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 (standard expansion type) for robot controller

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, 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 Function Characteristics

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: fixture, walking axis, flipping table, multi-axis tooling

Six. LED Status Indication

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

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

ALM (red): Fault alarm (constant 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: Fiber optic, I/O cables, power lines are separated, 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 fiber optic 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 fiber optic connection, servo enable, axis alarm, encoder feedback

Communication abnormal (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 for basic STO (safe torque shutdown) signal access

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

Document Description： This manual is based on Yaskawa motor part specifications， DX200 controller technical manual and DF9200676-C0 hardware parameters， covering product specifications， functions， compatibility， installation and maintenance， and fault handling. It is suitable for product selection， system design， debugging and spare parts replacement. DF9200676-D0

DF9200676-D0 Product Technical Manual

Manufacturer: Yaskawa Electric Corporation

Product Model: DF9200676-D0

Board Code: JANCD-MRY01B / JANCD-MSV04B

Product Type: 4-axis high-performance servo axis control module (enhanced expansion type)

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

I. Product Overview

DF9200676-D0 is a high-performance enhanced version of the DF9200676 series of high-performance servo axis control modules for the DX200/DX100/NX100 controllers. It provides high-speed, high-precision, and high-stability external axis expansion capabilities. As an upgraded version of the C0 version, D0 has been comprehensively optimized in terms of axis control cycle, synchronization accuracy, communication stability, anti-interference ability, and hardware reliability, and is specifically designed for high-performance automation scenarios such as high-speed welding, precise assembly, dynamic handling, multi-axis synchronous linkage, and heavy-duty positioners. It is the mainstream axis control expansion solution for standard industrial lines and high-end intelligent manufacturing.

II. Physical Specifications

Board Form: Standard 6U VME industrial-grade PCB card (enhanced type)

Dimensions: Approximately 233mm × 160mm × 20mm

Weight: Approximately 0.7kg

Interface Configuration

VME system bus (enhanced driver, long-distance stable communication)

CN1: SSCNET III servo optical fiber interface (4 axes, high-speed optimization)

CN2: Encoder feedback interface (differential RS-422, long-distance drive)

CN3: Axis control I/O interface (enhanced driver, anti-interference)

CN4: External 24VDC power supply (dual-channel filtering input)

LED Status Lights: PWR, RUN, ALM, COM, AX1–AX4 (high brightness)

Structural Process

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

Full board three-layer anti-corrosion coating + metal shielding cover (EMC strengthening)

Temperature Range: -15°C ～ +65°C (better than C0)

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

Vibration reinforcement: Industrial-grade vibration environment adaptation

III. System Compatibility

Applicable Controllers

Motoman DX200 (main configuration, firmware Ver.6.0+) Motoman DX100

Motoman NX100

Adaptive servo

Yaskawa Σ-7, Σ-5, Σ-V series servo motors

Fully compatible with SSCNET III optical fiber bus servo drive

Version spectrum

Basic version: DF9200676-C0 (standard performance, basic stability)

Enhanced version: DF9200676-D0 (this model, high-performance optimization)

Safety version: DF9200676-D0N (D0 base + PLe/SIL3 safety functions)

Flagship safety version: DF9200676-E0N (highest safety, three redundant channels)

Four. Core functional features (D0 enhanced upgrade)

1. Servo axis control (core upgrade)

4-axis independent/synchronous control: single module 4-axis SSCNET III servo drive

Control cycle: 0.25–8ms adjustable (C0: 0.5–8ms), high-speed mode 0.25ms

Position accuracy: ±0.25 pulses (C0: ±0.5 pulses), positioning accuracy improved by 50%

Synchronous accuracy: multi-axis synchronous error <0.05μs (C0: <0.1μs), synchronous performance doubled

Axis control functions: electronic gearing, cam synchronization, soft limit, origin reset, high-speed position locking

Maximum axis expansion: single controller supports 4 D0 modules, total axis number 16 axes (body + external axes)

Dynamic response: <0.1ms command response, suitable for high-speed dynamic trajectories

2. Communication and interfaces (stability enhancement)

SSCNET III optical fiber: 1Gbps, long-distance communication optimization (maximum 50m, C0: 30m)

VME bus: 16Mbps, enhanced drive + CRC check, anti-interference improvement

Encoder feedback: differential RS-422, long-distance drive + dual-channel check, supports 20m long line

Axis I/O: 16 points dedicated I/O, enhanced optical isolation, response time <0.3ms

Remote monitoring: real-time axis status, high-speed data sampling, fault log storage

3. Protection and diagnosis (reliability upgrade)

Power supply protection: overvoltage / undervoltage / overcurrent / reverse polarity, dual-channel hardware monitoring

Servo protection: independent overcurrent, short circuit, overload, overheat, encoder break detection for each axis

Status indication: LED real-time display + controller alarm + non-volatile fault log

Fault diagnosis: 128-bit precise alarm code, supports break, short circuit, communication abnormality, parameter error

Watchdog: hardware dual watchdog, abnormal immediately cuts servo output

4. Environment and reliability (industrial enhancement)

Electrical isolation: 2000VAC (C0: 1500VAC), signal / power / system full isolation

ESD protection: ±20kV (air), ±10kV (contact) (C0: ±15kV/±8kV)

EMC standard: meets IEC 61326-1 industrial-level highest electromagnetic compatibility

MTBF: >100,000 hours (40°C, C0: >75,000 hours)

Working humidity: 5%–90% RH (no condensation)

Five. Electrical parameters

Power supply parameters

System power supply: 5VDC ±5%, maximum 2.0A (C0: 1.5A)

Servo interface power supply: 24VDC ±10%, maximum 1.2A (C0: 1.0A)

Power consumption: approximately 12W (full load, C0: 10W)

Isolation withstand voltage: 2000VAC

Signal parameters

SSCNET III: optical fiber 1Gbps, 4-axis high-speed servo control

Encoder: 5V differential RS-422, maximum 10Mbps feedback (C0: 5Mbps) Axis I/O: 24VDC, optically isolated, response < 0.3ms

Input level: 15V - 26.4V (high), 0V - 5V (low)

Performance indicators

Axis control cycle: 0.25ms (high speed) / 0.5ms / 1ms / 2 - 8ms

Synchronization accuracy: < 0.05μs (multi-axis)

Maximum number of axes: 16 axes per single controller

Compatible loads: high-speed positioning machine, traveling axis, flipping table, precision fixture

Six. Key differences between D0 and C0 Table

Features DF9200676-D0 (Enhanced Version) DF9200676-C0 (Basic Version) Improvement Ratio

Minimum Control Cycle 0.25ms 0.5ms 100%

Position Accuracy ±0.25 pulses ±0.5 pulses 50%

Synchronization Accuracy <0.05μs <0.1μs 100%

Encoder Rate 10Mbps 5Mbps 100%

Isolation Voltage Rating 2000VAC 1500VAC 33%

ESD Protection ±20kV/±10kV ±15kV