E Series Installation and Connection Manual
E Series Installation and Connection Manual
E Series Installation and Connection Manual
Installation and
Connection Manual
90202-1110DEM
E Series Controller (Standard spec.)
Kawasaki Robot Installation and Connection Manual
PREFACE
This manual describes the installation and connection of the E series controllers.
This manual covers the installation, wiring and connection with external controller, devices and
power. Please refer to “Operation Manual” and “External I/O Manual” for the operation of the
controller.
Read and understand the contents of this and safety manuals thoroughly and strictly observe all
rules for safety before proceeding with any operation.
This manual describes only the installation and connection of the controller. For the robot arms,
please refer to the separate manuals for them.
This manual also describes devices equipped as an option; however, all the controllers might not
include the devices explained here.
1. This manual does not constitute a guarantee of the systems in which the robot is utilized.
Accordingly, Kawasaki is not responsible for any accidents, damages, and/or problems
relating to industrial property rights as a result of using the system.
2. It is recommended that all personnel assigned for activation of operation, teaching,
maintenance or inspection of the robot attend the necessary education/training course(s)
prepared by Kawasaki, before assuming their responsibilities.
3. Kawasaki reserves the right to change, revise, or update this manual without prior notice.
4. This manual may not, in whole or in part, be reprinted or copied without the prior written
consent of Kawasaki.
5. Store this manual with care and keep it available for use at any time. If the robot is
reinstalled or moved to a different site or sold off to a different user, attach this manual to the
robot without fail. In the event the manual is lost or damaged severely, contact Kawasaki.
Copyright © 2016 Kawasaki Heavy Industries Ltd. All rights reserved.
1
E Series Controller (Standard spec.)
Kawasaki Robot Installation and Connection Manual
SYMBOLS
The items that require special attention in this manual are designated with the following symbols.
Ensure proper and safe operation of the robot and prevent physical injury or property damage by
complying with the safety matters given in the boxes with these symbols.
! DANGER
! WARNING
! CAUTION
[ NOTE ]
Denotes precautions regarding robot specification,
handling, teaching, operation, and maintenance.
! WARNING
1. The accuracy and effectiveness of the diagrams, procedures, and detail
explanations given in this manual cannot be confirmed with absolute
certainty. Accordingly, it is necessary to give one’s fullest attention
when using this manual to perform any work.
2. Safety related contents described in this manual apply to each individual
work and not to all robot work. In order to perform every work in
safety, read and fully understand the safety manual, all pertinent laws,
regulations and related materials as well as all the safety explanations
described in each chapter, and prepare safety measures suitable for
actual work.
2
E Series Controller (Standard spec.)
Kawasaki Robot Installation and Connection Manual
CONTENTS
3
E Series Controller (Standard spec.)
Kawasaki Robot Installation and Connection Manual
4
E Series Controller (Standard spec.) 1. Safety
Kawasaki Robot Installation and Connection Manual
1.0 SAFETY
This chapter only describes safety precautions during installation and connection of the controller.
For all other safety matters, refer to the “Safety Manual”, a separate-volume.
To transport the Kawasaki Robot Controller to its installation place, strictly observe the following
cautions while carrying out the transportation and installation work.
[ NOTE ]
The installation shall be made by qualified installation
personnel and should conform to all national and local codes.
! WARNING
1. When transporting a controller with a crane or a forklift, never support
the controller manually.
2. During the transportation, stay out from under the lifted controller.
! CAUTION
1. Since the controller is composed of precision parts, be careful not to
apply excessive shocks or vibrations to the controller during
transportation.
2. To carry out smooth and safe installation, remove all obstacles before
installing a controller. Clear a passage for the transportation of
controller before using a crane or forklift.
3. When transporting or storing a controller:
(1) keep the ambient temperature within the range of minus 10 - 60C
(2) keep the relative humidity within the range of 35 - 85% RH
(Non condensing)
(3) keep free from excessively large shock and vibration.
5
E Series Controller (Standard spec.) 1. Safety
Kawasaki Robot Installation and Connection Manual
Install the controller in a site that satisfies all the following environmental conditions:
! CAUTION
When E94/E97 controller is used under the environmental condition with the pollution
degree of 3 or above, the use of optional enclosed structure (IP54) is required.
! CAUTION
When installing the controller in the environment where metal dust, etc. is generated
in robot application to works shown below, mount fan filter prepared as option
(E1x/E2x/E3x/E4x controllers). For E91 controller (without optional filter) and
E94/E97 controllers (takes the air into the controller), they cannot be installed with
the following environment because air is taken into the controllers.
1. Metal workpiece polishing
2. Polished metal workpiece handling
3. Metal workpiece deburring
4. Deburred metal workpiece handling
5. Metal workpiece shotblasting
6. Aluminum package cutting (Cutting powder is generated.)
7. Other processing works where metal dust, etc. is generated.
6
E Series Controller (Standard spec.) 1. Safety
Kawasaki Robot Installation and Connection Manual
5. Free from electrical noise interference. (Controller external power noise: 1 kV/1 s or less)
! CAUTION
If the controller is installed near equipment that generates a lot of electrical
noise, be sure to provide appropriate surge killers around that equipment.
Noise producing equipment includes: induction motors, electromagnetic
brakes, solenoids, or contact equipment, etc.
E10/E12/E13/E14
E30/E32/E33/E34
E40/E42/E43/E44
IP54
E20/E22/E23/E24
IP53
IP22 IP22
7
E Series Controller (Standard spec.) 1. Safety
Kawasaki Robot Installation and Connection Manual
IP54
IP53
IP22
IP22
8
E Series Controller (Standard spec.) 1. Safety
Kawasaki Robot Installation and Connection Manual
E28
IP22
IP54
IP22
IP22
E70/E71/E73/E74/E76/E77
IP20
IP54
IP20 IP20
9
E Series Controller (Standard spec.) 1. Safety
Kawasaki Robot Installation and Connection Manual
! CAUTION
The controller shall not be located inside of the robot’s
motion range/workcell/safety fence.
Approx. 1 m
Safety fence
Approx. Approx.
1m 1m
Controller
Gate with safety plug
10
E Series Controller (Standard spec.) 1. Safety
Kawasaki Robot Installation and Connection Manual
Strictly observe the following precautions when connecting the robot arm with the robot
controller.
! WARNING
In order to prevent accidents caused by electric shock, do not connect the
external power until connections between the robot arm and robot
controller are complete.
! CAUTION
1. Be careful when connecting the harnesses. Be sure to use the correct
harnesses. Using an incorrect harness, or forcing or misconnecting the
harness may damage connectors or cause a break in the electrical
system.
2. Prevent people or equipment (forklift etc.) from stepping on or riding
over the signal and motor harnesses. Otherwise, the harness may
become damaged or the electrical system may break.
3. Separate the harnesses from any nearby high voltage lines (min. 1 m
apart). Do not bundle or run the harnesses in parallel with other
power lines. Otherwise, the noise generated from power lines will
cause malfunctions.
4. Even when the harnesses are long, do not bundle them winded or
bended. Bundling the harness causes the heat to build up in the
harness, resulting in over-heat and furthermore may cause fire.
Strictly observe the following precautions when connecting the external power.
! DANGER
Before beginning the connection work, confirm that the external power supply
for the controller is cut off at the source. To prevent external power from being
turned ON accidentally, tag the breaker and indicate clearly that work is in
progress. Or, assign a supervisor in front of the breaker until all the connections
are complete. Connecting components while power is supplied is extremely
dangerous and may cause electric shock.
11
E Series Controller (Standard spec.) 1. Safety
Kawasaki Robot Installation and Connection Manual
! WARNING
1. Confirm that the connected supplying power meets specifications shown on
the rating plate and the label attached on the side of the breaker. Supplying
out-of-specification power will damage electric components in the controller.
2. Earth the controller to prevent against electrical noise and shock.
3. Use dedicated earth wire (100 or less), which is equal to or larger than the
recommended power cable size (3.5 - 8.0 mm2).
4. Never share an earth line with workpiece to be welded or another machine
(weld machine, etc.).
5. In arc welding applications, connect the minus pole of the weld power supply
to a jig or directly to workpiece to be welded. Insulate the robot body and
controller so that they do not share a common earth line.
6. Without fail, before turning ON the external power to controller, make sure
the power supply wiring is complete and all the covers reattached properly.
Otherwise, failure to do so may cause electric shock.
! CAUTION
NOTE* Proximity switch directly connected with power line etc. may suffer from the
influence.
12
E Series Controller (Standard spec.) 1. Safety
Kawasaki Robot Installation and Connection Manual
Warning labels for electric shock are located on the controller s shown below.
E1x controller
The terminals are alive even when
the controller power switch is OFF.
Controller
power switch
DC power
supply (AVR)
Servo amplifier
MC unit
13
E Series Controller (Standard spec.) 1. Safety
Kawasaki Robot Installation and Connection Manual
Controller
power switch
DC power
supply (AVR)
Servo amplifier
MC unit
14
E Series Controller (Standard spec.) 1. Safety
Kawasaki Robot Installation and Connection Manual
E28 controller
Cooler
Controller
power
switch
Transformer
Additional
Front regenerative Right Rear
resistor unit
The terminals are alive even when
the controller power switch is OFF.
DC power
Single-axis supply (AVR)
amp. unit
MC unit
E3x controller
The terminals are alive even
when the controller power
switch is OFF.
DC power
supply
Controller (AVR)
power
switch
MC unit
Servo amplifier
16
E Series Controller (Standard spec.) 1. Safety
Kawasaki Robot Installation and Connection Manual
Transformer
Left Rear
Top
17
E Series Controller (Standard spec.) 1. Safety
Kawasaki Robot Installation and Connection Manual
E4x controller
Controller
The terminals are alive even when
power switch the controller power switch is OFF.
DC power
supply (AVR)
MC unit
Servo
amplifier
18
E Series Controller (Standard spec.) 1. Safety
Kawasaki Robot Installation and Connection Manual
Transformer
Transformer
Left Rear
19
E Series Controller (Standard spec.) 1. Safety
Kawasaki Robot Installation and Connection Manual
E7x controller
Power unit
MC
Controller power switch
The terminals are alive even when
Top the controller power switch is OFF.
20
E Series Controller (Standard spec.) 1. Safety
Kawasaki Robot Installation and Connection Manual
E9x controller
DC power supply (AVR)
Controller power switch Servo amplifier
Front Capacitor
External power input connector
Power
unit
Regenerative Servo
Power unit Power unit
resistor amplifier
21
E Series Controller (Standard spec.) 1. Safety
Kawasaki Robot Installation and Connection Manual
22
E Series Controller (Standard spec.) 1. Safety
Kawasaki Robot Installation and Connection Manual
ZH ZX/ZT/ZD
MT B Series
MX/MD MG
23
E Series Controller (Standard spec.) 1. Safety
Kawasaki Robot Installation and Connection Manual
Batteries are used for data backup in the robot mechanical unit and controller. Figures on the
next page show the location of the batteries on the 1TA/1VA board and the 1FG/1HG boards.
Batteries for 1FG/1HG board can be handled without removing connector plate on robot base,
only with removing the plate indicating “BATTERY” shown in figure on the next page (bottom).
If not used and disposed of properly, these batteries may malfunction, ignite, overheat, explode,
corrode, leak, etc. Always use and dispose of all batteries in compliance with the following
warnings and cautions.
Figure on the page after next shows the location of fuse F1 (1.0 A, 125 V/250 V) on the 1TR
board.
! WARNING
1. Only use batteries specified by Kawasaki.
2. Never re-charge, dismantle, convert and/or overheat batteries.
3. Never dispose of batteries into water or fire.
4. Batteries with damaged cases may short internally and must not
be used.
5. Never short the positive and negative poles of a battery with
material such as wire.
! CAUTION
Never dispose of depleted batteries with garbage that is disposed of in
an incinerator, land-fill, dumping-ground, etc. When disposing of
batteries, insulate with tape so as not to contact other metal. Comply
with local regulations and rules for battery disposal.
24
E Series Controller (Standard spec.) 1. Safety
Kawasaki Robot Installation and Connection Manual
Locations of Batteries
1FG board
BAT1
1HG board (in Robot Base)
Location Number: BAT1 CN3
Model: 50750-1007 or 50750-1018
Manufacturer: KHI
Connector: CN3
1HG board
Battery
plate
25
E Series Controller (Standard spec.) 1. Safety
Kawasaki Robot Installation and Connection Manual
Location of Fuse
1TR board
1.7 SAFETY FEATURES
To safeguard the user, Kawasaki robot systems are equipped with many safety features, including
the following:
1. All E-stops are hard-wired.
2. All robot controllers are equipped with a redundant dual channel safety circuit. Both
channels of the safety circuit must be closed to allow for robot operation in the teach and
repeat modes.
3. Safety circuits of E28/E3x/E76/E77/E97 and E4x/E70/E71/E91/E94 controllers satisfy
requirements of PLd in category 3 defined by ISO 13849-1:2006. Category and
Performance level (PL) are determined by the whole system and conditions.
4. (For E3x/E76/E77/E97 controllers) When the servo ON lamp (located on the mechanical
unit) is illuminated, servo motor power is available to the robot and motion is possible.
5. The teach pendant and operation panel are equipped with red mushroom-type E-stop
switches. And all robot controllers have external E-stop inputs.
6. The teach pendant is equipped with three-position, enabling devices. The enabling devices
must be pressed to enable motor power in teach and check modes.
7. Teach and check mode velocities are limited to a maximum of 250 mm/s (10.0 in/s).
8. The velocities are not limited to 250 mm/s (10.0 in/s) in the Fast Check Mode that satisfy
requirements for ISO 10218-1:2006. (E28/E4x/E70/E71/E91 controllers: Standard ,
E1x/E2x (exc E28)/E73/E74/E94 controllers: Option)
9. Optional overtravel limit switches are available on JT1, JT2 and JT3 of the arm. See the
specifications of the product for details.
10. Mechanical units have overtravel hardstops on the JT1, JT2 and JT3 (optional for JT2 and
JT3) axes. Mechanical hardstops are capable of stopping the robot at full speed and with
maximum payload. See the specifications of the product for details of the mechanical hard
stops.
11. All robot axes are equipped with 24 VDC electromechanical brakes that engage when power
is removed. If the robot loses power unexpectedly, the mechanical unit arm is held in
position by the brakes.
26
E Series Controller (Standard spec.) 1. Safety
Kawasaki Robot Installation and Connection Manual
The manual brake release switches allow the operator to move individual robot axes without
using motor power for maintenance and emergency situations. (E1x/E2x (exc E28)/E7x/E9x
controllers: Option, E28/E3x/E4x controllers: Standard)
! WARNING
When no servo power is applied, electromagnetic brakes lock to maintain the
robot arm posture. Unsupported axes may fall when the brake release
switch is pressed. Axes which are overhung, particularly JT2 and JT3, will
fall down the fastest, depending on robot position, weight of the end-of-arm
tooling, and wrist axis position. Position yourself to observe the entire robot
arm and keep your eyes on the arm when operating this switch.
27
E Series Controller (Standard spec.) 1. Safety
Kawasaki Robot Installation and Connection Manual
28
E Series Controller (Standard spec.) 1. Safety
Kawasaki Robot Installation and Connection Manual
BRAKE
29
E Series Controller (Standard spec.) 1. Safety
Kawasaki Robot Installation and Connection Manual
Accessory panel
Brake release switch connecting port
Connecting port of brake release switch is provided at the position shown in the figure.
・Brake release switch box is the option.
30
E Series Controller (Standard spec.) 1. Safety
Kawasaki Robot Installation and Connection Manual
! WARNING
To prevent injury to persons or damage to robotic equipment provide
suitable support for the robot arm, end-of arm tooling and payload, before
using a brake release switch. The robot arm can be supported overhead
using a sling and an overhead crane (see figure below).
31
E Series Controller (Standard spec.) 1. Safety
Kawasaki Robot Installation and Connection Manual
7. Press and hold the “RELEASE ENABLE” switch (see lower right figure). If the brake is
released at this time, do not use the switch (see CAUTION).
8. Press the manual brake release switch for the axis to release the brake (see lower right figure).
9. The brake remains released until the brake release switch is released.
10. After using the brake release switches, close the access door.
! CAUTION
Stop using the manual brake release switch immediately if the
electromagnetic brake is released by pressing only one switch. The switch
may be defective.
RELEASE
ENABLE
Switch
32
E Series Controller (Standard spec.) 2. Workflow - Robot Controller
Kawasaki Robot Installation and Connection Manual Installation and Connection
This workflow describes only the robot controller. For the robot arms, refer to the separate
manuals for them.
33
E Series Controller (Standard spec.) 2. Workflow - Robot Controller
Kawasaki Robot Installation and Connection Manual Installation and Connection
Confirm operation of
robot arm and tool Refer to “Operation Manual”.
(Teach mode)
Confirm other
various functions Refer to “Operation Manual”.
Work completed
[ NOTE ]
This manual only describes procedures from installation place
examination to connection with external power.
34
E Series Controller (Standard spec.) 3. Appearance and Specification
Kawasaki Robot Installation and Connection Manual of Robot Controller
Hook
Teach pendant
Coin lock
Left Front
USB port
RS-232C
port
Connectors for
separate
harnesses
(See section
6.1 for details.)
Connecting ports in
Right Rear the accessory panel
E10 controller
35
E Series Controller (Standard spec.) 3. Appearance and Specification
Kawasaki Robot Installation and Connection Manual of Robot Controller
550 550
External power inlet
Lifting eyebolt
Controller Accessory panel
power switch Operation panel
Hook
Teach pendant
Coin lock
Left Front
USB port
RS-232C
port
Connectors
for separate
harnesses
(See section
6.1 for
Right Rear details.) Connecting ports in the
accessory panel
E12 controller
36
E Series Controller (Standard spec.) 3. Appearance and Specification
Kawasaki Robot Installation and Connection Manual of Robot Controller
Teach pendant
Coin lock
Left Front
USB port
RS-232C
port
Connectors for
separate
harnesses
(See section 6.1
for details.)
Right Rear Connecting ports in
the accessory panel
E13 controller
37
E Series Controller (Standard spec.) 3. Appearance and Specification
Kawasaki Robot Installation and Connection Manual of Robot Controller
550 550
Hook
Teach pendant
Coin lock
Left Front
USB port
RS-232C
port
Connectors for
separate
harnesses
(See section
6.1 for details.)
Connecting ports in
Right Rear
the accessory panel
38
E Series Controller (Standard spec.) 3. Appearance and Specification
Kawasaki Robot Installation and Connection Manual of Robot Controller
Hook
Teach pendant
1200
Coin lock
Left Front
USB port
RS-232C
port
Connectors
for separate
harnesses
(See section
6.1 for
Right Rear details.) Connecting ports in
the accessory panel
39
E Series Controller (Standard spec.) 3. Appearance and Specification
Kawasaki Robot Installation and Connection Manual of Robot Controller
550 450
Teach pendant
Coin lock
Left Front
Connectors for
separate harnesses
(See section 6.1
for details.)
USB port
RS-232C
port
Right Rear
Connecting ports
in the accessory
E20 controller
40
E Series Controller (Standard spec.) 3. Appearance and Specification
Kawasaki Robot Installation and Connection Manual of Robot Controller
550 450
Teach pendant
Coin lock
Left Front
USB port
RS-232C
port
Connectors for
separate
harnesses
(See section 6.1
for details.)
Right Rear Connecting ports in
the accessory panel
E22 controller
41
E Series Controller (Standard spec.) 3. Appearance and Specification
Kawasaki Robot Installation and Connection Manual of Robot Controller
Teach pendant
Coin lock
Left Front
Connectors for
separate harnesses
(See section 6.1 for
details.)
USB port
RS-232C
port
Right Rear
Connecting ports in
the accessory panel
E23 controller
42
E Series Controller (Standard spec.) 3. Appearance and Specification
Kawasaki Robot Installation and Connection Manual of Robot Controller
550 450
Teach pendant
Coin lock
Left Front
USB port
RS-232C
port
Connectors for
separate Connecting ports in
harnesses the accessory panel
(See section 6.1
Right Rear for details.)
43
E Series Controller (Standard spec.) 3. Appearance and Specification
Kawasaki Robot Installation and Connection Manual of Robot Controller
Teach pendant
Coin lock
Left Front
USB port
RS-232C
port
Connecting ports in
the accessory panel
Connectors for
Right Rear separate harnesses
(See section 6.1 for
details.)
44
E Series Controller (Standard spec.) 3. Appearance and Specification
Kawasaki Robot Installation and Connection Manual of Robot Controller
Eye bolt
Accessory panel
External
power Operation panel
inlet
Hook
Controller
power
switch
Teach pendant
Coin lock
USB port
RS-232C
port
Connecting ports in
the accessory panel
E28 controller
45
E Series Controller (Standard spec.) 3. Appearance and Specification
Kawasaki Robot Installation and Connection Manual of Robot Controller
550 550
Teach pendant
Brake cable hook
release
switch Hook
Teach pendant connector
1200
Teach pendant
Coin lock
Left Front
USB port
RS-232C
port
Connecting ports
in the accessory
Connectors for
Right Rear separate harnesses
(See section 6.1
E30 controller
for details.)
46
E Series Controller (Standard spec.) 3. Appearance and Specification
Kawasaki Robot Installation and Connection Manual of Robot Controller
550 550
Teach pendant
1200
Coin lock
Left Front
USB port
RS-232C
port
Connectors for
separate
harnesses
(See section 6.1
for details.) Connecting ports in
the accessory panel
Right Rear
E32 controller
47
E Series Controller (Standard spec.) 3. Appearance and Specification
Kawasaki Robot Installation and Connection Manual of Robot Controller
Hook
Teach pendant
connector
Controller
power
switch
1200
Teach pendant
Brake
release
switch
Coin lock
Left Front
Connectors for
separate harnesses
(See section 6.1 for
details.)
USB port
RS-232C
port
Connecting ports in
the accessory panel
Right Rear
E33 controller
48
E Series Controller (Standard spec.) 3. Appearance and Specification
Kawasaki Robot Installation and Connection Manual of Robot Controller
550 550
Teach pendant
connector
1200
Teach pendant
Coin lock
Left Front
Connectors for
separate harnesses
(See section 6.1 for
details.)
USB port
RS-232C
port
Connecting ports in
the accessory panel
Right Rear
49
E Series Controller (Standard spec.) 3. Appearance and Specification
Kawasaki Robot Installation and Connection Manual of Robot Controller
Hook
Teach pendant
Controller connector
power
switch
1200
Teach pendant
Brake
release
switch
Coin lock
Left Front
Connectors for
separate harnesses
(See section 6.1 for
details.)
USB port
RS-232C
port
Connecting ports in
the accessory panel
Right Rear
50
E Series Controller (Standard spec.) 3. Appearance and Specification
Kawasaki Robot Installation and Connection Manual of Robot Controller
550 550
Hook
Teach pendant
1200
Coin lock
Left Front
Connectors for
separate harnesses
(See section 6.1 for
details.)
USB port
RS-232C
port
Connecting ports in
the accessory panel
Right Rear
E40 controller
51
E Series Controller (Standard spec.) 3. Appearance and Specification
Kawasaki Robot Installation and Connection Manual of Robot Controller
550 550
Hook
Teach pendant connector
1200
Teach pendant
Coin lock
Left Front
USB port
RS-232C
port
Connectors for
separate
harnesses
(See section 6.1
for details.) Connecting ports in
Right Rear the accessory panel
E42 controller
52
E Series Controller (Standard spec.) 3. Appearance and Specification
Kawasaki Robot Installation and Connection Manual of Robot Controller
Hook
Teach pendant connector
1200
Teach pendant
Coin lock
Left Front
USB port
RS-232C
port
Connectors for
separate harnesses
(See section 6.1 for
details.)
Connecting ports in
Right Rear
the accessory panel
E43 controller
53
E Series Controller (Standard spec.) 3. Appearance and Specification
Kawasaki Robot Installation and Connection Manual of Robot Controller
550 550
Hook
Teach pendant
Coin lock
Left Front
Connectors for
separate harnesses
(See section 6.1 for
details.)
USB port
RS-232C
port
54
E Series Controller (Standard spec.) 3. Appearance and Specification
Kawasaki Robot Installation and Connection Manual of Robot Controller
Hook
Teach pendant
Coin lock
Left Front
Connectors for
separate harnesses
(See section 6.1 for
details.)
USB port
RS-232C
port
Connecting ports in
the accessory panel
Right Rear
55
E Series Controller (Standard spec.) 3. Appearance and Specification
Kawasaki Robot Installation and Connection Manual of Robot Controller
420 500
Accessory panel Operation panel
Brake release panel
Controller
power
250
switch
9
Heat
exchange
fan
External power
Right input connector Rear
E70/E71 controllers
56
E Series Controller (Standard spec.) 3. Appearance and Specification
Kawasaki Robot Installation and Connection Manual of Robot Controller
420 500
Controller
power
250
switch
9
Heat
exchange
fan
E73/E74 controllers
57
E Series Controller (Standard spec.) 3. Appearance and Specification
Kawasaki Robot Installation and Connection Manual of Robot Controller
420 500
Heat
exchange
fan
USB port
Brake release
switch
RS-232C connecting port
BRAKE
port
E76/E77 controllers
58
E Series Controller (Standard spec.) 3. Appearance and Specification
Kawasaki Robot Installation and Connection Manual of Robot Controller
580 500
connector
Left Front
Connector for separate harness (See section 6.1 for details)
NOTE* The maximum length of the cable which can be connected to the Ethernet port is 30 m.
59
E Series Controller (Standard spec.) 3. Appearance and Specification
Kawasaki Robot Installation and Connection Manual of Robot Controller
580 500
connector
Left Front
External power
Right Rear
input connector
NOTE* The maximum length of the cable which can be connected to the Ethernet port is 30 m.
60
E Series Controller (Standard spec.) 3. Appearance and Specification
Kawasaki Robot Installation and Connection Manual of Robot Controller
Teach Pendant
61
E Series Controller (Standard spec.) 3. Appearance and Specification
Kawasaki Robot Installation and Connection Manual of Robot Controller
62
E Series Controller (Standard spec.) 3. Appearance and Specification
Kawasaki Robot Installation and Connection Manual of Robot Controller
63
E Series Controller (Standard spec.) 3. Appearance and Specification
Kawasaki Robot Installation and Connection Manual of Robot Controller
E28 controller
Construction Self-sustaining fully closed, indirect cooling system
Mass E28: 280 kg,
Temperature 0 - 45 C
Ambient Humidity 35 - 85 %RH (Non condensing)
environment Altitude Up to 1000 meters above mean sea level
Pollution degree 3 or below
AC 200-220 V±10 %, 50/60 Hz, 3 Phase (Japan spec)
Power source AC 380-415 V±10 %, 50/60 Hz, 3 Phase (Europe spec)
AC 440-480 V±10 %, 60 Hz, 3 Phase (North America spec)
Power capacity Refer to the table below.
Earthing Dedicated earthing (100 Ω or less)
Length of Teach pendant cable 5 m/10 m/15 m (5 m, 15 m are options.)
Length of separate harnesses* 5 m/7 m/10 m/15 m (5 m, 7 m, 15 m are options.)
NOTE* Harness length between robot arm and controller.
64
E Series Controller (Standard spec.) 3. Appearance and Specification
Kawasaki Robot Installation and Connection Manual of Robot Controller
E3x controller
Construction Self-sustaining fully closed, indirect cooling system
E30: 145 kg, E32, E34 (MX): 180 kg,
Mass
E33, E34 (MD): 195 kg
Temperature 0 - 45 C
Ambient Humidity 35 - 85 %RH (Non condensing)
environment Altitude Up to 1000 meters above mean sea level
Pollution degree 3 or below
Power source AC 440-480 V±10 %, 60 Hz, 3 Phase
AC 380-415 V, 440-480 V, 515 V, 575 V±10 %,
Optional 50/60 Hz, 3 Phase
AC 200-220 V±10 %, 50/60 Hz, 3 Phase…*
Power capacity Refer to the table below.
Earthing Dedicated earthing (100 or less)
Length of Teach pendant cable 5 m/10 m/15 m (5 m, 15 m are options.)
Length of separate harnesses* 5 m/7 m/10 m/15 m (5 m, 7 m, 15 m are options.)
NOTE* Harness length between robot arm and controller.
65
E Series Controller (Standard spec.) 3. Appearance and Specification
Kawasaki Robot Installation and Connection Manual of Robot Controller
E4x controller
Construction Self-sustaining fully closed, indirect cooling system
E40: 145 kg, E42, E44 (MX): 180 kg
Mass
E43, E44 (MD): 195 kg
Temperature 0 - 45 C
Ambient Humidity 35 - 85 %RH (Non condensing)
environment Altitude Up to 1000 meters above mean sea level
Pollution degree 3 or below
Power source AC 380-415 V±10 %, 50/60 Hz, 3 Phase
Power capacity Refer to the table below.
Earthing Dedicated earthing (100 or less)
Length of Teach pendant cable 5 m/10 m/15 m (5 m, 15 m are options.)
Length of separate harnesses* 5 m/10 m/15 m (5 m, 15 m are options.)
NOTE* Harness length between robot arm and controller.
66
E Series Controller (Standard spec.) 3. Appearance and Specification
Kawasaki Robot Installation and Connection Manual of Robot Controller
E7x controller
E70, E71, E73, E74, E76, E77: horizontal enclosed
Construction
structure, indirect cooling system
Mass E70, E71, E73, E74, E76, E77: 30 kg
Temperature 0 - 45 C (0 - 40C in vertical placing)
Ambient Humidity 35 - 85 %RH (Non condensing)
environment Altitude Up to 1000 meters above mean sea level
Pollution degree 3 or below
Power source AC 200-240 V±10 %, 50/60 Hz, Single phase
Power capacity Refer to the table below.
Earthing Dedicated earthing (100 or less)
Length of Teach pendant cable 5 m/10 m/15 m (5 m, 15 m are options.)
Length of separate harnesses* 5 m/10 m/15 m (5 m, 15 m are options.)
NOTE* Harness length between robot arm and controller.
67
E Series Controller (Standard spec.) 3. Appearance and Specification
Kawasaki Robot Installation and Connection Manual of Robot Controller
E9x controller
E91: horizontal enclosed structure, indirect cooling
system
Construction
E94, E97: horizontal open structure (Enclosed structure
is an option.)
Mass E91, E94, E97: 40 kg
E91: 0 - 40 C
Temperature
E94, E97: 0 - 45 C (0 - 40 C for enclosed type)
Humidity 35 - 85 %RH (Non condensing)
Ambient
Altitude Up to 1000 meters above mean sea level
environment
E91: 3 or below
Pollution degree E94, E97: 2 or below (3 or below for optional enclosed
structure)
Power source AC 200-230 V±10 %, 50/60 Hz, Single phase
Power capacity Refer to the table below.
Earthing Dedicated earthing (100 or less)
E91, E97: 5 m/10 m/15 m (5 m, 15 m are options.)
Length of Teach pendant cable
E94: 5 m/10 m/15 m (10 m, 15 m are options.)
E91, E97: 5 m/10 m/15 m (5 m, 15 m are options.)
Length of separate harnesses*
E94: 5 m/10 m/15 m (10 m, 15 m are options.)
NOTE* Harness length between robot arm and controller.
68
E Series Controller (Standard spec.) 4. Transportation of Robot Controller
Kawasaki Robot Installation and Connection Manual
When transporting the controller, strictly observe the precautions given in the sections below for
whichever transport method is chosen.
! WARNING
1. Never support the controller manually when it is lifted up. And,
never go under or stay too close to the controller during transport.
2. Hook the wire at the lifting eyebolts as shown below.
3. Ensure that the lifting eyebolts are not loose. Check each one and
retighten if loose. Otherwise, the controller may fall and suffer
damage.
Wire
1 m or more
Lifting ! CAUTION
eyebolt Hook
1. Prepare wire and crane capable of
hoisting 300 kg or more, sufficient for a
controller loaded with full options.
2. Remove the teach pendant and teach
pendant holder (if equipped) before lifting
with the wire sling.
3. Wire length: 1 m or more as shown in left
figure.
4. Be careful as the controller may lean
when lifted up.
5. Be careful not to let the wire snag on other
equipment.
[ NOTE ]
69
E Series Controller (Standard spec.) 4. Transportation of Robot Controller
Kawasaki Robot Installation and Connection Manual
! WARNING
1. If the transport path is flat enough then the controller can be
moved on its casters. Otherwise, it may happen that moving on an
incline or an uneven surface will topple the controller, and cause
serious damage.
2. The E2x controller falls if it is inclined as follows.
Back or forth: Approx. 20 (10) or more (10 is for E28 controller)
Right or left: Approx. 15 or more
The E1x/E3x/E4x controllers falls if it is inclined as follows.
Back or forth: Approx. 15 or more
Right or left: Approx. 15 or more
! CAUTION
1. Release the stoppers on the two casters in front of the controller
when moving the controller. (Push the “OFF” side pedal.)
2. Relock the casters after the transport is complete.
(Push the “ON” side pedal for locking.)
[ NOTE ]
Transportation of E7x and E9x controllers by caster is
not possible.
70
E Series Controller (Standard spec.) 4. Transportation of Robot Controller
Kawasaki Robot Installation and Connection Manual
! WARNING
To stop the controller from toppling over, fasten it to the forklift with a
belt as shown below.
! CAUTION
1. Remove the teach pendant and teach
pendant holder. The fork cannot be
passed from the side. Pass the fork
under the controller body as shown on the
left.
2. Be careful not to shock the controller
during transport.
3. Be careful not to get caught on other
equipment, cables, etc.
[ NOTE ]
Transportation of E2x, E7x and E9x controllers by forklift
is not possible.
71
E Series Controller (Standard spec.) 4. Transportation of Robot Controller
Kawasaki Robot Installation and Connection Manual
! CAUTION
1. Disconnect the Teach Pendant.
2. Be careful not to put an impact on the controller during transportation.
3. The clearance between the bottom of the controller and the floor is small
(E7x: 9 mm, E9x: 18 mm). Accordingly, hold up one side of the
controller then the other side, and get your fingers placed on the bottom
of controller body sufficiently before holding up the controller. Because
the controller has mass (E7x: 30 kg, E9x: 40 kg), it is impossible to carry
the controller with fingertips. On the left side of E7x controller, handle
is provided to hold up the controller.
[ NOTE ]
Transportation of E1x, E2x, E3x and E4x controllers by
two persons is not possible.
72
E Series Controller (Standard spec.) 5. Arrangement of Robot Controller
Kawasaki Robot Installation and Connection Manual
In order for the controller to maintain the proper internal temperature, the installation site must
conform to the four points below.
! CAUTION
Do not block the air inlet and
exhaust ports when arranging the
controller. Separate the
controller backside from the wall
by 200 mm or more.
73
E Series Controller (Standard spec.) 5. Arrangement of Robot Controller
Kawasaki Robot Installation and Connection Manual
E28 controller
74
E Series Controller (Standard spec.) 5. Arrangement of Robot Controller
Kawasaki Robot Installation and Connection Manual
E3x controller
E1x/E4x controllers
! CAUTION
1. Release the stoppers on the two casters in front of the controller
when moving the controller. (Push the “OFF” side pedal.)
2. Relock the casters after the transport is complete.
(Push the “ON” side pedal for locking.)
75
E Series Controller (Standard spec.) 5. Arrangement of Robot Controller
Kawasaki Robot Installation and Connection Manual
Horizontal arrangement is the standard for E7x and E9x controllers. Follow the procedure
below to arrange the controllers. For the E9x controller with the enclosed structure, the ambient
temperature should be between 0-40 C.
1. Arrange the controller on a flat, horizontal floor. An object cannot be placed on the top
surface of E7x controller. When an object is placed on the top surface of E9x controller, the
mass should be 40 kg or less. It is possible to place an E9x controller on another E9x
controller as far as the mass goes. However, when an object is placed on the top surface of
E9x controller, it is necessary to remove the object once in maintenance.
2. Separate the controller right/left side from the wall by 100 mm or more.
3. Separate the controller top surface from the wall by 200 mm or more.
200 mm or more
100 mm 100 mm
or more or more
! CAUTION
Do not block the air inlet and exhaust ports when arranging the E7x
controller. For the E7x controller, separate the controller backside
from the wall by 300 mm or more, leaving enough space for the
separate harness to be bent.
200 mm or
more
E7x: 300 mm or more
E9x: 200 mm or more
76
E Series Controller (Standard spec.) 5. Arrangement of Robot Controller
Kawasaki Robot Installation and Connection Manual
Follow the procedure below when arranging E7x/E9x controllers vertically. The ambient
temperature should be within 0-40 C when arranging the E7x controller vertically. For the
E9x controller, feet attached on the bottom of the controller can be reattached on the right side.
An object cannot be placed on the top surface of the controller when the controllers are placed
vertically.
100 mm
or more
77
E Series Controller (Standard spec.) 5. Arrangement of Robot Controller
Kawasaki Robot Installation and Connection Manual
E7x controller
E9x controller
NOTE: Replace foot rubbers together with fixing screws when the foot rubbers on the bottom are
attached on the right side. If the screw with ★ mark is too long, change it to the screw
whole length is 6 mm or less when changing the screw. Otherwise, internal parts may
be damaged.
78
E Series Controller (Standard spec.) 6. Connection Instructions
Kawasaki Robot Installation and Connection Manual
! CAUTION
1. When connecting the harnesses, be sure to use the correct harnesses. Using an
incorrect harness, or forcing or misconnecting the harness may damage
connectors or cause a break in the electrical system.
2. Prevent people or equipment (forklift etc.) from stepping on or riding over the
signal and motor harness lines. Otherwise, the harness may become damaged or
the electrical system may break.
3. Even when the harnesses are long, do not bundle them winded or bended.
Bundling the harness causes the heat to build up in the harness, resulting in
over-heat and furthermore may cause fire.
4. Separate the harnesses from any nearby high voltage lines (min. 1 m apart). Do
not bundle or run the harnesses in parallel with other power lines. Otherwise,
the noise generated from power lines will cause malfunctions.
5. Separate the motor harness from the communication and sensor cables, and
distribute the lines so they are neither bundled nor running in parallel.
Moreover, connect the communication and sensor cables using shield mesh wire
that includes twisted pair lines and connect the mesh wire to an adequate FG
terminal. Otherwise, PWM noise radiated from the robot’s motor drive lines
may penetrate into various cables, such as communication cable and cause
communication errors.
6. Separate the welder secondary cable from the robot’s signal harness. Do not
wire them in the same duct.
7. The motor harness (power line) between the robot and controller will generate
PWM noise due to the PWM control driving the motors. This noise may cause
interference with signal lines. Prevent interference using these countermeasures:
(1) Separate the power and signal lines as much as possible.
(2) Use the shortest possible length for the power line.
(3) Avoid bundling, wiring in parallel the power and signal lines as much as
possible.
(4) Do not wire the power and signal line within the same duct/conduit.
(5) Set and secure a firm earth line connection for the controller.
79
E Series Controller (Standard spec.) 6. Connection Instructions
Kawasaki Robot Installation and Connection Manual
E14 controller
! CAUTION
1. Fix each connector securely. The robot may malfunction if connectors loosen or
detach.
2. The harness should drop straight down from the connector. Because connectors
are located at the upper part of controller, the controller might topple over if the
connected harnesses are pulled to the controller side or to the rear direction.
80
E Series Controller (Standard spec.) 6. Connection Instructions
Kawasaki Robot Installation and Connection Manual
Signal harness
Wrist axis motor (X3B)
harness (X4-2)
Major axis motor Major axis motor
harness (X4-1) harness (X4B-2)
Brake and JT7 Major axis motor
motor harness (X5) harness (X4B-1)
Signal Wrist axis motor+
harness (X3) brake harness (X5B)
! CAUTION
1. Fix each connector securely. The robot may malfunction if connectors loosen or
detach.
2. The harness should drop straight down from the connector. Because connectors
are located at the upper part of controller, the controller might topple over if the
connected harnesses are pulled to the controller side or to the rear direction.
81
E Series Controller (Standard spec.) 6. Connection Instructions
Kawasaki Robot Installation and Connection Manual
Major axis
motor harness
Motor harness (X4)
(X4) Wrist axis
Signal harness motor harness
(X3) (X5)
Signal
harness (X3)
E34 controller
! CAUTION
1. Fix each connector securely. The robot may malfunction if connectors loosen or
detach.
2. The harness should drop straight down from the connector. Because connectors
are located at the upper part of controller, the controller might topple over if the
connected harnesses are pulled to the controller side or to the rear direction.
82
E Series Controller (Standard spec.) 6. Connection Instructions
Kawasaki Robot Installation and Connection Manual
Major axis
motor harness
Motor harness (X4)
(X4) Wrist axis motor
harness (X5)
Signal harness
(X3) Signal
harness (X3)
Wrist axis
motor harness
(X4-2)
Major axis
motor harness
(X4-1)
Brake and JT7
motor harness
(X5)
Signal
harness (X3)
E44 controller
! CAUTION
1. Fix each connector securely. The robot may malfunction if connectors loosen or
detach.
2. The harness should drop straight down from the connector. Because connectors
are located at the upper part of controller, the controller might topple over if the
connected harnesses are pulled to the controller side or to the rear direction.
83
E Series Controller (Standard spec.) 6. Connection Instructions
Kawasaki Robot Installation and Connection Manual
X4 X3
E7x controller
E9x controller
! CAUTION
84
E Series Controller (Standard spec.) 6. Connection Instructions
Kawasaki Robot Installation and Connection Manual
2. Arm side
YF003N
X4A X3A
Signal harness
(Cable radius: 15.5-17.6 mm)
Motor harness
(Cable radius: 20.2-22 mm)
85
E Series Controller (Standard spec.) 6. Connection Instructions
Kawasaki Robot Installation and Connection Manual
X401
X4A X3A
Motor harness
(Cable radius: 20.2-22 mm)
Signal harness Signal harness
(Cable radius: 15.5-17.6 mm) (Cable radius:
Motor harness 15.5-17.6 mm)
(Cable radius:
20.2-22 mm)
R series 20N/10L
X4A X3A
Signal harness
(Cable radius: 15.5-17.6 mm)
Motor harness
(Cable radius: 20.2-22 mm)
86
E Series Controller (Standard spec.) 6. Connection Instructions
Kawasaki Robot Installation and Connection Manual
R series 30N/50N/80N/15X
Signal harness
(Cable radius: 15.5-17.6 mm)
Wrist axis motor harness
(Cable radius: 17.7-19.8 mm)
Major axis motor harness
(Cable radius: 22.1-24 mm)
ZH
X5A
X4A X3A
Signal harness
(Cable radius: 15.5-17.6 mm)
Major axis motor harness
(Cable radius: 22.1-24 mm)
Wrist axis motor harness
(Cable radius: 17.7-19.8 mm)
87
E Series Controller (Standard spec.) 6. Connection Instructions
Kawasaki Robot Installation and Connection Manual
B series
Signal harness
Major axis motor harness (Cable radius: 15.5-17.6 mm)
(Cable radius: 22.1-24 mm)
Wrist axis motor harness
(Cable radius: 17.7-19.8 mm)
ZX/ZT/ZD
X5A
X4A X3A
Signal harness
(Cable radius: 15.5-17.6 mm)
Major axis motor harness
(Cable radius: 22.1-24 mm)
Wrist axis motor harness
(Cable radius: 17.7-19.8 mm)
88
E Series Controller (Standard spec.) 6. Connection Instructions
Kawasaki Robot Installation and Connection Manual
MT
MX/MD
Signal harness
(Cable radius: 15.5-17.6 mm)
Major axis motor harness
(Cable radius: 22.1-24 mm)
Wrist axis motor harness
(Cable radius: 22.1-24 mm)
Brake and JT7 motor harness
(Cable radius: 17.7-19.8 mm) 89
E Series Controller (Standard spec.) 6. Connection Instructions
Kawasaki Robot Installation and Connection Manual
MG
X4BA-2
90
E Series Controller (Standard spec.) 6. Connection Instructions
Kawasaki Robot Installation and Connection Manual
1. Connect the teach pendant cable with the connector, lower of operation panel. Pull up the
lever and insert the cable side connector, then pull down the lever to lock the connectors.
2. Hang the teach pendant and the teach pendant cable on the hook. (No hook is provided for
E7x/E9x controllers.)
Hook
! CAUTION
91
E Series Controller (Standard spec.) 7. Connection of External Power
Kawasaki Robot Installation and Connection Manual
Strictly observe the following precautions when connecting the external power.
! DANGER
Before beginning the connection work, confirm that the external power supply for
the controller is cut off at the source. To prevent external power from being turned
ON accidentally, tag the breaker and indicate clearly that work is in progress. Or,
assign a supervisor in front of the breaker until all the connections are complete.
Connecting components while power is supplied is extremely dangerous and may
cause electric shock.
! WARNING
1. Confirm that the connected supplying power meets specifications shown on the
rating plate and the label attached on the side of the breaker. Supplying
out-of-specification power will damage electric components in the controller.
2. Earth the controller to prevent against electrical noise and shock.
3. Use dedicated earth wire (100 or less), which is equal to or larger than the
recommended power cable size (3.5 - 8.0 mm2).
4. Never share an earth line with workpiece to be welded or another machine (weld
machine, etc.).
5. In arc welding applications, connect the minus pole of the weld power supply to
a jig or directly to workpiece to be welded. Insulate the robot body and
controller so that they do not share a common earth line.
6. Without fail, before turning ON the external power to controller, make sure the
power supply wiring is complete and all the covers reattached properly.
Otherwise, failure to do so may cause electric shock.
92
E Series Controller (Standard spec.) 7. Connection of External Power
Kawasaki Robot Installation and Connection Manual
! CAUTION
1. Prepare external power that meets the specifications of the controller in terms of
momentary power interruption, voltage fluctuation, power capacity, etc. If the
power is interrupted or the voltage goes out of the controller’s specified range
(above/below ratings), then the power monitoring circuit activates cutting off the
power, and an error is returned.
2. If the external power emits a lot of electrical noise, set up a noise filter to reduce
the interference.
3. PWM noise from robot motor lines may cause malfunction of low noise- resistant
devices via external power line. Confirm that there are no such devices in the
vicinity.
4. Install a separate external power switch (breaker) for the robot, independent and
unconnected to the weld machine.
5. To prevent shorting or accidental leakage on the external power switch, install an
earth leakage breaker. (Use a time delay type with sensitivity of 100 mA or
more.)
6. If there is a possibility that surge voltage such as lightning surge might be applied
from external power line, decrease the surge voltage level by mounting a surge
absorber.
NOTE* Proximity switch directly connected with power line etc. may suffer from the
influence.
93
E Series Controller (Standard spec.) 7. Connection of External Power
Kawasaki Robot Installation and Connection Manual
E1x/E2x/E4x controllers
Connect the external power according to the
following procedure.
Cable
9 - 12
Cutting position
~ 11 - 14
14 - 17 (xx: diameter of cable)
17 - 19
Controller enclosure
Lock nut
! CAUTION
1. Confirm current requirements and select a power cable with
adequate capacity. (See section 3.0.)
2. Do not install wire that is too small in diameter, the voltage may
drop or the cable may overheat.
94
E Series Controller (Standard spec.) 7. Connection of External Power
Kawasaki Robot Installation and Connection Manual
! DANGER
View A-A
Mount the external power cable connection
E1x/E4x controllers terminal cover when the wiring is complete.
Earth terminal Failing to mount the cover may lead to
electric shock due to accidental contact with
power line.
E3x controller
Connect the external power according to the
following procedure.
Connect with the 1. Turn OFF the external power for the
external power controller.
circuit breaker at the
installation site.
Power cable
Nut
! CAUTION
1. Confirm current requirements and select a power cable with
adequate capacity. (See section 3.0.)
2. Do not install wire that is too small in diameter, the voltage may
drop or the cable may overheat.
96
E Series Controller (Standard spec.) 7. Connection of External Power
Kawasaki Robot Installation and Connection Manual
! WARNING
Tighten the terminal screws securely. Operating
the robot with loose terminals is very dangerous and
may lead to electric shock, robot malfunction, or
breakdown of the electrical system.
! DANGER
View A-A Mount the external power cable connection terminal
cover when the wiring is complete. Failing to
mount the cover may lead to electric shock due to
accidental contact with power line.
97
E Series Controller (Standard spec.) 7. Connection of External Power
Kawasaki Robot Installation and Connection Manual
98
E Series Controller (Standard spec.) 7. Connection of External Power
Kawasaki Robot Installation and Connection Manual
E7x/E9x controllers
Connect with the 1. Turn OFF the external power for the
external power controller.
circuit breaker at
the installation
site.
2. Set CONTROLLER POWER switch on the
E7x controller front of the controller to the OFF position
without fail.
D A A AC(L)
B (N.C.)
C B
C AC(N)
D FG
! CAUTION
1. Confirm current requirements and select a power cable with
adequate capacity. (See section 3.0.)
2. Do not install wire that is too small in diameter, the voltage may
drop or the cable may overheat.
99
E Series Controller (Standard spec.) 7. Connection of External Power
Kawasaki Robot Installation and Connection Manual
Change the connection of the transformer connector before changing the external power input
voltage.
To change the connection, remove the bottom panel on the back side of the cabinet.
100
E Series Controller (Standard spec.) 8. Connection of Peripheral Control Equipment
Kawasaki Robot Installation and Connection Manual
E2x controller
Use cable support for wiring of
24Vdc or less such as I/O, Ethernet
and fieldbus cable etc. Make sure
not to put any stress on connectors on
Cable support each board.
Screw to connect
external I/O Cable
shield (M4)
External D-I/O
Connector CN2
(Output)
Terminal block
X7 Connector
External D-I/O
Terminal block Connector CN4
X8 Connector (Input)
Terminal block
X9 Connector
Ethernet port
NOTE*: The upper RS-232C port and the upper USB port are
connected to each port in the accessory panel for
standard specification.
101
E Series Controller (Standard spec.) 8. Connection of Peripheral Control Equipment
Kawasaki Robot Installation and Connection Manual
E1x/E3x/E4x controllers
Use cable support for wiring of
24Vdc or less such as I/O, Ethernet
and fieldbus cable etc. Make sure
not to put any stress on connectors on
Cable support
each board.
Screw to connect
external I/O Cable
shield (M4)
1TR Board
1TW Board
External D-I/O
Connector CN2
(Output)
Terminal block
1TA/1VA X7 Connector
Board Terminal block
X8 Connector
External D-I/O
Connector CN4
(Input)
Terminal block
X9 Connector
USB port*
Ethernet port
NOTE*: The upper RS-232C port and the upper USB port are
connected to each port in the accessory panel for
standard specification.
102
E Series Controller (Standard spec.) 8. Connection of Peripheral Control Equipment
Kawasaki Robot Installation and Connection Manual
E7x controller
1TW Board
Terminal block X9
1TR Board
Terminal block X8
1TA/1VA
Terminal block X7
Board
AVR
Left
NOTE*: The left RS-232C port and the left USB port are
connected to each port in the accessory panel for
standard specification.
103
E Series Controller (Standard spec.) 8. Connection of Peripheral Control Equipment
Kawasaki Robot Installation and Connection Manual
E9x controller
External D-I/O
Connector CN2
AVR (Output)
Terminal block X7
Terminal block X8
Terminal block X9
1VA Board
External D-I/O
Connector CN4 (Input)
1TR Board
1TW Board
Top
NOTE*: The left RS-232C port and the left USB port are
connected to each port in the accessory panel for
standard specification.
104
E Series Controller (Standard spec.) 8. Connection of Peripheral Control Equipment
Kawasaki Robot Installation and Connection Manual
! WARNING
Turn OFF the power supply to the controller and peripheral equipment when
connecting external I/O. Prevent accidental turn ON of the power until all
connections are complete by take procedures shown below or by tagging the
breaker to indicate that work is in progress or by assigning a supervisor to
stand in front of the breaker. Failure to do so is extremely dangerous and
may result in electric shock or damage to the electrical system.
! CAUTION
1. Take the necessary noise countermeasures on equipment with external I/O
connections to the controller. Electrical noise that interferes with the I/O
signals may cause malfunction or damage to the electrical system.
2. Do not mistake pin Nos. on the connectors when connecting external I/O.
Misconnecting pins may cause breakdown of the electrical system.
3. Prevent people or equipment (forklift, objects, etc.) from stepping on or
riding over the external I/O cables. An unprotected cable may become
damaged causing breaks in the electrical system.
4. Avoid wiring the external I/O cables and the power lines close together or
in parallel as much as possible. Separate the cables and lines by at least
20 cm. (either in or outside the controller) Electromagnetic induction
noise from the robot motor cable, the power lines for peripheral
equipment, welding cable, etc. may penetrate into the I/O cables and lead
to malfunction.
5. Use a shield cable for the external I/O cable and connect the shield wire to
the controller.
6. When connecting I/O cables to connectors or terminals, fix them with
tying bands in the harness support set on the top of the controller,
preventing them from excessive force. (pulling, snagging of cable, etc.)
7. Install the seal connector so that external I/O cables never cause insulation
failure or disconnection at the inlet.
105
E Series Controller (Standard spec.) 8. Connection of Peripheral Control Equipment
Kawasaki Robot Installation and Connection Manual
The robot can operate synchronously with the peripheral equipment or other robots when
connecting I/O signals to the peripheral controller with connectors CN2 and CN4 on the 1TW
board. (Connectors on the cable side of CN2 and CN4 are optional.)
plate
seal connector
inside
outside
E9x controller
hole
cable
I/O signal
inlet
*
I/O signal inlet
*
2. Remove the connector cover for CN2 and CN4, and wire for general purpose signal.
3. Solder the connector pin after putting the insulation tube through the electric cable.
4. Strip off the cable coating by 2-3 mm and apply solder to the wire end.
5. Solder the cable to the connector pin.
106
E Series Controller (Standard spec.) 8. Connection of Peripheral Control Equipment
Kawasaki Robot Installation and Connection Manual
[ NOTE ]
On the plate part shown with *, cables can be put through by mounting
commercial cable entry (manufactured by PHOENIX CONTACT, KEL cable
entry system).
7. After wiring is complete, attach connector cover and fix the cable securely.
107
E Series Controller (Standard spec.) 8. Connection of Peripheral Control Equipment
Kawasaki Robot Installation and Connection Manual
8. Insert the connector into 1TW board and fix with locking screws at both ends.
[ NOTE ]
Tighten the screw thoroughly. The connection may fail if the screw is loose
and the connector pins are exposed to excessive stress/force.
Cover
17JE-37H2-1A-CF (DDK) or equivalent
Stripped wire
2-3 mm
Harness
Insulation tube
Connector
Connector pin
CN2 17JE-13370-02(D1)A (DDK) or equivalent
CN4 17JE-23370-02(D1) (DDK) or equivalent
E1x/E2x/E3x/E4x controllers
Connector
CN2: DC-37S-NR (JAE) or equivalent
CN4: DC-37P-NR (JAE) or equivalent
Stripped wire
2-3 mm
Harness
Cable clamp
E7x/E9x controllers
108
E Series Controller (Standard spec.) 8. Connection of Peripheral Control Equipment
Kawasaki Robot Installation and Connection Manual
It is possible to construct a safety circuit using the hardware circuit by connecting the external
emergency stop signal or hold signal line to the terminal connector on the 1TR board. Refer to
“External I/O Manual” for more details about signals and their connection to each terminal block.
A PCcan be used as a terminal for the robot controller, when loaded with tetminal softwares
KRterm/KCwin32 and connected to the RS-232C port in the accessory panel. Also a PC loaded
with KRterm /KCwin TCPIP can be used as terminal by connecting it to the ethernet port on
1TA/1VA board with Ethernet cable. Refer to the “AS Language Reference Manual” for more
details.
Data communication is possible with the host computer when the host computer is connected to
the RS-232C port on the 1TA/1VA board with an RS-232C cable. Refer to the option manual
90210-1177DE* for details.
109
E Series Controller (Standard spec.) 8. Connection of Peripheral Control Equipment
Kawasaki Robot Installation and Connection Manual
Adding the 1TJ/1UK board for fieldbus (option) enables communication with peripheral devices
such as DeviceNet on the fieldbus. Refer to the option manual 90210-1184DE* for details.
Input from sensors mounted on arm and control of output of driving energy to the valves become
available by adding arm ID and machine I/O boards, such as 1PV, 1JD, 1JE, 1TK and 1TY boards.
Refer to the option manuals 90210-1246DE* and 90210-1247DE* for details.
The E28 controller is equipped with a cooler and the drain water is discharged during the
operation. Carry out the drain piping following the procedure shown below.
1. Connect a drain hose to the drain pipe located on the back side of the cooler.
2. Make sure to connect hoses to both the main and secondary drain pipes.
3. Fix the drain hose, the drain pipe, and the L-shaped pipe using a tying band as shown in the
figure below.
*Make sure that the clamp for the tying band faces upward.
Cooling coil
To the
polyethylene
container or a
Secondary drain outlet
Auxiliary drain pipe
drain pan *Drain water flows continually in the main drain pipe. Make
sure to connect it to a polyethylene container or a drain outlet.
*The secondary drain pipe is a drain pipe for emergency use
when the main drain pipe is blocked with something.
110
E Series Controller (Standard spec.) 8. Connection of Peripheral Control Equipment
Kawasaki Robot Installation and Connection Manual
Trap shape
2. If discharging the drain water by linking two drain pipes into one, the drain water may flow
backward or leak. Make sure to arrange the main drain pipe and secondary drain pipe
separately.
3. Make sure that the corner section to which an L-shaped pipe is connected is not raised.
111
E Series Controller (Standard spec.)
Kawasaki Robot Installation and Connection Manual
112
E SERIES
INSTALLATION AND CONNECTION MANUAL
90202-1110DEM