1.1 Basic Information

• Model: JANCD-YSF22-E / JANCD-YSF22B-E, Yaskawa Motoman DX200 dedicated safety I/O logic PCB

• Function Name: Machine Safety I/O Logic Board, core safety control board for DX200 robot cabinet

• Matching configuration: Main CPU JANCD-YCP21-E, servo axis board JANCD-YIF01-4E, backplane YBB21; matched external safety terminal block JANCD-YFC22-E

• Safety compliance: IEC61508 SIL3 safety specification, dual-channel redundant safety circuit design for emergency stop and safety interlock

• Install location: Fixed dedicated slot on DX200 YBB21 backplane inside control cabinet

1.2 Core Functions

1. Dual-channel redundant safety input processing: External emergency stop, cabinet safety door lock, safety plug interlock, teach pendant enable/ESTOP, tool collision shock input

2. Safety chain logic judgment & servo cutoff control: Output servo disable signal to YIF01 board to cut off all servo power once safety loop is broken

3. Safety signal communication with main CPU via dedicated high-speed serial bus, feed all safety status & fault codes to controller system

4. Drive interlock output: External system ready, system running status output, safety fault alarm output to peripheral equipment

5. Cooperate with YFC22-E terminal board to expand all field safety wiring terminals for workshop safety circuit connection

2. Electrical & Environmental Specifications

2.1 Power Spec

• Operating power: DC24V ±10% supplied from cabinet backplane slot

• Rated power consumption: 12W max

• Onboard protection fuse: 1.25A slow-blow fuse for safety circuit overcurrent protection

2.2 I/O Electrical Parameter

• Safety Digital Input: Dual redundant DC24V sink/source universal input; input ON=DC24V applied, OFF=open circuit; rated input current 4~6mA per point

• Safety Digital Output: Relay isolated output, each contact rated load DC24V/0.5A max for safety interlock control

• All safety signals adopt dual-circuit redundant wiring to prevent single wire breakage from losing safety protection

2.3 Ambient Condition

• Operating temperature: -10℃ ~ +55℃

• Storage temperature: -25℃ ~ +70℃

• Humidity: 30%~80%RH non-condensing; avoid corrosive gas, welding spatter, strong high-frequency electromagnetic interference, water vapor

• Cooling: Passive natural convection cooling without fan

3. On-board Connector Definition

CN200: Backplane Bus Connector

CN218: Safety Bus to YIF01 Servo Board

CN219: Main External Safety Signal Port (Connect to JANCD-YFC22-E safety terminal block)

1. EXESP1+, EXESP1- / EXESP2+, EXESP2-: Dual-channel external emergency stop input (normally closed factory jumper shorted)

2. SAFF1+, SAFF1- / SAFF2+, SAFF2-: Safety fence door interlock / safety plug dual redundant input (factory shorted by jumper)

3. TP-ESP: Teach pendant emergency stop dual redundant input

4. ENABLE: Teach pendant deadman enable switch input

5. SHOCK: Tool collision shock sensor safety input

6. SYSRUN: System normal running contact output

7. SAFE-FAULT: Safety loop abnormal alarm output

CN220: Auxiliary I/O Connector

4. PCB LED Indicator Description

1. PWR(Green): Power LED

   ON=DC24V supply normal; OFF=fuse blown or backplane power failure

2. RUN(Green): Communication status LED

   Slow flashing=normal communication with CPU & YIF01; steady OFF=bus communication breakdown

3. SAFE(Orange): Safety loop status LED

   ON=All safety chains closed, servo enable allowed; OFF=E-stop pressed/safety door open/interlock broken

4. ERR(Red): Fault LED

   Steady ON=Safety input short/open or dual-channel signal inconsistency fault; Flashing=board internal logic error or address conflict

5. DIP Switch Setting (S1 on PCB)

• BIT1~BIT3: Station address coding, factory default fixed address for safety board (no modification permitted normally)

• BIT4: SHOCK sensor input logic: ON=active high(24V trigger), OFF=active low(open trigger)

• BIT5: EXESP input mode: ON=normally open safety switch, OFF=normally closed(default factory)

• BIT6: Reserved factory setting, keep OFF permanently

NOTE: All DIP adjustment must be done under full cabinet power OFF.

6. Standard Installation Steps

Step 1 Power Cutoff Safety Operation

Step2 DIP Pre-setting

Step3 Board Mounting

Step4 External Wiring

1. Use shielded cable for CN219 → YFC22-E connection; single-point ground of shielding layer at cabinet earth bar

2. Remove factory jumper on YFC22 terminal for field external E-stop/safety door wiring according to site safety schematic

3. Connect shock sensor/limit switch to CN220 as needed.

Step5 Power-on Verification

7. DX200 System Software Configuration

8. Common Troubleshooting

Fault 1: PWR LED always OFF

1. Check onboard 1.25A fuse burnout, replace same-spec slow-blow fuse

2. Re-seat YSF22 board to fix poor gold finger contact; test slot DC24V from backplane.

Fault2 SAFE LED OFF, servo cannot switch on

1. Check all E-stop buttons, safety fence door switch: confirm all normally closed circuits are connected; restore factory jumper temporarily for troubleshooting

2. Measure dual-channel input voltage of EXESP/SAFF on CN219 with multimeter, repair open/short wiring.

Fault3 ERR Red LED steady ON

1. Check dual redundant safety input wiring for inconsistent open/close between two channels

2. Recheck S1 DIP switch setting mismatch with field switch type.

Fault4 RUN LED extinguished with normal PWR

9. Version Distinction

• JANCD-YSF22-E: Standard original version for standard DX200 cabinet

• JANCD-YSF22B-E: Optimized upgrade version with enhanced surge protection for heavy welding environment cabinet

10. Maintenance Safety Notes

1. All wiring, replacement, maintenance must be performed under complete power-off state of controller cabinet.

2. Periodic maintenance every 6 months: Clean PCB dust with dry lint-free cloth, inspect connector looseness and cable insulation aging.

3. For damaged board: Whole-unit replacement recommended; prohibited to disassemble and replace discrete onboard components on site.

4. Keep board away from welding arc splash, high-frequency inverter electromagnetic field and moisture environment.