1.1 Basic Description

1.2 System Matching Configuration

• Main CPU: JANCD-YCP21-E (DX200 main control board)

• Safety Board: JANCD-YSF21-E

• Backplane: YBB21 DX200 rack

• Install position: free option slot on YBB21 backplane inside DX200 control cabinet

• Incompatible: DX100 controller (DX100 uses YEW series for older racks)

1.3 Core Functions

1. 2CH analog output: Output analog command voltage to welder for preset welding current/voltage

2. 2CH analog input: Receive analog feedback signal of actual welding current/voltage from welder

3. Multi-channel digital contact I/O: Welder ready, arc ON/OFF, gas shortage, wire break, cooling fault, welding completion signal

4. Wire stick detection dedicated input: Detect electrode short-circuit stick fault during welding

5. Starting point search output: Analog trigger output for arc seam search sensor (CN321 port)

2. Hardware Electrical Specifications

2.1 Analog Parameter Specification

2.2 Digital Contact I/O Spec

• Digital Input: 8-point DC24V sink/source compatible, input rated current 5mA MAX

• Digital Output: Relay contact output, rated load DC24V/0.5A per point

• Wire Stick Detection: 1 dedicated isolated digital input terminal

2.3 Power & Environment Spec

• Board operating power: DC24V ±10% supplied from DX200 backplane slot

• Fuse: F1/F2 fast acting fuse 1A/250V (Littelfuse 217001 standard part)

• Operating ambient temperature: -10℃ ~ +55℃

• Storage temperature: -20℃ ~ +70℃

• Ambient humidity: 30%~80%RH non-condensing; avoid dew, corrosive gas, heavy dust, strong electromagnetic interference

• Cooling mode: Passive natural cooling (no built-in fan)

3. On-board Connector Definition

CN320: Backplane Bus Connector

CN321: Starting Point Detection Output

CN322: Main Welder Interface Terminal (Core port for welder wiring)

1. Analog Output 1: Welding Voltage Command Output (-5~+5V)

2. Analog Output 2: Wire Feed Speed / Welding Current Command Output (-5~+5V)

3. Analog Input 1: Actual Welding Voltage Feedback from Welder

4. Analog Input 2: Actual Welding Current Feedback from Welder

5. Digital Input Signals: Gas shortage alarm, wire cut fault, welder ready signal, cooling water abnormal

6. Digital Output Signals: Arc ON trigger, shielding gas valve output, wire feed enable, welding finish reset

7. Wire stick detection dedicated input terminal

CN323 / CN324: Auxiliary 24VDC Power Terminal

4. DIP Switch Setting Instruction (S1 Switch on PCB)

4.1 Switch Purpose

• Switch BIT 1~BIT4: Binary coding for station No. setting (factory default: Station No.01)

• BIT5: Analog output polarity selection (ON=invert output voltage, OFF=standard polarity -5~+5V)

• BIT6: Wire detection input logic selection (ON=active high, OFF=active low DC24V)

Mandatory: Set all DIP switches before board installation with cabinet full power OFF.

5. Standard Installation Procedure

Step 1: Safety Pre-operation

1. Cut off DX200 main AC power, wait minimum 15min for internal main capacitor full discharge to avoid electric shock and board burnout.

2. Open DX200 cabinet front door, confirm all internal voltage is zero with multimeter test.

Step 2: Pre-set DIP Switch

Step3: Board Insertion

Step4: External Cable Wiring

1. Use shielded twisted cable for CN322 analog signal wiring, single-point ground for shielding layer at cabinet grounding bar only.

2. Connect welder control cable between CN322 and analog welder terminal block per welder manufacturer wiring diagram.

3. Connect seam search sensor cable to CN321 if tracking function is equipped.

Step5: Cabinet Close & Power-on Check

6. DX200 System Software Setting

6.1 I/O Module Configuration

1. Enter DX200 teach pendant: [SYSTEM]-[OPTION]-[HARDWARE CONFIGURATION]

2. Activate YEW01-E welding option module with preset station address matching S1 switch setting

3. Save parameter, reboot controller for configuration to take effect.

6.2 Welding Parameter Setup

1. Enter welding menu: [ARC WELD SETUP], select analog welder control mode

2. Calibrate D/A output gain/offset for voltage/current analog output to match welder input specification

3. Calibrate A/D input feedback coefficient for actual current/voltage feedback correction

7. LED Status Indicator Definition

• PWR LED(Green): ON=24V board power normal; OFF=power supply/fuse open circuit

• RUN LED(Green): Slow flash=normal data communication with main CPU; steady OFF=bus communication fault

• ERR LED(Red): ON=analog channel overvoltage/short or digital I/O short-circuit fault; flash=station address conflict error

8. Troubleshooting Guide

Fault 1: PWR LED OFF

1. Check F1/F2 1A fuse blowout, replace same specification Littelfuse fuse if damaged

2. Re-seat YEW01-E board to fix poor backplane contact; test rack slot DC24V output voltage.

Fault2: RUN LED OFF, ERR ON

1. Recheck S1 DIP station address setting for duplicate address conflict

2. Verify JANCD-YCP21 main CPU normal operation; check other system boards status.

Fault3: Welder cannot receive analog command voltage

1. Check CN322 analog output wiring open/short circuit, test D/A output voltage via multimeter

2. Re-calibrate analog output offset/gain inside DX200 welding parameter menu.

Fault4: No actual current/voltage feedback from welder

1. Check welder analog feedback output wiring polarity and shield grounding

2. Confirm A/D input range matches welder signal output specification (-5~+5V).

Fault5: Wire stick detection always triggered

9. Maintenance & Safety Notes

1. CAUTION: All wiring/board replacement must be done under complete cabinet power OFF state.

2. Periodic maintenance (every 6 months): Clean PCB dust with dry lint-free cloth, check connector terminal looseness and cable insulation aging.

3. Prohibited: Modify onboard circuit components or replace non-standard fuse; faulty board requires full unit replacement (no field component repair).

4. Ambient prohibition: Install away from welding arc spatter, strong high-frequency magnetic field, water vapor and chemical corrosive gas.

10. Related Model Distinction

• JANCD-YEW01-E: Standard analog welder interface for single analog welding source (DX200)

• Digital welder uses optional digital communication board instead of YEW01-E (WELDCOM network option)