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90202-1083DEF Installation Connection D7x.unlocked
90202-1083DEF Installation Connection D7x.unlocked
90202-1083DEF Installation Connection D7x.unlocked
D7x Series
Installation and
Connection Manual
902021083DEF
D7x Series Controller
Kawasaki Robot Installation and Connection Manual
PREFACE
This manual describes the installation and connection of the D7x series controller. Unless
otherwise indicated, descriptions herein apply to both specifications.
Read and understand the contents of this and safety manuals thoroughly and strictly observe all rules
for safety before proceeding with any operation. Kawasaki cannot take any responsibility for any
accidents and/or damages caused by operations that are based on only the limited part of this
manual.
This manual describes only the installation and connection of the Control Unit, the wiring, and
the external power source. Please refer to the following manuals for information on the robot
arm.
INSTALLATION AND CONNECTION =ROBOT ARM =
1. This manual does not constitute a guarantee of the systems in which the robot is utilized.
Accordingly, Kawasaki is not responsible for any accidents, damages, and/or problems
relating to industrial property rights as a result of using the system.
2. It is recommended that all personnel assigned for activation, operation, teaching, maintenance
or inspection of the robot attend the necessary education/training course(s) prepared by
Kawasaki, before assuming their responsibilities.
3. Kawasaki reserves the right to change, revise, or update this manual without prior notice.
4. This manual may not, in whole or in part, be reprinted or copied without the prior written
consent of Kawasaki.
5. Store this manual with care and keep it available for use at any time. If the robot is
reinstalled or moved to a different site or sold off to a different user, attach this manual to the
robot without fail. In the event the manual is lost or damaged severely, contact Kawasaki.
Copyright 2007 Kawasaki Heavy Industries Ltd. All rights reserved.
1
D7x Series Controller
Kawasaki Robot Installation and Connection Manual
SYMBOLS
The items that require special attention in this manual are designated with the following symbols.
Ensure proper and safe operation of the robot and prevent physical injury or property damage by
complying with the safety matters given in the boxes with these symbols.
DANGER
Failure to comply with indicated matters can result in
imminent injury or death.
WARNING
CAUTION
Failure to comply with indicated matters may lead to
physical injury and/or mechanical damage.
[ NOTE ]
Denotes precautions regarding robot specification,
handling, teaching, operation and maintenance.
WARNING
2
D7x Series Controller
Kawasaki Robot Installation and Connection Manual
CONTENTS
1.0 Safety5
1.1 Precautions during Transportation and Storage5
1.2 Installation Environments of Robot Controller 6
1.3 When Connecting the Harness7
1.4 When Connecting the External Power8
1.5 Warning Label 9
3
D7x Series Controller
Kawasaki Robot Installation and Connection Manual
4
D7x Series Controller 1. Safety
Kawasaki Robot Installation and Connection Manual
1.0 SAFETY
This chapter only describes safety precautions during installation and connection of the Controller
Unit. For all other safety matters, refer to the SAFETY MANUAL, a separate-volume.
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
CAUTION
5
D7x Series Controller 1. Safety
Kawasaki Robot Installation and Connection Manual
Install the controller in a site that satisfies all the following environmental conditions:
CAUTION
6
D7x Series Controller 1. Safety
Kawasaki Robot Installation and Connection Manual
Strictly observe the following precautions when connecting the Robot Arm with the Robot
Controller.
WARNING
Do not connect the external power until connections between the Robot Arm
and Robot Controller are completed.
Accidents may occur, such as electric shock, etc.
CAUTION
1. Be careful when connecting the harness. Be sure to use the correct harness
cable and check that the connector fittings match between the harness and
robot/controller before attempting connection. Using an incorrect harness,
or forcing or misconnecting the harness may damage connectors or cause a
break in the electrical system.
2. Use conduits, ducts, etc. to prevent people or equipment (forklift, objects, etc.)
from stepping on or riding over the signal and motor harness lines. An
unprotected harness may become damaged causing breaks in the electrical
system.
3. Separate the harness from any nearby high voltage lines (min. 1 m apart).
Do not bundle or run the harnesses in parallel with other power lines. The
noise generated from power lines will cause malfunctions.
7
D7x Series Controller 1. Safety
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. Connect with earth wires to prevent against electrical noise and shock.
2. Use dedicated earth wire (100 or less), which is equal to or larger than the
recommended power cable size (3.5 ~ 8.0 mm2).
3. Never use a minus pole (base metal) or a common earth wire for both
controller and another machine (weld machine, etc.).
4. In arc welding applications, connect the minus pole of the weld power supply
to a jig or directly to base metal. Insulate the robot body and controller so
that they do not share a common earth line.
5. Without fail, before turning ON the external power to controller, make sure
the power supply is connected and all the covers reattached properly.
Failure to do so may cause electric shock.
CAUTION
1. Prepare external power that meets the specifications of the controller in
terms of momentary power interruption, voltage fluctuation, power
capacity, etc.
If the power is interrupted or the voltage goes out of the controllers
specified range (above/below ratings), then the power monitoring circuit
activates cutting off the power, and an error is returned.
2. If the external power emits a lot electrical noise, set up a noise filter to
reduce the interference.
3. Install a separate external power switch (breaker) for the robot,
independent and unconnected to the weld machine.
4. To prevent shorting or accidental leakage on the external power switch,
install a breaker with anti-leak specification. (Use a Time Delay Relay and
sensitivity of 100 mA or more.)
8
D7x Series Controller 1. Safety
Kawasaki Robot Installation and Connection Manual
DC Power
Supply (AVR)
Front (D76)
Left
This workflow describes only the Robot Controller. For the Mechanical Unit, refer to
INSTALLATION AND CONNECTION =Arm.
Instructions.
and separation harness See also Installation and
Connection =Arm.
10
D7x Series Controller 2. Workflow - Robot Controller Installation and Connection
Kawasaki Robot Installation and Connection Manual
Work completion
[ NOTE ]
11
D7x Series Controller 3. Appearance and Specification of Robot Controller
Kawasaki Robot Installation and Connection Manual
500 270
Operation
panel
T/P
connector
420
470
Accessory
panel
50
Note) For D73, the bar and lock on controller power switch are optional.
12
D7x Series Controller 3. Appearance and Specification of Robot Controller
Kawasaki Robot Installation and Connection Manual
500 36 270
Operation
panel
T/P
connector
420
520
Accessory
100 panel
Note) For D74, the bar and lock on controller power switch are optional.
13
D7x Series Controller 3. Appearance and Specification of Robot Controller
Kawasaki Robot Installation and Connection Manual
500 270
Operation
panel
T/P
connector
470
Accessory
panel
14
D7x Series Controller 3. Appearance and Specification of Robot Controller
Kawasaki Robot Installation and Connection Manual
500 307
Operation
panel
T/P
connector
520
Accessory
panel
15
D7x Series Controller 3. Appearance and Specification of Robot Controller
Kawasaki Robot Installation and Connection Manual
16
D7x Series Controller 4. Transportation of Robot Controller
Kawasaki Robot Installation and Connection Manual
The mass of the controller is approx. 30 kg. When transporting the controller, strictly observe
the precautions given in the sections below for whichever transport method is chosen.
WARNING
1. Never support the controller manually while it is being lifted up. And,
never go under or stay too close to the controller during transport.
2. Hook the wire on the controller as shown in figure below.
CAUTION
1. Prepare wire and crane capable of
hoisting 100 kg or more.
2. Remove the teach pendant before
lifting with the wire sling.
3. Be careful as the controller may
lean when lifted up.
4. Be careful not to let the wire snag
on other equipment.
17
D7x Series Controller 4. Transportation of Robot Controller
Kawasaki Robot Installation and Connection Manual
CAUTION
1. Remove the teach pendant before transporting.
2. Be careful not to shock the controller during transport.
18
D7x Series Controller 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.
1. Arrange the controller on a horizontal floor.
2. Separate the right and left side and ceiling of the controller from the wall by 100 mm or more.
CAUTION
The inlet and exhaust ports for air-cooling are on the left side of D71/74/77
controller. Do not block these ports when arranging the controller.
100 mm 100 mm
or more or more
100 mm 100 mm
or more Inlet port Exhaust port or more
3. The inlet and exhaust ports for air-cooling are on the rear of the controller.
CAUTION
Do not block these ports when arranging the controller. Separate
the rear of the controller from the wall by 200 mm or more.
4. Make fixing bracket(s), and fix the controller referring to the figure below.
Front Right
D70/73/76
Front Right
D71/74/77
20
D7x Series Controller 6. Connection Instructions
Kawasaki Robot Installation and Connection Manual
WARNING
Do not connect the external power until connections between controller and robot
are completed. Accidents may occur, such as electric shock, etc.
CAUTION
1. Be careful when connecting the harness. Be sure to use the correct harness
cable and check that the connector fittings match between the harness and
robot/controller before attempting connection. Using an incorrect harness, or
forcing or misconnecting the harness may damage connectors or cause a break
in the electrical system.
2. Use conduits, ducts, etc. to prevent people or equipment (forklift, objects, etc.)
from stepping on or riding over the signal and motor harness lines. An
unprotected harness may become damaged causing breaks in the electrical
system.
3. Separate the harness from any nearby high voltage lines (min. 1 m apart). Do
not bundle or run the harnesses in parallel with other power lines. The noise
generated from power lines will cause malfunctions.
4. Separate the motor harness from the communication and sensor cables, and
distribute the lines so they are neither bundled nor running in parallel.
Moreover, connect the communication and sensor cables using shield mesh wire
that includes twisted pair lines and an adequate FG terminal. (See Appendix
4.) These measures stop PWM noise from the robots motor control from
radiating through the various cables and causing communication errors.
5. Separate the welder secondary cable from the robots signal harness. Do not
wire them in the same duct.
6. The motor harness (power line) between the robot and controller will generate
switch noise due to the PWM control driving the motors. This noise may
cause interference with signal lines. Prevent interference using these
countermeasures:
(1) Separate the power and signal lines as much as possible.
(2) Use the shortest possible length for the power line.
(3) Avoid bundling, wiring in parallel the power and signal lines as much as
possible.
(4) Ground the shield of the power line securely with the FG terminal.
(5) Do not wire the power and signal line within the same duct/conduit.
(6) Set and secure a firm earth line connection for the controller.
21
D7x Series Controller 6. Connection Instructions
Kawasaki Robot Installation and Connection Manual
1. Controller side
Connect the separation harnesses to the controller following the procedures below.
1. (For D71/74/77 only) Remove 4 screws and the plate for air-cooling fan motor power
connector, and remove the motor power (X207).
2. Remove 9 screws and the controller cover.
3. Pass the signal and motor cables through the cable intake port, and fix them to the fixing plate
with the cable clamp.
Plate for air-cooling fan
Cover
motor power connector
(D71/74/77 only)
Air-cooling fan
(D71/74/77 only)
Shield part
Fix shield part
with cable clamp
Cable clamp
Cable
intake port
Cable
fixing plate
Left and top
(Cover is removed.)
22
D7x Series Controller 6. Connection Instructions
Kawasaki Robot Installation and Connection Manual
X701
X702
X704
X703
X506
X507
Motor cable
Signal cable
CAUTION
Fix each connector securely using locking latch. The robot may
malfunctions if connectors loosen or detach.
23
D7x Series Controller 6. Connection Instructions
Kawasaki Robot Installation and Connection Manual
2. Arm side
FS06N, FS10E/N/C
(C001)
X4A X3A
FS03N
Lock lever
Motor harness
Signal harness
24
D7x Series Controller 6. Connection Instructions
Kawasaki Robot Installation and Connection Manual
Connect the teach pendant cable with the connector, lower right of operation panel. Pull down
the lever and lock after pulling it up and inserting the connector.
25
D7x Series Controller 7. Connection of External Power
Kawasaki Robot Installation and Connection Manual
DANGER
Confirm that external power supply for the controller is cut off before
starting connection process. It is extremely dangerous to connect
power terminals with the power supply turned ON and accidents may
occur, electric shock, etc. To prevent external power from being
turned ON, tag the breaker to indicate clearly that work is in progress.
Or, assign a supervisor in front of the breaker until all connections are
complete.
WARNING
1. Make sure the power supply meets the specifications listed on the
name plate on the controllers front panel. Connecting to a power
source outside specifications may damage internal components.
2. Install a dedicated earth wire (100 or less). Also, install a
separate earth wire for the weld machine, do not use a common
earth wire.
CAUTION
1. Check for fluctuations in the power supply before making any power
connections to the robot. Ensure a stable power supply, fluctuations
of +/-10 % or more will degrade the robots efficiency.
2. If there is danger of electrical noise coming through the power line
from other equipment, then be sure to place noise filters. (Noise
level: 2kv/1s or more)
3. Likewise, PWM noise coming through the power line from the robot
motors may also affect machines with low noise tolerance, resulting
in malfunction. Plan and arrange the system so that all the
peripheral equipment* can withstand the PWM noise.
26
D7x Series Controller 7. Connection of External Power
Kawasaki Robot Installation and Connection Manual
CAUTION
1. Confirm current requirements and select a
power cable with adequate capacity. (See 3.0)
2. Do not install wire that is too small in
diameter, the voltage may drop or the cable
may overheat.
External power
intake port
Controller Power
switch
27
D7x Series Controller 7. Connection of External Power
Kawasaki Robot Installation and Connection Manual
Connect the earth wire with the earth 5. Process the end of the external power cable as
terminal as shown below. below.
Power terminal block: Strip off the cover coating
by approx.10mm.
Earth terminal: M4 Crimp-type terminal (North
America Spec.: UL listed type)
The crimp-type terminal should be crimped with
appropriate tools in accordance with
manufacturers instruction manual.
To assure the wiring, the use of ferrules is
Power terminal Push flat-head Earth terminal
block screwdriver. recommend.
Recommended model: 216-206 (WAGO, for
AWG#14)
Recommended crimping tool: 206-204 (WAGO)
(Stripped wire length: 10 mm)
6. Connect the external power cable with the breaker
terminal (2 screws), and the dedicated earth
terminal. Push the flat-head screwdriver into the
power terminal block to open the cable clamp and
pass the cable, and remove the screwdriver.
WARNING
Tighten the cables securely. Opening the
robot with loose cables is very dangerous and
may lead to electric shock, robot malfunction,
or breakdown of the electrical system.
28
D7x Series Controller 8. Connection of Peripheral Control Equipment
Kawasaki Robot Installation and Connection Manual
According to application or specification, connect each connector in the Controller Unit described
below with the Peripheral Control Equipment. Especially for DC (under 24V) wiring, use the
Harness support.
1KB/1RB 1KA/1RA
1NR board 1KP board board board 1GW/1HW board (Option)
RS232C port
RS232C port
(In accessory panel)
Left
29
D7x Series Controller 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 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
30
D7x Series Controller 8. Connection of Peripheral Control Equipment
Kawasaki Robot Installation and Connection Manual
The robot can operate synchronously with the peripheral equipment or another robot when
connecting DI/O signals to the peripheral control equipment with connectors CN2 and CN4 on
the 1GW/1HW board.
1. Pass the cable through cable intake port on the lower left of the controller.
Shield part
Fix shield part
with cable clamp
Cable clamp
Cable
intake port
Cable
fixing plate
8. After wiring is complete, attach connector cover and fix securely by turning the harness clamp
screw.
31
D7x Series Controller 8. Connection of Peripheral Control Equipment
Kawasaki Robot Installation and Connection Manual
9. Insert the connector into 1GW/1HW board and fix with locking screws at both ends.
[ NOTE ]
Tighten the screw thoroughly. The connection may fail if the
screw is loose and the connector pins are exposed to above
standard stress/force.
Connector
CN2 DC-37S-N (JAE) or equivalent
CN4 DC-37P-N (JAE) or equivalent
Stripped wire
2-3 mm
Harness
Cable clamp
Cover DC19678-3 Insulation tube
(JAE) or equivalent
Locking screw
CN2 D20419-16J (JAE) or equivalent: M2.6 Connector pin
CN4 D20419-21J (JAE) or equivalent: M2.6
32
D7x Series Controller 8. Connection of Peripheral Control Equipment
Kawasaki Robot Installation and Connection Manual
It is possible to construct a safety circuit using the hard circuit by connecting the external
emergency stop signal or hold signal with the terminal connector on the 1KP board. Refer to
External I/O Manual for more details about signals and their connection to each terminal block.
It is possible to use a PC as terminal for the Robot Controller, when connecting a PC loaded with
KRterm/KCwin32 software with the RS232C Port in the Accessory Panel. Refer to AS
Language Reference Manual for more details.
Data communication is possible between the host computer and 1KA/1RA board, when
connecting to the RS232C Port on the 1KA/1RA board with an RS232C cable. Refer to Option
Manual for details.
It is possible to build an Ethernet LAN of 10baseT/100baseTX using the communication port: the
1KA board comes equipped with on the optional 1KN/1QN add-on board, the 1RA board is
equipped with as standard. Refer to the specific Option Manual because cables differ according
to application or specification.
33
D7x Series Controller 8. Connection of Peripheral Control Equipment
Kawasaki Robot Installation and Connection Manual
Adding the 1JF/1QK board for fieldbus (option) enables communication with peripheral devices
on the fieldbus such as DeviceNet. Refer to Option Manual for details.
34
D7x Series Controller Appendix1. Connection of
Kawasaki Robot Installation and Connection Manual Sensor Cable
WARNING
CAUTION
[ NOTE ]
Ensure that the proximity and limit switches are suitable for
the robot system and compatible with its electrical specs.
A-1
D7x Series Controller Appendix1. Connection of
Kawasaki Robot Installation and Connection Manual Sensor Cable
FS06/10
FS03N
A-2
D7x Series Controller Appendix1. Connection of
Kawasaki Robot Installation and Connection Manual Sensor Cable
F series
Sensor cable
RFV-K38
(0.3Sq 6P Outside diameter : 11mm)
FS003N:
Sensor input signal 1 (SIG1) Brown
Sensor input signal 2 (SIG2) Red
Sensor input signal 3 (SIG3) Yellow
Sensor input signal 4 (SIG4) Orange
+24V Blue, Purple
+24G Green, Black, Gray, White
[ NOTE ]
1. ItIt isisalso
alsopossible
possibletoto
useuse external
external +24V
+24V power
power supply
supply for internal
for the the internal
sensor and and valve.
valve. In Inthis
thiscase,
case,remove
removejumpers
jumpers between
between 9-10,
9-10, 11-12
11-12
pins of ofX9X9connector,
connector,andand connect
connect +24V
+24V to 10topin,
10 24G
pin, to
24G to 12 pin.
12 pin.
When using an an internal
internal+24V
+24Vpowerpowersupply,
supply,short
shortbetween
between9-10,9-10,11-12
11-12
pins. (Wiring at shipment.)
2. Select aa proximity
proximitysensor,
sensor,etc.
etc.that
thatdoes
doesnot
notexceed
exceedthe
thecurrent
currentcapacity
capacity
of the built-in power supply.
Current capacity: 0.2 A or less.
(Approx. 10 mA is necessary for each channel, SIG1~4.)
A-3
D7x Series Controller Appendix1. Connection of
Kawasaki Robot Installation and Connection Manual Sensor Cable
It is possible to connect proximity or limit switches with a faston terminal and to download it as a
WX signal. As per below, take note that connections differ between proximity and limit
switches and these are for non-Europe controller. (Refer to page A-16 for Europe controller.)
Connecting a proximity switch
Faston/Connector Proximity switch
+24V (5) +24V
SIG1 (1) SIG
24G (6) GND
CAUTION
1. For various reasons the sensor cable may receive noise interference from the
axis motors, due to wiring of the cables inside the arm, the type of proximity
switch being used, etc. This noise may cause the robot to malfunction.
Take the following measures to reduce noise:
(1) Connect the sensor by wiring the cable outside the robot arm.
(2) Use a proximity switch specified for high noise resistance.
(3) Take the necessary noise counter-measures.
(Refer to Appendix 4.0 Protecting Sensor Line from Noise)
2. Use twisted pair shield line when wiring the harness outside the robot arm.
A-4
D7x Series Controller Appendix1. Connection of
Kawasaki Robot Installation and Connection Manual Sensor Cable
When using solenoid valve signals SOL1-4 (D70/73/76), SOL1-7 (D71/74/77) via the internal
valve wiring in handling specification, they are assigned to the general purpose output signals
OUT 9-12 (D70/73/76), OUT9-15 (D71/74/77). Set them in Aux. 0605 to correspond to clamp
signals.
CAUTION
CAUTION
Set jumpers JT3 and JT4 on the 1GW/1HW board without fail as
shown below.
J3 J4
1 {{{ 1 {{{
2 {{{ 2 {{{
3 {{{ 3 {{{
4 {{{ 4 {{{
5 {{{ 5 {{{
6 {{{ 6 {{{
A B C A B C
A-5
D7x Series Controller Appendix1. Connection of
Kawasaki Robot Installation and Connection Manual Sensor Cable
When using sensor signals SIG1-4 via the internal wiring, they are assigned to the general
purpose input signals IN13-16.
CAUTION
CAUTION
J5 1GW/1HW board
1 {{ {
2 {{ {
3 {{ {
4 {{ {
5 {{ {
A B C
A-6
D7x Series Controller Appendix2. Solenoid Valve
Kawasaki Robot Installation and Connection Manual Wiring Diagram
(1) FS06/10
Controller Robot
1KP board 1NX board 1NR board
Separation
harness
P2 CN1 X703
SIGO1
A29 A26 B10
SIGO2
B30 B26 A10
SIGO3
A30 C26 B9
SIGO4
B31 A27 A9
SIGO5
A31 A28 B8
SIGO6
B32 A29 A8
SIGO7
A32 B29 B7
SIGO8
A7
(2) FS03N
Controller Robot
1KP board 1NX board 1NR board
Separation
harness VALV1
P2 CN1 X703 X401
SIGO1 2
A29 A26 B10 41
1
SIGO2
B30 B26 A10 42 4
SIGO3
3
A30 C26 B9 43
SIGO4
B31 A27 A9 44 VALV2
2
A31 A28 B8
1
B32 A29 A8
A32 B29 B7
SIGO8
A7 39
A-7
D7x Series Controller Appendix2. Solenoid Valve
Kawasaki Robot Installation and Connection Manual Wiring Diagram
I/O24V SOL
I/O24V
I/O24G
1KP board
I/O24V
SOL
I/O24G
I/O24G
1KP board
[ NOTE ]
Be aware that solenoid driving conditions are different as shown above
between Non-Europe and Europe Specifications.
CAUTION
Select the solenoid valve with consumption current between 15 and 100 mA.
If consumption current is too small, the solenoid valve may malfunction due
to the noise. As LED for the solenoid valve motion may light slightly due
to the noise, select the type without LED for solenoid valve motion or add a
capacitor of about 4700 pF ex. Matsushita ECKANA472ME between
the solenoid valve input and the common lines.
A-8
D7x Series Controller Appendix3. Sensor Wiring Diagram
Kawasaki Robot Installation and Connection Manual
(1) FS06/10
Controller
B12 B6
C12 A5
C13 B5
B27/C27 B3/B4
B28/C28 A3/A4
Robot
Separation
harness
A-9
D7x Series Controller Appendix3. Sensor Wiring Diagram
Kawasaki Robot Installation and Connection Manual
(2) FS03N
Controller
A12 A6
B12 B6
C12 A5
C13 B5
B27/C27 B3/B4
B28/C28 A3/A4
Robot
Separation
harness X401
66
67
54
55
68
56
A-10
D7x Series Controller Appendix3. Sensor Wiring Diagram
Kawasaki Robot Installation and Connection Manual
OUT
SIG1-4
I/O24G
I/O24G
Limit switch
I/O24G
1KB/1RB board
NOTE* Confirm that Dip Switch S10on the 1KB/1RB board is set to filled circle side for 24
V supply. (See below.)
CAUTION
1. For various reasons the sensor cable may receive noise interference from the
axis motors, due to wiring of the cables inside the arm, the type of proximity
switch being used, etc. This noise may cause the robot to malfunction.
Take the following measures to reduce noise:
(1) Connect the sensor by wiring the cable outside the robot arm.
(2) Use a proximity switch specified for high noise resistance.
(3) Take the necessary noise counter-measures.
(Refer to Appendix 4.0 Protecting Sensor Line from Noise)
2. Use twisted pair shield cable when wiring the harness outside the robot arm.
A-11
D7x Series Controller Appendix3. Sensor Wiring Diagram
Kawasaki Robot Installation and Connection Manual
SIG1-4
OUT
I/O24G
I/O24G
Limit switch
I/O24G
1KB/1RB board
NOTE* Confirm that Dip Switch S10on the 1KB/1RB board is set to non-filled circle side
for connection to I/O 24 ground. (See below.)
CAUTION
1. For various reasons the sensor cable may receive noise interference from the
axis motors, due to wiring of the cables inside the arm, the type of proximity
switch being used, etc. This noise may cause the robot to malfunction.
Take the following measures to reduce noise:
(1) Connect the sensor by wiring the cable outside the robot arm.
(2) Use a proximity switch specified for high noise resistance.
(3) Take the necessary noise counter-measures.
(Refer to Appendix 4.0 Protecting Sensor Line from Noise)
2. Use twisted pair shield cable when wiring the harness outside the robot arm.
A-12
D7x Series Controller Appendix4. Protecting Sensor Line
Kawasaki Robot Installation and Connection Manual from Noise
(1) Use a twisted pair shield cable for the sensor connection line. And, connect the shield jacket
with the appropriate FG terminal.
Shield jacket
Make as short as possible.
Draw the shield jacket without patching via general electric wiring.
Make as short as possible. (Or, connect it with a similar wire mesh.) Fasten it to the controller
case with a screw. However, be sure to remove any insulating
material such as paints between the screw and casing/paneling when
fixing the shield jacket.
(2) Install the earth line between the noise source and AC power supply(0V side) with a capacitor.
AC sensor
AC power supply
Place the capacitor near the sensor to optimize the shielding. When possible, we recommend
pulling the sensor from the terminal board to reduce slack in the line.
(3) Put insulator between the sensor and installation table (metal). (Plastic, rubber, etc.)
Insulator
Sensor
A-13
D7x Series Controller
Kawasaki Robot Installation and Connection Manual
MEMO
A-14
Kawasaki Robot Controller D7x Series
INSTALLATION AND CONNECTION MANUAL
90202-1083DEF