Motion Coordinator - 4xx Range

HARDWARE REFERENCE MANUAL

Version 7.4
 Hardware Reference Manual

Trio Motion Technology

Motion Coordinator 4xx Range
Hardware Reference Manual

Seventh Edition • 2013

Revision 4.1

INTRODUCTION 1-1

Trio Motion Technology

All goods supplied by Trio are subject to Trio’s standard terms and conditions of sale.
This manual applies to systems based on the Motion Coordinator MC4 range.

The material in this manual is subject to change without notice. Despite every effort, in a manual
of this scope errors and omissions may occur. Therefore Trio cannot be held responsible for any
malfunctions or loss of data as a result.

Copyright (C) 2000-2013 Trio Motion Technology Ltd.

All Rights Reserved

UK
Trio Motion Technology Ltd.
Phone: +44 (0)1684 292333
Fax: +44 (0)1684 297929

USA
Trio Motion Technology LLC.
Phone: +1 724 540 5018
Fax: +1 724 540 5098

CHINA
Trio Shanghai
Tel: +86 21 5879 7659
Fax: +86 21 5879 4289

INDIA
Trio India
Phone: +91 20 681 149 02

1-2 INTRODUCTION

 Hardware Reference Manual

SAFETY WARNING
During the installation or use of a control system, users of Trio products must ensure there is no
possibility of injury to any person, or damage to machinery.
Control systems, especially during installation, can malfunction or behave unexpectedly. Bearing
this in mind, users must ensure that even in the event of a malfunction or unexpected behaviour
the safety of an operator or programmer is never compromised.

This manual uses the following icons for your reference:

M 
Information that relates to Information to highlight key Useful tips and techinques.
safety issues and critical features or methods.
software information

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 Hardware Reference Manual

Contents

INTRODUCTION TO THE MC4XX RANGE........... 1-3 Analogue Inputs.............................................2-18

Typical System Configuration.............................. 1-3 Analogue Outputs...........................................2-18
Setup and Programming.....................................1-4 LED Display...................................................2-18
Features.......................................................1-5 MC403 Feature Summary..................................2-19
The Trio Motion Technology Website.....................1-6 MC403 Axis Configuration Summary .................... 2-20
Configuration Key.......................................... 2-20
HARDWARE.............................................. 2-3 Motion Coordinator MC405................................... 2-22
Motion Coordinator MC464..................................... 2-3 Overview.................................................... 2-22
Overview...................................................... 2-3 Programming................................................ 2-22
Programming.................................................. 2-3 I/O Capability............................................... 2-22
I/O Capability................................................. 2-3 Communications............................................ 2-22
Communications..............................................2-4 Removable Storage........................................ 2-23
Removable Storage..........................................2-4 Axis Positioning Functions................................ 2-23
Axis Positioning Functions..................................2-4 Connections to the MC405................................ 2-23
Connections to the MC464..................................2-5 Ethernet Port Connection................................ 2-23
Ethernet Port Connection..................................2-5 MC405 Serial Connections................................ 2-24
Ethernet Sync Port...........................................2-5 Serial Connector........................................... 2-24
MC464 Serial Connections..................................2-5 MC405 Pulse+direction Outputs / Encoder Inputs ... 2-25
Serial Connector ............................................2-5 Registration................................................. 2-26
Sync Encoder.................................................2-6 5-Way Connector........................................... 2-26
Registration...................................................2-6 I/O Connector 1............................................ 2-26
24V Power Supply Input..................................... 2-7 I/O Connector 2............................................ 2-27
Amplifier Enable (Watchdog) Relay Outputs............. 2-7 24V Input Channels........................................ 2-27
CANbus........................................................2-8 I/O Power Inputs........................................... 2-27
Analogue Inputs..............................................2-8 24V I/O Ch annels.......................................... 2-27
24V Input Channels..........................................2-8 I/O Connector 3............................................ 2-28
24V I/O Channels.............................................2-8 Amplifier Enable (Watchdog) Relay Outputs........... 2-28
Battery.........................................................2-8 Analogue Inputs............................................ 2-28
Backlit Display................................................2-9 Analogue Outputs.......................................... 2-28
MC464 Feature Summary..................................2-11 Backlit Display.............................................. 2-29
Motion Coordinator MC403....................................2-12 MC405 Feature Summary................................. 2-30
Overview.....................................................2-12 Motion Coordinator Euro404 /408...........................2-31
Programming.................................................2-12 Overview ....................................................2-31
I/O Capability................................................2-12 Programming ................................................2-31
Communications.............................................2-12 I/O Capability................................................2-31
Removable Storage.........................................2-13 Communications ............................................2-31
Axis Positioning Functions.................................2-13 Removable Storage ........................................2-31
Connections to the MC403.................................2-13 Axis Configuration......................................... 2-32
Ethernet Port Connection.................................2-13 5 Volt Power Supply....................................... 2-32
MC403 Serial Connections.................................2-14 Euro404 / 408 Backplane Connector................... 2-32
Serial Connector ...........................................2-14 Amplifier Enable (Watchdog) Relay Output............ 2-35
MC403 Pulse Outputs / Encoder Inputs..................2-15 24V Input Channels........................................ 2-35
Registration..................................................2-16 24V Output Channels...................................... 2-36
5-Way Connector............................................2-16 Registration Inputs......................................... 2-36
I/O Connector 1.............................................2-16 Differential Encoder Inputs............................... 2-36
24V Input Channels.........................................2-16 Voltage Outputs............................................ 2-36
I/O Power Inputs............................................2-16 Analogue Inputs............................................ 2-36
24V I/O Channels............................................2-17 Using End of Travel Limit Sensors....................... 2-37
I/O Connector 2.............................................2-17 Ethernet Port Connection................................ 2-37
Amplifier Enable (Watchdog) Relay Outputs............2-17 Serial Connector B:........................................ 2-38

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Trio Motion Technology

Euro404 / 408 - Feature Summary...................... 2-39 CAN Analogue I/O Module (P326)............................ 4-10
CANbus...................................................... 4-10
MC464 EXPANSION MODULES........................ 3-3 Input Terminals............................................. 4-10
Assembly..........................................................3-3 Output Terminals.......................................... 4-10
Module SLOT Numbers......................................3-3 LED Indicators.............................................. 4-11
Fitting Expansion Modules..................................3-4 Configuration Switches.................................... 4-11
RTEX Interface (P871)...........................................3-5 Specification P326......................................... 4-11
Realtime Express.............................................3-5 CAN 8-Relay Module (P327).................................. 4-12
RJ45 Connector (tx).........................................3-5 CANbus...................................................... 4-12
RJ45 Connector (Rx).........................................3-5 Relay Channels............................................. 4-12
Time Based Registration....................................3-5 LED Indicators.............................................. 4-13
Registration connector......................................3-5 Configuration Switches.................................... 4-13
LED Functions.................................................3-6 Specification P327......................................... 4-13
Sercos Interface (P872).........................................3-7 Controller I/O mapping....................................... 4-14
Sercos Connections..........................................3-7 Digital I/O order............................................ 4-14
Connector (Rx)...............................................3-7 Analogue I/O order........................................ 4-14
Connector (Tx)...............................................3-7 General Description....................................... 4-15
Time Based Registration....................................3-7 Protocol Selection......................................... 4-15
SLM Interface (P873)............................................3-9 Controller Setup............................................ 4-16
Time Based Registration.................................. 3-10 Update Rates............................................... 4-16
Registration Connector................................... 3-10 Digital I/O................................................... 4-16
LED Functions............................................... 3-10 Analogue I/O................................................ 4-16
FlexAxis Interface (P874 / P879).............................3-11 Digital CAN I/O addressing............................... 4-17
Encoder Connector ........................................3-11 Analogue I/O addressing.................................. 4-18
Multifunction Connector.................................. 3-12 Error codes.................................................. 4-18
Analogue Outputs.......................................... 3-12 Digital Input, Output and I/O modules................. 4-18
Position Based Registration.............................. 3-12 Troubleshooting............................................ 4-20
PSWITCH Outputs.......................................... 3-12 CANopen DS401................................................ 4-21
Multifunction Connector Pin Out........................ 3-12 General Description....................................... 4-21
LED Functions............................................... 3-13 Protocol Selection......................................... 4-21
EtherCAT Interface (P876).................................... 3-14 Controller Setup............................................ 4-22
RJ45 Connector............................................ 3-14 Module Addressing......................................... 4-22
Time Based Registration.................................. 3-14 Error Codes................................................. 4-22
Registration Connector................................... 3-14 LED state definitions....................................... 4-22
LED Functions............................................... 3-14 PWR LED error code....................................... 4-22
Anybus-CC Module (P875).................................... 3-15 ERR LED error code........................................ 4-23
Anybus Module Fitting..................................... 3-15
INSTALLING HARDWARE.............................. 5-3
GENERAL DESCRIPTION OF I/O MODULES......... 4-3 Installing the MC464............................................5-3
Product Code:................................................4-3 Packaging.....................................................5-3
CAN 16-Output Module (P317) ............................... 4-4 Expandable design...........................................5-3
CANbus....................................................... 4-4 Items supplied with the MC464........................... 5-4
24V Output Channels ...................................... 4-4 Connectors:.................................................. 5-4
LED Indicators............................................... 4-4 Panel mounting set:........................................ 5-4
Configuration Switches......................................4-5 Mounting MC464............................................. 5-4
Specification P317............................................4-5 General....................................................... 5-4
CAN 16-Input Module (P318) .................................. 4-6 DIN Rail....................................................... 5-4
CANbus....................................................... 4-6 IP rating: IP 20................................................5-5
24V Input Channels ........................................ 4-6 Instaling the MC405 / MC403................................. 5-6
Configuration Switches......................................4-7 Packaging.................................................... 5-6
Specification P318............................................4-7 Items supplied with the MC405 / MC403.................5-7
CAN 16-I/O Module (P319)......................................4-8 Connectors....................................................5-7
CANbus........................................................4-8 Mounting MC405 / MC403...................................5-7
24V Input/ Output Channels ...............................4-8 General........................................................5-7
Configuration Switches......................................4-9 DIN Rail........................................................5-7
Specification P319............................................4-9 Screw Mounting..............................................5-7

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Environmental Considerations.............................5-7
IP rating: IP 20................................................5-7
Installing the CAN I/O Modules................................5-8
Packaging .....................................................5-8
Items Supplied with CAN I/O modules....................5-8
Mounting CAN I/O Modules.................................5-8
Environmental Considerations.............................5-9
IP rating: IP 20 ...............................................5-9
Bus Wiring.....................................................5-9

EMC CONSIDERATIONS................................ 6-3

EMC Earth - MC464 ............................................ 6-4
EMC Earth – MC405 / MC403.................................. 6-4
EMC Earth - CAN I/O Modules..................................6-5
Cable Shields.................................................... 6-6
Surge protection................................................ 6-6
Single power supply........................................ 6-6
Distributed Power supply...................................6-7
Recommended protection device.........................6-7
MC464 and IO devices.......................................6-8
MC403/MC405.................................................6-9
Background to EMC Directive..................................6-9
Testing Standards............................................6-9
Emissions - BS EN61000-6-4 : 2007. .................... 6-10
Immunity - BS EN61000-6-2 : 2005. ..................... 6-10
Requirements For EMC Conformance................... 6-10

INDEX....................................................... III

CONTENTS III

INTRODUCTION 1
Trio Motion Technology

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 Hardware Reference Manual

Introduction to the MC4xx Range

The MC4 range Motion Coordiantors are the latest in the Trio pedigree representing over 25 years of motion
control experience. Run your machine faster and with greater precision with these new generation Motion
Coordinators based on a 64 bit technology.
Choose the motor and drives to best suit your application without compromise, the MC4xx range provides
interface options for traditional servo, stepper and piezo control together with many digital interfaces for
current digital servo drives. Increase the flexibility of your equipment with support for up to 64 axes of
motion control. Trio’s tradition of modular configuration has evolved into convenient MC464 clip-on modules
allowing the system designer to precisely build the configuration needed for the job.
The MC405 and MC403 share the same advanced software and hardware techniques with the MC464, but
come in 2 compact and cost-effective packages for machine applications requiring lower axis counts.

HMI
SERVO DRIVES

LAPTOP
MOTORS

FACTORY
NETWORK

NETWORKED
SERVO DRIVES
MC464
CAN I/O MOTION COORDINATOR

MOTORS

Typical System Configuration

TYPICAL SYSTEM CONFIGURATION

The MC4 range supports programs written in TrioBASIC, allowing a smooth upgrade path from earlier types
of Motion Coordinator. In addition, the standard IEC 61131-3 languages are supported, allowing both logical
I/O and motion programming in Ladder, Function Block, Structured Text and Sequential Function Chart. A
rich set of motion function blocks allows the programmer to have full access to the familiar Trio Motion
command set.
I/O expansion is provided via a built-in CANbus interface. The built-in Ethernet port supports both the
programming interface and many Ethernet based fieldbuses. These can be used simultaneously. Further
fieldbus networks supporting common factory protocols are supported in the MC464 via the HMS AnyBus®
adapter module.

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Trio Motion Technology

The MC464 axis expansion modules feature many options for Drive Network interfaces, analogue servo,
pulse/direction, absolute or incremental feedback and accurate hardware registration. Up to 7 half-height
expansion modules or 3 full-height expansion modules can be attached. This modular approach along with
Trio’s feature enable code system for axis activation allows the whole system to be scaled exactly to need.
The MC403 and MC405 each come in 2 main variants; either 3 or 5 axis pulse+direction output, or as 2 or 4
axis servo with a single 5th axis encoder port.

SETUP AND PROGRAMMING

To program the Motion Coordinator, a PC is connected via an Ethernet link. The dedicated Motion Perfect
program is normally used to provide a wide range of programming facilities on a PC running Microsoft
Windows XP, Vista or Windows 7 versions.

Motion Perfect 3

Once connected to the Motion Coordinator, the user has direct access to TrioBASIC which provides an easy
and rapid way to develop control programs. All the standard program constructs are provided; variables,
loops, input/output, maths and conditions. Extensions to this basic instruction set exist to permit a
wide variety of motion control facilities, such as single axis moves, synchronised multi axis moves and
unsynchronised multi axis moves as well as the control of the digital I/O.
The MC4 range features multi-tasking TrioBASIC and the standard IEC 61131-3 language. Multiple TrioBASIC
programs plus Ladder Diagram (LD), Function Block (FB), Structured Text (ST) and Sequential Function
Chart (SFC) can be constructed and run simultaneously to make programming complex applications much
easier. Motion Perfect version 3 is needed to access the full IEC 61131-3 functionality. MPv3 provides a

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 Hardware Reference Manual

seamless programming, compilation and debug environment that can work in real-time with any of the MC4
range Motion Coordinators. A motion library is provided which enables the familiar Trio Motion Technology
commands to be included in IEC 61131-3 programs.

FEATURES
• Supports digital drive systems up to 64 axis
• Based on 64bit MIPS and ARM processor technology
• 64bit position integers
• High accuracy double floating point resolution
• Multi-tasking BASIC programming
• IEC61131-3 programming support
• Motion buffers up to 64 moves
• Robotics, gears, interpolation and synchronisation built-in
• I/O expansion up to 528 I/O points
• Ethernet programming interface
• Backlit LCD display (MC464 and MC405)
• Expansion flexibility with clip on modules allowing quick interchangibility (MC464 only)
• Anybus Module support allowing flexible factory communication options (MC464 only)

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Trio Motion Technology

THE TRIO MOTION TECHNOLOGY WEBSITE

The Trio website contains up to the minute news, information and support for the Motion Coordinator
product range.

• Website Features
• Latest News
• Product Information
• Manuals
• Programming Tools
• System Software Updates
• Technical Support
• User’s Forum
• Application Examples
• Employment Opportunities

WWW.TRIOMOTION.COM

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Hardware Reference Manual

INTRODUCTION 1-7

HARDWARE OVERVIEW 2
Trio Motion Technology

2-2 HARDWARE OVERVIEW


 Hardware Reference Manual

Hardware

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 256 external Input/Output channels connected using DIN
rail mounted CAN I/O modules. These units connect to the built-in CAN channel.

HARDWARE OVERVIEW 2-3

Motion Coordinator MC464
Trio Motion Technology

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
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.

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Motion Coordinator MC464
 0 8
1 9

Backlit 2
3
10
11 Hardware Reference Manual
Display
4 12
5 ENABLE 13
6 14
7 15

CONNECTIONS TO THE MC464

MC 464

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 Expansion
Module
The Ethernet port is the default connection between the Motion Coordinator and the
I/O, CAN,
host PC running Motion Perfect programming.
Analogue,
Power SYNC PORT
ETHERNET
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
3
1 RS485 Data In A Rx+ 6
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 MC464
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 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
*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.

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Motion Coordinator MC464
 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 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
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.

00ALL STEPPER AND SERVO AMPLIFIERS MUST BE INHIBITED WHEN THE AMPLIFIER ENABLE OUTPUT IS OPEN CIRCUIT

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Motion Coordinator MC464
Trio Motion Technology

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 AIN 0V CAN/AIN
modules. It may be used for other purposes when I/O expansion is not AIN0 CAN LOW
required. AIN1 CAN SHIELD
The CANbus port is electrically equivalent to a DeviceNet node. WDOG+ CAN HIGH
WDOG- 24V CAN/AIN SUPPLY
ANALOGUE INPUTS I0 I/O/8
I1 I/O/9
Two built-in 12 bit analogue inputs are provided which are set up with a scale Ain
of 0 to 10V. External connection to these inputs is via the 2-part terminalI 2 I/O/10
22k
strip
on the lower front panel. I3 I/O/11 A to D
CONVERTER
I4 I/O/12 100uf
22k
A 24V d.c. supply must be applied to the CANbus port to provide power for the
I5 I/O/13
analogue input circuit.
I6 I/O/14
0V
I7 I/O/15 0V
24V INPUT CHANNELS 0V I/O 24V I/0 SUPPLY
The Motion Coordinator has 16 24V Input channels built into the master unit.
0V SUPPLY 24V SUPPLY 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
Input Pin
directional channels may be used for Input or Output to suit the application. If
the channel is to be used as an Input then the Output should not be switched Vin
on in the program. I/O 0V

24V I/O CHANNELS

Input/output channels 8..15 are bi-directional and may be used Optical
I/O 24V

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

group of 8 outputs does not exceed 1A

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.

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Motion Coordinator MC464
 Hardware Reference Manual

C A

00TO 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

101011
A

ERROR An error has occurred (see Error Display Codes table below for details).
ENABLE When illuminated, WDOG is ON.
BATTERY LOW When illuminated
B 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.

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Motion Coordinator MC464
Trio Motion Technology

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 nn
Caa Configuration error on unit nn ie: too many axes
Exx System error E00 - RAM error 8bit BB - RAM (VR)
E01 - RAM error 16 bit BB - RAM (TABLE)
E02 - Not used
E03 - Battery Error

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Motion Coordinator MC464
 Hardware Reference Manual

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).

HARDWARE OVERVIEW 2-11

Motion Coordinator MC464
Trio Motion Technology

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.

2-12 HARDWARE OVERVIEW

Motion Coordinator MC403
 Hardware Reference Manual

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

HARDWARE OVERVIEW 2-13

Motion Coordinator MC403
Trio Motion Technology

The Ethernet port is the default connection between the Motion Coordinator and the host PC running the
Motion Perfect development application. MC 403

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

2-14 HARDWARE OVERVIEW

Motion Coordinator MC403
 Hardware Reference Manual

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

HARDWARE OVERVIEW 2-15

Motion Coordinator MC403
Trio Motion Technology

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

2-16 HARDWARE OVERVIEW

Motion Coordinator MC403
 Hardware Reference Manual

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.

HARDWARE OVERVIEW 2-17

Motion Coordinator MC403
Trio Motion Technology

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

0V 0V
0V 0V

00ALL 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

2-18 HARDWARE OVERVIEW

Motion Coordinator MC403
 Hardware Reference Manual

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

HARDWARE OVERVIEW 2-19

Motion Coordinator MC403
Trio Motion Technology

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

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
76 Incremental encoder with Z input

2-20 HARDWARE OVERVIEW

Motion Coordinator MC403
 Hardware Reference Manual

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

HARDWARE OVERVIEW 2-21

Motion Coordinator MC403
Trio Motion Technology

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

2-22 HARDWARE OVERVIEW

Motion Coordinator MC405
 Hardware Reference Manual

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

HARDWARE OVERVIEW 2-23

Motion Coordinator MC405
Trio Motion Technology

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

2-24 HARDWARE OVERVIEW

Motion Coordinator MC405
 Hardware Reference Manual

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)

HARDWARE OVERVIEW 2-25

Motion Coordinator MC405
Trio Motion Technology

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

Input Pin
Optical 6k8
Input
Signal

0V Pin

2-26 HARDWARE OVERVIEW

Motion Coordinator MC405
 Hardware Reference Manual

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 CH ANNELS

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

HARDWARE OVERVIEW 2-27

Motion Coordinator MC405
Trio Motion Technology

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 system and application software is ready. The Enable 1 24V 0V 0V

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 Enable 2 Enable
on a servo axis OR the user program sets it open with the
WDOG=OFF command. V+

VIN +
The amplifier enable relay may, for example, be
incorporated within a hold-up circuit or chain that must be V- VIN-

intact before a 3-phase power input is made live.

Trio Controller

00ALL 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.

Aout
ANALOGUE OUTPUTS 100R
The MC405 has 4 12-bit analogue outputs scaled at +/-10V. Each output is D to A
CONVERTER
assigned to one servo axis, or in the case where the axis is not used, or is set
100nF
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 2 to provide power for the 0V
0V

2-28 HARDWARE OVERVIEW

Motion Coordinator MC405
 Hardware Reference Manual

analogue output circuit.

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
Exx System error E00 - RAM error 8bit BB - RAM (VR)
E01 - RAM error 16 bit BB - RAM (TABLE)

HARDWARE OVERVIEW 2-29

Motion Coordinator MC405
Trio Motion Technology

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

2-30 HARDWARE OVERVIEW

Motion Coordinator MC405
 Hardware Reference Manual

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.

HARDWARE OVERVIEW 2-31

Motion Coordinator Euro404 /408
Trio Motion Technology

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

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
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 I/O expansion is not required.

EURO404 / 408 BACKPLANE CONNECTOR

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

2-32 HARDWARE OVERVIEW

Motion Coordinator Euro404 /408
 Hardware Reference Manual

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

HARDWARE OVERVIEW 2-33

Motion Coordinator Euro404 /408
Trio Motion Technology

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

2-34 HARDWARE OVERVIEW

Motion Coordinator Euro404 /408
 Hardware Reference Manual

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.

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

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.

HARDWARE OVERVIEW 2-35

Motion Coordinator Euro404 /408
Trio Motion Technology

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)

2-36 HARDWARE OVERVIEW

Motion Coordinator Euro404 /408
 Hardware Reference Manual

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.

HARDWARE OVERVIEW 2-37

Motion Coordinator Euro404 /408
Trio Motion Technology

SERIAL CONNECTOR B:
Euro404 / 408 Serial Port Connections

Pin Function Note

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

2-38 HARDWARE OVERVIEW

Motion Coordinator Euro404 /408
 Hardware Reference Manual

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, 8axis servo

HARDWARE OVERVIEW 2-39

Motion Coordinator Euro404 /408
Trio Motion Technology

2-40 HARDWARE OVERVIEW


 Hardware Reference Manual

HARDWARE OVERVIEW 2-41


Trio Motion Technology

2-42 HARDWARE OVERVIEW


MC464 EXPANSION MODULES 3
Trio Motion Technology

3-2 MC464 EXPANSION MODULES


 Hardware Reference Manual

MC464 Expansion Modules

Assembly
A maximum of 7 half height modules or 3 full height modules may be fitted to the MC464. A system may be
made using any combination of half and full height modules providing that the full height modules are the
last to be attached.

MODULE SLOT NUMBERS

SLOT Numbers are allocated by the system software in order, left to right, starting with the lower bus.
Lower modules are allocated slots 0 to m, then the upper modules become slots m+1 to n. Finally, the
Sync Encoder Port is allocated slot n+1. The Sync Encoder Port has SLOT number -1 in addition to the one
allocated (1) in this sequence.

SLOT 1 1 0 7 4 5 6 4 1 2 3

SLOT 0 0 1 2 3 0

MC464 EXPANSION MODULES 3-3

Assembly
Trio Motion Technology

FITTING EXPANSION MODULES

• Remove the 2 covers (B) if fitted to the MC464 or to the previous expansion module (C).
• Locate the 2 hooks at the front of the module, while holding the rear out at an angle
• Push forward to engage the hooks and at the same time swing the rear of the module in so as to
locate the connector.
• Press the connector “home” once it is located.
• Tighten the screw (A) using the tool provided or a small coin
• Clip the provided covers (B) in place as shown.

B
Removing modules is the reversal of the above procedure.
If the system is to be panel mounted, a kit (P8) comprising 2 x panel mounting brackets and 2 x countersunk
screws may be purchaced separately from your Trio distributor.

3-4 MC464 EXPANSION MODULES

Assembly
 Hardware Reference Manual

RTEX Interface (P871)

For use with Panasonic amplifiers supporting the Panasonic Real Time Express (RTEX) network. Allows Plug &
Play interconnection with Shielded twisted pair (TIA/
EIA-568B CAT5e or more) Ethernet cables.
A single interface supports up to 32 axes on the RTEX
network. The module comes with 2 axes enabled. Further
axes can be enabled with Trio’s Feature Enable Codes.

REALTIME EXPRESS
The P871 communicates with up to 32 servo amplifiers
using Ethernet Real Time Express. The physical layer is
standard Ethernet connected in a ring. Each node has
a transmit socket and a receive socket to allow easy
connection. The maxium cable length between any 2
nodes is 60 meters and the overall network length is
limited to 200 meters.

RJ45 CONNECTOR (TX)

(Top connector)100Mbps Panasonic
RTEX transmit – connect to receive of
first
drive.

RJ45 CONNECTOR (RX)

(Bottom connector) 100Mbps Panasonic RTEX receive – connect to transmit of last drive.

TIME BASED REGISTRATION

Time based registration uses a 10MHz clock to record the time of a registration event which is then
referenced to time stamps on the axis position from the digital drive network. An accurate registration
position is then calculated. The 10MHz clock gives a time resolution of 100nsec. The position and speed of
the axis are recorded so that the user can compensate for any fixed delays in the registration circuit.
Any time based registration input can be assigned to any Digital or Virtual axis. This makes the registration
very flexible and enables multiple registration channels per axis. Each registration channel can be armed
independently and assigned to an axis at any time.

R0 R4
R1 R5
R2 R6
R3 R7
R0V R0V
R0V R0V
REGISTRATION CONNECTOR

MC464 EXPANSION MODULES 3-5

RTEX Interface (P871)
Trio Motion Technology

R0-R7 registration inputs (24V).

0V common 0V return.
Registration inputs can be allocated to any axis by software.

LED FUNCTIONS
LED LED colour LED function
ok Green ON=Module Initialised Okay
0 Red ON=Module Error
1 Yellow Status 1
2 Yellow Status 2

3-6 MC464 EXPANSION MODULES

RTEX Interface (P871)
 Hardware Reference Manual

Sercos Interface (P872)

The sercos interface module is designed to control up to 16 servo amplifiers using the standard sercos
fibre-optic ring. Benefits of this system include full isolation from
the amplifiers and greatly reduced wiring.
For use with any sercos IEC61491 compliant drive. The module
allows control of up to 16 axes via sercos with cycle times down to
250usec. Multiple sercos interface modules can be used to increase
axes count to 64.
2, 4, 8 and 16 Mbit / sec
Software settable intensity

SERCOS CONNECTIONS
Sercos is connected by 1mm polymer or glass fibre optic cable
terminated with 9mm FSMA connectors. The sercos ring is
completed by connecting TX to RX in a series loop. The maximum
fibre cable length between 2 nodes is 40m for plastic optical fibre
(POF) and 200m for hard clad silica (HCS). The total length for POF
is 680m and 3,400 for HCS.

CONNECTOR (RX)
(Top connector) sercos fibre-optic transmit. 9mm FSMA.

CONNECTOR (TX)
(Bottom connector) sercos fibre-optic receive. 9mm FSMA.

TIME BASED REGISTRATION

Time based registration uses a 10MHz clock to record the time of a registration event which is then
referenced to time stamps on the axis position from the digital drive network. An accurate registration
position is then calculated. The 10MHz clock gives a time resolution of 100nsec. The position and speed of
the axis are recorded so that the user can compensate for any fixed delays in the registration circuit.
Any time based registration input can be assigned to any Digital or Virtual axis. This makes the registration
very flexible and enables multiple registration channels per axis. Each registration channel can be armed
independently and assigned to an axis on the fly.

MC464 EXPANSION MODULES 3-7

Sercos Interface (P872)
Trio Motion Technology

REGISTRATION CONNECTOR

R0 R4 R0 - R7 registration inputs (24V).

R1 R5 R0V registration common 0V return.
R2 R6
R3 R7 Registration inputs can be allocated to any axis by software.
R0V R0V
R0V R0V

LED FUNCTIONS

LED LED colour LED function

ok Green ON=Module Initialised Okay
0 Red ON=Module Error
1 Yellow Status 1
2 Yellow Status 2

sercos phase LED 1 LED 2

0 OFF FLASH
1 OFF ON
2 FLASH OFF 1
3 ON OFF 2
4 ON ON

3-8 MC464 EXPANSION MODULES

Sercos Interface (P872)
 Hardware Reference Manual

SLM Interface (P873)

For use with drives supporting the Control Techniques SLM protocol. Each module supports 6 axes which can
be individual drives or two drives using the CT Multiax concept.

SLM CONNECTOR

Pin Upper D-Type Lower D-Type

1 Com Axis 0 Com Axis 3
6
1 11
2 /Com Axis 0 /Com Axis 3
3 Hardware Enable Hardware Enable
4 0V Output 0V Output

5 15
5 24V Output 24V Output
10 6 Com Axis 1 Com Axis 4
7 /Com Axis 1 /Com Axis 43
8 No Connection No Connection
9 No Connection No Connection
10 No Connection No Connection
11 24V Output 24V Output
12 0V Output 0V Output
13 Com Axis 2 Com Axis 5
14 /Com Axis 2 /Com Axis 5
15 Earth / Shield Earth / Shield

MC464 EXPANSION MODULES 3-9

SLM Interface (P873)
Trio Motion Technology

TIME BASED REGISTRATION

Time based registration uses a 10MHz clock to record the time of a registration event which is then
referenced to time stamps on the axis position from the digital drive network. An accurate registration
position is then calculated. The 10MHz clock gives a time resolution of 100nsec. The position and speed of
the axis are recorded so that the user can compensate for any fixed delays in the registration circuit.
Any time based registration input can be assigned to any Digital or Virtual axis. This makes the registration
very flexible and enables multiple registration channels per axis. Each registration channel can be armed
independently and assigned to an axis on the fly.

REGISTRATION CONNECTOR
R0 R3 R0 - R5 registration inputs (24V).
R1 R4
R2 R5
0VR common 0V return.
R0V R0V 0V PWR Power input for SLM system.
0V PWR 24V
24V Power input for SLM system.

LED FUNCTIONS
LED LED Colour LED Function
ok Green ON = Module initalised ok
0 Red ON = Module error
1 Yellow Status 1
2 Yellow Status 2

3-10 MC464 EXPANSION MODULES

SLM Interface (P873)
 Hardware Reference Manual

FlexAxis Interface (P874 / P879)

For use with Stepper, Analogue Servo & Piezo motors. The FlexAxis Interface is available in 4 axes (P879)
and 8 axes (P874) versions.
Each axis provides a 16 bit analogue output, up to 8 x 24Vdc high
speed registration inputs and a 6MHz encoder input. The encoder
port can be configured to drive a stepper motor or an encoder
simulation port, both at 2MHz.

ENCODER CONNECTOR
Pin Incremental Pulse + Absolute
Encoder Direction Encoder
1 Enc. A n Step+ n Clock+ n
2 Enc. /A n Step- n Clock- n
3 Enc. B n Direction+ n n/c
4 Enc. /B n Direction- n n/c
5 0V Enc 0V Enc 0V Enc
6 Enc. Z n Enable+ n Data+ n
7 Enc. /Z n Enable- n Data- n
8 5V* 5V* 5V*
9 Enc A n+4 Step+ n4 Clock+ n+4
10 Enc /A n+4 Step- n4 Clock- n+4
11 Enc B n+4 Direction+ n+4 n/c
12 Enc /B n+4 Direction- n+4 n/c
13 Enc Z n+4 Enable+ n+4 Data+ n+4
14 Enc /Z n+4 Enable- n+4 Data- n+4
15 0V Enc 0V Enc 0V Enc
*5V supply is limited to 150mA per axis.

Absolute encoder is only available on axes 4-7 on the P874 and on axes 2-3 on P879.

Connector 8 Axes (P874) 4 Axes (P879)

1 0 and 4 0
2 1 and 5 1
3 2 and 6 2
4 3 and 7 3

MC464 EXPANSION MODULES 3-11

FlexAxis Interface (P874 / P879)
Trio Motion Technology

MULTIFUNCTION CONNECTOR
The 22 pin multifunction connector provides terminals for 8 registration inputs, 8 voltage
outputs and 4 hardware PSWITCH outputs. ok
0

1 1

ANALOGUE OUTPUTS 2

8 +/-10V 16Bit analogue outputs are available for servo axis control (4 in the P879).
Connect V0 as the velocity command signal for the first axis, V1 for the second axis and so
on. The maximum load per axis together is 10mA.
2
POSITION BASED REGISTRATION
Position based registration uses the encoder signal. When the registration event occurs
the encoder position is latched in hardware. The speed of the axis is also recorded so
that the user can compensate for any fixed electronic delays in the registration circuit.
3
Flexible allocation of registration inputs to axes is provided. Each axis can have a number
of registration events assigned to it and the source of these events can be from any of the
registration channels.
The Flex Axis module has 8 registration inputs in addition to the Z mark for each axis. The
first axis has 8 registration events which can be assigned to use any of the registration 4
inputs or its own Z mark. The remaining axes have 2 registration events which can be
assigned to use any of the registration inputs or their own Z mark.

PSWITCH OUTPUTS
Inputs R4 to R7 are bi-directional and can be used as outputs for high accuracy PSWITCH
operation. When used in this mode, the outputs are controlled by the position value of an
axis within the same P874 / P879 module.

MULTIFUNCTION CONNECTOR PIN OUT

DAC 0V DAC 0V 0V DAC common 0V return
DAC 0V DAC 0V
V0 V4 V0 - V7 Voltage outputs
V1 V5
V2 V6 R0 - R3 24V Registration Inputs
V3 V7 R4/PS4 - R7/PS7 Bidirectional 24V registration In/24V: PSWITCH outputs
R0 R4/PS4
R1 R5/PS5 Inputs / 24V PSwitch outputs
R2 R6/PS6
0V PWR Power Input
R3 R7/PS7
0V PWR 24V 24V Power Input

4 axis version uses voltage outputs V0 - V3 only.

3-12 MC464 EXPANSION MODULES

FlexAxis Interface (P874 / P879)
 Hardware Reference Manual

LED FUNCTIONS
LED LED Colour LED Function
ok Green ON = Module initalised ok
0 Red OFF = Operational mode
SLOW FLASH = Not in Operational mode
QUICK FLASH = EtherCAT error
1 Yellow No function
2 Yellow Network activity

MC464 EXPANSION MODULES 3-13

FlexAxis Interface (P874 / P879)
Trio Motion Technology

EtherCAT Interface (P876)

For use with EtherCAT compliant drives, this module allows control of up to 64 axes via standard shielded
twisted pair (TIA/EIA-568B CAT5e or more) Ethernet cables.
Multiple EtherCAT Interface Modules can be used.
EtherCAT is an open, high performance ethernet based fieldbus
system, which has been integrated into several IEC standards
(IEC 61158, IEC 61784 and IEC61800). It is a high performance,
deterministic protocol, with high bandwidth usage, low latency
and low communication jitter. Various network topologies are
supported, including line, tree or star. The EtherCAT compliant
servo amplifiers from any number of vendors may be included in
a network.
The module supports both the CANopen and servo drive (sercos,
IEC 61491) EtherCAT profiles, along with the mailbox transfer
protocol to exchange configuration, status and diagnostic
information between the master and slave.

RJ45 CONNECTOR
100 base-T Ethernet (EtherCat Master).

TIME BASED REGISTRATION

Time based registration uses a 10MHz clock to record the time of a registration event which is then
referenced to time stamps on the axis position from the digital drive network. An accurate registration
position is then calculated. The 10MHz clock gives a time resolution of 100nsec. The position and speed of
the axis are recorded so that the user can compensate for any fixed delays in the registration circuit.
Any time based registration input can be assigned to any Digital or Virtual axis. This makes the registration
very flexible and enables multiple registration channels per axis. Each registration channel can be armed
independently and assigned to an axis on the fly.

REGISTRATION CONNECTOR

R0 R4 R0 - R7: registration inputs (24V).

R1 R5
R6
R0V: registration common 0V return.
R2
R3 R7 Registration inputs can be allocated to any axis by software.
R0V R0V
R0V R0V

LED FUNCTIONS
LED LED colour LED function
ok Green ON=Module Initialised Okay

3-14 MC464 EXPANSION MODULES

EtherCAT Interface (P876)
 Hardware Reference Manual

0 Red ON=Module Error

1 Yellow Status 1
2 Yellow Status 2

Anybus-CC Module (P875)

Open communications is an important aspect to any control system. This module adds support for the
Anybus CompactCom device modules.
Anybus-CC is a plug-in module supporting all major Fieldbus and
Ethernet networks. Its innovative design and versatile functionality
offers the Anybus-CC optimal flexibility for OEM manufacturers.
The Anybus modules can be found at:
www.anybus.com

Anybus CompactCom Module shown for illustration only. Anybus

CC Modules may be purchased seperately.

ANYBUS MODULE FITTING

Push the Anybus® module (A) into the Trio Expansion Interface taking
care to keep its base in contact with the PCB and align guide slots (B)
with the connector rails inside.
Ensure that the moulded hooks (C) on the lower front edge of the
Anybus® module locate under the P875 PCB
at the front. B

When the module is flush with the face

of the Trio Expansion Interface, tighten
the two “Torx” head screws (D) to locate
the two lugs (E) and secure the Anybus®
module.
To remove the module, reverse this
procedure.
A

E
D C

MC464 EXPANSION MODULES 3-15

Anybus-CC Module (P875)
I/O EXPANSION MODULES 4
Trio Motion Technology

4-2 I/O EXPANSION MODULES


 Hardware Reference Manual

General Description of I/O Modules

Trio Motion Technology’s range of digital and analogue input/output expansion modules are designed to
enable simple and scalable I/O extension for Trio’s Motion Coordinators. In addition to 24V input, output and
bi-directional modules, there are relay and analogue I/O modules.
The Motion Coordinator I/O expansion system uses CANbus to reduce wiring and allow input/output modules
to be distributed remotely. Up to 32 Digital modules and up to 4 Analogue modules may be added to the
system.
All CAN Input, Output and I/O modules are DIN rail mounted with the I/O connections located conveniently
on the front face. They have been designed with a spaced-saving footprint only 26mm wide so allowing
large amounts of Digital and Analogue I/O to be packed in an area no bigger than the average PLC. Address
selection is simply done by setting DIP switches that are neatly located under the pull-up flap. LEDs show the
I/O state and indicate an error code for straight forward system commissioning and de-bugging.
CANbus is used for communication and control between the Motion Coordinator and the CAN I/O modules.
CANbus is a tried and tested, well known industrial data link which is reliable, noise immune and flexible.
All CAN I/O modules are compatible with any Motion Coordinator that has a CANbus port and they support
various CAN protocols.

PRODUCT CODE:
CAN 16-Output Module P317
CAN 16-Input Module P318
CAN 16-I/O Module P319
CAN Analogue I/O Module P326
CAN 8-Relay Module P327

I/O EXPANSION MODULES 4-3


Trio Motion Technology

CAN 16-Output Module (P317)

The Trio CAN 16 Output module offers a compact DIN rail mounted relay input expansion capability for all
Trio Motion Coordinators. Using remote
I/O on the Trio CANbus can significantly
reduce the machine wiring.
Up to 16 output modules may be
connected to the CAN network which
may be up to 100m long. This provides
up to 256 distributed output channels at V- (black)

24V DC Class 2
-
24Vdc level. All outputs are short-circuit CAN_L (blue)

L
0 Out 0 Shield
proof and completely isolated from the 1 Out CAN_H (white)

H
1

CANbus. P317 modules may be mixed on 2 Out 2

V+ (red)

+
3 Out 3
the same bus, with other types of Trio 4 Out 4

CAN I/O modules on the same network 5

6
Out
Out
5
6
to build the I/O configuration required 7 Out 7
24V
for the system. 0V
24V

0V

Convenient disconnect terminals are 8 Out 8

used for all I/O connections. 9 Out 9

10 Out 10

11 Out 11

12 Out 12

CANBUS 13 Out 13

14 Out 14
The CANbus port has over voltage and 15 Out 15

reverse polarity protection. Various 24V

0V
24V

0V
protocols can selected using the
configuration switches.

24V OUTPUT CHANNELS

The P317 has two banks of eight outputs,
both banks of outputs are electrically isolated and require their own 24V and 0V. Output channels have a
protected 24V sourcing output connected to the output pin. The output circuit has electronic over-current
protection and thermal protection which shuts the output down when the current exceeds 250mA.
Care should 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.
I/O 24V
Optical
Output
Control
Signal Protected
Switch

Output Pin

LED INDICATORS
The green power (PWR) LED and red error (ERR) LED display the status of the CAN I/O module. The actual

4-4 I/O EXPANSION MODULES

CAN 16-Output Module (P317)
 Hardware Reference Manual

status displayed will depend on the protocol selected.

The status LEDs marked 0 - 15 represent the output channels 0 - 15 of the module. The actual outputs as
seen by the Motion Coordinator software will depend on the modules’ address.

CONFIGURATION SWITCHES
The switches are hidden under the display window. These can be adjusted to set the module address,
protocol and data rate.

SPECIFICATION P317
Outputs: 16 24 Volt output channels with 2500V isolation
Configuration: 16 output channels
Output Capacity: 1A per bank of 250mA / channel
Protection: Outputs are overcurrent and over temperature protected
Indicators: Individual status LED’s
Address Setting: Via DIP switches
Power Supply: 24V dc, Class 2 transformer or power source
18 ... 29V dc / 1.5W.
Mounting: DIN rail mount
Size: 26mm wide 85mm deep 130mm high
Weight: 128g
CAN: 500kHz, Up to 256 expansion I/O channels
EMC: EN 61000-6-2 : 2005 Industrial Noise Immunity / EN 61000-6-4 : 2007 Industrial Noise
CAN protocol: Trio CAN I/O or CANopen DS401.

I/O EXPANSION MODULES 4-5

CAN 16-Output Module (P317)
Trio Motion Technology

CAN 16-Input Module (P318)

The Trio CAN 16 Input module offers a compact DIN rail mounted relay input expansion capability for all Trio
Motion Coordinators. Using remote I/O on
the Trio CANbus can significantly reduce
the machine wiring.
Up to 16 input modules may be connected
to the CAN network which may be up
to 100m long. This provides up to 256
distributed input channels at 24Vdc level. V- (black)

24V DC Class 2
-
All input points are high level (24V in = CAN_L (blue)

L
0 In 0 Shield
ON) and completely isolated from the 1 In 1
CAN_H (white)

H
CANbus. P318 modules may be mixed on 2 In 2
V+ (red)

+
3 In 3
the same bus, with other types of Trio 4 In 4

CAN I/O modules on the same network to 5 In

6 In
5
6
build the I/O configuration required for 7 In 7
N/C
the system. 0V
24V

0V

Convenient disconnect terminals are used 8 In 8

for all I/O connections. 9 In 9

10 In 10

11 In 11

12 In 12

CANBUS 13 In 13

14 In 14
The CANbus port has over voltage and 15 In 15

reverse polarity protection. Various N/C

0V
24V

0V

protocols can selected using the

configuration switches.

24V INPUT CHANNELS

The P318 has two banks of eight inputs,
both banks of outputs are electrically isolated and have independent 0V. Input channels are opto-isolated
24V, which are designed to be ON when the input voltage is greater than 18 Volts and OFF when the signal
voltage is below 2V. The input has a 6k8 resistor in series and so provides a load of approximately 3.5mA at
24V.
Input Pin
6k8
Optical
Input
Signal
I/O OV
LED INDICATORS
The green power (PWR) LED and red error (ERR) LED display the status of the CAN I/O module. The actual
status displayed will depend on the protocol selected.
The status LEDs marked 0 - 15 represent the input channels 0 - 15 of the module. The actual input as seen
by the Motion Coordinator software will depend on the modules’ address.

4-6 I/O EXPANSION MODULES

CAN 16-Input Module (P318)
 Hardware Reference Manual

CONFIGURATION SWITCHES
The switches are hidden under the display window. These can be adjusted to set the module address,
protocol and data rate.

SPECIFICATION P318
Inputs: 16 24 Volt input channels with 2500V isolation
Configuration: 16 input channels
Protection: Inputs are reverse polarity protected
Indicators: Individual status LED’s
Address Setting: Via DIP switches
Power Supply: 24V dc, Class 2 transformer or power source
18 ... 29V dc / 1.5W.
Mounting: DIN rail mount
Size: 26mm wide 85mm deep 130mm high
Weight: 128g
CAN: 500kHz, Up to 256 expansion I/O channels
EMC: EN 61000-6-2 : 2005 Industrial Noise Immunity / EN 61000-6-4 : 2007 Industrial Noise
Emissions
CAN protocol: Trio CAN I/O or CANopen DS401.

I/O EXPANSION MODULES 4-7

CAN 16-Input Module (P318)
Trio Motion Technology

CAN 16-I/O Module (P319)

The Trio CAN 16 Input/ Output module offers a compact DIN rail mounted relay input expansion capability
for all Trio Motion Coordinators. Using
remote I/O on the Trio CANbus can
significantly reduce the machine wiring.
Up to 16 I/O modules may be connected
to the CAN network which may be up
to 100m long. This provides up to 256 16-I/O
DIGITAL
distributed bi-directional input/output P319 V- (black)

24V DC Class 2
-
CAN_L (blue)
channels at 24Vdc level. All input

L
0 I/O 0 Shield
points are high level (24V in = ON) all 1 I/O CAN_H (white)

H
1
2 I/O
outputs are short-circuit proof and the 2
V+ (red)

+
3 I/O 3

I/O is completely isolated from the 4 I/O 4

5 I/O
CANbus. P319 modules may be mixed
5
6 I/O 6

on the same bus, with other types of 7 I/O 7

24V
Trio CAN I/O modules on the same
24V

0V 0V

network to build the I/O configuration

8 I/O
required for the system.
8

9 I/O 9

10 I/O 10

Convenient disconnect terminals are 11 I/O 11

12 I/O
used for all I/O connections. 13 I/O
12
13

14 I/O 14

15 I/O 15

CANBUS 24V 24V

0V 0V

The CANbus port has over voltage and

reverse polarity protection. Various
protocols can selected using the
configuration switches.

24V INPUT/ OUTPUT CHANNELS

The P319 has two banks of eight bi-directional input/ outputs, both banks are electrically isolated and
require their own 24V and 0V. Input/output channels are bi-directional, so can be used as an input or
output. Bi-directional inputs have a protected 24V sourcing output connected to the same pin. If the output
is unused, the pin may be used as an input in the program. The output circuit has electronic over-current
protection and thermal protection which shuts the output down when the current exceeds 250mA.
Care should 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.

4-8 I/O EXPANSION MODULES

CAN 16-I/O Module (P319)
 Hardware Reference Manual

I/O 24V
Optical
Output
Control
Signal Protected
Switch

Input/Output
6k8 Pin
Optical
Input
Signal
I/O OV

LED INDICATORS
The green power (PWR) LED and red error (ERR) LED display the status of the CAN I/O module. The actual
status displayed will depend on the protocol selected.
The status LEDs marked 0 - 15 represent the I/O channels 0 - 15 of the module. The actual I/O as seen by
the Motion Coordinator software will depend on the modules’ address.

CONFIGURATION SWITCHES
The switches are hidden under the display window. These can be adjusted to set the module address,
protocol and data rate.

SPECIFICATION P319
Inputs: 16 24 Volt input channels with 2500V isolation
Outputs: 16 24 Volt output channels with 2500V isolation
Configuration: 16 input/output channels
Output Capacity: Outputs are rated at 250mA/channel. (1 Amp total/bank of 8 I/O’s)
Protection: Outputs are overcurrent and over temperature protected
Indicators: Individual status LED’s
Address Setting: Via DIP switches
Power Supply: 24V dc, Class 2 transformer or power source. 18 ... 29V dc / 1.5W.
Mounting: DIN rail mount
Size: 26mm wide 85mm deep 130mm high
Weight: 128g
CAN: 500kHz, Up to 256 expansion I/O channels
EMC: EN 61000-6-2 : 2005 Industrial Noise Immunity / EN 61000-6-4: 2007 Industrial Noise
CAN protocol: Trio CAN I/O or CANopen DS401.

I/O EXPANSION MODULES 4-9

CAN 16-I/O Module (P319)
Trio Motion Technology

CAN Analogue I/O Module (P326)

The Trio CAN Analogue I/O module offers a compact DIN rail mounted relay output expansion capability for
all Trio Motion Coordinators. Using remote I/O
on the Trio CANbus can significantly reduce the
machine wiring.
Up to 4 analogue modules may be connected
to the CAN network which may be up to 100m
long. This provides up to 32 distributed V- (black)

24V DC Class 2
-
analogue inputs and 16 analogue outputs CAN_L (blue)

L
. Each module provides 8 channels of 12- 0 Ain
1 Ain
0
1
Shield
CAN_H (white)

H
bit analogue inputs (+/-10v) and 4 channels 2 Ain 2
V+ (red)

+
3 Ain 3
of 12-bit (+/-10v) analogue outputs. All 4 Ain 4

analogue I/O are completely isolated from the 5 Ain

6 Ain
5
6

CANbus. P326 modules may be mixed on the 7 Ain

N/C
7

same bus, with other types of Trio CAN I/O

24V

0V 0V

modules on the same network to build the I/O 0 Vout 8

configuration required for the system. 0V 9

1 Vout 10

Convenient disconnect terminals are used for 0V

2 Vout
11
12

all I/O connections. 0V

3 Vout
13
14

0V 15

N/C 24V

CANBUS 0V 0V

The CANbus port has over voltage and reverse

polarity protection. Various protocols can
selected using the configuration switches.

INPUT TERMINALS
The 8 analogue inputs are single-ended and have a common 0V. Analogue input nominal impedance = 42k
Ohm.

Ain
100R 42k
A to D
CONVERTER
1uF

0V
0V

OUTPUT TERMINALS
The 4 analogue outputs are single-ended and have a common 0V. Analogue output nominal impedance = 100
Ohm.
The recommended minimum load resistance on the output is 2k Ohm.

4-10 I/O EXPANSION MODULES

CAN Analogue I/O Module (P326)
 Hardware Reference Manual

Aout
100R
D to A
CONVERTER
100nf

0V
0V

LED INDICATORS
The green power (PWR) LED and red error (ERR) LED display the status of the CAN I/O module. The actual
status displayed will depend on the protocol selected.
The status LEDs marked 0 - 3 are only used to display an error.

CONFIGURATION SWITCHES
The switches are hidden under the display window. These can be adjusted to set the module address,
protocol and data rate.

SPECIFICATION P326
Analogue Inputs: 8 +/-10 Volt inputs with 500V isolation from CAN bus.
Resolution: 12 bit.
Protection: Inputs are protected against 24V over voltage.
Analogue Outputs: 4 +/-10 Volt outputs with 500V isolation from CAN bus.
Resolution: 12Bit.
Address Setting: Via DIP switches.
Power Supply: 24V dc, Class 2 transformer or power source.
18 ... 29V dc / 1.5W.
Mounting: DIN rail mount.
Size: 26mm wide 85mm deep 130mm high.
Weight: 128g
CAN: 500kHz, Up to 32 analogue input channels and 16 analogue output channels.
EMC: EN 61000-6-2 : 2005 Industrial Noise Immunity / EN 61000-6-4 : 2007 Industrial Noise
Emissions.
CAN Protocol: Trio CAN I/O or CANopen DS401.

I/O EXPANSION MODULES 4-11

CAN Analogue I/O Module (P326)
Trio Motion Technology

CAN 8-Relay Module (P327)

The Trio CAN 8 Relay module offers a compact DIN rail mounted relay output expansion capability for all Trio
Motion Coordinators. Using remote I/O on
the Trio CANbus can significantly reduce
the machine wiring.
Up to 16 relay modules may be connected
to the CAN network which may be up
to 100m long. This provides up to 128 8-RELAY
OUT
distributed low power relay channels at up P327 V- (black)

24V DC Class 2
-
CAN_L (blue)
to 30Vdc or 49Vac. Four of the 8 channels

L
Com0 0 Shield
in each module are change-over contact NO0 1
CAN_H (white)

H
and the remaining four are normally-open NC0 2
V+ (red)

+
Com1 3

contacts. All output points are voltage- NO1 4

NC1
free contacts and are completely isolated Com2
5
6

from the CANbus. P327 modules may be NO2 7

Com3
mixed on the same bus, with other types
24V

NO3 0V

of Trio CAN I/O modules on the same

Com4 8
network to build the I/O configuration NO4 9

required for the system. NC4 10

Com5 11

Convenient disconnect terminals are used NO5

NC5
12
13
for all I/O connections. Com6 14

NO6 15

Com7 24V

CANBUS NO7 0V

The CANbus port has over voltage and

reverse polarity protection. Various
protocols can selected using the
configuration switches.

RELAY CHANNELS
Each relay channel is an independent isolated voltage free set of contacts. Channels 0, 1, 4 and 5 are
change-over contacts and channels 2, 3, 6 and 7 are normally open contacts only. Each contact is rated
at 30Vdc (24 Watts) or 49Vac (62.5 VA). Absolute maximum current for any one contact is 1A under all
conditions.
Relay contacts do not have built-in suppression so external EMC suppression components must be fitted as
required.

00SWITCHING)
USING THE RELAY IN A CIRCUIT WHERE THE RELAY WILL BE ON CONTINUOUSLY FOR LONG PERIODS (WITHOUT
CAN LEAD TO UNSTABLE CONTACTS, BECAUSE THE HEAT GENERATED BY THE COIL ITSELF WILL AFFECT
THE INSULATION, CAUSING A FILM TO DEVELOP ON THE CONTACT SURFACES. BE SURE TO USE A FAIL-SAFE CIRCUIT
DESIGN THAT PROVIDES PROTECTION AGAINST CONTACT FAILURE OR COIL BURNOUT.

4-12 I/O EXPANSION MODULES

CAN 8-Relay Module (P327)
 Hardware Reference Manual

Output N/O
Control
Signal

COM

Output N/O
Control
Signal
N/C

COM

LED INDICATORS
The green power (PWR) LED and red error (ERR) LED display the status of the CAN I/O module. The actual
status displayed will depend on the protocol selected.
The status LEDs marked 0 - 7 represent the relay channels 0 - 7 of the module. The actual output as seen by
the Motion Coordinator software will depend on the modules’ address.

CONFIGURATION SWITCHES
The switches are hidden under the display window. These can be adjusted to set the module address,
protocol and data rate.

SPECIFICATION P327
Outputs: 8 relays 30Vdc / 49Vac
Configuration: 4 NO relays and 4 change-over relays
Output Capacity: Maximum switching power per contact: 62.5 VA, 24W (dc) Max current 1 Amp.
Protection: Outputs to CAN circuit isolation, 1,500V dc.
Indicators: Individual status LED’s
Address Setting: Via DIP switches
Power Supply: 24V dc, Class 2 transformer or power source. 18 ... 29V dc / 1.5W.
Mounting: DIN rail mount
Size: 26mm wide 85mm deep 130mm high
Weight: 174g
CAN: 500kHz, Up to 128 expansion relay channels
EMC: EN 61000-6-2: 2005 Industrial Noise Immunity / EN 61000-6-4: 2007 Industrial Noise
CAN protocol: Trio CAN I/O or CANopen DS401

I/O EXPANSION MODULES 4-13

CAN 8-Relay Module (P327)
Trio Motion Technology

Controller I/O mapping

DIGITAL I/O ORDER
The controller has different sources of I/O which it has to map to IN and OP. This includes I/O from built
in I/O, module I/O and CAN I/O. All of these sources are mapped in blocks of 8, some modules have more
than 8 I/O so will take up multiple blocks. Any modules using less than 8 will consume a block of 8 and the
remainder of the block will be virtual I/O.
By default built in controller I/O is mapped first followed by module I/O then CAN I/O. MODULE _ IO _
MODE is used to configure a different order or to disable the module I/O. When mapping the blocks of
separate input and outputs the controller will overlap any inputs and outputs. Please note that bi-directional
I/O cannot be split so can cause gaps in the I/O map.
All supported CAN protocols are mapped into the CAN section. For example a system with a MC464, FlexAxis
8, 1 CAN input and 1 CAN output module would be mapped as follows.
I/O source Inputs Outputs I/O
MC464 I/O 0-7 8-15
FlexAxis 8 16-19 20-23
CAN address 0 24-40 24-40

The FlexAxis is mapped to one block of I/O, as only 4 pins are bi-directional, outputs 16-19 are now virtual.
A different system using a MC464, EtherCAT, 1 CAN input and 1 CAN output module would be mapped as
follows.
I/O source Inputs Outputs I/O
MC464 I/O 0-7 8-15
Ethercat 16-23
CAN address 0 24-40 16-23

You can see that the EtherCAT inputs and CAN Output module are mapped to the same numbers. It is
important to remember that the IN and OP are separate unless they are combined in a bi-directional I/O
point.

ANALOGUE I/O ORDER

Up to 32 CAN analogue inputs can be added to the system these are mapped to AIN in order of the module
address. Analogue inputs are mapped as follows:
AIN Source
0 to 31 CAN analogue inputs
32-33 Built in analogue inputs
33+ Module analogue inputs

Analogue outputs are mapped to AOUT in order of the module address starting at 0.

4-14 I/O EXPANSION MODULES

Controller I/O mapping
 Hardware Reference Manual

TrioCANv2 Protocol
GENERAL DESCRIPTION
The MC4xx range controllers by default will use TrioCANv2 protocol, this has various enhancements of
previous versions of TrioCAN. The protocol allows for a combination of current and older CAN I/O modules
though not all features of TrioCANv2 will be available if a P325, P315 or P316 module is used.
Enhancements to the protocol allow for the following:
• Increase the number of CAN inputs to 256
• Increase the maximum number of CAN outputs to 256
• Increase the total sum of Inputs and Outputs to 512 (bi-directional I/O counts as 1 input and 1
output)
• Allow new analogue output functionality
• Recognise digital input modules
• Recognise digital output modules
• Allow up to 32 digital modules by overlapping input and output addresses.
• Allow expansion module registration inputs and hardware PSWITCH outputs to be used as I/O
• Improved error handling – any error on the network is reported to the controller

If you need to revert to TrioCANv1 protocol you can set CANIO _ MODE and MODULE _ IO _ MODE.
When using CANIO _ MODE=1 all digital input, output and relay modules are treated as bi-directional
I/O modules.

These changes will impact how you address the CAN I/O modules and how the I/O is mapped into the
controller.

PROTOCOL SELECTION
Trio Mode CANopen Mode

1 1
2 2
4 Address 4 Address
8 8
16 16
32 32 DR B0
PR (Trio Mode) PR (CANopen Mode)
DR N/A DR DR B1

TrioCAN (all versions) can be selected on the CAN I/O modules using the protocol (PR) switch. When the
controller initialises the CAN network it will tell the module to either use TrioCANv1 or TrioCANv2. It is
recommended to leave the controller using TrioCANv2 however TrioCANv1 can be manually set in the
controller using CANIO _ MODE.

The data rate is fixed to 500kHz for TrioCANv2 Protocol, the data rate (DR) switch has no function.
It is not possibleCANopen
Trio Mode to mix the CAN I/O modules which are running the TrioCANv2 protocol with DeviceNet
Mode
equipment or CANopen devices on the same network
1 1
2 2
4 4 Address I/O EXPANSION MODULES 4-15
8 Address 8 Controller I/O mapping
16 16
32 32 DR B0
Trio Motion Technology

CONTROLLER SETUP
All Motion Coordinators are configured by default to look for a TrioCAN network, MC4xx range controllers
will automatically use TrioCANv2 if the modules on the network all support it. To force the controller to
always use TrioCANv1 you can set CANIO _ MODE.
To automatically search the CAN bus for TrioCAN modules on power up, CANIO _ ADDRESS must be set to 32.
There is no need to set this as it is the default value.
There are various system parameters available on the controller to check and change the status of the
TrioCAN network, these include CANIO _ STATUS, CANIO _ ADDRESS, CANIO _ ENABLE and CANIO _
MODE.
When choosing which I/O devices should be connected to which channels the following points need to be
considered:
• Inputs 0 - 63 ONLY are available for use with system parameters which specify an input, such as
FWD _ IN, REV _ IN, DATUM _ IN etc.
• The built-in I/O channels have the fastest operation <1mS
• CAN input modules with addresses 0-3 have the next fastest operation up to 2mS
• The remaining CAN input modules operate up to 20mS
• Outputs are set on demand.

UPDATE RATES

DIGITAL I/O
The digital I/O are cascaded through the modules, this means that lower address modules have a higher
update rate.

Function Update rate

Inputs address 0-3 2ms, no more than 50ms when state unchanged
Inputs address 4-11 10ms, no more than 50ms when state unchanged
Inputs address 12-15 20ms, no more than 50ms when state unchanged
Output address 0-3 5ms or on change of state
Output address 4-7 6ms
Output address 8-11 6ms (offset by 2ms from outputs address 4-7)
Output address 12-15 6ms (offset by 4ms from outputs address 4-7)

ANALOGUE I/O
Analogue inputs have a standard operation which is enabled by default. Some applications require higher
speed updates for example when using the analogue inputs as feedback into a servo loop.

Function Update rate

Analogue Inputs, standard mode 10ms
Analogue Inputs fast mode 2ms

4-16 I/O EXPANSION MODULES

Controller I/O mapping
 Hardware Reference Manual

Function Update rate

Analogue outputs On state change

Standard operation is selected by default by the analogue module on power up. Fast operation has to be
selected by executing the following BASIC in a configuration or startup program:
CAN(-1, 5, 4, $50, 8 ,1)
CAN(-1, 7, 4, $04, module_address, $00, $20, $00, $00, $00, $01)
DIGITAL CAN I/O ADDRESSING
To enable up to 32 modules on the TrioCANv2 network and up to 512 I/O points Inputs and Outputs are
addressed separately. There are 16 addresses (0-15) available for input modules and 16 addresses (0-15)
available for outputs. Bi-directional modules take the same address from both the input and output range.
There must be no gaps in the input address range, but gaps are allowed in the output address range.

Relay modules are addressed as per digital outputs, they use a block of 16 outputs even though they
only have 8.

The total number of digital outputs, digital inputs and total digital I/O are reported by the system
parameters NIN, NOP, NIO. The digital configuration is also reported in the startup message.

It is important to remember that IN and OP are only connected if you are using a bi-directional
module. When using Input and Output modules with the same address IN(x) and OP(x) can be
physically different I/O. If you need to read the state of an output you should use READ _ OP(x).

For example a system with 5 CAN 16-Input, 2 16-IO, 7 16-Output and one Relay module could be mapped as
per the table below. The CAN I/O start at 16 as the controller has 16 I/O built-in and no module I/O. The
start position will move depending on the number of built in I/O and module I/O.

I/O source Inputs Outputs Relay I/O

Controller I/O 0-7 8-15
CAN address 0 16-31
CAN address 1 32-47
CAN address 2 48-63 48-63
CAN address 3 64-79 64-79
CAN address 4 80-95 80-95
CAN address 5 96-111 96-111
CAN address 6 112-127 112-127
CAN address 7 128-135 (136-143
virtual)
CAN address 8 144-159
CAN address 9 160-175

You can see from this chart how the input and output modules are allowed to have overlapping addresses.
Bi-directional I/O modules must have a unique address. The relay module only has 8 outputs but uses 1 bank

I/O EXPANSION MODULES 4-17

Controller I/O mapping
Trio Motion Technology

of 16 outputs.

00TRIOCAN (V1) TREATS ALL MODULES AS BI-DIRECTIONAL I/O AND SO EVERY MODULE MUST HAVE A UNIQUE ADDRESS.
THE TOTAL NUMBER OF I/O POINTS IS LIMITED TO 256 AND THE NETWORK IS LIMITED TO 15 MODULES.

ANALOGUE I/O ADDRESSING

The address switches on the analogue I/O modules will affect the order in which the I/O is mapped into AIN
and AOUT. The first analogue module should be address 16 the second to 17 etc, Trio Protocol
there should be no gaps in the analogue I/O addressing. The addresses are set as a Address = 16 CANope
binary sum so for address 17 both switch 16 and 1 must be ON. Analogue Inputs 0..7 Addr

The total number of analogue outputs, analogue inputs and total analogue I/O are 1 1
reported by the system parameters NAOUT, NAIN, NAIO. The analogue configuration 2 2
is also reported in the startup message. 4 4
8 8
The analogue I/O are addressed as per the following table. 16 16
32
Address AIN AOUT PR TRIO CANopen
16 0-7 0-3 DR NA DR

17 8-15 4-7
18 16-23 8-11
19 24-31 12-15

ERROR CODES
When there is a problem with the TrioCANv2 network an error code is displayed on the LED’s. All CAN I/O
modules have a power LED (PWR) and an error LED (ERR). The power led should be illuminated while the 24V
is applied to the CAN connector and the error LED will turn ON when there is an error. The actual error can
be read from the status LED’s

You can detect which modules have errors by reading CANIO _ STATUS in the motion coordinator

DIGITAL INPUT, OUTPUT AND I/O MODULES

When there is an error the left bank of LED’s will flash and the ERR LED will be ON. The error code will be
displayed as a binary number on LED’s 8-11

4-18 I/O EXPANSION MODULES

Controller I/O mapping
 Hardware Reference Manual

PWR ERR

0 8
Error Code
1 9
displayed on
2 10 IO 8 .. 11
Whole Bank 3 11
Flashing
4 12
5 13
6 14
7 15

Relay module and Analogue I/O module

When there is an error the error code will be displayed as a binary number on LED’s 0-3 and the ERR LED will
be ON.

PWR ERR PWR ERR

0 0 2
1 1 3
2
3
P327 P326

I/O EXPANSION MODULES 4-19

Controller I/O mapping
Trio Motion Technology

ERROR CODES
Once the binary number has been read from the CAN I/O LED’s then the error is as per the table below.
Please note that only the error LED's are shown.

Code P317, P318, P319, P327 LEDs P326 LEDs Error Description
1 Invalid Protocol

2 Invalid Module Address

3 Invalid Data Rate

4 Uninitialised

5 Duplicate Address

6 Start Pending

7 System Shutdown

8 Unknown Poll

9 Poll Not Implemented

10 CAN Error

11 Receive Data Timeout

TROUBLESHOOTING
If the network configuration is incorrect 2 indications will be seen: The CAN module will indicate an error
and the Motion Coordinator will report the wrong number of digital or analogue I/O.
If the error is ‘uninitialised’ then please check:
• Terminating 120 Ohm Network Resistors fitted?
• 24Volt Power to Network?
• Are the addresses correct?

4-20 I/O EXPANSION MODULES

Controller I/O mapping
 Hardware Reference Manual

• Have you power cycled the I/O modules after setting the address?
• Cable used is the correct CAN bus specification?
• Is CANIO _ ADDRESS=32?
If the network is OK but you are having I/O problems please check:
• 24Volt Power to each I/O bank required?
• You are using the correct I/O in the controller?
• MODULE _ IO _ MODE is set as you expect?
• CANIO _ MODE is set as you expect?
If the network stops during use please check:
• Terminating 120 Ohm Network Resistors fitted?
• The CAN cable is shielded with the shields correctly connected to earth
Cable used is the correct CAN bus specification?
• Connectors/ wires are not loose

CANopen DS401
GENERAL DESCRIPTION
The CAN modules can support CANopen DS401 so that they can be used with another manufacturers master
or with a Trio Motion Coordinator and another manufacturer’s module on the network.

PROTOCOL SELECTION
CANopen is selected on the CAN I/O modules using the protocol (PR) switch on the module.

Trio Mode CANopen Mode

1 1
2 2
4 Address 4 Address
8 8
16 16
32 32 DR B0
PR (Trio Mode) PR (CANopen Mode)
DR N/A DR DR B1

CANopen allows the use of different data rates, this is selected by setting the switches marked 32 and DR.
Switch 32 sets bit 0 of the data rate and DR sets bit 1.
(DR B0) DR (DR B1) Data Rate
0Trio Mode 0 1Mb Mode
CANopen
0 1 500KB
1 1
2 2
4 4 Address
8 Address 8
16 16
I/O EXPANSION MODULES 4-21
32 32
CANopen DS401
DR B0
PR (Trio Mode) PR (CANopen Mode)
Trio Motion Technology

1 0 250KB
1 1 125KB

CONTROLLER SETUP
To use CANopen DS402 an initialisation program must be run that configures the network. Examples of this
program can be found on the Trio website. Once The CANopen network is configured then you can use the
CAN I/O with the standard IN, OP, READ _ OP, AIN and AOUT *commands as normal.
(*Future software release)

MODULE ADDRESSING
Each CAN I/O module becomes a node on the CANopen network. The address switches are used to assign a
unique node number to the module.

ERROR CODES
The power (PWR) and error (ERR) LEDs display the modules current state as per the tables below.

LED STATE DEFINITIONS

LED state Description
LED on The LED constantly on.
LED off The LED constantly off.
LED flickering The LED flashes on and off with a frequency of
approximately 10 Hz.
LED blinking The LED flashes on and off with a frequency of
approximately 2.5Hz: on for approximately 200ms followed
by off for approximately 200ms.
LED single flash The LED indicates one short flash.
LED double flash The LED indicates a sequence of two short flashes.
LED triple flash The LED indicate a sequence of three short flashes.
LED quadruple The LED indicates a sequence of four short flashes.
flash

PWR LED ERROR CODE

The PWR LED is used as the ‘CANopen run LED’ as recommended by CANopen. Its state displays the
following:

CAN Run LED State Description

Flickering AutoBitrate/LSS The auto-bitrate detection is in progress
or LSS services are in progress (alternately
flickering with error LED)

4-22 I/O EXPANSION MODULES

CANopen DS401
 Hardware Reference Manual

CAN Run LED State Description

Blinking PRE-OPERATIONAL The device is in state PRE-OPERATIONAL
Single flash STOPPED The device is in state STOPPED
Double flash Reserved for
further use
Triple flash Program/ A software download is running on the
Firmware device
download
On OPERATIONAL The device is in state OPERATIONAL

ERR LED ERROR CODE

The ERR LED is used as the ‘CANopen error LED’ as recommended by CANopen. Its state displays the
following:

ERR LED State Description

Off No error The device is in working condition
Flickering AutoBitrate/LSS The auto-bitrate detection is in progress
or LSS services are in progress (alternately
flickering with run LED)
Blinking Invalid General configuration error
Configuration
Single flash Warning limit At least one of the error counters of the
reached CAN controller has reached or exceeded the
warning level (too many error frames)
Double flash Error control A guard event (NMT-slave or NMTmaster) or
event a heartbeat event (heartbeat consumer) has
occurred
Triple flash Sync error The sync message has not been received
within the configured communication cycle
period time out.
Quadruple Event-timer error An expected PDO has not been received
flash before the event-timer elapsed
On Bus off The CAN controller is bus off

I/O EXPANSION MODULES 4-23

CANopen DS401
INSTALLATION 5
Trio Motion Technology

5-2 INSTALLATION

 Hardware Reference Manual

Installing Hardware

Installing the MC464

PACKAGING
The Motion Coordinator MC464 is designed to be mounted on a DIN rail or, by use of optional mounting clips,
it can be screwed to a backplate.
A cast metal chassis provides mechanical stability and a reliable earth connection to aid EMC immunity.
The rugged plastic case includes ventilation holes, top and bottom, and a removable cover to access the
memory battery.

EXPANDABLE DESIGN
System expansion is done by adding either single or double height modules. These are clipped to the MC464
and secured by a bolt which also acts as the earth connection between the MC464 and the module

34mm

128mm

184mm

201mm

56mm 155mm

MC464 Dimensions

INSTALLATION 5-3
Installing the MC464
Trio Motion Technology

ITEMS SUPPLIED WITH THE MC464

CONNECTORS:
• 9 way D-Type plug
• Quick connect I/O connector (30 way)

PANEL MOUNTING SET:

• 2 x Mounting bracket
• 1 x M3 x 10mm Countersunk screw
• 1 x M3 x 6mm Countersunk screw
• Quick start guide
• CD ROM with software and documentation

MOUNTING MC464

GENERAL
The MC464 must be mounted vertically and should not be subjected to mechanical loading. Care must be
taken to ensure that there is a free flow of air vertically around the MC464.

DIN RAIL
Pull down the clip to allow the MC464 to be mounted on a single DIN rail. Push up the clip to lock it to the
rail.

5-4 INSTALLATION
Installing the MC464
 Hardware Reference Manual

Mounting Clips
Remove the 2 mounting clips from their packaging and insert one at the top rear of the case, by fitting the
small tab into the rectangular slot and fix with the M3 x 6mm screw provided.
The second clip fits to the bottom of the case rear. Line up the DIN rail lever with the hole and slot in the
metal chassis, fit the clip into the slot and fix it with the M3 x 10mm screw.

Environmental Considerations
The MC464 should not be handled whilst the 24 Volt power is connected.

00ADDITIONAL
ENSURE THAT THE AREA AROUND THE VENTILATION HOLES AT THE TOP AND BOTTOM OF THE MC464 AND ANY
MODULES ARE KEPT CLEAR. AVOID VIOLENT SHOCKS TO, OF VIBRATION OF, THE MC464, SYSTEM AND
MODULES WHILST IN USE OR STORAGE.

IP RATING: IP 20
The MC464 and add-on modules are protected against solid objects intruding into the case and against
humidity levels that do not induce condensation to occur.

INSTALLATION 5-5
Installing the MC464
Trio Motion Technology

Instaling the MC405 / MC403

PACKAGING
Motion
The 56mm 56mmCoordinator MC405 / 155mm
MC403 is designed to be mounted on a DIN rail or optionally, using the 3
155mm
mounting holes, it can be screwed to a back-plate.
A cast metal chassis provides superb mechanical stability and a dedicated earth connection point to aid EMC
immunity.
The rugged plastic case has conveniently placed access ports for the I/O, encoder inputs, pulse outputs,
Ethernet and serial connections. A slot is provided for the optional Micro SD card.
171mm171mm
6mm 6mm

122mm122mm

186mm186mm
26mm 26mm
MC405 Dimensions

120mm120mm
6mm 6mm

122mm
122mm

135mm
135mm
MC403 Dimensions

5-6 INSTALLATION
Instaling the MC405 / MC403
 Hardware Reference Manual

ITEMS SUPPLIED WITH THE MC405 / MC403

CONNECTORS
• 3 or 5 x 9 way D-Type plug and shell
• 1 x 5 way quick dis-connect screw terminal block
• 8 way and 14 way quick dis-connect screw terminal block (MC403)
• 2 x 10 way and 1 x 16 way quick dis-connect screw terminal block (MC405)
• Quick start guide
• CD ROM with software and documentation

MOUNTING MC405 / MC403

GENERAL
The MC405 / MC403 must be mounted vertically and should not be subjected to mechanical loading. Care
must be taken to ensure that there is a free flow of air vertically around the MC405/MC403.

DIN RAIL
Pull down the clip to allow the MC405 / MC403 to be mounted on a single DIN rail. Release the spring-loaded
clip to lock it to the rail.

SCREW MOUNTING
Drill and tap 3 mounting holes using the dimensions shown below. Use 3 x M4 pan-head screws, (not
supplied) of a suitable length, to fix the MC405 / MC403 to the panel. Screw the upper 2 screws into the
panel, leaving the screw head between 4 and 6 mm above the panel surface. Slide the MC405/MC403 up on
to the 2 screws and insert the remaining lower screw. Tighten all 3 screws.

ENVIRONMENTAL CONSIDERATIONS
The MC403 / MC405 should not be handled whilst the 24 Volt power is connected.

00ENSURE THAT THE AREA AROUND THE TOP AND BOTTOM OF THE MC405 / MC403 AND ANY ADDITIONAL I/O MODULES
IS KEPT CLEAR. AVOID VIOLENT SHOCKS TO, OF VIBRATION OF, THE MC405 / MC403, SYSTEM AND MODULES WHILST
IN USE OR STORAGE.

IP RATING: IP 20
The MC405 / MC403 are protected against solid objects intruding into the case and against humidity levels
that do not induce condensation to occur.

INSTALLATION 5-7
Instaling the MC405 / MC403
Trio Motion Technology

Installing the CAN I/O Modules

PACKAGING
The CAN I/O modules are designed to be mounted on a DIN rail.
The rugged plastic case includes ventilation holes, top and bottom.
The dimensions are shown below.

26mm
85mm

19mm

33mm

130mm

CAN Module Dimensions

ITEMS SUPPLIED WITH CAN I/O MODULES

• 5 way CAN connector
• 2x 10 way I/O connectors
• 2x 120 Ohm terminating resistors
• Quick start guide

MOUNTING CAN I/O MODULES

The CAN I/O modules should be mounted vertically and should not be subjected to mechanical loading. Care
must be taken to ensure that there is a free flow of air vertically around the CAN I/O module.
To mount pull down the sprung loaded clip, slot over the DIN rail and release the clip to lock the module to
the rail.

5-8 INSTALLATION
Installing the CAN I/O Modules
 Hardware Reference Manual

ENVIRONMENTAL CONSIDERATIONS
The CAN I/O should not be handled whilst the 24 Volt power is connected.

00ENSURE THAT THE AREA AROUND THE VENTILATION HOLES AT THE TOP AND BOTTOM OF THE CAN I/O ARE KEPT
CLEAR. AVOID VIOLENT SHOCKS TO, OF VIBRATION OF, THE CAN I/O MODULES WHILST IN USE OR STORAGE.

IP RATING: IP 20

BUS WIRING
The CAN 16-I/O Modules and the Motion 120Ω
Terminating
Coordinator are connected together on Resistor
a CAN network running at 500kHz. The 0
1
2
3
8
9
10
11

network is of a linear bus topology. That is

4 12
5 ENABLE 13
6 14
7 15

the devices are daisy-chained together with

MC 464

spurs from the chain. The total length is 101011

allowed to be up to 100m, with drop lines or

A

spurs of up to 6m in length. At both ends of B

the network, 120 Ohm terminating resistors

are required between the CAN_H and CAN_L
connections. The resistor should be 1/4 120Ω
watt, 1% metal film. Terminating
Resistor
The cable required consists of:
• Blue/White 24AWG data twisted 24V Power Supply
to Network
pair
• Red/Black 22AWG DC power twisted
pair
• Screen
A suitable type is Belden 3084A.
The CAN 16-I/O modules are powered from
the network. The 24 Volts supply for the
network must be externally connected. The Motion Coordinator does NOT provide the network power. In
many installations the power supply for the Motion Coordinator will also provide the network power.

It is recommended that you use a separate power supply from that used to power the I/O to power
the network as switching noise from the I/O devices may be carried into the network.

INSTALLATION 5-9
Installing the CAN I/O Modules
EMC 6
Trio Motion Technology

6-2 EMC

 Hardware Reference Manual

EMC Considerations
Most pieces of electrical equipment will emit noise either by radiated emissions or conducted emissions
along the connecting wires. This noise can cause interference with other equipment near-by which could
lead to that equipment malfunctioning. These sort of problems can usually be avoided by careful wiring and
following a few basic rules.
• Mount noise generators such as contactors, solenoid coils and relays as far away as possible from the
Motion Coordinator.
• Where possible use solid-state contactors and relays.
• Fit suppressors across coils and contacts.
• Route heavy current power and motor cables away from signal and data cables.
• Ensure all the modules have a secure earth connection.
• Where screened cables are used terminate the screen with a 360 degree termination rather than
a “pig-tail”. Connect both ends of the screen to earth. The screening should be continuous, even
where the cable passes through a cabinet wall or connector.
These are just very general guidelines and for more specific advice on specific controllers, see the
installation requirements later in this chapter. The consideration of EMC implications is more important
than ever since the introduction of the EC EMC directive which makes it a legal requirement for the supplier
of a product to the end customer to ensure that it does not cause interference with other equipment and
that it is not itself susceptible to interference from other equipment.

EMC 6-3

Trio Motion Technology

EMC Earth - MC464

Best EMC performance is obtained when the MC464 is attached to an earthed, unpainted metal panel using
the two mounting clips. When screwed directly to the panel, the clips provide the required EMC earth
connection.
If the MC464 is mounted on a DIN rail, then an additional EMC earth must be attached as shown below. Use
a flat braided conductor, minimum width; 4mm. Connect to the earthed metal panel as close to the MC464
as possible. Do not use circular cross-section wire. Do not run the conductor to a central star point.

MC464 Earth Braid

EMC Earth – MC405 / MC403

Best EMC performance is obtained when the MC405/MC403 is attached to an earthed, unpainted metal panel
using three mounting screws. When screwed directly to the panel, the metal chassis provides the required
EMC earth connection.
If the MC405/MC403 is mounted on a DIN rail, then an additional EMC earth must be attached as shown
below. Use a flat braided conductor, minimum width 4mm. Connect to the earthed metal panel as close to
the Motion Coordinator as possible. Do not use circular cross-section wire. Do not run the conductor to a
central star point.

6-4 EMC
EMC Earth - MC464
 Hardware Reference Manual

MC403 Earth Braid. MC405 is Similar

EMC Earth - CAN I/O Modules

Best EMC performance is obtained when the CAN I/O modules have the screen of the CAN cable connected
to the shield pin of the 5 way connector. Both ends of the CAN cable must be connected to an earth point
on the back panel of the cabinet. The connection must be as close as possible to the last I/O module. Use
a flat braided conductor, minimum width 4mm. Do not use circular cross-section wire. Do not run the
conductor to a central star point.

MC403 and CAN I/O Modules

EMC 6-5
EMC Earth - CAN I/O Modules
Trio Motion Technology

Cable Shields
All encoder cables must be terminated in the correct D-type plug,
either 9 way or 15 way as required. For best EMC performance use
a metal or metalised plastic cover for the D-type connector. Clamp
the screen of the encoder cable where it enters the connector
cover. Do not make a “pig-tail” connection from the screen to the
plug cover. When plugging the D-type into the MC464, use the jack-
screws to firmly attach the D-type plug to the socket on the MC464
or its axis module.

Both ends of the encoder cable’s screen must be connected using a 360 degree contact and not a pig-
tail connection.

The 0V must be connected separately from the screen. Make sure that encoder cables are specified
with one extra wire to carry the 0V.

All serial cables must be terminated in an 8-pin mini-DIN connector. For best EMC performance, clamp the
screen of the serial cable where it enters SCREEN CONNECTED INTERNALLY SCREEN CLAMPED TO EARTH
the connector cover. Do not make a TO METAL SHIELD

“pig-tail” connection from the screen to

the plug cover.

Both ends of the serial cable’s screen must be connected using a 360 degree contact and not a pig-tail
connection.
The 0V must be connected separately from the screen. Make sure that serial cables are specified with
one extra wire to carry the 0V. This applies to RS422/RS485 serial connections as well as RS232.

Surge protection
This section applies to all devices including Motion Coordinators, CAN IO modules and HMIs. The surge
protection described is to enable the system components to comply with EMC Generic Immunity for
industrial environments standard IEC 61000-6-2:2005.

SINGLE POWER SUPPLY

Where the device is supplied with 24V dc from one dedicated 24V power source and the connecting cable is
less than 3 metres, there is no need for a separate surge protection device.

6-6 EMC
Cable Shields
 Hardware Reference Manual

MC464

24V dc
POWER SUPPLY

AC
SUPPLY
< 3M LONG

Motion Coordinator with dedicated power source

DISTRIBUTED POWER SUPPLY

If the device is connected to a distributed power supply or the cable length between the power source and
the device is longer than 3 metres, then a surge protection device must be fitted to comply with the CE EMC
directive.

MC464 MC464 MC464

I/O MODULES

SURGE SURGE SURGE SURGE

PROTECTOR PROTECTOR PROTECTOR PROTECTOR

AC
SUPPLY

24V dc
POWER SUPPLY

Distributed power supply with surge protection

RECOMMENDED PROTECTION DEVICE

If a surge protector is required, a device conforming to the specification below must be installed as close as
possible to the 24V power input requiring protection. In addition, the MC405 and MC403 require 2 x 220 µF
electrolytic capacitors to complete the protection circuit.

EMC 6-7
Surge protection
Trio Motion Technology

Protection device - Minimum specification

Operating Voltage 24V dc
Suppression Begins:
Stage Two 30V
Stage Three 35V
Max. Clamp Volts for transients on the line:
Stage Two 65V
Stage Three 77V
Surge Current (8/20mSec Pulse)
+ to - 9000A
+ to Earth 4000A
- to Earth 4000A
Surge Energy (2mSec Pulse)
+ to - 94 Joules
+ to Earth 44 Joules
- to Earth 44 Joules
Response Time <5 nsec
Resistance to Earth:
Max Over-Voltage 0.01 Ω
Operating Voltage > 1 MΩ

A suggested device is the DC Surge protector TSP-WG6-24VDC-10A-01 from Axiomatic. This protection device
is easy to implement with Trio products and is DIN rail mountable. The DC Surge protector and Trio product
must be connected to EARTH to make the protection effective.

MC464 AND IO DEVICES

24V
24V

SURGE 0V MC464
0V PROTECTOR
EARTH
EARTH

Surge protection device

24V
24V
220uf
SURGE 63V 0V MC403
6-80V EMC PROTECTOR MC405
Surge protection 220uf
EARTH
EARTH
63V
 Hardware Reference Manual

MC403/MC405

24V
24V
220uf
SURGE 63V 0V MC403
0V PROTECTOR MC405
EARTH
EARTH 220uf
63V

Surge protection device

If the I/O power is from a different power source to the main device power, then the I/O power must
also have a surge protector fitted.

Background to EMC Directive

Since 1st January 1996 all suppliers of electrical equipment to end users must ensure that their product
complies with the 89/336/EEC Electromagnetic Compatibility directive. The essential protection
requirements of this directive are:
Equipment must be constructed to ensure that any electromagnetic disturbance it generates allows radio
and telecommunications equipment and other apparatus to function as intended.
Equipment must be constructed with an inherent level of immunity to externally generated electromagnetic
disturbances.
Suppliers of equipment that falls within the scope of this directive must show “due diligence” in ensuring
compliance. Trio has achieved this by having products that it considers to be within the scope of the
directive tested at an independent test house.
As products comply with the general protection requirements of the directive they can be marked with the
CE mark to show compliance with this and any other relevant directives. At the time of writing this manual
the only applicable directive is the EMC directive. The low voltage directive (LVD) which took effect from
1st January 1997 does not apply to current Trio products as they are all powered from 24V which is below
the voltage range that the LVD applies to.
Just because a system is made up of CE marked products does not necessarily mean that the completed
system is compliant. The components in the system must be connected together as specified by the
manufacturer and even then it is possible for some interaction between different components to cause
problems but obviously it is a step in the right direction if all components are CE marked.

TESTING STANDARDS
For the purposes of testing, a typical system configuration was chosen because of the modular nature of the
Motion Coordinator products. Full details of this and copies of test certificates can be supplied by Trio if
required.
For each typical system configuration testing was carried out to the following standards:

EMC 6-9
Background to EMC Directive
Trio Motion Technology

EMISSIONS - BS EN61000-6-4 : 2007.

The MC4 range of products conform to the Class A limits.

IMMUNITY - BS EN61000-6-2 : 2005.

This standard sets limits for immunity in an industrial environment and is a far more rigorous test than part
1 of the standard.

REQUIREMENTS FOR EMC CONFORMANCE

00WHEN THE TRIO PRODUCTS ARE TESTED THEY ARE WIRED IN A TYPICAL SYSTEM CONFIGURATION. THE WIRING
PRACTICES USED IN THIS TEST SYSTEM MUST BE FOLLOWED TO ENSURE THE TRIO PRODUCTS ARE COMPLIANT WITHIN
THE COMPLETED SYSTEM.

A summary of the guidelines follows:

The MC464 modules must be earthed via the main chassis of the MC4 range using the lower panel mounting
clip or an earth strap. This must be done even if DIN rail mounted.
If any I/O lines are not to be used they should be left unconnected rather than being taken to a terminal
block, for example, as lengths of unterminated cable hanging from an I/O port can act as an antenna for
noise.
Screened cables MUST be used for encoder, stepper and registration input feedback signals and for the
demand voltage from the controller to the servo amplifier if relevant. The demand voltage wiring must be
less than 1m long and preferably as short as possible. The screen must be connected to earth at both ends.
Termination of the screen should be made in a 360 degree connection to a metallised connector shell. If the
connection is to a screw terminal e.g. demand voltage or registration input the screen can be terminated
with a short pig-tail to earth.
Ethernet cables should be shielded and as a minimum, meet the TIA Cat 5e requirements.
Connection to the serial ports should be made with a fully screened cable.
As well as following these guidelines, any installation instructions for other products in the system must be
observed.

6-10 EMC
Background to EMC Directive
Hardware Reference Manual

EMC 6-11

INDEX
Trio Motion Technology

ii INDEX

 Hardware Reference Manual

Index

A Sercos Interface (P872) ... 3-7

SLM Interface (P873) ... 3-9
Axis Positioning Functions ... 2-4, 2-13

F
B Feature Summary: Euro408 / 404 ... 2-39
Backplane Connector: Euro408 / 404 ... 2-32 Feature Summary: MC403 ... 2-19
Battery: MC464 ... 2-8 Feature Summary: MC405 ... 2-30
Feature Summary: MC464 ... 2-11

C I
Cable Shields ... 6-6
Communications: Euro408 / 404 ... 2-31 Input / Output Modules
Communications: MC403 ... 2-12 CAN 8-Relay Module (P327) ... 4-12
Communications: MC405 ... 2-22 CAN 16-Input Module (P318) ... 4-6
Communications: MC464 ... 2-4 CAN 16-I/O Module (P319) ... 4-7
Connections to the Euro408 / 404 ... 2-32 CAN 16-Output Module (P317) ... 4-4
Connections to the MC403 ... 2-13 CAN Analogue I/O Module (P326) ... 4-10
Connections to the MC405 ... 2-23 Installation of CAN I/O Modules ... 5-8
Connections to the MC464 ... 2-5 Installation of MC405 / MC403 ... 5-6
Controller I/O mapping ... 4-14 Installation of MC464 ... 5-3
Introduction to the MC4xx Range ... 1-3
Introduction to Typical System Configuration ... 1-3
D I/O Capability ... 2-3, 2-12, 2-22
I/O Modules: General Description ... 4-3
Display: Backlit: MC405 ... 2-29
Display: Backlit MC464 ... 2-9
Display: LED: MC403 ... 2-18
M
Motion Coordinator Euro404 /408 ... 2-31
E Motion Coordinator MC403 ... 2-12
Motion Coordinator MC405 ... 2-22
EMC Conformance: requirements ... 6-10
EMC considerations ... 6-3 Motion Coordinator MC464 ... 2-3
EMC Directive: background ... 6-9 Mounting: CAN I/O Modules ... 5-8
EMC Earth - CAN I/O Modules ... 6-5 Mounting: MC403 / MC405 ... 5-7
EMC Earth – MC405 / MC403 ... 6-4 Mounting: MC464 ... 5-4
EMC Earth - MC464 ... 6-4
EMC Testing Standards ... 6-9
Expansion Modules MC464 P
Anybus-CC Module (P875 ... 3-15 Product Code: I/O Modules ... 4-3
Assembly ... 3-3 Protocol: CANopen DS401 ... 4-21
EtherCAT Interface (P876) ... 3-14 Protocol: TrioCANv2 ... 4-15
Fitting ... 3-4
FlexAxis Interface (P874 / P879) ... 3-11
RTEX Interface (P871) ... 3-5 R
INDEX iii

Trio Motion Technology

Removable Storage: Euro404 /408 ... 2-31

Removable Storage: MC403 ... 2-13
Removable Storage: MC405 ... 2-23
Removable Storage: MC464 ... 2-4

S
Serial Connections: Euro408 / 404 ... 2-38
Serial Connections: MC403 ... 2-14
Serial Connections: MC405 ... 2-24
Serial Connections: MC464 ... 2-5
SLOT Numbers ... 3-3
Surge protection ... 6-6

iv INDEX

Hardware Reference Manual

INDEX v