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90202-1038DED Z-Series Install&Connection
90202-1038DED Z-Series Install&Connection
AND
CONNECTION
= Robot Arm =
This manual is subject to change without prior notice and without our legal
responsibility.
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.
KHI cannot anticipate every possible circumstance that might involve a potential
hazard. If a procedure, work method or operating technique not specifically
recommended by KHI 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 things.
If you discover physical defects in the manual, KHI will replace the manual at no
charge during 90 days period after you purchased the robot.
Whenever you see the symbols shown below in this manual or on the machine, read and
understand their messages.
! 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 correctly followed, may
result in injury.
[ NOTE ]
This note symbol identifies supplementary
information, or to emphasize a point or
procedure, or to give a tip for easier operation.
ZX200U, ZX200W,ZX300S,
ZT130S, ZT130U, ZT165U, ZT200S, ZT200U, ZT200W,
ZD130S, ZD250S
! WARNING
1 For the confirmation of acceptability and effectiveness of
drawings, detailed specification of documents, procedures etc.
it shall be still insufficient.
Therefore, if you desire to operate/serve/maintain/adjust/
modify, and to do miscellaneous works, you must pay utmost
attentions to them.
Safety
Safety
Safety
! WARNING
● When the robot is required to be transported by using a crane or a
forklift, never support the manipulator manually.
Because it is dangerous.
! CAUTION
● First, prior to install the robot, remove all obstacles from the place for
installation, and arrange the place properly.
Next, clear a passage for the transportation of robot by using a crane
or forklift.
Safety
● When a floor type robot is installed on the floor, the level must be within ±5°.
● Be sure that the floor/stand should be provided with sufficient rigidity.
● To secure a leveled place so as to prevent the installing location from undue
force application (If an accurate level is unobtainable, insert liners and adjust
the height).
● The ambient temperature during operation should be within the range of 0°C
∼ 45°C. (Deviation or overload error may occur due to high viscosity of
grease/oil when starting operation at low temperatures. In this case,
warm-up robot at low speed before regular operation.)
● The ambient humidity during operation should be 35% ∼ 85%RH: free from
dew condensation.
● The robot installing place should be less dust, hume, smoke, water, and other
foreign matters. (In such a reverse condition, use an Arm with dust-proof &
water-proof spec.).
● The robot installing place should be free from inflammable or corrosive liquid
or gas. (Use an arm with explosion-proof spec, in such a inflammable
environmental state)
● The robot installing place should be free from excessively large vibration.
● The robot installing place should be free from electric noise interference.
● The robot installing place should be a sufficiently large place far exceeding
the Robot arm movement. In the peripheral section of Robot installing place,
provide a safety fence that the maximum movement of fully equipped Robot
arm with hands and guns does not interfere with the surrounding objects.
• An entrance and a door with a safety plug should be provided to the
safety fence.
Approx.1m
A door
Scope of Robot Motion with Safety Plug
(The hand and gun are included)
Safety Fence
Approx.1m Approx.1m
Mechanical Mechanical
stopper stopper
Approx.1m Approx.1m
CONTENTS
Safety........................................................................................................................ 5
FORKLIFT.......................................................................................................................................29
4. Installing Method................................................................................................. 32
This working flow covers only for the robot arm section. For the details of controller, they
should refer to "INSTALLATION AND CONNECTION =CONTROLLER=".
Refer to
Transportation of Robot Arm
"1. ROBOT TRANSPORTATION
METHOD"
Completion of Work
Scope of
Movement
at Point B
Point B Location
Tool
The following scope of movements of Robot is represented by the Scope of Movement at Point B in the figure above.
Therefore, referring to the figure, the safety fence dimensions should be set up as follow: Secure dimensions;
L0+L1+L2. That is; from the center of arm (Point A shown in the figure above) to Dimensions of L0 + Sum of
Dimensions up to the Wrist flange & Tool, Hand and Work-piece Max. dimensions with Allowance : L1.and
allowance dimensions L2. For the Dimensions of L0, refer to the drawings of “Scope of Movements & Specifications
of Robot” on following pages.
L2 Safety Fence
L1
Location of L0 Location of
Mechanical Mechanical
Stopper Stopper
ZX130S
ZX130U
ZX130L
ZX165U
ZX200S
ZX200U
ZX200W
ZX300S
ZT130S
ZT130U
ZT165U
ZT200S
ZT200U
ZT200W
ZD130S
Scope of moment
at point P
15 Flange thick
ZD250S
Scope of moment
at point P
15 Flange thick
Referring to the figure, hoist up the robot by triple wire slings utilizing three eyebolts provided on the robot.
When hoisting up the robot, be careful that the robot may fall
forward/backward depending on the robot posture and
installation condition of the gun and options. If the robot will
3 Slings be hoisted up in an inclined posture, it might swing by a
shock, the sling might damage the wrist motor or harness or
piping etc. or it might be damaged interfering with externals.
Moreover, protect the robot with the application board etc. if
Eyebolts the wire and the balancer, etc. come in contact with a part of
the robot.
The jig for the forklift has installed with the base, and utilizing this.
Make the posture of the robot as below when you transport the robot by the forklift.
When you transport the robot, do not fall with the forklift losing the balance by the road etc. with the inclination ground
and irregularity.
Use the forks of the forklift with 54mm or less in height when you install the retract stopper or the retract pin option.
When installing base section, fix it by means of high tension bolts utilizing the bolt holes.
Dimensions of Base
Section
Cross-section of
Base installation
Load applied to the installation face during robot operation are shown below:
Consider these values at the installation shown in the following pages.
ZX Series
Model ZX 300S ZT Series ZD Series
(Excluding ZX300S)
M
34000N・m 41000N・m 35000N・m 26000N・m
(Inversion Moment)
T
12000N・m 12000N・m 12000N・m 10000N・m
(Rotating Torque)
4. Installing Method
(1) In case base is installed directly on the floor:
Referring to the below figure, steel plate (35mm Min. thick) must be buried on the concrete floor or fixed by using
anchors.
Moreover, the steel plate should be fixed firmly so as to endure reaction forces produced by the robot.
M20
Tightening torque
431.2N・m
30mm
Steel plate min. 35mm
min.
Concrete
4. Installing Method
(2) In case base plate of correspondence installation compatibility is installed on the floor:
Install the base plate utilizing 8 places of φ22 hole.
Install the base plate on a concrete floor or the steel plate floor.
The reaction force received from the robot is the same as occasioning to install the base directly on the floor.
There are two-place pin hole for positioning on the base plate, and it is possible to positioning it between holes on
the base portion. As a result, when abnormally occurring, it is possible to exchange easily for the reserve robot.
(However, the JT1 is not precision zeroing usually. Therefore, correspond by the option when this function is
necessary.)
4. Installing Method
(3) In case the installing block is used:
Install the installing block to conform to the following dimensions shown below:
200 mm or more
5. Mounting of Tools
! WARNING
EMERGENCY STOP When tools including hand, etc. are required to mount,
surely press the "EMERGENCY STOP" switch, and make
sure that the "MOTOR POWER" is set to OFF.
Pin holes
Drill holes
Tap holes
φD φD
Spigot hole
Hand mounting
Hand mounting
section (Flange)
section (Flange)
Hand member
! CAUTION
If the screwing depth has exceeded the specified depth, the
fixing bolt might bottom out. As a result, the tool can not be
fixed.
5. Mounting of Tools
ZX130S, ZX130U,
ZX165U, ZX200U, ZX200S, ZX200W
Model ZX130L ZX300S
ZT130S,ZT130U, ZT200S, ZT200W
ZT165U, ZT200U
Tap Holes 10-M10 10-M10
φD φ 125 φ 160
Pin Holes 2-φ 10H7 Deep 12 2-φ 10H7 Deep 12
Spigot hole φ 80H7 Deep 8 φ 100H7 Deep 8
Tap Depth 12mm 12mm
Screwing Depth 10~11mm 10~11mm
High Tension Bolt SCM435,10.9 Min SCM435,10.9 Min
Tightening Torque 56.84N・m 56.84N・m
[ NOTE ]
Above-mentioned installation size (ZX,ZT) conforms to ISO. In case of a
conventional type, install the adapter plate (option), and then, install the tool.
5.Mounting of Tools
Load Capacity
The robot's load capacity is being specified by including the mass of hand, gun, etc. per the model of robot. Moreover,
the load capacity of wrist is also provided with the specified condition.
In addition, the following restricted conditions are applied to the rotating load torque and load moment of inertia on
wrist axes (JT4,JT5,JT6). Therefore, the user is requested to observe the conditions strictly.
! CAUTION
If you use the robot, exceeding its load capacity; exceeding
over the specified range of movement performance, it might
result in the deterioration of movement performance, as well
as shortening of machine service life. The specified range
includes the hand mass, tool changer mass and spot weld
gun mass. If you desire to use the robot exceeding the
specified specification, please contact with us without fail.
The load torque and the moment of inertia are procurable from the calculation expression below :
Calculation Expression
2 2
Load Moment of Inertia: I=M・L +IG(kg・m )
L 6(m)
IG M: Load Capacity (For example)
ZX130 …Mmax. : 130kg
L 4 , 5(m)
ZX165 …Mmax. : 165kg
L6 :Length from JT6 axis
rotated center to load ZX200 …Mmax. : 200kg
M(kg) center of gravity. L: Length from axis rotated center to load
L 4,5 :Length from JT4(5) center of gravity. (Unit : m)
axis rotated center to
load center of gravity. I : Moment of inertia about center of gravity.
If you desire to calculate the load section after divided it into plural numbers of load (for
example, a hand section, load section, and other sections), the total values should be
considered to the load torque and the moment of inertia respectively.
ZX Series, ZT Series
PT3/8
Joint for air φ12 One-touch Joint
(Input:0.147~0.588MPa)
The following valves can be installed on the above-mentioned arm as an option. The valve can be ON/OFF by the Multi
Function Panel (or, Teach Pendant) without interlock.
PT3/8
Joint for air PT3/8 Joint for air
(Input:0.147~0.588MPa)
Referring to the figure below, the air connection port is provided on the base section of robot arm.
! CAUTION
Supply input pressure; 0.147~0.588MPa to the air inlet port
(PT3/8 Joint, 2 places).
Port A
In case air regulator is connected
Filter
Input Pressure
+
Regulator 0.147~0.588MPa
✎ MEMO
90202-1038DED