HARDWARE OVERVIEW 2

Trio Motion Technology

2-2 HARDWARE OVERVIEW

 Hardware Reference Manual

Hardware

Motion Coordinator MC664 (-X)

OVERVIEW
The Motion Coordinator MC664 is Trio’s highest specification modular
servo control positioner with the ability to control servo or stepper
motors by means of Digital Drive links (e.g. EtherCAT, RTEX, etc)
or via traditional analogue and encoder or pulse and direction. A
maximum of 7 expansion modules can be fitted to control up to 128
axes which gives the flexibility required in modern system design.
The MC664 is housed in a rugged plastic case with integrated earth
chassis and incorporates all the isolation circuitry necessary for direct
connection to external equipment in an industrial environment.
Filtered power supplies are included so that it can be powered from
the 24V d.c. logic supply present in most industrial cabinets.
It is designed to be configured and programmed for the application
using a PC running the Motion Perfect application software, and
then may be set to run “standalone” if an external computer is not
required for the final system.
There are two versions of the MC664. A single core processor allowing
the MC664 to replace the MC464 in most applications. The MC664-X
includes a quad-core A9 processor and is recommended for high
performance applications such as robotics and for systems with large
numbers of axes.
The Multi-tasking version of TrioBASIC for the MC664 allows up to
22 TrioBASIC programs to be run simultaneously on the controller
using pre-emptive multi-tasking. In addition, the operating system
software includes the IEC 61131-3 standard run-time environment
(licence key required).

PROGRAMMING
The Multi-tasking ability of the MC664 allows parts of a complex application to be developed, tested and
run independently, although the tasks can share data and motion control hardware. IEC 61131-3 programs
can be run at the same time as TrioBASIC allowing the programmer to select the best features of each. The
MC664-X runs applications and motion in seperate cores for increased performance.

I/O CAPABILITY
The MC664 has 8 built-in 24V inputs and 8 bi-directional I/O channels. These may be used for system
interaction or may be defined to be used by the controller for end of travel limits, registration, datuming
and feedhold functions if required. Each of the Input/Output channels has a status indicator to make it easy
to check them at a glance. The MC664 can have up 512 external Input/Output channels connected using DIN

HARDWARE OVERVIEW 2-3

Motion Coordinator MC664 (-X)
Trio Motion Technology

rail mounted CAN I/O modules. These units connect to the built-in CAN channel. In addition, the built-in
EtherCAT port can support up to 1024 I/O points.

COMMUNICATIONS
A 10/100 base-T Ethernet port is fitted as standard and this is the primary communications connection to the
MC664. Many protocols are supported including Telnet, Modbus TCP, Ethernet IP and TrioPCMotion. Check
the Trio website (www.triomotion.com) for a complete list.
The MC664 has one built in RS232 port and one built in duplex RS485 channel for simple factory
communication systems. Either the RS232 port or the RS485 port may be configured to run the Modbus or
Hostlink protocol for PLC or HMI interfacing.
If the built-in CAN channel is not used for connecting I/O modules, it may optionally be used for CAN
communications. E.g. DeviceNet slave or CanOpen master.
A second RJ45 socket is enabled for precisely timed EtherCAT communication with drives and I/O devices.
The Anybus CompactCom Carrier Module (P875) can be used to add other fieldbus communications options

REMOVABLE STORAGE
The MC664 has a SD Card slot which allows a simple means of transferring programs,
firmware and data without a PC connection. Offering the OEM easy machine
replication and servicing.
The memory slot is compatable with a wide range of SD cards up to 16Gbytes using
the FAT32 compatible file system.

AXIS POSITIONING FUNCTIONS

The motion control generation software receives instructions to move an axis or axes from the TrioBASIC or
IEC 61131-3 language which is running concurrently on the same processor. The motion generation software
provides control during operation to ensure smooth, coordinated movements with the velocity profiled as
specified by the controlling program. Linear interpolation may be performed on groups of axes, and circular,
helical or spherical interpolation in any two/three orthogonal axes. Each axis may run independently or
they may be linked in any combination using interpolation, CAM profile or the electronic gearbox facilities.
Consecutive movements may be merged to produce continuous path motion and the user may program the
motion using programmable units of measurement (e.g. mm, inches, revs etc.). The module may also be
programmed to control only the axis speed. The positioner checks the status of end of travel limit switches
which can be used to cancel moves in progress and alter program execution.
The processing power of the MC664 allows real-time robotic transforms to be run which convert world
coordinates into the required motor angles. Many typical mechanical arrangements are handled including
Scara, Delta, complex “wrist” and 6 degrees of freedon (D.O.F).

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Motion Coordinator MC664 (-X)
 Hardware Reference Manual

CONNECTIONS TO THE MC664

Ethernet 101011
RS232 and
A
Port RS485 Port

Ethernet
B
Sync Port
Sync Encoder

SD Card

ETHERNET PORT CONNECTION

Physical layer: 10/100 base-T
Connector: RJ45
The Ethernet port is the default connection between the Motion Coordinator and the
host PC running Motion Perfect programming.

ETHERCAT PORT
EtherCAT master port for connection to servo/stepper drives and I/O devices using
industry standard EtherCAT protocols.

MC664 SERIAL CONNECTIONS

The MC664 features two serial ports. Both ports are accessed through a single 8 pin connector.

SERIAL CONNECTOR
Pin Function Note
1 RS485 Data In A Rx+ 6 3
1
Serial Port #2 7 4
2 RS485 Data In B Rx- 2
8
5
3 RS232 Transmit Serial Port #1
4 0V Serial
5 RS232 Receive Serial Port #1
6 Internal 5V 5V supply is limited to 150mA, shared with sync
port
7 RS485 Data Out Z Tx- Serial Port #2
8 RS485 Data Out Y Tx+ Serial Port #2

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Motion Coordinator MC664 (-X)
Trio Motion Technology

SYNC ENCODER
The sync encoder port is bidirectional. It can be used as a reference encoder input or as
an encoder simulation output to act as a master reference for other parts of the system.
Pin Encoder Absolute Pulse & Direction 1
6
2
7
1 Enc. A Clk + Step + 3
8
4
2 Enc. /A Clk - Step - 9
5

3 Enc. B N/C Direction +

4 Enc. /B N/C Direction -
5 0V Encoder 0V Enc. 0V Stepper
6 Enc. Z Data + Enable +
7 Enc. /Z Data - Enable -
8 5V* 5V 5V*
9 Registration Input (5V)
*5V supply is limited to 150mA (shared with serial port)

REGISTRATION
The MC664 built in port has 2 available registration events. These can be used with the Z mark, the
registration input on the sync port, or up to 2 inputs of the MC664 digital inputs 0 - 7, mapped by REG _
INPUTS.

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Motion Coordinator MC664 (-X)
 Hardware Reference Manual

24V POWER SUPPLY INPUT

0V AIN 0V CAN/AIN
AIN0 CAN LOW
AIN1 CAN SHIELD
WDOG+ CAN HIGH
WDOG- 24V CAN/AIN SUPPLY
I0 I/O/8
I1 I/O/9
I2 I/O/10
I3 I/O/11
I4 I/O/12
I5 I/O/13
I6 I/O/14
I7 I/O/15
0V I/O 24V I/0 SUPPLY
0V SUPPLY 24V SUPPLY

The MC664 is powered entirely via the 24V d.c.supply connections. The unit uses internal DC-DC converters
to generate independent 5V logic supply, the encoder/serial 5V supply and other internal power supplies.
I/O, analogue and CANbus circuits are isolated from the main 24V power input and must be powered
separately. For example; it is often necessary to power the CANbus network remotely via the CANbus cable.

24V d.c., Class 2 transformer or power source required for UL compliance. The MC664 is grounded via
the metal chassis. It MUST be installed on an unpainted metal plate or DIN rail which is connected to
earth.

AMPLIFIER ENABLE (WATCHDOG) RELAY OUTPUTS

One internal relay contact is available to enable external amplifiers when the controller has powered up
correctly and the system and application software is ready. The amplifier enable is a solid-state relay with
an ON resistance of 25 ohms at 100mA. The enable relay will be open circuit if there is no power on the
controller OR a motion error exists on a servo axis OR the user program sets it open with the WDOG=OFF
command.
The amplifier enable relay may, for example, be incorporated within a hold-up circuit or chain that must be
intact before a 3-phase power input is made live.

 All stepper and servo amplifiers must be inhibited when the amplifier enable output is open circuit

HARDWARE OVERVIEW 2-7

Motion Coordinator MC664 (-X)
Trio Motion Technology

CANBUS
The MC664 features a built-in CAN channel. This is primarily intended for
Input/Output expansion via Trio’s range of CAN digital and analogue I/O 0V CAN/AIN
modules. It may be used for other purposes when I/O expansion is not CAN LOW
required. CAN SHIELD
The CANbus port is electrically equivalent to a DeviceNet node. CAN HIGH
24V CAN/AIN SUPPLY
ANALOGUE INPUTS
Two built-in 12 bit analogue inputs are provided which are set up with a scale Ain
22k
of 0 to 10V. External connection to these inputs is via the 2-part terminal strip
on the lower front panel. A to D
CONVERTER
22k 100uf
A 24V d.c. supply must be applied to the CANbus port to provide power for the
analogue input circuit.
0V
0V
24V INPUT CHANNELS
The Motion Coordinator has 16 24V Input channels built into the master unit. I/O 24V
These may be expanded to 1024 Inputs by the addition of CAN-16 I/O modules
and EtherCAT I/O.
The first 8 channels (0 ... 7) are input only, using high speed opto-isolators 6k8 Ohms
suitable for position capture (REGISTRATION). Channels 8 to 15 are bi- Input Pin
directional and may be used for Input or Output to suit the application.
Vin
I/O 0V
24V I/O CHANNELS
Input/output channels 8..15 are bi-directional and may be Optical
I/O 24V

used for Input or Output to suit the application. The inputs Output
have a protected 24V sourcing output connected to the same Control
Signal
pin. If the channel is to be used as an Input then the Output Protected
Switch
should not be switched on in the program. The output circuit
has electronic over-current protection and thermal protection Input/Output
which shuts the output down when the current exceeds 250mA. 6k8 Pin
Optical
Care should be taken to ensure that the 250mA limit for the Input
output circuit is not exceeded, and that the total load for the Signal

group of 8 outputs does not exceed 1A I/O OV

BACKLIT DISPLAY
The information display area shows the IP address and subnet mask during power-up and whenever an
Ethernet cable is first connected to the MC664. During operation, this display shows run, Off or Err to
indicate the MC664 status. Below the main status display are the ERROR and ENABLE indicators.

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Motion Coordinator MC664 (-X)
 Hardware Reference Manual

Information Display

0 8
Input Status 1 9
I/O Status
2 10
3 11
4 12
5 ENABLE 13
6 14
Ok 7 15
Status

ERROR An error has occurred (see Error Display Codes table below for details).
ENABLE When illuminated, WDOG is ON.
A bank of 8 indicators at the left side shows the Digital Input States and a similar bank on the right shows
the state of I/O8 to I/O15. The I/O displayed can be altered using the DISPLAY command.
Two LED’s are provided to show the processor (OK) and system status.
Error Display Codes
Unn Unit error on slot nn
Ann Axis error on axis aa
Caa Configuration error on unit aan ie: too many axes
Exx System error E00 - RAM error 8bit BB - RAM (VR)
E01 - RAM error 16 bit BB - RAM (TABLE)
E04 - VR/TABLE corrupt entry
E05 – Invalid MC_CONFIG file
E06 – Started in SAFE mode (system timeout)
E07 - FPGA Error
E08 - Flash memory error
E09 - ProcessoR Exception

HARDWARE OVERVIEW 2-9

Motion Coordinator MC664 (-X)
Trio Motion Technology

RECOVERY SWITCH

Recovery Mode

Normal Operation

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Motion Coordinator MC664 (-X)
 Hardware Reference Manual

MC664 FEATURE SUMMARY

Size 201 mm x 56 mm x 155 mm (HxWxD).
Weight 750g
Operating Temp. 0 - 45 degrees C.
Control Inputs Forward Limit, Reverse Limit, Datum Input, Feedhold Input.
Communication Ports RS232 channel: up to 38400 baud.
RS485 channel: up to 38400 baud.
CANbus port (DeviceNet and CANopen compatible)
Ethernet: 10/100 BaseT multiple port connection.
Position Resolution 64 bit position count.
Speed Resolution 32 bits. Speed may be changed at any time. Moves may be merged.
Servo Cycle 4ms max. 125μs minimum (50μs MC664-X)
Programming Multi-tasking TrioBASIC system, maximum 22 user processess.
IEC 61131-3 programming system.
Interpolation modes Linear 1-64 axes, circular, helical, spherical, CAM Profiles, speed control,
electronic gearboxes.
Memory 8 Mbyte user memory. 2 Mbyte TABLE memory. Automatic flash EPROM program
storage.
Table 512,000 table positions. 196,608 positions in Flash memory. Option to store
table.
VR 65,536 VR positions in Flash memory.
SD Card Standard SD Card compatible to 16Gbytes. Used for storing programs and/or
data.
Power Input 24V d.c., Class 2 transformer or power source.
18..29V d.c. at 625mA typical.
Amplifier Enable Output Normally open solid-state relay rated 24V ac/dc nominal. Maximum load 100mA.
Maximum voltage 29V.
Analogue Inputs 2 isolated x 12 bit 0 to 10V.
Serial / Encoder Power 5V at 150mA.
Output
Digital Inputs 8 Opto-isolated high speed 24V inputs.
Digital I/O 8 Opto-isolated 24V outputs. Current sourcing (PNP) 250 mA. (max. 1A per bank
of 8).

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Motion Coordinator MC664 (-X)
Trio Motion Technology

Motion Coordinator MC508

OVERVIEW
The Motion Coordinator MC508 is based on Trio’s
high-performance ARM Coretex-A9 ® double-precision
technology and provides 8 axes of servo, or 8 - 16 axes
of pulse+direction control for stepper drives or pulse-
input servo drives. Trio uses advanced FPGA techniques
to reduce the size and fit the pulse output and servo
circuitry in a compact DIN-rail mounted package. The
MC508 is housed in a rugged plastic case with integrated
earth chassis and incorporates all the isolation circuitry
necessary for direct connection to external equipment
in an industrial environment. Filtered power supplies
are included so that it can be powered from the 24V d.c.
logic supply present in most industrial cabinets.

It is designed to be configured and programmed for

the application using a PC running Trio’s Motion Perfect application software, and then may be set to run
“standalone” if an external computer is not required for the final system. Programs and data are stored
directly to FLASH memory, thus eliminating the need for battery backed storage.
The Multi-tasking version of TrioBASIC for the MC508 allows up to 22 TrioBASIC programs to be run
simultaneously on the controller using pre-emptive multi-tasking. In addition, the operating system
software includes a the IEC 61131-3 standard run-time environment (licence key required).

PROGRAMMING
The Multi-tasking ability of the MC508 allows parts of a complex application to be developed, tested and run
independently, although the tasks can share data and motion control hardware. The 22 available tasks can
be used for TrioBASIC or IEC 61131-3 programs, or a combination of both can be run at the same time, thus
allowing the programmer to select the best features of each.

I/OCAPABILITY
The MC508 has 16 built in 24V inputs, selectable in banks of 8 between NPN and PNP operation and 16
output channels. These may be used for system interaction or the inputs may be defined to be used
by the controller for end-of-travel limits, registration, homing and feedhold functions if required. 16
programmable status indicators are provided for I/O monitoring. The MC508 can have up 512 additional
external Input and Output channels connected using DIN rail mounted CAN I/O modules. These units
connect to the built-in CANbus port.

COMMUNICATIONS
A 10/100 Base-T Ethernet port is fitted as standard and this is the primary communications connection to
the MC508. Many protocols are supported including Telnet, Modbus TCP, UDP, Ethernet IP and TrioPCMotion.
Check the Trio website (www.triomotion.com) for a complete list.

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Motion Coordinator MC508
 Hardware Reference Manual

The MC508 has one built in RS232 port and one built in duplex RS485 channel for simple factory
communication systems. Either the RS232 port or the RS485 port may be configured to run the Modbus or
Hostlink protocol for PLC or HMI interfacing.
If the built-in CAN channel is not used for connecting I/O modules, it may optionally be used for CAN
communications. E.g. DeviceNet, CanOpen etc.

REMOVABLE STORAGE
The MC508 has a micro-SD Card slot which allows a simple means of transferring
programs, firmware and data without a PC connection. Offering the OEM easy
machine replication and servicing.
The memory slot is compatible with a wide range of micro-SD cards up to 16 GB using
the FAT32 compatible file system.

AXIS POSITIONING FUNCTIONS

The motion control generation software receives instructions to move an axis or axes from the TrioBASIC or
IEC 61131-3 language which is running concurrently on the same processor. The motion generation software
provides control during operation to ensure smooth, coordinated movements with the velocity profiled as
specified by the controlling program. Linear interpolation may be performed on groups of axes, and circular,
helical or spherical interpolation in any two/three orthogonal axes. Each axis may run independently or
they may be linked in any combination using interpolation, CAM profile or the electronic gearbox facilities.
Consecutive movements may be merged to produce continuous path motion and the user may program the
motion using programmable units of measurement (e.g. mm, inches, revs etc.). The module may also be
programmed to control only the axis speed. The positioner checks the status of end of travel limit switches
which can be used to cancel moves in progress and alter program execution.

CONNECTIONS TO THE MC508

ETHERNET PORT CONNECTION

Physical layer: 10/100 Base-T

CONNECTOR: RJ45

The Ethernet port is the default connection between the Motion Coordinator and the host PC running the
Motion Perfect development application.

HARDWARE OVERVIEW 2-13

Motion Coordinator MC508
Trio Motion Technology

SERIAL CONNECTIONS
The MC508 features two serial ports. Both ports are accessed through a single 8 pin connector.

SERIAL CONNECTOR
Pin Function Note
1 RS485 Data In A Rx+ Serial Port #2
2 RS485 Data In B Rx-
3 RS232 Transmit Serial Port #1
4 0V Serial
5 RS232 Receive Serial Port #1
3
6 Internal 5V 5V supply is limited to 150mA, 6
1
shared with encoder ports 7 4
2
7 RS485 Data Out Z Tx- Serial Port #2 8
5
8 RS485 Data Out Y Tx+ Serial Port #2

PULSE+DIRECTION OUTPUTS / ENCODER INPUTS

The MC508 is designed to support any combination of servo and pulse driven motor drives on the standard
controller hardware. There are 2 versions of the MC508; the servo version and the pulse output only version.
In the P848 pulse output version, only axes 0 to 7 can be configured. The P849 servo version makes axes 8 to
15 available as pulse and direction output.
Each of the first eight axes (0-7) can be enabled as servo (P849 version), pulse output or encoder according
to the user’s requirements by setting the axis ATYPE parameter. Axes 8 to 15 can be set as either pulse
output or encoder on the P849 version.
The function of the 20-pin MDR connectors will be dependent on the specific axis configuration which has
been defined. If the axis is setup as a servo, (P849 only) the connector will provide the analogue speed signal
and encoder input. If the axis is configured as a pulse output, the connector provides differential outputs
for step/direction or simulated encoder, and enable signals.
The flexible axis connector also provides 2 digital inputs (24V) and a current-limited 5V output capable of
powering most encoders. This simplifies wiring and eliminates external power supplies.

Pin Incremental Encoder Pulse & Direction Pulse & Direction Function Absolute Encoder
Function Function (P849 ONLY) Function
1 Enc A(n) Pulse(n) Pulse(n) Clock(n)
2 Enc /A(n) /Pulse(n) /Pulse(n) /Clock(n)
3 Enc B(n) Dir(n) Dir(n) NC
4 Enco /B(n) /Dir(n) /Dir(n) NC
5 +5V Enc (100mA max.)
6 Do not connect
7 WDOG(n)+

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Motion Coordinator MC508
 Hardware Reference Manual

Pin Incremental Encoder Pulse & Direction Pulse & Direction Function Absolute Encoder
Function Function (P849 ONLY) Function
8 WDOG(n)-
9 Input A+ (16 + n*2)
10 Input A/B Common
11 Enc Z(n) Enable(n) Pulse(n+8) Data(n)
12 Enc /Z(n) /Enable(n) /Pulse(n+8) /Data(n)
13 NC NC Dir(n+8) NC
14 NC NC /Dir(n+8) NC
15 0V Enc
16 Do not connect
17 VOUT + (n)
18 VOUT - (n)
19 Do not connect
20 Input B + (17 + n*2)
Shell Screen

1. n=axis number
2. WDOG(n)+/- = normally open solid state relay, rated 24V@100mA (one per axis)
3. Input A/B Common, 0V_Enc & VOUT- are all isolated so must be connected with the correct
signals.
4. +5V Output 400mA maximum current output is shared between all 8 axis connectors and the
serial connector. 100mA maximum per axis connector.

REGISTRATION
Axes 0 to 7 each have 2 available registration events. These are assigned in a flexible way to any of the first
8 digital inputs or can be used with the Z mark input on the encoder port.

5-WAY CONNECTOR
SHIELD
CAN_H

CAN_L
V+

V-

This is a 5 way 3.5 mm pitch connector. The connector is used both to provide the 24 Volt power to the
MC508 and provide connections for I/O expansion via Trio’s digital and analogue CAN I/O expanders. 24 Volts

HARDWARE OVERVIEW 2-15

Motion Coordinator MC508
Trio Motion Technology

must be provided as this powers the unit.

This 24 Volt input is internally isolated from the I/O 24 Volts and the +/-10V voltage outputs.
24V d.c., Class 2 transformer or power source required for UL compliance. The MC508 is grounded via the
metal chassis. It MUST be installed on an unpainted metal plate or DIN rail which is connected to earth. An
earth screw is also provided on the rear of the chassis for bonding the MC508 to ground.

I/O CONNECTOR A

Common A
Input
6k8

0
1
2
3
4
5
6
7
Optical

Input

Input
Input
Input
Input
Input
Input
Input
Input
N/C
Input
Signal

Common

I/O CONNECTOR B
Common B

10
11
12
13
14
15
8
9
Input

Input
Input
Input
Input
Input
Input
Input
Input
N/C

24V INPUT CHANNELS

The MC508 has 32 dedicated 24V Input channels built into the master unit. A further 512 inputs can be
provided by the addition of CAN I/O modules. The dedicated input channels are labelled channels 0..7,
8..15 and 2 per flexible axis connector (16..31). Two terminals marked XAC and XBC are provided for the
input common connections. Connect XAC/XBC to 0V for PNP (source) input operation or connect to +24V for
NPN (sink) operation. Input connectors A and B are independent so one can be PNP while the other is NPN.
Flexible axis connector inputs are fixed function PNP inputs.
Inputs 0 to 7 can be used as registration inputs for axes 0 to 7, using the REGIST command.

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 Hardware Reference Manual

I/O CONNECTOR C
OP 24V A

output 10
output 11
output 12
output 13
output 14
output 15
OP 24V A
Optical

output 8
output 9
OP 0V A
Output
Control
Signal Protected
Switch

I/O CONNECTOR D

analogue 0V

analogue 0V
output 16
output 17
output 18
output 19
output 20
output 21
output 22
output 23
OP 24V B

WDOG +
OP 0V B

WDOG -

Ain 0

Ain 1
24V OUTPUT POWER
The XC-/XD- 0 Volts and XC+/XD+ 24 Volts are used to power the 24 Volt digital outputs. XD-/XD+ also
powers the analogue I/O, including the servo DAC outputs.
Each digital I/O connector is isolated from the module power inputs and from the other I/O connectors.

24V OUTPUT CHANNELS

Output channels 8..23 are output only of PNP type 24V source. The output circuit has electronic over-
current protection and thermal protection which shuts the output down when the current exceeds 500mA.
Care should be taken to ensure that the 500mA limit for each output circuit is not exceeded, and that the
total load for the group of 8 outputs does not exceed 4 Amps.

AMPLIFIER ENABLE (WATCHDOG) RELAY OUTPUTS

Amplifier
Enable 1 24V 0V 0V

Amplifier
Enable 2 Enable

Trio Controller Servo Amplifier

Enable or Safety
Relay

HARDWARE OVERVIEW 2-17

Motion Coordinator MC508
Trio Motion Technology

An internal relay contact is available to enable external amplifiers when the controller has powered up
correctly and the system and application software is ready. The amplifier enable is a solid-state relay
with an ON resistance of 25Ω at 100mA. The enable relay will be open circuit if there is no power on the
controller OR a motion error exists on a servo axis OR the user program sets it open with the WDOG=OFF
command.
The amplifier enable relay may, for example, be incorporated within a hold-up circuit or chain that must be
intact before a 3-phase power input is made live.

 All stepper and servo amplifiers must be inhibited when the amplifier enable output is open circuit

ANALOGUE INPUTS
Ain
Two built-in 12 bit analogue inputs are provided which are set up 22k
with a scale of 0 to 10V. External connection to these inputs is via A to D
the 2-part terminal strip I/O connector D. CONVERTER
A 24V d.c. supply must be applied to I/O connector D (XD+/XD-) to 22k 30pF
provide power for the analogue input circuit.

0V
0V

ANALOGUE OUTPUTS Vout

The MC508 has 8 12-bit analogue outputs, one per flexible axis 100R
connector, scaled at +/-10V. Each output is assigned to one servo axis, D to A
or in the case where the axis is not used, or is set as a pulse+direction/ CONVERTER
simulated encoder output, the analogue output may be set to a voltage 100nF
directly in software.
A 24V d.c. supply must be applied to I/O connector D to provide power
for the analogue output circuit.
0V
0V

BACKLIT DISPLAY 0 8

On power-up, the information display area shows bt during the boot

1 9
2 10
process, then the MC508 version is displayed, showing P848 for the 8 3 11
axis pulse output version and P849 for the 8 axis servo + 8 axis pulse 4 12
5 ENABLE 13
output version. The IP address and subnet mask is shown on power-up 6 14
and whenever an Ethernet cable is first connected to the MC508. 7 15

During operation, this display shows run, OFF or Err to indicate the
MC508 status. Below the main status display are the ERROR and ENABLE indicators.
ERROR: An error has occurred (see Error Display Codes table below for details).
ENABLE: When illuminated, WDOG is ON.

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Motion Coordinator MC508
 Hardware Reference Manual

A bank of 8 indicators at the left side shows the State of digital Inputs 0..7 and a similar bank on the right
shows the state of inputs 8..15. The I/O displayed can be altered using the DISPLAY command.
Two LED’s are provided to show the processor (OK) and system status.

ERROR DISPLAY CODES

Ann Axis error on axis nn
Caa Configuration error on unit aa Ie: too many axes
Exx System error E00 - RAM error 8bit BB - RAM (VR)
E01 - RAM error 16 bit BB - RAM (TABLE)
E03 – N/A
E04 - VR/TABLE corrupt entry
E05 – Invalid MC_CONFIG file
E06 – Started in SAFE mode
E07 – FPGA error
E08 – Flash memory error
E09 – Processor exception

MC508 FEATURE SUMMARY

Size 132 mm x 226 mm x 35 mm (HxWxD).
Weight 640g
Operating Temp. 0 - 45 degrees C.
Control Inputs Forward Limit, Reverse Limit, Datum Input,
Feedhold Input.
Communication Ports RS232 channel: up to 128k baud.
CANbus port (DeviceNet and CANopen compatible)
Ethernet: 10/100 BaseT multiple port connection.
Position Resolution 64 bit position count.
Speed Resolution 32 bits. Speed may be changed at any time. Moves
may be merged.
Servo Cycle 125μs minimum, 1ms default, 2ms max.
Programming Multi-tasking TrioBASIC system and IEC 61131-3
programming system. Maximum 22 user processes.
Interpolation modes Linear 1-8 axes, circular, helical, spherical, CAM
Profiles, speed control, electronic gearboxes.
Memory 8 Mbyte user memory. Automatic flash EPROM
program and data storage.

HARDWARE OVERVIEW 2-19

Motion Coordinator MC508
Trio Motion Technology

VR 16384 global VR data in FLASH memory. (automatic-

store)
TABLE 512,000 x 64 bit TABLE memory. Option to auto-
save 64,000 TABLE points
SD Card Standard micro-SD Card compatible to 16 GB. Used
for storing programs and/or data.
Real Time Clock Capacitor backed for 10 days of power off.
Power Input 24V d.c., Class 2 transformer or power source.
Processor/CANbus 18..29V d.c. at 225mA.
Analogue I/O 18..29V d.c. at 50 mA.
Digital Outputs, 18..29V d.c at up to 4 Amps per
bank of 8.
Amplifier Enable Output Normally open solid-state relay rated 24V ac/dc
nominal. Maximum load 100mA. Maximum Voltage
29V.
Analogue Inputs 2 isolated, 12 bit, 0 to 10V.
Serial / Encoder Power Output 5V at 150mA.
Digital Inputs 32 Opto-isolated 24V inputs. 16 are selectable PNP/
NPN.
Digital Outputs 16 Opto-isolated 24V outputs. Current sourcing
(PNP) 500 mA. (max. 4A per bank of 8).
Product Code P848 : MC508, 8 axis stepper
P849 : MC508, 8 axis servo or stepper + 8 axis
stepper or encoder

2-20 HARDWARE OVERVIEW

Motion Coordinator MC508
 Hardware Reference Manual

Motion Coordinator MC464

OVERVIEW
The Motion Coordinator MC464 is Trio’s new generation
modular servo control positioner with the ability to control
servo or stepper motors by means of Digital Drive links
(e.g. EtherCAT, Sercos, etc) or via traditional analogue and
encoder or pulse and direction. A maximum of 7 expansion
modules can be fitted to control up to 64 axes which gives
the flexibility required in modern system design. The MC464
is housed in a rugged plastic case with integrated earth
chassis and incorporates all the isolation circuitry necessary
for direct connection to external equipment in an industrial
environment. Filtered power supplies are included so that
it can be powered from the 24V d.c. logic supply present in
most industrial cabinets.
It is designed to be configured and programmed for
the application using a PC running the Motion Perfect
application software, and then may be set to run
“standalone” if an external computer is not required for the
final system.
The Multi-tasking version of TrioBASIC for the MC464 allows
up to 22 TrioBASIC programs to be run simultaneously on
the controller using pre-emptive multi-tasking. In addition,
the operating system software includes the IEC 61131-3
standard run-time environment (licence key required).

PROGRAMMING
The Multi-tasking ability of the MC464 allows parts of a
complex application to be developed, tested and run independently, although the tasks can share data and
motion control hardware. IEC 61131-3 programs can be run at the same time as TrioBASIC allowing the
programmer to select the best features of each.

I/O CAPABILITY
The MC464 has 8 built in 24V inputs and 8 bi-directional I/O channels. These may be used for system
interaction or may be defined to be used by the controller for end of travel limits, registration, datuming
and feedhold functions if required. Each of the Input/Output channels has a status indicator to make it easy
to check them at a glance. The MC464 can have up 512 external Input/Output channels connected using DIN
rail mounted CAN I/O modules. These units connect to the built-in CAN channel.

COMMUNICATIONS
A 10/100 base-T Ethernet port is fitted as standard and this is the primary communications connection to the
MC464. Many protocols are supported including Telnet, Modbus TCP, Ethernet IP and TrioPCMotion. Check
the Trio website (www.triomotion.com) for a complete list.
The MC464 has one built in RS232 port and one built in duplex RS485 channel for simple factory

HARDWARE OVERVIEW 2-21

Motion Coordinator MC464
Trio Motion Technology

communication systems. Either the RS232 port or the RS485 port may be configured to run the Modbus or
Hostlink protocol for PLC or HMI interfacing.
If the built-in CAN channel is not used for connecting I/O modules, it may optionally be used for CAN
communications. E.g. DeviceNet slave or CANopen master.
The Anybus CompactCom Carrier Module (P875) can be used to add other fieldbus communications options

REMOVABLE STORAGE
The MC464 has a SD Card slot which allows a simple means of transferring programs,
firmware and data without a PC connection. Offering the OEM easy machine
replication and servicing.
The memory slot is compatable with a wide range of SD cards up to 2Gbytes using the
FAT32 compatible file system.

AXIS POSITIONING FUNCTIONS

The motion control generation software receives instructions to move an axis or axes from the TrioBASIC or
IEC 61131-3 language which is running concurrently on the same processor. The motion generation software
provides control during operation to ensure smooth, coordinated movements with the velocity profiled as
specified by the controlling program. Linear interpolation may be performed on groups of axes, and circular,
helical or spherical interpolation in any two/three orthogonal axes. Each axis may run independently or
they may be linked in any combination using interpolation, CAM profile or the electronic gearbox facilities.
Consecutive movements may be merged to produce continuous path motion and the user may program the
motion using programmable units of measurement (e.g. mm, inches, revs etc.). The module may also be
programmed to control only the axis speed. The positioner checks the status of end of travel limit switches
which can be used to cancel moves in progress and alter program execution.

CONNECTIONS TO THE MC464

Ethernet 101011
RS232 and
A
Port RS485 Port

Sync Encoder

SD Card

2-22 HARDWARE OVERVIEW

Motion Coordinator MC464
 Hardware Reference Manual

ETHERNET PORT CONNECTION

Physical layer: 10/100 base_T
Connector: RJ45
The Ethernet port is the default connection between the Motion Coordinator and the
host PC running Motion Perfect programming.

ETHERNET SYNC PORT

Not used.

MC464 SERIAL CONNECTIONS

The MC464 features two serial ports. Both ports are accessed through a single 8 pin connector.

SERIAL CONNECTOR
Pin Function Note
1 RS485 Data In A Rx+ 6 3
1
Serial Port #2 7 4
2 RS485 Data In B Rx- 2
8
5
3 RS232 Transmit Serial Port #1
4 0V Serial
5 RS232 Receive Serial Port #1
6 Internal 5V 5V supply is limited to 150mA, shared with sync
port
7 RS485 Data Out Z Tx- Serial Port #2
8 RS485 Data Out Y Tx+ Serial Port #2

SYNC ENCODER
The sync encoder port is bidirectional. It can be used as a reference encoder input or as
an encoder simulation output to act as a master reference for other parts of the system.
Pin Function Pulse & Direction 1
6
2
7
1 Enc. A Step+ 3
8
4
9
2 Enc. /A Step- 5

3 Enc. B Direction+
4 Enc. /B Direction-
5 0V Encoder 0V Stepper
6 Enc. Z Enable+
7 Enc. /Z Enable-
8 5V * 5V*
9 5V Registration input 5V Registration input

HARDWARE OVERVIEW 2-23

Motion Coordinator MC464
Trio Motion Technology

Pin Function Pulse & Direction

*5V supply is limited to 150mA (shared with serial port)

REGISTRATION
The MC464 built in port has 2 available registration events. These can be used with the Z mark, the
registration input on the sync port, input 0 or input 1.

24V POWER SUPPLY INPUT

0V AIN 0V CAN/AIN
AIN0 CAN LOW
AIN1 CAN SHIELD
WDOG+ CAN HIGH
WDOG- 24V CAN/AIN SUPPLY
I0 I/O/8
I1 I/O/9
I2 I/O/10
I3 I/O/11
I4 I/O/12
I5 I/O/13
I6 I/O/14
I7 I/O/15
0V I/O 24V I/0 SUPPLY
0V SUPPLY 24V SUPPLY

The MC464 is powered entirely via the 24V d.c.supply connections. The unit uses internal DC-DC converters
to generate independent 5V logic supply, the encoder/serial 5V supply and other internal power supplies.
I/O, analogue and CANbus circuits are isolated from the main 24V power input and must be powered
separately. For example; it is often necessary to power the CANbus network remotely via the CANbus cable.

24V d.c., Class 2 transformer or power source required for UL compliance. The MC464 is grounded via
the metal chassis. It MUST be installed on an unpainted metal plate or DIN rail which is connected to
earth.

AMPLIFIER ENABLE (WATCHDOG) RELAY OUTPUTS

One internal relay contact is available to enable external amplifiers when the controller has powered up
correctly and the system and application software is ready. The amplifier enable is a solid-state relay with
an ON resistance of 25 ohms at 100mA. The enable relay will be open circuit if there is no power on the
controller OR a motion error exists on a servo axis OR the user program sets it open with the WDOG=OFF

2-24 HARDWARE OVERVIEW

Motion Coordinator MC464
 Hardware Reference Manual

command.
The amplifier enable relay may, for example, be incorporated within a hold-up circuit or chain that must be
intact before a 3-phase power input is made live.

 All stepper and servo amplifiers must be inhibited when the amplifier enable output is open circuit

CANBUS
The MC464 features a built-in CAN channel. This is primarily intended for
Input/Output expansion via Trio’s range of CAN digital and analogue I/O 0V CAN/AIN
modules. It may be used for other purposes when I/O expansion is not CAN LOW
required. CAN SHIELD
The CANbus port is electrically equivalent to a DeviceNet node. CAN HIGH
24V CAN/AIN SUPPLY
ANALOGUE INPUTS
Two built-in 12 bit analogue inputs are provided which are set up with a scale Ain
22k
of 0 to 10V. External connection to these inputs is via the 2-part terminal strip
on the lower front panel. A to D
CONVERTER
22k 100uf
A 24V d.c. supply must be applied to the CANbus port to provide power for the
analogue input circuit.
0V
0V
24V INPUT CHANNELS
The Motion Coordinator has 16 24V Input channels built into the master unit.
I/O 24V
These may be expanded to 256 Inputs by the addition of CAN-16 I/O modules.
All of the 24V Input channels have the same circuit although 8 on the master
unit have 24V Output channels connected to the same pin. These bi-
6k8 Ohms
directional channels may be used for Input or Output to suit the application. If Input Pin
the channel is to be used as an Input then the Output should not be switched
on in the program. Vin
I/O 0V

24V I/O CHANNELS

I/O 24V
Input/output channels 8..15 are bi-directional and may be used Optical
for Input or Output to suit the application. The inputs have a Output
Control
protected 24V sourcing output connected to the same pin. If Signal Protected
the channel is to be used as an Input then the Output should not Switch
be switched on in the program. The input circuitry is the same
Input/Output
as on the dedicated inputs. The output circuit has electronic 6k8 Pin
over-current protection and thermal protection which shuts the Optical
output down when the current exceeds 250mA. Input
Signal
Care should be taken to ensure that the 250mA limit for the I/O OV
output circuit is not exceeded, and that the total load for the
group of 8 outputs does not exceed 1A

HARDWARE OVERVIEW 2-25

Motion Coordinator MC464
Trio Motion Technology

BATTERY
The MC464 incorporates a user replaceable battery for the battery back-up RAM. For replacement, use
battery model CR2450 or equivalent.
To replace the battery, insert screwdriver under the frontmost ventilation slot (A) and prize off the battery
cover (B) and pull the battery ribbon to lift the battery (C) from the MC464. Replacing is the reverse of the
procedure.

C A

 To Avoid losing the memory contents, the new battery should be inserted within 30 seconds of the
old one being removed.

BACKLIT DISPLAY
The information display area shows the IP address and subnet mask during power-up and whenever an
Ethernet cable is first connected to the MC464. During operation, this display shows run, Off or Err to
indicate the MC464 status. Below the main status display are the ERROR, ENABLE and BATTERY LOW
indicators.

Information Display

0 8
Input Status 1 9
I/O Status
2 10
3 11
4 12
5 ENABLE 13
6 14
Ok 7 15
Status
MC 464

2-26 HARDWARE OVERVIEW

Motion Coordinator MC464
 Hardware Reference Manual

ERROR An error has occurred (see Error Display Codes table below for details).
ENABLE When illuminated, WDOG is ON.
BATTERY LOW When illuminated the battery needs replacing.
A bank of 8 indicators at the left side shows the Digital Input States and a similar bank on the right shows
the state of I/O8 to I/O15. The I/O displayed can be altered using the DISPLAY command.
Two LED’s are provided to show the processor (OK) and system status.
Error Display Codes
Unn Unit error on slot nn
Ann Axis error on axis aa
Caa Configuration error on unit aan ie: too many axes
Exx System error E00 - RAM error 8bit BB - RAM (VR)
E01 - RAM error 16 bit BB - RAM (TABLE)
E03 - Battery Error
E04 - VR/TABLE corrupt entry
E05 – Invalid MC_CONFIG file
E06 – Started in SAFE mode

HARDWARE OVERVIEW 2-27

Motion Coordinator MC464
Trio Motion Technology

MC464 FEATURE SUMMARY

Size 201 mm x 56 mm x 155 mm (HxWxD).
Weight 750g
Operating Temp. 0 - 45 degrees C.
Control Inputs Forward Limit, Reverse Limit, Datum Input, Feedhold Input.
Communication Ports RS232 channel: up to 38400 baud.
RS485 channel: up to 38400 baud.
CANbus port (DeviceNet and CANopen compatible)
Ethernet: 10/100 BaseT multiple port connection.
Position Resolution 64 bit position count.
Speed Resolution 32 bits. Speed may be changed at any time. Moves may be merged.
Servo Cycle 125μs minimum, 1ms default, 2ms max.
Programming Multi-tasking TrioBASIC system, maximum 20 user processess.
IEC 61131-3 programming system.
Interpolation modes Linear 1-64 axes, circular, helical, spherical, CAM Profiles, speed control,
electronic gearboxes.
Memory 8 Mbyte user memory. 2 Mbyte TABLE battery-backed memory. Automatic flash
EPROM program storage.
Table 512,000 table positions. 196,608 positions in battery backed memory.
VR 65,536 VR positions in battery backed memory.
SD Card Standard SD Card compatible to 2Gbytes. Used for storing programs and/or
data.
Power Input 24V d.c., Class 2 transformer or power source.
18..29V d.c. at 625mA typical.
Amplifier Enable Output Normally open solid-state relay rated 24V ac/dc nominal. Maximum load 100mA.
Maximum voltage 29V.
Analogue Inputs 2 isolated x 12 bit 0 to 10V.
Serial / Encoder Power 5V at 150mA.
Output
Digital Inputs 8 Opto-isolated 24V inputs.
Digital I/O 8 Opto-isolated 24V outputs. Current sourcing (PNP) 250 mA. (max. 1A per bank
of 8).

2-28 HARDWARE OVERVIEW

Motion Coordinator MC464
 Hardware Reference Manual

Motion Coordinator MC4N-Mini EtherCAT Master

OVERVIEW
The MC4N-ECAT is a new concept in high performance Motion
Coordinators which is dedicated to running remote servo and
stepper drives via the EtherCAT real time automation bus. It is
based on an up-rated version of the 532MHz ARM 11 processor
which makes it ideal for high axis count machines or robotic
applications.
It is designed to be configured and programmed for the
application using a PC running the Motion Perfect application
software, and then may be set to run “standalone” if an
external computer is not required for the final system.
The Multi-tasking version of TrioBASIC for the MC4N-ECAT allows
up to 22 TrioBASIC programs to be run simultaneously on the
controller using pre-emptive multi-tasking. In addition, the
operating system software includes the IEC 61131-3 standard
run-time environment (licence key required).
Versions of the MC4N-ECAT are available for 2, 4, 8, 16 and
32 motor axes. All versions feature 32 software axes any of
which may be used as virtual axes if not assigned to EtherCAT
hardware.

PROGRAMMING
The Multi-tasking ability of the MC4N-ECAT allows parts
of a complex application to be developed, tested and run
independently, although the tasks can share data and motion
control hardware. IEC 61131-3 programs can be run at the
same time as TrioBASIC allowing the programmer to select the
best features of each.

I/O CAPABILITY
The MC4N has 8 built in 24V inputs and 8 bi-directional I/O
channels. These may be used for system interaction or may be
defined to be used by the controller for end of travel limits,
registration, datuming and feedhold functions if required.
Each of the Input/Output channels has a status indicator to
make it easy to check them at a glance. The MC4N-ECAT can
have up 512 external Input/Output channels connected using
DIN rail mounted CAN I/O modules. These units connect to the built-in CAN channel.

COMMUNICATIONS
A 10/100 base-T Ethernet port is fitted as standard and this is the primary communications connection to
the MC4N-ECAT. Many protocols are supported including Telnet, Modbus TCP, Ethernet IP and TrioPCMotion.
Check the Trio website (www.triomotion.com) for a complete list.

HARDWARE OVERVIEW 2-29

Motion Coordinator MC4N-Mini EtherCAT Master
Trio Motion Technology

The MC4N-ECAT has one built in RS232 port and one built in duplex RS485 channel for simple factory
communication systems. Either the RS232 port or the RS485 port may be configured to run the Modbus or
Hostlink protocol for PLC or HMI interfacing.
If the built-in CAN channel is not used for connecting I/O modules, it may optionally be used for CAN
communications. E.g. DeviceNet slave or CanOpen master.

REMOVABLE STORAGE
The SD Card maybe used for storing or transfering programs, reciepes and data to and
from the MC4N-ECAT. The card must be FAT32 format and a maximum 16Gb size.

 SD Cards may be FAT16 formatted when purchased. Re-format in a PC to FAT32

prior to use.

AXIS POSITIONING FUNCTIONS

The motion control generation software receives instructions to move an axis or axes from the TrioBASIC or
IEC 61131-3 language which is running concurrently on the same processor. The motion generation software
provides control during operation to ensure smooth, coordinated movements with the velocity profiled as
specified by the controlling program. Linear interpolation may be performed on groups of axes, and circular,
helical or spherical interpolation in any two/three orthogonal axes. Each axis may run independently or
they may be linked in any combination using interpolation, CAM profiles or the electronic gearbox facilities.
Consecutive movements may be merged to produce continuous path motion and the user may program the
motion using programmable units of measurement (e.g. mm, inches, revs etc.). The module may also be
programmed to control only the axis speed. The positioner checks the status of end of travel limit switches
which can be used to cancel moves in progress and alter program execution.

CONNECTIONS TO THE MC4N

ETHERNET PORT CONNECTION

Physical layer: 10/100 base_T
Connector: RJ45
A standard Ethernet connector is provided for use as the primary programming
interface.
The Trio programming software, Motion Perfect, must be installed on a Windows
based PC that is fitted with an Ethernet connection. The IP address is displayed on
the MC4N display for a few seconds after power-up or when an Ethernet cable is
plugged in.

Ethernet cable must be CAT 5 or better.

The Standard Ethernet connection may also be used for Ethernet-IP, Modbus and other factory
communications.

2-30 HARDWARE OVERVIEW

Motion Coordinator MC4N-Mini EtherCAT Master
 Hardware Reference Manual

SERIAL CONNECTIONS
Pin Function Note 5
8
2
1 RS485 Data In A Rx+ 7
Serial Port #2 1 4
2 RS485 Data In B Rx- 3
6

3 RS232 Transmit Serial Port #1

4 0V Serial/Encoder
5 RS232 Receive Serial Port #1
6 5V Output 150mA max (Current shared with encoder port)
7 RS485 Data Out Z Tx-
Serial Port #2
8 RS485 Data Out Y Tx+

FLEXIBLE AXIS PORT

Pin Encoder Stepper Axis Absolute Encoder
1 Enc. A Step + Clock
2 Enc. /A Step - /Clock
3 Enc. B Direction + --------
4 Enc. /B Direction - --------
5 0V Serial/Encoder 0V Serial/Encoder 0V 0V Serial/Encoder
6 Enc. Z Enable + Data
7 Enc. /Z Enable - /Data
8 5V* 5V* 5V*
9 Not Connected Not Connected Not Connected
*Current limit is 150mA max. Shared with serial port.

ETHERCAT PORT
The MC4N-ECAT acts as an EtherCAT master. EtherCAT drives and I/O devices are
normally connected in a chain. Other topologies are possible when specialised
EtherCAT routers are used in the network.
Up to 32 EtherCAT axes and 1024 digital I/O points may be connected via the EtherCAT
bus.

HARDWARE OVERVIEW 2-31

Motion Coordinator MC4N-Mini EtherCAT Master
Trio Motion Technology

I/O CONNECTOR

Not Used
Enable
(Watchdog) Not Used
Input 0 I/O 8
Input 1 I/O 9
Input 2 I/O 10
Input 3 I/O 11
Input 4 I/O 12
Input 5 I/O 13
Input 6 I/O 14
Input 7 I/O 15
I/O 0V I/O 24V
0V 24V

2k7 on inputs 0 - 3
6k8 on all other inputs
Input Pin
Inputs 0 - 3 have fast Optical
opto-couplers for use as Input
Signal
axis registration inputs.
Inputs 4-7 may also be I/O 0V
used as registration inputs.

I/O 24V
Optical
Output
Control
Signal Protected
Switch
Inputs / Outputs 8 - 15
I/O Pin
Optical 6k8
Input
Signal

I/O 0V

 The MC4N is grounded via the metal chassis. Fit a short shield connection between the chassis earth
screw and the earthed metal mounting panel / plate.

2-32 HARDWARE OVERVIEW

Motion Coordinator MC4N-Mini EtherCAT Master
 Hardware Reference Manual

AMPLIFIER ENABLE (WATCHDOG) RELAY OUTPUT

An internal relay may be used to enable external
amplifiers when the controller has powered up correctly
and the system and application software are ready. The Enable
amplifier enable is a single pole solid state relay with a
normally open “contact”. The enable relay contact will be Input 0
open circuit if there is no power on the controller OR an Input 1
axis error exists OR the user program sets it open with the
WDOG=OFF command. Input 2
Input 3
Input 4

 EtherCAT drives will be enabled via the EtherCAT network so the “Amplifier Enable” connection is not
normally required.

All non EtherCAT stepper and servo amplifiers MUST be inhibited when the amplifier enable output is
open circuit

An additional safety relay may be required so as to meet machine safety approvals.

5 WAY CAN CONNECTOR

This is a 5 way 3.5mm pitch connector. The connector is used both to CAN 0V
provide the 24 Volt power to the MC4N CAN circuit and provide connections
for I/O expansion via Trio’s CAN I/O expanders. A 24V dc, Class 2 transformer C-Low
or power source should be used.
This 24 Volt input is internally isolated from the I/O 24V and main 24V
power. C-High

The CAN connector may be left unused. CAN 24V

HARDWARE OVERVIEW 2-33

Motion Coordinator MC4N-Mini EtherCAT Master
Trio Motion Technology

DISPLAY
The IP address and subnet mask of the MC4N-ECAT is shown on the LCD display for a few seconds after
power-up. The factory default IP address is 192.168.0.250. This can be changed using the IP _ ADDRESS
commands via the Motion Perfect software tool.
Display Description Details IP Address / Run / Error code
Example (see table below)
Communications active
SYS Displayed on EtherCAT (detecting)
controller start EtherCAT detected (steady)
Error
901 Model code : P900 : 2 axes
Displayed on P901 : 4 axes
power up P902 : 8 axes
I/O channels On / OFF
P903 : 16 axes
P904 : 32 axes
192.168.0.250 IP Address : Displayed on power up OR after
ethernet connection for 15 seconds
Unn Unit error on
slot nn Enable status LED

Ann Axis error on Power LED

axis nn
Caa Configuration ie: too many axes
error on unit aa
Run / Off Enable status
Err xx Error codes Ann : Error on Axis nn
Unn : Unit error on slot nn
Caa : Configuration error on unit nn,
ie: too many axes
E04 : VR/TABLE corrupt entry

COMMUNICATIONS ACTIVE
This symbol appears when the firmware has detected one or more valid EtherCAT nodes on the
network.

ETHERCAT DETECTION
This symbol shows the EtherCAT connection status.

Indicator EtherCAT State

Flashing INIT, PRE-OP or SAFE-OP
Steady OPERATIONAL

2-34 HARDWARE OVERVIEW

Motion Coordinator MC4N-Mini EtherCAT Master
 Hardware Reference Manual

ERROR
This symbol shows when an error condition has occurred. See the numerical display for more
information.

NETWORK SET-UP

NETWORK CONNECTION DCHP Server

Set IP _ ADDRESS in MC4N-ECAT to an available unused
address. It MUST match the subnet in use. Set the PC
to use DHCP server.

The MC4N always has a fixed IP _ ADDRESS.

PC Laptop Switch MC4N

POINT-TO-POINT OR CLOSED NETWORK

(No DHCP server)

 The PC MUST be set to a fixed IP_ADDRESS.

The first 3 “octets” MUST be the same as the MC4N- PC Laptop MC4N
ECAT and the last MUST be different, but not 000, 254 Example : 192.168.0.100 Example : 192.168.0.250
or 255.

SETTING A FIXED IP ADDRESS

In Windows 7. Open “Network and Sharing Centre” then change
“Adapter Settings”. Select the properties of the Local Area Network
and the IPv4 properties. The IP Address is set to 192.168.0.100 with
subnet mask set to 255.255.255.0. Assuming that the MC4N has IP _
ADDRESS=192.168.0.250 or similar.

HARDWARE OVERVIEW 2-35

Motion Coordinator MC4N-Mini EtherCAT Master
Trio Motion Technology

MC4N FEATURE SUMMARY

Size 157 mm x 40 mm x 120 mm (HxWxD).
Weight 432g
Operating Temp. 0 - 45 degrees C.
Control Inputs Forward Limit, Reverse Limit, Datum Input, Feedhold Input.
Communication Ports RS232 channel: up to 38400 baud.
RS485 channel: up to 38400 baud.
CANbus port (DeviceNet and CANopen compatible)
Ethernet: 10/100 BaseT multiple port connection.
EtherCAT Port
Flexible Axis Port
Position Resolution 64 bit position count.
Speed Resolution 32 bits. Speed may be changed at any time. Moves may be merged.
Servo Cycle 125μs minimum, 1ms default, 2ms max.
Programming Multi-tasking TrioBASIC system, maximum 22 user processess.
IEC 61131-3 programming system.
Interpolation modes Linear 1-32 axes, circular, helical, spherical, CAM Profiles, speed control,
electronic gearboxes.
Memory 8 Mbyte user memory. Automatic flash EPROM program and data storage.
Table 512,000 table positions stored in flash memory.
VR 4096 stored in flash memory.
SD Card Standard SD Card (FAT 32) compatible to 16Gbytes. Used for storing programs
and/or data.
Power Input 24V d.c., Class 2 transformer or power source.
18..29V d.c. at 625mA typical.
Amplifier Enable Output Normally open solid-state relay rated 24V ac/dc nominal. Maximum load 100mA.
Maximum voltage 29V.
Serial / Encoder Power 5V at 150mA.
Output
Digital Inputs 8 Opto-isolated 24V inputs.
Digital I/O 8 Opto-isolated 24V outputs. Current sourcing (PNP) 250 mA. (max. 1A per bank
of 8).
Product Codes P900 : MC4N-ECAT 2 Axis
P901 : MC4N-ECAT 4 Axis
P902 : MC4N-ECAT 8 Axis
P903 : MC4N-ECAT 16 Axis
P904 : MC4N-ECAT 32 Axis

2-36 HARDWARE OVERVIEW

Motion Coordinator MC4N-Mini EtherCAT Master
 Hardware Reference Manual

Motion Coordinator MC4N-Mini RTEX Master

OVERVIEW
The MC4N-RTEX is a new concept in high performance Motion
Coordinators which is dedicated to running remote servo and
stepper drives via the RTEX Real Time EXpress automation
bus. It is based on an up-rated version of the 532MHz ARM 11
processor which makes it ideal for high axis count machines or
robotic applications.
It is designed to be configured and programmed for the
application using a PC running the Motion Perfect application
software, and then may be set to run “standalone” if an
external computer is not required for the final system.
The Multi-tasking version of TrioBASIC for the MC4N-RTEX
allows up to 22 TrioBASIC programs to be run simultaneously
on the controller using pre-emptive multi-tasking. In addition,
the operating system software includes the IEC 61131-3
standard run-time environment (licence key required).
Versions of the MC4N are available for 2, 4, 8, 16 and 32 motor
axes. All versions feature 32 software axes any of which may be
used as virtual axes if not assigned to RTEX hardware.

PROGRAMMING
The Multi-tasking ability of the MC4N-RTEX allows parts
of a complex application to be developed, tested and run
independently, although the tasks can share data and motion
control hardware. IEC 61131-3 programs can be run at the
same time as TrioBASIC allowing the programmer to select the
best features of each.

I/O CAPABILITY
The MC4N-RTEX has 8 built in 24V inputs and 8 bi-directional
I/O channels. These may be used for system interaction
or may be defined to be used by the controller for end of
travel limits, registration, datuming and feedhold functions
if required. Each of the Input/Output channels has a status
indicator to make it easy to check them at a glance. The
MC4N-RTEX can have up 512 external Input/Output channels
connected using DIN rail mounted CAN I/O modules. These
units connect to the built-in CAN channel.

COMMUNICATIONS
A 10/100 base-T Ethernet port is fitted as standard and this is the primary communications connection to
the MC4N-RTEX. Many protocols are supported including Telnet, Modbus TCP, Ethernet IP and TrioPCMotion.
Check the Trio website (www.triomotion.com) for a complete list.
The MC4N-RTEX has one built in RS232 port and one built in duplex RS485 channel for simple factory

HARDWARE OVERVIEW 2-37

Motion Coordinator MC4N-Mini RTEX Master
Trio Motion Technology

communication systems. Either the RS232 port or the RS485 port may be configured to run the Modbus or
Hostlink protocol for PLC or HMI interfacing.
If the built-in CAN channel is not used for connecting I/O modules, it may optionally be used for CAN
communications. E.g. DeviceNet slave or CanOpen master.

REMOVABLE STORAGE
The SD Card maybe used for storing or transfering programs, reciepes and data to and
from the MC4N-RTEX. The card must be FAT32 format and a maximum 16Gb size.

 SD Cards may be FAT16 formatted when purchased. Re-format in a PC to FAT32

prior to use.

AXIS POSITIONING FUNCTIONS

The motion control generation software receives instructions to move an axis or axes from the TrioBASIC or
IEC 61131-3 language which is running concurrently on the same processor. The motion generation software
provides control during operation to ensure smooth, coordinated movements with the velocity profiled as
specified by the controlling program. Linear interpolation may be performed on groups of axes, and circular,
helical or spherical interpolation in any two/three orthogonal axes. Each axis may run independently or
they may be linked in any combination using interpolation, CAM profiles or the electronic gearbox facilities.
Consecutive movements may be merged to produce continuous path motion and the user may program the
motion using programmable units of measurement (e.g. mm, inches, revs etc.). The module may also be
programmed to control only the axis speed. The positioner checks the status of end of travel limit switches
which can be used to cancel moves in progress and alter program execution.

CONNECTIONS TO THE MC4N-RTEX

ETHERNET PORT CONNECTION

Physical layer: 10/100 base_T
Connector: RJ45
A standard Ethernet connector is provided for use as the primary programming
interface.
The Trio programming software, Motion Perfect, must be installed on a Windows
based PC that is fitted with an Ethernet connection. The IP address is displayed
on the MC4N-RTEX display for a few seconds after power-up or when an Ethernet
cable is plugged in.

Ethernet cable must be CAT 5 or better.

The Standard Ethernet connection may also be used for Ethernet-IP, Modbus and other factory
communications.

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SERIAL CONNECTIONS
Pin Function Note 5
8
2
1 RS485 Data In A Rx+ 7
Serial Port #2 1 4
2 RS485 Data In B Rx- 3
6

3 RS232 Transmit Serial Port #1

4 0V Serial
5 RS232 Receive Serial Port #1
6 5V Output 150mA max (Current shared with encoder port)
7 RS485 Data Out Z Tx-
Serial Port #2
8 RS485 Data Out Y Tx+

FLEXIBLE AXIS PORT

Pin Encoder Stepper Axis Absolute Encoder
1 Enc. A Step + Clock
2 Enc. /A Step - /Clock
3 Enc. B Direction + --------
4 Enc. /B Direction - --------
5 0V Serial/Encoder 0V Serial/Encoder 0V Serial/Encoder
6 Enc. Z Enable + Data
7 Enc. /Z Enable - /Data
8 5V* 5V* 5V*
9 Not Connected Not Connected Not Connected
*Current limit is 150mA max. Shared with serial port.

REAL TIME EXPRESS PORT

The MC4N-RTEX acts as an Panasonic RTEX master. RTEX drives are normally connected in a ring.
Up to 32 RTEX axes may be connected via the RTEX bus.

Tx Rx

HARDWARE OVERVIEW 2-39

Motion Coordinator MC4N-Mini RTEX Master
Trio Motion Technology

I/O CONNECTOR

Not Used
Enable
(Watchdog) Not Used
Input 0 I/O 8
Input 1 I/O 9
Input 2 I/O 10
Input 3 I/O 11
Input 4 I/O 12
Input 5 I/O 13
Input 6 I/O 14
Input 7 I/O 15
I/O 0V I/O 24V
0V 24V

2k7 on inputs 0 - 3
6k8 on all other inputs
Input Pin
Inputs 0 - 3 have fast Optical
opto-couplers for use as Input
Signal
axis registration inputs.
Inputs 4-7 may also be I/O 0V
used as registration inputs.

I/O 24V
Optical
Output
Control
Signal Protected
Switch
Inputs / Outputs 8 - 15
I/O Pin
Optical 6k8
Input
Signal

I/O 0V

 The MC4N is grounded via the metal chassis. Fit a short shield connection between the chassis earth
screw and the earthed metal mounting panel / plate.

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AMPLIFIER ENABLE (WATCHDOG) RELAY OUTPUT

An internal relay may be used to enable external
amplifiers when the controller has powered up correctly
and the system and application software are ready. The Enable
amplifier enable is a single pole solid state relay with a
normally open “contact”. The enable relay contact will be Input 0
open circuit if there is no power on the controller OR an Input 1
axis error exists OR the user program sets it open with the
WDOG=OFF command. Input 2
Input 3
Input 4

 RTEX drives will be enabled via the RTEX network so the “Amplifier Enable” connection is not
normally required.

All non RTEX stepper and servo amplifiers MUST be inhibited when the amplifier enable output is
open circuit

An additional safety relay may be required so as to meet machine safety approvals.

5 WAY CAN CONNECTOR

This is a 5 way 3.5mm pitch connector. The connector is used both to CAN 0V
provide the 24 Volt power to the MC4N CAN circuit and provide connections
for I/O expansion via Trio’s CAN I/O expanders. A 24V dc, Class 2 transformer C-Low
or power source should be used.
This 24 Volt input is internally isolated from the I/O 24 Volts and main 24V
power. C-High

The CAN connector may be left unused. CAN 24V

HARDWARE OVERVIEW 2-41

Motion Coordinator MC4N-Mini RTEX Master
Trio Motion Technology

DISPLAY
The IP address and subnet mask of the MC4N is shown on the LCD display for a few seconds after power-up.
The factory default IP address is 192.168.0.250. This can be changed using the IP _ ADDRESS command via
the Motion Perfect v3 software tool.
Display Description Details IP Address / Run / Error code
Example (see table below)
Communications active
SYS Displayed on RTEX detection (detecting)
controller start RTEX detected (steady)
Error
901 Model code : P906 : 2 axes
Displayed on P907 : 4 axes
power up P908 : 8 axes
I/O channels On / OFF
P909 : 16 axes
P910: 32 axes
192.168.0.250 IP Address : Displayed on power up OR after
ethernet connection for 15 seconds
Unn Unit error on
slot nn Enable status LED

Ann Axis error on Power LED

axis nn
Caa Configuration ie: too many axes
error on unit aa
Run / Off Enable status
Err xx Error codes Ann : Error on Axis nn
Unn : Unit error on slot nn
Caa : Configuration error on unit
nn, ie: too many axes
E04 : VR/TABLE corrupt entry

COMMUNICATIONS ACTIVE
This symbol appears when the firmware has detected one or more valid RTEX nodes on the network.

RTEX DETECTION
This symbol shows the RTEX connection status.

Indicator RTEX State

Flashing Detecting Drives
Steady OPERATIONAL

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ERROR
This symbol shows when an error condition has occurred. See the numerical display for more
information.

NETWORK SET-UP

NETWORK CONNECTION DCHP Server

Set IP _ ADDRESS in MC4N-RTEX to an available unused
address. It MUST match the subnet in use. Set the PC
to use DHCP server.

The MC4N always has a fixed IP _ ADDRESS.

PC Laptop Switch MC4N

POINT-TO-POINT OR CLOSED NETWORK

(No DHCP server)

 The PC MUST be set to a fixed IP_ADDRESS.

The first 3 “octets” MUST be the same as the MC4N- PC Laptop MC4N
RTEX and the last MUST be different, but not 000, 254 Example : 192.168.0.100 Example : 192.168.0.250
or 255.

SETTING A FIXED IP ADDRESS

In Windows 7. Open “Network and Sharing Centre” then change
“Adapter Settings”. Select the properties of the Local Area Network
and the IPv4 properties. The IP Address is set to 192.168.0.100 with
subnet mask set to 255.255.255.0. Assuming that the MC4N has IP _
ADDRESS=192.168.0.250 or similar.

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Motion Coordinator MC4N-Mini RTEX Master
Trio Motion Technology

MC4N-RTEX FEATURE SUMMARY

Size 157 mm x 40 mm x 120 mm (HxWxD).
Weight 432g
Operating Temp. 0 - 45 degrees C.
Control Inputs Forward Limit, Reverse Limit, Datum Input, Feedhold Input.
Communication Ports RS232 channel: up to 38400 baud.
RS485 channel: up to 38400 baud.
CANbus port (DeviceNet and CANopen compatible)
Ethernet: 10/100 BaseT multiple port connection.
RTEX Port (x2: Tx and Rx)
Flexible Axis Port
Position Resolution 64 bit position count.
Speed Resolution 32 bits. Speed may be changed at any time. Moves may be merged.
Servo Cycle 125μs minimum, 1ms default, 2ms max.
Programming Multi-tasking TrioBASIC system, maximum 22 user processess.
IEC 61131-3 programming system.
Interpolation modes Linear 1-32 axes, circular, helical, spherical, CAM Profiles, speed control,
electronic gearboxes.
Memory 8 Mbyte user memory. Automatic flash EPROM program and data storage.
Table 512,000 table positions stored in flash memory.
VR 4096 stored in flash memory.
SD Card Standard SD Card (FAT 32) compatible to 16Gbytes. Used for storing programs
and/or data.
Power Input 24V d.c., Class 2 transformer or power source.
18..29V d.c. at 625mA typical.
Amplifier Enable Output Normally open solid-state relay rated 24V ac/dc nominal. Maximum load 100mA.
Maximum voltage 29V.
Serial / Encoder Power 5V at 150mA.
Output
Digital Inputs 8 Opto-isolated 24V inputs.
Digital I/O 8 Opto-isolated 24V outputs. Current sourcing (PNP) 250 mA. (max. 1A per bank
of 8).
Product Codes P906 : MC4N-RTEX 2 Axis
P907 : MC4N-RTEX 4 Axis
P908 : MC4N-RTEX 8 Axis
P909 : MC4N-RTEX 16 Axis
P910 : MC4N-RTEX 32 Axis

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Motion Coordinator MC403

OVERVIEW
The Motion Coordinator MC403 is based on Trio’s high-
performance ARM11 double-precision technology and
provides 2 axes of servo plus a master encoder axis, or 3
axes of pulse+direction control for stepper drives or pulse-
input servo drives. Trio uses advanced FPGA techniques to
reduce the size and fit the pulse output and servo circuitry
in a compact DIN-rail mounted package. The MC403 is
housed in a rugged plastic case with integrated earth chassis
and incorporates all the isolation circuitry necessary for
direct connection to external equipment in an industrial
environment. Filtered power supplies are included so that
it can be powered from the 24V d.c. logic supply present in
most industrial cabinets.
It is designed to be configured and programmed for the
application using a PC running Trio’s Motion Perfect
application software, and then may be set to run
“standalone” if an external computer is not required for
the final system. Programs and data are stored directly to
Flash memory, thus eliminating the need for battery backed
storage.
The Multi-tasking version of TrioBASIC for the MC403 allows up to 6 TrioBASIC programs to be run
simultaneously on the controller using pre-emptive multi-tasking. In addition, the operating system
software includes a the IEC 61131-3 standard run-time environment (licence key required).
A reduced functionality version, the MC403-Z has all the fesatures of the full MC403 except that there are no
analogue outputs and the encoder function of axes 0 and 1 is incremental encoder only.

PROGRAMMING
The Multi-tasking ability of the MC403 allows parts of a complex application to be developed, tested and run
independently, although the tasks can share data and motion control hardware. The 6 available tasks can
be used for TrioBASIC or IEC 61131-3 programs, or a combination of both can be run at the same time, thus
allowing the programmer to select the best features of each.

I/O CAPABILITY
The MC403 has 8 built in 24V inputs and 4 bi-directional I/O channels. These may be used for system
interaction or may be defined to be used by the controller for end of travel limits, registration, datuming
and feedhold functions if required. The MC403 can have up 512 external Input and Output channels
connected using DIN rail mounted CAN I/O modules. These units connect to the built-in CANbus port.

COMMUNICATIONS
A 10/100 base-T Ethernet port is fitted as standard and this is the primary communications connection to the
MC403. Many protocols are supported including Telnet, Modbus TCP, Ethernet IP and TrioPCMotion. Check
the Trio website (www.triomotion.com) for a complete list.

HARDWARE OVERVIEW 2-45

Motion Coordinator MC403
Trio Motion Technology

The MC403 has one built in RS232 port and one built in duplex RS485 channel for simple factory
communication systems. Either the RS232 port or the RS485 port may be configured to run the Modbus or
Hostlink protocol for PLC or HMI interfacing.
If the built-in CAN channel is not used for connecting I/O modules, it may optionally be used for CAN
communications. E.g. DeviceNet, CANopen etc.

REMOVABLE STORAGE
The MC403 has a micro-SD Card slot which allows a simple means of transferring
programs, firmware and data without a PC connection. Offering the OEM easy
machine replication and servicing.
The memory slot is compatible with a wide range of micro-SD cards up to 16Gbytes
using the FAT32 compatible file system.

AXIS POSITIONING FUNCTIONS

The motion control software receives instructions to move an axis or axes from
the TrioBASIC or IEC 61131-3 language which is running concurrently on the same processor. The motion
generation software provides control during operation to ensure smooth, coordinated movements with the
velocity profiled as specified by the controlling program. Linear interpolation may be performed on groups
of axes, and circular, helical or spherical interpolation in any two/three orthogonal axes. Each axis may run
independently or they may be linked in any combination using interpolation, CAM profile or the electronic
gearbox facilities.
Consecutive movements may be merged to produce continuous path motion and the user may program the
motion using programmable units of measurement (e.g. mm, inches, revs etc.). The module may also be
programmed to control only the axis speed. The positioner checks the status of end of travel limit switches
which can be used to cancel moves in progress and alter program execution.

CONNECTIONS TO THE MC403

ETHERNET PORT CONNECTION

MC 403

Physical layer: 10/100 base_T

Connector: RJ45

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 Hardware Reference Manual

The Ethernet port is the default connection between the Motion Coordinator and the host PC running the
Motion Perfect development application.

To reset the IP _ ADDRESS, IP _ GATEWAY and IP _ NETMASK to their default values press
the IP reset button and power cycle the controller while keeping the button pressed.

MC403 SERIAL CONNECTIONS

6 3
MC 403 1
7 4
2
8
5

The MC403 features two serial ports. Both ports are accessed through a single 8 pin connector.

SERIAL CONNECTOR
Pin Function Note
1 RS485 Data In A Rx+
Serial Port #2
2 RS485 Data In B Rx-
3 RS232 Transmit Serial Port #1
4 0V Serial
5 RS232 Receive Serial Port #1
6 Internal 5V 5V supply is limited to 150mA, shared with sync
port
7 RS485 Data Out Z Tx- Serial Port #2
8 RS485 Data Out Y Tx+ Serial Port #2

HARDWARE OVERVIEW 2-47

Motion Coordinator MC403
Trio Motion Technology

MC403 PULSE OUTPUTS / ENCODER INPUTS

MC 403

1
6
2
7
3
8
4
9
5

The MC403 is designed to support any combination of servo and pulse input motor drives on the standard
controller hardware. The MC403 has 3 versions: 1 axis servo, 2 axis servo and pulse output only. There are
also 2 versions of the MC403-Z: 2 axis pulse output and 3 axis pulse output.
Each of the first two axes (0-1) can be enabled as servo(1), pulse and direction or encoder according to the
user’s requirements by setting the axis ATYPE parameter. Axis 2 can be set as either pulse+direction or
encoder in all versions.
The function of the 9-pin ‘D’ connectors will be dependent on the specific axis configuration which has been
defined. If the axis is setup as a servo or encoder, the connector will provide the encoder input. If the axis
is configured as a pulse+direction, the connector provides differential outputs for step/direction and enable
signals.
The encoder port also provides a current-limited 5V output capable of powering most encoders. This
simplifies wiring and eliminates external power supplies.
(1) Servo versions of the MC403 only.
Pin Function Pulse & Direction Absolute Encoder **
1 Enc. A Step+ Clock+
2 Enc. /A Step- Clock-
3 Enc. B Direction+ N/C
4 Enc. /B Direction- N/C
5 0V Encoder 0V Pulse+direction 0V Encoder
6 Enc. Z Enable+ Data+
7 Enc. /Z Enable- Data-
8 5V * 5V* 5V*
9 N/C N/C N/C
*5V supply is limited to 150mA (shared with serial port)
**Not available on axes 0 and 1 of the MC403-Z

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REGISTRATION
Each MC403 encoder port has 2 available registration events. These are assigned in a flexible way to any of
the 8 digital inputs or can be used with the Z mark input on the encoder port.

5-WAY CONNECTOR

CA D
-H

-L
L
N

N
IE
CA
V+

SH

V-
MC 403

This is a 5 way 3.5 mm pitch connector. The connector is used both to provide the 24 Volt power to the
MC403 and provide connections for I/O expansion via Trio’s digital and analogue CAN I/O expanders. 24 Volts
must be provided as this powers the unit.
This 24 Volt input is internally isolated from the I/O 24 Volts and the +/-10V Voltage outputs.

24V d.c., Class 2 transformer or power source required for UL compliance. The MC403 is grounded via
the metal chassis. It MUST be installed on an unpainted metal plate or DIN rail which is connected to
earth. An earth screw is also provided on the rear of the chassis for bonding the MC403 to ground.

Input 4 Input 5
I/O CONNECTOR 1 Input 3 Input 6
Input 2 Input 7
24V INPUT CHANNELS Input 1 I/O 8
I/O 9
The MC403 has 8 dedicated 24V Input Input 0
I/O 24V I/O 10
channels built into the master unit. A further I/O 0V I/O 11
256 inputs can be provided by the addition
of CAN I/O modules. The dedicated input
channels are labelled channels 0..7.
Inputs 0 to 7 can be used as registration
inputs for axes 0 to 2, using the REGIST 24V Power / Inputs / I/O
command.

I/O POWER INPUTS Input Pin

The I/O 0 Volts (I/O-) and I/O 24 Volts Optical 6k8
(I/O+) are used to power the 24 Volt digital IO and the Input
Signal
analogue I/O, including the servo DAC outputs.
The digital I/O connections are isolated from the module 0V Pin

HARDWARE OVERVIEW 2-49

Motion Coordinator MC403
Trio Motion Technology

power inputs. The analogue inputs and outputs are isolated from the digital I/O and the module power
inputs.

24V I/O CHANNELS

Input/output channels 8..11 are bi-directional. The 24V Pin
inputs have a protected 24V sourcing output connected Optical
Output
to the same pin. If the output is unused it may be used Control
as an input in the program. The input circuitry is the Signal Protected
Switch
same as on the dedicated inputs. The output circuit
has electronic over-current protection and thermal
protection which shuts the output down when the Input / Output Pin
Optical 6k8
current exceeds 250mA. Input
Signal
Care should be taken to ensure that the 250mA limit for
each output circuit is not exceeded, and that the total
0V Pin
load for the group of 4 outputs does not exceed 1 amp.

I/O CONNECTOR 2

AMPLIFIER ENABLE (WATCHDOG) RELAY OUTPUTS

An internal relay contact is
available to enable external Analogue Input 0 Analogue Input 1
amplifiers when the controller Analogue 0V Analogue Out Axis 0 (MC403-Z : N/C)
WDOG Analogue Out Axis 1 (MC403-Z : N/C)
has powered up correctly and
WDOG Analogue 0V
the system and application
software is ready. The
amplifier enable is a solid-state
relay with an ON resistance
of 25Ω at 100mA. The enable
relay will be open circuit WDOG / Analogue Inputs / Outputs
if there is no power on the
controller OR a motion error
exists on a servo axis OR the user program sets it open with the WDOG=OFF command.
The amplifier enable relay may, for example, be incorporated within a hold-up circuit or chain that must be
intact before a 3-phase power input is made live.

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Ain
100R 42k Aout
100R
A to D
D to A
CONVERTER
CONVERTER
1uF 100nf

0V 0V
0V 0V

 All stepper and servo amplifiers must be inhibited when the amplifier enable output is open circuit

ANALOGUE INPUTS
Two built-in 12 bit analogue inputs are provided which are set up with a scale of 0 to 10V. External
connection to these inputs is via the 2-part terminal strip I/O connector 2.
A 24V d.c. supply must be applied to I/O connector 1 to provide power for the analogue input circuit.

ANALOGUE OUTPUTS
The MC403 has 2 12-bit analogue outputs scaled at +/-10V. Each output is assigned to one servo axis, or in
the case where the axis is not used, or is set as a pulse+direction/simulated encoder output, the analogue
output may be set to a voltage directly in software.
A 24V d.c. supply must be applied to I/O connector 1 to provide power for the analogue output circuit.
The MC403-Z does not have any analogue outputs.

LED DISPLAY
On power-up, the LEDs flash to show the MC403 version and the SD card status.
P821 2 axis pulse output MC403-Z: 3 flashes of the RED LED.
P822 3 axis pulse output MC403-Z 3 flashes of both LEDs alternately.
P823 3 axis pulse output version: 3 flashes of the RED LED.
P824 2 axis servo version: 3 flashes of both LEDs alternately.
P825 1 axis servo version: 3 flashes of the GREEN LED.
SD card loading system software: Both LEDs flash together until the system SW load is completed.

During operation, the two LED’s show the processor (OK) and system status.

Display at start-up Display with WDOG on Display Error

green - ON red - ON green - ON red - OFF green - ON red - FLASHING

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Motion Coordinator MC403
Trio Motion Technology

MC403 FEATURE SUMMARY

Size 122 mm x 135 mm x 35 mm (HxWxD).
Weight 325g
Operating Temp. 0 - 45 degrees C.
Control Inputs Forward Limit, Reverse Limit, Datum Input, Feedhold Input.
Communication Ports RS232 channel: up to 128k baud. RS485 channel: up to 128k baud.
CANbus port (DeviceNet and CANopen compatible). Ethernet: 10/100
BaseT multiple port connection.
Position Resolution 64 bit position count.
Speed Resolution 32 bits. Speed may be changed at any time. Moves may be merged.
Servo Cycle 125μs minimum, 1ms default, 2ms max.
Programming Multi-tasking TrioBASIC system and IEC 61131-3 programming system.
Maximum 6 user processes.
Interpolation modes Linear 1-3 axes, circular, helical, spherical, CAM Profiles, speed control,
electronic gearboxes.
Memory 8 Mbyte user memory. 512,000 x 64 bit TABLE memory. Automatic flash
EPROM program and data storage.
VR 4096 global VR data in FLASH memory (automatic-store).
SD Card Standard micro-SD Card compatible to 16Gbytes. Used for storing
programs and/or data.
Power Input 24V d.c., Class 2 transformer or power source.
18..29V d.c. at 300mA + IO supply.
Amplifier Enable Output Normally open solid-state relay rated 24V ac/dc nominal. Max load
100mA. Max Voltage 29V.
Analogue Inputs 2 isolated, 12 bit, 0 to 10V.
Serial / Encoder Power Output 5V at 150mA. (Max)
Analogue Outputs 2 isolated 12 bit, +/- 10V (MC403 only)
Digital Inputs 8 Opto-isolated 24V inputs.
Digital I/O 4 Opto-isolated 24V outputs. Current sourcing (PNP) 250 mA. (max. 1A
per bank of 4).
Product Codes P821 : MC403-Z 2 axis stepper output / 2 encoder input
P822 : MC403-Z 3 axis stepper output / 3 encoder input
P823 : MC403 3 axis stepper output / 3 encoder input
P824 : MC403 2 axis servo + 1 encoder / 3 axis stepper
P825 : MC403 1 axis servo + 1 encoder / 2 axis stepper

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MC403 AXIS CONFIGURATION SUMMARY

CONFIGURATION P823 P824 P825 P821 P822
Axis 0 Core Extended+AS Extended+AS Core Core
Axis 1 Core Extended+AS Core Core
Axis 2 Core Extended Core Extended
AXES
# of axes (max) 3 3 2 2 3
# of virtual axes (max) 16 16 16 16 16
DRIVE INTERFACES
Stepper (Step & Direction) Yes Yes Yes Yes Yes
Servo (±10V & Encoder) No Yes Yes No No
ENCODER PORTS
Feedback input No Yes Yes (1 axis) No No
Reference input Yes Yes Yes Yes Yes
Pulse + direction output Yes Yes Yes Yes Yes
Incremental (A+B) output Yes Yes Yes Yes Yes
BUILT-IN I/O
Inputs 24Vdc 8 8 8 8 8
Bi-directional I/O 24Vdc 4 4 4 4 4
0-10V analogue inputs 2x12bit 2x12bit 2x12bit 2x12bit 2x12bit
±10V analogue Outputs 2x12bit 2x12bit 2x12bit No No
# registration inputs 6 6 6 6 6
Registration input speed 20μs 20μs 20μs 20μs 20μs

CONFIGURATION KEY

CORE FUNCTIONALITY
CORE AXES – can be configured in software as pulse and direction outputs with stepper or servo drives. They
can also be configured for incremental encoder feedback.
Core functionality is a set of ATYPEs (Axis TYPEs) that are available on all controllers. They are based on
pulse outputs and incremental encoder feedback.
ATYPE Description
43 Pulse and direction output with enable output
45 Quadrature encoder output with enable output
63 Pulse and direction output with Z input
64 Quadrature encoder output with Z input

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76 Incremental encoder with Z input

78 Pulse and direction with VFF _ GAIN and enable output 1

EXTENDED FUNCTIONALITY
EXTENDED AXES – in addition to the Core functionality these axes can also be configured for absolute
encoders and closed loop servos (requires voltage output).

ANALOGUE SERVO - Only axes marked as AS have an analogue output and can be used for closed loop
control.
All Extended Axes can use these ATYPE’s as feedback.
If you want to just use the feedback and not complete a closed loop servo system set SERVO = OFF
ATYPE Description
30 Analogue feedback Servo
44 Incremental encoder Servo with Z input
46 Tamagawa absolute Servo
47 Endat absolute Servo
48 SSI absolute Servo
60 Pulse and direction feedback Servo with Z input
77 Incremental encoder Servo with enable output

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Motion Coordinator MC405

OVERVIEW
The Motion Coordinator MC405 is based on Trio’s high-performance ARM11 double-precision technology and
provides 4 axes of servo plus a master encoder axis,
or 5 axes of pulse+direction control for stepper drives
or pulse-input servo drives. Trio uses advanced FPGA
techniques to reduce the size and fit the pulse output
and servo circuitry in a compact DIN-rail mounted
package. The MC405 is housed in a rugged plastic
case with integrated earth chassis and incorporates
all the isolation circuitry necessary for direct
connection to external equipment in an industrial
environment. Filtered power supplies are included so
that it can be powered from the 24V d.c. logic supply
present in most industrial cabinets.
It is designed to be configured and programmed
for the application using a PC running Trio’s Motion
Perfect application software, and then may be set
to run “standalone” if an external computer is not
required for the final system. Programs and data are
stored directly to FLASH memory, thus eliminating
the need for battery backed storage.
The Multi-tasking version of TrioBASIC for the MC405 allows up to 10 TrioBASIC programs to be run
simultaneously on the controller using pre-emptive multi-tasking. In addition, the operating system
software includes a the IEC 61131-3 standard run-time environment (licence key required).

PROGRAMMING
The Multi-tasking ability of the MC405 allows parts of a complex application to be developed, tested and run
independently, although the tasks can share data and motion control hardware. The 10 available tasks can
be used for TrioBASIC or IEC 61131-3 programs, or a combination of both can be run at the same time, thus
allowing the programmer to select the best features of each.

I/O CAPABILITY
The MC405 has 8 built in 24V inputs and 8 bi-directional I/O channels. These may be used for system
interaction or may be defined to be used by the controller for end of travel limits, registration, datuming
and feedhold functions if required. Each of the Input/Output channels has a status indicator to make it easy
to check them at a glance. The MC405 can have up 512 external Input and Output channels connected using
DIN rail mounted CAN I/O modules. These units connect to the built-in CANbus port.

COMMUNICATIONS
A 10/100 base-T Ethernet port is fitted as standard and this is the primary communications connection to the
MC405. Many protocols are supported including Telnet, Modbus TCP, Ethernet IP and TrioPCMotion. Check
the Trio website (www.triomotion.com) for a complete list.
The MC405 has one built in RS232 port and one built in duplex RS485 channel for simple factory

HARDWARE OVERVIEW 2-55

Motion Coordinator MC405
Trio Motion Technology

communication systems. Either the RS232 port or the RS485 port may be configured to run the Modbus or
Hostlink protocol for PLC or HMI interfacing.
If the built-in CAN channel is not used for connecting I/O modules, it may optionally be used for CAN
communications. E.g. DeviceNet, CANopen etc.

REMOVABLE STORAGE
The MC405 has a micro-SD Card slot which allows a simple means of transferring
programs, firmware and data without a PC connection. Offering the OEM easy
machine replication and servicing.
The memory slot is compatible with a wide range of micro-SD cards up to 2Gbytes
using the FAT32 compatible file system.

AXIS POSITIONING FUNCTIONS

The motion control generation software receives instructions to move an axis or
axes from the TrioBASIC or IEC 61131-3 language which is running concurrently on the same processor. The
motion generation software provides control during operation to ensure smooth, coordinated movements
with the velocity profiled as specified by the controlling program. Linear interpolation may be performed
on groups of axes, and circular, helical or spherical interpolation in any two/three orthogonal axes. Each
axis may run independently or they may be linked in any combination using interpolation, CAM profile or the
electronic gearbox facilities.
Consecutive movements may be merged to produce continuous path motion and the user may program the
motion using programmable units of measurement (e.g. mm, inches, revs etc.). The module may also be
programmed to control only the axis speed. The positioner checks the status of end of travel limit switches
which can be used to cancel moves in progress and alter program execution.

CONNECTIONS TO THE MC405

ETHERNET PORT CONNECTION

Physical layer: 10/100 base_T

2-56 HARDWARE OVERVIEW

Motion Coordinator MC405
 Hardware Reference Manual

CONNECTOR: RJ45
The Ethernet port is the default connection between the Motion Coordinator and the host PC running the
Motion Perfect development application.

MC405 SERIAL CONNECTIONS

The MC405 features two serial ports. Both ports are accessed through a single 8 pin connector.

SERIAL CONNECTOR

6 3
1
7 4
2
8
5

Pin Function Note

1 RS485 Data In A Rx+
Serial Port #2
2 RS485 Data In B Rx-
3 RS232 Transmit Serial Port #1
4 0V Serial
5 RS232 Receive Serial Port #1
6 Internal 5V 5V supply is limited to 150mA, shared
with encoder ports
7 RS485 Data Out Z Tx- Serial Port #2
8 RS485 Data Out Y Tx+ Serial Port #2

HARDWARE OVERVIEW 2-57

Motion Coordinator MC405
Trio Motion Technology

MC405 PULSE+DIRECTION OUTPUTS / ENCODER INPUTS

1
6
2
7
3
8
4
9
5

The MC405 is designed to support any combination of servo and pulse driven motor drives on the standard
controller hardware. There are 2 versions of the MC405; the servo version and the pulse output only version.
In the pulse output only version, only axis 4 can be configured as an encoder input.
Each of the first four axes (0-3) can be enabled as servo(1), pulse output or encoder(1) according to the
user’s requirements by setting the axis ATYPE parameter. Axis 4 can be set as either pulse output, encoder
output or encoder input on all versions.
The function of the 9-pin ‘D’ connectors will be dependent on the specific axis configuration which has
been defined. If the axis is setup as a servo, the connector will provide the encoder input(1). If the axis is
configured as a pulse output, the connector provides differential outputs for step/direction or simulated
encoder, and enable signals.
The encoder port also provides a current-limited 5V output capable of powering most encoders. This
simplifies wiring and eliminates external power supplies.
(1) Servo version of the MC405 only.
Pin Encoder in/out Pulse + Direction Absolute Encoder
1 Enc. A Step+ Clock+
2 Enc. /A Step- Clock-
3 Enc. B Direction+ N/C
4 Enc. /B Direction- N/C
5 0V Encoder 0V Pulse+direction 0V Encoder
6 Enc. Z Enable+ Data+
7 Enc. /Z Enable- Data-
8 5V * 5V* 5V*
9 N/C N/C N/C
*5V supply is limited to 150mA (shared with serial port)

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Motion Coordinator MC405
 Hardware Reference Manual

REGISTRATION
Each MC405 encoder port has 2 available registration events. These are assigned in a flexible way to any of
the 8 digital inputs or can be used with the Z mark input on the encoder port.

5-WAY CONNECTOR

CA D
-H

-L
L
N

N
IE
CA
V+

SH

V-
This is a 5 way 3.5 mm pitch connector. The connector is used both to provide the 24 Volt power to the
MC405 and provide connections for I/O expansion via Trio’s digital and analogue CAN I/O expanders. 24 Volts
must be provided as this powers the unit.
This 24 Volt input is internally isolated from the I/O 24 Volts and the +/-10V voltage outputs.
24V d.c., Class 2 transformer or power source required for UL compliance. The MC405 is grounded via the
metal chassis. It MUST be installed on an unpainted metal plate or DIN rail which is connected to earth. An
earth screw is also provided on the rear of the chassis for bonding the MC405 to ground.

I/O CONNECTOR 1
I/O 0V
I/O 0V
Input 0
Input 1
Input 2
Input 3
Input 4
Input 5
Input 6
Input 7

HARDWARE OVERVIEW 2-59

Motion Coordinator MC405
Trio Motion Technology

I/O CONNECTOR 2

24V INPUT CHANNELS

The MC405 has 8 dedicated 24V I/O 0V
Input channels built into the master I/O 24V
unit. A further 256 inputs can be Input / Output Channel 8
Input / Output Channel 9
provided by the addition of CAN Input / Output Channel 10
I/O modules. The dedicated input Input / Output Channel 11
channels are labelled channels Input / Output Channel 12
Input / Output Channel 13
0..7. Two terminals marked IN- are Input / Output Channel 14
provided for the input 0V common Input / Output Channel 15
connections.
24V Power / I/O 8-15
Inputs 0 to 7 can be used as
registration inputs for axes 0 to 4,
using the REGIST command.

I/O POWER INPUTS

The I/O 0 Volts (I/O-) and I/O 24 Volts (I/O+) are used to Input Pin
power the 24 Volt digital IO and the analogue I/O, including 6k8
Optical
the servo DAC outputs. Input
Signal
The digital I/O connections are isolated from the module
power inputs. The analogue inputs and outputs are isolated
from the digital I/O and the module power inputs. 0V Pin

24V I/O CHANNELS

Input/output channels 8..15 are bi-directional. The 24V Pin
inputs have a protected 24V sourcing output connected Optical
to the same pin. If the output is unused it may be used Output
Control
as an input in the program. The input circuitry is the Signal Protected
same as on the dedicated inputs. The output circuit Switch
has electronic over-current protection and thermal
protection which shuts the output down when the Input / Output Pin
current exceeds 250mA. Optical 6k8
Input
Care should be taken to ensure that the 250mA limit for Signal
each output circuit is not exceeded, and that the total
load for the group of 8 outputs does not exceed 1 amp. 0V Pin

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Motion Coordinator MC405
 Hardware Reference Manual

I/O CONNECTOR 3

Analogue 0V Analogue Out Axis 2

Analogue Out Axis 1 Analogue Out Axis 3
Analogue Out Axis 0 Analogue 0V
Analogue Input 1 N/C
Analogue Input 0 N/C
Analogue 0V Analogue 0V
WDOG N/C
WDOG N/C

WDOG / Analogue Inputs / Analogue Outputs

AMPLIFIER ENABLE (WATCHDOG) RELAY OUTPUTS To other axis enables

An internal relay contact is available to enable external

amplifiers when the controller has powered up correctly and the
24V 0V 0V
system and application software is ready. The amplifier enable Enable 1

is a solid-state relay with an ON resistance of 25Ω at 100mA.

The enable relay will be open circuit if there is no power on the
Enable
controller OR a motion error exists on a servo axis OR the user Enable 2

program sets it open with the WDOG=OFF command. V+

The amplifier enable relay may, for example, be incorporated VIN +

within a hold-up circuit or chain that must be intact before a V- VIN-

3-phase power input is made live. Trio Controller

 All stepper and servo amplifiers must be inhibited when the amplifier enable output is open circuit

Ain
ANALOGUE INPUTS 22k
A to D
Two built-in 12 bit analogue inputs are provided which are set up with a scale of CONVERTER

0 to 10V. External connection to these inputs is via the 2-part terminal strip I/O 22k 30pF

connector 3.
A 24V d.c. supply must be applied to I/O connector 2 to provide power for the 0V
0V
analogue input circuit.

ANALOGUE OUTPUTS Aout

The MC405 has 4 12-bit analogue outputs scaled at +/-10V. Each output is 100R
assigned to one servo axis, or in the case where the axis is not used, or is set D to A
CONVERTER
as a pulse+direction/simulated encoder output, the analogue output may be
100nF
set to a voltage directly in software.
A 24V d.c. supply must be applied to I/O connector 2 to provide power for the
analogue output circuit. 0V
0V

HARDWARE OVERVIEW 2-61

Motion Coordinator MC405
Trio Motion Technology

BACKLIT DISPLAY
On power-up, the information display area shows bt during the boot process, then the MC405 version is
displayed, showing P826 for the 5 axis pulse output version and P827 for the 4 axis servo version. The IP
address and subnet mask is shown on power-up and whenever an Ethernet cable is first connected to the
MC405.
During operation, this display shows run, Off or Err to indicate the MC405 status. Below the main status
display are the ERROR and ENABLE indicators.
ERROR: An error has occurred (see Error Display Codes table below for details).
ENABLE: When illuminated, WDOG is ON.

A bank of 8 indicators at the left side shows the Digital Input States and a similar bank on the right shows
the state of I/O8 to I/O15. The I/O displayed can be altered using the DISPLAY command.
Two LED’s are provided to show the processor (OK) and system status.

Error Display Codes

Ann Axis error on axis nn
Caa Configuration error on unit aa ie: too many axes
Exx System error E00 - RAM error 8bit BB - RAM (VR)
E01 - RAM error 16 bit BB - RAM (TABLE)
E03 - Battery Error
E04 - VR/TABLE corrupt entry
E05 – Invalid MC_CONFIG file
E06 – Started in SAFE mode

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Motion Coordinator MC405
 Hardware Reference Manual

MC405 FEATURE SUMMARY

Size 122 mm x 186 mm x 35 mm (HxWxD).
Weight 476g
Operating Temp. 0 - 45 degrees C.
Control Inputs Forward Limit, Reverse Limit, Datum Input, Feedhold Input.
Communication Ports RS232 channel: up to 128k baud.
RS485 channel: up to 128k baud.
CANbus port (DeviceNet and CANopen compatible)
Ethernet: 10/100 BaseT multiple port connection.
Position Resolution 64 bit position count.
Speed Resolution 32 bits. Speed may be changed at any time. Moves may be merged.
Servo Cycle 125μs minimum, 1ms default, 2ms max.
Programming Multi-tasking TrioBASIC system and IEC 61131-3 programming system.
Maximum 10 user processes.
Interpolation modes Linear 1-5 axes, circular, helical, spherical, CAM Profiles, speed control,
electronic gearboxes.
Memory 8 Mbyte user memory. 512,000 x 64 bit TABLE memory. Automatic flash
EPROM program and data storage.
Real Time Clock Capacitor backed for 10 days or power off.
VR 4096 global VR data in FLASH memory. (automatic-store)
SD Card Standard micro-SD Card compatible to 2Gbytes. Used for storing programs
and/or data.
Power Input 24V d.c., Class 2 transformer or power source.
18..29V d.c. at 350mA + IO supply.
Amplifier Enable Normally open solid-state relay rated 24V ac/dc nominal. Maximum load
Output 100mA. Maximum Voltage 29V.
Analogue Inputs 2 isolated, 12 bit, 0 to 10V.
Serial / Encoder 5V at 150mA.
Power Output
Digital Inputs 8 Opto-isolated 24V inputs.
Digital I/O 8 Opto-isolated 24V outputs. Current sourcing (PNP) 250 mA. (max. 1A per
bank of 8).
Product Code P826 : MC405, 5 axis stepper
P827 : MC405, 4 axis servo / 5 axis stepper

HARDWARE OVERVIEW 2-63

Motion Coordinator MC405
Trio Motion Technology

Motion Coordinator Euro404 /408

OVERVIEW
The Motion Coordinator Euro404 and Euro408 are Eurocard
stepper/servo positioners with the built-in ability to control up
to 8 servo or stepper motors in any combination. The Euro404 /
408 is designed to provide a powerful yet cost-effective control
solution for OEM machine builders who are prepared to mount
the unit and provide the power supplies required. It is designed
to be configured and programmed for the application with
TrioBASIC or IEC61131-3 standard languages using a PC. It may
then may be set to run “standalone” if an external computer
is not required for the final system. The Multi-tasking version
of TrioBASIC for the Euro404 / 408 allows up to 10 TrioBASIC
programs to be run simultaneously on the controller using pre-
emptive multi-tasking.

PROGRAMMING
The Multi-tasking ability of the Euro404 / 408 allows parts
of a complex application to be developed, tested and run
independently, although the tasks can share data and motion
control hardware.

I/O CAPABILITY
The Euro404 / 408 has 16 built in 24V inputs and 8 built-in output channels. These may be used for system
interaction or may be defined to be used by the controller for end of travel limits, datuming and feedhold
functions if required. 8 status LEDs are available which can be set to display the status of banks of inputs
or outputs. The Euro404 / 408 can have up to 512 external Input/Output channels, up to 32 analogue input
channels and up to 16 analogue output channels connected using DIN rail mounted I/O modules. These units
connect to the built-in CAN channel of the Euro404 / 408.

COMMUNICATIONS
The Euro404 / 408 has one Ethernet port for primary communications, one RS-232 port and one RS-485 built
in.
The Ethernet port, RS-232 port or the RS485 port may be configured to run the MODBUS protocol for PLC or
HMI interfacing. If the built-in CAN channel is not used for connecting I/O modules, it may optionally be
used for CAN communications or DeviceNet.

REMOVABLE STORAGE
A micro SD card can be used with the Euro404 / 408 allows a simple means of
transferring programs without a PC connection. Offering the OEM easy machine
replication and servicing. The Euro404 / 408 supports SD cards up to 16Gbytes. Each
Micro SD Card must be pre-formatted using a PC to FAT32 before it can be used in the
SD Card Adaptor.

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Motion Coordinator Euro404 /408
 Hardware Reference Manual

AXIS CONFIGURATION
The Euro404 / 408 is available in 2 configurations. Either as an 8 axis pulse output card or as the full axis
servo card.

96 way connector

Ethernet Connector
Serial Port

CAN Connector
Battery
SD Card Connector
LED Array

RST-IP NORM 1

IP Reset Switch Analogue Inputs

Connections to the Euro404 / 408

5 VOLT POWER SUPPLY

The minimum connections to the Euro404 / 408 are just the 0V and 5V pins. The Euro404 / 408 is protected
against reverse polarity on these pins. Application of more than 5.25 Volts will permanently damage the
Motion Coordinator beyond economic repair. All the 0V are internally connected together and all the 5v pins
are internally connected together. The 0V pins are, in addition, internally connected to the AGND pins. The
Euro404 / 408 has a current consumption of approximately 500mA on the 5V supply. The supply should be
filtered and regulated within 5%.
BUILT-IN CAN CONNECTOR
0V
The Euro404 / 408 features a built-in CAN channel. This is primarily intended for Input/
Output expansion via Trio’s CAN I/O modules. It may be used for other purposes when CAN-L
I/O expansion is not required. SHIELD
CAN-H

EURO404 / 408 BACKPLANE CONNECTOR

Most connections to the Euro404 / 408 are made via the 96 Way DIN41612 backplane
Connector.

HARDWARE OVERVIEW 2-65

Motion Coordinator Euro404 /408
Trio Motion Technology

Euro408 C B A
1 5V 5V 5V
2 5V 5V 5V
3 0V 0V 0V
4 IO GND OP13 OP10
5 OP9 OP12 OP15
6 OP8 OP11 OP14
7 IO 24V IN0 / R0 IN1 / R1
8 IN2 / R2 IN3 / R3 IN4 / R4
9 IN5 / R5 IN6 / R6 IN7 / R7
10 IN8 IN9 IN10
11 IN11 IN12 N13
12 IN14 0V IN15
13 A7- / STEP7- B7- / DIR7- Z7- / ENABLE7-
14 A7+ / STEP7+ B7+ / DIR7+ Z7+ / ENABLE7+
15 A6- / STEP6- B6- / DIR6- Z6- / ENABLE6-
16 A6+ / STEP6+ B6+ / DIR6+ Z6+ / ENABLE6+
17 A5- / STEP5- B5- / DIR5- Z5- / ENABLE5-
18 A5+ / STEP5+ B5+ / DIR5+ Z5+ / ENABLE5+
19 A4- / STEP4- B4- / DIR4- Z4- / ENABLE4-
20 A4+ / STEP4+ B4+ / DIR4+ Z4+ / ENABLE4+
21 A3- / STEP3- B3- / DIR3- Z3- / ENABLE3-
22 A3+ / STEP3+ B3+ / DIR3+ Z3+ / ENABLE3+
23 A2- / STEP2- B2- / DIR2- Z2- / ENABLE2-
24 A2+ / STEP2+ B2+ / DIR2+ Z2+ / ENABLE2+
25 A1- / STEP1- B1- / DIR1- Z1- / ENABLE1-
26 A1+ / STEP1+ B1+ / DIR1+ Z1+ / ENABLE1+
27 A0- / STEP0- B0- / DIR- Z0- / ENABLE0-
28 A0+ / STEP0+ B0+ / DIR+ Z0+ / ENABLE0+
29 VOUT7 VOUT6 VOUT5
30 AGND VOUT4 VOUT3
31 VOUT2 VOUT1 VOUT0
32 ENABLE1 ENABLE2 Earth

2-66 HARDWARE OVERVIEW

Motion Coordinator Euro404 /408
 Hardware Reference Manual

Euro404 C B A
1 5V 5V 5V
2 5V 5V 5V
3 0V 0V 0V
4 IO GND OP13 OP10
5 OP9 OP12 OP15
6 OP8 OP11 OP14
7 IO 24V IN0 / R0 IN1 / R1
8 IN2 / R2 IN3 / R3 IN4 / R4
9 IN5 / R5 IN6 / R6 IN7 / R7
10 IN8 IN9 IN10
11 IN11 IN12 N13
12 IN14 0V IN15
13 N/C N/C N/C
14 N/C N/C N/C
15 N/C N/C N/C
16 N/C N/C N/C
17 N/C N/C N/C
18 N/C N/C N/C
19 N/C N/C N/C
20 N/C N/C N/C
21 A3- / STEP3- B3- / DIR3- Z3- / ENABLE3-
22 A3+ / STEP3+ B3+ / DIR3+ Z3+ / ENABLE3+
23 A2- / STEP2- B2- / DIR2- Z2- / ENABLE2-
24 A2+ / STEP2+ B2+ / DIR2+ Z2+ / ENABLE2+
25 A1- / STEP1- B1- / DIR1- Z1- / ENABLE1-
26 A1+ / STEP1+ B1+ / DIR1+ Z1+ / ENABLE1+
27 A0- / STEP0- B0- / DIR- Z0- / ENABLE0-
28 A0+ / STEP0+ B0+ / DIR+ Z0+ / ENABLE0+
29 N/C N/C N/C
30 AGND N/C VOUT3
31 VOUT2 VOUT1 VOUT0
32 ENABLE1 ENABLE2 Earth

HARDWARE OVERVIEW 2-67

Motion Coordinator Euro404 /408
Trio Motion Technology

AMPLIFIER ENABLE (WATCHDOG) RELAY OUTPUT

To other axis enables

Enable 1 24V 0V 0V

Enable 2 Enable

V+

VIN +

V- VIN-

Trio Controller

An internal relay contact is used to enable external amplifiers when the controller has powered up correctly
and the system and application software is ready. The amplifier enable is a solid-state relay on the Euro404
/ 408 with normally open “contacts”. The enable relay will be open circuit if there is no power on the
controller OR a following error exists on a servo axis OR the user program sets it open with the WDOG=OFF
command. The amplifier enable relay may, for example, be incorporated within a hold-up circuit or chain
that must be intact before a 3-phase power input is made live.

circuit
Note: all stepper and servo amplifiers MUST be inhibited when the amplifier enable output is open

24V INPUT CHANNELS

I/O 24V

6k8 Ohms
Input Pin

Vin
I/O GND

The Motion Coordinator has 16 24V Input channels built into the master unit. These may be expanded to
256 Inputs by the addition of CAN-16 I/O modules.

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 Hardware Reference Manual

24V OUTPUT CHANNELS

I/O 24V
Optical Output
Control Switch
Protected Switch

Output Pin

I/O GND
8 output channels are provided. These channels are labelled 8..15 for compatibility with other Motion
Coordinators, but are NOT bi-directional as on some Motion Coordinators. Each channel has a protected 24v
sourcing output. The output circuit has electronic over-current protection and thermal protection which
shuts the output down when the current exceeds 250mA. Care should still be taken to ensure that the
250mA limit for the output circuit is not exceeded, and that the total load for the group of 8 outputs does
not exceed 1 amp. Up to 256 further Outputs may be added by the addition of CAN-16I/O modules).

REGISTRATION INPUTS
The registration inputs are 24 Volt isolated inputs that are shared with digital inputs 0 to 7. The Euro404 /
408 can be programmed to capture the position of an encoder axis in hardware when a transition occurs on
the registration input.

DIFFERENTIAL ENCODER INPUTS

The encoder inputs on the Euro404 / 408 are designed to be directly connected to 5 Volt differential output
encoders. Incremental or absolute encoders can be connected to the ports.
The encoder ports are also bi-directional so that when axes are set to pulse and direction, the encoder port
for that axis becomes a Differential output.
Encoder ports and pulse direction ports on the Euro404 / 408 are NOT electrically isolated.

VOLTAGE OUTPUTS
The Euro404 can generate up to 4 +/-10Volt analogue outputs and the Euro408 can generate up to 8 +/-
10Volt analogue outputs for controlling servo-amplifiers. Note that for servo operation the card must
be configured as a 4 or 8 axis servo. However, the voltage outputs can be used seperately via the DAC
command in TrioBASIC even when the servo axis is not enabled.

ANALOGUE INPUTS
Two built-in 12 bit analogue inputs are provided which are set up with a scale of 0 to 10 Volts. In order to
make connection to these inputs, there is a 2 part molex connector behind the front panel. Pin 1 is nearest
the front panel.
Pin 1 AIN(32) Mating MOLEX connector part number
Pin 2 AIN(33) Connector housing: 22-01-2035
Pin 3 0V Crimp receptacles : 08-50-0032 (3 required)

HARDWARE OVERVIEW 2-69

Motion Coordinator Euro404 /408
Trio Motion Technology

USING END OF TRAVEL LIMIT SENSORS

Each axis of the Motion Coordinator system may have a 24v Input channel allocated to it for the functions:
FORWARD Limit Forward end of travel limit
REVERSE Limit Reverse end of travel limit
DATUM Input Used in datuming sequence
FEEDHOLD Input Used to suspend velocity profiled movements until the input is released

Switches used for the FORWARD/REVERSE/DATUM/FEEDHOLD inputs may be normally closed or normally open
but the NORMALLY CLOSED type is recommended.
Each of the functions is optional and may be left unused if not required. Each of the 4 functions are
available for each axis and can be assigned to any input channel iincluding remote CAN I/O. An input can be
assigned to more than one function if desired.
The axis parameters: FWD _ IN,REV _ IN, DATUM _ IN and FH _ IN are used to assign input channels to the
functions. The axis parameters are set to -1 if the function is not required.

ETHERNET PORT CONNECTION

Pysical layer: 10/100 baseT
Connector: RJ-45
Connection and activity LED indicators
Fixed IP address
User settable subnet mask and default gateway
DHCP client: Not available (fixed IP only)

A switch is provided on the board to reset the IP address

to a known value. To reset to the default value of
192.168.000.250, slide the switch to the left (RST_IP) and RST_IP NORM
power up the Euro404 / 408. Make connection with the
Euro404 / 408 using Motion Perfect on the default address
and use the IP _ ADDRESS command to set the required
address. e.g. for 192.168.000.123 set IP _ ADDRESS=192.168.0.123.
NOTE: The switch also sets the following:
subnet mask to 255.255.255.0
default gateway to 192.168.0.255
Once the IP address has been set, slide switch 1 to NORM and power down the Eurocard. Next time the
Euro404 / 408 is powered up, the new IP address can be used.

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Motion Coordinator Euro404 /408
 Hardware Reference Manual

SERIAL CONNECTOR B:
Euro404 / 408 Serial Port Connections

Pin Function Note

1 RS485 Data In A Rx+ 6 3
Serial Port #2 4
1
2 RS485 Data In B Rx- 7 2
8
3 RS232 Transmit 5

4 Serial 0V Serial Port #1

5 RS232 Receive
6 5V OUT
7 RS485 Data Out Z Tx- Serial Port #2
8 RS485 Data Out Y Tx+

HARDWARE OVERVIEW 2-71

Motion Coordinator Euro404 /408
Trio Motion Technology

EURO404 / 408 - FEATURE SUMMARY

Size 170 mm x 129 mm Overall (160mm x 100 mm PCB) 25mm deep
Weight 160 g
Operating Temp. 0 - 45 degrees C
Control Inputs Forward Limit, Reverse Limit, Datum Input, Feedhold Input.
Communication Ports RS232 channel: up to 128k baud.
RS485 channel: up to 128k baud.
CANbus port (DeviceNet and CANopen compatible)
Ethernet: 10/100 BaseT multiple port connection.
Position Resolution 64 bit position count
Speed Resolution 32 bits. Speed may be changed at any time. Moves may be merged.
Interpolation modes Linear 1-8 axes, circular, helical, CAM Profiles, speed control, electronic
gearboxes.
Programming Multi-tasking TrioBASIC system, maximum 10 user tasks. IEC61131-3
programming languages.
Servo Cycle 125μs minimum, 1ms default, 2ms max.
Memory 8 Mbyte user memory. 512,000 x 64 bit TABLE memory. Automatic flash
EPROM program and data storage.
Real Time Clock Capacitor backed for 10 days or power off.
VR 4096 global VR data in FLASH memory. (automatic-store)
Expansion Memory Socket for Micro SD Card. Used for storing programs and/or data. Format:
FAT32, up to 16 GBytes.
Power Input 600mA at 5V d.c.
Amplifier Enable Output Normally open solid-state relay. Maximim load 100mA, maximum voltage 29V.
Analogue Outputs 4 Isolated 12 bit +/-10V or 8 isolated 12 bit +/-10V.
Analogue Inputs 2 x 12 bit 0 to 10V
Digital Inputs 16 Opto-isolated 24V inputs
Registration Inputs 8 shared with inputs 0 to 7.
Encoder Inputs 4 / 8 differential 5V inputs, 6MHz maximum edge rate
Stepper Outputs 4 / 8 differential step / direction outputs 2MHz max rate
Digital Outputs 8 Opto-isolated 24V outputs. Current sourcing (PNP) 250 mA. (max. 1A per
bank of 8)
Product Code P831 : Euro404, 4 axis stepper
P832 : Euro404, 4 axis servo
P833 : Euro408, 8 axis stepper
P834 : Euro404, 8 axis servo

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Motion Coordinator Euro404 /408
 Hardware Reference Manual

HARDWARE OVERVIEW 2-73

Motion Coordinator MC508
Trio Motion Technology

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Motion Coordinator MC508