1008DEF C3x C4x C70 C80 External IO Signals

KAWASAKI ROBOT
C3✱/C4✱/C70/C80 Controller
EXTERNAL
I/O SIGNAL
KAWASAKI HEAVY INDUSTRIES, LTD.

ROBOT DIVISION
90204－1008DEF
Preface
Preface
This manual is subject to change without prior notice and without our
legal responsibility.
Kawasaki pursues a policy of continuing improvement in design and

specification of the product. The right is therefore reserved to vary this
manual without prior notice.
This manual is copyrighted and all rights are reserved by Kawasaki.

This manual may not in whole or part be reproduced in any form or by
any means without prior written permission from Kawasaki.
This manual is prepared with the best care but anyway it is impossible to
exclude any misinterpretation by the user or any spelling mistakes.
In case of doubts or if the robot behavior is different from that reported in
this manual please would you get in touch with the nearest Kawasaki or
Kawasaki’s agent.
Kawasaki cannot anticipate every possible circumstance that might

involve a potential hazard. If a procedure work method or operating
technique not specifically recommended by Kawasaki is used, you must
satisfy yourself that it is safe for you and others. In this case you are
completely responsible for eventual damages on human bodies or thing.
If you discover physical defects in the manual, Kawasaki will replace the
manual at no charge during 90 days period after you purchased the
robot.
If you do not observe warnings and/or caution to be taken in the manual

as described below, it might result in the serious injuries or damages on
human bodies or robots.
Therefore you must take extreme care to observe these warnings and
caution.
All rights reserved. Copyright  2001 by KAWASAKI HEAVY INDUSTRIES, LTD.
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller EXTERNAL I/O SIGNAL i

Preface
Safety
The following symbols are present in all Kawasaki Robot documentation to signify to the user that
proper guidelines, as set forth in the text, are designed to provide pertinent information.
！ DANGER
This danger symbol identifies special warnings

or procedures which, if not strictly observed, will
result in serious injury or death.
！ WARNING
This warning symbol identifies special warnings or

procedures which, if not strictly observed, could
result in serious injury or death.
！ CAUTION
This caution symbol identifies special

instructions or procedures which, if not strictly
followed, may result in injuly.
IMPORTANT
This important symbol identifies special instructions
or produces which, if not correctly followed, could
result in serious machine damage.
NOTE: This note symbol identifies supplementary

information, or to emphasize a point or procedure,
or to give a tip for easier operation.
ii KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller EXTERNAL I/O SIGNAL

Preface
もくじ CONTENTS
I.0. INTRODUCTION.................................................................................................I-3
I.1. HARDWARE DEDICATED SIGNAL ...................................................................I-3
I.2. SOFTWARE DEDICATED SIGNAL....................................................................I-3
I.3. GENERAL PURPOSE SIGNAL..........................................................................I-3
1.0. SAFETY ............................................................................................................1-3

1.1. INTRODUCTION...............................................................................................1-3
1.2. PERSONAL SAFETY .......................................................................................1-4
1.2.1. Personnel Safety Categories ..............................................................................................1-4
1.2.1.1. Personal Safety........................................................................................................................ 1-4
1.2.1.2. Safety During Operation .......................................................................................................... 1-6
1.2.1.3. Safety During Programming .................................................................................................... 1-7
1.2.1.4. Safety During Inspection and Maintenance ............................................................................. 1-8
1.2.2. Safety Features ...................................................................................................................1-9
2.0. I/O SIGNALS ....................................................................................................2-3

2.1. HARDWARE DEDICATED SIGNALS...............................................................2-3
2.2. SOFTWARE DEDICATED SIGNALS ...............................................................2-6
2.2.1. Software Dedicated Input Signals.......................................................................................2-7
2.2.2. Software Dedicated Output Signals ....................................................................................2-8
2.3. GENERAL PURPOSE I/O SIGNALS................................................................2-9
2.3.1. Types of General Purpose Signals ...................................................................................2-10
2.3.2. I/O Timing of General Purpose Signals ............................................................................2-10
2.3.2.1. I/O Timing for Block Step Programs ...................................................................................... 2-10
2.3.2.2. I/O Timing Using AS Language ............................................................................................. 2-12
3.0. EXTERNAL I/O SIGNAL CONFIGURATIONS .................................................3-3

3.1. HARDWARE DEDICATED SIGNALS...............................................................3-3
3.1.1. External Control Power .......................................................................................................3-3
3.1.2. External Motor Power ON ...................................................................................................3-6
3.1.3. External Emergency Stop ...................................................................................................3-8
3.1.4. External Hold .....................................................................................................................3-12
3.1.5. Teach/Repeat Output ........................................................................................................3-14
3.1.6. Power Contactor Output....................................................................................................3-15
3.1.7. Safety Fence Input ............................................................................................................3-16
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller EXTERNAL I/O SIGNAL 3

3.1.8. External Trigger Input........................................................................................................3-19
3.2. GENERAL PURPOSE I/O SIGNALS..............................................................3-22
3.2.1. External Input Signals .......................................................................................................3-22
3.2.2. External Output Signals.....................................................................................................3-25
4.0. CONNECTION OF EXTERNAL I/O SIGNALS .................................................4-2

4.1. CONNECTION OF HARDWARE DEDICATED SIGNALS................................4-4
4.2. CONNECTION OF GENERAL PURPOSE SIGNALS ....................................4-11
A.1. STOPPING THE ROBOT WITH EXTERNAL I/O SIGNALS......................... A-3

A.1.1. External Hold...................................................................................................................... A-3
A.1.2. External Emergency Stop .................................................................................................. A-4
A.2. EXTERNAL PROGRAM SELECTION FUNCTION ......................................... A-5
A.2.1. Program Selection Using AS Language “IF” Instruction. .................................................. A-6
A.2.2. Program Selection Using RPS Function ........................................................................... A-7
A.2.3. Signal Timing ..................................................................................................................... A-8
A.2.4. Program Selection Using the Jump Function.................................................................... A-9
A.2.4.1. Signal Timing.........................................................................................................................A-10
A.3. HOME POSITION SIGNAL OUTPUT FUNCTION ........................................ A-11

A.4. MUTUAL INTERLOCK.................................................................................. A-12
A.5. CLAMP SIGNAL OUTPUT TIMING .............................................................. A-13
A.6. DEDICATED SIGNALS CLASSIFIED BY APPLICATION ......................... A-15
A.6.1. Handling Specification ..................................................................................................... A-15
A.6.2. Spot Welding Specification.............................................................................................. A-18
A.6.3. Spot Welding Control....................................................................................................... A-20
A.7. EXTERNAL I/O SIGNAL PIN ASSIGNMENTS ............................................. A-24
A.7.1. 1GW/1HW Board Pin Assignments................................................................................. A-24
A.7.2. TB2 Dedicated Signal Pin Assignments (C3X Controller) .............................................. A-26
A.7.3. TB2 Dedicated Signal Pin Assignments (C4X Controller) .............................................. A-27
A.7.4. X204, X206 Dedicated Signal Pin Assignments (C70 Controller) .................................. A-28
A.8. GENERAL PURPOSE SIGNAL ASSIGNMENTS ......................................... A-29
GLOSSARY ............................................................................................................G-1
INDEX .................................................................................................................... IN-1
4 KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller EXTERNAL I/O SIGNAL

INTRODUCTION
UNIT 1 SAFETY
UNIT 2 I/O SIGNALS
UNIT 3 EXTERNAL I/O SIGNAL CONFIGURATIONS
UNIT 4 CONNECTION OF EXTERNAL I/O SIGNALS
APPENDIX
GLOSSARY
INDEX
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller EXTERNAL I/O SIGNAL I-1

Introduction
I.0. INTRODUCTION............................................................................................... I-3

I.1. HARDWARE DEDICATED SIGNAL................................................................. I-3
I.2. SOFTWARE DEDICATED SIGNAL ................................................................. I-3
I.3. GENERAL PURPOSE SIGNAL........................................................................ I-3
I-2 KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller EXTERNAL I/O SIGNAL

Introduction
I.0. INTRODUCTION
When using a robot for various applications, an interlock system with peripheral equipment, a central control of
RUN/HOLD, or a safety interlock may be required. To provide control of these functions, external I/O
(input/output) signals are used to send or receive information to, or from, these external devices. External I/O
signals can be classified into the following three types.
I.1. HARDWARE DEDICATED SIGNAL

Hardware dedicated signals are hard-wired. They are optional and are selectable by the user. These signals
differ from software dedicated signals because they cannot be used as general purpose signals.
I.2. SOFTWARE DEDICATED SIGNAL

A software dedicated signal can be selected with the multi function panel from the auxiliary function screens [111
(dedicated input signal) and 112 (dedicated output signal)] and defined as a dedicated signal.
I.3. GENERAL PURPOSE SIGNAL

General purpose signals are I/O signals which can be selected by the user during programming and teaching.
They are similar to software dedicated signals, but may be used for purpose other than those defined by software
dedicated signals.
[ NOTE ]
The number of system I/O signals is the sum of software dedicated

signals and general purpose signals.
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller EXTERNAL I/O SIGNAL I-3

✎ MEMO
I-4 KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller EXTERNAL I/O SIGNAL

INTRODUCTION
UNIT 1 SAFETY
UNIT 2 I/O SIGNALS
APPENDIX
GLOSSARY
INDEX
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller EXTERNAL I/O SIGNAL 1-1

Safety
1.0. SAFETY............................................................................................................ 1-3

1.1. INTRODUCTION .............................................................................................. 1-3
1.2. PERSONAL SAFETY ....................................................................................... 1-4
1.2.1. Personnel Safety Categories .............................................................................................. 1-4
1.2.1.1. Personal Safety........................................................................................................................ 1-4
1.2.1.2. Safety During Operation........................................................................................................... 1-6
1.2.1.3. Safety During Programming..................................................................................................... 1-7
1.2.1.4. Safety During Inspection and Maintenance ............................................................................. 1-8
1.2.2. Safety Features ................................................................................................................... 1-9
1-2 KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller EXTERNAL I/O SIGNAL

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 program Kawasaki robots, attend
a Kawasaki approved training course that would be pertinent 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 country, 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.
All safety related issues and descriptions, either presented in written or oral from any representative of Kawasaki,
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.

Safety
1.2. PERSONAL SAFETY

1.2.1. Personnel 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
1.2.1.1. 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 designed 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 understand and comprehend
all maintenance, operating and programming procedures, 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 local, state, country, 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.
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 perform 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.

Safety
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 person.
Utilize Emergency-Stops only to stop robot motion.

Safety
1.2.1.2. Safety During Operation
During operation of the robot, identify the maximum reach of the robot in all directions, 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 Multi Function Panel, the only person allowed in the work envelope is
the teacher, or the person operating the Multi Function Panel. The Multi Function Panel has provisions
to protect the operator. These safety provisions include an Emergency-Stop and deadman switch.
Never block the operator’s path retreat.
During the teach operation of the robot always have a path of retreat planned.
AVOID pinch points.

Safety
1.2.1.3. 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 Multi Function Panel. The Multi Function Panel has provisions to protect the operator including
Emergency-Stop 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.

Safety
1.2.1.4. Safety During Inspection and Maintenance
Before entering the work envelope to perform either inspection or maintenance procedures, turn off three-phase
power on the disconnect and tag, and lock-out 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 lock-out
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 pressure and purge all lines to
remove any residual pressure.
Assign only qualified personnel to perform all maintenance procedures.
Consult al available documentation before attempting any repair or service procedures.
Use only replacement parts approved by Kawasaki.
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.

Safety
1.2.2. Safety Features
To safeguard the user, the Kawasaki robot system is equipped with many safety features.
Some of these safety items include:
All Emergency-Stops are hardwired.
The Multi Function Panel, and operation panel are all equipped with red mushroom Emergency-Stop push
buttons.
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.
All robot axes have software limits.
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.

Safety
✎ MEMO

INTRODUCTION
UNIT 1 SAFETY
UNIT 2 I/O SIGNALS
APPENDIX
GLOSSARY
INDEX

I/O Signals
2.0. I/O SIGNALS ...................................................................................................................2-3

2.1. HARDWARE DEDICATED SIGNALS ..........................................................................2-3
2.2. SOFTWARE DEDICATED SIGNALS ...........................................................................2-6
2.2.1. Software Dedicated Input Signals ....................................................................................... 2-7
2.2.2. Software Dedicated Output Signals .................................................................................... 2-8
2.3. GENERAL PURPOSE I/O SIGNALS............................................................................2-9
2.3.1. Types of General Purpose Signals ................................................................................... 2-10
2.3.2. I/O Timing of General Purpose Signals ............................................................................ 2-10
2.3.2.1. I/O Timing for Block Step Programs ...................................................................................... 2-10
2.3.2.2. I/O Timing Using AS Language ............................................................................................. 2-12

I/O Signals
2.0. I/O SIGNALS

2.1. HARDWARE DEDICATED SIGNALS
The primary purpose of hardware dedicated signals is to function as external remote control signals. These
signals can be selected by making connections to the terminal block number two (TB2: C4X Controller). Or
these signals can be selected by making connections to the connector number X204 (X204 : C70 Controller).
The following hardware dedicated signals are available:
Input
1) External Control Power ON/OFF

2) External Motor Power ON
3) External HOLD
Output
1) TEACH Mode Output
WARNING
The external control power ON/OFF signal, switches
control power only. Prior to performing control
panel maintenance, ensure the main switch is OFF,
and lock with padlocks.

I/O Signals
or Leading edge trigger
or Trailing edge trigger
Level trigger (active high)
Level trigger (active low)
Pulse trigger (specified duration)
Figure Signal Types
WARNING
External motor power ON must be precisely set for a
duration of 0.3 ∼ 0.5 seconds. If the duration is too
short, the signal may not be recognized. Ensure
external motor power ON is not applied continuously. In
this case, if an emergency stop is applied, motor power is
reapplied as soon as the emergency stop switch is

I/O Signals
Table Hardware Dedicated signals
Signal name Description Signal Type

External Control This +24 VDC signal sets control power ON.
Power ON/OFF When removed, control power is set to OFF. There is a
wait time of 2∼3 seconds before the next ON signal can be
effectively applied.
External Motor Power When applied for 0.3 ∼ 0.5 seconds, motor power is set to
ON ON.
External HOLD This signal temporarily stops repeat operation of the robot
(when in the repeat mode), and maintains the “cycle start”
state. When this signal is applied, the robot continues its
motion from the point where it stopped.
TEACH Mode Output This signal originates at the TEACH/REPEAT switch on
the operation panel. The signal is close when the switch
is set to the TEACH MODE position.

I/O Signals
2.2. SOFTWARE DEDICATED SIGNALS
WARNING
Software dedicated signals are defined and
operated on via AS system software. Safety
interlocks must not be accomplished using only
software dedicated signals.
Software dedicated signals can be used for external remote control and interlock configuration.
Once defined by the operator, software dedicated signals use a portion of the total system I/O signals, which
includes hardware and general purpose signals. There are 32 input and 32 output channels per I/O board. Up
to four I/O boards can be used, for a total of 128 input and 128 output channels (In case of C4X Controller).
Or Up to three I/O boards can be used, for a total of 96 input and 96 output channels (In case of C70 Controller).
The number of available general purpose signals decreases as additional software dedicated signals are defined.
Software dedicated signals and general purpose signals function in the same way.
[ NOTE ]
Ensure that defined software dedicated signals do not conflict
with hardware dedicated Signals. Refer to unit 3,
“Connection of External I/O Signals”.
Software dedicated signals can be assigned by:
1) Using auxiliary functions 111 (dedicated input signal) or 112 (dedicated output signal)
(refer to the C Controller Operations and Programming manual), or
2) Using the DEFSIG command (Refer to AS Language Manual).

I/O Signals
2.2.1. Software Dedicated Input Signals
Table Software Dedicated Input Signals

Signal
Signal name Description of Function
Type
External Motor Powr ON Externally switches motor power to ON.
(EXT_MOTOR_ON) Performs the same function as the MOTOR POWER switch on
the operation panel.
External Error Reset Externally resets an error condition.
(EXT_ERR_RESET) Performs the same function as the ERROR switch on the
operation panel.
External Cycle Start Externally selects cycle start.
(EXT-C/S) Performs the same function as the CYCLE START switch on the
operation panel.
RPS_ON At an auxiliary data “END” taught point, this signal is used to
select execution of a program changeover, according to and
external program number. (refer to Appendix A.2)
JUMP_ON At an auxiliary data “JUMP” taught point, this signal is used to
select execution of a program changeover, according to an
external program number. (refer to Appendix A.2)
JUMP_OFF At an auxiliary data “JUMP” taught point, this signal disables
selecting execution of a program changeover. The current
program continues. (refer to Appendix A.2)
External Program Number This signal selects an external program number.
(RPSxx) Up to 99 programs can be selected. (refer to Appendix A.2)
External Program Reset This external signal causes a cycle stop and resets the main
(EXT_PGM_RESET) program to the first step. When this signal is input, with RPS
(random program selection) mode enabled, the external program
number is read and reset to the first step.
(Refer to Appendix A.2)

I/O Signals
2.2.2. Software Dedicated Output Signals

Table Software Dedicated Output Signals
Signal
Signal Name Description of Function
Type
Motor Power ON Indicates that motor power is set to ON, and performs the same function as
(MOTOR_ON) the signal that indicates motor power on via the control panel.
Error Occurrence Indicates an error condition, and performs the same function as the signal
(ERROR) that indicates an error via the control panel.
AUTOMATIC Indicates the operating safe of the robot (with the HOLD/RUN switch set to
(AUTOMATIC) RUN). The following status information is transmitted:
1) external HOLD
2) input signal OFF
3) repeat mode
4) cycle auto mode
5) step auto mode
6) TEACH LOCK OFF
7) cycle start
8) RGSO ON
9) dryrun OFF
In Repeat Indicates that the controller is in the repeat mode (during cycle start), and
(C/S) performs the same function as the signal that indicates cycle start on the
control panel.
Teach mode Indicates that the controller is in the teach mode, when the
(TEACH) TEACH/REPEAT switch on the operation panel is set to TEACH.
Home Position 1 Indicates that the robot is in the first home position. (refer to Appendix
(HOME_POS1) A.3)
Home Position 2 Indicates that the robot is in the second home position.
(HOME_POS2) (refer to Appendix A.3)
Power ON Indicates that control power is set to ON, and performs the same function as
(POWER_ON) the signal that indicates that control power is on via the control panel.
RGSO Indicates that the servo motor brake is released.
External Program Indicates that the program selection mode is valid (RPS valid).
Selection valid (refer to Appendix A.2)
(RPS)
RPS_ST Indicates that the robot is at the auxiliary data END taught point of the
external program.(refer to Appendix A.2)
JUMP_ST Indicates that the robot is at the auxiliary data JUMP taught point of the
external program. (refer to Appendix A.2)

I/O Signals
2.3. GENERAL PURPOSE I/O SIGNALS

General purpose I/O signals are assigned during teaching or programming. In repeat mode, when executing a
program, these signals are sent to, or received from, external devices. General purpose signals function
similarly to software dedicated signals. Software dedicated signals are assigned prior to program creation and
are used for specific, commonly used functions. General purpose signals can be assigned for any desired
external function.
WARNING
When using general purpose signals for safety
interlocks, ensure additional physical safety procedures
are also used. The method of agreement to the
relating standard is necessary.
CAUTION
When assigning general purpose signal numbers
and functions, ensure they are not duplicates of
those previously assigned as hardware or software
dedicated signals, or other general purpose signals.
If duplicate assignments are made, the conflict may
cause the controller to function unpredicatebly.

I/O Signals
2.3.1. Types of General Purpose Signals
There are two types general purpose I/O signals, external and internal. This section addresses external I/O
signals only. For information about internal I/O signals, refer to section five of this manual and the C Series
Controller AS Language manual.
External I/O signals include both software dedicated signals and general purpose signals. When determining
general purpose signal requirements, remember that the total number of assignments includes software dedicated
signals.
[ NOTE ]
Expansion of external I/O signals is made in
increments of 32 input and output channels, based on
the physical configuration of the I/O board.
2.3.2. I/O Timing of General Purpose Signals
The I/O timing of general purpose signals is dependent on the method of robot operation (teaching or
programming). It is important to understand the difference in I/O timing between these two methods.
2.3.2.1.I/O Timing for Block Step Programs
When teaching the robot, using the multi function panel or small teach pendant, the following information is
recorded for each step:
1) robot joint angle

2) motion auxiliary data (interpolation mode, speed, accuracy, and tool)
3) clamp data
4) general purpose I/O signals
This method of programming is called “block step” programming. When performing block step programming,
taught general purpose signals are designated OX (output) and WX (input). The I/O timing to execute OX and
WX signals when the taught program is executed is shown in next page figure.

I/O Signals
[ NOTE ]
Timing of advancement to the next step occurs when the robot arrives at
the taught step. This does not necessarily coincide with the taught point.
This variation depends on the accuracy data taught at the step. The finer
the accuracy, the closer to the taught point that advancement occurs.
Step 10
Step 7 Step 8
OX5 Step 9
OX6 OX6
WX3 WAIT
OX5
OX6
WX3(waiting for input)
WX3
Figure System Switch OX.PREOUT ON
OX5: Taught in step 8.
1) When the robot reaches the accuracy range of step 7 and moves toward the point taught in step 8, OX5 is set
to ON.
to OFF because OX5 is not taught in step 9.
OX6: Taught in step 8 and 9.
to ON.
2) When the robot reaches the accuracy range of step 8 and moves toward the point taught in step 9, OX6 stays
ON because it is also taught in step 9.
[ NOTE ]
Normally, upon arriving at the accuracy range of step 9, the robot would move
toward the point taught in step 10, and OX 6 would immediately be set to OFF
(because it is not taught in step 10); however, in this example, the controller is
waiting to receive WX3 (taught in step 9). Step 9 is not completed until WX3 is
received.
3) When WX3 is received OX6 is set to OFF.

I/O Signals
WX3: Taught in step 9
1) Upon arriving at the accuracy range of the point taught in step 9, the robot waits until WX3 is received.
2) When WX3 is received, the robot moves toward the point taught in step 10.
[ NOTE ]
When the robot is stopped by setting MOTOR POWER to OFF, setting CYCLE
START to OFF, or setting HOLD/RUN to HOLD, currently active OX signals are
temporarily set to OFF. When the robot is restarted, these OX signals are
restored to the ON state.
2.3.2.2. I/O Timing Using AS Language
In addition to the block step teaching method for assigning general purpose I/O signals (OX and WX), I/O
signals can be also be assigned using AS language commands. Using this programming method, various
instructions are available to control input and output signals (see table below). Refer to the C Series Controller
AS Language manual for a more detailed explanation of these program instructions.
Table AS Language Instructions
Input/Output
Instruction Function
Signal Control
SIGNAL Sets specified external output signals to ON/OFF.
BITS Arranges signals in a binary pattern and sets signal states according to
the binary equivalent of the decimal value specified.
Output RESET Sets all external output signals to OFF.
RUNMASK Allow signals to be ON only while the program is executing.
PULSE Sets signal to ON for a specified duration.
DLYSIG Sets signal to ON/OFF after a specified delay time.
SWAIT Causes program execution to wait until the specified external I/O
signals are set to a given state.
SIG( ) Returns the logical AND of the specified binary signal states.
BITS( ) Reads consecutive binary signals, and returns the decimal value
Input
corresponding to the binary bit pattern of the specified signals.
ON/ONI Starts monitoring the specified external input signal, and when the
signal is set to the desired state, calls the specified subroutine
(or jumps to the given label).

I/O Signals
Timing of general purpose I/O signals using AS Language programming is shown in figure below.
Example Program:
11 JMOVE #lc1
12 SIGNAL 5,6
13 JMOVE #lc2
14 SIGNAL -5
15 JMOVE #lc3
16 SWAIT 1003
17 SIGNAL -6
18 JMOVE #lc4
#lc4
#lc2
#lc1
#lc3
wait
OUT5
OUT6
IN3(waiting for input)
IN3
Figure System Switch PREFETCH. SIGINS Off
[ NOTE ]
For the timing diagram shown in figure above, positioning accuracy
(ACCURACY) is assumed to be fine. When the accuracy is coarse,
transitions occur sooner than when the robot reaches the actual taught point.
OUT5:
1) When the robot moves toward #1c2, general purpose output signal (OUT5) is set to ON.
2) After reaching #1c2, the robot moves toward #1c3. and OUT5 is set to OFF.
OUT6:
1) When the robot moves toward #1c2, general purpose output signal (OUT6) is set to ON.
2) After reaching #1c2, the robot moves toward #1c3, OUT6 remains ON.
3) When the robot moves toward “#1c4, OUT6 is set to OFF.
IN3:
1) When the robot moves towards #1c3, the controller begins to monitor universal input signal IN3.
2) Upon reaching #1c3, IN3 stays OFF and the controller waits for the input.
3) When signal 1003 is received, IN3 is set to ON, the robot moves toward #1c4, and OUT6 is set to OFF.
[ NOTE ]
Normally, if the robot is stopped, OUT signals are not turned OFF (OX signals are
temporarily set to OFF); however, if a signal is defined with a RUNMASK instruction,
the OUT signal is temporarily set to OFF when the robot is stopped.

✎ MEMO

INTRODUCTION
UNIT 1 SAFETY
UNIT 2 I/O SIGNALS
APPENDIX
GLOSSARY
INDEX

External I/O Signal Configurations
3.0. EXTERNAL I/O SIGNAL CONFIGURATIONS ................................................. 3-3

3.1. HARDWARE DEDICATED SIGNALS .............................................................. 3-3
3.1.1. External Control Power ....................................................................................................... 3-3
3.1.2. External Motor Power ON ................................................................................................... 3-6
3.1.3. External Emergency Stop.................................................................................................... 3-8
3.1.4. External Hold ..................................................................................................................... 3-12
3.1.5. Teach/Repeat Output ........................................................................................................ 3-14
3.1.6. Power Contactor Output .................................................................................................... 3-15
3.1.7. Safety Fence Input ............................................................................................................ 3-16
3.1.8. External Trigger Input ........................................................................................................ 3-19
3.2. GENERAL PURPOSE I/O SIGNALS ............................................................. 3-22
3.2.1. External Input Signals ....................................................................................................... 3-22
3.2.2. External Output Signals..................................................................................................... 3-25

3.0. EXTERNAL I/O SIGNAL CONFIGURATIONS

This section describes external I/O hardware, general purpose, and software dedicated signal configurations.
3.1. HARDWARE DEDICATED SIGNALS

When using hardware dedicated signals, ensure connections are made according to the information provided in
the following sections.
3.1.1. External Control Power
● C3X/C4X Controller
CAUTION
Ensure that connection to terminal block TB2
terminal No.1 and 2 is not reversed; damage to
diode can occur.
Figure External Control Power Enable
[ NOTE ]
The external contact must match the following specifications:
Relay Coil ：7mA at 24VDC
Power Supply ：24VDC±10％
There is a cycle wait time of 2 ∼ 3 seconds from OFF to ON for relay.

Figure External Control Power Disabled
[ NOTE ]
The controller is shipped with TB2-3/4 jumpered (external control

power not used). To use the external control power capability, ensure
the jumper is removed and connection of the external device to TB2 is
configured as shown in previous page figure.

● C70/C80 Controller
CAUTION
Ensure that connection to X204 connector Pin No.1
and 14 is not reversed; damage to diode can occur.
Figure External Control Power Enable
[ NOTE ]
Relay Coil ：7mA at 24VDC
Power Supply ：24VDC±10％
There is a cycle wait time of 2 ∼ 3 seconds from OFF to ON for relay.
Figure External Control Power Disabled

[ NOTE ]
The controller is shipped with X204 connector Pin No.2 and 15 jumpered (external
control power not used). To use the external control power capability, ensure the
jumper is removed and connection of the external device to X204 connector is
configured as shown in figure above.

3.1.2. 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 operation panel.
WARNING
If external motor power ON (contact closed) is
applied when the controller EMERGENCY STOP
switch is pressed, motor power will resume when
the switch is released.
Figure External Motor Power ON
[ NOTE ]
Photo Coupler：10mA at 24 VDC

Figure External Motor Power ON
[ NOTE ]
The external contact match match the following specifications:
Photo Coupler：10mA at 24 VDC

3.1.3. 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 operation panel.
WARNING
Functional operation of the external emergency stop
is extremely important for the safety of personnel,
and must be designed in accordance with IEC
204-1/EN 60204-1 and EN 775
Figure External Emergency Stop 1
[ NOTE ]
External switches must match the following specifications:
Relay Coil：30mA at 24VDC


Figure External Emergency Stop Disabled
[ NOTE ]
When the controller is shipped, motor power cannot be turned on because
TB2-5/6 and TB2-9/10 are not jumpered.
[ NOTE ]

Figure External Emergency Stop Disabled

[ NOTE ]
When the controller is shipped, motor power cannot be turned on beause

X204-3/16 and X204-4/17 are not jumpered.

3.1.4. External Hold
External hold is an external input signal that stops the robot temporarily, and is effective only when the robot is in
the repeat mode.
Figure External Hold
[ NOTE ]
External switches or relay contact must match the following specifications:
Photo Coupler：10mA at 24VDC
figure External Hold Disabled
[ NOTE ]
When the controller is shipped, the robot is in the HOLD mode because
pins TB2-19/20 are not jumpered.

Figure External Hold
[ NOTE ]
External switches or relay contact must match the following specifications:

Photo Cpupler：10mA at 24VDC
Figure External Hold Disable
[ NOTE ]
When the controller is shipped, the robot is in the HOLD mode

because pins X204-7/20 are not jumpered.

3.1.5. Teach/Repeat Output
The teach/repeat output is provided via TB2-31/32.
Figure Teach/Repeat Output
The teach/repeat output is provided via X204-9/22.
[ NOTE ]
When controller’s control power supply is turning off, the
contact becomes Teach mode by “open” regardless of the
state of the TEACH & REPEAT switch.
Figure Teach/Repeat Output
[ NOTE ]
The load should not exceed the circuit specification.

Contact specification : 24 VDC, 0.1A or less.

3.1.6. Power Contactor Output
● C4X Controller
The power contactor output is provided via TB2-13/14.
Figure Power Contactor Output
The power contactor output is provided via X204-10/23.
Figure Power Contactor Output
[ NOTE ]
The load should not exceed the circuit specification.

Contact specification : 24 VDC, 0.1A or less.

3.1.7. Safety Fence Input
The safety fence input signal interrupts motor power and is effective only when the robot is in the repeat mode.
WARNING
Functional operation of the safety fence switch is
extremely important for the safety of personnel and
must be designed in accordance with IEC 204-1/EN
60204-1 and EN 775.
Figure Safety Fence

[ NOTE ]


Figure Safety Fence Disabled
[ NOTE ]
When the controller is shipped, the jumpers for TB2-15/16 and

TB2-17/18 are not installed.

Figure Safety Fence
[ NOTE ]

Figure Safety Fence Disable
[ NOTE ]
When the controller is shipped, the jumpers for X204-5/18 and
X204-6/19 are not installed.

3.1.8. External Trigger Input
The external trigger input signal interrupts motor power, and is effective only when the robot is in the teach
mode.
WARNING
Function operation of the external trigger switch is
extremely important for the safety of personnel and
must be designed in accordance with IEC 204-1/EN
60204-1 and EN 775.
Figure External Trigger

[ NOTE ]


Figure External Trigger Disabled
[ NOTE ]
When the controller is shipped, the jumpers for TB2-25/26 and
TB2-27/28 are not installed

Figure External Trigger
[ NOTE ]

Figure External Trigger Disabled
[ NOTE ]
When the controller is shipped, the jumpers for X206-2/10 and

X206-3/11 are not installed.

3.2. GENERAL PURPOSE I/O SIGNALS

All general purpose I/O signals (including software dedicated signals) are processed by the 1GW or 1HW board.
For connector pin assignments, refer to Appendix A.7.
3.2.1. External Input Signals
The 1HW board provides the capability to connect 32 input signals. These are two common connections (CN4
pins 18 and 19 respectively), each is connected to an External +24V (1GW) or an External 0V (1HW).Each of
these common inputs provids power for 16 input circuits. External input signals are connected to pins 1 ∼ 16
and 20 ∼ 35 of CN4.
Input Specifications:
・Number of Circuits : 32
・Input Device : photo coupler
・Voltage : 24VDC ±10%
・Current : 10mA
・Connector Type : 37 pin D-type Female (board side)
Male (harness side)
CAUTION
Ensure that the polarity of the external 24 VDC
power supply is correct. If incorrectly connected,
damage to the 1GW/1HW board, power supply, and
contacts may occur.

Figure General Purpose Input Signals-1GW

Figure General Purpose Input Signals-1HW

3.2.2. External Output Signals
There are 32 available output signals from the 1GW or 1HW board. The +24V External provides power to the
output circuitry via pins 18 and 19 of CN2. The two commons (CN2 pins 36 and 37) provide 0V for the output
circuitry for OUT1 ∼ OUT16 and OUT17 ∼ OUT32 respectively.
CAUTION
Ensure that the correct polarity of the +24V External
is observed when connecting it to CN2. If
connected incorrectly, damage to components on
the 1GW or 1HW board may occur.
Output Specifications:
・Number of Circuits : 32
・Output Device : transistor
・Voltage : 24VDC ±10%
・Maximum Load Current : ± 0.1A or less
・Connector Type : 37 pin D-type Male (board side)
Female (harness side)
CAUTION
Ensure that surge protection is provided for all
inductive loads (i.e., relay coils, solenoids, etc.).

Figure General Purpose Output Signals-1GW

Figure General Purpose Output Signals-1HW

✎ MEMO

INTRODUCTION
UNIT 1 SAFETY
UNIT 2 I/O SIGNALS
APPENDIX
GLOSSARY
INDEX

Connection of External I/O Signals
4.0. CONNECTION OF EXTERNAL I/O SIGNALS ................................................. 4-3

4.1. CONNECTION OF HARDWARE DEDICATED SIGNALS ............................... 4-4
4.2. CONNECTION OF GENERAL PURPOSE SIGNALS .................................... 4-11

4.0. CONNECTION OF EXTERNAL I/O SIGNALS

This section desribes the procedures for connecting external I/O signals. Hardware dedicated signals are
connected to terminal block TB2 (C4X Controller). Or Hardware dedicated signals are connected to Connector
X204 (C70 Controller). General purpose I/O signals are connected to CN2 (output signals) and CN4 (input
signals) of the 1GW or 1HW.
[ NOTE ]
Ensure that the wire is securely fastened to the cabinet using tie wraps, to
prevent stress on the connection to the terminal block and chafing of the
insulation at the point of entry into the cabinet (access hole on the left side
of the cabinet).
[ NOTE ]
Refer to sections 3.1 and 3.2, and Appendix A.7 for a description of I/O
signal pin assignments.

4.1. CONNECTION OF HARDWARE DEDICATED

SIGNALS
WARNING
There is a risk of electric shock and the possibility of damage to
controller components when connecting external I/O devices. Set
mains power to OFF at the controller and external device main switch,
and lock with padlocks before making external I/O connections. Do
not remove safety tags and reapply power until connections are
completed.
1) Set mains power to OFF at the controller and external device main switch, and lock with padlocks.
2) Remove access hole cover from the left side of the controller and drill the adequate hole
(see figure on next page).
3) Secure access hole cover to the left side of the controller.
4) Open the controller front door.
5) Strip 8-9 mm of insulation from the end of the wires from the external device.
6) Feed the wires into the controller cabinet through the hole.
7) Connect the wires to the appropriate terminal numbers on the top side of the Terminal Block TB2
(see figures on 4-6 page).
8) Secure the wires to the cabinet using tie wraps at its entry into the cabinet, near TB2, and at intermediate
points as required, and to access hole cover using cable gland.

Access Hole Cover
Figure Controller Cabinet (Left Side)

1GW or 1HW
CN2
Figure Controller Cabinet (Front View, Door Open)
Figure Terminal Block No.2 (TB2)

● C70 Controller
WARNING
There is a risk electric shock and the possibility of damage to controller
components when connecting external I/O devices. Set mains power
to OFF at the controller and external device main switch, and lock a
main switch of external device with the key before making external I/O
connections. Do not remove safety tags and reapply power until
connections are completed.
1) Set mains power to OFF at the controller and external device, and lock a main switch of external devoce
with the key.
2) Remove the controller top and side cover (See figure on next page).
3) Take off the connector X204, X206 from 1HM board (See figure on next page).
4) Connect the wires to appropriate pin number of Connector X204.
5) Secure the connector X204, X206 to 1HM board using locking screws.
6) Fix the cable to the cable fixed plate using the cable clamps (See figure on next page).
7) Reinstall the controller cover.

X206
Connector
X204
Connector
Side Cover
Front Panel 1HM Board
Figure C70 Controller Cabinet Figure C70 Controller Cabinet (Side View)
Cable Fixes Plate
Figure Cable Fixed

● C80 Controller
WARNING
There is a risk of electric shock and the possibility of damage to
controller components when connecting external I/O devices. Set
mains power to OFF at the controller and external device main switch,
and lock with padlocks before making external I/O connections. Do
not remove safety tags and reapply power until connections are
completed.
2) Remove access hole cover from the left side of the controller and drill the adequate hole
(see figure below).
5) Strip 8-9 mm of insulation from the end of the wires from the external device.

7) Take off the connector X204, X206 from 1HM board (See figure below).
8) Connect the wires to appropriate pin number of Connector X204.
9) Secure the connector X204, X206 to 1HM board using locking screws.
10) Secure the wires to the cabinet using tie wraps at its entry into the cabinet at intermediate points as required,
and to access hole cover using cable gland.

4.2. Connection of general purpose

signals
● C3X/C4X/C80 Controller
WARNING
2) Remove access hole cover from the left side of the controller and drill the adequate hole (see figure 4-1).
6) Connect the wire to the appropriate pin numbers of Connector CN2 and CN4.
7) Secure the connector CN2 and CN4 to 1GW or 1HW board using locking screws.
8) Secure the wires to the cabinet using tie wraps at its entry into the cabinet, near TB2, and at intermediate
points as required, and to access hole cover using cable gland.

● C70 Controller
WARNING
1) Set mains power to OFF at the controller and external and external device, and lock main switch of external
device with the key.
2) Remove the controller top and side cover (See figure on 4-8 page).
3) Take off the connector CN2 and CN4 from 1GW/1HW board.
4) Connect the wires to the appropriate pin number of connector CN2 and CN4.
5) Secure the connector CN2 and CN4 to 1GW/1HW board using locking screws.
6) Fix the cable to the cable fixed plate using the cable clamps (See figure below).
7) Reinstall the controller cover.
1GW/1HW Board
Figure 1GW/1HW Board

INTRODUCTION
UNIT 1 SAFETY
UNIT 2 I/O SIGNALS
APPENDIX
GLOSSARY
INDEX
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller EXTERNAL I/O SIGNAL A-1

Appendix
A.1. STOPPING THE ROBOT WITH EXTERNAL I/O SIGNALS .........................A-3

A.1.1. External Hold.......................................................................................................................A-3
A.1.2. External Emergency Stop ...................................................................................................A-4
A.2. EXTERNAL PROGRAM SELECTION FUNCTION..........................................A-5
A.2.1. Program Selection Using AS Language “IF” Instruction. ...................................................A-6
A.2.2. Program Selection Using RPS Function ............................................................................A-7
A.2.3. Signal Timing ......................................................................................................................A-8
A.2.4. Program Selection Using the Jump Function .....................................................................A-9
A.2.4.1. Signal Timing .........................................................................................................................A-10
A.3. HOME POSITION SIGNAL OUTPUT FUNCTION .........................................A-11
A.4. MUTUAL INTERLOCK...................................................................................A-12
A.5. CLAMP SIGNAL OUTPUT TIMING ...............................................................A-13
A.6. DEDICATED SIGNALS CLASSIFIED BY APPLICATION ..........................A-15
A.6.1. Handling Specification ......................................................................................................A-15
A.6.2. Spot Welding Specification...............................................................................................A-18
A.6.3. Spot Welding Control ........................................................................................................A-20
A.7. EXTERNAL I/O SIGNAL PIN ASSIGNMENTS ..............................................A-24
A.7.1. 1GW/1HW Board Pin Assignments..................................................................................A-24
A.7.2. TB2 Dedicated Signal Pin Assignments (C3X Controller) ...............................................A-26
A.7.3. TB2 Dedicated Signal Pin Assignments (C4X Controller) ...............................................A-27
A.7.4. X204, X206 Dedicated Signal Pin Assignments (C70 Controller) ...................................A-28
A.8. GENERAL PURPOSE SIGNAL ASSIGNMENTS ..........................................A-29
A-2 KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller EXTERNAL I/O SIGNAL

Appendix
A.1. STOPPING THE ROBOT WITH EXTERNAL

I/O SIGNALS
The Controller allows the operator to stop the manipulator using two primary method;
External hold and External emergency stop. In case of an emergency, the manipulator can be immediately
stopped, using the External emergency stop signal. When control power is switched off and then on, motion of
the manipulator resumes from the point where it was stopped.
A.1.1. External Hold
WARNING
When external hold is applied, the manipulator is
stopped under electronic control. Before entering
the work cell, set the main switch to OFF and lock
with padlocks.
When the manipulator is stopped using an External hold signal, the position is maintained with the brakes.
External hold is valid only when the robot is in the repeat mode; in teach mode, manual operation is still
available.
[ NOTE ]
When External hold is applied, the state of the following output signals is:
Auxiliary data OX signals - all temporarily set to off.
Clamp signals - (HANDLING TYPE and OUT; not designated in the RUNMASUK
instruction) maintain the same state.
When External hold is released, the manipulator continues operation immediately; however, if cycle start has
been set to OFF (e.g., controller was set to TEACH), the TEACH/REPEAT switch must be set to REPEAT and
the CYCLE START switch set to ON, before motion resumes.

Appendix
A.1.2. External Emergency Stop
WARNING
When entering the work cell, set the main switch to OFF
and lock with padlocks, unless the robot is in the teach
mode.
External Emergency Stop signal sets motor power to OFF, and cycle start to OFF (cycle stop):
the manipulator stops immediately. This method of stopping should only be used in emergency situations; when
the manipulator stops quickly, excessive stress is applied to its components. For stopping the robot in normal
situations (non-emergency), use of the hold signal is preferred.
WARNING
When teaching the robot, a second person should
be present safety purposes. In the teach mode,
cell door safety plugs are not functional.

Appendix
A.2. EXTERNAL PROGRAM SELECTION FUNCTION

To select programs externally, the following methods are available:
1) AS program “IF” instruction.
2) RPS (Random Program Selection) function (software dedicated signal).
3) JUMP function (software dedicated signal).
Judge the selection signal code by At completion of a program During the execution of a
the IF instruction, and select and (taught step “END”), the next program, when a JUMP
call the corresponding program program is selected (RPS function taught step is encountered, a
(RPS function is not used). is not used). selection is made to continue
with the current program
Main Program (JUMP OFF), or select
pg1 another program (JUMP
Main Program ON).
pg00
END Program
pg2
Main
Program
pg3 Jump ON
END OFF
pg01
END
Main
Program
pg5
pg02
END Program
pg5
pg08 Upon completion of a program, if END

the external program number
(RPSXX) is set to 0, pg0 is
selected.
pg10 Pg0
END
pg1 pg3 pg5
END END END
Figure Program Selection Using Figure Program Selection Figure Program Selection Using the
AS Language IF instruction Using RPS Function JUMP Function

Appendix
A.2.1. Program Selection Using AS Language “IF” Instruction.
By using the following AS instructions, selection of signal codes is obtained by means of the BIT function.
By determining the value using the “IF” instruction, the applicable program is selected and executed.
Example program:
.PROGRAM pg00()
100 HOME ; Moves toward the home position.
WAIT SIG(1009) ; Program selection OK signal from external device (wait for input signal IN9).
TWAIT 0.1 ; Wait for program selection signal (Set up time of input signals IN10 ∼ 13).
pg.no = BITS(1010,4) ; Get the program selection signal (IN 10 ∼ 13).
IF pg.no = = 1 THEN ;
CALL pg1 ;
END ;
IF pg.no = = 2 THEN ; Call the subprogram according to the program selection.
CALL pg2 ;
END ;
CALL pg8 ;
END ;
CALL pg10 ;
END ;
GOTO 100
.END
[ NOTE ]
In the previous program example, AS Language instructions BITS and IF ∼
THEN ∼ END are used. AS Language instructions BITS, CASE ∼ VALUE ∼
END, or EXTCALL can also be used. Refer to the C Controller AS
Language manual for a complete description of instructions.

Appendix
A.2.2. Program Selection Using RPS Function
To select programs externally using the RPS function, the following dedicated signals can be used. These are
software dedicated signals and are defined using the DEFSIG command.
External program selection Output occurs when the external program selection mode is
mode is valid “RPS” valid (RPS ON).
Output
This indicates that external program selection mode is valid
RPS-ST
(RPS ON).
This signal enables program selection using an external
program number. The external program number (RPSxx)
RPS-ON
is selected when the RPS mode is valid, and if this signal is
set to ON at a step where “END” is taught.
External Program Number This external signal (binary code) indicates a program
“RPSxx” number. The number of signal bits can be set by the user.
Input
Program Reset This signal causes a program reset to the first step of a
“EXT_PGM_RESET” main program. In automatic operation, a cycle stop is
executed, and reset to the first step of the program occurs.
Also, when the RPS mode is valid (in external program
selection mode), if this signal is selected, external program
number (RPSxx) is fetched and reset to the first step.
Table Example of RPS Codes (7-bits)
SIGNAL
PROGRAM
RPS1 RPS2 RPS4 RPS8 RPS16 RPS32 RPS64
PG0 × × × × × × ×
PG1 ○ × × × × × ×
PG2 × ○ × × × × ×
PG3 ○ ○ × × × × ×
PG15 ○ ○ ○ ○ × × ×
PG16 × × × × ○ × ×
PG99 ○ ○ × × × ○ ○
○: ON
×: OFF
In table A-1, seven bits are used for the binary code. BCD (binary-code decimal notation) codes can also be
selected via software.
[ NOTE]
Ensure that external program numbers (RPSxx) do not conflict with other program numbers
(e.g., for the first 10 external program numbers, use PG0 ∼ PG9, vice PG00 ∼ PG09).

Appendix
A.2.3. Signal Timing
This section describes signal timing for program selection using RPS.
Step in which “END” is taught First Step

(example : PG1) (example : PG3)
Robot
“RPS-ST” (Output)
External
“RPSxx” (Input)
“RPS-ON” (Input)
100ms Min
Figure Signal Timing Using RPS
When the RPS mode is valid, and a step in which auxiliary data END is executed, the program input OK RPS-ST
signal is sent. When this occurs, the required external program number “RPSxx” must be set at the external
device (including the interface panel). After being set, a wait time of 100 ms is required before the program
input OK RPS-ON signal is sent. When the position of the manipulator coincides with the END taught point,
the controller confirms the RPS-ON signal. The controller then fetches RPSxx, sets the next executing program
internally, and sets RPS-ST to OFF. For external devices, RPS-ON and RPSxx signals must be maintained until
the RPS-ST signal is set to OFF.
CAUTION
If the RPS-ON signal is input when the RPSxx
signal is not set, the controller could fail to fetch
RPSxx and the wrong program could be selected.
“RPS-ST”
ON
“RPS-ON”
？ OFF
ON
“RPSxx”
FETCHING
PROGRAM
CHANGEFOVER
“RPS-ST”
OFF
Figure RPS Program Selection Flow Diagram

Appendix
A.2.4. Program Selection Using the Jump Function
To select programs externally using the JUMP function, the following dedicated signals can be used. These are
software dedicated signals and are defined using the DEFSIG command.
This indicates that external program number selection is ready.

JUMP-ST Output occurs when the RPS mode is valid and during the
Output
execution of a step where the JUMP or EXTCALL instruction
is taught.
This signal enables program selection using an external
program number. The external program (RPSxx) is selected
JUMP-ON
when the RPS mode is valid and if this signal is set to ON at a
step where JUMP is taught.
This signal disables program selection using an external
INPUT program number. When the RPS mode is valid, if the signal
JUMP-OFF
is externally set to ON at a step where JUMP is taught, the
program change is not performed and the current program
advances to the next step.
External Program This external signal (binary code) indicates a program number.
Number “RPSxx” The number of signal bits can be set by the user.
“JUMP-ST”
ON
OFF
JUMP-ON?
OFF
ON JUMP-OFF?
“RPSxx”
FETCHING ON
Current program : currently executing program.

CURRENT PROGRAM ＝ Requested program : program number fetched by RPSxx.
=REQUESTED PROGRAM
SAME* * When the EXTCALL instruction is used, the

≠ following error message is displayed:
PROGRAM Error(-314) Cannot execute because the
CHANGEOVER program is already used.
When JUMP-ON and JUMP-OFF are both
entered, JUMP-ON takes precedence.
“JUMP-ST”
OFF Even when JUMP-ON is entered, if the currently
executing program number is the same as the
requested program number, the program change
Figure JUMP Function Flow Diagram
is not performed.

Appendix
A.2.4.1. Signal Timing

This section describes signal timing for program selection using the JUMP function.
Step in which “JUMP” is taught First step
(example: PG2) (example:PG5)
robot
Jump-ST (output)
(external)
JUMP-CODE (input)
JUMP-ON (input)
100msMin.
(ON)
JUMP-OFF (input)
(OFF)
Figure Signal Timing Using the JUMP Function
When the RPS mode is valid and a step in which auxiliary data JUMP is executed, the Program input OK
JUMP-ST signal is sent.
When this occurs, the external program number (RPSxx) must be set at the external device (including the
interface panel).
After being set, a wait time of 100ms or more is required before the Program input OK JUMP-ON signal
is sent.
When the manipulator’s position coincides with the JUMP taught point, the controller confirms the
JUMP-ON signal.
The controller fetches RPSxx, sets the next executing program internally, and sets JUMP-ST to OFF;
however , if the program number is the same as the current program number, a program change is not
made and the robot continues to the next step.
For external devices, the JUMP-ON and RPSxx signals must be maintained until the JUMP-ST signal is
set to OFF.
Step in which “JUMP” is taught First step
(example: PG2) (example: PG5)
(robot)
“JUMP-ST” (output)
(external)
“RPSxx” (input)
(ON)
“JUMP-ON” (Input) (OFF)
“JUMP-ON” (Input)
Figure JUMP Function When Continuous Motion is Required

Appendix
A.3. HOME POSITION SIGNAL OUTPUT FUNCTION
WARNING
The home position signal is generated by the
encoder, provided on each joint of the manipulator.
This software signal is different from hardware
controlled signals (e.g., limit switches, etc.). This
signal must not be the only safety interlock used,
additional hardware type interlocks (e.g., limit
switches, etc.) must be used for safety purposes.
Out of the home position signal occurs when the manipulator is positioned within the range of the predesignated
home position. Two home position signals (first and second) can be set (see figure below); the location, range,
and signal number of the home position can be programmed.
Home Position
Range of
Home Position
Figure Home Position Range
Location of Home Position : Joint angle values.

Range of Home Position : The range in millimeters from the home position.
Ensure that the range value is not less than 1mm.
The output channel number for the home position signal is selected using the DEFSIG command. The home
position location and range is selected using the SETHOME and SET2HOME commands respectively.

Appendix
A.4. MUTUAL INTERLOCK

When robots are installed in close proximity to each other, their work envelopes may overlap. In this situation,
interlocking (mutual interlocking) between the robots is required. For example, the area of interference between
robots A and B in figure below is represented by the shaded area.
Mutual Interference Zone
Positions WXa and WXb represent locations where

the robots monitor for the OX signals output from
Robot A Robot B the other robot to determine whether or not the other
robot is in the mutual interference zone. If the
zone is not clear, the robot waits at this location
until the zone is clear, before continuing its motion
into the zone. The dashed line indicates an interval
for which OXa and Oxb signals are continuously
output, allowing movement of the other robot into
the interference zone.
Figure Mutual Interference Zone
When referenced from robot A:
1) Before entering the interference zone, robot A confirms, by means of WXa (OX output from robot B), that
robot B is located outside the zone.
2) When robot A is located outside the interference zone, the OXa signal is output, allowing robot B to enter
the zone.

Appendix
A.5. CLAMP SIGNAL OUTPUT TIMING
WARNING
Do not set controller power to OFF during a material
handling operation; damage to materials,
equipment, and personnel may occur. When
controller power is set to OFF, all output signals
(inching clamp signals) are set to OFF. If the
controller is set to OFF during a material handling
process, the clamp signal is lost and the gripper
releases the object being held.
Clamp signals are used for many purposes, depending upon the application. They are commonly used for spot
welding applications and control of grippers for material handling operations. To use a clamp signal for an
application, the optional solenoid valve must be installed on the arm of the manipulator. To configure the
controller for using a clamp signal to control the solenoid valve, jumper selection on the 1GW or 1HW board and
software selection (clamp setting or HSETCLAMP command) is required.
[ Teach Mode ]
During teaching operations, the CLAMP signal is selected using the Multi Function Panel, by selecting the
TEACHING screen and pressing the CLAMP SIGNAL key.
Single solenoid, normally closed specification.
CLAMP key
(LED)
Illuminated
CLAMP
Single solenoid, normally open specification.
CLAMP key
(LED) Illuminated
CLAMP
Double solenoid specification.
CLAMP key
(LED) Illuminated
CLAMP A
CLAMP B
Figure Selection of the CLAMP Signal During Teach Operation

Appendix
[ Repeat/Check Mode ]
× ×
× CLAMP ON × CLAMP OFF
CLAMP OFF CLAMP ON Teach Data
CLAMP A
CLAMP B
Figure Clamp Signal Outputs (Double Solenoid Specification)
Figure A-16 shows two clamp signal outputs (CLAMP A and CLAMP B) during repeat or check modes.
A maximum of eight clamp signals can be assigned in the teach mode

Appendix
A.6. DEDICATED SIGNALS CLASSIFIED

BY APPLICATION
This section summarizes dedicated signals for material handling and spot welding applications.
A.6.1. Handling Specification
CAUTION
To enable/disable sensor signals (Js series only), set all
jumpers on J5 (for IN13∼IN16) either to the AB position (not
used), or the BC position (used)(e.g.,do not set jumpers 1∼3 to
AB, and jumpers 4∼5 to B-C). See table on next page for
jumper settings.
Table Material Handling Dedicated Input Signals
Signal
Type
CONTROL POWER H Refer to section 2.1
ON/OFF
MOTOR POWER ON H
HOLD H
EXTERNAL MOTOR S Refer to section 2.2 Not required when hardware dedicated
POWER ON signal is used.
EXTERNAL ERROR S Refer to section 2.2
RESET
EXTERNAL CYCLE S
START
EXTERNAL S
PROGRAM RESET
RPS_ON S
JUMP_ON S
JUMP_OFF S
RPExx S
SENSOR SIGNAL - Signal from sensors (e.g., proximity switch, limit switch, etc,)
Only Js-Series can be used as general purpose input signals (IN13-16). To
make these signals available, set jumpers on J5 of the
1GW/1HW board (see table on next page and figure on next
page). Sensors, related hardware, and wiring are optional and are
not included with the standard robot.
H: Hardware Dedicated Signal
S: Software Dedicated Signal

Appendix
Table 1GW/1HW Board J5 Jumper Settings
Not Used Use
Figure 1GW/1HW Board Jumper Locations
CAUTION
To enable/disable clamp signals, set all jumpers on J3 (for OUT
9∼12) and J4 (for OUT 13∼16) either to the AB position (not used),
or the BC position (used)(e.g.,do not set jumpers 1∼3 to AB, and
jumpers 4∼6 to B-C). See table above for jumper settings.
Table Material Handling Dedicated Output Signals

Signal
Type
TEACH/REPEAT H Refer to section 2.1.
SWITCH OUTPUT
MOTOR POWER S Refer to section 2.2.
ON
IN REPEAT S
ERROR S
OCCURRED
AUTOMATIC S
TEACH MODE S Refer to section 2.2. Not required when hardware dedicated
signal is used.
FIRST HOME S Refer to section 2.2.
POSITION
SECOND HOME S
POSITION
RGSO S
RPS MODE S
RPS-ST S
JUMP-ST S
CLAMP S This signal is used of material handling application. A maximum
(maximum of eight of 7 system outputs are available. Both single and double
channels) solenoids can be used (refer to section A.5 for clamp signal
output timing). For the Js series manipulators, an internal or
solenoid (optional) can be installed by making connections to the
internal cable harness. Ensure that connection is made to
OUT9∼16.

Appendix
Table 1GW/1HW Board J3 and J4 Jumper Settings
Not Used Use
[ NOTE ]
Clamp signals are not available by setting jumpers only; in addition to setting
the jumpers, ensure that software dedicated signal assignments are also made.
Table Material Handling Software Dedicated Signals (Standard Shipment Settings)

Output Signal Input Signal
Dedicated Signal Name Signal Number Dedicated Signal Name Signal Number
DURING MOTOR POWER OUT 1 1 IN 1 1001
ON
IN REPEAT OUT 2 2 IN 2 1002
ERROR OCCURRED OUT 3 3 IN 3 1003
OUT 4 4 IN 4 1004
OUT 5 5 IN 5 1005
OUT 6 6 IN 6 1006
OUT 7 7 IN 7 1007
OUT 8 8 IN 8 1008
CLAMP 1 OFF* OUT 9 9 IN 9 1009
CLAMP 1 ON* OUT 10 10 IN 10 1010
OUT 11 11 IN 11 1011
OUT 12 12 IN 12 1012
OUT 13 13 IN 13 1013
OUT 14 14 IN 14 1014
OUT 15 15 IN 15 1015
OUT 16 16 IN 16 1016
* May vary from specification.

Appendix
A.6.2. Spot Welding Specification
Table Spot Welding Dedicated Input Signals
Signal
Type
CONTROL POWER H Refer to section 2.1.
ON/OFF
MOTOR POWER ON H
HOLD H
EXTERNAL MOTOR S Refer to section 2.2. Not required when hardware dedicated
MOTOR POWER ON signal is used.
EXTERNAL ERROR S
RESET
EXTERNAL CYCLE S
START
EXTERNAL S
PROGRAM RESET
RPS-ON S
JUMP-ON S
JUMP-OFF S
RPSxx S Refer to section 2.2.

Max. 7 bits.
WELD COMPLETED S Received from up to two weld controllers (timer contactors).
After the weld initiate command is sent, the robot waits for
this signal before moving to next location.
WELD FAULT S Received from up to eight weld controllers (timer
contactors). When this signal is received, the robot stops
automatically.
RETRACTABLE S Used to detect the gun stroke retract state. An individual
detection for each clamp (maximum right channels) can be
GUN RETRACT
made.
DETECTION
RETRACTABLE S Used to detect a retractable welding gun with a short stroke.
An individual detection for each clamp (maximum eight
GUN EXTEND
channels) can be made.
DETECTION

Appendix
Table Spot Welding Dedicated Output Signals

Signal
Type
TEACH/REPEAT H Refer to section 2.1.
SWITCH OUTPUT
MOTOR POWER ON S Refer to section 2.2.
IN REPEAT S
ERROR OCCURED S
AUTOMATIC S
TEACH MODE S Refer to section 2.2. Not required when hardware dedicated
signal is used.
FIRST HOME S Refer to section 2.2.
POSITION
SECOND HOME S
POSITION
RGSO S
RPS MODE S
RPS_ST S
JUMP_ST S
WELD COMMAND S Transmitted to weld controller (up to eight). Signal type is

(maximum eight selectable; level or pulse (pulse duration is adjustable). or
channels)
WELD SCHEDULE S Weld schedule number (maximum of six bits) transmitted to
(maximum six weld controller. May be either binary or individual, and is
channels) selectable.
WELD FALT RESET S Resets the weld control (timer contactor) weld fault condition.
(maximum eight
channels)
GUN CLAMP S Weld gun clamp command signal. Clamp commands can be
COMMAND output individually, using the clamp setting.
(maximum eight
channels)
STROKE CHANGE S Stroke selection (extend or retract) for retractable weld guns.
(maximum eight Separate signals may be used for extend and retract. Stroke
channels, twice) selection can be output individually, using the clamp setting.
CLAMP * S Provides manual control for material handling applications.
(maximum eight The ON/OFF state for each clamp can be controlled separately. or
channels) Control of both single and double solenoids is available.
[ NOTE ]
Both WELD COMMAND and CLAMP (for material handling) signals are controlled by the
system’s clamp function (i.e., the maximum total number of WELD COMMAND and CLAMP
signals is eight).

Appendix
A.6.3. Spot Welding Control

1) Spot Welding Specifications.
Table Spot Welding Specifications
Single stroke
Type Cylinder-type, retractable
Stopper-type, retractable
Weld Gun
Maximum number of simultaneous guns is two.
Quantity Multiple guns can be controlled by a single
weld controller
Weld Controller Maximum of two, controlled individually.
(Timer Contactor)
Maximum of six bits.
Weld Schedule
Maximum of 63 for binary output.
2) Weld Controller/Valve/Gun Connections
Gun Clamp Valve

Gun
One Gun (Standard Type)
Weld Controller
Gun Clamp Valve 1

Gun 1
Two Guns without Gun Clamp Valve 2
simultaneous welding Gun 2
Weld Controller
Gun Clamp Valve 1

Gun 1
Weld Controller 1
Two Guns with simultaneous
welding Gun Clamp Valve 2
Gun 2
Weld Controller 2
Gun Clamp Valve

Gun 1
Weld Controller
Gun Change
Gun 2
Gun 5

Appendix
3) Welding I/O Signals
Weld Schedule (maximum 6-bits)
Robot Controller Weld

Weld Command Controller
Weld Complete Timer
Weld Fault Contactor
Weld Fault Reset Gun
Gun Clamp
Stroke Change (single/double solenoid)
Retractable Gun retract Detection
Retractable Gun Extend Detection
Figure Welding I/O Signals
［ NOTE ］
Some weld controllers may not have a separate input for
weld command and weld schedule.
4) Weld Timing Diagram
Robot
t1 t2
Gun Clamp Output
Weld Command
Output
Weld Command
Input
Weld Schedule
Output
Figure Weld Timing Diagram
t1: Gun clamp and weld command signals can be output before reaching the actual taught point
(variable 0 ∼ 0.99 second).
t2: Upon receiving the weld complete signal from the weld controller, movement to the next taught point can be
delayed (variable 0∼0.99 second).
［ NOTE ］
The weld command signal shown in figure above is a level output (a
pulsed output is also available). This example shows a gun clamp
that is controlled by the robot controller, not a weld controller. The
weld complete signal duration must be greater than 100 msec; an
alternative is to keep the signal ON until the weld command is set to
OFF (if the weld command is a level output).

Appendix
5) Timing Diagram (Retractable Gun)
(1) Spot Welding (2) Spot Welding (3) Spot Welding (4) Spot Welding
Retract→Extend Extend Extend→Retract Retract
Moving Moving Moving Moving Moving

Robot Motion Teach Data Teach Data Teach Data Teach Data
Extend Extend Retract Retract
t1 t1 t1 t6 t1 t6
t2 t2
Gun Clamp Output
Stroke Select
Retractable Gun
t4 t5
Cylinder Type
Retract Gun
Stopper Type
t3 t3
Weld Initiate
Command Output
Weld Complete
Input
Weld Schedule
Output
Figure Timing Diagram (Retractable Gun)
t1: Anticipation time for the gun clamp output signal (0∼0.99 sec., variable).
t2: Delay time from receipt of the weld complete input signal until gun is open and motion can begin (retract to
extend); for extend to retract, delay time is T6 (0∼0.99 sec.,variable).
t3: Delay time of the weld initiate command output from the gun clamp output (retract to extend). Used for a
retractable gun only (00∼9.9 sec. variable).
t4: Delay time of the stroke select output from the gun clamp output (retract to extend), for a stopper type
retract change (00∼9.9 sec., variable).
t5: Delay time of the output (retract to extend)for a stopper type retract change (00∼9.9 sec.,variable).
t6: Delay time from receipt of the weld complete input signal until motion can begin (time until gun is open,
extend to retract) (00∼9.9sec., variable).

Appendix
Table Spot Welding Software Dedicated Signals (Standard Shipment)

Dedicated Signal Name Signal Number Dedicated Signal Name Signal Number
DURING MOTOR POWER ON OUT 32 32 EXTERNAL MOTOR POWER ON IN 32 1032

ERROR OCCURRED OUT 31 31 EXTERNAL ERROR RESET IN 31 1031
AUTOMATIC OUT 30 30 EXTERNAL CYCLE START IN 30 1030
IN REPEAT OUT 29 29 #1 WELD COMPLETE IN 29 1029
TEACH MODE OUT 28 28 IN 28 1028
FIRST HOME POSITION OUT 27 27 IN 27 1027
OUT 26 26 IN 26 1026
OUT 25 25 IN 25 1025
CLAMP2 ON (HANDLING) OUT 24 24 IN 24 1024
#1 WELD COMMAND OUT 23 23 IN 23 1023
CLAMP1
OUT 22 22 IN 22 1022
(WELD GUN CLAMP)
OUT 21 21 IN 21 1021
#1 WELD SCHEDULE WS8 OUT 20 20 IN 20 1020
#1 denotes weld controller number 1.

Appendix
A.7. EXTERNAL I/O SIGNAL PIN ASSIGNMENTS

A.7.1. 1GW/1HW Board Pin Assignments
CN2
1
20 OUT 1
OUT17 2
21 OUT 2
OUT18 3
22 OUT 3
OUT19 4
23 OUT 4
OUT20 5
24 OUT 5
OUT21 6
25 OUT 6
OUT22 7
26 OUT 7
OUT23 8
27 OUT 8
OUT24 9
28 OUT 9
OUT25 10
29 OUT10
OUT26 11
30 OUT11
OUT27 12
31 OUT12
OUT28 13
32 OUT13
OUT29 14
33 OUT14
OUT30 15
34 OUT15
OUT31 16
35 OUT16
OUT32 17
36 COM1 NC
(OUT1∼16) 18 VIN1
37 COM2 (OUT1∼16)
(OUT17∼32) 19 VIN2
(OUT17∼32)
Figure 1GW/1HW Board Connector CN2 Pin Assignments
[ NOTE ]
The mating plug for CN2 is a 37 pin D-type connector (Female).
For channel numbers of additional 1GW/1HW boards, add 32 to the channel
numbers shown above for each addition board.
C4X : up to three additional boards,
C70 : up two additional boards.

Appendix
CN 4
19 COM2
37 (IN17∼32)
ＮＣ 18 COM1
36 (IN1∼16)
ＮＣ 17
35 ＮＣ
IN32 16
34 IN16
IN31 15
33 IN15
IN30 14
IN14
32
IN29 13
IN13
31
IN28 12
IN12
30
IN27 11
IN11
29
IN26 10
IN10
28
IN25 9
IN 9
27
IN24 8
IN 8
26
IN23 7
IN 7
25
IN22 6
IN 6
24
IN21 5
IN 5
23
IN20 4
IN 4
22
IN19 3
IN 3
21
IN18 2
IN 2
20
IN17 1
IN 1
Figure 1GW/1HW Board Connector CN4 Pin Assignments
[ NOTE ]
The mating plug for CN2 is a 37 pin D-type connector (Female).
For channel numbers of additional 1GW/1HW boards, add 32 to the channel
numbers shown above for each addition board.
C4X : up to three additional boards,
C70 : up two additional boards.

Appendix
A.7.2. TB2 Dedicated Signal Pin Assignments (C3X Controller)
External
External Control Power
External
The Jumper between 3 and 4
must be removed when using
External Control Power On.
Internal
External Emergency Stop CH1
Internal
Internal
Internal
Internal Safety Fence CH1

Internal
Internal
Internal
External Hold
Internal
External Trigger Input 1
Internal
External Motor Power On
Internal
Teach/Repeat Output
Internal
Internal
To Manipulator
Figure TB2 Connections (C3X Controller)

Appendix
A.7.3. TB2 Dedicated Signal Pin Assignments (C4X Controller)
External
External
Internal
Internal
Internal
Internal
Power Contactor Output
Internal
Internal
Safety Fence CH2
Internal
Internal
External Hold
Internal
Internal
Internal External Motor Power On
Teach/Repeat Output
Internal
Internal
To Manipulator
Figure TB2 Connections (C4X Controller)

Appendix
A.7.4. X204, X206 Dedicated Signal Pin Assignments (C70/C80 Controller)
External
External
Internal
Internal
Internal
Internal
Power Contactor Output
Internal
Safety Fence CH1
Internal
Internal
Internal
External Hold
Internal
Internal
External Motor Power On
Internal
Teach/Repeat Output
Internal
Internal
To Manipulator
Figure X204, X206 Connections

Appendix
A.8. GENERAL PURPOSE SIGNAL ASSIGNMENTS

Table General Purpose Signals
Signal Name Dedicated Signal Name Signal Name Dedicated Signal Name
OUT 1 1 IN 1 1001
OUT 2 2 IN 2 1002
OUT 3 3 IN 3 1003
OUT 4 4 IN 4 1004
OUT 5 5 IN 5 1005
OUT 6 6 IN 6 1006
OUT 7 7 IN 7 1007
OUT 8 8 IN 8 1008
OUT 9 9 IN 9 1009
OUT 10 10 IN 10 1010
OUT 11 11 IN 11 1011
OUT 12 12 IN 12 1012
OUT 13 13 IN 13 1013
OUT 14 14 IN 14 1014
OUT 15 15 IN 15 1015
OUT 16 16 IN 16 1016

Appendix
Table General Purpose Signals (continued)
Signal Name Dedicated Signal Name Signal Name Dedicated Signal Name
OUT 17 17 IN 17 1017
OUT 18 18 IN 18 1018
OUT 19 19 IN 19 1019
OUT 20 20 IN 20 1020
OUT 21 21 IN 21 1021
OUT 22 22 IN 22 1022
OUT 23 23 IN 23 1023
OUT 24 24 IN 24 1024
OUT 25 25 IN 25 1025
OUT 26 26 IN 26 1026
OUT 27 27 IN 27 1027
OUT 28 28 IN 28 1028
OUT 29 29 IN 29 1029
OUT 30 30 IN 30 1030
OUT 31 31 IN 31 1031
OUT 32 32 IN 32 1032

INTRODUCTION
UNIT 1 SAFETY
UNIT 2 I/O SIGNALS
APPENDIX
GLOSSARY
INDEX
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller EXTERNAL I/O SIGNAL G-1

Glossary
This glossary contains definitions of terms used by operators, programmers and maintenance personnel who work
with Kawasaki Robots. The definitions are listed in alphabetical 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 program step-by-step.
ALPHANUMERIC
Pertaining to a set of symbols that contain both letters and numbers, either individually 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 equivalent to one (1) amp.
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 BEAING
A rolling element which is used to support a rotating shaft.
G-2 KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller EXTERNAL I/O SIGNAL

Glossary
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 instance, 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)
ASSIGNMENT
An instruction used to express a sequence of operations, or used to assign operands to specified variables, or
symbols, or both.
ASYCHRONOUS
A means of data communication where the data is sent a character at a time preceded 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.).

Glossary
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.
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.

Glossary
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 analogous to reverse point and forward point operations
in other robot models.
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 processed 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

Glossary
A location in the Cartesian coordinate system that is defined relative to another Cartesian coordinate
location.
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 problem.
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.
CYCLE
A complete path of projectory performed by the robot for a specific application.

Glossary
CYCLOIDAL DRAIVE
A mechanical gear reduction unit that reduces the speed of the input and increase the torque capacity.
The cyclodial 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 transmitted, 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 difference. However, if the controller detects a
condition where the difference between this mechanical value and the desired electrical position is larger
than the established 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 operator7s program is checked for mistakes and then corrected.
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.
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 an 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.

Glossary
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 boars 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.
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
error messages.
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.

Glossary
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.
FILE
A set of related records or data elements, which are stored using one name and are arranged in a structire that
can be used by a program.
FILESPEC
Includes the name, creation data and size of the specified file.
FIXED DISK
An electromagnetic mass storage device which is not removable. Hard disks have much highter 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 column 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 direction at a time.

Glossary
HANDSHAKING PROTOCOL
Communication rules used for data transmissions between devices. Each device must recognize the same
protocol in order to communicate.
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 in 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
Refer 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 in composed of an
incremental encoder that generates incremental pulses, and an absolute encoder that generaters 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 is small minute
increments.
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 alternating opaque and generated by an encoder through the use of an optical
disk with alternating 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.

Glossary
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 where by the operation of one part or mechanism automatically brings about or prevents the
operation of another.
INTERPETER
A program that changes English-like commands into machine language. An interpreter 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 compatible 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.
INTERRUPT
An external signal that halts program execution so that the computer can service the needs of some peripheral
device or subsytstem.
INTRINSIC SAFETY BARRIER (ISB)

An electronic device used in robot controllers to restrict current and voltage to a safe lavel.
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 coputer and its peripheral devices
communicate.
IPM
Acronym for Intelligent Power Module

Glossary
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 location, or part of a
program.
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 an 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.

Glossary
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.
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 magahertz. 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 instructions from user programs to direct the robot, and
performs the computations necessary to control the robot.
MSB
Abbreviation for most significant bit.

Glossary
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 interpreted 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.
OVERFLOW
When a value or buffer exceeds a predefined limit.
OVERTRAVEL
An error condition that exists when the robot exceeds its normal software limit values, 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.

Glossary
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.
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 position 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 hog 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 divice.

Glossary
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.
PRINTING
A process in which characters are stamped on a surface, usually paper.
PROGRAM
A predefined, step-by -step 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 referred 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 provided.
REAL NUMBER
A number with a fractional part, such as 1.75 ∼ -61.89, .5, -4.00, etc.
REAL-TIME
The actual time during which the computer analyzes and processes data : information 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 information at a selscted speed
value, in a continuous or a step by step type of movement of the mechanical unit.

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 information enters the screen from the bottom.
SENSOR
A device used to detect various conditions: proximity, heat, pressure, etc. An electrical signal from the
sensor can be used to communicate information to a robot program.
SERIAL
A method of transmitting data by which only one bit is sent or received at any one point in time.
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.

Glossary
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 language 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 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 something.
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.
SYSTEM DATA
Data that is specific to a individual robot. Zeroing data, upper and lower software limits, and software
switch setting are all examples of system data.
SYSTEM SWITCH
Software switches that are set to determine various configurations and characteristics 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 operations.
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.

Glossary
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 location.
TRAP POINT
see pinch point.
TTL
Acronym for transistor-transistor logic.
TWO’s COMPLEMENT
A means of representing a negative number as one more than the binary complement 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 equivalent to the force required
to produce one amp of current through one ohm of resistance.

Glossary
W
WORK ENVELOPE
The effective range or reach of a robot’s axes.
WORLD COORDINATES
A Cartesian coordinate system in which the origin points is near the base of the robot, and robot movement
can be expressed in terms of a 3-dimensional space representation 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 controller. 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 manufactures call this procedure mastering or calibration.

INTRODUCTION
UNIT 1 SAFETY
UNIT 2 I/O SIGNALS
APPENDIX
GLOSSARY
INDEX
KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller EXTERNAL I/O SIGNAL IN-1

Index
1GW/1HW Board, 3-23, 3-24, 3-26, 3-27, 4-6, 4-12, A-16, A-17
1GW/1HW Board, Pin Assignments, A-24
1HM Board, 4-8
A
Access Hole Cover, 4-5
AS Language, Instructions, 2-12
AS Language, I/O Timing, 2-12
AUTOMATIC, 2-8
B
Block Step Programming, 2-10
C
CLAMP Signal, A-13, A-16, A-19
CLAMP Signal, Key, A-13
CLAMP Signal, Output Timing, A-13
CLAMP Signal, Outputs, A-13
CLAMP Signal, Teach Operation, A-13
CN2, 4-6, A-24
CN4, 4-6, A-25
Control Power, 3-3
Controller Cabinet, 4-5, 4-6, 4-8
D
Dedicated Input Signals, Material Handling, A-15
Dedicated Input Signals, Spot Welding, A-18
Dedicated Output Signals, Material Handling, A-16
Dedicated Output Signals, Spot Welding, A-19
Dedicated Signals, A-15
DEFSIG, 2-6
E
Error Occurrence, 2-8
EXT_PGM_RESET, 2-7, A-7
EXTCALL, A-9
External Control Power ON/OFF, 2-3, 2-5, 3-3
External Cycle Start, 2-7
External Emergency Stop, 3-8, A-4
External Error Reset, 2-7
External HOLD, 2-5, 3-12, A-3
External Input Signals, Number of Inputs, 3-22
External I/O Signals, 4-3
IN-2 KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller EXTERNAL I/O SIGNAL

Index
External I/O Signals, Configurations, 3-3

External I/O Signals, Connection, 4-3
External I/O, Signals, Pin Assignments, A-24
External Motor Power ON, 2-5, 2-7, 3-6
External Output Signals, 3-26
External Program Number, 2-7, A-7, A-9
External Program Reset, 2-7
External Program Selection Function, A-5
External Trigger Input, 3-19
G
General Purpose I/O Signals, I-3, 2-9, 3-22
General Purpose I/O Signals, Assignment, 2-9, A-29
General Purpose I/O Signals, Connection, 4-11
General Purpose I/O Signals, Inputs, 3-22
General Purpose I/O Signals, I/O Timing, 2-10
General Purpose I/O signals, Types, 2-10
Gun Clamp, A-20
Gun Clamp Command, A-19
H
Handling Specification, A-15
Hardware Dedicated Singles, I-3, 2-3, 2-5, 3-3
Hardware Dedicated Signals, Connection, 4-4
Hold, 3-12
Home Position, 2-8, A-11
Home Position, Range, A-11
HSETCLAMP, A-13
I
IF Instruction, A-5, A-6
In Repeat, 2-8
Interference, A-12
Interference Zone, A-12
Interlock, I-3
I/O Board, 2-6
I/O Signals, 2-3
I/O Signals, Welding, A-21
I/O Timing, AS Language, 2-12
I/O Timing, Teaching, 2-10
J
Jumpers, A-16, A-17
Jumper Settings, A-16, A-17

Index
JUMP Function, A-5, A-9

JUMP Function, Signal Timing, A-10
JUMP-OFF, 2-7, A-9
JUMP-ON, 2-7, A-9
JUMP-ST, 2-8, A-9
M
Material Handling, A-15
Material Handling, Dedicated Input Signals, A-15
Material Handling, Dedicated Output Signals, A-16
Material Handling, Software Dedicated Signals, A-17
Motor Power ON, 2-8
Mutual Interference Zone, A-12
Mutual Interlock, A-12
O
OK RPS-ST, A-8
OX. PREOUT, 2-11
P
Personal Safety, 1-4
Personnel Safety Categories, 1-4
Pin Assignments, 1FR/1HW Board, A-24
Pin Assignments, External I/O Signals, A-24
Power Contactor Output, 3-15
Power ON, 2-8
Program Selection, AS Language “IF” Instruction, A-5, A-6
Program Selection Function, A-5
Program Selection, JUMP Function, A-5, A-9
Program Selection, RPS Function, A-5, A-7
R
Range, Home Position, A-11
Retractable Gun, Extend Detection, A-18
Retractable Gun, Retract Detection, A-18
Retractable Gun, Timing, A-22
RGSO, 2-8
RPS Codes, A-7
RPS Function, A-5, A-7
RPS-ON, 2-7, A-7
RPS Program Selection, A-5
RPS, Signal Timing, A-8
RPS-ST, 2-8, A-7

Index
S
Safety, 1-3
Safety, During Inspection and Maintenance, 1-8
Safety, During Operation, 1-6
Safety, During Programming, 1-7
Safety Features, 1-9
Safety Fence Input, 3-16
Sensor signal, A-15
SET2HOME, A-11
SETHOME, A-11
Signal Assignment, 2-6
Signal Timing, A-8, A-10
Single Timing, RPS, A-8
Single Types, 2-4
Software Dedicated Signals, I-3, 2-6, 2-7, 2-8
Software Dedicated Signals, Inputs, 2-7
Software Dedicated Signals, Material Handling, A-17
Software Dedicated signals, Outputs, 2-8
Software Dedicated signals, Spot Welding, A-23
Solenoid Valve, A-13
Spot Welding, A-18, A-20
Spot Welding, Dedicated Input Signals, A-18
Spot Welding, Dedicated Output Signals, A-19
Spot Welding, Software Dedicated Signals, A-23
Spot Welding, Specification, A-18, A-20
Stopping the Robot, A-3
Stroke Change, A-19
T
TB2, 4-6
TB2 Connections, A-26
TB2 Dedicated Signal, Pin Assignment, A-26
Teach Mode, 2-8
TEACH Mode Output, 2-3, 2-5
Teaching, I/O Timing, 2-12
TEACH/REPEAT, Output, 3-14
Terminal Block2(TB2), 4-6
Timing Diagram, Retractable Gun, A-22
Timing Diagram, Welding, A-21
Trap Points 1-4
Trigger Input, 3-19
V
Valve, A-20

Index
W
Weld Command, A-19
Weld Command Signals, A-20, A-21
Weld Complete Signal, A-18
Weld Controller, A-20
Weld Fault, A-18
Weld Fault Reset, A-19
Weld Gun, A-20
Welding, I/O Signals, A-21
Weld Schedule, A-19
Weld Timing Diagram, A-21
Work Cell, 1-3, 1-4
Work Envelope, 1-4, 1-5, A-13
X
X204, 4-8, 4-10
X206, 4-8, 4-10
X204, X206 Connections, A-28
X204, X206 Dedicated Signal, Pin assignment, A-28

KAWASAKI ROBOT CONTROLLER
✻/C4✻
C3✻ ✻/C70/C80 Controller
EXTERNAL I/O SIGNAL
December 1998 : 1st Edition

March 2001 : 6th Edition
Publication : KAWASAKI HEAVY INDUSTRIES, LTD.

ROBOT DIVISION
90204-1008DEF
All rights reserved. Copyright  2001 KAWASAKI HEAVY INDUSTRIES, LTD.

Kawasaki Robotics
(UK) Limited
Kawasaki Robotics GmbH
Kawasaki Robotics Kawasaki Heavy

(USA), Inc. Industries, LTD.
Tokyo Head Office
Kawasaki Machine
Systems Korea, Ltd.
KAWASAKI HEAVY INDUSTRIES, LTD.

ROBOT DIVISION
KAWASAKI ROBOTICS CO., LTD.
Kawasaki Heavy 4-1, 2-Chome Hamamatsu-cho Minato-ku Tokyo, 105-6116 JAPAN TEL 81-(0)3-3435-6908
Industries, Ltd. (World Trade Center building) FAX 81-(0)3-3437-9880
Kawasaki Robotics 1-1, Kawasaki-cho Akashi, 673-8666 JAPAＮ TEL 81-(0)78-921-1565

Co., Ltd. FAX 81-(0)78-923-0685
Kawasaki Robotics 28059 Center Oaks Court Wixom, TEL 1-248-305-7610

(USA), Inc. Michigan, 48393 U.S.A FAX 1-248-305-7618
Kawasaki Robotics Greengate, Middleton Manchester, M24 1SA TEL 44-(0)161-9565400

(UK) Limited UNITED KINGDOM FAX 44-(0)161-9565404
Kawasaki Robotics Sperberweg29, 41468 Neuss, GERMANY TEL 49-(0)2131-3426-0

GmbH FAX 49-(0)2131-342622
Kawasaki Machine 3FI(307), Industrial Complex Support Bidg., 637 TEL 82-32-821-6941
Systems Korea, Ltd. Kojan-Dong, Namdong-Gu, Inchon, 405-310 Korea FAX 82-32-821-6947
Akashi Works 1-1, Kawasaki-cho Akashi, 673-8666 JAPAN TEL 81-(0)78-921-1560

FAX 81-(0)78-923-6548
• All descriptions in this booklet subject to change for improvement without prior notice.

1008DEF C3x C4x C70 C80 External IO Signals

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

1008DEF C3x C4x C70 C80 External IO Signals

Uploaded by

Copyright:

Available Formats

KAWASAKI ROBOT

KAWASAKI HEAVY INDUSTRIES, LTD.

Kawasaki pursues a policy of continuing improvement in design and

This manual is copyrighted and all rights are reserved by Kawasaki.

Kawasaki cannot anticipate every possible circumstance that might

If you do not observe warnings and/or caution to be taken in the manual

All rights reserved. Copyright  2001 by KAWASAKI HEAVY INDUSTRIES, LTD.

KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller EXTERNAL I/O SIGNAL i

This danger symbol identifies special warnings

This warning symbol identifies special warnings or

This caution symbol identifies special

NOTE: This note symbol identifies supplementary

ii KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller EXTERNAL I/O SIGNAL

1.0. SAFETY ............................................................................................................1-3

2.0. I/O SIGNALS ....................................................................................................2-3

3.0. EXTERNAL I/O SIGNAL CONFIGURATIONS .................................................3-3

KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller EXTERNAL I/O SIGNAL 3

4.0. CONNECTION OF EXTERNAL I/O SIGNALS .................................................4-2

A.1. STOPPING THE ROBOT WITH EXTERNAL I/O SIGNALS......................... A-3

A.3. HOME POSITION SIGNAL OUTPUT FUNCTION ........................................ A-11

INDEX .................................................................................................................... IN-1

4 KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller EXTERNAL I/O SIGNAL

UNIT 2 I/O SIGNALS

UNIT 3 EXTERNAL I/O SIGNAL CONFIGURATIONS

UNIT 4 CONNECTION OF EXTERNAL I/O SIGNALS

KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller EXTERNAL I/O SIGNAL I-1

I.0. INTRODUCTION............................................................................................... I-3

I-2 KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller EXTERNAL I/O SIGNAL

I.1. HARDWARE DEDICATED SIGNAL

I.2. SOFTWARE DEDICATED SIGNAL

I.3. GENERAL PURPOSE SIGNAL

The number of system I/O signals is the sum of software dedicated

KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller EXTERNAL I/O SIGNAL I-3

I-4 KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller EXTERNAL I/O SIGNAL

UNIT 2 I/O SIGNALS

UNIT 3 EXTERNAL I/O SIGNAL CONFIGURATIONS

UNIT 4 CONNECTION OF EXTERNAL I/O SIGNALS

KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller EXTERNAL I/O SIGNAL 1-1

1.0. SAFETY............................................................................................................ 1-3

1-2 KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller EXTERNAL I/O SIGNAL

KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller EXTERNAL I/O SIGNAL 1-3

1.2. PERSONAL SAFETY

Personnel safety can be described in one of four categories:

Safety during operation

Safety during programming

Safety during inspection and maintenance

A description of each follows in this section

1.2.1.1. Personal Safety

Locate all emergency stop buttons or switches.

1-4 KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller EXTERNAL I/O SIGNAL

KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller EXTERNAL I/O SIGNAL 1-5

1.2.1.2. Safety During Operation

Never block the operator’s path retreat.

AVOID pinch points.

1-6 KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller EXTERNAL I/O SIGNAL

1.2.1.3. Safety During Programming

AVOID pinch points.

KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller EXTERNAL I/O SIGNAL 1-7

1.2.1.4. Safety During Inspection and Maintenance

Assign only qualified personnel to perform all maintenance procedures.

Consult al available documentation before attempting any repair or service procedures.

Use only replacement parts approved by Kawasaki.

1-8 KAWASAKI ROBOT C3✻/C4✻/C70/C80 Controller EXTERNAL I/O SIGNAL