Estun Trio MC404-Z User manual

USER MANUAL
MC404-Z
4 AXIS MOTION COORDINATOR

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About this Manual
Purpose
This manual provides the information required for the Selection, Wiring, Connection, Setup,
Operation and Functions of the MC404-Z Motion Coordinator.
Please read and understand this manual to ensure correct usage of the product.
Terms
Terms that may be used in this manual are defined as follows.
Term
Meaning
Axis
A software control that operates a Servo or Stepper Motor.
Drive
A Servo or Stepper Drive, which is used for controlling the Motor.
Servo System
A Servo Control System that includes a Motor, a Drive, a host controller (Motion
Coordinator) and peripheral devices.
WDOG ON
Closing a solid-state relay to signal that the Drives may be Enabled.
WDOG OFF
Open the solid-state relay to signal that the Drives must be Disabled.
Motion Perfect
The PC Tool for commissioning and programming the Trio product suite.
Pulse+Direction
An electronic output from the Motion Coordinator that produces one pulse per step
of the motor position, with a second output to signal the direction of motion.

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Revision History
Date
Version
Revised Contents
10 Nov 2020
1.00
Draft
12 Nov 2020
1.01
Update 1 –minor edits
27 Nov 2020
1.02
Update 2 –added EMC section and panel mount dimensions
22 Dec 2020
1.03
Updated product comparison table
28 May 2021
1.04
Added AOUT and absolute encoder information to specifications
28 Jun 2021
1.05
New section for Firmware Recovery procedure

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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 MC404-Z.
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 Motion Technology Ltd.
cannot be held responsible for any malfunctions or loss of data as a result.
Copyright (C) 2020-21 Trio Motion Technology Ltd.
All Rights Reserved
UK
Trio Motion Technology Ltd.
Phone: [phone]
USA
Trio Motion Technology LLC.
Phone: + 1 724 472 4100
CHINA
Trio Shanghai
Tel: [phone]
INDIA
Trio India
Phone: [phone]

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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.
Users must ensure that in all cases of normal operation, controller malfunction, or
unexpected behaviour, the safety of operators, programmers or any other person is totally
ensured.

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Contents
Revision History ............................................................................................2
User Manual MC404-Z......................................................................................7
Overview .................................................................................................7
Programming.............................................................................................7
I/O Capability............................................................................................7
Communications.........................................................................................8
IP Address reset .........................................................................................8
Removable storage......................................................................................8
Axis positioning functions ..............................................................................8
LED indicators ...........................................................................................9
Connections to the MC404-Z...........................................................................9
Serial connections ....................................................................................9
CANbus connections..................................................................................9
Amplifier enable (Watchdog) relay output ..................................................... 10
Analogue I/O ........................................................................................ 10
Axis ports ............................................................................................ 10
Registration ......................................................................................... 12
I/O connector 1..................................................................................... 12
I/O connector 2..................................................................................... 12
Auxiliary connector ................................................................................ 13
Grounding and Shielding........................................................................... 13
Connection example 1 ............................................................................. 14
Connection example 2 ............................................................................. 14
Software ................................................................................................ 15
Motion Perfect version 5 .......................................................................... 16
Firmware............................................................................................. 18
Firmware recovery ................................................................................. 18
Dimensions ............................................................................................. 18
Mounting................................................................................................ 19
Specifications .......................................................................................... 19
Product Comparison Table........................................................................... 21

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Electromagnetic Compatibility...................................................................... 24
Intended conditions of use ........................................................................ 24
EMC Considerations ................................................................................ 24
Product specific requirements ................................................................... 24
Recommended Installation........................................................................ 26
Surge Protection.................................................................................... 26
Surge protection device ........................................................................... 27
Cable Shields ........................................................................................ 28

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User Manual MC404-Z
Overview
The Motion Coordinator MC404-Z is
based on Trio’s high-performance
ARM Cortex-M7 double-precision
technology and provides 4 axes of
pulse+direction or quadrature
output 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 panel mounted package.
The MC404-Z 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 Motion-iX for the MC404-Z allows up to 10 Motion-iX 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 that has
access to the full library of motion functions.
Programming
The Multi-tasking ability of the MC404-Z 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 Motion-iX 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 MC404-Z has 16 built in 24V inputs that can be configured as either source or sink in
banks of 8, and 8 sinking NPN 24V outputs. These may be used for system interaction or may

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be defined to be used by the controller for end of travel limits, registration, datuming and
feedhold functions if required. The MC404-Z can have up to 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 MC404-Z. Protocols supported include Telnet (Client and Server), Modbus
TCP (Client and Server), Ethernet IP (Client) and the TrioPCMotion DLL/ActiveX channel.
The MC404-Z 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.
IP Address reset
To reset the IP _ ADDRESS, IP _ GATEWAY
and IP _ NETMASK to their default values
press the IP reset button located next to
the SD card slot and power cycle the
controller while keeping the button
pressed.
The factory default IP address is
192.168.0.250. This can be changed using
the ETHERNET or IP_ADDRESS commands via
Motion Perfect.
Removable storage
The MC404-Z 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 32 GBytes using the FAT32 compatible file system.
Axis positioning functions
The motion control generation software receives instructions to move an axis or axes from
the Motion-iX 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 using interpolation, electronic gearboxes and simple kinematics.

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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.
LED indicators
2 LEDs show the status of the power and the enable circuit. The enable circuit drives the
watchdog relay and activates the pulse output signals.
Red LED ON shows that the WDOG is off and the axes are disabled. When the red LED is
OFF, the axes are enabled and ready to move. A flashing red LED indicates that one or more
axes are in error.
Connections to the MC404-Z
Ethernet port connection
RJ45 socket 10/100 base_T
The Ethernet port is the default connection between the Motion
Coordinator and the host PC running the Motion Perfect development
application.
Serial connections
The MC404-Z features two serial ports. Port 1 is a standard RS232 serial connection and Port
2 is configurable as RS422 or RS485 by external wiring. Both ports are
accessed through the 15-way auxiliary connector.
The serial ports are not isolated therefore the 0V terminal MUST be
connected.
CANbus connections
A CANbus port for connection to Trio’s digital and analogue CAN I/O
expansion modules is provided on the auxiliary connector. CAN-H on pin7
and CAN-L on pin 15.
The CANbus port is not isolated therefore the 0V terminal MUST be
connected.

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Amplifier enable (Watchdog) relay output
An internal solid-state relay contact is available to enable external drives when the
controller has powered up correctly and the system and application software are ready. The
amplifier enable relay has an ON resistance of 25Ω at 100mA. The enable relay will be open
circuit if there is no power on the controller OR a motion error exists on an 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
safety relay circuit that must be intact before torque is applied to motor windings.
Analogue I/O
The 15-way auxiliary connector includes a single built-in 12 bit analogue input with a scale
of 0 to 10V. A 10 bit, 0 to 10V analogue output is also provided for general use. For
example, to send a control voltage to an open-loop inverter drive.
Axis ports
The MC404-Z is designed to support pulse driven motor drives on the
standard controller hardware. All 4 axes are available as standard and no
additional axis feature enable codes are required. In addition, axis 3 can
be configured as an encoder input for systems that need a master
encoder reference.
Each of the axes (0-3) may be enabled as pulse+direction or quadrature
AB output according to the user’s requirements by setting the axis ATYPE
parameter. Axis 3 only can be set as either pulse output, encoder
output or encoder input.
The function of the 9-pin ‘D’ connectors will be dependent on the
specific axis configuration which has been defined. If the axis is
configured as a pulse output, the connector provides differential outputs
(RS422) for step+direction or simulated encoder, and enable signals. If
axis 3 is set as encoder input, there is an input for the Z channel as well
as A and B. The Z can be used for position registration capture.
The 9-way socket for axis 3 provides a current-limited 5V output capable of powering most
encoders. This simplifies wiring and reduces the need for external power supplies.

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Axes 0, 1 and 2
RS422 line driver output for Step, Direction and Enable signals or alternatively can be set
for A, B and Enable.
Axis 3
RS422 line driver / receiver. Output for Step, Direction and Enable or A, B and Enable.
Inputs for A, B and Z incremental encoder or Clock and Data absolute encoders.
Pin #
Description
1
Step + / A +
2
Step - / A -
3
Direction + / B +
4
Direction - / B -
5
0V
6
Enable +
7
Enable -
8
No connection
9
No connection
Pin #
Output
AB Enc In
Absolute Enc In
1
Step + / A +
A +
Clock +
2
Step - / A -
A -
Clock -
3
Direction + / B +
B +
No Connection
4
Direction - / B -
B -
No Connection
5
0V
6
Enable +
Z +
Data +
7
Enable -
Z -
Data -
8
+5V 150mA out
9
No connection

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Registration
MC404-Z encoder port has 2 available registration events. These are assigned in a flexible
way to any of the first 8 digital inputs or can be used with the Z mark input on the encoder
port.
I/O connector 1
This connector is used both to provide the 24 Volt power to the MC404-Z and provide power
and connections for the 24V NPN outputs. The 24 Volt main supply input is internally isolated
from the I/O 24 Volts.
A 24V d.c., Class 2 transformer or power source required for UL compliance. The MC404-Z is
grounded via the metal chassis. It MUST be installed on an unpainted metal plate which is
connected to earth. An earth connection screw should be applied to the lower mounting
point for bonding the MC404-Z to ground.
24V Output channels (NPN)
Output channels 8..15 are NPN sinking outputs.
The output circuit has electronic over-current
protection and thermal protection which shuts
the output down when the current exceeds
500mA.
Care should be taken to ensure that the 500mA
limit for each output circuit is not exceeded, and
that the total load for the group of 8 outputs does
not exceed 4 Amps.
I/O connector 2
24V Input channels (PNP / NPN)
16 channels of 24V digital inputs are provided in 2 banks of 8. Each set of 8 inputs has a
common connection which determines the mode of the inputs.
If the common is connected to 0V
then the 8 inputs are PNP and a
24V source signal will set the input
ON.
When the common is connected to
24V, the inputs are NPN and the
source signal must be a path to 0V
for the ON condition.

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Inputs 0 to 7 can be used as registration inputs allocated by REG_INPUTS for axis 3, using the
REGIST command.
Auxiliary connector
The 15 way D-Type connector is a multi-function socket that has 1 x RS232 port, 1 x
RS422/RS485 port, 1 x CANbus port, Anlogue I/O and connections for the WDOG solid-state
relay.
Grounding and Shielding
Good quality screened cables should be used for the auxiliary port. The serial ports and
CANbus port are not galvanically isolated, therefore the 0V return MUST be connected to all
peripheral devices. In addition, bond together the 0V (24V return) terminals of all system
components to minimise current flowing in the serial cables.
Ensure that:
1. 0V connection is NOT used for terminating screens.
2. For fully opto-isolated inputs on the drive, the 0V may be ommitted.
3. Screen should be connected to the 9 or 15 way D-type shell.
4. The MC404-Z 24V supply has common 0V with the drive(s).
Pin #
Description
Pin #
Description
1
RS232 Transmit
9
RS232 Receive
2
RS485 Data In A (Rx+)
10
RS485 Data In B (Rx-)
3
RS485 Data Out Y (Tx+)
11
RS485 Data Out Z (Tx-)
4
0V
12
0V
5
AIN (Analogue Input)
13
AOUT (Analogue Output)
6
WDOG-A
14
WDOG-B
7
CAN High
15
CAN Low
8
0V

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Connection example 1
Stepper drives.
All outputs are RS422
differential line drivers rated
at 5V 10mA.
The 0V may be omitted if the
stepper drive inputs are fully
opt0-isolated.
Connection example 2
Servo drives with 24V enable
Many Servo drives that have pulse and direction inputs for motion also use a 24V enable
input. The WDOG connection, pins 6 and 14 on the Auxiliary connector can be used to
directly enable the drives. The same signal can be used to enable all 4 axes.
A risk assessment must be done to decide if any of the motors that are controlled by
the MC404-Z might cause harm to an operator. The MC404-Z WDOG and Enable outputs
are NOT Safety outputs. An additional safety circuit may be needed to comply with
regulations.

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The WDOG signal may be
connected to multiple
drive enable inputs.
WDOG-A and WDOG-B
are a volt-free solid-
state relay. They may
be used with +24V on
either terminal.
Software
Motion Perfect version 5 or later is required for configuring, programming and system debug.
A PC running Microsoft Windows (Windows 10 or later recommended) is required. Download
Motion Perfect from www.triomotion.com and install on the PC.
Connection is via the Ethernet
port. Ensure that the PC has a
valid Ethernet Address. For single
point-to-point connection, a fixed
IP address must be set in the PC.
Go to Settings, Network and
Internet then open Change
Adapter Settings. Open the
Ethernet port.
Click the Properties button and
then select Internet Protocol
Version 4 (TCP/IPv4).

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Click Properties and select Use the following IP
address. Set an IP address in the same subnet as
the MC404-Z. Usually this will be 192.168.0.xxx.
Click OK and close the Ethernet setup dialogues.
Motion Perfect version 5
Launch Motion Perfect and select the IP address of the MC404-Z. By default this will be
192.168.0.250. Click the Apply and Connect button.

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If the IP Address of the MC404-Z is not known, then reset it by holding the IP Reset button
located next to the SD card slot while powering up the MC404-Z. This will reset the
IP_ADDRESS to 192.168.0.250.
Motion Perfect in Synchronised connection mode.
The MC404-Z is capable of running up to 16 axes total including virtual axes, of which 4
are real axes. Up to 6 program processes may be run at any time. (0 to 5)

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Firmware
The MC404-Z comes pre-installed with the firmware version which was released to
production at the time of manufacture. Newer versions may be available to download from
the Trio website and it is recommended to check if an update is available before using the
Motion Coordinator for an application.
New firmware can be installed using Motion Perfect. Click the Controller menu and select
Load Firmware …. The firmware file must be extracted from the zip folder before it can be
used. Firmware file names start MC404Z_ and have the extension .out. Do not attempt to
load firmware designed for a different Motion Coordinator type.
Firmware recovery
Firmware can be re-installed without using Motion Perfect by adding the firmware file to a
micro SD card so that the MC404-Z will automatically re-load the firmware at power-on.
Format the micro SD card to FAT 32, rename the firmware file to r_406.out and copy the file
on to the SD card. Insert the card into the slot on the Motion Coordinator and power up.
The Red LED will flash during the firmware loading process. When the Red LED becomes
steady it will be possible to re-connect to the MC404-Z via Ethernet.
All applications programs will be deleted when the new firmware is installed
Dimensions

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Mounting
2 x upper slots 4.2 mm width. 1 x lower mounting hole 4.4 mm dia.
Ventilation: When the MC404-Z is mounted in an enclosed cabinet, there must be an
adequate volume of circulating air to maintain the environmental temperature within the
operating temperature range. If clearance is allowed for cable connections, there is no
further limit on spacing next to other components that do not emit heat.
Place below heat sources such as drives and power supplies.
Specifications
Specification table
Size
176.5 mm x 115 mm x 28 mm (HxWxD)
Weight
430g
Operating Temp.
0 - 45 degrees C
EMC (CE)
EMISSIONS - EN61000-6-4 : 2019
IMMUNITY - EN61000-6-2 : 2019