E0x Series

External Axis
Addition Manual

Kawasaki Heavy Industries, Ltd.

90210-1292DEC
E0x Series Controller Preface
Kawasaki Robot External Axis Addition Manual

Preface

This manual describes how to add peripheral equipment to the robot system and to enable the E0x series
controller to control the equipment as external axes that work in cooperation with the robot arm. The
following tasks are required in order to add external axes to your system:
 Proper selection of the external axis component parts
 Installation of the hardware
 Setting of the external axis parameter values in the teach pendant
 Servo tuning of the external axis motors via the teach pendant

Customers must carefully examine the mechanical strength, service life of the components to be added
as external axes to their robot system and servo performance.

Read and understand the contents of this manual and “Safety Manual” thoroughly, and strictly observe
all rules for safety before proceeding with any operation.

This manual only describes the addition of external axes. For installation and connection of the
controller and cables, refer to “Installation and Connection Manual”. For necessary hardware
installation, refer to “Options Installation Manual”. For robot operation, refer to “Operation Manual”.
For information on external I/O signals, refer to “External I/O Manual”.

Never proceed with any operation until you understand the contents of this manual completely.
Kawasaki is not responsible for any accidents and/or damages resulting from operations/ maintenance
based on only a limited reading or limited understanding of some parts of this manual. Should any
unexplained questions or problems arise during robot operation, please contact the nearest Kawasaki.

1. This manual does not constitute a guarantee of the systems in which the robot is utilized.
Accordingly, Kawasaki is not responsible for any accidents, damages, and/or problems relating to
industrial property rights as a result of using the system.
2. It is recommended that all personnel assigned for activation of operation, teaching, maintenance or
inspection of the robot attend the necessary education/training course (s) prepared by Kawasaki,
before assuming their responsibilities.
3. Kawasaki reserves the right to change, revise, or update this manual without prior notice.
4. This manual may not, in whole or in part, be reprinted or copied without the prior written consent of
Kawasaki.
5. Store this manual with care and keep it available for use at any time. If the robot is reinstalled or
moved to a different site or sold off to a different user, attach this manual to the robot without fail. In
the event the manual is lost or damaged severely, contact Kawasaki.
Copyright © 2015 Kawasaki Heavy Industries Ltd. All rights reserved.

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E0x Series Controller Symbols
Kawasaki Robot External Axis Addition Manual

Symbols

The items that require special attention in this manual are designated with the following symbols.

Ensure proper and safe operation of the robot and prevent physical injury or property damages by
complying with the safety matters given in the boxes with these symbols.

！ DANGER
Failure to comply with indicated matters can result in
imminent injury or death.

！ WARNING
Failure to comply with indicated matters may possibly lead
to injury or death.

！ CAUTION
Failure to comply with indicated matters may lead to
physical injury and/or mechanical damage.

[NOTE]
Denotes precautions regarding robot specification,
handling, teaching, operation, and maintenance.

！ WARNING
1. The accuracy and effectiveness of the diagrams, procedures, and detail
explanations given in this manual cannot be confirmed with absolute certainty.
Accordingly, it is necessary to give one’s fullest attention when using this manual
to perform any work. Should any unexplained questions or problems arise, please
contact Kawasaki.
2. Safety related contents described in this manual apply to each individual work
and not to all robot work. In order to perform every work in safety, read and
fully understand “Safety Manual”, all pertinent laws, regulations and related
materials as well as all the safety explanation described in each chapter, and
prepare safety measures suitable for actual work.

ii
E0x Series Controller Table of Contents
Kawasaki Robot External Axis Addition Manual

Table of Contents

Preface ........................................................................................................................................................... i
Symbols ..........................................................................................................................................................ii
1 Selection of External Axis Component Parts ............................................................................... 1
1.1 Servomotor Type ............................................................................................................................ 1
1.1.1 SANYO Motor Which can be Used in External Axis ................................................................ 4
1.1.2 MITSUBISHI Motor Which can be Used in External Axis....................................................... 8
1.2 SANYO Motor Selection Procedure ............................................................................................ 9
1.2.1 Rotation Axis .................................................................................................................................. 9
1.2.2 Linear Axis (Rack and Pinion Drive)..........................................................................................11
1.2.3 Linear Axis (Ball Screw Drive)...................................................................................................14
1.3 MITSUBISHI Motor Selection Procedure.................................................................................15
1.4 Check of Brake Current, Average Consumption Power and Average Regenerative Power .16
1.5 Motor Applicability for External Axis Specifications ...............................................................20
2 Hardware Installation ...................................................................................................................21
2.1 When Using MITSUBISHI MELSERVO-J3/J4 Series Motor ...............................................22
2.1.1 Necessary Hardware for MITSUBISHI Motor .........................................................................23
2.1.2 Mounting/Connection Procedure ................................................................................................25
3 Setting of External Axis Parameter Values ................................................................................33
3.1 Linear Axis Parameter Value Setting..........................................................................................35
3.2 Rotation Axis Parameter Value Setting ......................................................................................40
4 Setting of Servo Parameter Value ...............................................................................................44
4.1 When Using KHI Amplifier ........................................................................................................44
4.1.1 Simple Tuning...............................................................................................................................45
4.1.1.1 Tuning Gain Values (KV) ...........................................................................................................45
4.1.1.2 Setting Delay Time.......................................................................................................................47
4.1.2 Full Spec Tuning...........................................................................................................................47
4.2 When Using MITSUBISHI Amplifier .......................................................................................48
4.2.1 Simple Tuning...............................................................................................................................49
4.2.1.1 Auto Tuning Mode 1....................................................................................................................50
4.2.1.2 Manual Mode 1.............................................................................................................................50
4.2.2 Full Spec Tuning...........................................................................................................................51
5 Cooperative Control Function .....................................................................................................55
5.1 Linear Axis Cooperative function ...............................................................................................56
5.1.1 Check of Linear Axis Cooperative Function..............................................................................56
5.2 Rotation Axis Cooperative Function...........................................................................................57
5.2.1 Setting of Rotation Axis Cooperative Function .........................................................................58

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E0x Series Controller Table of Contents
Kawasaki Robot External Axis Addition Manual

5.3 Positioner Cooperative Function .................................................................................................60

5.3.1 Setting of Single-axis Positioner Cooperation............................................................................60
5.3.1.1 Registration of Positioner Setting Position .................................................................................61
5.3.1.2 Registration of Positioner Cooperation Start and End Axes .....................................................63
5.3.1.3 Check of Positioner Cooperation Setting....................................................................................64
5.3.2 Double-axis Positioner Cooperation ...........................................................................................64
5.3.2.1 Check of Positioner Rotating Direction and Dimensions .........................................................65
5.3.2.2 Registration of Positioner Setting Position .................................................................................67
5.3.2.3 Registration of Positioner Cooperation Start/End Axes and Link Structure............................69
5.3.2.4 Check of Positioner Cooperation Setting....................................................................................71
5.3.3 Troubleshooting for Positioner Cooperation ..............................................................................72
6 Endless Positioner Function.........................................................................................................82
6.1 Setting of Endless Positioner Function .......................................................................................82
6.2 Setting a Rotation Number by RTSET Command/Instruction.................................................83
7 Dual Servo Function.....................................................................................................................86
7.1 Setting of Dual Servo Function ...................................................................................................86
7.2 Tuning of Dual Servo Function ...................................................................................................88
7.2.1 Setting of Dual Servo Tuning Run Mode...................................................................................88
7.2.2 Tuning Procedure for Dual Servo Function ...............................................................................89
8 J3/J4 Series MITSUBISHI Amplifier.........................................................................................90
8.1 Home Position Setting..................................................................................................................91
8.1.1 Executing the Home Position Setting .........................................................................................91
8.2 Cautions When Connecting MITSUBISHI Amplifier/Motor for the First Time ...................94
8.2.1 Switching of Setting on MITSUBISHI Amplifier (J3 Compatible Mode) .............................94
8.2.2 Occurrence of Absolute Position Erasing Error .........................................................................94
8.2.3 Execution of Home Position Setting ...........................................................................................94
8.3 Errors .............................................................................................................................................95
Appendix Examples of External Axes ...................................................................................................... A-1

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E0x Series Controller 1 Selection of External Axis Component Parts
Kawasaki Robot External Axis Addition Manual

1 Selection of External Axis Component Parts

Follow the procedures below to examine and determine the specifications for adding an external axis.
1. Determine the necessary number of external axes and their desired operating specifications.
2. Determine the overall mechanical structure of each axis.
3. Select an appropriate servomotor while adjusting details of the mechanical structure so each axis
can satisfy the desired operating specs.

Selection work only applies to the servomotor itself. Hardware (amplifier, etc.) related to the selected
servomotor is specified in this manual for each type of servomotor.

1.1 Servomotor Type

Servo motors manufactured by SANYO Electric Co. (hereafter SANYO motor) and MITSUBISHI
Electric Corp. (hereafter MITSUBISHI motor) can be used in the external axis. When using the
SANYO motor, use a KHI amplifier. Add a multi-axis controller if using external axes more than the
number of axes that can be controlled by one controller.

MITSUBISHI MELSERVO-J3/J4_B series motor is available. (However, it does not support optional
specifications such as full-closed control.) When using the MITSUBISHI motor, prepare the control
panel which can house MITSUBISHI amplifier (hereinafter called MITSUBISHI motor control panel)
outside the controller separately referring to Chapter 2 and use a MITSUBISHI amplifier installed in the
control panel.

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E0x Series Controller 1 Selection of External Axis Component Parts
Kawasaki Robot External Axis Addition Manual

Table below shows the maximum addable number of external axes when using SANYO/MITSUBISHI
motors per controller.
Max. addable number of external
Max. addable number
axes for SANYO motor
Controller of external axes for
Controller main multi-axis
MITSUBISHI motor
body controller
3 axes*1, 2
E01/E02 Standard number of axes (Required number of
7 axes 8 axes
controller 7 axes additional amplifier:
2*2)
Standard number of axes 1 axis*2
E03 6 axes (1 axis for power (Required number of
N/A 8 axes
controller regenerative control additional amplifier:
included) 12)
2 axes*2
E04 Standard number of axes (Required number of
7 axes 8 axes
controller 6 axes additional amplifier:
2*2)
NOTE*1 E01/E02 controllers have amplifiers for seven axes on board as standard. Therefore, the
amplifier for one axis can be used for external axis in case of six-axis arm.
2
NOTE* When using a munti-axis controller, Jt9 (JT C) on the controller main body is not available.
[NOTE]
Free combination of motors is not always possible due to power capacity
restriction of selected motors and brakes. In section 1.4, observe the total brake
current restriction values of external axes. Examples for external axis additions
are shown in the Appendix. MITSUBISHI motors are not applicable to some
specifications. See section 1.5 for details.

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 E0x Series Controller 1 Selection of External Axis Component Parts
Kawasaki Robot External Axis Addition Manual

(Example: E01 controller + multi-axis controller)

AC power AC power KHI 1-axis amplifier

Jt9 (JT C) Main body KHI 6-axis

not available axis amplifier
X3
amplifier X3A
X4
X4A Motor
KHI uniaxis X5 X5A
amplifier

E01 controller Multi-axis controller Distribution box

(Example: E01 controller + MITSUBISHI motor control panel)

AC power
AC電源 AC power
AC電源

Main
本体軸 body
axis amplifier
アンプ
(For SANYO motor)
(山洋モータ用)
MITSUBISHI MELSERVO amplifier
三菱MELSERVOアンプ
External
外部軸 axis
amplifier
アンプ

MITSUBISHI MELSERVO amplifier

三菱MELSERVOアンプ

E01 controller
E01コントローラ MITSUBISHI motor control panel
三菱モータ制御盤

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E0x Series Controller 1 Selection of External Axis Component Parts
Kawasaki Robot External Axis Addition Manual

1.1.1 SANYO Motor Which can be Used in External Axis

This section describes the specifications of SANYO motors which can be used in external axis.

Tap M-P x Q
Depth R

Position of Mount with M-T bolt

taper reference Tightening torque: U N·m

Involute spline shaft dimensions for automobile

Tap M-P x Q Addendum modification coefficient +0.8
Depth R Tooth profile Stub tooth

Tool
Module 1.0
Pressure angle 20ﾟ
Number of teeth 18
L Ref. pitch diameter 18
Base tangent length
Tooth thickness

Taper 1/10 8.140(-0.030~+0.005)

(number of teeth in the span=3)
At 0 from taper
reference position Grade Grade b
Over pin diameter
21.671(-0.057~+0.010)
(Pin diameter=φ1.80)

Remarks Side fit

Item Unit ① ◎ ② ◎ ③ ④ ⑤ ⑥ ◎ ⑦ △ ⑧ ◎ ⑨
Part No. [-] 50601-0128 50601-1412 50601-1413 50601-1403 50601-1414 50601-1490 50601-1460 50601-1485 50601-0156
Model No. [-] R2AA2250ALCPKL P80B22450LCPUB P60B13200LCPUA P60B13200LCPUH P60B13150HCPUG R2AA13200LCP2R R2AA13200LCP2S P20B10200LCP67 R2AA1020AFCPKB
Brake [-] with with with with with with with with with
Involute spline
Shaft shape [-] Taper Taper shaft for Straight Straight Straight Taper Straight Straight
automobile
Capacity [W] 5000 4200 3100 3100 2100 2000 2000 2000 2000
Max. rotation speed [rpm] 4300 3300 3000 3000 3000 5000 5000 3500 6000
Rated rotation speed [rpm] 2000 2400 3000 3000 3000 2000 2000 3000 3000
Max. instant torque [Nm] 70 68.6 26.5 26.5 16.2 30 30 16.7 17.75
Rated torque [Nm] 24 16.7 9.8 9.8 6.7 9.5 9.5 6.37 6.37
-4 2
Moment of inertia [10 kgm ] 95.1 75 12.5 12.5 8.2 12.3 12.3 3.2 7.15
Mass [kg] 27 28 10.8 10.8 8.7 12 12 9.5 7.8
KHI uniaxial am plifier [-] 100A 100A 50A 50A 50A 50A 50A 50A 50A
A [mm] 220(±3) 220(±3) 135(-3 to +2) 135(-3 to +2) 135(-3 to +2) 135(-3 to +2) 135(-3 to +2) 100(±2) 100(±2)
B [mm] 65(±1) 65(±1) 61(±1) 55(±1) 53(±1) 55(±1) 42(±1) 55(±1) 55(±1)
C [mm] 235(±3) 229(±3) 241(±3) 241(±3) 218(±3) 224(±3) 224(±2) 258(±3) 243(±3)
D [mm] 4 4 3 3 3 3 3 3 3
E [mm] 20 16 12 12 12 12 12 10 17
F [mm] 58(-0.4 to 0) 58(-0.39 to 0) 28 50 44.65(0 to +0.14) 50 36 50 50
G [mm] 3 3 - - - - 3 - -
H [mm] 4 4 - 3 8 3 3 - 3
I [mm] 50 50 - 42 36 42 32 - 42

Dimensions
J [mm] 35 35 19.8(0 to +0.1) 22(-0.013 to 0) 19(-0.013 to 0) 28(-0.013 to 0) 24 19(-0.013 to 0) 19(-0.013 to 0)
K [mm] 6(-0.030 to 0) 6(-0.030 to 0) 6(-0.030 to 0) 6(-0.030 to 0) 8(-0.036 to 0) 5(-0.030 to 0) - 6(-0.030 to 0)
L [mm] - - For other 2.5(-0.2 to 0) 2.5(-0.2 to 0) 3(-0.4 to 0) - - 2.5(-0.2 to 0)
specifications of
M [mm] 6(-0.030 to 0) 6(-0.030 to 0) output axis, refer 6 6 7 5(-0.030 to 0) - 6
to "involute spline
N [mm] 12.55(-0.1 to 0) 12.55(-0.1 to 0) shaft data for - - - 8.1(-0.1 to 0) - -
automobile".
O [mm] 29 29 - - - 18 - -
P [mm] 10 10 6 6 - 8 6 - 6
Q [mm] 1.5 1.5 1 1 - 1.25 1 - 1
R [mm] 30 30 20 22 - 25 20 - 20
S [mm] 235(±0.23) 235(±0.23) 160(±0.2) 160(±0.2) 160(±0.2) 160(±0.2) 160(±0.2) 115(±0.2) 115(±0.2)
T [mm] 12 12 10 10 10 10 10 8 8
U [Nm] 98 98 57 57 57 57 57 29 29

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E0x Series Controller 1 Selection of External Axis Component Parts
Kawasaki Robot External Axis Addition Manual

Item Unit ⑩ ◎ ⑪ ◎ ⑫ △ ⑬ ⑭ ⑮ ◎ ⑯ △ ⑰
Part No. [-] 50601-1366 50601-1491 50601-1465 50601-1435 50601-1432 50601-1492 50601-1461 50601-1404
Model No. [-] P20B10150DCPU3 R2AA13120LCP2D R2AA13120LCP2E P50B08100VCLGS P50B08075DCLGD R2AA08075FCP63 R2AA08075FCP3N P50B07050DCLG7
Brake [-] with with with with with with with with
Shaft shape [-] Straight Straight Taper Straight Straight Straight Taper Straight
Capacity [W] 1500 1200 1200 1000 750 675 675 475
Max. rotation speed [rpm] 4500 6000 6000 4000 4500 6000 6000 5000
Rated rotation speed [rpm] 3000 2000 2000 3000 3000 3000 3000 3000
Max. instant torque [Nm] 14.7 16 16 11.76 8.82 8.5 8.5 5.19
Rated torque [Nm] 4.79 5.7 5.7 3.185 2.381 2.15 2.15 1.52
-4 2
Moment of inertia [10 kgm ] 2.41 6.5 6.5 2.989 2.264 2.07 2.07 1.205
Mass [kg] 8.9 8 8 5.5 4.35 3.5 3.5 2.77
KHI uniaxial amplifier [-] 50A 30A 30A 30A 30A 30A 30A 30A
A [mm] 100(±2) 130(±2) 130(±2) 86 86 80 80 76
B [mm] 55(±1) 55(±1) 34(±1) 60(±0.8) 45(±0.8) 40(±0.8) 35(±0.8) 35(±0.8)
C [mm] 233(±3) 160(±3) 160(±3) 214 191 153(±1) 157(±1) 156
D [mm] 3 4 4 3 3 3 3 3
E [mm] 10 12 12 8 8 8 8 8
F [mm] 50 50 28 43 40 35(±0.3) 28(±0.2) 28(+0.1 to +0.2)
G [mm] - - 2 - - - 4 -
H [mm] - 3 2 3.5 3 4 - 4
I [mm] - 42 25 42 35 25 25 25

Dimensions
J [mm] 19(-0.013 to 0) 22(-0.013 to 0) 19 16(-0.011 to 0) 16(-0.011 to 0) 16(-0.011 to 0) 16 16(-0.011 to 0)
K [mm] - 6(-0.030 to 0) 4(-0.030 to 0) 5(-0.03 to 0) 5(-0.03 to 0) 5(-0.03 to 0) 3(-0.025 to 0) 5(-0.03 to 0)
L [mm] - 2.5(-0.2 to 0) - 2(-0.2 to 0) 2(-0.2 to 0) 2(-0.2 to 0) 1.2(-0.2 to 0) 2(-0.2 to 0)
M [mm] - 6 4(-0.030 to 0) 5 5 5 3 5
N [mm] - - 6.3(-0.1 to 0) - - - - -
O [mm] - - 14 - - - 14 -
P [mm] - 6 5 5 5 5 4 -
Q [mm] - 1 0.8 0.8 0.8 0.8 0.7 -
R [mm] - 20 15 12 12 12 10 -
S [mm] 115(±0.2) 145(±0.2) 145(±0.2) 100(±0.3) 100(±0.3) 90(±0.3) 90(±0.3) 90(±0.3)
T [mm] 8 8 8 6 6 5 5 5
U [Nm] 29 29 29 12 12 6.9 6.9 6.9

Item Unit ⑱ ⑲ ⑳ ㉑ ㉒ ㉓ ◎
Part No. [-] 50601-0119 50601-0120 50601-1462 50601-1371 50601-1463 50601-1370
Model No. [-] R2AA08040FCPGT R2AA08040FXPGS R2AA06020FCP3G P50B05020DCLEG R2AA06010FCP3H P50B04007DCLEF
Brake [-] with with with with with with
Shaft shape [-] Straight Straight Straight Straight Straight Straight
Capacity [W] 400 400 200 200 100 75
Max. rotation speed [rpm] 6000 6000 6000 5000 6000 4500
Rated rotation speed [rpm] 3000 3000 3000 3000 3000 3000
Max. instant torque [Nm] 4.4 4.4 2.2 1.96 1.13 0.647
Rated torque [Nm] 1.27 1.27 0.637 0.637 0.318 0.239
-4 2
Moment of inertia [10 kgm ] 1.29 1.04 0.279 0.197 0.177 0.057
Mass [kg] 2.7 1.8 1.2 1.27 0.94 0.63
KHI uniaxial am plifier [-] 30A 30A 15A 15A 15A 15A
A
B
[mm]
[mm]
80
33(±0.8)
80
33(±0.8)
60
27(±0.8)
54
27(±0.8)
60
23(±0.8)
42
29.5(±0.8)
◎: recommended model
C
D
[mm]
[mm]
124(±1)
3
88.3(±1)
3
107.5(±1)
3
140
2.5
92.5(±1)
3
127
2
ᇞ: shaft shape differs from
E
F
[mm]
[mm]
8
27(±0.3)
8
27(±0.3)
6
23(±0.3)
5
21(0 to +0.1)
6
19(±0.3)
5
20.8(0 to +0.1)
those of recommended
G
H
[mm]
[mm]
-
2 2
- -
-
-
5
-
-
-
2.9
motors (external axis
I
J
[mm]
[mm]
20
14(-0.011 to 0)
20
14(-0.011 to 0)
-
11(-0.011 to 0)
16
11(-0.011 to 0)
-
8(-0.009 to 0)
16
8(-0.009 to 0)
spec.) described at each
Dimensions
K
L
[mm]
[mm]
5(-0.03 to 0)
2(-0.2 to 0)
5(-0.03 to 0)
2(-0.2 to 0)
-
-
4(-0.03 to 0)
1.5(-0.2 to 0)
-
-
3(-0.025 to 0)
1.2(-0.2 to 0)
left, though electrical
M
N
[mm]
[mm]
5
-
5
-
-
-
4
-
-
-
3
-
characteristics are same.
O
P
[mm]
[mm]
-
5 5
- -
-
-
-
-
-
-
-
Use them after
Q [mm] 0.8 0.8 - - - -
R [mm] 12 12 - - - -
confirming the shaft
S [mm] 90(±0.3) 90(±0.3) 70(±0.3) 60(±0.3) 70(±0.3) 48(±0.3)
T [mm] 5 5 5 4 5 3 shape.
U [Nm] 6.9 6.9 6.9 3.4 6.9 1.5

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E0x Series Controller 1 Selection of External Axis Component Parts
Kawasaki Robot External Axis Addition Manual

[NOTE]
1. Figure in ( ) of Rotation Speed represent max. speed (Nmax).
2. Resolution per one rotation of servomotor is 8192 p/rev.
3. Contact Kawasaki if a motor drawing is required.
4. Servo parameter files differ according to types of servo motors. See “Servo
parameter” in “3.1 Linear Axis Parameter Value Setting” for details.

Table below shows external axis amplifier information, available external axis motor and connecting
destination of amplifier per controller.

Axis number on hardware

JT7/JT A JT8/JT B JT9/JT C

(1)Mounting position Standard installation inside 7-axis servo amplifier unit for Additional 1 axis amplifier (100 A) Additional 1 axis amplifier (100 A)
of amplifier (part No.) main body (50 A) (50607-0128) (50607-0128)

(2)Available motor 75 W to 3.1 kW

E01 controller 75 W to 5.0 kW 75 W to 5.0 kW
capacity (Restriction required when using 4.2kW)

(3)Connecting
X4 separate harness JT8/JT B rear harness JT9/JT C rear harness
destination of amplifier

(1)Mounting position Standard installation inside 7-axis servo amplifier unit for Additional 1 axis amplifier (100A) Additional 1 axis amplifier (100A)
of amplifier (part No.) main body (50 A) (50607-0128) (50607-0128)

(2)Available motor 75 W to 3.1 kW

E02 controller 75 W to 5.0 kW 75 W to 5.0 kW
capacity (Restriction required when using 4.2kW)

(3)Connecting
X5 separate harness JT8/JT B rear harness JT9/JT C rear harness
destination of amplifier

(1)Mounting position Additional 1 axis amplifier (100 A)

Not available Not available
of amplifier (part No.) (50607-0128)
75W to 3.1kW
(2)Available motor
E03 controller - (Restriction required by machine -
capacity
harness)
*
(3)Connecting
- X5 separate harness or -
destination of amplifier JT8/JT B rear harness
(1)Mounting position Additional 1 axis amplifier 100 A) Additional 1 axis amplifier (100 A)
Not available
of amplifier (part No.) (50607-0128) (50607-0128)

(2)Available motor
E04 controller - 75 W to 5.0 kW 75 W to 5.0 kW
capacity

(3)Connecting
- JT8/JT B rear harness JT9/JT C rear harness
destination of amplifier

JT D,E,F,G,H.J JT K

(1)Mounting position 6-axis amplifier (100 A) Additional 1 axis amplifier (100 A)

of amplifier (part No.) (50607-0129) (50607-0128)

(2)Available motor
multi-axis controller 75W to 5.0kW 75 W to 5.0 kW
capacity

(3)Connecting
X4, X5 separate harness JT K rear harness
destination of amplifier

** Selectable

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E0x Series Controller 1 Selection of External Axis Component Parts
Kawasaki Robot External Axis Addition Manual

See the figure below for the mounting position of external axis amplifier and position of rear harness per
controller.
JT9/JT
JT9/JTCCrear harness
背面出しﾊｰﾈｽ JT9/JT
JT9/JTCCrear harness
背面出しﾊｰﾈｽ
E01/E02 E03 JT8/JT
JT8/JTB rear harness
B 背面出しﾊｰﾈｽ E04
JT8/JT
JT8/JTBBrear harness X5
背面出しﾊｰﾈｽ X5separate
分離ﾊｰﾈｽ harness JT8/JT
JT8/JTBBrear harness
背面出しﾊｰﾈｽ

JT9/JT C
Not available
使用不可 JT9/JT C
JT7/JT A
(Standard)
（標準）

JT8/JT B JT8/JT B JT8/JT B

Multi-axis controller

X4, X5 separate harness

JT K rear harness
(to distribution box)

JT D,E,F,G,H,J

JT K

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Kawasaki Robot External Axis Addition Manual

1.1.2 MITSUBISHI Motor Which can be Used in External Axis

For external axes, the following combinations of MITSUBISHI motors (corresponding to

MELSERVO-J3/J4 series) and amplifiers can be used.

NOTE:
Both MELSERVO-J3 and J4 series motors can be used whose operation check has been done.
Refer to the instruction manual issued by MITSUBISHI Electric Corp. for details of motor and
amplifier.
However, the following points should be considered carefully when using MITSUBISHI motor control
panel prepared by customer.
・Selection of breaker and magnetic contactor according to motor capacities
・Brake power capacity (*Brake power is supplied from E0x controller. Refer to section 1.4 for the
brake current which can be used in each robot.)
Refer to section 2.1 for details.

Unit (1) (2)

MITSUBISHI motor model － HG-SR152B HG-KR053B
Brake － Fitted Fitted
Capacity W 1500 50
Max. rotation speed rpm 3000 6000
Rated rotation speed rpm 2000 3000
Instantaneous max. torque Nm 21.5 0.56
Rated torque Nm 7.2 0.16
Moment of inertia 10 kgm2
-4
18.2 0.0472
Weight kg 9.3 0.54
MITSUBISHI amplifier
－ MR-J4-200B MR-J4-10B
model

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Kawasaki Robot External Axis Addition Manual

1.2 SANYO Motor Selection Procedure

This section describes the procedure of selecting motors for the following three types of external axes. If
your intended axis is not one of these types, use this section as a reference during motor selection.
Contact Kawasaki for any further questions.

[NOTE]
Motor cannot be used with its maximum performance when motor
of 4.2 kW or more is used for JT7/JT A in E01/E02 controller,
because the instantaneous maximum torque and rated torque are
limited to half.

1.2.1 Rotation Axis

1. Determination of load output axis specification

Determine specifications for load output axis.
Load mass MW (kg)
Offset to load center of gravity LO (m)
Load moment of inertia on load center of JW (kgm2)
gravity
Angular motion range θ ()
Max. angular speed ω (/s)
Max. angular acceleration α (/s2)

2. Selection of reducer
Select a reducer and determine the following data.
Motor inertia moment JM (kgm2)
Flywheel inertia moment JF (kgm2)*
Reducer inertia moment JR (kgm2)
Load axis rotations 1/i
Reduction ratio
Motor rotations (Normal i > 1)
Starting efficiency η (0 to 1.0)

NOTE* JF=0 except when mounting flywheel on motor.

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Kawasaki Robot External Axis Addition Manual

Reducer Motor

LO

MW,JW
Load

[NOTE]
Also, consider allowable torque, service life calculation, etc. when selecting reducer.

3. Check of condition expressions and selection of motor

Calculate each of the condition expressions from the values determined in 1 and 2 above and the
values in the expressions below. Design an external axis that satisfies all the condition expressions
and select an appropriate motor.

Condition expression Expression

1 Peak torque on motor 9.8MWLO+（JW+MWLO2）απ/180
TP = ηi
TP ≤ 0.9TPS (Nm)
+ (JR+JF+JM) αiπ/180
2 Holding torque of motor 9.8MWLO
TH = ηi
TH ≤ 0.8TC (Nm)

3 Average motor torque on operation ΣtiTi2 ti: Each motion time

TR = Ti: Each motion torque
TR ≤ 0.9TC (Nm) Σti

4 Max. motor RPM when operating ωi

N= 6
N ≤ Nmax (rpm)

5 Number of encoder rotations when θi

Erev = 360
operating
Erev ≤ 65536 (rev)

6 Ratio of load side moment of inertia to JW+MWLO2

RJ = i2(J +J +J )
that of motor axis side reduced to that R F M

of motor axis side

RJ ≤ 6

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1.2.2 Linear Axis (Rack and Pinion Drive)

Outline of motor selection procedure for traveling, traverse and up-down axes is below.
1. Determination of load output axis specifications
2. Selection of reducer and guide
3. Check of condition expressions and selection of motor/encoder

1. Determination of load output axis specification

Determine specifications for load output axis.
Load mass MW (kg)
Motion stroke X (m)
Max. speed V (m/s)
Max. acceleration a (m/s2)

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Kawasaki Robot External Axis Addition Manual

2. Selection of reducer and guide

Determine specifications for the reducer.
Reduction ratio i
Starting efficiency η (0 to 1.0)
Moment of inertia of reducer JR (kgm2)

Determine rack and pinion data.

Module m
Number of pinion gear Z

Determine guide data.

Guide friction μ (around 0.05 to 0.1)

Determine motor and flywheel data.

Motor inertia moment JM (kgm2)
Flywheel inertia moment JF (kg·m2)

Flywheel
Reducer
Motor
Traveling table
Guide

9.8 MW X, V, a
Pinion
Rack

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Kawasaki Robot External Axis Addition Manual

3. Check of condition expressions and selection of motor

Calculate each of the condition expressions from the values determined in 1 and 2 above and the
values in the expressions below. Design an external axis that satisfies all the condition expressions
and select an appropriate motor.

Condition expression Expression

1 Peak torque on motor mZ（9.8μMW+MWa）
TP = 2000ηi
TP ≤ 0.9TPS (Nm)
2000ia(JR+JF+JM)
+ mZ
9.8mZMW
+ 2000ηi (Up-down axis only)

2 Holding torque of motor 9.8mZMW

TH = 2000ηi (Up-down axis only)
TH ≤ 0.8TC (Nm)

3 Average motor torque on operation ΣtiTi2 ti: Each motion time

TR =
TR ≤ 0.9TC (Nm) Σti Ti: Each motion torque

4 Max. motor RPM when operating 60Vi

N = πmZ
N ≤ Nmax (rpm)

5 Number of encoder rotations when Xi

Erev = πmZ
operating
Erev ≤ 65536 (rev)
6 Ratio of load side moment of inertia 10-6MWm2Z2
RJ = 4i2(J +J +J )
to that of motor axis side reduced to R F M

that of motor axis side

RJ ≤ 6

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1.2.3 Linear Axis (Ball Screw Drive)

Outline of motor selection procedure for traveling, traverse and up-down axes is below.
1. Determination of load output axis specifications
2. Selection of reducer and guide
3. Check of condition expressions and selection of motor/encoder

1. Determination of load output axis specification

Determine specifications for load output axis.
Load mass MW (kg)
Motion stroke X (m)
Max. speed V (m/s)
Max. acceleration a (m/s2)

2. Selection of reducer and guide

Determine specifications for the reducer (gear).
Reduction ratio i
Starting efficiency η1 (around 0.95)

Determine specifications of ball screw.

Lead L (m)
Starting efficiency η2 (around 0.95)
Inertia moment JB (kgm2)

Determine guide data.

Guide friction μ (around 0.05 to 0.1)

Determine motor and flywheel data.

Motor inertia moment JM (kgm2)*
Flywheel inertia moment JF (kgm2)*
NOTE* Note the units of moment of inertia for motor and flywheel.

Flywheel Motor

Traveling table
Reducer (gear)
Ball screw

Guide

9.8 MW X, V, a
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Kawasaki Robot External Axis Addition Manual

3. Check of condition expressions and selection of motor

Calculate each of the condition expressions from the values determined in 1 and 2 above and the
values in the expressions below. Design an external axis that satisfies all the condition expressions
and select an appropriate motor.

Condition expression Expression

1 Peak torque on motor L（9.8μMW+MWａ）
TP = 2πη1η2i
TP ≤ 0.9TPS (Nm)
2π(JB/(i2η1)+JF+JM)ia
+ L
9.8LMW
+ 2πη1η2i (Up-down axis only)
2 Holding torque of motor 9.8LMW
TH = 2πη η i
TH ≤ 0.8TC (Nm) 1 2

3 Average motor torque on ΣtiTi2 ti: Each motion time

TR =
operation Σti Ti: Each motion torque
TR ≤ 0.9TC (Nm)
4 Max. motor RPM when operating 60Vi
N= L
N ≤ Nmax (rpm)

5 Number of encoder rotations Xi

Erev = L
when operating
Erev ≤ 65536 (rev)
6 Ratio of load side moment of MWL2 JB
RJ = 4π2i2(J +J ) + i2(J +J )
inertia to that of motor axis side F M F M

reduced to that of motor axis side

RJ ≤ 6

1.3 MITSUBISHI Motor Selection Procedure

Selection procedures described in 1.2 can also be applied to selection of a MITSUBISHI motor,
however, we recommend using software MRZJW3-MOTSZ111E by MITSUBISHI Electronic Corp.
when setting MITSUBISHI motor.

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Kawasaki Robot External Axis Addition Manual

1.4 Check of Brake Current, Average Consumption Power and Average Regenerative
Power

E0x series controller has restrictions on the brake current, average consumption power and average
regenerative power to drive external axes, and it is necessary to select external axis motors according to
the restrictions.

When selecting the external axis motor, check if;

1. The total brake current of the motors to be used is less than the brake current restriction in table 3.
(Available motor and its brake current are shown in tables 1 and 2.)
2. The total average consumption power and average regenerative power of SANYO motors to be
used for external axes are less than the restrictions in table 4.

When motor rotates with horizontal load such as traveling unit at the speed/torque shown below, the
average consumption power and regenerative power of external axis can be calculated by the following
formula.

0.0524NT1t1+0.1047NT2·t2 (N: Rotation speed of

Average consumption power (W)＝
t1+t2+t3+t4 motor (r/min))
0.0524NT3t3
Average regenerative power (W)＝ (T1, T2, T3: Torque (r/min))
t1+t2+t3+t4
Speed (r/min)

Time (s)
Resultant torque (N·m) t1 t2 t3 t4
T1

T2
Time (s)

T3

For example, as a guide, the consumption power and regenerative power of each motor are shown in
table 1 when an external axis moves under the following conditions.
Acceleration time (t1): 1.5(s)
Constant speed time (t2): 12(s)
Deceleration time (t3): 1.5(s)
Downtime (t4): 45(s)
Torque in acceleration (T1): instantaneous maximum torque
Torque in constant speed (T2): 60% of rated torque

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Kawasaki Robot External Axis Addition Manual

Torque in deceleration (T3): instantaneous maximum torque  60% of rated torque

Motor rotating speed (N): rated rotating speed

Table 1. Characteristics of SANYO motors

Estimated Estimated
Motor Brake capacity value of value of
Part No. Type
capacity factor consumption regenerative
power (kW) power (kW)
50601-0128 R2AA2250ALCPKL 5.0 kW 1.0 A 0.786 0.146
50601-1412 P80B22450LCPUB 4.2 kW 1.6 A 0.719 0.184
50601-1413 P60B13200LCPUA 0.474 0.081
3.1 kW 1.0 A
50601-1403 P60B13200LCPUH 0.474 0.081
50601-1414 P60B13150HCPUG 2.1 kW 0.62 A 0.316 0.048
50601-1490 R2AA13200LCP2R 0.317 0.064
50601-1460 R2AA13200LCP2S 2.0 kW 0.66 A 0.317 0.064
50601-0156 R2AA1020AFCPKB 0.310 0.055
50601-1485 P20B10200LCP67 2.0 kW 0.83 A 0.306 0.051
50601-1366 P20B10150DCPU3 1.5 kW 0.83 A 0.238 0.046
50601-1491 R2AA13120LCP2D 1.2 kW 0.185 0.033
0.51 A
50601-1465 R2AA13120LCP2E 0.185 0.033
50601-1435 P50B08100VCLGS 1.0 kW 0.33 A 0.166 0.039
50601-1432 P50B08075DCLGD 750 W 0.33 A 0.124 0.029
50601-1492 R2AA08075FCP63 0.114 0.028
675 W 0.37 A
50601-1461 R2AA08075FCP3N 0.114 0.028
50601-1404 P50B07050DCLG7 475 W 0.3 A 0.078 0.017
50601-0119 R2AA08040FCPGT 0.065 0.014
400 W 0.37 A
50601-0120 R2AA08040FXPGS 0.065 0.014
50601-1462 R2AA06020FCP3G 200 W 0.32 A 0.033 0.007
50601-1371 P50B05020DCLEG 200 W 0.4 A 0.032 0.006
50601-1463 R2AA06010FCP3H 100 W 0.27 A 0.016 0.004
50601-1370 P50B04007DCLEF 75 W 0.26 A 0.012 0.002

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Kawasaki Robot External Axis Addition Manual

Table 2. Characteristics of MITSUBISHI MELSERVO (J3/J4 series) motors (with electromagnetic

brake)

Specifications
Type Motor Brake consumption Brake current*
Amplifier type
capacity power
HG-SR152B 1.5 kW 20 W MR-J4-200B 0.83 A
HG-KR053B 0.05 kW 6.3 W MR-J4-10B 0.2625 A
NOTE*: Regarding other MITSUBISHI motors, calculate the brake current coefficient by multiplying
the brake power capacity (W) by 1/24.

Table 3. Brake current restrictions for external axis per robot arm

Robot arm Controller Brake current restriction**

CP130/180/250/300 E03 3.28 A
CX165/210 E02 3.61 A
BA006 E01 9.14 A
MX350/420/500/700 E04 1.60 A
ZX100/130/165/200/300
ZT130/165/200,ZB100/150, E02 3.40 A
ZH070/100, MT400, MX320L
BX100L/100X/130X/150L
BX165N/165L/200N/200L E02 5.77 A
BT165L/200L
BX250L/BX300L E02 5.19 A
RS015X E02 7.04 A
RS030/050/080 E02 7.11 A
RD080 E03 7.34 A
BX100S/100N/150N E02 5.87 A
RS020/010L E01 7.87 A
RS010N/006 E01 9.05 A
Multi-axis
- 11.2 A
controller
NOTE**: When using MITSUBISHI motor, it is necessary to subtract the current to drive the magnetic
contactor for control power cut, which is supplied to MITSUBISHI motor control panel
(26Vdc power supply), from the brake current limit.

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Kawasaki Robot External Axis Addition Manual

Table 4. Estimated values of available average power for external axis motor (Reference values)

Available average Available average

Controller Robot arm consumption power for regenerative power for
external axis motor (kW) external axis motor (kW)
E01 BA006 4.1 0.21
RS020/010L 3.3 0.21
RS010N/006 3.5 0.22
E02 CX165/210 2.1 0.42
ZX100/130/165/200/300
ZT130/165/200,ZB100/150, 1.7 0.40
ZH070/100, MT400, MX320L
BX100L/100X/130X/150L
BX165N/165L/200N/200L 2.1 0.42
BT165L/200L
BX250L/BX300L 1.9 0.38
RS015X 2.5 0.61
RS030/050/080 2.2 0.48
BX100S/100N/150N 2.3 0.48
E03 CP130/180/250/300 1.8 3.91
RD080 4.8 3.91
E04 MX350/420/500/700 5.0 0.40
Multi-axis
- 7.8 0.62
controller

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Kawasaki Robot External Axis Addition Manual

1.5 Motor Applicability for External Axis Specifications

MITSUBISHI motors are not applicable to some specifications as shown in the table below.

External axis SANYO MITSUBISHI

Note
specification motor motor
1 Traverse axis Applicable Applicable Including traverse axis cooperation.
2 Positioner Applicable Applicable Including positioner cooperation.
3 Rotation axis Applicable Applicable Including rotation axis cooperation.
Hand
4 Applicable Applicable
(position control)
Combination use of SANYO and
5 Dual servo Applicable Applicable
MITSUBISHI motors is not applicable.
6 Endless function Applicable Applicable
7 External axis spin Applicable Not applicable
8 Servo gun Applicable Not applicable
9 Servo torch Applicable Not applicable
Partly not Partly not Hardware separate control using MC
applicable applicable cannot be performed for E0x controller and
10 Separate control
multi-axis controller. Only software
separate control can be performed.
Partly not
11 Cubic-S Not applicable
applicable*

* Cubic-S does not support external axes connected to a multi-axis controller.

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Kawasaki Robot External Axis Addition Manual

2 Hardware Installation

To control an external axis by the robot controller, mount the servomotor selected in chapter 1 into the
external axis, install the necessary hardware in the controller and connect cables between the motor and
controller.

For details of hardware installation method when using SANYO motor, refer to a separate “Options
Installation Manual” for E0x controller.
For installation method of the multi-axis controller, refer to the separate “Installation and Connection
Manual” for the multi-axis controller.

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2.1 When Using MITSUBISHI MELSERVO-J3/J4 Series Motor

When using MITSUBISHI motor (corresponding to MELSERVO-J3/J4 series), prepare MITSUBISHI

motor control panel following this section. Figure below shows connecting system diagram when using
a MITSUBISHI motor.

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Kawasaki Robot External Axis Addition Manual

2.1.1 Necessary Hardware for MITSUBISHI Motor

Based on system diagram above, use only the parts below when adding an external axis.

No. Name KHI Part No. Remarks

1 SSCNET-III I/F board (PCI) 50999-0220 1 board required per system
PCI bus adaptor board (1YQ board) 50999-0430 Manufactured by KHI
EMG/24 V harness 50977-0770 Manufactured by KHI
2 SSCNET-III cable － Manufactured by MITSUBISHI
3 SSCNET-III cable － Manufactured by MITSUBISHI
4 Connector for terminal － Manufactured by MITSUBISHI
5 Motor － Manufactured by MITSUBISHI
6 Amplifier － Manufactured by MITSUBISHI
7 Encoder cable － Manufactured by MITSUBISHI
8 Motor connector set － Manufactured by MITSUBISHI,
wiring required
9 Brake connector set － Manufactured by MITSUBISHI,
wiring required
10 Brake connector set (CN3) － Manufactured by MITSUBISHI,
wiring required
11 Battery － Manufactured by MITSUBISHI
12 Brake drive relay (RA1, 2, 3) － *1
13 DC24V power － *1
14 Switch for manual brake release － *2
(PB1, PB2, PB3)
15 Breaker for main power cut － *3
16 Magnetic contactor for motor power － *3
cut
17 AC210V, 3 power supply － *3

For MITSUBISHI parts other than the parts mentioned above such as SSCNET-III cable and
regenerative options, refer to the instruction manual of MELSERVO-J3/J4 issued by MITSUBISHI
Electric Corp.

NOTE： For the MELSERVO-J3/J4 series servo motor, disconnecting the encoder cable between
servo motor and servo amplifier erases encoder values immediately, and zeroing
must be executed again. In order to avoid the erasing when replacing the servo
amplifier, it is recommended to use following parts.

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Kawasaki Robot External Axis Addition Manual

MELSERVO-J3 series
Battery connection junction cable: MR-J3BTCBL03M

MELSERVO-J4 series
Battery for battery connection junction cable: MR-BAT6V1BJ
Battery junction cable: MR-BT6VCBL03M

*1 Brake drive relay (RA1, 2, 3)

Use a brake drive relay with the following rating.
Coil rating: Operable at DC26 V±10%/40 mA or less
Contact rating: DC30 V or more/3 A or more
In addition, it is necessary to supply DC24 V to CN3 for the brake relay coil drive. Prepare for it
separately.

*2 Switch for manual brake release (PB1, 2, 3)

Use a switch meeting the following spec. for manual brake release.
Rated spec. for contact of switch: DC30 V or more/3 A or more

*3 Motor power cutoff circuit

It is necessary to prepare for AC210V 1 for control power of MITSUBISHI MELSERVO-J3/J4
system and AC210V 3 for motor power separately from E0x controller.
Prepare for a breaker dedicated to power cut and a magnetic contactor.
See the next section 2.1.2 for details.

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2.1.2 Mounting/Connection Procedure

This section describes how to mount and connect the following parts.
1. Motor power cutoff circuit
2. Brake power circuit
3. Main circuit/Controller power/Regenerative option
4. SSCNET-III I/F board
5. SSCNET-III cable connection, battery mounting, ground
6. Brake drive relay
7. Encoder cable between amplifier and motor
8. Motor/brake cable between amplifier and motor

1. Motor power cutoff circuit

Connect the circuit to X313 connector of 1VH board inside E0x controller.

External wire inlet

1VH board

X312

X313

Without the top plate of E0x controller

No. Housing Contact Maker Wire
Motor power cutoff X313 J21DF-12V-KX-L SJ2F-21GF-P1.0 JST 0.75sq
(Safety duplexing output) Blue

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Example of cutoff circuit connection is shown below.

E0x controller
E0xコントローラ ダイオードを
1VH board
1VHボード 入れてください。
Insert a diode.
26Vdc X313
MC1
A3
Motor power ON state
outputコントローラの
for controller B3
モータ電源ON状態出力
(safety duplexing MC2
（安全二重化出力）
output) A4
*Test pulse included
※テストパルス含む
B4

A1
BRG
To weld detection
溶着 B1
circuit 検出回路へ 6mA

Housing: J21DF-12V-KX-L/manufactured by JST

ハウジング：J21DF‐12V‐KX‐L /JST製
Contact: SJ2F-21GF-P1.0
コンタクト：SJ2F‐21GF‐P1.0

Motor
モータ動力 power
L1,L2,L3
AC210V, 3 power
AC210V,φ3 電源
(external power)
(外部電源) CB
Control
制御電源 power
L11,L21

[NOTE]
・Select magnetic contactor (MC) which satisfies the following.
Rated voltage of coil: Operable at 26 V±10%
Rated current of coil: 0.35 A or less
Minimum current at contact b: 5 mA or more
Main contact: Satisfies rated load capacity of motor/amplifier to be used
・Output current from X313 is added to the brake power current inside E0x controller. Subtract this
output current from X313 for the brake current limit shown in table 3 in section 1.4.
・Output section of X313 includes the test pulse shown below. Prevent the connected circuit from
malfunctioning due to the test pulse. Moreover, do not connect capacitive load.

ON

OFF
最大500μs
Max. 500 s

Period of 250 ms
250ms周期

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2. Brake power circuit

Connect to X312 connector of 1VH board inside E0x controller.
No. Housing Contact Maker Wire
Brake power X312 J21DF-12V-KY-L SJ2F-21GF-P1.0 JST 0.75sq
Blue

Example of connector connection is shown below.

E0x controller
E0xコントローラ
1VH board
1VHボード
Max. 4.3 A per pin
1pinあたり最大4.3A
26Vdc
X312
26Vdc(BRKV)
A1 Power for brake release
ブレーキ解除用電源
Brake power ON
ブレーキ電源ON *Links with motor power inside
※コントローラ内のモータ電源に連動
A5 BRG
*Test pulse included
※テストパルス含む controller.
26Vdc(BRKV)
A2 GND for brake power
ブレーキ電源用GND
BRG
A6
BRG
26Vdc(REV)
A3
Power for manual
手動 brake
26Vdc(REV) release
ブレーキリリース用電源
A4

Housing: J21DF-12V-KY-L/manufactured by JST

ハウジング：J21DF‐12V‐KY‐L /JST製
Contact: SJ2F-21GF-P1.0
コンタクト：SJ2F‐21GF‐P1.0

[NOTE]
BRKV of X312 (26 V brake power) includes the test pulse shown below. Prevent the
connected circuit from malfunctioning due to the test pulse. Moreover, do not connect
capacitive load.

12.5 ms

Max. 1.5 ms

Period of 250 ms

3. Main circuit/Control power/Regenerative option

Connect the L1, L2, L3, L11, L21 terminals of each servo amplifier. For connection with servo
amplifier and regenerative option, connect them according to the instruction manual or manual issued
by MITSUBISHI Electric Corporation.

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4. SSCNET-III I/F board

Mount the SSCNET-III I/F board (manufactured by MITSUBISHI Electric Corporation) on the PCI
bus adaptor (1YQ) board and insert it in robot controller.

Outline view of PCI bus adaptor (1YQ) board

④
③②

[Unit: mm]

Outline view of SSCNET-III I/F board

(1) Board ID selection, setting, interrupt mask selection switches (SW1): Set all to OFF
(2) Motion display LED (Green): ON at Power ON, blinks at system start-up
(3) Error display LED (Red): ON when an error occurs
(4) USB connector: test tool, for communication with MR Configurator 2
(5) SSCNET connector: connector for communication with servo amplifiers
(6) EMI input connector: connector for inputting the external emergency stop signal, connect
EMG/24V harness to 1TR board (CN10) and 1VZ board (X214)

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Mounting method
(1) Mount the SSCNET-III I/F board on the salient of the plate attached on the PCI bus adaptor
(1YQ) board to fit the groove of the front panel of SSCNET-III I/F board, and fix it using M3
screws.
Plate attached on 1YQ board

Mount the board to fit the groove.

SSCNET-III I/F board

Fix using M3 screws.

[NOTE]
Fix the salient of the plate to fit the groove of the front panel of the SSCNET-III I/F
board. If the salient is not fixed properly, the SSCNET-III I/F board may interfere with
a board of other slot and may malfunction.

(2) Mount the SSCNET-III I/F board on which a plate is mounted on the PCI bus adaptor (1YQ)
board and fix it using M3 screws.

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(3) Connect the FG terminal of 1YQ board and the spacer of controller body by attached grounding
wire (KHI part No.: 50977-0151) using screws.

1YQ board

FG terminal

Fix it using M3 screws.

(4) Mount the PCI bus adaptor (1YQ) board on which the SSCNET-III I/F board is mounted on the
card rack of E0x controller.

[NOTE]
・Another optional board cannot be mounted on the right slot of 1YQ board.
・Do not insert/remove the adjoining optional board with the PCI bus adaptor
(1YQ) board mounted when other optional boards are mounted adjacent to the
PCI bus adaptor (1YQ) board. The front panel of the SSCNET-III I/F board
and optional boards may interfere with each other.

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Kawasaki Robot External Axis Addition Manual

EMG/24V harness connection

Connect each connector as shown in the figure below. X214M is not connected.

X214M 1VZ-X214

X214F 1TR board

SSCNET-III I/F board

1VA board

1TR-CN10

AVR

EMI EMI

5. SSCNET-III cable connection, battery mounting, ground

(1) Connect between SSCNET-III I/F board and servo amplifier and between servo amplifiers with
SSCNET-III cables.
(2) Mount the battery and battery junction cable to each servo amplifier.
(3) Connect the servo amplifier to the ground securely.

[NOTE]
The battery usually requires to be replaced every one year.

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6. Brake drive relay

Connect between CN3 and brake drive relay referring to the figure below. Be careful not to mix up
plus and minus of relay coil and diode.

3 DOCOM
DC24V
5 DICOM
20 EM2
13 MBR
RA1
10 DICOM

7. Encoder cable between amplifier and motor

Connect the cable according to the instruction manual or manual issued by MITSUBISHI Electric
Corporation.

8. Motor/brake cable between amplifier and motor

Connect the cable according to the instruction manual or manual issued by MITSUBISHI Electric
Corporation.

Connect a surge protection diode as shown in the figure below.

ダイオードを
モータ
Motor 入れてください。
Insert a diode.
26Vdc(BRKV)

Electro-
電磁
magnetic B
ブレーキ
brake

BRG

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E0x Series Controller 3 Setting of External Axis Parameter Values
Kawasaki Robot External Axis Addition Manual

3 Setting of External Axis Parameter Values

Set the data for external axes by the procedure below. With the exception of some setting items for
specific motors, this setting is applicable to both SANYO motor and MITSUBISHI motor. For the
setting of cooperative control operation between robot arm and external axes, refer to chapter 5.

！ CAUTION
Turn the motor power OFF before setting or modifying
external axis data.

1. Activate B area on the teach pendant and press MENU to display the pull-down menu below.

2. Move the cursor to [Aux. Function] and press  to call up the auxiliary function screen as in the
figure below.

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3. Input “899” by NUMBER (0 to 9) and press . [Enable maintenance function] screen as below is
displayed.

In the screen, input “3” for [Operation Level]. Next, move the cursor to [Password] and input “9894”
as the password.

Check that both items are input, and press . All settings are stored when “Setting complete.” is
displayed.

4. Return to the auxiliary function screen. This time, select [Aux.2002 External Axis].

5. Enter the axis number to be used and press <Next Page>.

6. Select the axis type and press <Next Page>. The screen for servo parameter setting appears.

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3.1 Linear Axis Parameter Value Setting

The screen below appears when [Linear Axis] is selected as the axis type in “Aux.2002 External Axis”.
Enter the necessary data for each item.

Upper Motion Limit

Enter the upper limit of mechanical motion range.

Lower Motion Limit

Enter the lower limit of mechanical motion range.

Resolution Mantissa
Resolution Exponent (10^-n)
Enter the motion amount per bit of encoder value. For example, in case of 1.234  10-3 mm/bit, enter
1.234 mm/bit for mantissa and 3 for exponent.

Motion Direction (Plus/Minus)

Select the rotation direction of the axis to be used for increasing encoder value. Encoder value increases
as it rotates clockwise when viewed from the shaft end.

Max Speed
Enter the maximum speed.

Accel Time
Enter the time it takes to accelerate from 0 to the maximum speed. Set 0.5 s or less usually.

Coupling Factor
Enter 0.00. (Linear axis does not induce any motion).

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When the parameter data in this page are set, press <Next Page> and go on to the next screen.

Servo board No.

Enter the servo board number to which the axis to be used is connected. The setting is valid only when
KHI amplifier (SANYO motor) is used. Select 1 for the robot controller and 2 for the multi-axis
controller. Normally, this setting is done at factory shipment.

Channel No.
Enter the channel number according to the type of amplifier that will be used. When using the KHI
amplifier (SANYO motor), set 1 to 9 depending on the number of the axis to which the amplifier is set.
When using the MITSUBISHI amplifier, set the channel number beginning at 11 in order of the axes to
be connected (MITSUBISHI amplifier: Set the channel number 11 for the amplifier to which 0 is
selected with axis selection rotary switch (SW1)). Normally, this setting is done at factory shipment.

The table below shows the relation between servo board axis numbers, channel numbers, hardware axis
numbers and encoder battery check settings. For the hardware axis numbers, refer to the table on page 6.
E01/E02
Servo board No. 1 1 1 2 2 2 2 2 2
Channel No. 7 8 9 1 2 3 4 5 6
Hardware axis No. 7/A 8/B 9/C D E F G H J
Encoder battery
Disable Enable Enable Enable Enable Enable Enable Enable Enable
check
*

Controller Multi-axis controller

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Kawasaki Robot External Axis Addition Manual

E03
Servo board No. 1 1 1
Channel No. 7 8 9
Hardware axis No. Not applicable 8/B Not applicable
Encoder battery check - Disable -
*

Controller
* JT C is not available when a multi-axis controller is connected.

E04
Servo board
1 1 1 2 2 2 2 2 2
No.
Channel No. 7 8 9 1 2 3 4 5 6
Hardware axis Not
8/B 9/C D E F G H J
No. applicable
Encoder
- Enable Enable Enable Enable Enable Enable Enable Enable
battery check
*
Controller Multi-axis controller

* JT C is not available when a multi-axis controller is connected.

Encoder Battery Check

Enables/disables battery check. This setting is valid only when KHI amplifier (SANYO motor) of robot
controller is used. Select [Enable] when 1HG board is mounted and the wiring from amplifier to motor
passes through a different separate harness other than that for the arm. Otherwise, select [Disable].
Normally, this setting is done as shown above at factory shipment.

MC unit number
Enter 1. Normally, this setting is done at factory shipment.

Servo Parameter
Select whether to use internal data or external data. Here, select [External Setting]. After changing
internal/external setting, turn OFF/ON the controller power before operating the external axis.

[NOTE]
Servo parameters cannot be set when [Internal data] is selected.

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Kawasaki Robot External Axis Addition Manual

！ WARNING

Servo parameters include those of velocity and current loops for servo motor
control and parameters depending on the hardware. Wrong settings may lead
to damage on the hardware (servo motor/servo amplifier) or to the
malfunction of the servo motor.

[NOTE]
1. For the system shipped after the setup by KHI, the servo parameter values are set at
KHI in shipping and servo parameter files are attached with the robot.
2. When adding an external axis after the shipping from KHI, select [External
Setting] for the [Servo Parameter] as mentioned above. In addition, it is necessary
to load servo parameter files. Servo parameter files differ according to hardware
types, which are provided by KHI. Contact KHI when the servo parameter values
to load are unknown.

Brake install check

Enables/disables brake install check. Select [Disable] when the brake is not installed in the motor to use.
Otherwise, select [Enable]. Normally, this setting is done at factory shipment.
[NOTE]
Set [Enable]/[Disable] correctly. If [Disable] is set for the motor installed with
brake, the error detection is not executed for the motor even though errors
such as brake line error etc. occur.

When the parameters data in this page are set, press <Next Page> and go on to the next screen.

Amp./Motor
Enter the motor number to use. Normally, this setting is done at factory shipment.

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When the data in this page are set, press <Next Page> and go on to the next screen.

Linear Cooperation
Sets the condition number for robot and axis cooperation. Enter 0 to cancel robot and external axis
cooperation. When cooperating, select from 1 to 6 to specify the robot axis direction (on base or tool
coordinate axes) that matches the positive direction of the external axis. For details of linear cooperation,
refer to “5 Cooperative Control Function”. Set “0: Non” for conveyors when using the conveyor
synchronous function (option).

Coop.(eration) Type
Selects the coordinate system used for cooperating with the external axis. This setting is invalid when
cooperation is disabled.

Motion Based on Fixed Tool

Enables/Disables motion based on fixed tool. Selecting [Enable] allows the external axis to move with
the tool pose kept stationary when in teach mode.

Axis Connect Mode (option)

Connects/Disconnects the linear axis.

After setting all data, press . Confirmation screen appears. Select [Yes] to set the entered data. Select
[No] to cancel.

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3.2 Rotation Axis Parameter Value Setting

The screen below appears when [Rotary Axis] is selected as the axis type in “Aux.2002 External Axis”.
Enter the necessary data in each item.

For setting parameter values, [Upper Motion Limit] to [Coupling Factor], see the procedure for linear
axis in “3.1 Linear Axis Parameter Value Setting”.

Equivalent Radius
Used when calculating the speed in mm/s while moving (circumferential speed) in rotating axes such as
positioner. In teach mode, the rotation speed [deg/s] is controlled so that the circumferential speed
calculated based on the equivalent radius becomes 250 [mm/s] or less. The circumferential speed is
calculated by the following formula.
Circumferential speed [mm/s] = 2  Equivalent radius [mm]  Rotation speed [deg/s]/360[deg]

！ WARNING

1. The smaller the equivalent radius is, the faster the rotation speed is in
teach mode.
2. It is dangerous to set smaller value than the actual size of the system
including a workpiece for the equivalent radius of a rotating axis such
as a positioner because the end of rotating axis moves at high speed.
Therefore, set an adequate value.

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Example: Speed when moving the positioner in teach mode with the workpiece whose radius is 1000
[mm] on it.
1. When setting the equivalent radius to 1000 [mm]:
the speed becomes 250 [mm/s] or less at the end of workpiece.

250mm/s

Rotation
ポジショナ
direction of
回転方向
positioner

Workpiece
ワーク

2. When setting the equivalent radius to 200 [mm]:

the risk increases because the speed can be increased up to 1250 [mm/s] at the end of workpiece.

1250mm/s

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When the parameter data in this page are set, press <Next Page> and go on to the next screen.

For setting parameter values, [Servo board No.] to [Brake install check], see the procedure for linear
axis in “3.1 Linear Axis Parameter Value Setting”. Press <Next Page> when done.

Set [Amp./Motor] in the same way as with linear axis. Press <Next Page> when done.

Rotation Set
Enables/Disables cooperation between the robot and the rotation axis on which the robot is installed.
When [Off] is selected, the settings below are ignored. For details of function of cooperation with
rotation axis, refer to “5 Cooperative Control Function”.

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Kawasaki Robot External Axis Addition Manual

Rotation Axis X, Y
Enter the offset value(s) from the robot base coordinates to center of the rotation axis. When an external
axis other than the rotation axis is used, enter the offset value when the external axis is at its home
position. The offset value is 0 in the case of Start position, or enter the values of “x” and “y” as the offset
value in the case of End position in the example below.

Setting Position
Specifies the position of the rotation axis. Select [Start Pos.(ition)] when the rotation axis is attached
directly to the robot. Select [End Pos.(ition)] when it is set at other positions in the system configuration.
Start position End position

Rotation axis
Robot arm

Base coordinate Y
Base coordinate X
Robot arm
Traverse axis (x, y, 0)
home position
y
Traverse axis (0, 0, 0) x
Traverse axis Rotation axis
home position

Rotating Direction
Sets the positive rotational direction of rotation axis around the base X and Y axes. Specify Y->X or
X->Y as the positive rotational direction with reference to the figure below.
Rotation axis Rotation axis
X→Y direction Y→X direction
Robot base
Z Z
coordinates
+ +
X Rotation axis X

Y Y

After setting all data, press . Confirmation screen appears (see linear axis). Move the cursor to <Yes>
to record the setting or <No> to cancel and press .

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E0x Series Controller 4 Setting of Servo Parameter Value
Kawasaki Robot External Axis Addition Manual

4 Setting of Servo Parameter Value

The servo parameter value settings vary depending on the selected amplifier, either KHI amplifier or
MITSUBISHI amplifier. This chapter describes the setting method for both types of amplifiers.

4.1 When Using KHI Amplifier

！ CAUTION
Turn OFF motor power before setting or modifying
servo parameter values.

Before modifying servo parameter values, load the servo parameter file provided with the robot.
For the system shipped after the setup by KHI, the servo parameter values are set at KHI in shipping
and servo parameter files are attached with the robot. When adding an external axis after the shipping
from KHI, it is necessary to load the servo parameter file. Servo parameter files differ according to
hardware types, which are provided by KHI. Contact KHI when the servo parameter values to load are
unknown.

Adjust servo parameter values according to the usage environment after servo parameter load.

When modifying servo parameter values, set [Operation Level] to 3 in the [Enable maintenance
function] screen via the teach pendant with reference to “3 Setting of External Axis Parameter Values”.

Then, select [Aux.2007 External Axis Servo Parameter].

There are two methods for adjusting external axis servo parameters: [1. Simple Tuning] and [2. Full
Spec Tuning]. Unless fine tuning of the servo parameter is necessary, we recommend only using [1.
Simple Tuning].

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4.1.1 Simple Tuning

Follow the procedure below to set parameter values in [Simple Tuning].

1. Enter the axis number to which parameter values are set and press <Next Page>.

2. Set [KV] and [Delay Time] in displayed screen as shown below. For details of [KV] and [Delay
Time], refer to “4.1.1.1 Tuning Gain Values (KV)” and “4.1.1.2 Setting Delay Time”.

4.1.1.1 Tuning Gain Values (KV)

Follow the procedures below to tune the gain for each axis.

1. Turn the motor power ON and move the axis slightly using the DEADMAN switch in teach mode.

！ CAUTION
1. Be careful when moving the robot because the adjustment of servo
parameter values has not been completed.
2. Always be ready to press the EMERGENCY STOP button when
turning ON the motor power after parameter setting.

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Kawasaki Robot External Axis Addition Manual

2. If the currently set value is not over oscillation (vibration) limit, turn OFF the motor power and
DEADMAN switch and enter a slightly higher value for [KV].

3. Continue trying steps 1 and 2 again until the limit is found.

[NOTE]
Oscillation limit is judged by sense of hearing and touch. Motor causes vibration and
sound if the axis exceeds its oscillation limit.

It may not be possible to raise the Gain (KV) for the following cases, and it is necessary
to adjust/modify the driving mechanism.
1. Not enough grease applied around gear  Grease the gear.
2. Backlash occurs  Adjust backlash.
If there is backlash, moving the corresponding axis will not cause vibration, but slight
vibration may occur by only pressing the DEADMAN switch (a beeping sound may
occur).

4. Turn the motor power OFF before going on to the next procedure.

5. From the oscillation limit recorded in step 3, calculate the gain (KV) using the following equation:
KV to set = KV at oscillation limit  0.32
(For example, if KV at oscillation limit is 300, and then KV value to set is 300  0.32 = 96.)

6. Enter the value from step 5 (96 in above example) as the gain (KV) for simple tuning in “Aux.2007
External Axis Servo Parameter-1. Simple Tuning” screen.

[NOTE]
1. When adjusting servo parameter values without jig and fixture or workpiece mounted,
set the gain a little high assuming the effect that the jig and fixture/workpiece will have
on robot motion. Change the constant (0.32) to a number greater than 0.32 and smaller
than 1 (e.g. 0.5 or 0.7) in the above equation.
2. After setting is complete, turn ON the motor power and check if the gain is appropriate
using the teach pendant.
3. If error “(E1124) Deviation error of Jt XX.” occurs, raise the parameter values of
PERLM in the “2. Full Spec Tuning” screen. PERLM sets the deviation error check
range.

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4.1.1.2 Setting Delay Time

Delay time is set at factory shipment, do not change this parameter value.

4.1.2 Full Spec Tuning

In [Aux.2007 External Axis Servo Parameter]-[2. Full Spec. Tuning], each of the parameter values can
be set manually.

1. Enter the axis number to be set and press <Next Page>.

2. Set parameter values in displayed screen as shown below.

！ CAUTION
1. Expert knowledge of how parameter value changes affect the behavior
of the servo system is needed in order to use this screen. Do not change
the parameter values except in special cases.
2. Always be ready to press the EMERGENCY STOP button when
turning ON the motor power after parameter setting.

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Kawasaki Robot External Axis Addition Manual

4.2 When Using MITSUBISHI Amplifier

This section explains the method for setting and modifying the servo parameter values.

Refer to the following documents issued by MITSUBISHI Electric Corp. for setting and modifying
servo parameter values. Hereinafter, the MITSUBISHI Electric Corporation issue document is referred
to as “Amplifier manufactured by MITSUBISHI Electric Corp. instruction manual”.
For J3 series: “MR-J3- B SERVO AMPLIFIER INSTRUCITON MANUAL (MODEL: MR-J3-B
INSTRUCTIONMANUAL)”
For J4 series: “MR-J4-_B SERVO AMPLIFIER INSTRUCITON MANUAL (MODEL: MR-J4-B
INSTRUCTIONMANUAL)”

！ CAUTION
Turn OFF motor power before setting or modifying servo
parameter values.

Before setting or modifying servo parameter values, ensure the servo parameter file provided with the
robot is loaded. Normally, it is loaded at factory shipment.

Set [Operation Level] to 3 in the “Enable maintenance function” screen via the teach pendant referring
to “3 Setting of External Axis Parameter Values”.

Select [Aux. 2007. External Axis Servo Parameter].

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E0x Series Controller 4 Setting of Servo Parameter Value
Kawasaki Robot External Axis Addition Manual

There are two methods for setting/adjusting external axis servo parameter values: [1 Simple Tuning
(Joint No.)] and [2 Full Spec Tuning (Joint No.)]. Select [1 Simple Tuning (Joint No.)] when adjusting
via auto tuning mode 1 or manual mode 1 by auto tuning*. Select [2 Full Spec Tuning (Joint No.)] to
use other auto tuning or to set each individual parameter value.

NOTE* To auto tuning, refer to parameter “ATU” in the “Parameters” chapter and the “General gain
adjustment” chapter in the “Amplifier manufactured by MITSUBISHI Electric Corp.
instruction manual”.

4.2.1 Simple Tuning

Follow the procedure below to set parameter values in [Simple Tuning].

Enter the axis number to be set and press <Next Page>. The following appears.

Select an auto tuning mode, and press <Next Page>.

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4.2.1.1 Auto Tuning Mode 1

J4 series (J3 compatible mode)

RSP* is set in [Auto tuning mode 1]. Pressing  registers the value set in [RSP]. If external axis motion
has delay compared with the robot motion after the adjustment of RPS, adjust KPCF3 on “Aux.2007-2
Full Spec Tuning” (see 4.2.2). Increase KPCF3 gradually up to about 30 until the delay of external axis
motion is eliminated.
NOTE* For RSP, refer to parameter “RSP” in the “Parameters” chapter and the “General gain
adjustment” chapter of “Amplifier manufactured by MITSUBISHI Electric Corp. instruction
manual”.

4.2.1.2 Manual Mode 1

J4 series (J3 compatible mode)

GD2, PG1, PG2, VG2 and VIC** are set in [Manual mode 1]. Pressing  registers the set value for
each parameter.
NOTE** For GD2, PG1, PG2, VG2 and VIC, refer to parameters “GD2”, “PG1”, “PG2”, “VG2”
and “VIC” in the “Parameters” chapter and the “General gain adjustment” chapter of
“Amplifier manufactured by MITSUBISHI Electric Corp. instruction manual”.

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4.2.2 Full Spec Tuning

In [2. Full Spec Tuning], all parameter values can be set.

Expert knowledge of how parameter value changes affect the behavior of the servo system is needed in
order to change parameter values in this screen. Do not change the parameter values except in very
special cases.

！ CAUTION
1. Expert knowledge of how parameter value changes affect the behavior of
the servo system is needed in order to use this screen. Do not change the
parameter values except in special cases.
2. Always be ready to press the EMERGENCY STOP button when turning
ON the motor power after parameter setting.

Enter the number of axis to which the parameter values are set and press <Next Page>.

J4 series (J3 compatible mode)

For J4 (J3 compatible mode) series, there are total of nine setting screens as shown below.
Page 1

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Page 2

Page 3

Page 4

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Page 5

Page 6

Page 7

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Page 8

Page 9

Refer to the “Parameters” chapter of “Amplifier manufactured by MITSUBISHI Electric Corp.

instruction manual” for the parameters in pages 1 to 8. Normally set 250 (ms) for No.2 “MBR” in page
3 (Group PC).

“FFCT” in the last page (Group SP) shows the set value of parameter “FFC” in teach mode. “KPCF3T”
is the set value of parameter “KPCF3” in teach mode. Both “FFCT” and “KPCF3T” are the parameters
used when external axes lag behind a robot in motion, and are used when changing values between
teach and repeat modes.

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E0x Series Controller 5 Cooperative Control Function
Kawasaki Robot External Axis Addition Manual

5 Cooperative Control Function

The robot and the external axes can be operated together via two different control functions,
synchronous control or cooperative control.
Synchronous control : External axes are used only for positioning the robot arm and robot arm
performs welding, etc.
Cooperative control : External axes and robot arm move together cooperatively to perform welding,
etc.

Cooperative control is the function which the synchronous control function is upgraded significantly.

Synchronous control

Welds by arm axes only

Linear axis only for robot arm positioning

Cooperative control

Welding by all axes including linear axis

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Cooperative control is classified into the 3 functions below. Each of these functions is described in
separate sections.
1. Linear axis cooperative function
2. Rotational cooperative function
3. Positioner cooperative function

5.1 Linear Axis Cooperative function

The cooperative function is most commonly used in applications where robot arm moves on a linear
axis. This axis must be parallel with one of the X, Y, or Z coordinate axes on either the base or tool
coordinate systems. Also, because this function cannot correct for mechanical parallelism error in the
traverse unit, machine precision of the linear axis must be ensured for the cooperative function to
operate accurately. Implementation and simultaneous operation of two or more linear axes is possible.
To set the linear axis cooperative function, refer to “3.1 Linear Axis Parameter Value Setting”.

5.1.1 Check of Linear Axis Cooperative Function

協調設定軸のみ動作
Only cooperative control set axes move.

For example, teach two points to only the linear axis to check, as shown above. Specify an absolute
velocity and drive the robot from first point (P1) to second point (P2).
If cooperative control is set properly,
robot travel time = distance P1 to P2/specified absolute velocity
Perform this check on every linear axis registered under cooperative control.

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5.2 Rotation Axis Cooperative Function

External axes move parallel in linear axis cooperation as described above, on the other hand, they rotate
in rotational cooperation. The figure below shows an example of the system of the external axes
including a rotation axis.

2. Up and down

1. Back and forth

3. Rotate

This system has two linear axes and one rotation axis. In linear/circular interpolation motion, the tool
center point can trace the specified path on the workpiece coordinates at the specified speed even when
the three external axes move simultaneously together with the robot arm. When using the rotation axis
cooperative function, comply with the restrictions below.
1. Center axis of rotation is perpendicular to robot base X-Y plane.
2. Only one rotation axis can be installed.

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5.2.1 Setting of Rotation Axis Cooperative Function

Setting of rotation axis cooperative function is described in “3.2 Rotation Axis Parameter Value
Setting”. This section describes how to calculate [Rotation Axis X/Y].

Rotation Axis X/Y

Enter the offset value(s) from the robot base coordinates to center of the rotation axis. When an external
axis other than the rotation axis is used, input the offset value when the external axis is at its home
position.

To calculate the X/Y values to the rotation axis, use “st_turne” program if [Setting Position] is set to
[End Pos.(ition)], or use “st_turn2e” program if [Start Pos.(ition)] is selected.
Load st_turne program from application file st_turne.pg.
Load st_turn2e program from application file st_turn2e.pg.

[NOTE]
When using one of these programs, observe these precautions.
1. Prior to using the program, register the tool data precisely.
2. Prior to using the program, set [Rotation Set] to [Off] in “Aux. 2002 External Axis”.
3. To calculate [Rotation Axis X/Y], teach the same point twice in different postures, as
shown below. Teach a point in space and turn the rotation axis, and then teach the
same point in a different robot posture. ([Setting Position] is set to [End Pos.(ition)]
in figure below.)
4. If linear axis is used in cooperation, the axis can be moved when teaching the 2
points. Keep non-cooperative linear axes at their home positions.
5. After program starts, follow instructions from the program.

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Posture
姿勢１ 1

Posture 2
姿勢２

Linear axis home position

走行軸原点
Y
X

Rotation
旋回軸原点 axis
home position

Procedure
Execute “st_turne” or “st_turn2e” as a PC program, in this example:
>PCEXECUTE st_turne
1. Enter the axis number to be used in cooperation, the rotating direction in this procedure, etc.
2. Mark a point in space so that it can be taught twice.
3. Teach the marked point as the first step. The [Rotation axis X/Y] is calculated more accurately the
farther the point is taught from rotation axis center.
4. Rotate axis as widely as possible, and then teach the marked point as the second step.

Enter the calculated X/Y values in [Rotation Axis X/Y] of “Aux. 2002 External Axis”. Set [Rotation
Set] to [On] to enable rotation axis cooperative function.

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5.3 Positioner Cooperative Function

This function is used to process workpieces set on and rotated by a positioner, for welding applications,
etc. In positioner cooperation, the tool center point can trace the taught path on the workpiece
coordinates in linear/circular interpolation motion. This function can operate on either a single or double
axis positioner. Examples below describe the setting process for a single-axis positioner with one
rotation axis and a double-axis positioner with rotation axis and tilting axis. In contrast to 5.2, where
robot changes tool pose while external axes move the arm, in the positioner cooperation robot changes
workpiece pose while external axes move the arm.

Rotation

Center impeller
positioner
Rotation
Left and right
Tilt
Traverse unit

Single-axis positioner
Double-axis positioner

5.3.1 Setting of Single-axis Positioner Cooperation

Select [Rotary Axis] for [Axis Type] in “Aux. 2002 External Axis” with reference to “3 Setting of
External Axis Parameter Values”.

Set [Rotation Set] to [Off], [Rotation Axis X] and [Rotation Axis Y] to “0,” [Setting Position] to [End
Pos.(ition)] and [Rotating direction] to [Y->X].

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Positioner cooperative function is effective for only one positioner. If several positioners are mounted,
do not move any non-cooperative positioner while cooperative positioner is moving with the robot.

To set cooperation with a single-axis positioner, perform the following three tasks. The following
sections describe the individual works.
1. Registration of Positioner Setting Position
2. Registration of Positioner Cooperation Start and End Axes
3. Check of Positioner Cooperation Setting

5.3.1.1 Registration of Positioner Setting Position

1. Display “Aux. 2003 External Axis Option” in the same way as Aux. 2002 and select [1. Positioner
Cooperation].

2. Prior to calculating positioner setting position, input 0 in [Start Joint No.] and [End Joint No.], and
press <Next Page>.

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3. In [Link Structure Registration] set the transformation values for all axes to 0 and press .

Use the “POS.SET2” program to calculate the positioner setting position. Load the POS.SET2 program
from application file SETPOS2E.PG.

[NOTE]
When using this program, observe these precautions.
1. If any linear axis is in cooperation, the linear axis does not need to be at its home position.
However, do not move the linear axis during registration of the positioner setting position.
2. Prior to using this program, register the tool data precisely.
3. When using this program, place nothing on the turntable.
4. Prior to using this program, move the positioner to its home position.
5. Prior to using this program, execute the following command after turning OFF motor power:
>ZSETPOS NULL
6. To calculate the positioner setting position, teach the same point on the positioner three times
in three consecutive steps, changing the posture of the positioner at each step.
7. After program starts, follow instructions from the program.

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Procedure
Execute the following program as a PC program:
>PCEXECUTE POS.SET2

1. Mark a point on the positioner.

2. Teach the marked point as the first step.
3. Rotate positioner widely in positive direction and teach the marked point as the second step.
4. Rotate positioner widely in positive direction again and teach the marked point as the third step.

Rotation 3

Positive Rotation 2
direction
Rotation 1

Marking position

Completing 1 to 4 above automatically creates the transformation values of “POS.STRUCT”.

Execute the following command after turning OFF the motor power:
>ZSETPOS POS.STRUCT

5.3.1.2 Registration of Positioner Cooperation Start and End Axes

After registering positioner setting position, register the start and end joint numbers to be used in
positioner cooperation.

Select [1. Positioner Cooperation] in “Aux. 2003 External Axis Option”. Enter the axis number of the
single-axis positioner in [Start Joint No.] and [End Joint No.].

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5.3.1.3 Check of Positioner Cooperation Setting

Use “POS.CHECK” program to check if positioner cooperation is set correctly.

[NOTE]
When using this program, note the following.
1. Prior to using this program, register the tool data precisely.
2. Teach a point to check the positioner position.
3. After program starts, follow instructions from the program.
4. If check shows positioner cooperation does not function properly, redo registration of
positioner setting position in “5.3.1.1 Registration of Positioner Setting Position” and
reregister positioner setting position.

Procedures
Execute the following program as a PC program:
>PCEXECUTE POS.CHECK

Teach a point on the positioner and mark the point. Move the positioner axis slightly. If any linear axis is
in cooperation, move it slightly.

This program creates the point “POS.CHK”. Move the robot to this point by JMOVE instruction, etc.
and check if robot reaches the marked point keeping the same orientation. Up to 5 mm deviation is
allowable.

5.3.2 Double-axis Positioner Cooperation

To set cooperation with a double-axis positioner, perform the following four tasks. The following
sections describe the individual works. In this example, JT7 is set for tilting axis and JT8 is set for
turntable.

1. Check of Positioner Rotating Direction and Dimensions

2. Registration of Positioner Setting Position
3. Registration of Positioner Cooperation Start/End Axes and Link Structure
4. Check of Positioner Cooperation Setting

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5.3.2.1 Check of Positioner Rotating Direction and Dimensions

1. Check the rotating direction of the turntable.

(a) Turntable rotating direction JT8+ (b) Turntable rotating direction JT8+

JT7+ JT7+

Tilting axis Tilting axis

Check if turntable rotates in direction (a) or (b).

2. Measure the positioner dimensions noted in the drawing.

len1

Measure len1 = distance between center of turntable and rotation center of tilting axis = noted in the
drawing.

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If the centerline of tilting axis does not intersect with turntable axis, measure the following dimensions.

Positioner (overhead view)

len2

Positioner (side view)

Turntable axis

len1

len2

Tilting axis

Measure len2 = distance between rotation center of tilting axis and turntable axis = noted in the
drawing. len2 must be perpendicular to len1.

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5.3.2.2 Registration of Positioner Setting Position

1. Select [1. Positioner Cooperation] in “Aux. 2003 External Axis Option”.

2. Prior to calculating positioner setting position, input 0 in [Start Joint No.] and [End Joint No.], and
press <Next Page>.

3. In [Link Structure Registration] set the transformation values for all axes to 0 and press .

Use the “POS.SET” program to calculate the positioner setting position. Load the POS.SET program
from application file SETPOSBE.PG.

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[NOTE]
When using this program, note the following.
1. If any linear axis is in cooperation, the linear axis does not need to be at its home
position. However, do not move the linear axis during registration of the positioner
setting position.
2. Prior to using this program, register the tool data precisely.
3. When using this program, place nothing on the turntable.
4. Prior to using this program, move tilting axis and turntable to their home positions.
5. Prior to using this program, execute the following command after turning OFF motor
power:
>ZSETPOS NULL
6. To calculate positioner setting position, teach the data of 6 points to 6 steps, 3 points on
the circumference of the turntable and a point on the turntable taught three times in
different tilting postures.
7. After program starts, follow instructions from the program.

Procedure
Execute the following program as a PC program:
>PCEXECUTE POS.SET

1. Teach 3 points on the edge of turntable in counter-clockwise order to calculate center of turntable.
(See figure below.) Keep the points as far apart as possible to obtain more accurate figures. Do not
move the tilting axis while teaching points.

2nd point 1st point

3rd point

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2. Calculate center of tilting axis. Mark a point on the turntable. Move the tilting axis in positive
direction and teach the marked point three times. Keep the points as far apart as possible to obtain
more accurate figures. As much as possible do not move the wrist axes at this time.
Tilting axis rotation 3

Tilting axis rotation 2

Tilting axis rotation 1

Positive
direction

Completing 1 to 2 above automatically creates the transformation values of “POS.STRUCT”.

Execute the following command after turning OFF the motor power:
>ZSETPOS POS.STRUCT

5.3.2.3 Registration of Positioner Cooperation Start/End Axes and Link Structure

After registering positioner setting position, register the start, end joint numbers and link the structure to
be used in positioner cooperation.

1. Select [1. Positioner Cooperation] in “Aux.2003 External Axis Option”.

2. Enter the first joint number to be used in positioner cooperation in [Start Joint No.], and the last joint
number to be used in [End Joint No.]. In this example, axes 7 and 8 respectively.

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3. Press <Next Page>. Enter transformation values for each axis following the steps below.

(1) Link structure registration for tilting axis

z1
x1

y1

x2
z2

y2 +

Enter the XYZOAT transformation values for coordinate system (x1,y1,z1) to coordinate system
(x2,y2,z2) which is the coordinate system of the tilting axis, JT7 in this example. Len1 and len2
are measured in step 2 of 5.3.2.1.

X Y Z O A T
0 ±len2 -len1 180 90 180

(2) Link structure registration for turntable axis

Setting varies according to the rotating direction of the turntable, noted step1 of 5.3.2.1.

Rotating in direction (a) +

x3
y3
z3
x2
z2

+
y2

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Enter the XYZOAT transformation values for coordinate system (x2,y2,z2) of tilting axis to
coordinate system (x3,y3,z3) of turntable axis, JT8 in this example.

X Y Z O A T
len1 ±len2 0 180 90 180

Rotating in direction (b)

+
z3
x3

y3
x2
z2

+
y2

Enter the xyzoat transformation values for coordinate system (x2,y2,z2) of tilting axis to
coordinate system (x3,y3,z3) of turntable axis, JT8 in this example.
x y z o a t
len1 ±len2 0 0 90 0

5.3.2.4 Check of Positioner Cooperation Setting

Use the “POS.CHECK” program to check if positioner cooperation is set correctly.

[NOTE]
When using this program, note the following.
1. Prior to using this program, register the tool data precisely.
2. Teach a point to check positioner position.
3. After program starts, follow instructions from the program.
4. If check shows positioner cooperation does not function properly, redo check
of positioner rotating direction and dimensions in “5.3.2.1 Check of
Positioner Rotating Direction and Dimensions”.

Procedure
Execute the following program as a PC program:
>PCEXECUTE POS.CHECK

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Teach a point on the turntable of the positioner and mark the point. Move the turntable axis and tilting
axis slightly. If any linear axis is in cooperation, move it slightly.

This program creates the point “POS.CHK”. Move the robot to this point by JMOVE instruction, etc.
and check if robot reaches the marked point keeping the same orientation. Up to 5 mm deviation is
allowable.

2. Move the tilting axis and turntable axis slightly. Then, move the robot
to the point POS. CHK created by program execution.

1. Mark a point. Turntable axis

Tilting axis

5.3.3 Troubleshooting for Positioner Cooperation

When some problems happen while using the positioner cooperation function, refer to the following
flowchart and take suitable measures. The problems include:
1. Tool center point (TCP) speed decreases during continuous path (CP) operation
2. Desired trajectory cannot be obtained.

Explanation of each item of the flowchart is shown in the following pages to the flowchart.

Following explanation is mainly given assuming the positioner cooperation in arc welding.
1. Statement after “Only in ARC welding:” is effective for application in arc welding.
2. For application other than arc welding, interpret the statement of “welding speed” as “speed”.

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Problem in positioner cooperation

1. Confirm the problem.

Confirm whether the problem occurs at low welding speed (1 cm/min) or not.

Does problem occur?

NO
YES

2. Confirm the positioner cooperation setting.

Confirm the positioner cooperation setting.

Is problem solved?
NO
YES

3. Tune servo parameter.

1) When using KHI amplifier, refer to “4.1.1 Simple Tuning”.
2) When using MITSUBISHI amplifier, refer to “4.2.1 Simple Tuning ".

Is problem solved?
YES
NO

4. Check the speed of TCP (Tool Center Point)

Check the speed of TCP by using data storage function.

Does speed of TCP fall? A

YES
NO
5. Check motion direction.
Check whether motion direction has large change or not.
Check the angle in base coordinates and in workpiece (world) coordinates.

Is problem solved?
YES
NO

12. Report to KHI. Problem is solved.

Report all details to KHI.

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6. Confirm the relation between positioner delay and TCP speed fall.
Check the speed of TCP after changing data of Aux.2104.

YES
Does speed of TCP fall? B

NO

7. Take countermeasures against the delay of positioner.

Reduce the positioner speed in either of two ways below.
(1) Increase distance between two points in workpiece (world) coordinates.
(2) Decrease the amount of positioner motion between two points.

Only in ARC welding:

If the delay does not satisfy the following formula, modify teaching to reduce the
positioner speed.
ABS(Vpos/2 + ERRpos) < ACCUpos - formura(1)

YES
Is problem solved?

NO
8. Adjust acceleration/deceleration time by ZARCACC command.
Only in ARC welding:
Adjust the time. TCP speed will slow down if the time is too long.

YES
Is problem solved?

NO
A 9. Change parameter value which determines whether robot waits positioner or not.
Only in ARC welding:
Use system switch (ARCCOMCOIN ON/OFF) in the problem step.
Use this switch after confirming the welding completion at lower welding speed.

YES
Is problem solved?

NO

12. Report to KHI. Problem is solved.

Report all details to KHI.

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5. Check motion direction.

Check whether motion direction has large change or not.
Check the angle in base coordinates and in workpiece (world) coordinates.

YES
Is problem solved?

NO

10. Check the speed of positioner.

If speed is too high, reduce positioner speed.
Only in ARC welding:
Check whether the speed of TCP satisfies the formula (1) or not.
ABS(Vpos/2 + ERRpos) < ACCUpos - formura(1)

YES
Is problem solved?

NO

11. Check the distance between two teaching points and weld speed.
Only in ARC welding:
Check whether the distance between two points satisfies the formula below or
not.
distance > weld_speed(cm/min) * 10/60 * Tzarcacc

YES
Is problem solved?

NO

12. Report to KHI. Problem is solved.

Report all details to KHI.

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1. Confirm the problem.

Confirm whether the problem occurs with low welding speed (approximately 1 cm/min) or not.
If the problem also occurs with low welding speed, it is supposed that the setting for the positioner
cooperation is unsuitable.

2. Confirm the positioner cooperation setting.

Refer to “5.3.1.3 Check of Positioner Cooperation Setting” for single-axis positioner or “5.3.2.4
Check of Positioner Cooperation Setting” for double-axis positioner and check the positioner
cooperation setting again.

3. Tune servo parameter.

When the external axis motion has delay compared with the robot motion, at first confirm the servo
tuning.

(1) When using KHI amplifier

1) Aux.200701 Simple Tuning
Refer to “4.1.1 Simple Tuning” and confirm the servo tuning.

2) Aux.2104 Feed-Forward parameter

Check for the setting difference between JT1 and the external axis about KVFF/KAFF in
“Aux.2104 Feed-Forward parameter”.
If the two values are not same, change KVFF/KAFF for the external axis to the same value as
that of JT1. Do not change KVFF/KAFF for robot axes of JT1 to JT6.

(2) When using MITSUBISHI amplifier

1) Simple Tuning
Refer to “4.2.1.1 Auto Tuning Mode 1” and confirm the parameter value. Adjust servo
response setting parameter (“RPS”).

2) Aux.200702 Full Spec. Tuning

Adjust parameters “KPCF3” and “KPCF3T”. These parameters show the constant to the
command value at the time of third filtering, and KPCF3 is valid in repeat mode and KPCF3T
in teach mode. When the external axis has a delay, increase these parameter values gradually
up to 30 and confirm the effect.
Parameters “FFC” and “FFCT” are also valid when the external axis has a delay. FFC is valid
in repeat mode and FFCT in teach mode. For details of “FFC” and “FFCT”, refer to the
“Parameter” chapter in the “Amplifier manufactured by MITSUBISHI Electric Corp.
instruction manual”.

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4. Check the speed of TCP (Tool Center Point).

Check whether the speed of TCP falls or not near the teaching point by using data storage function or
“where 16” command.

5. Check motion direction.

Check whether motion direction has large change or not in base coordinates and also in workpiece
(world) coordinates.

Check the change in welding direction (motion direction) using the following program “deg”.
.PROGRAM deg()
POINT fr = FRAME(degp[0],degp[1],degp[2],degp[0])
x = DX(-fr+degp[2])
y = DY(-fr+degp[2])
ang = ATAN2(y,x)
.END
Each point in program “deg” is as shown in the following figure.
degp[1]

ang
degp[2] degp[0]

Angle from 0 to 90, or from 270 to 360 is not good. If the angle is not good, modify teaching point
because the angle change is too large.

6. Confirm the relation between positioner delay and TCP speed fall.
(1) In ARC welding application
Change the value of [LIMIT OF COINCEDENCE BY CUR.POS.] in Aux.2102 to 0.9 mm, and
check the speed of TCP around the teaching point during welding. (Record the current set value
before changing the value of [LIMIT OF COINCEDENCE BY CUR.POS.] to 0.9 mm. Default
value of [LIMIT OF COINCEDENCE BY CUR.POS.] is 3.0 mm.)

If the speed of TCP does not fall with 0.9 mm setting, the problem is due to the delay of the
positioner.

After check, set the value of [LIMIT OF COINCEDENCE BY CUR.POS.] to original value
before this check.

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(2) In other application

Log joint command value and current joint value by data storage function, and compare delays.
When the delay of positioner is larger than that of robot axes, the delay of positioner may cause
the problem. In this case, go to “NO” in next branch of flowchart at first. If problem cannot be
solved, check also “YES” in next branch of flowchart.

7. Take countermeasures against the delay of positioner.

Reduce rotation speed of the positioner to remedy the all of TCP speed if the positioner delay is the
cause of the fall.

Reduce rotation speed of positioner in either of following two ways.

(1) Increase the distance between two teaching points in workpiece (world) coordinates.
(2) Decrease the amount of positioner motion between two teaching points.

Only in ARC welding:

In weld steps of arc welding, robot moves at constant acceleration and deceleration time.
(Acceleration and deceleration time are set by ZARCACC command.) The accuracy at the middle
weld point is 50 mm, and robot moves to the next step after reaching the point within regulated
accuracy (50 mm) from the taught point.

Accordingly, if the positioner has large delay, the arrival of robot within 50 mm delays and there is a
possibility of the deceleration of TCP.

When the delay (ERRpos) of the positioner does not satisfy the following formula (1), the TCP speed
may fall. Modify teaching so that delay becomes within the limit.

ABS(Vpos/2 + ERRpos)<ACCUpos -- formula (1)

ERRpos = CMDpos – FBpos

Vpos = (CMDpos(i)-CMDpos(i-1))*Tzarcacc/Tsamp
ACCUpos = 50 * 360/(2 * π * Rextaxis)
Rextaxis = 250/VMAXpos/(π/180)/TRratio * 100

ERRpos:
Delay of positioner axis (unit: degree)
CMDpos:
Position command value of positioner axis (unit: degree)
([JT command] in data storage function)

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CMDpos(i):
Position command value of positioner axis at a certain time (unit: degree)
FBpos:
Current position of positioner axis (unit: degree)
([JT angle] in data storage function)
Vpos:
Velocity of position command for positioner axis (unit: degree/s)
Tzarcacc:
Acceleration and deceleration time at arc welding steps (default value: 128 ms) (unit: ms)
Tsamp:
Sampling cycle of position command values (unit: ms) ([Time Interval Setting] in data
storage function)
TRratio:
[Teach/Repeat ratio] in Aux. 2002 (unit: %) (The value of [Equivalent radius] is used as the
value of Rextaxis when there is no [Teach/Repeat ratio].)
VMAXpos:
[Max speed] in Aux. 2002 (unit: degree/s)
ACCUpos:
Accuracy for positioner axis (50 mm)

Rextaxis:
Equivalent radius of positioner axis (unit: mm) (Set value of [Equivalent radius] in Aux.
2002 or calculated value from TRratio.)

CMDpos and FBpos are obtained by data storage function.

If the delay does not fill the formula (1), modify teaching to reduce speed of positioner.

Reduce speed in either of following two ways.

(1) Increase the distance between two teaching points in workpiece (world) coordinates.
(2) Decrease the amount of positioner motion between two teaching points.

Also, calculate the speed of the positioner as follows.

Motion time of positioner = (distance of two teaching points in workpiece (world)
coordinates)/(welding speed)
Speed of positioner = (amount of positioner motion between two teaching points)/ (motion
time)

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[NOTE]
1. To calculate distance of two teaching points on workpiece (world) coordinates, use
TRADD and DISTANCE functions.
2. When using TRADD function, set positioner cooperation parameters correctly.
When using separate control function, set the group with positioner cooperation
parameters to calculate and use the TRADD function.

8. Adjust acceleration/deceleration time by ZARCACC command.

Only in ARC welding:
By increasing the acceleration/deceleration time, deceleration becomes gradual. Accordingly,
ERRpos on formula (1) at teaching point becomes smaller and the effect to the delay becomes
smaller. As a result, the fall of TCP speed is expected to be recovered.

On the other hand, Vpos on formula (1) becomes larger by increasing the acceleration/ deceleration
time. Accordingly, there is also a possibility of the fall of TCP speed if the acceleration/deceleration
time is too large.

Adjust acceleration/deceleration time as follows.

(1) ZARCACC command can set the time up to 50000 ms. Default value is 128 ms.
(2) Change the acceleration/deceleration time gradually up to 1000 mm and confirm the effect.

9. Change parameter value that determines whether robot waits positioner arrival or not.
Only in ARC welding:
Change the setting whether robot waits the axis coincidence of positioner or not by system switch
(ARCCOMCOIN ON/OFF) in the problem step.

ARCCOMCOIN OFF:
Robot waits positioner arrival on teaching point. Default setting.

ARCCOMCOIN ON:
Robot does not wait positioner arrival on teaching point and moves to the next step after the axis
coincidence by the command value.

Before making the ARCCOMCOIN ON, ensure that the teaching is appropriate so that, with the
ARCCOMCOIN OFF, good welding result is obtained in about half of the goal welding speed. Then,
make the ARCCOMCOIN ON.

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10. Check the speed of positioner.

If positioner speed is too high, the TCP speed may fall. Change teaching as follows.
(1) Increase the distance between two teaching points in workpiece (world) coordinates.
(2) Decrease the amount of positioner motion between two teaching points.

Only in ARC welding:

Confirm whether the speed of TCP satisfies the condition of formula (1) or not.
ABS(Vpos/2 + ERRpos) < ACCUpos - formula(1)
See “7. Take countermeasures against the delay of positioner.” about formula (1).

For ARC welding application, following changes also has possibility of improvement.
(1) Reduce welding speed.
(2) Decrease acceleration/deceleration time at middle welding point by ZARCACC command.
However, if the time is too short, vibration will occur.

11. Check the distance between two teaching points and welding speed.
Only in ARC welding:
Confirm whether the distance between two teaching points satisfies the following formula or not.
(See “7. Take countermeasures against the delay of positioner.” about Tzarcacc.)

distance > welding speed(cm/min) * 10/60 * Tzarcacc - formula (2)

If distance is too short, change teaching as follows.

(1) Increase the distance between two teaching points in workpiece (world) coordinates.
(2) Reduce welding speed.

12. Report details to KHI.

If the problem cannot be solved by the above countermeasures, report all details including robot
model, controller model, machine number, AS/servo software versions, the contents of program lists
and operation in occurrence, any options, etc. to KHI

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6 Endless Positioner Function

This function enables a turntable positioner to rotate continuously in one direction. In previous systems,
when positioner rotated for a circumferential weld, reverse rotation would be required before starting the
next circumferential weld. This function eliminates the need for reversing by specifying a rotation count
to the turntable. This saves time, especially if application rotates positioner many times in one direction
or if the positioner can only rotate slowly.
この部分を省略できる
1周回し溶接 Reverse rotation not required
Weld a circle 逆転１周

6.1 Setting of Endless Positioner Function

Select [2. Endless Positioner Function] in “Aux. 2003. External Axis Option”.

Endless JT No.
Input axis number to be applied with the endless positioner rotation function.

Reduction ratio (r=n2/n1)

n1: (1 to 100000) n2: (1 to 1000)
Input the reduction ratio. Do not round off values, otherwise deviation increases when positioner rotates
many times.

For system with several external rotation axes, press <Prev Page>/<Next Page> to change screens and
set data for each rotation axis.

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6.2 Setting a Rotation Number by RTSET Command/Instruction

When an endless positioner axis is taught to move continuously in one direction (e.g. from 0 to
30000), repositioning by reverse rotation (from 30000 to 0) will be necessary after completing each
work. Using RTSET Command/Instruction of AS language makes it possible to change the current
position data to some desired number of rotations from 0 (in this example, near 0) without actually
moving the endless positioner axis.

Example program

#a positioner axis position＝0

#b positioner axis position＝30000

JMOVE #a Moves endless positioner axis to 0 (Starting position).

JMOVE #b Moves endless positioner axis to 30000.

RTSET 0 Sets the current position of endless positioner axis to 120.

(360 into 30000  83, remainder 120)
JMOVE #a Moves remaining 120 to the starting position.

For details on RTSET Command/Instruction, refer to next page.

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Monitor Command
Program Instruction

RTSET Rotation number

Function
Forcibly changes the current position data of the spin or external rotation axis to correspond to the
position specified by the number of rotations from 0°.

Parameter
Rotation number
Sets the rotation number for specifying the number of rotations from 0° by real-value formula. Setting
range is integer of -100 to 99 (Varies with robot and application.).

Explanation
The current position data of JT6 or external rotation axis in the robot is forcibly changed to the position
corresponding to the specified rotation number. In appearance the position after change is not identical
to that before change, but the rotation number from the origin point differs. In short, neither robot nor
external rotation axis actually moves at this time, but the current position data displayed after that
corresponds to the specified rotation number.

When this instruction is executed in the program, robot stops temporarily and forcibly changes the
current position data in calculation after completing the previous motion instruction.

In programs where the spin or external rotation axis is spun many times in one direction, RTSET is a
convenient means of resetting current position data back into the middle of motion range limits. This
eliminates the need to actually backspin the axis and thus saves time.

Example
RTSET 0 For example, if current position is 3620° when executing this instruction,
it becomes 20°.
360° into 3620° = 10, remainder 20°

RTSET 10 For example, if current position is -90° when executing this instruction,
it becomes 3870°.
-90° is 270° in rotation number 0 (0° to 360°)
270° + (360°  10) = 3870°

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Monitor Command
Program Instruction

SPINAXIS Axis number

Function
Switches axis to be operated as spin/endless rotation positioner axis for which monitor
commands/program instructions for endless rotation such as RTSET etc. is executed.

Parameter
Axis number
Sets the external axis number. Setting range is 7 to 7 + number of endless rotation axes (Varies with
robot and application.). This setting is effective only for external rotation axis.

Explanation
Switches axis to be operated as spin/endless rotation positioner axis. After switching, instructions such
as RTSET etc. are executed for the specified axis.

When this instruction is executed in the program, robot stops temporarily and changes the endless
rotation axis to be operated after completing the previous motion instruction.

This instruction is used to move several spin/endless rotation positioner axes.

Example
SPINAXIS 7
RTSET 0 When executing this instruction, RTSET is executed for JT7.

SPINAXIS 8
RTSET 10 When executing this instruction, RTSET is executed for JT8.

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7 Dual Servo Function

This function allows two motors to be controlled as one axis of the robot. This is useful if the application
requires two motors to perform work, because load exceeds single motor specification, etc.

This function designates one external motor axis as the master joint and transfers control of the other
motor axis as slave joint to the master. Moving the master joint causes simultaneous motion in the slave
joint. This provides one additional degree of freedom to the robot even though in the hardware there are
two additional axes.

7.1 Setting of Dual Servo Function

1. Select [3. Dual Servo] in “Aux. 2003 External Axis Option”. Select [1. Dual Servo Setting] in the
displayed screen as shown below.

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2. Set the data in the screen below.

Master Joint No.

Enter the axis number to be designated as master joint. Highest axis number in the system is
automatically set as slave joint. Dedicate only one master joint number for dual servo function, two or
more Master joint numbers cannot be set.

Bumpless Velocity/Repeat Max Velocity (%)

Enter ratio of bumpless velocity to maximum repeat velocity.* Normally, this parameter requires no
changing.

Between Master-Slave Joints

Sets the PI controller gain to eliminate deviation between the current position feedback values from the
master and slave joints. Normally, these parameters require no changing.
P-Gain: Enter proportional gain.
I-Gain: Enter integral gain.

NOTE* At servo ON, the Bumpless feature compensates deviation in the master and slave joints over a
fixed time period. At Motor Power OFF, Hold ON, and Emergency Stop, deviation may arise
between command and current values in both the master and slave joints. In axes not set for
dual servo, large deviation of this kind is normally resolved by converting the command value
into the current value so that the axes do not move at servo ON. However, in a dual servo
system the slave command value is determined as master command value + an offset value
(described later), and the slave joint may bump and move suddenly at servo ON if deviation is
large. So, for the slave joint, if the difference between its command and current values exceeds
the certain level, the slave command value is changed to the slave current value at servo ON,
and then over a fixed time period the slave command value converts back to the original
command value calculated from the master joint.

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7.2 Tuning of Dual Servo Function

This section describes how to tune the dual servo function. Detailed use of this tuning function is
explained below.

Tuning run mode

Use this mode to correct deviation arising between master and slave joints, at time of system installation
and due to some abnormality, etc. Pressing the AXIS keys of master joint on teach pendant moves both
master and slave joints. In tuning run mode, pressing AXIS keys of slave joint moves only slave joint
(normally it will not move).

Master/slave joint offset

Slave joint can be automatically given an offset value to the master joint. Offset is normally set to 0
except when:
1. completing Tuning run mode, the deviation is automatically set as offset value.
2. zeroing, offset value is set to 0.

7.2.1 Setting of Dual Servo Tuning Run Mode

Set tuning run mode via auxiliary function or by executing ZDUAL command. Turning OFF/ON the
controller power cancels tuning run mode.

1. Setting tuning run mode via auxiliary function

(1) Select [3. Dual Servo] in “Aux. 2003 External Axis Option”. Select [2. Tuning Run Mode
Setting].

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(2) Selecting [Enable] activates tuning run mode. Selecting [Disable] ends tuning run mode.

2. Setting tuning run mode by ZDUAL command

Executing the following commands enables and disables tuning run mode.
>ZDUAL ON: Enable
>ZDUAL OFF: Disable

7.2.2 Tuning Procedure for Dual Servo Function

Follow the procedures below to tune dual servo function.

1. Align both joints to the zeroing position specified in the drawing or visually.
2. Execute zeroing.
3. Enable Tuning run mode in teach mode.
4. Move both joints while checking their current values on the Axis monitor screen of teach pendant.
Move slave joint so as to minimize current deviation between the two joints.
5. Disable Tuning run mode.
6. Zero master/slave joint again so the offset value between the joints becomes 0.

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E0x Series Controller 8 J3/J4 Series MITSUBISHI Amplifier
Kawasaki Robot External Axis Addition Manual

8 J3/J4 Series MITSUBISHI Amplifier

This chapter describes the setting method and troubleshooting when using the J3/J4 series
MITSUBISHI amplifier.

Select [9. Mitsubishi amp. setting] in “Aux. 2003 External Axis Option”. Select [1. Series setting] on the
next screen to be displayed.

When using the J3/J4 series, select [J4 series(J3 compatibility mode)] and press . When series setting
is changed, a message “(W1008) Parameter changed. Turn OFF & ON the control power.” is displayed,
so turn OFF/ON the controller power.

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8.1 Home Position Setting

In the J3/J4 series, appropriate encoder values cannot be obtained without setting the home position. For
the MITSUBISHI amplifier, home position setting means operations to set the home position. The term
“home position” here indicates the home position used inside the MITSUBISHI amplifier and differs
from those of Zeroing (Aux. 501) and Home Position (Aux. 402).

When connecting the MITSUBISHI amplifier for the first time or disconnecting the backup battery line,
the home position needs to be set in order to obtain appropriate encoder values if the absolute position
on the MITSUBISHI amplifier is erased due to the encoder battery voltage drop, etc. Execute zeroing
after the home position setting.

！ CAUTION
Battery backup of encoder values:
Encoder values are erased immediately if a battery backup line of the
encoder is disconnected for J3/J4 series. See “2.1.1 Necessary
Hardware for MITSUBISHI Motor” for details.

8.1.1 Executing the Home Position Setting

Select [9. Mitsubishi amp. setting] in “Aux. 2003 External Axis Option”. Select [2. Home position
setting] on the next screen to be displayed.

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A message “Absolute position is erased.” is displayed for the axis whose appropriate encoder value
cannot be obtained.

1. Specifying the axis to execute

Specifies the axis number to execute the home position setting in [Joint No.].
Specifying 0 in [Joint No.] executes the home position setting for all axes in which MITSUBISHI
amplifier is used. When executing the home position setting again for the axis whose home position
setting has been executed, the encoder value obtained from the MITSUBISHI amplifier does not
change before and after the execution.

2. Operation method in execution

After specifying the axis number, turn ON the motor power in teach mode and servo ON by
pressing DEADMAN on the TP. Pressing  with the above home position setting screen displayed
under the condition executes the home position setting. The message “Absolute position is erased”
disappears when the home position setting is completed normally.

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A message is displayed as shown in the screen below to prompt to execute the home position
setting after servoing ON if the home position setting is executed without executing servoing ON.

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8.2 Cautions When Connecting MITSUBISHI Amplifier/Motor for the First Time

This section describes cautions when connecting MITSUBISHI amplifier/motor for the first time.

8.2.1 Switching of Setting on MITSUBISHI Amplifier (J3 Compatible Mode)

An error “(D2039) (SSCNET)Communication error on JtXX at initialization.” may occur when

connecting the amplifier/motor to the robot controller for the first time. D2039 error also occurs by other
factors. See “8.3 Errors” for details of other factors.

Robot controller is used with the MITSUBISHI amplifier set in J3 compatible mode, and D2039 error
occurs if the MITSUBISHI amplifier is not set in the mode. Turning OFF/ON the controller power is
required to switch to J3 compatible mode.

There are two cases to switch the settings on the MITSUBISHI amplifier: settings of all axes are
switched and setting of one axis is switched when turning OFF/ON the controller power, which
depends on the software version of the MITSUBISHI amplifier.

“E7” is displayed on 7-segment display for the MITSUBISHI amplifier which has been activated
properly after switching to J3 compatible mode. “Ab” is displayed on the 7-segment display when not
in J3 compatible mode.

8.2.2 Occurrence of Absolute Position Erasing Error

Turn OFF/ON the controller power when the error “(D1533) (SSCNET)Absolute position of JtXX is
erased.(Code25)” occurred at the time of controller power ON. This error always occurs at the time of
the first connection.

8.2.3 Execution of Home Position Setting

Execute the home position setting according to the procedure in 8.1 because the home position setting is
required when connecting for the first time.

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8.3 Errors

This section describes the information of errors specific to J3/J4 series and messages.
When several countermeasures are mentioned, execute the countermeasures from the top and execute
the next one if the error cannot be resolved.

D1532 (SSCNET)Encoder communication error.(JtXX)(CodeXX)

Contents
1. Communication error occurred between MITSUBISHI amplifier and encoder. CodeXX at the end
indicates the alarm number of the MITSUBISHI amplifier.

Causes
1. Refer to the Troubleshooting in “Amplifier manufactured by MITSUBISHI Electric Corp.
instruction manual”, which mentions causes per alarm number.

Countermeasures
1. Refer to the Troubleshooting in “Amplifier manufactured by MITSUBISHI Electric Corp.
instruction manual”, which mentions countermeasures per alarm number.

D1533 (SSCNET)Absolute position of JtXX is erased.(Code25)

Contents
1. The encoder absolute position of MITSUBISHI amplifier has been erased.

Causes
1. Power was applied for the first time.
2. Encoder battery was replaced with the controller power OFF.
3. See the cause of alarm number 25 in Troubleshooting in “Amplifier manufactured by
MITSUBISHI Electric Corp. instruction manual” for other details.

Countermeasures
1. Turn OFF/ON the controller power. See the countermeasures of alarm number 25 in
Troubleshooting in “Amplifier manufactured by MITSUBISHI Electric Corp. instruction manual”
for details.

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D1581 (SSCNET) Alarm of JtXX error (code XX)(Servo alarm)

(SSCNET) Alarm of JtXX error (code XX)(Operation alarm)

Contents
1. Servo or operation alarm was generated on MITSUBISHI amplifier. Code XX in the error message
indicates the alarm number of the MITSUBISHI amplifier.

Causes
1. For the cause of servo alarm, refer to the Troubleshooting in “Amplifier manufactured by
MITSUBISHI Electric Corp. instruction manual”, which mentions causes per alarm number.
2. There are some abnormalities on the operation alarm, which normally do not occur.

Countermeasures
1. For the countermeasures of the servo alarm, refer to the Troubleshooting in “Amplifier
manufactured by MITSUBISHI Electric Corp. instruction manual”, which mentions
countermeasures per alarm number.
2. First, reset the error as countermeasures of the operation alarm.
Turn OFF/ON the controller power if the error is not resolved after the error reset. If this error
occurs after turning OFF/ON the controller power, report all details to KHI, including information
of all messages, robot model, controller model, machine number, AS/servo software versions,
operation at the time of error occurrence, the contents of program lists, equipped options, etc.

D2028 (SSCNET)Initialization error. (Code0xXX)

Contents
1. Error occurred during activation processing of the I/F board.

Causes
1. Error occurred during activation processing of the I/F board for some reason.

Countermeasures
1. Turn OFF/ON the controller power if the error is not resolved after the error reset. If this error
occurs after turning OFF/ON the controller power, report all details to KHI, including information
of all messages, robot model, controller model, machine number, AS/servo software versions,
operation at the time of error occurrence, the contents of program lists, equipped options, etc.

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D2038 (SSCNET)Interface board is not installed.

Contents
1. I/F board of MITSUBISHI amplifier was not detected.

Causes
1. The I/F board of the MITSUBISHI amplifier (J3/J4:MR-MC210-S02) was not mounted.

Countermeasures
1. Mount the I/F board of the MITSUBISHI amplifier properly. See “4. SSCNET-III I/F board” in
2.1.2. Implement the next countermeasures if the mounting method is appropriate.
2. Check series settings via “1. Series setting” in Aux. 200309 “Mitsubishi amp. setting”. If the series
supporting the I/F board is set, implement the next countermeasures.
3. Replace the I/F board.

D2039 (SSCNET)Communication error on JtXX at initialization.

Contents
Communication error occurred during the initialization of MITSUBISHI amplifier axis.

Causes
1. The SSCNET cable between robot controller and MITSUBISHI amplifier is not connected.
2. Software settings (channel number in Aux. 2002 “External Axis”) and hardware settings
(MITSUBISHI amplifier: Axis selection rotary switch (SW1)) do not match.
3. Setting of J4 series amplifier is not in J3 compatible mode (only J4 series). See “8.2.1 Switching of
Setting on MITSUBISHI Amplifier (J3 Compatible Mode)” for details.

Countermeasures
1. Check the connection between the robot controller and the MITSUBISHI amplifier axis. See “5.
SSCNET-III cable connection, battery mounting, ground” in 2.1.2. If the connection is appropriate,
implement the next countermeasures.
2. Check if the settings of software and hardware match. See the section of channel number in “3.1
Linear Axis Parameter Value Setting”. If the settings are appropriate, implement the next
countermeasures.
3. Turn OFF/ON the controller power.

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D2073 (SSCNET)System alarm occurred in I/F board. (code XX)

Contents
1. System error occurred in SSCNET I/F board.

Causes
1. “(Code XX)” at the end indicates the error element of the system alarm, which does not occur
normally.

Countermeasures
1. Reset the error.
Turn OFF/ON the controller power if the error is not resolved after the error reset. If this error
occurs after turning OFF/ON the controller power, report all details to KHI, including information
of all messages, robot model, controller model, machine number, AS/servo software versions,
operation at the time of error occurrence, the contents of program lists, equipped options, etc.

W2972 (SSCNET)Absolute position of JtXX is erased. Set home position.

Contents
1. The absolute position of encoder has been erased, and home position is needed to be set.

Causes
1. The absolute position of encoder has been erased.

Countermeasures
1. Execute the home position setting, referring to “8.1 Home Position Setting”.

P2116 (SSCNET)Turn ON servo before executing home position setting.

Contents
1. Home position setting cannot be executed because the servoing was OFF when executing the home
position setting.

Causes
1. Home position setting was executed while servoing OFF.

Countermeasures
1. Servo ON when setting the home position. Refer to “8.1 Home Position Setting” for details.

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P2118 (SSCNET)Absolute position is erased. Set home position.

Contents
1. The absolute position of encoder has been erased, and home position is needed to be set.

Causes
1. It was attempted to execute a program while the absolute position of encoder was erased.

Countermeasures
1. Execute the home position setting, referring to “8.1 Home Position Setting”.

E1160 (SSCNET)Servo error and monitor setting error of JtXX.

Contents
1. Monitor function of MITSUBISHI amplifier was abnormal.

Causes
1. Monitor function settings of the MITSUBISHI amplifier became abnormal for some reason.

Countermeasures
1. Reset the error.
Turn OFF/ON the controller power if the error is not resolved after the error reset. If this error
occurs after turning OFF/ON the controller power, report all details to KHI, including information
of all messages, robot model, controller model, machine number, AS/servo software versions,
operation at the time of error occurrence, the contents of program lists, equipped options, etc.

E1452 (SSCNET)JtXX is out of the in-position range.

Contents
1. Home position setting was not completed because the axis did not enter the in-position range within
the specified time.

Causes
1. The axis did not enter the in-position range within the specified time. Refer to “Amplifier
manufactured by MITSUBISHI Electric Corp. instruction manual” for details of the in-position.

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Countermeasures
1. Reset the error. Execute the home position setting again after the reset.
Turn OFF/ON the controller power if the error is not resolved after the error reset. If this error
occurs after turning OFF/ON the controller power, report all details to KHI, including information
of all messages, robot model, controller model, machine number, AS/servo software versions,
operation at the time of error occurrence, the contents of program lists, equipped options, etc.

E1453 (SSCNET)Failed to set home position of JtXX

Contents
1. Home position setting has been failed.

Causes
1. Home position setting was failed due to servoing OFF while the home position is being set.
2. The axis did not enter the in-position range.

Countermeasures
1. Reset the error. Execute the home position setting again after the reset.
Turn OFF/ON the controller power if the error is not resolved after the error reset. If this error
occurs after turning OFF/ON the controller power, report all details to KHI, including information
of all messages, robot model, controller model, machine number, AS/servo software versions,
operation at the time of error occurrence, the contents of program lists, equipped options, etc.

E1454 (SSCNET)Interface board access error. (address +XXh)

Contents
1. Access to the I/F board of MITSUBISHI amplifier was failed.

Causes
1. Error occurred while accessing to the I/F board from the main CPU board for some reason

Countermeasures
1. Reset the error.
Turn OFF/ON the controller power if the error is not resolved after the error reset. If this error
occurs after turning OFF/ON the controller power, report all details to KHI, including information
of all messages, robot model, controller model, machine number, AS/servo software versions,
operation at the time of error occurrence, the contents of program lists, equipped options, etc.

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Appendix Examples of External Axes

For your reference, examples showing typical system installations of robot arm + external axes are
given on the following pages.

When actually adding an external axis, make sure that motor and brake capacity do not exceed the
restrictions in “1.4 Check of Brake Current, Average Consumption Power and Average Regenerative
Power”.

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E0x Series Controller Appendix Examples of External Axes
Kawasaki Robot External Axis Addition Manual

Example 1: Type 1 (E01/E02 controllers)

No. of additional 1 (Linear axis: 1 axis)

axes
Motor capacity Linear axis: 1.5 kW  1

Standard
controller
(E01/E02
controllers)

M1 M2

Construction Robot
S1 S2

M3 S3

Motor Linear axis

Fixed motor/signal harness

Movable motor/signal harness

Motor 1.5 kW (SANYO) 50601-1366×1

Additional parts M2 motor harness ×1
S2 signal harness ×1
M3 motor harness ×1
S3 signal harness ×1

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E0x Series Controller Appendix Examples of External Axes
Kawasaki Robot External Axis Addition Manual

Example 2: Type 2-1 (E03 controller) CP series

No. of additional 1 (Hand axis: 1 axis)

axes
Motor capacity Hand axis: 1.5 kW

Standard
Controller
(E03 controller)

Construction
M1
CP series robot Motor
S1

Hand axis

Fixed motor/signal harness

Additional parts Motor 1.5 kW (SANYO) 50601-1366×1

KHI external axis amplifier 50607-0128×1
JT8/JT B addition harness set (E03) 49094-0331×1

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E0x Series Controller Appendix Examples of External Axes
Kawasaki Robot External Axis Addition Manual

Example 2: Type 2-2 (E03 controller) RD80N

No. of additional 1 (Linear axis: 1 axis)

axes
Motor capacity Linear axis: 1.5 kW  1

Standard
Controller
(E03 controller)

M1 Robot
M2 X104
1HG
Construction S1 S2
XHG-CN2
(E03 JT8)
M3 S3

Motor Linear axis

Fixed motor/signal harness

Movable motor/signal harness

Motor 1.5 kW (SANYO) 50601-1366×1

M2 motor harness ×1
Additional parts S2 signal harness ×1
M3 motor harness ×1
S3 signal harness ×1
KHI external axis amplifier 50607-0128×1

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E0x Series Controller Appendix Examples of External Axes
Kawasaki Robot External Axis Addition Manual

Example 3: Type 3 (E01/E02/E04 controllers)

No. of additional 1 (Positioner: 1 axis)
axes
Motor capacity Positioner: 2.0 kW  1

(F)
Standard AM0
controller AS0 Motor Positioner
CB
(E01/E02/E04 AS1
controllers)

Construction

M1
Robot

S1
Fixed motor/signal harness
Movable motor/signal harness

Motor 2.0 kW (SANYO) 50601-1490×1

KHI external axis amplifier 50607-0128×1
JT8/JT B addition harness set 49094-0315×1
Additional parts External axis addition part set (ferrite core) 49094-0257×1
Connection box with 1HG board 50326-1093×1
AM0 motor harness ×1
AS0 signal harness ×1
AS1 signal harness ×1

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E0x Series Controller Appendix Examples of External Axes
Kawasaki Robot External Axis Addition Manual

Example 4: Type 4 (E01/E02/E04 controllers)

No. of additional 2 (Positioner: 2 axes)

axes
Motor capacity Linear axis: Positioner: 1.5 kW  2

(F)
Standard AM0
controller AS0 Motor Positioner
CB
(E01/E02/E04 AS1
AM0
controllers)
AS0 Motor Positioner
CB
AS1

Construction

M1
Robot
S1
Fixed motor/signal harness
Movable motor/signal harness

Motor 1.5 kW (SANYO) 50601-1366×2

KHI external axis amplifier 50607-0128×2
JT8/JT B addition harness set 49094-0315×1
JT9/JT C addition harness set 49094-0316×1
Additional parts External axis addition part set (ferrite core) 49094-0257×2
Connection box with 1HG board 50326-1093×2
AM0 motor harness ×2
AS0 signal harness ×2
AS1 signal harness ×2

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Example 5: Type 5 (E01/E02/E04 controllers)

No. of additional 2 (Linear axis: 1 axis + Positioner: 1 axis)

axes
Motor capacity Linear axis: 2.0 kW  1 Positioner: 2.0 kW  1
(F)
Standard AM0
controller AS0 Motor Positioner
CB
(E01/E02/E04 AS1
controllers)

(F)
Construction AM0
Motor Linear axis
CB
AS0 AS1

M1 M2
Robot
S1 S2

Fixed motor/signal harness

Movable motor/signal harness

Motor 2.0 kW (SANYO) 50601-1490×2

KHI external axis amplifier 50607-0128×2
JT8/JT B addition harness set 49094-0315×1
JT9/JT C addition harness set 49094-0316×1
External axis addition part set (ferrite core) 49094-0257×2
Additional parts Connection box with 1HG board 50326-1093×2
M2 motor harness
S2 signal harness
AM0 motor harness ×2
AS0 signal harness ×2
AS1 signal harness ×2

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E0x Series Controller Appendix Examples of External Axes
Kawasaki Robot External Axis Addition Manual

Example 6: Type 6 (E01/E02 controllers)

No. of additional 3 (Linear axis: 1 axis + Positioner: 2 axes)

axes
Motor capacity Linear axis: 2.0 kW  1 Positioner: 1.5 kW  2
(F)
Standard AM0
controller AS0 Motor Positioner
CB
(E01/E02 AS1
AM0
controllers)
AS0 Motor Positioner
CB
AS1

M1 M2
Robot
Construction
S2
S1

M3 S3

Linear
Motor axis

Fixed motor/signal harness

Movable motor/signal harness

Motor 1.5 kW (SANYO) 50601-1366×2

Motor 2.0 kW (SANYO) 50601-1490×1
KHI external axis amplifier 50607-0128×2
JT8/JT B addition harness set 49094-0315×1
JT9/JT C addition harness set 49094-0316×1
External axis addition part set (ferrite core) 49094-0257×2
Additional parts Connection box with 1HG board 50326-1093×2
AM0 motor harness ×2
AS0 signal harness ×2
AS1 signal harness ×2
M2 motor harness ×1
S2 signal harness ×1
M3 motor harness ×1
S3 signal harness ×1

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E0x Series Controller Appendix Examples of External Axes
Kawasaki Robot External Axis Addition Manual

Example 7: Type 7 (E03 controller)

No. of additional 1 (Positioner: 1 axis)

axes
Motor capacity Positioner: 2.0 kW  1

Standard (F)
AM0
controller AS0 Motor Positioner
(E03 controller) CB
AS1

Construction
M1
Robot
S1

Fixed motor/signal harness

Movable motor/signal harness

Motor 2.0 kW (SANYO) 50601-1490×1

KHI external axis amplifier 50607-0128×1
E03 JT8 1-axis amplifier controller 49094-0422×1
harness set
Additional parts External axis addition part set (ferrite 49094-0257×1
core)
Connection box with 1HG board 50326-1093×1
AM0 motor harness ×1
AS0 signal harness ×1

A-9
E0x Series Controller Appendix Examples of External Axes
Kawasaki Robot External Axis Addition Manual

Example 8: Type 8 (E01 controller + multi-axis controller)

No. of additional 4 (Traveling: 1 axis, Positioner: 3 axes)

axes
Motor capacity Traverse axis: 2.0 kW  1 Positioner: 4.2 kW  3
AM0
Standard Multi-axis Distribution AS0 Motor Positioner
controller controller box AM0
(E01 controller) AS0 Motor Positioner
AM0
AS0 Motor Positioner

AS1
Construction
M1 M2 Robot
S1 S2
M3
S3

Motor

Fixed motor/signal harness

Movable motor/signal harness

Motor 4.2 kW (SANYO) 50601-1412×3

Motor 2.0 kW (SANYO) 50601-1490×1
Multi-axis controller (including amplifiers) ×1
Harness between controllers 50979-0205×1
50979-0206×1
Harness between multi-axis controller and 50979-0448L×1
Additional parts distribution box 50979-0449L×1
50979-0450L×1
Distribution box (4 axes) 50326-0203×1
M2 motor harness ×1
S2 signal harness ×1
M3 motor harness ×1
S3 signal harness ×1
AM0 motor harness ×3
AS0 signal harness ×3

A-10
 E0x Series
External Axis Addition Manual

2015-05 : 1st Edition

2017-10 : 3rd Edition

Publication : Kawasaki Heavy Industries, Ltd.

90210-1292DEC

Copyright © 2015 Kawasaki Heavy Industries, Ltd. All rights reserved.