Motrona MC800 User manual

Hardware Manual
motrona GmbH, Zeppelinstraße 16, DE - 78244 Gottmadingen, Tel. [phone], Fax [phone], [email protected], www.motrona.com
MC800
Universal Motion Controller
Product features:
Suitable for various applications of drive technology, e.g.: Synchronization Control, Index and
Print Mark Evaluation Control, Rotating Cross Cutter Control, Flying Saw Control, Eccentric
Shear Control, Label Printing Machine Control, etc.
Interface module (option), e. g. CANopen, Modbus , Profibus DPV1
Free assignment of the control axes and index or print mark inputs
New included control loop enables to run torque loop applications
Tandem Drive Control

Mc800_02c_oi_e.doc / Nov-18 Page 2 / 18
Version:
Description:
MC80001a_oi_e/ag
First edition
MC80001b_oi_e/ag
Some pin-assignment corrections
MC80001c_oi_e/ag
Power consumption changed from 150 to 250 mA
MC80001d_oi_e/ag
Output current of the encoder supplies modulated to 150 mA (each)
Mc800_01e_oi_e/ag
Correction of the serial interface in chapter “Technical Specifications”
Mc800_02a_oi_d/TJ
Interface modules updated
Mc800_02b_oi_d/TJ
Serial interface updated
Mc800_02c_oi_d/TJ
DIL switch settings updated
Legal notices:
All contents included in this manual are protected by the terms of use and copyrights of motrona GmbH. Any
reproduction, modification, usage or publication in other electronic and printed media as well as in the internet
requires prior written authorization by motrona GmbH.

Mc800_02c_oi_e.doc / Nov-18 Page 3 / 18
Table of Contents
1. Safety Instructions and Responsibility ......................................................... 4
1.1. General Safety Instructions .................................................................................. 4
1.2. Use according to the intended purpose................................................................ 4
1.3. Installation............................................................................................................ 5
1.4. Cleaning, Maintenance and Service Notes.......................................................... 5
2. General........................................................................................................ 6
2.1. About MC800........................................................................................................ 6
2.2. Operational Area................................................................................................... 6
2.3. Essential Advantages ........................................................................................... 6
3. Power Supply............................................................................................... 6
4. Encoder inputs............................................................................................. 7
4.1. HTL / TTL and RS-422 Inputs ................................................................................ 7
4.2. SSI Inputs.............................................................................................................. 7
4.3. SinCos Inputs........................................................................................................ 8
5. Digital & Analog Inputs ............................................................................... 8
5.1. Control and Fast Interrupt Inputs.......................................................................... 8
5.2. Analog Inputs........................................................................................................ 9
6. Digital & Analog Outputs............................................................................. 9
6.1. Control Outputs..................................................................................................... 9
6.2. Incremental Output ............................................................................................. 10
6.3. Analog Outputs................................................................................................... 10
7. DIL-Switch................................................................................................. 11
8. Status LEDs ............................................................................................... 11
9. Interfaces and Bus Connections................................................................. 12
9.1. Operator Software.............................................................................................. 12
9.2. Serial Interfaces (On-Board) ............................................................................... 12
9.3. USB 2.0 Interface................................................................................................ 14
9.4. Ethernet .............................................................................................................. 14
9.5. Optional Interface Modules................................................................................ 14
10. Mechanical Installation ............................................................................. 14
11. Dimensions................................................................................................ 15
11.1. Housing (without connectors)............................................................................. 15
11.2. Housing (inclusive connectors) ........................................................................... 16
12. Technical Specifications ............................................................................ 17

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1. Safety Instructions and Responsibility
1.1. General Safety Instructions
This operation manual is a significant component of the unit and includes important rules and hints
about the installation, function and usage. Non-observance can result in damage and/or impairment
of the functions to the unit or the machine or even in injury to persons using the equipment!
Please read the following instructions carefully before operating the device and observe all safety
and warning instructions! Keep the manual for later use.
A pertinent qualification of the respective staff is a fundamental requirement in order to use these
manual. The unit must be installed, connected and put into operation by a qualified electrician.
Liability exclusion: The manufacturer is not liable for personal injury and/or damage to property and
for consequential damage, due to incorrect handling, installation and operation. Further claims due to
errors in the operation manual as well as misinterpretations are excluded from liability.
In addition the manufacturer reserves the right to modify the hardware, software or operation manual
at any time and without prior notice. Therefore, there might be minor differences between the unit
and the descriptions in operation manual.
The raiser respectively positioner is exclusively responsible for the safety of the system and
equipment where the unit will be integrated.
During installation or maintenance all general and also all country- and application-specific safety
rules and standards must be observed.
If the device is used in processes, where a failure or faulty operation could damage the system or
injure persons, appropriate precautions to avoid such consequences must be taken.
1.2. Use according to the intended purpose
The unit is intended exclusively for use in industrial machines, constructions and systems. Non-
conforming usage does not correspond to the provisions and lies within the sole responsibility of the
user. The manufacturer is not liable for damages which have arisen through unsuitable and improper
use. Please note that device may only be installed in proper form and used in a technically perfect
condition - in accordance to the “Technical Specifications”.
The device is not suitable for operation in explosion-proof areas or areas which are excluded by the
EN 61010-1 standard.

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1.3. Installation
The device is only allowed to be installed and operated within the permissible temperature range.
Please ensure adequate ventilation and avoid all direct contact between the device and hot or
aggressive gases and liquids.
Before installation or maintenance, the unit must be disconnected from all voltage-sources. Further it
must be ensured that no danger can arise by touching the disconnected voltage-sources.
Devices which are supplied by AC-voltages must be connected exclusively by switches, respectively
circuit-breakers with the low voltage network. The switch or circuit-breaker must be placed as near
as possible to the device and further indicated as separator.
Incoming as well as outgoing wires and wires for extra low voltages (ELV) must be separated from
dangerous electrical cables (SELV circuits) by using double or increased isolation.
All selected wires and isolations must be conforming to the provided voltage- and temperature-
ranges. Further all country- and application-specific standards, which are relevant for structure, form
and quality of the wires, must be ensured. Instructions about the permissible wire cross-sections for
wiring are described in the chapter “Technical Specifications”.
Before first start-up it must be ensured that all connections and wires are firmly seated and secured
in the screw terminals. All (inclusively unused) terminals must be fastened by turning the relevant
screws clockwise up to the stop.
Overvoltage at the connections must be limited to values in accordance to the overvoltage category
II.
For placement, wiring, environmental conditions, as well as shielding and earthing/grounding of the
supply lines, the general standards of industrial automation industry and the specific shielding
instructions of the manufacturer are valid. Please find all respective hints and rules on
www.motrona.com/download.html --> “[General EMC Rules for Wiring, Screening and Earthing]”.
1.4. Cleaning, Maintenance and Service Notes
To clean the front of the unit please use only a slightly damp (not wet!), soft cloth. For the rear no
cleaning is necessary. For an unscheduled, individual cleaning of the rear the maintenance staff or
assembler is self-responsible.
During normal operation no maintenance is necessary. In case of unexpected problems, failures or
malfunctions the device must be shipped back to the manufacturer for checking, adjustment and
reparation (if necessary). Unauthorized opening and repairing can have negative effects or failures to
the protection-measures of the unit.

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1
2
24 VDC
GND
X3
2. General
2.1. About MC800
The MC800 device is a universally applicable controller, which serves for sophisticated motion
control tasks in today’s machine engineering and drive technology. Functions, features and settings
are dependent on the equipped controller firmware. This operation manual is limited especially to the
hardware features of the MC800 and includes all hardware relevant data, e. g. wiring rules and
technical specifications. Pure functional features and instructions for the setting-up operation are
available in the relevant application file within the CD-ROM library.
2.2. Operational Area
The application range of the MC800 is very diverse. Typical control applications are e. g. drive
synchronization, index and print mark evaluation, rotating cross cutters, flying, eccentric shears, label
printing machines, etc..
2.3. Essential Advantages
The follow-up unit to the proof MC700 convinces by its higher band width and more flexible bus
architecture. A really special feature of the MC800 is the integrated tandem drive controller. This
allows reaching acceleration requirements of heavy loads by splitting the necessary power into two
independent drives.
3. Power Supply
The unit is supplied with an unstabilized DC voltage of 18… 35 VDC. The supply voltage must be
connected by the pluggable screw terminal X3. The power consumption depends on the power supply
level as well as the load of the + 5 V encoder supply. In unloaded condition the consumption is about
250 mA.
Connections:

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4. Encoder inputs
The universal MC800 controller is equipped with numerous inputs for diverse encoder types.
This chapter describes the pin assignment of each connector.
4.1. HTL / TTL and RS-422 Inputs
The pluggable 9-pin screw terminals X7 and X9 are used for the incremental encoder connections. The
encoder can be supplied by two different voltages, 5.2 VDC (max. 150 mA per terminal) or 16 to 33
VDC (max. 150 mA per terminal). Both inputs allow to connect HTL, TTL and RS422 (A, /A, B, /B, Z, /Z)
encoders. If no index evaluation is needed, the Z-pulse channels can be left unconnected.
Connections:
GND
+5.2V
+24V
A
/A
B
/B
Z
/Z
1
2
3
4
5
6
7
8
9
X7
GND
+5.2V
+24V
A
/A
B
/B
Z
/Z
1
2
3
4
5
6
7
8
9
X9
HTL/TTL/RS422 IN1 HTL/TTL/RS422 IN2
4.2. SSI Inputs
Supplemental to the incremental inputs two further inputs for connecting absolute SSI encoders
are available at the terminals X8 and X10. These selectively can be operated as Master or Slave
from 100 Hz up to 1 MHz. The resolution is 13 … 32 bit.
Optionally these inputs can be used as additional RS422 incremental inputs with channels A, /A,
B, /B.
Connections:
GND
+5.2V
+24V
Clk (A)
/ Clk (/A )
Data (B )
/Data (/ B)
1 2 3 4 5 6 7
X10
GND
+5.2V
+24V
Clk (A)
/ Clk (/A )
Data (B )
/Data (/ B)
1 2 3 4 5 6 7
X8
SSI IN1 SSI IN2

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4.3. SinCos Inputs
Two further inputs for 1 Vpp SinCos rotary encoders (SIN+, SIN-, COS+, COS-, REF+ and REF-) are
available at the 9-pin (male) SUB-D connectors X1 and X2. These can be combined with any other
encoder inputs of the MC800. Frequencies up to 400 kHz can be processed here.
Connections:
15
234
69
78
SinCos
IN1
X1
GND
COS+
COS-
SIN+
SIN-
5V2OUT
REF-
REF+
24VOUT
X2
S inCos
IN2
15
234
69
78
GND
COS+
COS-
SIN+
SIN-
5V2OUT
REF-
REF+
24VOUT
5. Digital & Analog Inputs
5.1. Control and Fast Interrupt Inputs
4 fast interrupt inputs (e. g. for light sensitive barriers or photocells) and 4 static inputs for control
tasks are available at the pluggable screw terminal X4. The fast interrupt inputs are NPN / PNP –HTL
and the 4 control inputs PNP –HTL, LOW < 2.5 VDC / HIGH > 10 VDC (24 VDC).
Connections:
GND
FAST IN 1
1
2
3
4
5
6
7
8
9
X4
FAST IN 2
FAST IN 3
FAST IN 4
CTRL IN 1
CTRL IN 2
CTRL IN 3
CTRL IN 4

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5.2. Analog Inputs
Two analogue inputs at the 6-pin terminal X12 allow connecting external set points or linear
potentiometers. Both inputs are connectable with 0…+/-10 V or 0 (4)… 20 mA (burden 100 Ohm).
The resolution is 14 Bit (±13 Bit) with an accuracy of 0.1 %. The reference voltage for linear
potentiometers is 4.096 V.
Connections:
1
2
3
4
5
6
+/- 10 V
20 mA
+/- 10 V
20 mA
GND
V ref.
X 12
Analog Analog
IN1 IN2
6. Digital & Analog Outputs
6.1. Control Outputs
At the 6-pin screw terminal X5 four digital push-pull outputs (marked with Out1, 2, 3, 4) are available.
The range of possible switching voltages is 5 …30 VDC (depending on the voltage level at „Com+“).
All control outputs are protected by a short proof circuit. The delay time is < 1 ms.
Connections:
GND
Com+
Ctrl out 1
Ctrl out 2
Ctrl out 3
Ctrl out 4
1
2
3
4
5
6
X5

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6.2. Incremental Output
The screw terminal X6 delivers an incremental output with three differential channels (A, /A, B, /B, Z,
/Z) and an output frequency of maximum 500 KHz. The differential voltage amounts from 3.5 up to 30
VDC (depends on voltage at the "Com+" input).
Connections:
1
2
3
4
5
6
7
8
Com +
Fast 1
/Fast 1
Fast 2
/Fast 2
GND
Fast 3
/Fast 3
X 6
Depending on the firmware, this output can be used for the following purposes:
Output of a frequency or pulse number as speed- or position-set-point for a
servo drive with an incremental input (in preparation, not yet available)
Output of a pilot frequency for virtual master drive applications
(in preparation, not yet available)
Cascading of several controllers (output of the signals of one of the encoder inputs)
Additional digital control outputs
6.3. Analog Outputs
At the screw terminal X13 two short circuit proof analog outputs are available. Both outputs provide
0… ±10 V (maximum load 2 mA) as well as 0/4… 20 mA (max. burden 270 Ohm). These outputs can
be used as drive set-points or for arbitrary other regulating functions.
Connections:
1 2 3 4 5 6
+/- 10 V
20 mA
+/- 10 V
20 mA
GND
X 13
GND
Analog Analog
Out1 Out2

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7. DIL-Switch
The DIL-switch provides the following settings:
DIL-Switch 1: Selects the protocol for the serial interface:
OFF: Serial interface is using Lecom protocol (motrona standard)
ON: Serial interface is using Modbus RTU protocol
DIL-Switch 2: Not used (reserved for further functions)
DIL-Switch 3: For factory testing only, please do not use. Must be set to OFF.
8. Status LEDs
On the left side of the DIL-switch 3 LEDs for diverse status messages are located.
Green LED ready for operation „ON“
Yellow LED status message 1
Yellow LED status message 2

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9. Interfaces and Bus Connections
For communication with external operator terminals, devices, computers or superior control systems
the unit is equipped with diverse interfaces, which are described below.
9.1. Operator Software
The controller can be adjusted and operated by using the motrona software OS 5.1
9.2. Serial Interfaces (On-Board)
Each interface (RS232 and RS485) can be connected with the 9-pin (female) SUB-D connector X11.
Important note: It is impossible to communicate with the MC800 via both interfaces at the same
time!
The serial interface operates asynchronously either with Lecom protocol or Modbus RTU and with
selectable Baud rates from 9600 up to 38400 bps.
The serial protocol is selected by DIL switch 1 (see chapter 7).
Connections:
RS-232/RS-485
INTERFACE
X11
51
432
96
87
R-
GND
R+
TXD
RXD
T+
T-
9.2.1. RS232
Anschluss eines PC an die RS232 Schnittstelle des MC800-Controllers
How to connect a PC to the RS232 interface of the MC800 controller

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9.2.2. RS485
The RS485 interface provides both, 2-wire mode and 4-wire mode.
Anschluss der RS485-Schnittstelle im 2-Draht-Verfahren
Use of the RS485 interface with 2-wire mode
Anschluss der RS485-Schnittstelle im 4-Draht-Verfahren
Use of the RS485 interface with 4-wire mode

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9.3. USB 2.0 Interface
Connection by a female USB Type B port. 
Serves for firmware download
Interface operates as USB-Device
Device Class: CDC (Communication Device Class)
9.4. Ethernet
The MC800 is already equipped with an on-board Ethernet TCP / IP interface, which is used only for
parameter settings. The Ethernet connection of the MC800 is based on the IEEE.802.3 standard with
a transfer rate of 10 Mbps.
Function in preparation, not yet available
9.5. Optional Interface Modules
Optional plug-in modules for fieldbus or ethernet communication.
The following interfaces are currently available:
CANopen
Profibus DPV1
Modbus RTU
In preperation / available on request:
CC-Link
DeviceNet
EtherCAT
Ethernet / IP
Modbus TCP
Powerlink
Profinet
SERCOS-III
10. Mechanical Installation
The MC800 easily can be fastened by snapping onto a mounting rail (35 mm C-Profile).

Mc800_02c_oi_e.doc / Nov-18 Page 15 / 18
50 mm 155 mm
155 mm
127 mm
127 mm
11. Dimensions
11.1. Housing (without connectors)

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1 2 3
4 5
6 7
1 2
3 4
5 6
7 8
9
1 2
3 4
5 6
7 8
9
1
2 3
4 5
6
7
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
161 mm
170 mm
163 mm
175 mm
11.2. Housing (inclusive connectors)

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12.Technical Specifications
Power supply:
Input voltage:
Protection circuit:
Consumption:
Connections:
18 … 35 VDC
reverse polarity protection
approx. 250 mA (unloaded)
screw terminal, X3, 2-pin, 1.5 mm² / AWG 16
Encoder supply:
Output voltages:
Output current:
Protection circuit:
2 x 5.2 VDC and
2 x 16 … 33 VDC (input voltage minus ca. 2 V)
5.2 VDC max. 150 mA (per terminal)
16… 33 VDC max. 150 mA (per terminal)
reverse polarity protection
SinCos inputs:
Number of inputs:
Amplitude:
DC offset:
Frequency:
Connections:
2
min. 0.8 … max. 1.2 Vpp
min. 1.8 … max. 3.1 V
max. 400 kHz
SUB-D (male) connectors, X1 and X2, 9-pin
Incremental inputs:
Number of inputs:
Format:
Frequency:
Differential voltage:
Connections:
2
RS422 (differential signal A, /A, B, /B, Z, /Z)
max. 2 MHz
> 1 VDC
screw terminals, X9 and X7, 9-pin, 1.5 mm² /
AWG 16
Control inputs:
Number of inputs:
Application:
Signal level:
Pulse width:
Input resistance:
Connections:
4
fast interrupt-inputs (light barriers, photocells, ...)
NPN/PNP HTL, LOW < 2.5 VDC - HIGH > 10 VDC
min. 4 µs
Ri ≈3 kOhm
screw terminal, X4, 9-pin, 1.5 mm² / AWG 16
Number of inputs:
Application:
Signal level:
Pulse width:
Input resistance:
Connection:
4
control inputs
PNP HTL, LOW < 2.5 VDC - HIGH > 10 VDC
min. 1 ms
Ri ≈ 10 kOhm
screw terminal, X4, 9-pin, 1.5 mm² / AWG 16
SSI inputs:
(On request)
Number of inputs:
SSI-Mode:
Frequency:
Resolution:
Format:
Connection:
2
Master and Slave
100 Hz …1 MHz
13 …32 Bit
RS422, optionally as pulse input 2 x A, /A, B, /B
screw terminals, X10 and X8, 7-pin, 1.5 mm² / AWG 14
Analogue inputs:
Number of inputs:
Current input:
Voltage input:
Reference voltage:
Resolution:
Accuracy:
Delay period:
Connection:
2
0/4 … 20 mA
0 … ±10 V (Ri ≈ 100 kOhm)
4.096 VDC (to connect linear potentiometers)
14 Bit (±13 Bit)
0.1 %
< 1 ms
screw terminal, X12, 6-pin, 1.5 mm² / AWG 16
Incremental outputs:
Number of outputs:
Format:
Frequency:
Differential voltage:
Output current:
Connection:
1
Differential signal A, /A, B, /B, Z, /Z
max. 500 kHz
3.5 … 30 VDC (depends „Com+“ input level)
30 mA each channel
screw terminal, X6, 8-pin, 1.5 mm² / AWG 16

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Control outputs:
Number of outputs:
Output voltage:
Output current:
Output Driver:
Protective circuit:
Delay period:
Connection:
4
5 … 30 VDC (depends on “Com+”input level)
max. total 350 mA
push-pull
short-circuit-proof
< 1 ms
screw terminal, X5, 6-pin, 1.5 mm² / AWG 16
Analogue outputs:
Number of outputs:
Output voltage:
Output current:
Resolution:
Accuracy:
Delay period:
Protective circuit:
Connection:
2
0 … ±10 V (load max. 2 mA)
0/4 … 20 mA (load max. 270 Ohm)
14 Bit (±13 Bit)
0.1%
< 1 ms
short-circuit-proof
screw terminal, X13, 6-pin, 1.5 mm² / AWG 16
Serial interface:
Format:
Data transmission:
Baud rate:
Protocol:
Connection:
RS232 or RS485 (only one can be used at the same time)
asynchronous
2400 … 38400
Lecom protocol (extended addressing)
SUB-D female, X11, 9-pin
USB-interface:
Version:
Connection:
USB 2.0
USB-B
Ethernet TCP / IP:
Standard:
Transmission rate:
Parameterization:
Connection:
IEEE 802.3
10 … 100 Mbps
Full / Half Duplex
RJ45
Interface module:
(optional)
Ethernet Interface:
(In preparation / on request: EtherCAT, Ethernet/IP, Modbus TCP,
Powerlink, PROFINET, SERCOS-III)
Fieldbus Interface (Slave):
CANopen, Modbus RTU, Profibus DPV1
(In preparation / on request: CC-Link, DeviceNet)
Display:
Number of LEDs:
Green LED:
Yellow LED:
Yellow LED:
3
Ready for operation „ON“
Status 1
Status 2
Switches:
DIL-switch:
3-pin
Conformity &
standards:
EMC 2004/108/EG:
Guideline 2011/65/EU
EN 61000-6-2
EN 61000-6-3
RoHS conform
Housing:
Material:
Mounting:
Dimensions (w x h x d):
Weight:
Protection class:
plastic
mm top hat rail (according to EN 60715)
50 x 160 x 160 mm / 1.969 x 6.299 x 6.299 inch
ca. 450 g
IP20
Ambient temperature:
Operating:
Storage:
0 °C … +60 °C / 32 °F … 140 °F (not condensing)
-25 °C … +70 °C / -11.2 °F … 158 °F (not condensing)