ZX200S Six-axis robotic arm (manipulator)
Large General Robots · Load capacity: 200kg · Reach: 2651mm
ZX200S specifications
The ZX200S is an industrial robot from Kawasaki Heavy Industries' ZX series, with a maximum payload of 200kg and a maximum reach of 2651mm.
Model introduction
The ZX200S belongs to Kawasaki Heavy Industries' ZX series of large general-purpose robots. Typical applications include: assembly, handling, and spot welding.
Large General Robots BX/ZX/BXP/BTP Series · Series technical features
Kawasaki's large general-purpose robot B Series offers a rich product lineup, covering loads of 100-300kg and working radius of 1500-3400mm, and is widely used in industries such as automotive, aerospace, machinery, metals, electrical and electronics, and food.
Multiple subseries including BX/ZX/BXP/BTP cover medium, heavy, and heavy loads with different arm spans, precisely matching various large-scale operation requirements.
The BX/BXP series cable conduits are built-in, enabling high-density installation, and the robotic arm structure is more compact.
The BX/ZX series is widely used in automotive spot welding operations and has been proven by the automotive industry over time.
The BXP series is lighter and more compact than the BX series, and when paired with the F series control cabinets, it delivers faster motion control.
Typical application scenarios
Common application processes for this model (click to view process details):
Large General Robots BX/ZX/BXP/BTP Series · Other models in the same series
Compare load and reach to choose the model that best suits your process.
ZX200S model positioning and working condition adaptation
ZX200S This is an industrial robot model belonging to Kawasaki's large general-purpose robot BX/ZX/BXP/BTP series, with a rated load of 200kg and a motion radius of 2651mm. Kawasaki's technical foundation is strong AS language capabilities and deep accumulation in semiconductor cleanliness and welding applications; The control platform is F series (partial) / E series, and the program ecosystem is AS language + teach pendant.
From the perspective of working condition adaptation, typical applications for positioning large loads (200kg) are:Integrated palletizing, die-casting and part-picking, heavy handling and weldingCommon application processes for this model include assembly, handling, and spot welding. The extra-long boom (2651mm) is suitable for large workpieces and cross-line services, with attention to stiffness and vibration during large overhanging postures. Foundation load-bearing and base fastening torque under heavy load conditions are essential items for installation acceptance; if the inertia ratio exceeds the limit, the cycle time will degrade significantly.
| Parameters | Engineering interpretation and usage recommendations |
|---|---|
| Rated load: 200kg | It is recommended to reserve a load margin of 20%–30%; Verification is made by combining end self-weight + workpiece + imbalanced load inertia, especially sensitive to high-speed conditions |
| Radius of movement: 2651mm | Determine the radius of the workcell layout: bins, tooling, and fences are bounded by maximum arm span + safety distance; Verify the accessibility of each pick-and-place point during cross-station service |
| Controllers F Series (partial) / E Series | Decide on the process ecosystem, spare parts channels, and second-hand residual value; Currently, spare parts channels are smooth, and repair and upgrade paths are mature |
Control systems and common failure modes
The ZX200S comes with some F series (partial) and E series controllers, with AS language + teach pendant as the programming language and development environment. Maintenance of this generation of control platforms focuses on three basic components: power, storage, and cooling—most "sudden downtime" can be detected in advance when preventive maintenance is in place.
| Failure mode | Typical performance | Disposal recommendations |
|---|---|---|
| 1FB/2FB board failure | 1FB/2FB board fault (driver control board aging) | Included as a mandatory inspection item for annual maintenance, with spare parts stocked in advance |
| The encoder battery is depleted, causing the origin to be lost | The encoder battery is depleted, causing the origin to be lost | Initial interpretation of alarm codes by reference with manuals, remote diagnosis allows for early positioning |
| The teach pendant's LCD and buttons are aging | The teach pendant's LCD and buttons are aging | Daily inspection coverage, with abnormal trends (abnormal noises/temperature rise/errors) recorded |
| Overcurrent alarm in the driver unit | Overcurrent alarm in the drive unit (motor or load abnormality) | Quarterly dust removal maintenance and cabinet temperature monitoring |
| Maintenance projects | Cycle recommendations | Key points |
|---|---|---|
| The battery is replaced annually | Every year | The battery should be replaced annually, and the original calibration should be performed after replacement |
| Reducer grease should be refilled periodically | By cycle | Reducer grease should be refilled periodically |
| Spare parts for boards and cards are recommended for key customers with in-house redundancy | According to the manufacturer's manual cycle | Spare parts for boards and cards are recommended for key customers with in-house redundancy |
| Cable and drag chain inspection | every six months | Insulation, shielding, and bending radius inspection of power and encoder lines, as well as wear of cables inside the drag chain, are the main causes of intermittent faults |
| Zero point and accuracy retest | Every year | Repeatability measured by dial gauges or laser trackers, drift trend digitization—accuracy degradation can be seen six months in advance |
| Control cabinet dust removal and fans | Every quarter | Filter cleaning, fan speed and noise checks, cabinet temperature recording; Dust environments shorten the cycle |
Henghuan's service capabilities for the ZX200S
This site is a third-party robotics technology service provider. The eight major business supports related to the ZX200S are as follows (sorted by service frequency for each model):
- Maintenance and repair: For ZX200S, on-site diagnostics, board-level repairs, and annual maintenance contracts—including annual battery replacement—we will follow SOPs and respond to Sichuan-Chongqing on the same day.
- Used & in-stock robot sales: Medium second-hand circulation, E/F series materials and board-level repair channels we have accumulated; The ZX200S or equivalent models in the inventory come with a full-function test report and a 12-month warranty.
- Sales of new industrial robots: When adding new production lines or replacing entire batches, we conduct cross-brand selection comparisons based on process requirements (including models of the same class as Kawasaki), and provide configuration and pricing plans.
- Applied technology services: ZX200S process programming, trajectory optimization, tap time potential, and model change formula management, with targeted tuning according to assembly, handling, and spot welding conditions.
- Research and development of automation equipment: Custom fixture ends, peripheral tooling, and safety fences for the ZX200S, with interfaces designed according to Kawasaki flange and IO standards.
- Robot rental: For short-term capacity or process validation periods, ZX200S models of the same class in stock can be rented, including transportation, installation, and commissioning, with flexible rental periods and flexible options for repurchase.
Common issues with this device
Is it easy to find spare parts for the ZX200S?
Kawasaki: The spare parts channel for this generation is smooth; we have in-stock or short-cycle channels for standard parts such as drivers, power modules, batteries, and teach pendant components; It is recommended to replace consumables for batteries annually according to the annual maintenance contract.
With a nominal load of 200kg, how much can it actually handle?
The rated load is the static load limit of the flange surface. In actual selection, three factors must be considered: the self-weight of the end fixture (vacuum suction cup groups or grippers often account for 2–5kg), the inertia generated by the workpiece offload (checked according to the inertia ratio when the center of gravity deviates from the flange center), and the dynamic load during high-speed movement. The conventional engineering practice is to keep the "end + workpiece" within 70%–80% of the rated value to ensure cycle time and service life.
If the equipment's accuracy deteriorates after several years of use, how can it be restored?
According to the inspection order: first check whether the zero point is drifting (common after collision or battery depletion), then perform zero calibration; Check the reducer's return error (actual measurement of forward and reverse positioning deviation; if exceeded, disassemble or replace); Then check the installation base fastening and foundation settlement; Finally, trajectory compensation parameter restructuring. Most accuracy issues can be mostly restored after calibration and maintenance, so there is no need to rush into major repairs—we first release the inspection data before deciding on the plan.
Is the used ZX200S worth buying?
Second-hand circulation is moderate, and we have accumulated experience in E/F series materials and board-level repair channels. Three essential items for second-hand procurement: comprehensive inspection reports (axial accuracy, driver status, insulation and battery), maintenance history and operating hours, controller generation, and software license integrity. Every used machine we sell comes with inspection records and a 12-month warranty, and we can also accept third-party inspections designated by customers.
Need technical support or procurement for this model?
Whether it's model selection comparison, installation and commissioning, or maintenance of in-use equipment, you can contact Henghuan. Tell us about your processes, loads, and equipment status, and we will provide third-party technical support and solution recommendations.
Contact Henghuan Back to the full series