YRC1000 DirectConnect IO Boards

General Overview:

The compact footprint of the YRC1000 gave Yaskawa the opportunity to redefine the layout and placement of IO within the robot cabinet. Yaskawa elected to develop a “plug-in” IO-card and plastic support/housing that is used in nearly all Arc Welding systems. This prevents use of remotely located IO cards and ribbon cables from consuming the limited space within the robot cabinet. The “DirectConnect” IO cards plug directly into the YRC’s IO card eliminating the need for ribbon cables.

One DirectConnect board take the place of two breakout cards and provides on-board relays which change what would be transistor outputs into higher amperage capable relay outputs. This is helpful when connecting high amperage loads or resistive/inductive loads. The relay outputs are designed for 24VDC loads up to 5A per output.

The above photo shows the DirectConnect boards connected in a standard ArcWorld configuration where two boards provide similar functionality as four traditional breakout cards.

Variations in DirectConnect boards and where Used:

To meet the various needs of Yaskawa products and customers, several variations of the DirectConnect boards exist for various applications. Boards are combined into kits where multiple boards are combined with the molded mounting support that allows easy installation of the board. The various kits are detailed in the following chart:

Some important facts regarding the DirectConnect Boards:

• DirectConnect boards are designed to accommodate a maximum voltage of 24VDC.
• Maximum allowable amperage across the relay contacts is 5Amp DC.
• Wire gauges for the screw terminals is 16-30AWG.
• Thin insulation wires are suggested due to the short pitch between the terminals.
• The following jumper bars can be utilized as needed. (they jumper between neighboring terminals on the same level!)
  • 198256-1 -- 2-terminal jumper
  • 198256-2 -- 3-terminal jumper
  • 198256-3 -- 4-terminal jumper

Additional Supporting Information & Manual:

Additional supporting information can be found in the 191713-1CD manual. In that manual you’ll find details regarding the following topics:

• Detailed breakdown of the “dedicated IO” and the associated “External IO” that they enter and exit the system on along with a description of the signal.
• Specific terminal #’s for what signals are on what terminals of the Direct Connect boards.
• System diagrams showing the templates for various DirectConnect board configurations.