YASKAWA JANCD-YEW01-E Instructions Manual

DX200 OPTIONS

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INSTRUCTIONS

JANCD-YEW01-E BOARD
(INTERFACE BOARD FOR WELDING POWER SOURCE)

Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and
retain for future reference.

MOTOMAN INSTRUCTIONS

MOTOMAN- INSTRUCTIONS
DX200 INSTRUCTIONS
DX200 OPERATOR’S MANUAL (for each purpose)
DX200 MAINTENANCE MANUAL

The DX200 Operator’s manual above corresponds to specific usage. Be sure to use the appropriate manual.

Part Number: 167646-1CD
Revision: 1

MANUAL NO.

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Copyright © 2016, 2013 YASKAWA America, Inc.

Terms of Use and Copyright Notice

All rights reserved. This manual is freely available as a service to
YASKAWA customers to assist in the operation of Motoman robots,
related equipment and software This manual is copyrighted property of
YASKAWA and may not be sold or redistributed in any way. You are
welcome to copy this document to your computer or mobile device for
easy access but you may not copy the PDF files to another website, blog,
cloud storage site or any other means of storing or distributing online
content.

Printed in the United States of America

First Printing, 2016

YASKAWA America, Inc.
Motoman Robotics Division
100 Automation Way
Miamisburg, OH 45342
Phone: [phone]

www.motoman.com

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MANDATORY

CAUTION

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• This manual explains about the JANCD-YEW01-E board of the
DX200 system. Read this manual carefully and be sure to
understand its contents before handling the DX200.

• General items related to safety are listed in the Chapter 1: Safety of
the DX200 Instructions. To ensure correct and safe operation,
carefully read the DX200 Instructions before reading this manual.

• Some drawings in this manual are shown with the protective covers
or shields removed for clarity. Be sure all covers and shields are
replaced before operating this product.

• The drawings and photos in this manual are representative
examples and differences may exist between them and the
delivered product.

• YASKAWA may modify this model without notice when necessary
due to product improvements, modifications, or changes in
specifications. If such modification is made, the manual number will
also be revised.

• If your copy of the manual is damaged or lost, contact a YASKAWA
representative to order a new copy. The representatives are listed
on the back cover. Be sure to tell the representative the manual
number listed on the front cover.

• YASKAWA is not responsible for incidents arising from unauthorized
modification of its products. Unauthorized modification voids your
product’s warranty.

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We suggest that you obtain and review a copy of the ANSI/RIA National
Safety Standard for Industrial Robots and Robot Systems (ANSI/RIA
R15.06-2012). You can obtain this document from the Robotic Industries
Association (RIA) at the following address:

Robotic Industries Association

900 Victors Way

P.O. Box 3724

Ann Arbor, Michigan 48106

TEL: [phone]

FAX: [phone]

www.roboticsonline.com

Ultimately, well-trained personnel are the best safeguard against
accidents and damage that can result from improper operation of the
equipment. The customer is responsible for providing adequately trained
personnel to operate, program, and maintain the equipment. NEVER
ALLOW UNTRAINED PERSONNEL TO OPERATE, PROGRAM, OR
REPAIR THE EQUIPMENT!

We recommend approved YASKAWA training courses for all personnel
involved with the operation, programming, or repair of the equipment.

This equipment has been tested and found to comply with the limits for a
Class A digital device, pursuant to part 15 of the FCC rules. These limits
are designed to provide reasonable protection against harmful
interference when the equipment is operated in a commercial
environment. This equipment generates, uses, and can radiate radio
frequency energy and, if not installed and used in accordance with the
instruction manual, may cause harmful interference to radio
communications.

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WARNING

CAUTION

MANDATORY

PROHIBITED

NOTE

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Notes for Safe Operation

Notes for Safe Operation

Read this manual carefully before installation, operation, maintenance, or
inspection of the DX200.

In this manual, the Notes for Safe Operation are classified as “DANGER”,
“WARNING”, “CAUTION”, “MANDATORY”, or “PROHIBITED”.

DANGER

Indicates an imminent hazardous
situation which, if not avoided,
could result in death or serious
injury to personnel.

Indicates a potentially hazardous
situation which, if not avoided,
could result in death or serious
injury to personnel.

Indicates a potentially hazardous
situation which, if not avoided,
could result in minor or moderate
injury to personnel and damage to
equipment. It may also be used to
alert against unsafe practices.

Always be sure to follow explicitly
the items listed under this heading.

Must never be performed.

Even items described as “CAUTION” may result in a serious accident in
some situations. At any rate, be sure to follow these important items.

To ensure safe and efficient operation at all times, be sure
to follow all instructions, even if not designated as
“DANGER”, “WARNING” and “CAUTION”.

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PROHIBITED

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Notes for Safe Operation

• Do not use or maintain this board under the following conditions:

– Direct sunlight

– Excessive vibration and shock

– High humidity

– Proximity to a strong magnetic field source

– Excessive dust

– Large temperature change

– Corrosive gas

– Condensation

Failure to observe this instruction may result in the failure of the board.

DANGER

• Do not touch the inside of the controller cabinet for at least 5
minutes after turning the power off.

Failure to observe this warning may result in electric shock or personal
injury because of the residual voltage of the condenser.

• During power on, make sure to close the door and mount the
protective cover, and do not touch the board.

Failure to observe this warning may result in fire or electric shock.

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TURN

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Notes for Safe Operation

WARNING

• Before operating the manipulator, check that servo power is turned
OFF when the emergency stop buttons on the front door of the
DX200 and the programming pendant are pressed.
When the servo power is turned OFF, the SERVO ON LED on the
programming pendant is turned OFF.

Injury or damage to machinery may result if the emergency stop circuit
cannot stop the manipulator during an emergency. The manipulator
should not be used if the emergency stop buttons do not function.

Fig. : Emergency Stop Button

• Once the emergency stop button is released, clear the cell of all
items which could interfere with the operation of the manipulator.
Then turn the servo power ON.

Injury may result from unintentional or unexpected manipulator motion.

Fig. : Release of Emergency Stop

• Observe the following precautions when performing teaching
operations within the P-point maximum envelope of the
manipulator:

– Be sure to use a lockout device to the safeguarding when going

inside. Also, display the sign that the operation is being
performed inside the safeguarding and make sure no one closes
the safeguarding.

– View the manipulator from the front whenever possible.

– Always follow the predetermined operating procedure.

– Keep in mind the emergency response measures against the

manipulator’s unexpected motion toward you.

– Ensure that you have a safe place to retreat in case of

emergency.

Improper or unintended manipulator operation may result in injury.

• Confirm that no person is present in the P-point maximum envelope
of the manipulator and that you are in a safe location before:

– Turning ON the DX200 power

– Moving the manipulator with the programming pendant

– Running the system in the check mode

– Performing automatic operations

Injury may result if anyone enters the P-point maximum envelope of the
manipulator during operation. Always press an emergency stop button
immediately if there is a problem. The emergency stop buttons are
located on the right of the front door of the DX200 and the programming
pendant.

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CAUTION

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Notes for Safe Operation

• Perform the following inspection procedures prior to conducting
manipulator teaching. If problems are found, repair them
immediately, and be sure that all other necessary processing has
been performed.

– Check for problems in manipulator movement.

– Check for damage to insulation and sheathing of external wires.

• Always return the programming pendant to the hook on the DX200
cabinet after use.

The programming pendant can be damaged if it is left in the
manipulator’s work area, on the floor, or near fixtures.

• Read and understand the Explanation of the Warning Labels in the
DX200 Instructions before operating the manipulator.

• Wiring and installation must be performed by authorized or certified
personnel.

Failure to observe this caution may result in fire or electric shock.

• Check to be sure that there is no foreign matter (metal piece, etc.)
on the board.

Failure to observe this caution may result in personal injury or
equipment damage because of malfunction.

• Check to be sure that there is no problem (damage, bend, etc.) with
the components of the board.

Failure to observe this caution may result in personal injury or
equipment damage because of malfunction.

• Connect the cables and connectors properly.

Failure to observe this caution may result in fire or equipment failure.

• Make sure to properly perform the setting of the switches, etc.

Failure to observe this caution may result in personal injury or
equipment damage because of malfunction.

• Do not touch the component-mounting surface of the board directly
with a finger.

Failure to observe this caution may result in the failure of IC, etc.
because of static electricity.

• Do not touch the solder surface of the board directly with a finger.

Failure to observe this caution may result in personal injury because of
solder projection, etc.

• Avoid shock on the board.

Failure to observe this caution may result in the failure of the board.

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Definition of Terms Used Often in This Manual

Power Supply

Definition of Terms Used Often in This Manual

The MOTOMAN is the YASKAWA industrial robot product.

The MOTOMAN usually consists of the manipulator, the controller, the
programming pendant, and manipulator cables.

In this manual, the equipment is designated as follows:

Equipment Manual Designation

DX200 Controller DX200

DX200 Programming Pendant Programming Pendant

Cable between the manipulator and the
controller

Descriptions of the programming pendant keys, buttons, and displays are
shown as follows:

Equipment Manual Designation

Programming
Pendant

Character Keys
Symbol Keys

Axis Keys
Numeric Keys

Keys pressed
simultaneously

Displays The menu displayed in the programming

The keys which have characters printed on
them are denoted with [ ].
ex. [ENTER]

“Axis Keys” and “Numeric Keys” are generic
names for the keys for axis operation and
number input.

When two keys are to be pressed
simultaneously, the keys are shown with a “+”
sign between them, ex. [SHIFT]+[COORD]

pendant is denoted with { }.
ex. {JOB}

Manipulator cable

Description of the Operation Procedure

In the explanation of the operation procedure, the expression “Select • • • “
means that the cursor is moved to the object item and the [SELECT] is
pressed.

Registered Trademark

In this manual, names of companies, corporations, or products are
trademarks, registered trademarks, or brand names for each company or
corporation. The indications of (R) and

™ are omitted.

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NOTE

[phone]

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Customer Support Information

Customer Support Information

If you need assistance with any aspect of your Interface Board for Welding
Power Supply system, please contact YASKAWA Customer Support at the
following 24-hour telephone number:

For routine technical inquiries, you can also contact YASKAWA Customer
Support at the following e-mail address:

When using e-mail to contact YASKAWA Customer Support, please
provide a detailed description of your issue, along with complete contact
information. Please allow approximately 24 to 36 hours for a response to
your inquiry.

167646-1CD

[e-mail]

Please use e-mail for routine inquiries only. If you have an
urgent or emergency need for service, replacement parts,
or information, you must contact YASKAWA Customer
Support at the telephone number shown above.

Please have the following information ready before you call Customer
Support:

• System Interface Board for Welding Power
Supply

• Primary Application ___________________________

• Controller DX200

• Software Version Access this information on the
Programming Pendant’s LCD
display screen by selecting {MAIN
MENU} - {SYSTEM INFO} ­{VERSION}

• Robot Serial Number Located on the robot data plate

• Robot Sales Order Number Located on the DX200 controller
data plate

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Table of Contents

Table of Contents

1 Outline ............................................................................................................................................ 1-1

1.1 System Configuration Example ......................................................................................... 1-1

2 Hardware Specifications ................................................................................................................. 2-1

2.1 Board Outline Drawing....................................................................................................... 2-1

2.2 Board Specifications .......................................................................................................... 2-1

2.3 Connector for Welding Power Source (CN322)................................................................. 2-2

2.4 Starting Point Detection Output Connector (CN321) ......................................................... 2-2

3 Function Settings ............................................................................................................................ 3-1

3.1 Description of Function Setting Switches .......................................................................... 3-1

3.2 Switch Settings .................................................................................................................. 3-2

4 Board Installation ............................................................................................................................ 4-1

4.1 Opening the Front Door of DX200 ..................................................................................... 4-3

4.2 Checking the Switch Setting of JANCD-YEW01-E Board ................................................. 4-3

4.3 Installing JANCD-YEW01-E Board to DX200 .................................................................... 4-3

4.4 Connecting Cables ............................................................................................................ 4-4

4.5 Closing the Front Door of DX200....................................................................................... 4-5

5 I/O Signal Allocation........................................................................................................................ 5-1

5.1 I/O Module Setting ............................................................................................................. 5-1

5.2 Transmission Data........................................................................................................... 5-10

6 Analog I/O Circuit............................................................................................................................ 6-1

6.1 Analog Output Circuit......................................................................................................... 6-1

6.2 Analog Input Circuit ........................................................................................................... 6-2

7 Contact I/O Circuit........................................................................................................................... 7-1

7.1 Contact Output Circuit ....................................................................................................... 7-1

7.2 Contact Input Circuit .......................................................................................................... 7-3

8 Stick Detection Circuit..................................................................................................................... 8-1

8.1 Stick Detection Input Circuit............................................................................................... 8-1

9 Example Connection....................................................................................................................... 9-1

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1Outline

1.1 System Configuration Example

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1 Outline

1.1 System Configuration Example

This instruction manual is for JANCD-YEW01-E, a welding power source
interface board. This board can connect an arc welding power source of
analog command to the DX200.

DX200 controller

Contact input Ch1 to 4

Contact output Ch1 to 5

JANCD-YEW01-E

Analog input Ch1

Analog input Ch2

Analog output Ch1

Analog output Ch2

Stick detection input

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CN324

24 VDC power input connector

CN323

CN322

Switch to set the transfer rate of I/O

Switch to set the bytes transferred of I/O

ARCON relay (K6)

F1 and F2 fuses
1 A, 250 V (fast-acting)
217001 (Littelfuse)

CN320

SW1

SW2

17 BYTE/32 BYTE

4 Mbps, 10 Mbps

S1

K1

K2

K3

K4

K5

K7

K6

F2

F1

24 VDC power output connector

Fuse (F2)

Fuse (F1)

Welding power source connector

Switch to set the station

Starting point detection command
signal output connector

I/O data transfer connector

JANCD­YEW01-E
REV.

CN324

CN323 F2

F1

F1,F2:
1A/250 V

CN322

S1

CN320 CN321

CN321

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2 Hardware Specifications

2.1 Board Outline Drawing

2 Hardware Specifications

2.1 Board Outline Drawing

2.2 Board Specifications

Item Specification

Board mounting
location

Optional-board mounting space in the DX200
cabinet

External I/O 4 welding power source specific inputs

4 welding power source specific outputs
1 general output

Stick detection input 1 input

Number of analog

2 channels

input channels

Number of analog
output channels

2 channels

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Details of connector (view from the fitting surface of the cable connector)

1

13

23

Note 1: Use either MR-34MG or MRP-34M01.
Note 2: When using MRP-34M01, use either MRP-M103 or MRP-F113.
Note 3: Cable connector is not attached. Must be prepared by user.

Connector type: MR-34MG (soldering type) See Note 1.
MRP-34M01 (crimping type insulator) See Note 1.
MRP-M103 (crimping type contact, strip form terminal) See Note 2.
MRP-M113 (crimping tyep contact, loose piece terminal) See Note 2.
MR-34L+ (vertical type case)
All manufactured by Honda Tsushin Kogyo Co., Ltd.

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1

5

Details of connector (view from the fitting surface of the cable connector)

Note 1: Cable connector is attached to the board.

Connector type: 231-105/037-000 See Note 1.
All manufactured by WAGO Company of Japan,Ltd.

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2.3 Connector for Welding Power Source (CN322)

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2 Hardware Specifications

2.3 Connector for Welding Power Source (CN322)

2.4 Starting Point Detection Output Connector (CN321)

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3 Function Settings

3.1 Description of Function Setting Switches

3 Function Settings

3.1 Description of Function Setting Switches

The names of the switches to set the functions of this board and how each
switch works are shown below. Make sure to perform proper settings
according to the following description. For details of the settings, refer to
the next page.

• S1: Sets the station of this board on the DX200.
The setting range of the station is 1 (ST#01) to D (ST#13).
0, E, or F cannot be set.

• SW1: Sets the transfer rate.
Switches between 4 Mbps and 10 Mbps.

Make sure to set SW1 to 4 Mbps.

If this board’s information is not displayed on the
programming pendant screen although the communication
cable and power cable are connected correctly according to
section 5.1 “I/O Module Setting” on page 5-1, SW1 may be
set to 10 Mbps. If so, change it to 4 Mbps.

10 Mbps cannot be used.

• SW2: Sets the I/O communication mode.
Switches between 17 BYTE or 32 BYTE.

Make sure to set SW2 to 17 BYTE.

used.
If this board’s information is not displayed on the
programming pendant screen although the communication
cable and power cable are connected correctly according to
section 5.1 “I/O Module Setting” on page 5-1, SW2 may be
set to 32 BYTE. If so, change it to 17 BYTE.

32 BYTE cannot be

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NOTE

4 Mbps 10 Mbps

13

SW1

4 Mbps 10 Mbps

13

SW1

17 BYTE/32 BYTE

13

SW2

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3.2 Switch Settings

3 Function Settings

3.2 Switch Settings

Switch How to set

S1

Station setting

Sets the station.
The relations of the switch settings and the stations are
shown below.
Set the arrow to the number corresponding to the desired
station by using a precision screwdriver (Phillips or
flathead).

0: Not available
1: ST#01 (factory setting)
2: ST#02
3: ST#03
4: ST#04
5: ST#05
6: ST#06
7: ST#07

The number after ST# is the station number which is
displayed on the programming pendant screen when
setting the I/O module.

SW1

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8: ST#08
9: ST#09
A: ST#10
B: ST#11
C: ST#12
D: ST#13
E: Not available
F: Not available

1 to 2 short circuit: 4 Mbps

(factory setting)

Transfer rate
setting

SW2

I/O communication
mode setting

• Do not set S1 to 0, E, or F. Also, do not set 2 or more
boards to the same station. Otherwise, this board cannot
be recognized correctly.

* Must be set to 4 Mbps.

2 to 3 short circuit: 10 Mbps

* Not available

SW2

13

17 BYTE/32 BYTE

1 to 2 short circuit: 17 BYTE

(factory setting)

* Must be set to 17 BYTE.

2 to 3 short circuit: 32 BYTE

* Not available

• Do not set SW1 to 10 Mbps. If it is set to 10 Mbps, this
board cannot be recognized correctly.

• Do not set SW2 to 32 BYTE. If it is set to 32 BYTE, this
board cannot be recognized correctly.

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DANGER

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4 Board Installation

4 Board Installation

• Before wiring or installation, make sure to turn the primary power

Failure to observe this warning may result in electric shock or personal
injury.

• Do not touch the inside of the controller cabinet for at least five

Failure to observe this warning may result in electric shock or personal
injury because of the residual voltage of the capacitors.

• During power on, make sure to close the door and mount the

supply off, and put up a warning sign. (e.g. DO NOT TURN THE
POWER ON.)

minutes after turning the power off.

protective cover, and do not touch the board.

Failure to observe this warning may result in fire or electric shock.

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4 Board Installation

• Wiring and installation must be performed by authorized or certified
personnel.

Failure to observe this caution may result in fire or electric shock.

• Check to be sure that there is no foreign matter (metal piece, etc.)
on the board.

Failure to observe this caution may result in personal injury or
equipment damage because of malfunction.

• Check to be sure that there is no problem (damage, bend, etc.) with
the components of the board.

Failure to observe this caution may result in personal injury or
equipment damage because of malfunction.

• Connect the cables and connectors properly.

Failure to observe this caution may result in fire or equipment failure.

• Make sure to properly perform the setting of the switches, etc.

Failure to observe this caution may result in personal injury or
equipment damage because of malfunction.

• Do not touch the component-mounting surface of the board directly
with a finger.

Failure to observe this caution may result in the failure of IC, etc.
because of static electricity.

• Do not touch the solder surface of the board directly with a finger.

Failure to observe this caution may result in personal injury because of
solder projection, etc.

• Avoid shock on the board.

Failure to observe this caution may result in the failure of the board.

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Clockwise
90

Door lock

Flathead screwdriver

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4.1 Opening the Front Door of DX200

4 Board Installation

4.1 Opening the Front Door of DX200

Install the JANCD-YEW01-E board according to the following procedure:

1. By using a coin or a flathead screwdriver, rotate the door locks on the
front of the DX200 (two places) 90 degrees clockwise.

2. Rotate the main power supply switch to the “OFF” position and open
the door gently.

4.2 Checking the Switch Setting of JANCD-YEW01-E Board

4.3 Installing JANCD-YEW01-E Board to DX200

1. Check to be sure that the settings of the switches on the
JANCD-YEW01-E board are correct.

2. For the switch setting, refer to chapter 3.

1. Check to be sure that the main power supply is turned OFF.

2. Securely fix the JANCD-YEW01-E board to the DX200 by tightening
the board fixing screws firmly.

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CN304

CN324

24VDC Power Cable

CN114

I/O Communications Cable

CN320

JANCD­YEW01-E
REV.

CN324

CN323F2

F1

F1,F2:
1A/250V

CN322

S1

CN320 CN321

Cable for
Welding Power Source
CN322

Terminal Connector

HB1370717-1

CBL-YRC020-1

HB1370660-N-2

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4 Board Installation

4.4 Connecting Cables

1. Connect the 24 VDC power cable to CN324 of the JANCD-YEW01-E
board.

2. Connect the I/O communication cable to CN320 of the
JANCD-YEW01-E board.
Connect the terminal connector which is connected to CN114 of the
JZNCD-YIF01-2E board to the unoccupied side of CN320 of the
JANCD-YEW01-E board.

3. Connect the cable for welding power source to CN322 of the
JANCD-YEW01-E board.

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counterclockwise 90

Flathead screwdriver

Door lock

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4.5 Closing the Front Door of DX200

4 Board Installation

4.5 Closing the Front Door of DX200

1. Close the door gently.

2. By using a coin or a flathead screwdriver, rotate the door locks on the
front of the DX200 (two places) 90 degrees counterclockwise.

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MENT

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5 I/O Signal Allocation

5.1 I/O Module Setting

5 I/O Signal Allocation

5.1 I/O Module Setting

To use the JANCD-YEW01-E board on the DX200, the I/O module must
be set according to the following procedure.

Check to be sure that the power supply of the DX200 is turned OFF.
Then, install the JANCD-YEW01-E board all of whose switches are
properly set to the inside of the DX200 cabinet. When installing the board,
refer to chapter 4 “Board Installation” .

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When setting the I/O module, set the security mode to the
management mode.

When the security mode is set either to the operation mode
or the editing mode, only the setting status can be referred
to.

1. Press and hold [MAIN MENU], and turn ON the power.

– The Main Menu is displays.

2. Select the {SYSTEM} under the Main Menu.

3. Set the security mode to the “Management Mode”.

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5 I/O Signal Allocation

5.1 I/O Module Setting

4. Select {SETUP}.

5. Select {IO MODULE}.

– The current installation status of I/O modules is displayed as shown

below.

– Press [ENTER] to display the other stations.

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5 I/O Signal Allocation

5.1 I/O Module Setting

6. Check the installation status of I/O modules.

– Only the currently installed I/O modules are shown. Check that the

details of each station (ST#) are the same as the installation status
of I/O modules.

– The meanings of the columns are as follows:

ST# Station number of I/O module

DI Number of contact inputs

DO Number of contact outputs

AI Number of analog inputs

AO Number of analog outputs

BOARD Board type

1 If “-” is displayed, the corresponding input or output is not

implemented.

2 If the board type cannot be determined, “*****” is displayed

in the BOARD column. Even so, there is no problem as
long as the values of DI, DO, AI, and AO are normal.

2)

1)

1)

1)

1)

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– The following combination of boards is displayed in this example.

ST#00: JANCD-YI021-E board

This board is shown as YSF21 on the IO module
display.
(Digital input 40 points, digital output 40 points)
This board is fixed to ST#00.

ST#01: JANCD-YEW01-E board

(16 contact inputs, 16 contact outputs, 2 analog inputs,
2 analog outputs)
Note that even though 16 contact inputs and 16 contact
outputs are displayed, they cannot be used for external
devices because they are used by the system.
Switch S1: Set to 1. (This value is the value of ST#.)

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NOTE

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5 I/O Signal Allocation

5.1 I/O Module Setting

7. Press {ENTER}.

– A confirmation dialog box appears.

8. Select {YES}.

– When the mounted status of an I/O module is correct, select “YES.”

The I/O module setting is updated, and the IO MODULE window
changes to the EXTERNAL IO SETUP window.

If the displayed details of each station (ST#) and the
installation status of I/O modules are different, check the
settings of cables and switches again. The following
causes are possible:

(1) Wrong I/O communication setting

The setting of SW1 or SW2 of the
JANCD-YEW01-E board may be wrong. If so, the
board cannot be determined correctly.

(2) Wrong station setting

S1 may be set to 0, E, or F (not available).
Also, only one optional board can be set to one
station. Change the setting of S1 so that two or
more boards are not set to one station.

(3) Wrong connection of the 24 VDC power cable or the

I/O communication cable
The 24 VDC power cable or the I/O communication
cable may not be connected correctly. If the 24
VDC power cable is not connected to CN324
correctly, the power cannot be supplied properly.
Check the connection of cables according to
chapter 4 “Board Installation”.

(4) Failure of I/O module

If the displayed details and the installation status are
still different even after the correction above, failure
of the
I/O module is possible. Contact your Yaskawa
representative.

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5 I/O Signal Allocation

5.1 I/O Module Setting

9. The EXTERNAL IO SETUP window appears.

10. Select {AUTO} or {MANUAL} in the ALLOCATION MODE.

– The selection menu appears after selecting {AUTO} or {MANUAL}.

If the allocation mode is changed from {MANUAL} to
{AUTO}, the set allocation data is discarded. The data will
be allocated by AUTO MODE again. Save the set
allocation data to the external devices in advance, if
needed.

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NOTE

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5 I/O Signal Allocation

5.1 I/O Module Setting

11. Select the allocation mode to set up.

– Select {AUTO} to allocate I/O signal allocation automatically.

Select {MANUAL} to allocate I/O signal allocation manually.

– The selected allocation mode is set up.

12. Select {DETAIL} of {EXTERNAL IO ALLOCATION}.

– When select {AUTO}, the following procedures No.13 to 15 are not

necessary. Operate the procedure from No.16.

– When select {MANUAL}, operate the following procedures No.13 to

15 accordant with the setting manually.

The IO allocation of the XEW board and the YEW board
cannot be changed even if select the {MANUAL} in the
allocation mode.

The error [ERROR 8230: Cannot change the setting for
XEW or YEW board.] occurs if attempt to change.

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5 I/O Signal Allocation

5.1 I/O Module Setting

13. Select the external I/O signal number (at the change source) to be
changed.

– The select menu appears.

– Select the {INIT} when add the YEW board to the system, which has

already allocated the external I/O allocation manually.

14. Select {MODIFY], and input the external input signal number (at the
change destination) to be changed.

– The external input signal number is changed.

15. Likewise, select/modify the number of the external input signal.

– Repeat select/modify until it becomes the desired allocation to set

up.

16. Press {ENTER}.

– The allocation window of the external output signal appears.

17. Select/modify the number of the external output signal same as the
external input signal.

– Repeat select/modify until it becomes the desired allocation to set

up.

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5 I/O Signal Allocation

5.1 I/O Module Setting

18. Press {ENTER}.

– Confirmation dialog appears.

19. Select {YES}.

– The settings are confirmed, and returns to the SETUP window.

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NOTE

Add a board

The external I/O
allocation is set
as manual.

NO: Automatic allocation

YES: Manual allocation

Add a board other
than EW board.

NO: Add the EW board

YES: Add the board
other than the EW board

Set the allocation for the added board
at the following windows.
EXTERNAL IO ALLOCATION
(INPUT) window
EXTERNAL IO ALLOCATION
(OUTPUT) window

Initialize the board at the
EXTERNAL IO ALLOCATION
(INPUT) window.
After the initialization, set the
adding board again manually,
and then set the allocation.

Initialize the board at the
EXTERNAL IO ALLOCATION
(OUTPUT) window.
After the initialization, set the
adding board again manually,
and then set the allocation.

Press {ENTER}.
Select {YES} in the confirmation
dialog to save the setting.

The added board is
automatically allocated.

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5 I/O Signal Allocation

5.1 I/O Module Setting

To add a board when using the YEW board

The XEW board and the YEW board (It is called EW board
below) do not support external I/O allocation function.

As for the external I/O allocation setting to add a optional
board in the system using the EW board, please refer to the
following flow chart.

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5.2 Transmission Data

5 I/O Signal Allocation

5.2 Transmission Data

Data transferred from the JANCD-YEW01-E board to the DX200 are
16 contact inputs, 16 contact outputs, and 3 analog outputs (12 bit each).
The I/O data of the JANCD-YEW01-E board are allocated to the external
I/O signals of the concurrent I/O signals.

Concurrent I/O

<Contact input>

20010 to 22567

(2048 inputs)

<Contact output>

30010 to 32567

(2048 outputs)

<Analog output>

M560 to M561

(2 outputs)

<Analog input>

M600 to M601

(2 inputs)





JANCD-YEW01-E board

Control by analog I/O
and contact I/O

Welding power source



When only the JANCD-YEW01-E board is installed as an optional board,
the concurrent I/O of the board are allocated as shown below:

Contact input Contact output

22550: GASOF (gas shortage) input 32550: System reservation

22551: WIRCUT (wire shortage) input 32551: ARCON (arc-ON) output

22552: ARCOFF (arc failure) input 32552: WIRINCH (wire inching) output

22553: ARCACT (arc establishment) input 32553: WIRRTR (wire retract inching) output

22554: STICK (wire stick) input 32554: System reservation

- 32555: Starting point detection command output
(optional)

22555 to 22557: System reservation 32556 to 32557: System reservation

22560 to 22567: System reservation 32560 to 32566: System reservation

- 32567: General output

Analog input Analog output

M600: Channel 1 M560: Channel 1

M601: Channel 2 M561: Channel 2

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Output voltage value

Register value
(hexadecimal notation)

+14 V

0 V

-14 V

0000H

8010H

7FF0H

Input voltage value

Register value
(hexadecimal notation)

+5 V

0 V

-5 V

0000H

8000H

7FFFH

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5.2 Transmission Data

The relationship between the write contents and the output voltage values
of the registers M560 to M561 are shown below.

Although the register setting value is 16-bit wide, the lower 4 bits of the
write content are invalid because the D/A resolution is 12 bit. (The output
voltage values of the write contents ***0H to ***FH are the same.)
Also, the write contents 8000H to 800FH are not used.

The relationship between the input voltage and the read contents of the
registers M600 to M601 are shown below.

The allocation of the concurrent I/O is shown above, but note that only the
2 analog inputs, 2 analog outputs, 5 contact inputs, and 4 contact outputs
can be used for communication between the JANCD-YEW01-E board and
external devices.
The contact inputs and outputs other than described above are used by
the system, so they cannot be used for communications with external
devices.

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NOTE

CH*

YEW01 side

0 V

(Analog ground)

CH*_G

Load

(R 2 kΩ)

L

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6 Analog I/O Circuit

6.1 Analog Output Circuit

6 Analog I/O Circuit

6.1 Analog Output Circuit

Two analog output circuits (channel 1 for voltage command, and channel
2 for current command) are available.

• When connecting a load to the analog output circuit, the

load resistance must be 2 k or more. If the load
resistance is less than 2 k, abnormal output voltage or
damage to the output circuit may result.

• The analog output becomes undefined when the DX200 is
turned on or off. Use an external circuit so that there is no
problem even if the analog output becomes undefined.

• Use shielded twisted-pair wires (24 to 28 AWG) for the
analog output wiring, and make the wiring length as short
as possible.

Number of channels and
application

Output range -14 V to +14 V

Digital resolution 12 bit

LSB value Approx. 6 mV (0.0068 V)

D/A output voltage error ±14 V, equal to or less than ±1%

Linearity error Equal to or less than ±0.2%

Forward and reverse error Equal to or less than ±1%

Ripple voltage Equal to or less than ±0.1 V

Temperature drift Equal to or less than ±1850 PPM/°C

Conversion cycle Every communication cycle

Conversion time Approx. 7 ms (including communication time)

External load resistance Equal to or more than 2 k

2 channels for voltage output

For 0 V, equal to or less than ±20.5 mV (3 LSB)

Fig. 6-1: Example connection

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NOTE

Input CH1

Input CH2

Switching signal

A/D conversion output

Filter

Filter

A/D

2-1

Selector

YEW01 side

0 V

(Analog ground)

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6 Analog I/O Circuit

6.2 Analog Input Circuit

Two analog input circuits (channel 1 for voltage feedback, and channel 2
for current feedback) are available.

• The input voltage must be within -5 V to +5 V.

• Use shielded twisted-pair wires (24 to 28 AWG) for the
analog input wiring, and make the wiring length as short
as possible.

Number of channels and
application

Output range -5 V to +5 V

Digital resolution 16 bit

LSB value Approx. 153 V (153 × 10

D/A output voltage error ±0.5% full scale

Linearity error ±5LSB

Conversion cycle Convert designated channel per every 2 ms.

Conversion time

Input impedance Equal to or more than 1 M

1 Includes the delay of 50 s from the input to the A/D converter.

1)

2 channels for voltage output

-6

Maximum 60 s

V/bit)

Fig. 6-2: Example connection

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7 Contact I/O Circuit

7.1 Contact Output Circuit

7 Contact I/O Circuit

7.1 Contact Output Circuit

Five contact output circuits (4 welding power source specific outputs
(arc-ON, wire inching, wire retract inching, starting point detection
command (optional function)), and 1 universal output) are available

.

Number of outputs and
application

Output method Relay contact output

Insulation method Insulation by photocoupler

Output current per point 0.5A (DC, AC, 250 V)

Number of commons No common connection.

Active level 0 output = "Contact ON", 1 output = "Contact OFF"

Output protection type JIS B3501, Output with no protection

1 This is a maximum value in the case of the resistive load. Maximum rate

differs depending on the type of the load (AC/DC, resistive/inductive/capacity
load). Relay contact sticking, and open-close life reduction may occur. When
connecting the inductive load, install elements such as flywheel diode on the
load side. In the case of using I/O current (+24 VU), maximum of approx.
500 mA can be taken out (fuses F1, F2 may blow out when the current
exceeds the above limit).

5 outputs ARCON

WIRINCH
WIRRTR
SEARCH
OUT

Independent for each output.

Stick start command
(Refer to the note 1)
Wire inching command
Wire retract command
Starting point detection
General output

1)

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NOTE

YEW01 side +24VU

MAX 0.5A

024VU

R

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7 Contact I/O Circuit

7.1 Contact Output Circuit

Fig. 7-1: Example connection

The life of the arc-ON output relay (ARCON relay) is
20 million times (approx. 10 years).
Therefore, periodical replacement is necessary. When
replacing the ARCON relay, specialized tool is required.
Contact your Yaskawa representative.
Be sure that the output current does not exceed 0.5 A even
instantaneously. When there is a possibility of exceeding

0.5 A due to inrush current etc., current limit measures such

as installing the resistors in series are required.

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YEW01 side

+24V/+24VU

024V/024VU

FG

Input circuit

FG

i

i

* Connect as indicated in (1) or (2).

0.1μF

0.1μF

(1) (2)

i : "Input current per point" as cited in the table

NOTE

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7.2 Contact Input Circuit

7 Contact I/O Circuit

7.2 Contact Input Circuit

The contact input circuit includes 4 welding power source specific inputs
(gas shortage, wire shortage, arc establishment, arc failure).

Fig. 7-2: Example connection

Number of inputs and
application

Input method Sink/Source switching available

Insulation method Insulation by photocoupler

Input current per point 6.9 mA (Type) (6.1 mA to 7.8 mA)

Number of commons No common connection.

Active level of the signal Contact ON = "0", Contact OFF = "1"

Input threshold 8.8 V (Type) (6.3 V to 11.4 V)

Input delay Ton = 850 s + communication cycle

1 The communication cycle depends on the communication cycle setting of the

master side.

4 inputs GASOF

WIRCUT
ARCOF
ARCACT

Independent for each output.

Toff = 958 s + communication cycle

Gas shortage detection signal
Wire shortage detection signal
Arc failure detection signal
Arc start detection signal

1)

1)

The contact input circuit is provided with a capacitor of

0.1 F as a noise control. When the input signal is ON,
large inrush current flows. Therefore, when the current
capacity of the input circuit is small, current limit measures
such as installing resistors in series are required.

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YEW01 side

Stick
detection
circuit

STICK

STICK*

Detection load

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8 Stick Detection Circuit

8.1 Stick Detection Input Circuit

8 Stick Detection Circuit

8.1 Stick Detection Input Circuit

Stick detection operates in a state where there is no arc signal. Detection
is available under a condition where the ARCON signal is disabled (stick
command OFF), and the STICK_EN is enabled.
The specifications are described in the following table:

Base voltage 5.7 [v]

Detection resistance 100 [] or less

Fig. 8-1: Example connection

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Logical
number

Connector
pin No.

Name Signal

(gas shortage)
(gas shortage)

(wire shortage)
(wire shortage)

(arc establishment)
(arc establishment)

(Current input)

(Voltage input)

(arc failure)

(arc failure)
(arc-ON) A
(arc-ON) B

(wire inching) A

(wire inching) B
(wire retract inching) A
(wire retract inching) B

(General output) B

(wire stick)

(wire stick)

(Voltage command)

(Current command)

Power source

MR Connector MS Connector

Detector

Case

Contact

Insulator

Each point
DC24V
5 mA MAX

WAGO Connector (231-105/026-A0)

(General output) A

Starting point detection command output A (optional)
Starting point detection command output B (optional)

DX200

DC24V
5 mA MAX

DC24V

0.5 A MAX

DC24V

0.5 A MAX

Welding power source

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9 Example Connection

Power Supply

9 Example Connection

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HEAD OFFICE
2-1 Kurosakishiroishi, Yahatanishi-ku, Kitakyushu 806-0004, Japan
Phone [phone] Fax [phone]

100 Automation Way, Miamisburg, OH 45342, U.S.A.
Phone [phone] Fax [phone]

YASKAWA America Inc. (Motoman Robotics Division)

Yaskawastrasse 1, 85391 Allershausen, Germany
Phone [phone] Fax [phone]

YASKAWA Europe GmbHRobotics Divsion )

Phone [phone] Fax [phone]

151 Lorong Chuan, #04-02A, New Tech Park, Singapore 556741
Phone [phone] Fax [phone]

YASKAWA Electric (Singapore) PTE Ltd.

No7 Yongchang North Road, Beijing E&T Development AreaChina 100176
Phone [phone] Fax [phone]

YASKAWA SHOUGANG ROBOT Co. Ltd.

#426, Udyog Vihar, Phase- IV,Gurgaon, Haryana, India

Fax [phone]Phone [phone]

YASKAWA India Private Ltd. (Robotics Division)

YASKAWA Electric (China) Co., Ltd.
22F, One Corporate Avenue, No.222, Hubin Road, Huangpu District, Shanghai 200021, China
Phone [phone] Fax 㸩86-21-5385-3299

YASKAWA Electric (Thailand) Co., Ltd.
59,1st-5th Floor, Flourish Building, Soi Ratchadapisek 18,Ratchadapisek Road,
Huaykwang, Bangkok 10310, THAILAND
Phone [phone] Fax [phone]

12F, No.207, Sec. 3, Beishin Rd., Shindian District, New Taipei City 23143, Taiwan

Fax [phone]Phone [phone]

YASKAWA Electric Taiwan Corporation

Secure Building-Gedung B Lantai Dasar & Lantai 1 JI. Raya Protokol Halim Perdanakusuma,
Jakarta 13610, Indonesia

Fax [phone]Phone [phone]

PT. YASKAWA Electric Indonesia

Phone [phone] Fax [phone]

YASKAWA Nordic AB
Verkstadsgatan 2, Box 504 ,SE-385 25 Torsas, Sweden

35F, Three IFC, 10 Gukjegeumyung-ro, Yeongdeungpo-gu, Seoul, Korea 07326

YASKAWA Electric Korea Corporation

DX200 OPTIONS

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INSTRUCTIONS

JANCD-YEW01-E BOARD

(INTERFACE BOARD FOR WELDING POWER SOURCE)

Specifications are subject to change without notice
for ongoing product modifications and improvements.

MANUAL NO.

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