DF9200664-D0N Product Technical Specification

Manufacturer: Yaskawa Electric Corporation

Product Model: DF9200664-D0N

Board Code: JANCU-MSV02N / JANCD-MSV01B

Product Type: Robot Controller, Safety Enhanced Servo Expansion / Axis Control Module

Applicable Systems: Yaskawa Motoman DX200, DX100, NX100 Controllers (Specialized for High Safety Configuration)

I. Product Overview

DF9200664-D0N (JANCU-MSV02N) is a safety-level servo expansion module specifically designed by Yaskawa for multi-axis robots and external axis collaborative control. It provides additional servo axis control capabilities and PLe/SIL3 safety functions for DX200/DX100/NX100 controllers. As a standard MIF interface axis expansion unit, its core positioning is to meet the ISO 13849-1 PLe, IEC 61508 SIL 3 highest safety level, suitable for 7-axis and above multi-joint robots, tool changers, walking axes, collaborative robots and other high safety requirement scenarios. D0N is the latest safety-enhanced version of this series. It has been comprehensively upgraded in axis control accuracy, safety response, redundant design and fault diagnosis. 

II. Physical Specifications

Card Form: Standard 6U VME industrial-grade PCB card (with safety reinforcement structure)

Dimensions: Approximately 233mm × 160mm × 22mm

Weight: Approximately 0.7kg

Interface Configuration (safely designed independently)

VME System Bus (CPU communication, safety CRC verification)

CN1: SSCNET III servo optical fiber interface (4 axes, safety channel)

CN2: Encoder feedback interface (differential RS-422, dual redundant)

CN3: Safety-specific axis control I/O (STO, SS1, safety door, emergency stop)

CN4: External 24VDC safety power supply (dual independent input)

CN5: System 5V power supply (VME power supply, safety filtering)

LED: PWR/RUN/ALM/COM/AX1-4/SAFE1/SAFE2 (dual safety status lights)

Structural Process

10-layer PCB, strict control of differential impedance, gold plating and thickening

Full board three-coat coating + EMI shielding cover (independent shielding of safety area)

Wide Temperature Range: -20°C to +60°C (industrial reinforcement)

Gold-plated interfaces: Insertion and removal life ≥ 1500 times

Vibration Reinforcement: Compatible with intense vibration environments in production lines

III. System Compatibility

Applicable Controllers

Motoman DX200 (main configuration, safety firmware Ver.7.5+)

Motoman DX100 (safety extended model)

Motoman NX100 (high safety configuration)

Compatible Servos

Yaskawa Σ-7, Σ-X series (native support for safety STO)

Compatible Σ-5 series (requires safety adapter board)

Version Spectrum

Basic Version: DF9200664-C0 (JANCU-MSV01, non-safety)

Standard Version: DF9200664-D0 (JANCU-MSV02, standard axis control)

Safety Enhanced Version: DF9200664-D0N (JANCU-MSV02N) - PLe/SIL3 safety level

IV. Core Functional Characteristics (Nth Version Safety Enhancement)

1. Safety Functions (PLe/SIL3 level, core differences)

Dual redundant safety channels: Axis safety I/O, STO, emergency stop are dual-channel independent circuits, single-point failure does not affect safety

Safety Torque Off (STO): PLe/SIL 3, response time < 0.5ms

Safety Stop (SS1/SS2), Safety Speed Limit (SLS), Safety Position (SOP) hardware support

Independent safety monitoring for each axis: position/velocity dual encoder verification

Safety I/O: 12 points safety-specific (6 input/6 output), 24VDC, 1500VAC isolation

Safety status hardware latch + non-volatile storage, must be manually reset after failure + password unlock

2. Servo Axis Control

SSCNET III optical fiber bus: 1Gbps, 4-axis synchronous safety control

Axis Number Expansion: Single controller can support up to 4 MSV modules, expanding to 16 axes (including the body + external axes)

Control Cycle: 0.5–8ms (fixed 0.5ms in safety mode)

Position Accuracy: ±0.5 pulses (safety monitoring)

Support for multi-axis collaboration, electronic gearing, cam synchronization, safety position locking

External Axes: Machine tool, traveling axis, flipping table safety linkage control

3. Communication and I/O

VME Bus: 16Mbps, safety CRC verification

Axis Status: Real-time safety monitoring, fault immediately cuts off servo Safety I/O: Physically isolated from the non-safety zone to prevent interference and crosstalk

High-speed position comparison: <0.1ms response, suitable for precise positioning scenarios

Remote diagnosis: Monitor the status of safety axes through the teaching device / upper computer

4. Protection and Diagnosis (Safety Level)

Overvoltage / Undervoltage / Overcurrent / Short Circuit: Dual-channel hardware protection + redundant monitoring

Safety Fault: 32-bit precise code + dual-channel independent diagnosis

LED + Controller + Safety Log Triple-state Display

Watchdog: Dual watchdog interlock, immediately cuts off safety output in case of abnormality

ESD Protection: ±25kV air, ±12kV contact (industry's highest level)

V. Electrical Parameters Power supply

System power supply: 5VDC ±5%, 2.2A (safety filtering)

Servo interface: 24VDC ±10%, 1.2A

Safety circuit: 24VDC ±10%, 0.6A (dual independent)

Isolation withstand voltage: 3000VAC (safety channel)

Power consumption: Approximately 13W (full load) Signal

SSCNET III: Fiber optic 1Gbps, extended security protocol

Encoder: 5V differential RS-422, dual redundant check

Security I/O: 24VDC, PLe/SIL3

General I/O: 24VDC, optically isolated Performance

Security Response: <0.5ms

Axis Control Cycle: 0.5ms (safety) / 1–8ms (standard)

MTBF: >100,000 hours (40°C)

Synchronization Precision: ±0.1μs (multi-axis)

VI. D0N vs D0 Key Upgrade

Security Level: D0N = PLe/SIL3; D0 = PLd/SIL2

Safety channel: D0N = Dual redundant independent circuits; D0 = Single channel

Safety function: D0N = STO + SS1 + SS2 + SLS + SOP; D0 = Basic STO

Response time: D0N = < 0.5ms; D0 = <1ms

Isolation withstand voltage: D0N = 3000VAC; D0 = 1500VAC

ESD protection: D0N = ±25kV/±12kV; D0 = ±15kV/±8kV

Axis safety monitoring: D0N = Independent dual encoders per axis; D0 = Single-channel monitoring

Firmware: D0N = Secure encryption + signature authentication; D0 = Standard firmware

VII. LED status indication

PWR (green): 5V power supply is normal

RUN (green): Running (1Hz flashing)

ALM (red): Fault (always on = hardware, flashing = safety fault)

COM (green): VME communication is normal

AX1–AX4 (yellow): Corresponding axis servo activated

SAFE1 (green): Safety channel 1 is normal

SAFE2 (green): Safety channel 2 is normal (double safety lights)

VIII. Installation and maintenance

Installation specifications

Slot: VME priority safety slot (1–4 slots)

Grounding: <0.5Ω (dual-ended independent grounding)

Cabling: Strict separation and shielding of safety cables, optical fibers, and power lines

Tightening: 0.22–0.25N・m

Heat dissipation: Vertical installation to ensure ventilation

Maintenance matters

Annual full-function safety circuit test

Regular cleaning of optical fibers to avoid contamination

Firmware: Use only Ansys official safety version

Fault replacement: Direct plugging and unplugging, automatic synchronization of safety parameters

IX. Safety fault diagnosis (typical)

SAFE1/SAFE2 extinguished: Dual-channel safety fault (emergency stop, STO, safety door)

ALM + SAFE flashing: Safety verification error (dual paths not consistent)

Axis without safety response: SSCNET safety message abnormal

Safety output not connected: Hardware latch / reset failure / password not unlocked

X. Safety certification ISO 13849-1 PLe

IEC 61508 SIL 3

UL 508, CE (LVD/EMC), RoHS, IEC 61010