Kawasakiexternal Axis Addition

Kawasaki Robot
E Controller
External Axis
Addition Manual
Kawasaki Heavy Industries, Ltd.
90210-1249DED
E Series Controller
Kawasaki Robot External Axis Addition Manual
PREFACE
This manual describes how to add peripheral equipment to the robot system and to enable the
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 the 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 robot operation, refer
to “Operation Manual”. For information on external I/O signals, refer to “External I/O Manual”.
For installation and connection of the multi-axis controller, refer to “Installation and Connection
Manual” for E controller (Multi-axis controller).
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 © 2013 Kawasaki Heavy Industries Ltd. All rights reserved.
1
E Series Controller
SAFETY
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.
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 the safety manual, all pertinent laws,
regulations and related materials as well as all the safety explanations
described in each chapter, and prepare safety measures suitable for
actual work.
2
E Series Controller
CONTENTS
Preface ................................................................................................................................................. 1
Safety ................................................................................................................................................... 2
1.0 Selection of External Axis Component Parts ....................................................................6

1.1 Servomotor Type ................................................................................................................ 6
1.1.1 SANYO Motor & KHI Amplifier Spec. ........................................................................... 8
1.1.2 MITSUBISHI Motor & Amplifier Spec. ........................................................................11
1.2 SANYO Motor Selection Procedure ...............................................................................12
1.2.1 Rotation Axis ....................................................................................................................12
1.2.2 Linear Axis (Rack & Pinion Drive) .................................................................................13
1.2.3 Linear Axis (Ball Screw Drive) .......................................................................................16
1.3 MITSUBISHI Motor Selection Procedure ......................................................................17
1.4 Check of Power Capacity .................................................................................................18
1.5 Motor Applicability for External Axis Specifications ....................................................20
2.0 Hardware Installation .......................................................................................................21

2.1 When Using SANYO Motor (E2x Controller) ...............................................................21
2.1.1 Adding JT7/JT A via Separate Harness for the Robot ....................................................22
2.1.2 Adding JT7/JT A via Dedicated Harness for JT7/JT A ..................................................23
2.1.3 Adding JT8/JT B ..............................................................................................................25
2.2 When Using SANYO Motor (E1x/E3x/E4x Controller) ................................................27
2.2.1 Adding JT7/JT A via Separate Harness for the Robot ....................................................28
2.2.3 Adding JT8/JT B ..............................................................................................................31
2.2.4 Adding JT9/JT C ..............................................................................................................33
2.3 Hardware Installation When Using SANYO Motors (E7x Controller) .........................35
2.3.1 Adding JT7/JT A via Separate Harness for Robot ..........................................................35
2.3.3 Adding JT8/JT B ..............................................................................................................38
2.3.4 How to Remove Controller Cover ...................................................................................40
2.4 When Using Multi-Axis Controller (for SANYO Motor) ..............................................42
2.4.1 When Adding an Axis among JT D  JT J......................................................................43
2.4.2 When Adding Either JT K or JT L ..................................................................................44
2.5 When Using MITSUBISHI Motor ..................................................................................45
2.5.1 Necessary Hardware for MITSUBISHI Motor ...............................................................46
2.5.2 Parts Arrangement ............................................................................................................48
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E Series Controller
2.5.3 Mounting/Connection Procedure .....................................................................................49
3.0 Setting of External Axis Parameter Values .....................................................................54

3.1 Linear Axis Parameter Value Setting ..............................................................................56
3.2 Rotation Axis Parameter Value Setting ...........................................................................60
4.0 Setting of Servo Parameter Value ....................................................................................63

4.1 When Using KHI Amplifier.............................................................................................63
4.1.1 Simple Tuning ..................................................................................................................64
4.1.1.1 Tuning Gain Values (KV) ................................................................................................64
4.1.1.2 Setting Delay Time ...........................................................................................................66
4.1.2 Full Spec Tuning ..............................................................................................................66
4.2 When Using MITSUBISHI Amplifier ............................................................................67
4.2.1 Simple Tuning ..................................................................................................................68
4.2.1.1 Auto Tuning Mode 1 ........................................................................................................69
4.2.1.2 Manual Mode 1.................................................................................................................69
4.2.2 Full Spec Tuning ..............................................................................................................70
5.0 Cooperative Control Function..........................................................................................72

5.1 Linear Axis Cooperative Function...................................................................................73
5.1.1 Check of Linear Axis Cooperative Function ...................................................................73
5.2 Rotation Axis Cooperative Function ...............................................................................74
5.2.1 Setting of Rotation Axis Cooperative Function ..............................................................75
5.3 Positioner Cooperative Function......................................................................................77
5.3.1 Setting of Single-Axis Positioner Cooperation ...............................................................77
5.3.1.1 Registration of Positioner Setting Position ......................................................................78
5.3.1.2 Registration of Positioner Cooperation Start and End Axes ...........................................80
5.3.1.3 Check of Positioner Cooperation Setting ........................................................................81
5.3.2 Double-Axis Positioner Cooperation...............................................................................81
5.3.2.1 Check of Positioner Rotating Direction and Dimensions ...............................................82
5.3.2.2 Registration of Positioner Setting Position ......................................................................84
5.3.2.3 Registration of Positioner Cooperation Start/End Axes and Link Structure ..................86
5.3.2.4 Check of Positioner Cooperation Setting ........................................................................88
5.3.3 Troubleshooting for Positioner Cooperation ...................................................................89
6.0 Endless Positioner Function .............................................................................................99

6.1 Setting of Endless Positioner Function ............................................................................99
6.2 Setting a Rotation Number by RTSET Command/Instruction .....................................100
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E Series Controller
7.0 Dual Servo Function.......................................................................................................103

7.1 Setting of Dual Servo Function......................................................................................103
7.2 Tuning of Dual Servo Function .....................................................................................105
7.2.1 Setting of Dual Servo Tuning Run Mode ......................................................................105
7.2.2 Tuning Procedure for Dual Servo Function ..................................................................106
Appendix Examples of External Axes ........................................................................................ A-1
5
E Series Controller 1. Selection of External Axis
Kawasaki Robot External Axis Addition Manual Component Parts
1.0 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. When using the MITSUBISHI motor,
prepare the MITSUBISHI amplifier expansion controller referring to 2.5 and use a MITSUBISHI
amplifier installed in the expansion controller.
Table below shows the availabilities of SANYO/MITSUBISHI motors and the maximum
addable number of external axes per controller.
SANYO motor MITSUBISHI motor

Availability Max. number of addable external Availability Max. number of
Controller axes addable external axes
Controller Multi-axis Total Expansion Total
controller* controller*
E1x Available 3 8 11 Not available Consult -
controller Kawasaki.
E2x Available 2 8 10 Not available Consult -
controller Kawasaki.
E3x Available 3 Unsupported 3 Available 8 8
controller
E4x Available 3 Unsupported 3 Available 8 8
controller
E7x Available 2 Unsupported 2 Not available - -
controller
NOTE* Refer to 2.4 for multi-axis controller and 2.5 for expansion controller.
6
[ NOTE ]
Free combination of motors is not always possible due to power capacity
restriction of selected motors and brakes. In 1.4, observe the total power
consumption of external axes and brake current restriction values.
Examples for external axis additions are shown in the Appendix.
MITSUBISHI motors are not applicable to some specifications. See 1.5
for details.
(Example 1: E2x controller + multi-axis controller for SANYO motor)
cable
KHI
single-axis
amplifier Max.
KHI 8 axes
single-axis KHI 6-axis
amplifier integrated
amplifier
Controller Multi-axis controller

(Standard spec.) (for external axis)
(Example 2: E4x controller + expansion controller for MITSUBISHI motor)
MITSUBISHI
KHI MELSERVO amplifier
single-axis
amplifier
Controller Expansion controller MITSUBISHI

(Standard spec.) (for external axes) MELSERVO amplifier
7
1.1.1 SANYO MOTOR & KHI AMPLIFIER SPEC.
For external axes, the following combinations of SANYO motors and KHI single-axis amplifiers
can be used.
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
8.140(-0.030~+0.005)
Taper 1/10 (number of teeth in the span=3)
At 0 from taper Grade Grade b

reference position
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
Part No. [-] 50601-1412 50601-1413 50601-1403 50601-1414 50601-1490 50601-1460 50601-1485
Model No. [-] P80B22450LCPUB P60B13200LCPUA P60B13200LCPUH P60B13150HCPUG R2AA13200LCP2R R2AA13200LCP2S P20B10200LCP67
Brake [-] with with with with with with with
Capacity [W] 4200 3100 3100 2100 2000 2000 2000
Max. rotation speed [rpm] 3300 3000 3000 3000 5000 5000 3500
Rated rotation speed [rpm] 2400 3000 3000 3000 2000 2000 3000
Max. instant torque [Nm] 68.6 26.5 26.5 16.2 30 30 16.7
Rated torque [Nm] 16.7 9.8 9.8 6.7 9.5 9.5 6.37
-4 2
Moment of inertia [10 kgm ] 75 12.5 12.5 8.2 12.3 12.3 3.2
Mass [kg] 28 10.8 10.8 8.7 12 12 9.5
KHI single-axis amp. [-] 100A 50A 50A 50A 50A 50A 50A
A [mm] 220(±3) 135(-3~+2) 135(-3~+2) 135(-3~+2) 135(-3～+2) 135(-3～+2) 100(±2)
B [mm] 65(±1) 61(±1) 55(±1) 53(±1) 55(±1) 42(±1) 55(±1)
C [mm] 229(±3) 241(±3) 241(±3) 218(±3) 224(±3) 224(±2) 258(±3)
D [mm] 4 3 3 3 3 3 3
E [mm] 16 12 12 12 12 12 10
F [mm] 58(-0.39~0) 28 50 44.65(0~+0.14) 50 36 50
G [mm] 3 - - - - 3 -
H [mm] 4 - 3 8 3 3 -
I [mm] 50 - 42 36 42 32 -
J [mm] 35 19.8(0~+0.1) 22(-0.013~0) 19(-0.013~0) 28(-0.013~0) 24 19(-0.013~0)
Dimensions
K [mm] 6(-0.030~0) 6(-0.030~0) 6(-0.030~0) 8(-0.036~0) 5(-0.030~0) -
L [mm] - 2.5(-0.2~0) 2.5(-0.2~0) 3(-0.4~0) - -
M [mm] 6(-0.030~0) For other 6 6 7 5(-0.030~0) -
specifications of
N [mm] 12.55(-0.1~0) output axis, refer - - - 8.1(-0.1~0) -
O [mm] 29 to "involute - - - 18 -
P [mm] 10 spline shaft data - - - 6 -
for automobile".
Q [mm] 1.5 - - - 1 -
R [mm] 30 - - - 20 -
S [mm] 235(±0.23) 160(±0.2) 160(±0.2) 160(±0.2) 160(±0.2) 160(±0.2) 115(±0.2)
T [mm] 12 10 10 10 10 10 8
U [Nm] 98 57 57 57 57 57 29
8
Item Unit ⑧ ⑨ ⑩ ⑪ ⑫ ⑬ ⑭
Part No. [-] 50601-1366 50601-1491 50601-1465 50601-1435 50601-1432 50601-1492 50601-1461
Model No. [-] P20B10150DCPU3 R2AA13120LCP2D R2AA13120LCP2E P50B08100VCLGS P50B08075DCLGD R2AA08075FCP63 R2AA08075FCP3N
Brake [-] with with with with with with with
Capacity [W] 1500 1200 1200 1000 750 675 675
Max. rotation speed [rpm] 4500 6000 6000 4000 4500 6000 6000
Rated rotation speed [rpm] 3000 2000 2000 3000 3000 3000 3000
Max. instant torque [Nm] 14.7 16 16 11.76 8.82 8.5 8.5
Rated torque [Nm] 4.79 5.7 5.7 3.185 2.381 2.15 2.15
-4 2
Moment of inertia [10 kgm ] 2.41 6.5 6.5 2.989 2.264 2.07 2.07
Mass [kg] 8.9 8 8 5.5 4.35 3.5 3.5
KHI single-axis amp. [-] 50A 30A 30A 30A 30A 30A 30A
A [mm] 100(±2) 130(±2) 130(±2) 86 86 80 80
B [mm] 55(±1) 55(±1) 34(±1) 60(±0.8) 45(±0.8) 40(±0.8) 35(±0.8)
C [mm] 233(±3) 160(±3) 160(±3) 214 191 153(±1) 157(±1)
D [mm] 3 4 4 3 3 3 3
E [mm] 10 12 12 8 8 8 8
F [mm] 50 50 28 43 40 35(±0.3) 28(±0.2)
G [mm] - - 2 - - - 4
H [mm] - 3 2 3.5 3 4 -
I [mm] - 42 25 42 35 25 25
J [mm] 19(-0.013~0) 22(-0.013~0) 19 16(-0.011~0) 16(-0.011~0) 16(-0.011~0) 16
Dimensions
K [mm] - 6(-0.030~0) 4(-0.030~0) 5(-0.03~0) 5(-0.03~0) 5(-0.03~0) 3(-0.025~0)
L [mm] - 2.5(-0.2~0) - 2(-0.2~0) 2(-0.2~0) 2(-0.2~0) 1.2(-0.2~0)
M [mm] - 6 4(-0.030~0) 5 5 5 3
N [mm] - - 6.3(-0.1~0) - - - -
O [mm] - - 14 - - - 14
P [mm] - - 5 - - - 4
Q [mm] - - 0.8 - - - 0.7
R [mm] - - 15 - - - 10
S [mm] 115(±0.2) 145(±0.2) 145(±0.2) 100(±0.3) 100(±0.3) 90(±0.3) 90(±0.3)
T [mm] 8 8 8 6 6 5 5
U [Nm] 29 29 29 12 12 6.9 6.9
Item Unit ⑮ ⑯ ⑰ ⑱ ⑲
Part No. [-] 50601-1404 50601-1462 50601-1371 50601-1463 50601-1370
Model No. [-] P50B07050DCLG7 R2AA06020FCP3G P50B05020DCLEG R2AA06010FCP3H P50B04007DCLEF
Brake [-] with with with with with
Capacity [W] 475 200 200 100 75
Max. rotation speed [rpm] 5000 6000 5000 6000 4500
Rated rotation speed [rpm] 3000 3000 3000 3000 3000
Max. instant torque [Nm] 5.19 2.2 1.96 1.13 0.647
Rated torque [Nm] 1.52 0.637 0.637 0.318 0.239
-4 2
Moment of inertia [10 kgm ] 1.205 0.279 0.197 0.177 0.057
Mass [kg] 2.77 1.2 1.27 0.94 0.63
KHI single-axis amp. [-] 30A 15A 15A 15A 15A
A [mm] 76 60 54 60 42
B [mm] 35(±0.8) 27(±0.8) 27(±0.8) 23(±0.8) 29.5(±0.8)
C [mm] 156 107.5(±1) 140 92.5(±1) 127
D [mm] 3 3 2.5 3 2
E [mm] 8 6 5 6 5
F [mm] 28(+0.1~+0.2) 23(±0.3) 21(0~+0.1) 19(±0.3) 20.8(0~+0.1)
G [mm] - - - - -
H [mm] 4 - 5 - 2.9
I [mm] 25 - 16 - 16
J [mm] 16(-0.011~0) 11(-0.011~0) 11(-0.011~0) 8(-0.009~0) 8(-0.009~0)
Dimensions
K [mm] 5(-0.03~0) - 4(-0.03~0) - 3(-0.025~0)
L [mm] 2(-0.2~0) - 1.5(-0.2~0) - 1.2(-0.2~0)
M [mm] 5 - 4 - 3
N [mm] - - - - -
O [mm] - - - - -
P [mm] - - - - -
Q [mm] - - - - -
R [mm] - - - - -
S [mm] 90(±0.3) 70(±0.3) 60(±0.3) 70(±0.3) 48(±0.3)
T [mm] 5 5 4 5 3
U [Nm] 6.9 6.9 3.4 6.9 1.5
9
[ NOTE ]
1. Figure in ( ) of Rotation Speed represent max. speed (Nmax).
2. Part Nos. for each single axis amp. are below.
For E1x/E2x/E3x/E4x For large motor: 1TC (100 A) 50607-1503
1TC (50 A)* 50607-1509
1VE (50 A) 50607-0044
For small motor: 1TD (30 A)* 50607-1504
1VD (30 A) 50607-0045
1TD (15 A)* 50607-1510
1VD (15 A) 50607-0046
For E7x For small motor: 1UZ (30 A) 50607-0019
1UZ (15 A) 50607-0017
3. Encoder pulse output per one rotation of servomotor is 8192 p/rev.
4. Contact Kawasaki if a motor drawing is required.
5. When using a multi-axis controller, KHI 6-axis integrated amplifier is used.
The specification of the KHI 6-axis integrated amplifier used is decided by
Kawasaki depending on the combination of the motors used.
NOTE* 1TC (50 A) and 1TD are to be deprecated in 2011.
10
1.1.2 MITSUBISHI MOTOR & AMPLIFIER SPEC.
For external axes, the following combinations of MITSUBISHI motors and amplifiers can be
used.
*No key
Mount with M-T bolt

Tightening torque: U N·m
Item Unit ① ② ③ ④ ⑤ ⑥
Part No. [-] 50601-1351 50601-1350 50601-1349 50601-1348 50601-1347 50601-1346
Model No. [-] HC-UFS502BK HC-RFS353BK HC-RFS203BK HC-RFS153BK HC-RFS103BK HC-SFS53BK
Brake [-] with with with with with with
Capacity [W] 5000 3500 2000 1500 1000 500
Max. rotation speed [rpm] 2500 4500 4500 4500 4500 3000
Rated rotation speed [rpm] 2000 3000 3000 3000 3000 3000
Max. instant torque [Nm] 71.6 27.9 15.9 11.9 7.95 4.77
Rated torque [Nm] 23.9 11.1 6.37 4.78 3.18 1.59
-4 2
Moment of inertia [10 kgm ] 123.6 11.8 2.65 2.25 1.85 8.6
Mass [kg] 30 15 8.3 7 6 7
M-amp. Model No. [-] MR-J2S-500B MR-J2S-500B MR-J2S-350B MR-J2S-200B MR-J2S-200B MR-J2S-60B
A [mm] 220 130 100 100 100 130
B [mm] 65 63 45 45 45 55
C [mm] 209 254 235 210 185 153
D [mm] 4 3 3 3 3 3
E [mm] 16 12 10 10 10 12
Dimensions
F [mm] 60 58 40 40 40 50
G [mm] - - - - - -
H [mm] 5 3 5 5 5 5
I [mm] 50 53 25 25 25 36
J [mm] 35(0～+0.01) 28(-0.013～0) 24(-0.013～0) 24(-0.013～0) 24(-0.013～0) 24(-0.013～0)
S [mm] 250 145 115 115 115 145
T [mm] 12 8 8 8 8 8
U [Nm] 98 29 29 29 29 29
V [mm] 10(-0.036～0) 8(-0.036～0) 8(-0.036～0) 8(-0.036～0) 8(-0.036～0) 8(-0.036～0)
W [mm] 30(-0.12～0) 24(-0.1～0) 20(-0.1～0) 20(-0.1～0) 20(-0.1～0) 20(-0.1～0)
11
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.
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 JW (kgm2)
of gravity
Angular motion range θ ()
Max. angular speed ω (/s)
Max. angular acceleration α (/s2)
2. Selection of reduction unit

Select a reduction unit and determine the following data.
Motor inertia moment JM (kgm2)
Flywheel inertia moment JF (kgm2)*
Reduction unit inertia moment JR (kgm2)
Load axis rotations 1/i
Reduction ratio
Motor rotations (Normal i > 1)
Starting efficiency η (0-1.0)
NOTE* JF=0 except when mounting flywheel on motor.
Reduction unit Motor
[ NOTE ]
LO Also, consider allowable torque, service
life calculation, etc. when selecting
reduction unit.
MW,JW Load
12
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 JW+MWLO2

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

RJ ≤ 6
1.2.2 LINEAR AXIS (RACK & 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 reduction unit and guide
3. Check of condition expressions and selection of motor/encoder

Load mass MW (kg)
Motion stroke X (m)
Max. speed V (m/s)
Max. acceleration a (m/s2)
13

Determine specifications for the reduction unit.
Reduction ratio i
Starting efficiency η (0-1.0)
Moment of inertia of reduction unit JR (kgm2)
Determine rack and pinion data.

Module m
Number of pinion gear Z
Determine guide data.

Guide friction μ (around 0.05-0.1)
Determine motor and flywheel data.

Motor inertia moment JM (kgm2)
Flywheel inertia moment JF (kg·m2)
Flywheel
Reduction unit
Motor
Moving table
Guide
9.8 MW X, V, a
Pinion
Rack
14


1 Peak torque on motor mZ（9.8μMW+MWa）
TP = 2000ηi
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 ΣtiTi2

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

N = πmZ
operating
N ≤ Nmax (rpm)
5 Number of encoder rotations Xi
Erev = πmZ
when operating
Erev ≤ 65536 (rev)
6 Ratio of load side moment of 10-6MWm2Z2
RJ = 4i2(J +J +J )
inertia to that of motor axis R F M
side reduced to that of motor

axis side
RJ ≤ 6
15
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
3. Check of condition expressions and selection of motor/encoder

Load mass MW (kg)
Motion stroke X (m)
Max. speed V (m/s)
Max. acceleration a (m/s2)

Determine specifications for the reduction unit (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 0.05-0.1)
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
Moving table
Reduction unit
(gear) Ball screw
Guide
9.8 MW X, V, a
16


1 Peak torque on motor L（9.8μMW+MWａ）
TP = 2πη1η2i
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

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

N= L
operating
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 F M F M
side 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.
17
1.4 CHECK OF POWER CAPACITY
・ E series controller has restrictions on the power it can supply for external axes. Check if the
total power consumption factor of the selected motors and the brake current factor in table 1
are less than the capacity restrictions in table 2. If exceeded, reconsider specifications to
satisfy the restrictions. Motor capacity restriction varies on the robot motion. Consult
Kawasaki to add external axes in the robot system if the robot motion is small.
・ For E30 and E40 controllers, the motor capacity restriction value can be raised by changing
the transformer and breaker to those for E32/E42 controller. For the changing method, see
Example 7 in Appendix.
・ For E10, E20, E30 and E40 controllers, change the regenerative resistance if the total motor
capacity factor exceeds the regenerative resistance restriction. However, this is just a rough
indication, and the regenerative resistance may need to be replaced depending on the
operation pattern of external axis even if the total motor capacity factor is less than the
regenerative resistance restriction. For the changing method, see Example 7 in Appendix.
・ When using the motor of 4.2 kW on JT7/JT A, use the dedicated harness for JT7/JT A to
drive the motor by 100 A amplifier, not use the separate harness for the robot. When using
50 A amplifier, the separate harness can be used. In this case, however, the full capacity of
4.2 kW motor cannot be utilized because the current is limited.
・ For E7x controller, internal IO and brake share the same power. Accordingly, it is necessary
to reduce the brake capacity restriction value by the current used for the internal IO when
using the internal IO.
1. Motor capacity and brake capacity factors

SANYO motors
Specifications
Motor capacity Brake capacity
Part No. Type Motor KHI factor factor
capacity amplifier
50601-1412 P80B22450LCPUB 4.2 kW 100 A/50 A 1.7 1.6 A
50601-1490 R2AA13200LCP2R 2 kW 50 A 1 0.66 A
50601-1485 P20B10200LCP67 2 kW 50 A 0.8 0.83 A
50601-1366 P20B10150DCPU3 1.5 kW 50 A 0.6 0.83 A
50601-1491 R2AA13120LCP2D 1.2 kW 30 A 0.5 0.51 A
50601-1492 R2AA08075FCP63 0.675 kW 30 A 0.4 0.37 A
50601-1370 P50B04007DCLEF 0.075 kW 15 A 0.03 0.26 A
18
MITSUBISHI MELSERVO motors (with electromagnetic brake)

Specifications
Part No. Type Motor
Amplifier type factor factor
capacity
50601-1351 HC-UFS502BK 5 kW MR-J2S-500B 2 1.4 A
50601-1350 HC-RFS353BK 3.5 kW MR-J2S-500B 1.4 1.0 A
50601-1349 HC-RFS203BK 2 kW MR-J2S-350B 0.8 0.8 A
50601-1348 HC-RFS153BK 1.5 kW MR-J2S-200B 0.6 0.8 A
50601-1347 HC-RFS103BK 1 kW MR-J2S-200B 0.4 0.8 A
50601-1346 HC-SFS53BK 0.5 kW MR-J2S-60B 0.2 0.8 A
2. Power capacity restrictions to external axes for each robot arm series and controller
Regenerative
Robot arm Controller resistance
restriction restriction
restriction
E24 1.8 1.6 A -
MX/MD series
E14/E34/E44 1.8 3.2 A -
E22 /E23 3.9 3.4 A -
Z series,
E12/E32/E42
MT series 3.9 5A -
E13/E33/E43
E12/E22 5.8 6A -
RS50 series
E32/E42 5.8 6A -
E10/E20 9.3 6A 2.4
RS20 series E30/E40 2.4 6A 2.4
E30/E40
9.3 6A 2.4
(Change transformer)
E10/E20 10.6 6A 3.7
E30/E40 3.7 6A 3.7
RS10 series E30/E40
10.6 6A 3.7
E71/E74/E77 0.8 0.45 A* -
RS05 series E71/E74/E77 1.6 1 A* -
RS03 series E70/E73/E76 2 0.79 A* -
E10/E20 8.9 6A 2
E30/E40 2 6A 2
YF03 series
E30/E40
8.9 6A 2
NOTE*: When using the IO, the total amount of consumption current for IO and the motor brake
current should be less than the brake capacity restriction.
19
3. Power capacity restrictions to external axes for multi-axis controller for SANYO motor
Regenerative
- Controller resistance
restriction restriction
restriction
SANYO motor
Multi-axis controller 12 11.2 A -
external axis
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 Travel axis Applicable Applicable Including travel 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
10 Separate control Applicable Applicable
11 Cubic-S Applicable Not applicable
20
E Series Controller 2. Hardware Installation
2.0 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.
！ CAUTION
Encoder value backup battery: Do not disconnect the battery backup
line to the encoder after installing motor.
· SANYO motor Between battery backup box and motor (encoder)
· MITSUBISHI motor Between amplifier and motor (encoder)
Disconnecting the line erases encoder values after 30 min or several
hours. If lost, zeroing must be executed again.
！ DANGER
After Motor Power OFF, power block unit and MC unit begin
discharging. Wait at least 7 minutes then confirm voltage between
P-N on power block is 0 V before working on hardware.
2.1 WHEN USING SANYO MOTOR (E2X CONTROLLER)
Mount the KHI amplifier in the controller as shown in figure below, and connect between motor
and controller with cables.
Single-axis power block

(JT8/JT B)
(JT7/JT A)
21
2.1.1 ADDING JT7/JT A VIA SEPARATE HARNESS FOR THE ROBOT
[ NOTE ]
The combination of 4.2 kW motor and 100 A amplifier is not
available in this way.
Follow the procedure below with reference to Figure 1.

1. Remove the lower dummy plate for single-axis amplifier and mount single-axis power block
(JT7/JT A).
2. Connect X517 and X566 (A) on PWM harness (JT7/JT A) (P/N: 50978-3911) to X517 on
1TB board and X566 on single-axis power block (JT7/JT A) respectively.
3. Connect X353 and X562 (A) on PN harness (JT7/JT A) (P/N: 50978-3909) to X353 on MC
unit and X562 on single-axis power block (JT7/JT A) respectively.
4. Connect X359 and X564 (A) on DC line harness (JT7/JT A) (P/N: 50978-3910) to X359 on
MC unit and X564 on single-axis power block (JT7/JT A) respectively.
5. Connect X551 (JT7/JT A) on internal harness to X551 on single-axis power block (JT7/JT
A).
Dummy plate
(Upper)
Single-axis power block PWM harness
(JT7/JT A) (JT7/JT A)
X566
X564
X562 X517
X551
X353
X359
PN harness (JT7/JT A)
(P/N: 50978-3909)
DC line harness (JT7/JT A)

(P/N: 50978-3910)
Figure 1
22
2.1.2 ADDING JT7/JT A VIA DEDICATED HARNESS FOR JT7/JT A
1. Remove the lower dummy plate for single-axis amplifier and mount single-axis power block
(JT7/JT A).
2. Connect X517 and X566 (A) on PWM harness (JT7/JT A) (P/N: 50978-3911) to X517 on
1TB board and X566 on single-axis power block (JT7/JT A).
3. Connect X353 and X562 (A) on PN harness (JT7/JT A) (P/N: 50978-3909) to X353 on MC
unit and X562 on single-axis power block (JT7/JT A).
4. Connect X359 and X564 (A) on DC line harness (JT7/JT A) (P/N: 50978-3910) to X359 on
MC unit and X564 on single-axis power block (JT7/JT A).
5. Remove top plate on the controller (with removing screws and eyebolts fixing the top plate).
Dismount the blank plate for JT7/JT A on the connector plate, and then pull and connect
internal harness for external axis (JT7/JT A) (P/N: 50978-3920) into the hole. (See Figure
2-3) Connect braided shield wires and G/Y wire from the rear side of the rear cover
referring to Figure 2-4.
6. Pull the harness into the controller so that the motor and brake lines pass through the upper
right hole viewed from the controller rear side, and the encoder line passes the left side of the
card rack. (See Figure 2-2)
7. Remount the top plate removed in step 5.
8. Connect X551 (A) on internal harness for external axis to X551 on single-axis power block
(JT7/JT A).
9. Disconnect the harness from X317 on MC unit, and then connect X317 on internal harness
for external axis to X317 on MC unit.
10. Disconnect the harness from X511 on 1TB board, and then connect X511 on internal harness
for external axis to X511 on 1TB board.
23
Top plate Eyebolt
Motor line,
Brake line
Encoder line
Dummy plate Motor line,

(Upper) Brake line
Figure 2-2
Single-axis power Inside view of connector plate
block (JT7/JT A)
PWM harness (JT7/JT A)
(P/N: 50978-3911)
X566
X564
X562
X517
X551
X317 PN harness (JT7/JT A)

(P/N: 50978-3909)
X353 DC line harness (JT7/JT A)
(P/N: 50978-3910)
X359 X511
Brake line
(Passed under
Figure 2-1
MC unit)
Internal harness for external axis (JT7/JT A)

(P/N: 50978-3920)
Inside view of part A
Figure 2-4
Figure 2-3
24
2.1.3 ADDING JT8/JT B
1. Remove the upper dummy plate for single-axis amplifier and mount single-axis power block
(JT8/JT B).
2. Connect X518 and X566 (B) on PWM harness (JT8/JT B) (P/N: 50978-3916) to X518 on
1TB board and X566 on single-axis power block (JT8/JT B).
3. Connect X563 (A) and X562 (B) on PN harness (JT8/JT B) (P/N: 50978-3914) to X563 on
single-axis power block (JT7/JT A) and X562 on single-axis power block (JT8/JT B).
4. Connect X565 (A) and X564 (B) on DC line harness (JT8/JT B) (P/N: 50978-3915) to X565
on single-axis power block (JT7/JT A) and X564 on single-axis power block (JT8/JT B).
Dismount the blank plate for JT8/JT B on the connector plate, and then pull and connect
internal harness for external axis (JT8/JT B) (P/N: 50978-3921) into the hole. (See Figure
3-3) Connect braided shield wires and G/Y wire from the rear side of the rear cover
referring to Figure 3-4.
6. Pull the harness into the controller so that the motor and brake lines pass through the upper
right hole viewed from controller rear side, and the encoder line pass the left side of the card
rack. (See Figure 3-2)
8. Connect X551 (B) on internal harness for external axis to X551 on single-axis power block
(JT8/JT B).
9. Disconnect harness from X318 on MC unit, and then connect X318 on internal harness for
external axis to X318 on MC unit.
10. Disconnect harness from X512 on 1TB board, and then connect X512 on internal harness for
external axis to X512 on 1TB board.
25
Eyebolt
Top plate
Motor line,
Brake line
Encoder line
Single-axis
power block
(JT8/JT B) Motor line,
Brake line
X566 Figure 3-2

X564 Inside view of connector plate
X562
X551 PWM harness (JT8/JT B)
(P/N: 50978-3916)
Single-axis
PN harness (JT8/JT B)
power block
(P/N: 50978-3914)
(JT7/JT A)
DC line harness (JT8/JT B)
X563 (P/N: 50978-3915)
X565
X518
X318
X512
Brake line
(Passed under
Figure 3-1
MC unit)
Internal harness for external axis (JT8/JT B)

(P/N: 50978-3921)
Figure 3-4
Figure 3-3
26
2.2 WHEN USING SANYO MOTOR (E1X/E3X/E4X CONTROLLER)
Mount the KHI amplifier in the controller as shown in figure below, connect between motor and
controller with cables.
Single-axis power Single-axis power

block (JT7/JT A) block (JT8/JT B)
Single-axis power
block (JT7/JT A)
Single-axis power
block (JT9/JT C)
The figures in the following pages show E4x controller.
27
2.2.1 ADDING JT7/JT A VIA SEPARATE HARNESS FOR THE ROBOT
Follow the procedure below with the reference to Figure 4.

1. Remove the left dummy plate for single-axis amplifier and install single-axis power block
(JT7/JT A).
2. Connect X517 and X566 (JT7/JT A) on PWM harness (JT7/JT A) (P/N: 50973-2986) to
X517 on 1TB board and X566 on single-axis power block (JT7/JT A) respectively.
3. Connect X353 and X562 (JT7/JT A) on PN harness (JT7/JT A) (P/N: 50977-0148) to X353
on MC unit and X562 on single-axis power block (JT7/JT A) respectively.
4. Connect X359 and X564 (JT7/JT A) on DC line harness (JT7/JT A) (P/N: 50977-0149) to
X359 on MC unit and X564 on single-axis power block (JT7/JT A) respectively.
5. Connect X551 (JT7/JT A) on internal harness to X551 on single-axis power block
(JT7/JT A).
X566
X562
(JT7/JT A)
X564
X551
(P/N:50977-0148)
X353
DC line harness (JT7/JT A)

(P/N: 50977-0149)
X359
PWM harness (JT7/JT A)
(P/N: 50973-2986)
X517
Figure 4
28
1. Remove the left dummy plate for single-axis amplifier and install single-axis power block
(JT7/JT A).
2. Connect X517 and X566 (JT7/JT A) on PWM harness (JT7/JT A) (P/N: 50973-2986) to
X517 on 1TB board and X566 on single-axis power block (JT7/JT A).
3. Connect X353 and X562 (JT7/JT A) on PN harness (JT7/JT A) (P/N: 50977-0148) to X353
on MC unit and X562 on single-axis power block (JT7/JT A).
4. Connect X359 and X564 (JT7/JT A) on DC line harness (JT7/JT A) (P/N: 50977-0149) to
X359 on MC unit and X564 on single-axis power block (JT7/JT A).
Dismount the blank plate for JT7/JT A on the connector plate, and then pull and connect
internal harness for external axis (JT7/JT A) (P/N: 50977-0107) into the hole. (See Figure
5-3.) Connect braided shield wires and G/Y wire from the inside of the rear cover referring
to Figure 5-4.
6. Pull the harness into the controller so that the motor and brake lines pass through the right
hole viewed from the controller rear side, and the encoder line pass the left side of the card
rack. (See Figure 5-2)
8. Connect X551 (JT7/JT A) on internal harness for external axis to X551 on single-axis power
block (JT7/JT A).
9. Disconnect the harness from X317 on MC unit, and then connect X317 on internal harness
for external axis to X317 on MC unit.
10. Disconnect the harness from X511 on 1TB board, and then connect X511 on internal harness
for external axis to X511 on 1TB board.
29
Motor line,
Brake line
Encoder line

(JT7/JT A)
X566
(P/N: 50977-0148) X562
X564
X551
X353
X317
X517
DC line harness
(JT7/JT A)
(P/N: 50977-0149) PWM harness (JT7/JT A)
(P/N: 50973-2986)
X359
X511
Figure 5-1
Internal harness for external axis (JT7/JT A)

Encoder line
(P/N: 50977-0107)
Top plate Eyebolt
Inside view
of part A
Motor line,
Figure 5-2 Brake line Figure 5-4
Figure 5-3
Inside view of connector plate
30
1. Remove the middle dummy plate for single-axis amplifier and install single-axis power block
(JT8/JT B).
2. Connect X518 and X566 (JT8/JT B) on PWM harness (JT8/JT B) (P/N: 50973-2897) to
X518 on 1TB board and X566 on single-axis power block (JT8/JT B).
3. Connect X563 (JT7/JT A) and X562 (JT8/JT B) on PN harness (JT8/JT B) (P/N:
50977-0111) to X563 on single-axis power block (JT7/JT A) and X562 on single-axis power
block (JT8/JT B).
4. Connect X565 (JT7/JT A) and X564 (JT8/JT B) on DC line harness (JT8/JT B) (P/N:
50977-0112) to X565 on single-axis power block (JT7/JT A) and X564 on single-axis power
block (JT8/JT B).
Dismount the blank plate for JT8/JT B on the connector plate, and then pull and connect
internal harness for external axis (JT8/JT B) (P/N: 50977-0108) into the hole. (See Figure
6-3.) Connect braided shield wires and G/Y wire from the inside of the rear cover referring
to Figure 6-4.
hole viewed from controller rear side, and the encoder line pass the left side of the card rack.
(See Figure 6-2)
7. Remount the connector plate removed in step 5.
8. Connect X551 (JT8/JT B) on internal harness for external axis to X551 on single-axis power
block (JT8/JT B).
9. Connect X318 on internal harness for external axis to X318 on MC unit.
10. Connect X512 on internal harness for external axis to X512 on 1TB board.
31
Top plate Eyebolt

Encoder line
Motor line,
Brake line
Single-axis power
block (JT8/JT B)
Single-axis power
block (JT7/JT A) X566
PN harness (JT8/JT B) X562
(P/N: 50977-0111) Motor line,
Figure 6-2
Brake line
X563 Inside view of connector plate
X564
X565
DC line harness (JT8/JT B)
(P/N:50977-0112)
X318 X551
X518
Brake line
(Passed under
MC unit) PWM harness (JT8/JT B)
(P/N: 50973-2987)
X512
Figure 6-1
Internal harness for external axis (JT8/JT B)

(P/N: 50977-0108)
Figure 6-4
Figure 6-3
32
2.2.4 ADDING JT9/JT C
1. Remove the right dummy plate for single-axis amplifier and install single-axis power block
(JT9/JT C).
2. Connect X519 and X566 (JT9/JT C) on PWM harness (JT9/JT C) (P/N: 50973-2988) to
X519 on 1TB board and X566 on single-axis power block (JT9/JT C).
3. Connect X563 (JT8/JT B) and X562 (JT9/JT C) on PN harness (JT9/JT C) (P/N:
50977-0152) to X563 on single-axis power block (JT8/JT B) and X562 on single-axis power
block (JT9/JT C).
4. Connect X565 (JT8/JT B) and X564 (JT9/JT C) on DC line harness (JT9/JT C) (P/N:
50977-0153) to X565 on single-axis power block (JT8/JT B) and X564 on single-axis power
block (JT9/JT C).
Dismount the blank plate for JT9/JT C on the connector plate, and then pull and connect
internal harness for external axis (JT9/JT C) (P/N: 50977-0109) into the hole. (See Figure
7-3) Connect braided shield wires and G/Y wire from the inside of the rear cover referring
to Figure 7-4.
hole viewed from controller rear side, and the encoder line pass the left side of the card rack.
(See Figure 7-2)
8. Connect X551 (JT9/JT C) on internal harness for external axis to X551 on single-axis power
block (JT9/JT C).
9. Connect X319 on internal harness for external axis to X319 on MC unit.
10. Connect X513 on internal harness for external axis to X513 on 1TB board.
33
Encoder line Top plate Eyebolt
Motor line,
Brake line
Single-axis power
block (JT9/JT C)
Single-axis power
X566
block (JT8/JT B)
X565
X563 Motor line,
X564
Figure 7-2 Brake line
Inside view of connector plate
X562
X319
X551
PWM harness (JT9/JT C)
Brake line
(P/N: 50973-2988)
(Passed under
MC unit) X519
X513
Figure 7-1
Internal harness for external axis (JT9/JT C)

(P/N: 50977-0109)
Figure 7-4
Figure 7-3
34
2.3 HARDWARE INSTALLATION WHEN USING SANYO MOTORS (E7X

CONTROLLER)
2.3.1 ADDING JT7/JT A VIA SEPARATE HARNESS FOR ROBOT
Follow the procedure below with the reference to Figure 8. (Part number for a set of amplifier
rack, fan and screws: 49094-0088)
1. Dismount the top cover (2) of the controller. For the procedure, refer to2.3.4-1.
2. Mount the amplifier rack (P/N: 50833-0006).
3. Mount a fan (P/N: 50973-2898) on the plate.
4. Connect CN1 and CN2 on 1UZ board (JT7/JT A) to CNAMP7S and CNAMP7P on 1UY
board along the guide rail of the amplifier rack.
5. Connect AMP7 of X4 harness wired in the controller to CN3 on 1UZ board (JT7/JT A).
6. Remount the top cover of the controller.
Fan
(P/N: 50973-2898)
Amplifier rack
(P/N: 50833-0006)
1UZ board for JT7/JT A

Top view
Figure 8
35
Follow the procedure below referring to Figure 9-1 to 9-4. (Part number for a set of amplifier
rack, fan, dedicated harness for JT7/JT A, rear box and screws: 49094-0089)
1. Dismount the top cover (2) of the controller. For the procedure, refer to2.3.4-1.
2. Mount the amplifier rack (P/N: 50833-0006).
3. Mount a fan (P/N: 50973-2898) on the plate.
4. Connect CN1 and CN2 on 1UZ board (JT7/JT A) to CNAMP7S and CNAMP7P on 1UY
board along the guide rail of the amplifier rack. (See Figure 9-1.)
5. Remove the connector plate (6) on the rear of the controller (see Figure 9-2) and mount the
rear box (P/N: 50833-0007) to which motor harness (JT7/JT A) (P/N: 50977-0209) and
signal harness (JT7/JT A) (P/N: 50977-0210) are connected.
6. Connect AMP7 of motor harness (JT7/JT A) to CN3 on 1UZ board (JT7/JT A).
7. Unscrew 11 screws fixing the plate to the rear of the controller and remove the plate from the
controller slightly. (See Figure 9-3.)
8. Remove X317 of X4 harness connected to X317 on 1TV board. Fix the removed X317 of
X4 harness inside the controller with tying band.
9. Connect X317 of motor harness (JT7/JT A) to X317 on 1TV board.
10. Place X511 of signal harness (JT7/JT A) at the position where it touches the bottom of the
controller.
11. Fix the plate to the rear of the controller with 11 screws.
13. Dismount the bottom cover (4) of the controller. For the procedure, refer to2.3.4-2.
14. Remove X511 of X3 harness connected to X511 on 1TB board. Fix the removed X511 of
X3 harness inside the controller with tying band. (See Figure 9-4.)
15. Connect X511 of signal harness (JT7/JT A) to X511 on 1TB board.
16. Remount the bottom cover of the controller.
Rear box (P/N: 50833-0007)
JT7/JT A motor harness (P/N: 50977-0209)
JT7/JT A signal harness (P/N: 50977-0210)
Fan
(P/N: 50973-2898)
Amplifier rack
(P/N: 50833-0006)
Figure 9-1 (Top view) 1UZ board for JT7/JT A
36
(6)
Rear view
Rear connector plate
Figure 9-2
Screw Rear view

Screw
Figure 9-3
X513
X501
X512
X511
567
X506 4 0
3 21
J2
X508 SW7
12 9
J9
X509
8 5
4 1
X510
PUSH PUSH PUSH

J3
J6
J4
X520 X514
J5
J7 J3
X502
X519
JTAG_CPU
J1
CN3
X518
X503
X503
X517
CN2
X515
TP24 X504 X505 X507 SW2
TP23 TP25
Figure 9-4
37
Follow the procedure below referring to Figure 10-1 to 10-4. (Part number for a set of dedicated
harness for JT8/JT B, rear box and screws: 49094-0090) To add JT8/JT B, it is necessary to add
JT7/JT A in 2.3.1. When adding JT7/JT A via dedicated harness for JT7/JT A in 2.3.2,
JT8/JT B cannot be added.
1. Dismount the top cover (2) of the controller. For the procedure, refer to2.4.1.
2. Connect CN1 and CN2 on 1UZ board (JT8/JT B) to CNAMP8S and CNAMP8P on 1UY
board along the guide rail of the amplifier rack. (See Figure 10-1.)
3. Remove the connector plate (6) on the rear of the controller (see Figure 10-2) and mount the
rear box (P/N: 50833-0007) to which motor harness (JT8/JT B) (P/N: 50977-0235) and
signal harness (JT8/JT B) (P/N: 50977-0236) are connected.
4. Connect AMP8 of motor harness (JT8/JT B) to CN3 on 1UZ board (JT8/JT B).
5. Unscrew 11 screws fixing the plate to the rear of the controller and remove the plate from the
controller slightly. (See Figure 10-3.)
6. Connect X318 of motor harness (JT8/JT B) to X318 on 1TV board.
7. Place X512 of signal harness (JT8/JT B) at the position where it touches the bottom of the
controller.
8. Fix the plate on the rear to the controller with 11 screws.
10. Dismount the bottom cover (4) of the controller. For the procedure, refer to 2.3.4-2.
11. Connect X512 of signal harness (JT8/JT B) to X512 on 1TB board. (See Figure 10-4.)
12. Remount the bottom cover of the controller.
Rear box (P/N: 50833-0007)
JT8/JT B motor harness (P/N: 50977-0235)
JT8/JT B signal harness (P/N: 50977-0236)
Top view 1UZ board for JT8/JT B

Figure 10-1
38
(6)
Rear view
Rear connector plate
Figure 10-2
Screw Rear view

Screw
Figure 10-3
X513
X501
X512
X511
567
X506 4 0
3 21
J2
X508 SW7
12 9
J9
X509
8 5
4 1
X510
PUSH PUSH PUSH

J3
J6
J4
X520 X514
J5
J7 J3
X502
X519
JTAG_CPU
J1
CN3
X518
X503
X503
X517
CN2
X515
TP24 X504 X505 X507 SW2
TP23 TP25
Figure 10-4
39
2.3.4 HOW TO REMOVE CONTROLLER COVER
1. Top cover of controller
(1) Unscrew the two screws fixing the meshed cover and dismount the cover by sliding
forward then upward a little. (The cover is caught on the metal plate by two cathes on
the back part.) Screw
Screw
(1)
Front view Left side view
(2) Unscrew the six screws fixing the left side cover (1) of the controller, and then dismount
the cover.
(3) Unscrew the screws* fixing the top cover (2) of the controller. For the screws，refer to
the note below.
(4) Lift the top cover (2) of the controller a little and dismount the connectors of the fan and
regenerative resistor, and then dismount the cover.
NOTE* Screw type

Three kinds of screws are used on the top cover (2) of the controller. Unscrew
Yellow M4 and Silver M3 screws to dismount the top cover of the controller.
Yellow M4: fixing the top cover of the controller and internal parts (Heat sink on 1UZ
board and power unit, etc.)
Silver M3: fixing the top cover of the controller and controller
Silver M4: fixing the top cover of the controller and external parts (Fan and
regenerative resistor, etc.)
40
Yel.M4 Sil.M3 Sil.M3 Sil.M3
Yel.M4
Yel.M4
(2) (2)
Yel.M4 Yel.M4 Sil.M3 Sil.M3

(when using JT7 and 8)
2. Bottom cover of controller
(1) Place the controller lengthwise as shown below.
(4)
Screw
Screw
Lengthwise Bottom view
(2) Unscrew the five screws fixing the bottom cover of the controller, and then dismount the
cover.
41
2.4 WHEN USING MULTI-AXIS CONTROLLER (FOR SANYO MOTOR)
Multi-axis controller is required when using SANYO motors of nine or more axes for E2x
controller and ten or more axes for E1x controller. For the installation of multi-axis controller,
refer to the separate Installation and Connection Manual for multi-axis controller
(90210-1275DE*). A multi-axis controller can connect with max. eight external axes (JT D, E,
F, G, H, J, K, L). Six-axis power block shown in the figure below is used (installed by default in
multi-axis controller) for six axes (JT D  JT J), and single-axis power block is used for JT K and
L as shown below.
Before shipment, Kawasaki decides the six-axis power block specifications and axis No. to be
used based on the motor configuration in your system and wires inside the multi-axis controller
for the necessary axes.

(JT L)

Six-axis power block
(JT K)
(JT DJ)
42
2.4.1 WHEN ADDING AN AXIS AMONG JT D  JT J
This section describes how to add JT G to the multi-axis controller in which JT D and H are used
at factory shipment as an example.
[ NOTE ]
Contact Kawasaki to find which axis of multi-axis controller is used
before selecting a motor to add. It is necessary to decide which axis is
appropriate according to the motor to be used by Kawasaki.
1. Prepare internal harnesses of external axis ((1) Power・・・P/N: 50977-0472, (2) Signal・・・
P/N: 50977-0461). (Common among JT D  J)
2. Attach mark tube and sticker for axis No. display attached on the multi-axis controller on the
harnesses shown in 1 according to the axis No. to be used.
3. Remove the rear plate and plates A and B for JT G shown in the figure below.
4. Connect harness (1) to the position of JT G plate A and harness (2) to the position of plate B.
At that time, fix earth wire and shield wire of harness (1) and shield wire of harness (2) to
the spacer on the rear of the plate with screws.
5. Relay connectors per axis can be found by opening the rear plate. Connect to the position
of JT G. (relay connector: XMOT(JT G), XBRK(JT G), XENC(JT G))
6. Return the rear plate where it was.
Before mounting JT G
(JT D, E, F, G, H, J from left) After mounting JT G
JT D, E, F, G, H, J from left
Rear plate is open. 43

2.4.2 WHEN ADDING EITHER JT K OR JT L
JT K and L are used when;

1. Selected motor cannot be used with the six-axis amplifier inside the multi-axis controller.
2. JT K and L are used when it is necessary for the multi axis controller to connect with the
motors of seven or more axes.
The procedure of adding JT K to the multi-axis controller is the same with that of installing JT7
(JT A) in E2x controller in 2.1.2 except P/N of the harness to be used.
(Internal harness part No. required for JT K addition)

・ PWM harness: 50977-0490
・ PN harness: 50977-0491
・ DC line harness: 50977-0492
・ Internal harness of external axis: 50977-0496
The procedure of adding JT L to the multi-axis controller is the same with that of installing JT8
(JT B) in E2x controller in 2.1.3 except P/N of the harness to be used.
(Internal harness part No. required for JT L addition)

・ PWM harness: 50977-0493
・ PN harness: 50977-0494
・ DC line harness: 50977-0495
・ Internal harness of external axis: 50977-0497
44
Mitsubishi MELSERVO-J2-SUPER Standard Amplifier / Motor
E Controller
X 1.5sq
A
Inrush Control Power
C
E Series Controller
MC Unit Current 210Vac 1φ

Control
K1(,K2) ircuit Motor Power
X
3 210Vac 3φ
8
3φ
3φ
6sq
3φ
1φ
1φ
1φ
2
AC210V
AC210V
AC210V
AC210V
AC210V
AC210V
Brake Power L1,L2,L3 L11,L12 L1,L2,L3 L11,L12

24Vdc L1,L2,L3 L11,L12
RA2 ② RA3 ②
0.75sq RA1 ② CN3 CN3
X
CN3
3
1 ⑩ ⑩
2 x 3pairs ⑩
Amplifier 1 Amplifier 2 Amplifier 3

Card Rack
⑥ ⑪ ⑥ ⑪ ⑥ ⑪
2.5 WHEN USING MITSUBISHI MOTOR
45
① CN1A CN1B CN1A CN1B
CN1A CN1B
② ③ ③ ④
1
L 1
U,V,W,E CN2
P T
U,V,W,E CN2 U,V,W,E CN2
R
RA1 PB1 RA2 PB2 RA3 PB3
6sq ⑦ ⑦
⑦
Motor
Brake
Brake
Motor
Brake
Motor
Encoder
Encoder
Encoder
below shows connecting system diagram when using a MITSUBISHI motor.
⑨ ⑧ ⑧ ⑧
⑤ ⑤ ⑤
When using MITSUBISHI motor, prepare expansion controller following this section. Figure
2. Hardware Installation
2.5.1 NECESSARY HARDWARE FOR MITSUBISHI MOTOR
Based on system diagram above, use only the parts below when adding an external axis.
1. MITSUBISHI parts
MITSUBISHI
No. Name KHI Part No. Remarks
Model No.
1 SSCNET I/F board (1LP board) 50999-2423 MR-KHDF80 Per 1 system
2 SSCNET bus cable (5 M) 50978-4009 MR-J2HBUS5M Select a cable (2 M or 5
SSCNET bus cable (2 M) 50978-2296 MR-J2HBUS2M M) per 1 system.
3 SSCNET bus cable (0.5 M) 50978-3327 MR-J2HBUS05M (Motor number-1) per 1
system
4 Bus terminator (SSCNET) 60652-2091 MR-A-TM Per 1 system
5 Motor (0.5 kW) 50601-1346 HC-SFS53BK
Motor (1 kW) 50601-1347 HC-RFS103BK
Motor (1.5 kW) 50601-1348 HC-RFS153BK
Motor (2 kW) 50601-1349 HC-RFS203BK
Motor (3.5 kW) 50601-1350 HC-RFS353BK
Motor (5 kW) 50601-1351 HC-UFS502BK
6 Amplifier (For 0.5 kW) 50607-1407 MR-J2S-60B For HC-SFS53BK
Amplifier (For 1 kW/1.5 kW) 50607-1408 MR-J2S-200B For HC-RFS103BK,
HC-RFS153BK
Amplifier (For 2 kW) 50607-1409 MR-J2S-350B For HC-RFS203BK
Amplifier (For 3.5 kW/5 kW) 50607-1410 MR-J2S-500B For HC-RFS353BK,
HC-UFS502BK
7 Encoder cable ( M)  MR-ENCBL Common for all motors
: 5/10/20/30 M-H
8 Motor connector set (0.5-2 kW)  MR-PWCNS1 Connector only.
Wiring required.
Motor connector set (3.5/5 kW)  MR-PWCNS2 Connector only.
Wiring required.
9 Brake connector set (5 kW  MR-BKCN Connector only.
motor) Wiring required.
10 Brake connector set (Amplifier  MR-J2CN1 Connector only.
CN3) Wiring required.
11 Battery (Absolute encoder 50750-1023 MR-BAT Common for all
system) amplifiers
46
2. Optional regenerative resistor (If necessary)

Name Model No. Remarks
Optional regenerative resistor for 0.5 kW (30 W) MR-RB032
Optional regenerative resistor for 0.5 kW (100 W) MR-RB12
Optional regenerative resistor for 1-5 kW (300 W) MR-RB30
Optional regenerative resistor for 1-5 kW (500 W) MR-RB50
3. Relay for brake drive (RA1, 2, 3)

Use a relay for the brake drive with the following rating.
Coil rating: DC24 V/40 mA or less Contact rating: DC30 V or more/3 A or more
4. 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
47
2.5.2 PARTS ARRANGEMENT
Example arrangement inside the expansion controller is shown below.
Cooling fan (on the door)
Amplifier (3.5/5 kW)

Amplifier (1/2 kW)
Amplifier (0.5 kW)
Brake drive relay
Encoder cable wiring hole
Motor wiring hole
Signal duct
Power duct
(Magnetic contactor for separate control)
Terminal block for power distribution
(Terminal block for separate control signal)
(DC power for separate control signal)
Cooling fan
Optional regenerative resistor
SSCNET bus cable hole
Power cable hole
Expansion controller fixing bolt hole
48
2.5.3 MOUNTING/CONNECTION PROCEDURE
This section describes how to mount and connect the following parts.
1. Power distribution terminal block

2. Main circuit/Controller power/Regenerative option
3. SSCNET I/F board (1LP board)
4. SSCNET bus cable connection, battery mounting, earth
5. Brake drive relay
6. Encoder cable between amplifier and motor
7. Motor/brake cable between amplifier and motor
1. Power distribution terminal block

Connect the following connectors to MC unit.
No. Housing Contact Maker Wire
Main circuit power X382 1-179958-3 316041-2 AMP 6sq Black
Controller power XAC-5 F35FDC-02V-K BF3F-71GF-P2.0 JST 1.5sq Black
Brake power X312 J21DF-12V-KY-L SJ2F-21GF-P1.0 JST 0.75sq
B24V, R24V: Blue
B24G:
Blue-and-white stripe
Example of terminal block connection is shown below.

Amplifier controller
Amplifier main circuit L1,L2,L3 power L11,L21
Fan power
Brake power
X382
Power thermistor
X382
(Approx. 22 Ω,
inrush current control)
XAC-5
XAC-5
X312
X312
B24V: A1, A2 R24V: A3, A4 B24G: A5, A6

Pair A1 with A5, A2 with A6, and A3 with A4.
49
2. Main circuit/Controller power/Regenerative option

Connect the L1, L2, L3, L11, L21 terminals of each servo amplifier to the terminal blocks in 1.
Refer to the figure below to connect optional regenerative resistors.
Servo amplifier Servo amplifier

MR-J2S-350B or less MR-J2S-500B
Terminal block L1 Terminal block L1

Terminal block 210L Terminal block 210L

Terminal block 210N Terminal block 210N
Misconnecting of
regenerative option may Misconnecting of
damage servo amplifier. regenerative option may
damage servo amplifier.
Regenerative
Regenerative
option
option
Disconnect between Disconnect between
P-D to connect C-P to connect
regenerative option regenerative option
to exterior. to exterior.
3. SSCNET I/F board (1LP board)

Mount 1LP board to the rear of 1TR board and fix it with the provided screws/spacers. Use
the cable provided on 1LP board to connect between 1TR-CN10 and 1LP-CN4. Set SW1-1
to ON and SW1-2, SW2-1 and SW2-2 to OFF (fix) as shown below.
CN1 (SSCNET I/F connector)

1TR-CN10 1TR board
1LP board
1LP-CN4
OFF
ON
SW1
1 2
Fixing parts (3)

OFF
ON
SW2
1 2
CN3 CN4
50
4. SSCNET bus cable connection, battery mounting, earth

(1) Connect between 1LP-CN1 and servo amplifier and between servo amplifiers with
SSCNET bus cables (MR-J2HBUS M).
(2) Mount terminal connector (MR-A-TM) on the last servo amplifier.
(3) Mount the battery (MR-BAT) to each servo amplifier.
(4) Connect servo amplifier to the earth securely.
Servo amplifier [ NOTE ]
MR-J2S- B
Main circuit power

The battery usually requires
to be replaced every one year.
Control circuit power
1LP board
MR-J2HBUS M cable
MR-J2HBUS M cable
Servo amplifier
MR-J2S- B
nd
(2 axis)
MR-J2HBUS M cable
Servo amplifier
MR-J2S- B
th
Insert terminal connector (MR-A-TM) (n axis)
to CN1B on servo bus terminator.
5. 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.
Servo amplifier
MR-J2S- B
10m or less
Magnetic brake
interlock
Connect VDD-COM
without fail. Do not
use external power.
51
6. Encoder cable between amplifier and motor

Connect between servo amplifier CN2 and encoder by MR-ENCBL M-H.
Servo amplifier
MR-J2S- B Servomotor
HC-SFS, RFS,
UFS2000r/min series
Encoder
Plate
Connector type (reference)

10120-3000VE 3M MS3106A20-29S (D190) DDK
10320-52F0-008 3M CE3057-12A-3 (D265) DDK
7. Motor/brake cable between amplifier and motor

Make motor/brake cables with connectors set for each motor and connect them.
(1) 0.5 kW (HC-SFS53B)/1 kW (HC-RFS103B)/2 kW (HC-RFS203B)
Servo amplifier Servomotor

MR-J2S- B HC-SFS53B
RFS103B/203B
Magnetic
brake
Connector set MR-PWCNS1
CE05-6A22-23SD-B-BSS DDK
CE3057-12A-2 (D265) DDK
52
(2) 3.5 kW (HC-RFS353B)
Servo amplifier
MR-J2S-500B Servo amplifier
HC-RFS353B
Magnetic
brake
Connector set MR-PWCNS2
CE3057-16A-2 (D265) DDK
(3) 5 kW (HC-UFS502B)
Servo amplifier
MR-J2S-500B Servo amplifier
HC-UFS502B
Magnetic
brake
Connector set MR-PWCNS2 (For motor)
CE3057-16A-2 (D265) DDK
Connector set MR-BKCN (For brake)
MS3106A10SL-4S DDK
YSO10-58 DAIWA DENGYO CO., LTD
53
E Series Controller 3. Setting of External Axis Parameter Values
3.0 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.
3. Input “899” by NUMBER (0 - 9) and press . [Enable maintenance function] screen as

below is displayed.
54
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.
55
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).
When the parameter data in this page are set, press <Next Page> and go on to the next screen.
56
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 robot controller and 2 for
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 9 or lower number 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. Normally, this setting is done at factory
shipment.
The table below shows the relation between servo board axis numbers/channel numbers and
hardware axis numbers. For the hardware axis numbers 7/A-9/C, D-J and K-L, refer to 2.1-2.3,
2.4.1 and 2.4.2, respectively.
Servo board No. 1 1 1 2 2 2 2 2 2 2 2

Channel No. 7 8 9 1 2 3 4 5 6 7 8
Hardware axis No. 7/A 8/B 9/C D E F G H J K L
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 at factory shipment.
MC unit number
Enter MC unit number 1-3 depending on the amplifier to use. Normally, this setting is done at
factory shipment.
57
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.
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.
When the data in this page are set, press <Next Page> and go on to the next screen.
58
Linear Cooperation
Sets the condition number for robot and axis cooperation. Enter 0 to cancel robot and external
axis cooperation. When cooperating, select from 1-6 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 chapter 5.
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.
59
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 chapter 3.1.
Equivalent Radius
Enter a value that satisfies the condition below.
Max Speed
360  Equivalent radius  2 > 250
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 chapter 3.1. Press <Next Page> when done.
60
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 chapter 5.
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.
61
Start position End position
Rotation axis
Robot arm
Base coordinate Y
Base coordinate X
Robot arm
Travel axis (x, y, 0)
home position
y
Travel axis (0, 0, 0) x
Travel 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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E Series Controller 4. Setting of Servo Parameter Value
4.0 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.
Normally, it is loaded at factory shipment.
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 chapter 3.
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 chapter 4.1.1.1 and 4.1.1.2.
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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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-M.” 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.
66
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 manu. by MITSUBISHI Electric Corp. instruction
manual”.
“MR-J2S- B INSTRUCITON MANUAL (SH (NA)-030007”)
！ 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 chapter 3.
Select [Aux. 2007. External Axis Servo Parameter].
There are two methods for setting/adjusting external axis servo parameter values: [1 Simple
Tuning] and [2 Full Spec Tuning]. Select [1 Simple Tuning] when adjusting via auto tuning
mode 1 or manual mode 1 by auto tuning*. Select [2 Full Spec Tuning] to use other auto tuning
or to set each individual parameter value.
NOTE* To auto tuning, refer to parameter No.8 “ATU” in the “Parameters” chapter and the
“General gain adjustment” chapter in the “Amplifier manu. by MITSUBISHI Electric
Corp. instruction manual”.
67
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
RSP* is set in [Auto tuning mode 1]. Pressing  registers the value set in [RSP] (Servo
response). 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 No.9 “RSP” in the “Parameters” chapter and the “General
gain adjustment” chapter of “Amplifier manu. by MITSUBISHI Electric Corp.
instruction manual”.
4.2.1.2 MANUAL MODE 1
GD2, PG1, VG2, and VIC** are set in [Manual mode 1]. Pressing  registers the set value for
each parameter.
NOTE** For GD2, PG1, VG2, and VIC, refer to parameter No.12 “GD2”, No.13 “PG1”, No.16
“VG2” and No.17 “VIC” in the “Parameters” chapter and the “General gain
adjustment” chapter of “Amplifier manu. by MITSUBISHI Electric Corp. instruction
manual”.
69
4.2.2 FULL SPEC TUNING
In [2. Full Spec Tuning], all parameter values can be set.
Enter the number of axis to which the parameter values are set and press <Next page>.
Refer to the “Parameter” chapter of “Amplifier manu. by MITSUBISHI Electric Corp. instruction
manual” for the parameters of this screen. For No.21“MBR”, normal setting is 250 (ms).
Pressing <Next Page> displays another parameter value setting screen as follows.
“FFCT” is the setting value of the parameter “FFC” in Teach mode and “KPCF3T” is the setting
value of the parameter “KPCF3” in Teach mode. Parameters “FFCT” and “KPCF3T” are used
when the motion of external axis has delays compared with that of robot, and are used when
changing values in Teach mode and Repeat mode.
Expert knowledge of how parameter value changes affect the behavior of the servo system is
needed in order to change other parameter values in this screen. Do not change the parameter
values except in very special cases.
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！ 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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E Series Controller 5. Cooperative Control Function
5.0 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 chapter 3.1.
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 chapter 3.2. 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１1
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 chapter 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 chapter 3.
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. Detailed
procedures are described in each section below.
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.
79
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 1-4 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 Cooperative] 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.
2. Teach a point to check the positioner position.
4. If check shows positioner cooperation does not function properly, redo registration of
positioner setting position in chapter 5.3.1.1 and reregister positioner setting position.
Procedures
>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. Detailed
procedures are described in each section below. 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.
83
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.
84
[ NOTE ]
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.
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.
Procedure
>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
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.
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Tilting axis rotation 3
Positive
direction
Completing 1-2 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.
86
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 chapter 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 chapter
5.3.2.1.
Rotating in direction (a) +
x3
y3
z3
x2
z2
+
y2
87
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 ]
2. Teach a point to check positioner position.
4. If check shows positioner cooperation does not function properly, redo
check of positioner rotating direction and dimensions in chapter 5.3.2.1.
Procedure
>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.

When using KHI amplifier, refer to 4.1.1.
When using MITSUBISHI amplifier, refer to 4.2.1.
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.
90
6. Confirm the relation between positioner delay and TCP speed fall.
Check the speed of TCP after changing data of Aux.2102.
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.
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.
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
91

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.
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.
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

92
1. Confirm the problem.

Confirm whether the problem occurs with low welding speed (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 chapter 5.3.1.3 for single-axis positioner or 5.3.2.4 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 chapter 4.1 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 chapter 4.2.1.1 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 manu. by MITSUBISHI Electric Corp.
instruction manual”.
93
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.

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.
94
(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.

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*pi*Rextaxis)
Rextaxis = 250/VMAXpos/(pi/180)/TRratio *100
ERRpos:
Delay of positioner axis (degree)
CMDpos:
Position command value of positioner axis (degree)
([JT command] in data storage function)
95
CMDpos(i):
Position command value of positioner axis at a certain time (degree)
FBpos:
Current position of positioner axis (degree)
([JT angle] in data storage function)
Vpos:
Velocity of position command for positioner axis (degree/s)
Tzarcacc:
Acceleration and deceleration time at arc welding steps (default value: 128 ms) (ms)
Tsamp:
Sampling cycle of position command values (ms) ([Time Interval Setting] in data
storage function)
TRratio:
[Teach/Repeat ratio] in Aux. 2002 (%) (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 (degree/s)
ACCUpos:
Accuracy for positioner axis (50 mm)
Rextaxis:
Equivalent radius of positioner axis (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.

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)
96
[ 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.

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.
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.
97
10. Check the speed of positioner.

If positioner speed is too high, the TCP speed may fall. Change teaching as follows.

Confirm whether the speed of TCP satisfies the condition of formula (1) or not.
ABS( Vpos/2 + ERRpos ) < ACCUpos - formula(1)
See chapter 7 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.
Confirm whether the distance between two teaching points satisfies the following formula or
not. (See chapter 7 about Tzarcacc.)
distance > welding speed(cm/min) * 10/60 * Tzarcacc - formula (2)
If distance is too short, change teaching as follows.

(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
98
E Series Controller 6. Endless Positioner Function
6.0 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.
Weld a circle Reverse rotation not required
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: (1-100000) n2: (1-1000)
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.
99
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.
100
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 minus 100 - 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° - 360°)
270° + (360°  10) = 3870°
101
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 - 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.
102
E Series Controller 7. Dual Servo Function
7.0 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.
103
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 in chapter 7.2), 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.
104
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].
105
(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.
106
E Series Controller Appendix. Examples of External Axes
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 chapter 1.4.
A-1
Example 1: Type 1
No. of add. axes 1 (Linear axis: 1 axis)
Motor capacity Linear axis: 1.5 kW  1 Positioner:
Standard
controller
(E controller)
M1 M2
Construction Robot
S1 S2
M3 S3
Motor Linear axis
Fixed motor/signal harness

Movable motor/signal harness
E2x E1x/E3x/E4x
Motor 1.5 kW (SANYO) 50601-1366×1
KHI amplifier (50 A) 50607-1509×1
PWM harness (JT7) 50978-3911×1 50973-2986×1
PN harness (JT7) 50978-3909×1 50977-0148×1
DC lien harness (JT7) 50978-3910×1 50977-0149×1
Additional parts M2 motor harness
S2 signal harness
M3 motor harness*
S3 signal harness*
NOTE*
M3 ≤ 2 m
S3 ≤ 2 m
A-2
Example 2: Type 2
No. of add. axes 2 (Positioner: 2 axes)

Motor capacity Linear axis: Positioner: 1.5 kW  2
AM0
Standard
AS0 Motor Positioner
controller CB
AS1
(E controller) AM0
CB
AS1
Construction
M1
Robot
S1
E2x E1x/E3x/E4x
Motor 1.5 kW (SANYO) 50601-1366×2
KHI amplifier (50 A) 50607-1509×2
JT7 addition harness set
PN harness (JT7) 50978-3909 50977-0148
DC harness (JT7) 50978-3910 50977-0149
PWM harness (JT7) 50978-3911 50973-2986
Rear harness (JT7) 50978-3920 50977-0107
Additional parts JT8 addition harness set
PN harness (JT8) 50978-3914 50977-0111
DC harness (JT8) 50978-3915 50977-0112
PWM harness (JT8) 50978-3916 50973-2987
Rear harness (JT8) 50978-3921 50977-0108
Connection box with 1HG board 50326-1093×2
AM0 motor harness ×2
AS0 signal harness ×2
A-3
Example 3: Type 3
No. of add. axes 2 (Linear axis: 1 axis + Positioner: 1 axis)

Motor capacity Linear axis: 2 kW  1 Positioner: 2 kW  1
AM1
Standard
controller CB
AS1
(E controller)
Construction AM1
Motor Linear axis
CB
AS0 AS1
M1 M2
Robot
S1 S2

A-4
E2x E1x/E3x/E4x
Motor 2 kW (SANYO) 50601-1490×2
KHI amplifier (50 A) 50607-1509×2
PN harness (JT7) 50978-3909 50977-0148
DC harness (JT7) 50978-3910 50977-0149
PWM harness (JT7) 50978-3911 50973-2986
Rear harness (JT7) 50978-3920 50977-0107
Additional parts PN harness (JT8) 50978-3914 50977-0111
DC harness (JT8) 50978-3915 50977-0112
PWM harness (JT8) 50978-3916 50973-2987
Rear harness (JT8) 50978-3921 50977-0108
M2 motor harness
S2 signal harness
A-5
Example 4: Type 4
Motor capacity Linear axis: Positioner: 2 kW  2
AM1
Standard Positioner
AS0 Motor
controller CB
AS1
(E controller) AM1
CB
AS1
Construction
M1
Robot
S1
E2x E1x/E3x/E4x
Motor 2 kW (SANYO) 50601-1490×2
KHI amplifier (50 A) 50607-1509×2
PN harness (JT7) 50978-3909 50977-0148
DC harness (JT7) 50978-3910 50977-0149
PWM harness (JT7) 50978-3911 50973-2986
Rear harness (JT7) 50978-3920 50977-0107
Additional parts JT8 addition harness set
PN harness (JT8) 50978-3914 50977-0111
DC harness (JT8) 50978-3915 50977-0112
PWM harness (JT8) 50978-3916 50973-2987
Rear harness (JT8) 50978-3921 50977-0108
A-6
Example 5: Type 5
No. of add. axes 1 (Positioner: 1 axis)
Motor capacity Linear axis: Positioner: 2 kW  1
AM1
Standard
controller CB
AS1
(E controller)
Construction
M1
Robot
S1
E2x E1x/E3x/E4x
Motor 2 kW (SANYO) 50601-1490×1
KHI amplifier (50 A) 50607-1509×1
PN harness (JT7) 50978-3909 50977-0148
DC harness (JT7) 50978-3910 50977-0149
Additional parts
PWM harness (JT7) 50978-3911 50973-2986
Rear harness (JT7) 50978-3920 50977-0107
A-7
Example 6: Type 6
Motor capacity Linear axis: 2 kW  1 Positioner:
Standard
controller
(E controller)
Construction
AM1
CB Motor Linear axis
AS0 AS1
M1 M2
Robot
S1 S2

E2x E1x/E3x/E4x
Motor 2 kW (SANYO) 50601-1490×1
KHI amplifier (50 A) 50607-1509×1
PN harness (JT7) 50978-3909 50977-0148
DC harness (JT7) 50978-3910 50977-0149
PWM harness (JT7) 50978-3911 50973-2986
Additional parts Rear harness (JT7) 50978-3920 50977-0107
M2 motor harness
S2 signal harness
A-8
Example 7: Type 7
No. of add. axes 2 (Linear axis: 1 axis + Positioner: 1 axis)
Motor capacity Linear axis: 2 kW  1 Positioner: 4.2 kW  1
Standard AM5
controller CB
AS1
(E controller)
Construction AM1
CB Motor Linear axis
AS0 AS1
M1 M2
Robot
S1 S2

E2x E1x/E3x/E4x
Motor 4.2 kW (SANYO) 50601-1412×1
Motor 2 kW (SANYO) 50601-1490×1
KHI amplifier (50 A) 50607-1509×1
KHI amplifier (100 A) 50607-1503×1
PN harness (JT7) 50978-3909 50977-0148
Additional parts DC harness (JT7) 50978-3910 50977-0149
PWM harness (JT7) 50978-3911 50973-2986
Rear harness (JT7) 50978-3920 50977-0107
PN harness (JT8) 50978-3914 50977-0111
DC harness (JT8) 50978-3915 50977-0112
PWM harness (JT8) 50978-3916 50973-2987
Rear harness (JT8) 50978-3921 50977-0108
A-9
E2x E1x/E3x/E4x
M2 motor harness
S2 signal harness
RS020N + E10/E20
Additional  Regenerative resistor 50977-0272
parts* RS020N + E30
 Transformer 60621-1215
 CB2 (25 A) 60569-1160
 Regenerative resistor 50977-0272
RS020N + E40
 Transformer 60621-1213
 CB1 (20 A) 60569-1139
 CB2 (25 A) 60570-1266
 Regenerative resistor 50977-0272
NOTE* Follow the procedure below when replacing the following parts in additional parts.
1. Regenerative resistor (placed in the back of servo amplifier)
(1) Remove the servo amplifier.
(2) Disconnect the connector of regenerative resistor and remove the regenerative
resistor.
(3) Fix a new regenerative resistor with the attached hexagonal spacer.
(4) Fix another regenerative resistor with attached screws.
(5) Connect the connector of the regenerative resistor.
(6) Mount the servo amplifier.
2. Transformer (placed inside of the left side panel)
(1) Remove the left side panel and the rear panel.
(2) Replace the transformer.
(3) Return the panels.
3. CB1 and CB2 (placed upper side of back left inside the controller)
(1) Remove the wiring of CB1 and CB2.
(2) Replace CB1 and CB2.
(3) Mount CB1 and CB2.
A-10
Example 8: Type 8 (only for E1x/E3x/E4x)

No. of add. axes 3 (Positioner: 2 axes + Turn table: 1 axis)
Motor capacity Turn table: 4.2 kW Positioner: 1.2 kW×2
AM1
Standard Positioner
AS0 Motor
controller CB
AS1
(E controller) AM1
CB
AS1
Construction
AM5
Turn table
CB Motor 4.2 kW
AS0 AS1
M1
Robot
S1
E2x E1x/E3x/E4x
Motor 1.2 kW (SANYO) 50601-1491×2
Motor 4.2 kW (SANYO) 50601-1412×1
KHI amplifier (100 A) 50607-1503×1
KHI amplifier (30 A) 50607-1504×2
PN harness (JT7) 50977-0148
DC harness (JT7) 50977-0149
PWM harness (JT7) 50973-2986
Rear harness (JT7) 50977-0107
Additional parts
A-11
Connection box with 50326-1093×3

1HG board
Additional parts AM1 motor harness ×2
A-12
Example 9: Type 9 (only for E7x)

Motor capacity Linear axis: 1.2 kW×1 Positioner:
Standard
controller
(E controller)
M1 M2
Construction Robot
S1 S2
M3 S3
Motor Linear axis

 Motor 1.2 kW (SANYO) 50601-1491×1

 KHI amplifier (30 A) 50607-0019×1
 Rack for additional amplifier 50833-0006
49094-0088
 Fan for additional amplifier 50973-2898
 M2 motor harness
Additional parts  S2 signal harness
 M3 motor harness
 S3 signal harness
NOTE
M3 ≤ 2 m
S3 ≤ 2 m
A-13
Example 10: Type 10 (only for E7x)
No. of add. axes 1 (Positioner: 1 axis)

Motor capacity Linear axis: Positioner: 1.2 kW×1
AM1
Standard AS0 Motor Positioner
controller CB
AS1
(E controller)
Construction
M1
Robot
S1
 Motor 1.2 kW (SANYO) 50601-1491×1
 KHI amplifier (30 A) 50607-0019×1
 JT7 addition harness set Rack for additional amplifier: 50833-0006

(49094-0089) Fan for additional amplifier: 50973-2898
Rear motor harness (JT7): 50977-0209
Additional parts Rear signal harness (JT7): 50977-0210
Rear box: 50833-0007
 Connection box with 1HG board 50326-1093×1
 AM1 motor harness ×1

 AS0 signal harness ×1
A-14
Example 11: Type 11

Motor capacity Linear axis: Positioner: 3.5 kW×4
AM
Standard AS2 Motor Positioner
controller AM
(E controller)
AM
AM
Construction
M1
Robot
S1
 Motor 3.5 kW (MITSUBISHI) HC-RFS353BK×4

 3.5 kW motor amplifier (MITSUBISHI) MR-J2S-500B×4
 SSCNET I/F board 50999-2423×1

 SSCNET bus cable (5 m) MR-J2HBUS5M×1
 SSCNET bus cable (0.5 m) MR-J2HBUS05M×3
 SSCNET terminal connector MR-A-TM×1
Additional parts  M1 motor harness

 S1 signal harness
 AM3 motor harness ×4

 Transformer
 NFB（F1）
 F2
A-15
Example 12: Type 12

Motor capacity Linear axis: Positioner: 2 kW×4
AM0
Standard JT D AS0 Motor Positioner
CB
AS1
controller
(E controller) AM0
JT E AS0 Motor Positioner
Multi-axis CB
AS1
controller AM0
JT F AS0 Motor Positioner
CB
AS1
Construction AM0
JT G AS0 Motor Positioner
CB
AS1
M1
Robot
S1
Multi-axis controller
Motor 2.0 kW 50601-1490×2
Multi-axis controller (including ×1
6-axis amplifier)
Harness between controllers 50979-0205×1
50979-0206×1
Multi-axis controller
Additional parts 1-axis additional harness set 50977-0472×4
Rear motor harness 50977-0461×4
Rear signal harness
Connection box with 1HG 50326-1093×4
board
A-16
Kawasaki Robot E Controller
External Axis Addition Manual (Option)
August 2009 : 1st Edition

January 2013 : 4th Edition
Published by KAWASAKI HEAVY INDUSTRIES, LTD.
90210-1249DED
Copyright  2013 KAWASAKI HEAVY INDUSTRIES, LTD. All rights reserved.

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Kawasaki Robot

Kawasaki Heavy Industries, Ltd.

1.0 Selection of External Axis Component Parts ....................................................................6

2.0 Hardware Installation .......................................................................................................21

2.5.3 Mounting/Connection Procedure .....................................................................................49

3.0 Setting of External Axis Parameter Values .....................................................................54

4.0 Setting of Servo Parameter Value ....................................................................................63

5.0 Cooperative Control Function..........................................................................................72

6.0 Endless Positioner Function .............................................................................................99

7.0 Dual Servo Function.......................................................................................................103

Appendix Examples of External Axes ........................................................................................ A-1

1.0 SELECTION OF EXTERNAL AXIS COMPONENT PARTS

1.1 SERVOMOTOR TYPE

SANYO motor MITSUBISHI motor

(Example 1: E2x controller + multi-axis controller for SANYO motor)

Controller Multi-axis controller

(Example 2: E4x controller + expansion controller for MITSUBISHI motor)

Controller Expansion controller MITSUBISHI

1.1.1 SANYO MOTOR & KHI AMPLIFIER SPEC.

Position of Mount with M-T bolt

At 0 from taper Grade Grade b

Remarks Side fit

1.1.2 MITSUBISHI MOTOR & AMPLIFIER SPEC.

Mount with M-T bolt

1.2 SANYO MOTOR SELECTION PROCEDURE

1.2.1 ROTATION AXIS

1. Determination of load output axis specification

2. Selection of reduction unit

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

Reduction unit Motor

3. Check of condition expressions and selection of motor

Condition expression Expression

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

4 Max. motor RPM when operating ωi

5 Number of encoder rotations when θi

6 Ratio of load side moment of JW+MWLO2

reduced to that of motor axis side

1.2.2 LINEAR AXIS (RACK & PINION DRIVE)

1. Determination of load output axis specification

2. Selection of reduction unit and guide

Determine rack and pinion data.

Determine guide data.

Determine motor and flywheel data.

3. Check of condition expressions and selection of motor

Condition expression Expression

2 Holding torque of motor 9.8mZMW

3 Average motor torque on ΣtiTi2

4 Max. motor RPM when 60Vi

side reduced to that of motor

1.2.3 LINEAR AXIS (BALL SCREW DRIVE)

1. Determination of load output axis specification

2. Selection of reduction unit and guide

Determine specifications of ball screw.

Determine guide data.

Determine motor and flywheel data.

3. Check of condition expressions and selection of motor

Condition expression Expression

3 Average motor torque on ΣtiTi2

4 Max. motor RPM when 60Vi

side reduced to that of motor