YASKAWA JANCD-YEW01-E Instructions Manual

DX200 OPTIONS

1 of 40

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.

HW1481264

1

Interface Board for Welding

2 of 40

Power Supply

167646-1CD

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

ii

HW1481264

167646-1CD

MANDATORY

CAUTION

3 of 40

Interface Board for Welding
Power Supply

• 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.

iii

HW1481264

Interface Board for Welding

4 of 40

Power Supply

167646-1CD

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.

iv

HW1481264

167646-1CD

WARNING

CAUTION

MANDATORY

PROHIBITED

NOTE

5 of 40

Interface Board for Welding
Power Supply

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”.

v

HW1481264

Interface Board for Welding

PROHIBITED

6 of 40

Power Supply

167646-1CD

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.

vi

HW1481264

167646-1CD

TURN

7 of 40

Interface Board for Welding
Power Supply

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.

vii

HW1481264

Interface Board for Welding

CAUTION

8 of 40

Power Supply

167646-1CD

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.

viii

HW1481264

167646-1CD

9 of 40

Interface Board for Welding

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.

ix

HW1481264

Interface Board for Welding

NOTE

[phone]

10 of 40

Power Supply

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

x

HW1481264

167646-1CD

11 of 40

Interface Board for Welding
Power Supply

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

xi

HW1481264

Interface Board for Welding

12 of 40

Power Supply

1Outline

1.1 System Configuration Example

167646-1CD

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

1-1

HW1481264