DF9200676-C0 Product Technical Manual

Manufacturer: Yaskawa Electric Corporation

Product Model: DF9200676-C0

Board Code: JANCD-MSV04 / RP1016-549A

Product Type: 4-axis servo axis control module for robot controllers (standard expansion type)

Applicable Systems: Yaskawa Motoman DX200, DX100, NX100 series robot controllers

I. Product Overview

DF9200676-C0 is a standard 4-axis servo axis control expansion module of the DF920067x series from Yaskawa Electric Corporation. It provides additional servo axis expansion capabilities for DX200/DX100/NX100 controllers, mainly used for external axes (tool changer, traveling axis, flipping table), multi-robot collaboration, multi-axis linkage fixtures, etc., in standard industrial automation scenarios. C0 is the basic stable version of this series, featuring mature hardware design and SSCNET III high-speed communication, balancing axis control accuracy, stability and cost, suitable for automotive welding, handling, assembly, general mechanical processing and other production lines.

II. Physical Specifications

Board Form: Standard 6U VME industrial-grade PCB card

Dimensions: Approximately 233mm (length) × 160mm (height) × 20mm (thickness)

Weight: Approximately 0.65kg

Interface Configuration

VME system bus connector (CPU communication)

CN1: SSCNET III servo optical fiber interface (4-axis control)

CN2: Encoder feedback interface (differential RS-422)

CN3: Axis control I/O interface (servo enable, alarm, limit, origin)

CN4: External 24VDC power input

LED Status Lights: PWR, RUN, ALM, COM, AX1–AX4

Structural Process

8-layer PCB design, gold plating process

Full board three-proof coating (dust-proof, moisture-proof, oil-proof)

Metal shielding cover, enhanced EMC anti-interference

Wide temperature components: -10°C to +60°C

Gold-plated connectors, plug-in life ≥1000 times

III. System Compatibility

Applicable Controllers

Motoman DX200 (mainstream compatibility, firmware Ver.5.0+) Motoman DX100

Motoman NX100

Adaptive Servo

Yaskawa Σ-7 and Σ-5 series servo motors

Support for SSCNET III high-speed fiber optic bus servo

Version association

Basic standard version: DF9200676-C0 (This model)

Performance enhancement version: DF9200676-D0 (Axis control cycle optimization, communication stability improvement)

Safety enhancement version: DF9200676-D0N/E0N (PLe/SIL3 safety functions)

Same series axis control module: DF9200674-C0/D0/E0N (4-axis general axis control)

Four. Core functional features

1. Servo axis control

4-axis independent servo control: Single module supports 4-axis SSCNET III servo drive

Control cycle: 0.5–8ms adjustable, standard mode 1ms

Position accuracy: ±0.5 pulses, repeat positioning accuracy <0.01mm

Synchronous control: Multi-axis synchronous error <0.1μs, supports external axes and robot collaboration

Axis control functions: Electronic gear, cam synchronization, soft limit, origin reset, position locking

Maximum axis expansion: Single controller supports 4 modules, total axis number up to 16 axes (including body axes)

2. Communication and interfaces

SSCNET III fiber bus: 1Gbps high-speed communication, strong anti-interference

VME bus: 16Mbps, real-time data interaction with CPU

Encoder feedback: Differential RS-422, supports incremental / absolute value encoders

Axis I/O: 16 points dedicated I/O (enable, alarm, positive/negative limit, origin)

Remote monitoring: Monitor axis status, alarm codes through teaching device / upper computer

3. Protection and diagnosis

Power protection: Overvoltage, undervoltage, overcurrent, reverse polarity protection

Servo protection: Independent overcurrent, short circuit, overload, overheat protection for each axis

Status indication: LED real-time display of power, operation, communication, axis status, fault

Fault diagnosis: Precise alarm codes, supports broken wire, short circuit, communication abnormality diagnosis

4. Reliability and environment

Electrical isolation: 1500VAC (signal / power / system interconnection)

ESD protection: ±15kV (air discharge), ±8kV (contact discharge)

EMC standard: Complies with industrial-level electromagnetic compatibility standards

MTBF: >75,000 hours (40°C environment)

Working humidity: 5%–85% RH (no condensation)

Five. Electrical parameters

Power supply parameters

System power supply: 5VDC ±5%, maximum 1.5A (VME bus power supply)

Servo interface power supply: 24VDC ±10%, maximum 1.0A

Power consumption: Approximately 10W (full load)

Isolation withstand voltage: 1500VAC

Signal parameters

SSCNET III: Fiber 1Gbps, 4-axis servo control

Encoder: 5V differential RS-422, maximum 5Mbps feedback rate

Axis I/O: 24VDC, optically isolated, response time <0.5ms

Input high level: 15V–26.4V; low level: 0V–5V

Performance indicators

Axis control cycle: 0.5ms (high speed) / 1ms (standard) / 2–8ms (ordinary)

Synchronous accuracy: Multi-axis <0.1μs

Maximum number of axes: Single controller 16 axes (4 modules × 4 axes)

Adaptable load: Positioning machine, walking axis, flipping table, multi-axis tooling

Six. LED status indication

PWR (green): System 5V power supply is normal (constantly on)

RUN (green): Module is running (1Hz flashing)

ALM (red): Fault alarm (constantly on = hardware fault, flashing = axis / communication fault) COM (green): VME bus communication is normal (flashing)

AX1-AX4 (yellow): Corresponding axis servo activation and operation status

VII. Installation and Maintenance

Installation Specifications

Install in the VME standard slots (recommended 2-5 slots)

Grounding impedance: <1Ω, reliable grounding

Cabling: Separate cabling for optical fibers, I/O cables, and power lines, spacing ≥30mm

Connector tightening torque: 0.22–0.25N·m

Installation direction: Vertical installation to ensure heat dissipation space

Maintenance matters

Regularly check the cleanliness of the optical fiber interface to avoid contamination

Clean the board and interface every 12 months to prevent dust accumulation

Firmware: Use only the official verification version of Yaskawa

Fault replacement: Directly plug and unplug for replacement, no need to reconfigure axis parameters

VIII. Fault Diagnosis and Troubleshooting

ALM constantly on: Check 5V/24V power supply, VME bus, board hardware

AX light not on: Servo optical fiber connection, servo enable, axis alarm, encoder feedback

Communication abnormality (COM not flashing): VME bus, CPU module, firmware version

Axis positioning不准： Encoder wiring， servo parameters， synchronization settings， mechanical installation

Servo alarm： Axis I/O wiring， servo drive， motor failure， overload

IX. Safety and Certification

Complies with standards： UL 508， CE (LVD/EMC)， RoHS， IEC 61010

Basic safety： Support access to basic STO (safety torque shutdown) signal

Safety features： Power isolation， hardware overcurrent protection， abnormal state output locking