Yaskawa JANCD-YCP21-E CPU Board for DX200 Robot Controller

The Yaskawa JANCD-YCP21-E (also known as YCP21-E) is the main CPU control circuit board used in the DX200 robot controller series. The DX200 is Yaskawa's advanced robot controller that can manage up to 72 axes of motion (including multiple robots, external positioners, and conveyors). This CPU board houses the processor, memory, and real-time operating system that executes robot motion planning, I/O handling, and communication with pendant and higher-level PLCs. It is a critical spare part for maintaining and repairing DX200-based robotic workcells.

Technical Specifications

• Model Number: JANCD-YCP21-E (YCP21-E)

• Compatible Controller: Yaskawa DX200 (standard, for arc welding, handling, general purpose)

• CPU Architecture: 32-bit RISC (ARM or PowerPC based), 400 MHz

• RAM: 256 MB SDRAM

• Flash Storage: 512 MB for system and user programs

• Backup Battery: CR2450 lithium for CMOS RAM (retains position data)

• Interfaces:

• PCI bus for servo and I/O boards

• Dual Ethernet ports (10/100 Mbps) for plant network and teach pendant

• RS-232C for external device communication

• VGA output (optional)

• I/O Mapping: Up to 2048 digital inputs / 2048 digital outputs via remote I/O racks

• Operating Temperature: 0°C to 45°C

• Power Supply: 5V DC, 2A from backplane; 12V DC for fan

• Dimensions: 233mm x 160mm (6U Eurocard format)

Functional Description

The YCP21-E board executes the DX200's real-time operating system (VxWorks-based Yaskawa proprietary OS). It handles trajectory generation (linear, circular, joint interpolation) for up to 8 robots simultaneously, with synchronous control of external positioners. The board communicates with servo amplifier boards via the high-speed PCI bus, sending position commands and receiving encoder feedback at 2 kHz update rate. It also manages the safety logic (emergency stop, safety fieldbus) and stores all user programs (INFORM III language) in flash memory.

Memory and Data Retention

User programs and system parameters are stored in non-volatile flash memory, which does not require a battery. However, the robot's absolute encoder position data is stored in battery-backed CMOS RAM (supplied by CR2450 coin cell). When replacing the CPU board, it is necessary to restore the robot's home position using the "Mastering" procedure. The board also contains an SD card slot for data backup and software updates.

Diagnostics and Status Indication

The YCP21-E board features a 7-segment LED display (two digits) showing the boot code and run status: "00" = normal operation, "0F" = fatal error, "12" = waiting for communication with servo, etc. There are also LEDs for power, run, error, and Ethernet link/activity. A built-in diagnostic self-test runs on power-up, checking RAM, flash checksum, and bus communication.

Software and Programming

The DX200 robot uses Yaskawa's INFORM III programming language, which is edited via the teach pendant or using the optional PC software (Robot Programming Interface). The CPU board supports multitasking (up to 32 user tasks), interrupt functions, and real-time I/O control. It also includes a built-in PLC functionality (ladder logic) for controlling peripheral equipment without an external PLC.

Communication and Fieldbus

Two Ethernet ports allow connection to a plant network (e.g., for data collection) and to the teach pendant. The board supports standard protocols: PROFINET, EtherNet/IP, Modbus TCP, and CC-Link (via optional hardware). An additional RS-232C port (9-pin D-sub) can be used for serial communication with barcode readers or vision systems.

Replacement and Compatibility

The JANCD-YCP21-E is a direct replacement for earlier YCP21 (Rev A-D) boards in DX200 controllers. When upgrading, the controller's boot software (version 1.30 or higher) must be updated to support the E revision. Always verify that the CPU board's firmware matches the robot's configuration (e.g., arc welding vs. handling). After replacement, perform a "Cold Start" and restore the backup from the SD card.

Environmental and Reliability

The board is rated for industrial use with conformal coating to resist moisture and dust. MTBF is specified at 200,000 hours. The board withstands vibration of 0.5g (10-55 Hz) and shock of 5g. Storage temperature: -20°C to 60°C.

Typical Applications

This CPU board is used in all DX200-based robotic systems: arc welding, spot welding, material handling, palletizing, and dispensing. It is also found in dual-arm robots and synchronized multi-cell lines.

Conclusion

The Yaskawa JANCD-YCP21-E CPU board is the brain of the DX200 controller, providing robust processing power and extensive connectivity for modern robot applications.