional
space representation of X,Y, and Z projections.

• TOOL MODE
A mode of operation in which all motions are calculated to maintain the orientation of
the tool in space.

• TORQUE
Something which produces or tends to produce rotation or torsion and whose
effectiveness is measured by the product of the force and the perpendicular distance
from the line of action of the force to the axis of rotation.

• TRANSFORMER
A device to convert the current of a primary circuit into variations of voltage and
current used in secondary circuits.

• TRANSFORMATION
A mathematical description of a location that defines the position and orientation of
the location without regard for the configuration of the robot when it is at that loca-
tion.

• TRAP POINT
see pinch point

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GLOSSARY

• TTL
Acronym for transistor-transistor logic.

• TWO’S COMPLEMENT
A means of representing a negative number as one more than the binary comple-
ment of the absolute value of the number.

• TRIANGULAR WAVEFORM
A waveform that has the shape of a triangle and is used in determining sampling
values for servo drive circuits that utilize pulse width modulation.

U
• UHF
Acronym for ultra-high frequency.

V
• VARIABLE
The name of a memory location or stored value. A variable can refer to a scalar or
an array.

• VELOCITY COMMAND
This analog signal is directly proportional to motor speed, and provides the initial
signal that is processed by the servo drive system to drive a servo motor.

• VELOCITY ERROR
When the robot controller detects an axis that has exceeded a preset value for
velocity, the robot controller will E-stop the robot.

• VOLT
A unit of electrical potential difference and electromotive force. One volt is equiva-
lent to the force required to produce one amp of current through one ohm of resis-
tance.

W
• WORK ENVELOPE
The effective range or reach of a robot’s axes.

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GLOSSARY

• WORLD COORDINATES
A Cartesian coordinate system in which the origin point is near the base of the robot,
and robot movement can be expressed in terms of a 3-dimensional space represen-
tation of X, Y, and Z projections.

• WRITE
In computer systems, a process in which information is output to and stored by a
device or area in memory.

• WS (WELD SCHEDULE)
Data that is stored in the weld controller and provides the specific current, clamp
pressures, etc. for spot welding applications.

• WX (WAIT EXTERNAL)
The wait external signal is one of many inputs that are processed by the robot con-
troller. When the robot encounters a wait external condition, the robot will cease
motion and the servo power will be removed.

Z
• ZEROING
This procedure provides the robot controller with encoder data that is referenced
from a known mechanical position (zeroing witness marks, in simple zeroing, or
inclinometer values in precision zeroing) and then establishes an encoder value for
this known position. Two methods can be used, simple and precision zeroing. Some
robot manufacturers call this procedure mastering or calibration.

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 Kawasak C SERIES CONTROLLER
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INDEX

INDEX .......................................................................................................................... 1-2

April 26, 1999 IN-1

 Kawasak C SERIES CONTROLLER
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INDEX

Symbols
1FP Board, 7-2, 7-22, 7-28
1FR Board, 6-10, 7-2, 7-20

A
Accuracy, I-11
Amphenal Connectors, 6-4
Anchor Fixtures, 4-3
Anchors, 8-7
ANSI/RIA, 1-2
Auxiliary Axis, I-2

B
B-axis, I-2
Base (World) Coordinates, I-3
Base Plate, 8-7
Base Plate Mounting Dimensions, 8-8
Bolt Holes, 4-4
Bolt Tension, 8-11
Brake Release Switches, 8-18
Brakes, 3-3

C
Casters, 3-3
CMOS RAM, I-11
Contact Specification, 7-22
Contact Specifications, 7-23
Control Power, 7-4
Controller Cooling, 4-3
Controller Design Specifications, I-11
Coordinate Systems, I-3

D
D-axis, I-2
Data Editing, I-11
Data Plates, 4-2
Dedicated Input Signals, 7-2
Dedicated Output Signals., 7-2
Dedicated Signals, 7-2
Inputs, I-13
Outputs, I-12
Dimensions, I-14

E
E-Stop Connections, 7-22
Emergency Stop, 7-8
Emergency Stop Signal, 7-2
Error Messages, I-13
External I/O, Signal Configurations, 7-4

IN-2 April 26, 1999

 Kawasak C SERIES CONTROLLER
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INDEX

F
Flange Dimensions, 8-16
Fork Pockets, 8-4, 8-6
Function Diagram, Limit Switch, 6-12, 6-13

G
General Purpose I/O Signals, 7-20
General Purpose Signals, 6-10
Ground Straps, 6-4
Ground Wire, 6-2

H
Hardware Dedicated Signals, 7-4
Harness Connections, 6-6
Harness Connectors, 6-6
Hold, 7-10

I
I/O Circuit Board, 7-2
I/O Signals, I-12
Input Signal, 7-3
Input Signals, 6-10

J
JA10/JS10 Work Envelope, 1-12
JA5/JC5/JS5/JW5 Work Envelope, 1-11
Jogging Operations, 8-17
Jogging Speed, 8-17
Jumper Configuration for Sensor Cable Usage, 6-10

L
Lifting Device, 8-3
Limit Switches, 6-9
Line Voltage, 6-3

M
Major Axes, I-2
Memory Capacity, I-11
Minor Axes, I-2
Motor Power ON, 7-6
Mounting Flange, 8-16
Multi Function Panel, I-13, 8-18

O
O-axis, I-2
OSHA, 1-2

April 26, 1999 IN-3

 Kawasak C SERIES CONTROLLER
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INDEX

P
Packing Crate, 8-5
Packing Material, 2-4
Positioning the Robot Controlle, 4-3
Power Requirements, I-14
Primary Power Supply, 6-2
Proximity Switches, 6-9

R
R-axis, I-2
RISC CPU, I-11
Robot Specifications, I-4, I-5, I-6, I-7, I-8, I-9

S
S-axis, I-2
Sensor Cable, 6-10
Sensor Signal Inputs, 6-10
Sensor Signals, 6-10
Sensor Wiring Diagrams, 6-11
Sling Load, 8-4
Sling Loading, 8-6
Small Teach Pendant, 8-17, 8-18
Software Features, I-12
Special Features, I-13
Speed, I-11
Standard Packing, 8-2

T
T-axis, I-2
Teach Lock, 8-17
Teach Pendant, I-13, 8-2, 8-5
TEACH/REPEAT Output, 7-12
Tool Attachment, 8-16
Tool Coordinates, I-3
Transformer, 6-3
Transporting, 8-6
Trap Points, 1-4
Trigger Key, 8-17

U
UD100 Sensor Cable, 6-8
Unpacking, 2-2
UT-Series Work Envelope, 1-24

V
V-axis, I-2
Voltage Taps, 6-3

IN-4 April 26, 1999

 Kawasak C SERIES CONTROLLER
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INDEX

W
Wall Clearance, 4-3
Weight, I-14
Wire Harnesses, 6-4
Wire Specifications, 6-2
Wiring Harness, 8-5
Work Cell, 1-4
Work Envelope, 1-4

April 26, 1999 IN-5