Content .. 1 2 3 ..

Kawasaki Robot Controller F Series. Installation and Connection Manual (2016) - page 2

F Series Controller

1 Safety

Kawasaki Robot Installation and Connection Manual



Connector plates on arm base section

R series: 03N/05N/05L

R series: 10N/06L

R series : 07N/07L

MC (Backside connector
spec.)

MC/MS (Base connector spec.)

F Series Controller

1 Safety

Kawasaki Robot Installation and Connection Manual

1.7 Battery and Fuse Use and Disposal

Batteries are used for data backup in the robot arm and controller.
If not used and disposed of properly, these batteries may malfunction, ignite, overheat,
explode, corrode, leak, etc. Strictly observe the following precautions.

WARNING

1.  Only use batteries specified by Kawasaki.
2.  Never re-charge, dismantle, convert and/or overheat batteries.
3.  Never dispose of batteries into water or fire.
4.  Batteries with damaged cases may short internally and must not be used.
5.  Never short the positive and negative poles of a battery with material

such as wire.

Never dispose of depleted batteries with garbage that is disposed of in an
incinerator, land-fill, dumping-ground, etc. When disposing of batteries,
insulate with tape so as not to contact other metal. Comply with local
regulations and rules for battery disposal.

CAUTION

！

F Series Controller

1 Safety

Kawasaki Robot Installation and Connection Manual



Locations of batteries

Battery locations of 2AA board and 1HG board are as follows:

•

2AA board

Location Number: E1
Model:

BR2032

Manufacturer: Panasonic

•

1HG board (in robot base)

Location Number: BAT1
Model:

50750-1007 or

50750-1018

Manufacturer:

KHI

Connector:

CN3

– Replacement method

Batteries can be replaced only by removing a small plate on which “BATTERY” is
written.

Small plate for

battery

F Series Controller

1 Safety

Kawasaki Robot Installation and Connection Manual

1.8 Safety Features

To safeguard the user, Kawasaki robot systems are equipped with the following features:

1. All E-stops are hard-wired.
2. All robot controllers are equipped with a redundant dual channel safety circuit.

Both channels of the safety circuit must be closed to allow for robot operation in the teach
and repeat modes. Refer to the “External I/O Manual” for details.

3. Safety circuits of controllers satisfy requirements of PLe in category 4 defined by ISO

13849-1: Category and Performance level (PL) are determined by the whole system and
conditions.

4. (For the arms which are equipped with servo lamp ON) When servo motor power is

supplied, the servo ON lamp is illuminated.

5. The teach pendant and operation panel are equipped with E-stop switches.

And all robot controllers have external E-stop inputs.

6. The TP is equipped with three-position, enabling devices. The enabling devices must be

pressed and held down to enable motor power in teach and check modes.

7. TCP speeds in teach and check modes are limited to a maximum of 250 mm/s (10.0 in/s).
8. The speed limit can be 250 mm/s (10.0 in/s) or more in the Fast Check Mode if an

optional Fast Check Mode switch is used (defined by ISO 10218-1).

F Series Controller

1 Safety

Kawasaki Robot Installation and Connection Manual

1.9 Emergency Movement without Drive Power

The brake release switches (option) allow the operator to move arm without using motor drive
power for maintenance and emergency situations.

•

Brake release switch box (option)



Precautions

When no motor drive power is applied to the arm, electromagnetic brakes lock to maintain the
robot posture. Unsupported axes may fall when pressing the brake release switch.
Axes which are overhung, particularly JT2 and JT3, will fall down the fastest, depending on
conditions. Therefore, be careful when operating this switch.



Operating procedure

To manually release axes brakes, follow the procedure below.

1. Press EMERGENCY STOP of the controller and the TP, and cut off the motor power.
2. Make sure that the safety measures are followed.

•

There are no personnel around the robot.

•

Plug of safety fence is inserted.

WARNING

Position yourself to observe the entire robot arm and keep your eyes on
the arm when operating the brake release switch.

！

XRLS

Relay connector

F Series Controller

1 Safety

Kawasaki Robot Installation and Connection Manual

3. Provide suitable support of the robot arm, end-or-arm tooling, and payload if there is a

risk of personal injury and facilities before using the brake release switch.
Robot arm can be supported by using a crane and a wire (see figure below).

4. Connect the harness from the brake release switch box to the brake release switch

connection connector.

•

Brake release switch connection connector position of F60 controller

WARNING

Failure to take measures may lead to an accident or damage on robot.

CAUTION

Do not block the front of the XRLS connector so that the connector can be
connected to the brake release switch immediately in emergency.

Brake release switch connection connector (XRLS)

！

F Series Controller

1 Safety

Kawasaki Robot Installation and Connection Manual



When connecting the brake release switch box to the sealed chassis, connect the
wires so that the relay connector is located outside of the chassis as shown in the
figure below.

5. Make sure that the brake is not released by pressing one switch.

If the brake is released, do not use the switch.

(1) Press the brake release switch for the axis to release the brake for a moment.

(2) Press and hold the Enable switch.

6. Press the brake release switch for the axis to release the brake while pressing the Enable

switch.

CAUTION

Stop using the brake release switch immediately if the electromagnetic brake
is released by pressing only one switch. The switch may be defective.

Brake release switch

Enable switch

！

Relay connector

F Series Controller

1 Safety

Kawasaki Robot Installation and Connection Manual

7. The brake remains released until releasing the brake release switch.

Robot axis to release the brake

6-axis robot

CAUTION

For the safety, release the brake per axis. Pressing more than one switch
at the same time may lead to an accident or damage on robot.

！

F Series Controller

2 Workflow - Robot Controller Installation and Connection

Kawasaki Robot Installation and Connection Manual

2 Workflow - Robot Controller Installation and Connection

This workflow describes the robot controller.
For the robot arms, refer to the separate manuals for them.

Examine installation place

(including ground) environment

Confirm power supply voltage

and power capacity

Transport robot controller

Arrange and install

robot controller

Connect TP and separate

harness

Connect peripheral control

devices and equipment

Connect external power

Turn ON “controller power” and

confirm

Turn ON “motor power” and

confirm

Confirm operation of robot arm

and tool (Teach mode)

Confirm other

various functions

Work completed

Pre
p.

ork

ctu

ork

fte

r c

nec
ting

robot
cont
rol

ler

e r

obo
t

Refer to “6 Connection Instructions” and

“Installation and Connection Manual” for

arm.

Refer to “External I/O Manual” for external

control power supply.

Refer to “3 Appearance and Specifications

of Robot Controller”.

See “4 Transportation of Robot Controller”.

Refer to “5 Arrangement of Robot Controller”.

Refer to “7 Connection of External Power”.

Refer to “8 Connection of Peripheral

Control Equipment”.

Refer to “External I/O Manual” for external

control power supply.

Refer to “Operation Manual”.

Refer to “3 Appearance and Specifications

of Robot Controller”.

This manual only describes procedures from installation place examination
to connection with external power.

[

NOTE

]

F Series Controller

3 Appearance and Specifications of Robot Controller

Kawasaki Robot Installation and Connection Manual

3 Appearance and Specifications of Robot Controller

3.1 Controller Appearance



F60 controller



Standard open specification

Connecting ports in the accessory panel

Rear connecting port

Left

Front

Right

Rear

Controller power switch

Operation panel

Accessory panel

RS-232C port

USB port

Ethernet port

(Connectable cable length: max. 30 m)

TP connector

Brake release switch connection connector

Connectors for separate harnesses (See “6.1”.)

External power input connector (XPOW)

F Series Controller

3 Appearance and Specifications of Robot Controller

Kawasaki Robot Installation and Connection Manual



Sealed specification

Left

Front

Right

Rear

500

300

185

F Series Controller

3 Appearance and Specifications of Robot Controller

Kawasaki Robot Installation and Connection Manual

3.2 TP Appearance

Liquid crystal display

Teach lock switch

Emergency stop switch

F Series Controller

3 Appearance and Specifications of Robot Controller

Kawasaki Robot Installation and Connection Manual

3.3 F60 Controller Specifications



Controller

Specification

Standard open
specification

Sealed specification

Construction

Open structure, direct
cooling system

Sealed structure, indirect
cooling system

Mass

F60: 8.3 kg

F60: 15 kg

Ambient

environment

Temperature

0 to 45

Humidity

35 to 85 %RH (Non condensing)

Altitude

Up to 1000 meters above mean sea level

Pollution

degree

2 or below

3 or below

Vibration

condition

10 to 57 Hz

Half amplitude 0.075 mm

57 to150 Hz

1 G

Power source

AC 200-230 V±10%, 50/60 Hz, Single phase

Power capacity

Refer to the table below.

Grounding

Dedicated grounding (100

Ω

or less)

TP cable length

5 m/10 m/15 m

Not including optional components



Power capacity for external power connection and cable specifications

F60 controller is equipped with a power cable with connector (AWG14, standard 2 m) as
shown in the figure below. See “7 Connection of External Power” for the connecting method.

Controller

model

Arm model

Power

capacity

Recommended power

cable size (including

ground wire)

Length

requirement

F60 controller

R series 03 to10

BA/MC/MS

Excluding
10L

2.0 kVA max.

2.0 mm

or more

(AWG14 or more)

200 m or less

XPOW connector

Model

Manufacturer

Cable side (female)

1971239-1

TYCO ELECTRONICS

Controller side (male)

1-1318983-2

TYCO ELECTRONICS

F Series Controller

3 Appearance and Specifications of Robot Controller

Kawasaki Robot Installation and Connection Manual



Circuit breaker spec. for external power connection

Controller model

Rated current Rated voltage

Rated interrupting

capacity

F60 controller

15 A

AC240 V

5000 A (UL489)

CAUTION

If a cable with an unspecified diameter is used for the sealed specification,
sealability cannot be ensured, causing failure. Be sure to use cables with the
specified diameter.

Cable:

AWG14 (3 cables)

Cable diameter:

11.4

0.4 mm

Green/yellow

White

Black

F Series Controller

4 Transportation of Robot Controller

Kawasaki Robot Installation and Connection Manual

4 Transportation of Robot Controller

When transporting the controller, follow the procedure below.

1. Remove harnesses connected to TP and other external devices.
2. Hold the bottom of the controller firmly.

•

F60 controller weight: 8.3 kg (Standard open specification)/15 kg (Sealed
specification)

3. Lift up the controller.

CAUTION

Be careful not to put an impact on the controller during transportation.

！

F Series Controller

5 Arrangement of Robot Controller

Kawasaki Robot Installation and Connection Manual

5 Arrangement of Robot Controller

5.1 Horizontal Arrangement of Controller

Horizontal arrangement is the standard for F60 controller. In order for the controller to
maintain the proper internal temperature, the installation site must conform to the following.



Precautions

•

In case of horizontal installation, up to three controllers can be stacked.

•

It is necessary to remove the object on the top surface of the controller in maintenance.



Locations

•

Arrange the controller on a flat, horizontal stand and adjust its height so that the heights of
controller power switch and operation switches from the floor are between 0.6 to 1.9 m.

•

Provide a clearance of 200 mm or more between the controller rear side and the wall.

Standard open specification

Double stack

arrangement of controllers

Controller power

switch

0.6 to 1.9 m

200 mm or more

Airflow direction of fan

Controller power

switch

0.6 to 1.9 m

200 mm or more

Airflow direction of fan

Content .. 1 2 3 ..