Trio MC403-X User manual

USER MANUAL
MC403-X
3 AXIS MOTION COORDINATOR

MC403-X
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1
About this Manual
Purpose
This manual provides the information required for the Selection, Wiring, Connection,
Setup, Operation and Functions of the MC403-X 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.
Analogue Servo
+/- 10v output to give speed signal to the servo drive. Associated encoder input
provides position feedback

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Revision History
Date
Version
Revised Contents
20 Dec 2022
1.00
First Release

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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 MC403.
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) 2022-23 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 MC403-X.................................................................................. 6
Overview ............................................................................................. 6
Programming......................................................................................... 6
I/O Capability........................................................................................ 6
Communications..................................................................................... 6
Removable storage.................................................................................. 7
AXIS POSITIONING FUNCTIONS..................................................................... 7
CONNECTIONS TO THE MC403 ETHERNET PORT CONNECTION ................................ 8
MC403-X SERIAL CONNECTIONS.................................................................... 8
SERIAL CONNECTOR ................................................................................. 9
MC403-X PULSE OUTPUTS / ENCODER INPUTS .................................................. 9
REGISTRATION ..................................................................................... 10
5-WAY CONNECTOR ............................................................................... 10
I/O CONNECTOR 1................................................................................. 11
24V INPUT CHANNELS .......................................................................... 11
I/O POWER INPUTS ............................................................................. 11
24V I/O CHANNELS ............................................................................. 11
I/O CONNECTOR 2................................................................................. 12
AMPLIFIER ENABLE (WATCHDOG) RELAY OUTPUTS ........................................ 12
ANALOGUE INPUTS ............................................................................. 12
ANALOGUE OUTPUTS........................................................................... 12
LED DISPLAY........................................................................................ 13
MC403-X FEATURE SUMMARY .................................................................... 14
MC403-X AXIS CONFIGURATION SUMMARY ..................................................... 15
CONFIGURATION KEY ............................................................................. 15
CORE FUNCTIONALITY ......................................................................... 15
EXTENDED FUNCTIONALITY ................................................................... 16

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User Manual MC403-X
Overview
The Motion Coordinator MC403-X uses high
performance Cortex M7 Processor with 3
flexible Axis ports. Provides 2 axes of servo
plus a master encoder axis, or 3 axes of
pulse+direction control for stepper drives or
pulseinput 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-X 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 MC403-X allows up to 6 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 (licence key required).
Programming
The Multi-tasking ability of the MC403-X 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 MC403-X 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-X 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 100 base-T Ethernet port is fitted as standard and this is the primary communications
connection to the MC403-X. Many protocols are supported including Telnet, Modbus TCP,
Ethernet IP and TrioPCMotion. Check the Trio website (www.triomotion.com) for a
complete list.

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The MC403-X 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-X 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 32Gbytes using the FAT32 compatible file system.
AXIS POSITIONING FUNCTIONS
The motion control 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 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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CONNECTIONS TO THE MC403 ETHERNET PORT CONNECTION
Physical layer: 100 base_T
Connector: RJ45
The Ethernet port is the default connection between the Motion Coordinator and the host
PC running the Motion Perfect development application.
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-X SERIAL CONNECTIONS
The MC403-X features two serial ports. Both ports are accessed through a single 8 pin
connector.

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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
MC403-X PULSE OUTPUTS / ENCODER INPUTS
The MC403-X is designed to support any combination of servo and pulse input motor
drives on the standard controller hardware. The MC403-X has 3 versions, which are
selected by applying Feature Enable Codes (FECs)
1) 2 axis as either encoder or pulse output. (P865)
2) 1 axis servo with the other 2 axis as either encoder or pulse output. (P866)
3) 2 axis servo and the other axis as either encoder or pulse output. (P867)
The axis configuration can then be set with the axis ATYPE parameter.
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, encoder and stepper versions of the MC403-X

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Pin
Function
Pulse and 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
OV 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)
REGISTRATION
Each MC403-X encoder port has 2 available registration events. These are assigned in a
flexible way using REG_INPUTS to any of the 8 digital inputs or can be used with the Z
mark input on the encoder port.
5-WAY CONNECTOR
This is a 5 way 3.5 mm pitch connector. The connector is used both to provide the 24 Volt
power to the MC403-X 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.

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24V d.c., Class 2 transformer or power source required for UL compliance. The MC403-X 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-X to ground.
I/O CONNECTOR 1
24V INPUT CHANNELS
The MC403-X has 8 dedicated 24V Input
channels built into the master unit. A further
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 high speed registration
inputs for axes 0 to 2, using the REGIST
command.
I/O POWER INPUTS
The I/O 0 Volts (IO-) and I/O 24 Volts (IO+) are used to power
the 24 Volt digital IO and the analogue I/O, including the servo
DAC outputs. 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.
24V I/O CHANNELS
Input/output channels 8..11 are bi-directional. The
inputs have a protected 24V sourcing output
connected to the same pin. If the output is unused
it may be used as an input in the program. The
input circuitry is the same as on the dedicated
inputs. 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 each output circuit is not exceeded, and
that the total load for the group of 4 outputs does not exceed 1 amp.

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I/O CONNECTOR 2
AMPLIFIER ENABLE (WATCHDOG) RELAY OUTPUTS
An internal relay contact is
available to enable external
amplifiers when the
controller has powered up
correctly and the system
and application software is
ready. The amplifier enable
is a solid-state relay with an
ON resistance of 25Ω at
100mA. The enable relay will be open circuit if there is no power on the controller OR a
motion error exists on a servo axis OR the user program sets it open with the WDOG=OFF
command.
The amplifier enable relay may, for example, be incorporated within a hold-up circuit or
chain that must be intact before a 3-phase power input is made live.
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-X 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

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pulse+direction/simulated encoder output, the analogue output may be set to a voltage
directly in software, using the DAC parameter
A 24V d.c. supply must be applied to I/O connector 1 to provide power for the analogue
output circuit.
LED DISPLAY
On power-up, the LEDs flash to show the MC403-X version and the SD card status.
P865 2 axis pulse output version:
3 flashes of the RED LED.
P866 1 axis servo version:
3 flashes of the GREEN LED.
P867 2 axis servo version:
3 flashes of both LEDs alternately.
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 Axis Error

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MC403-X FEATURE SUMMARY
Dimensions
122 mm x 135 mm x 35 mm (HxWxD).
Weight
346g
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: 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, 4ms 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 32Gbytes. Used for storing programs
and/or data.
Power Input
24V d.c., Class 2 transformer or power source required. 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
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
P865 : MC403-X 2 axis stepper output / 2 encoder input P866 : MC403-X 1 axis
servo + 2 encoder / 2 axis stepper P867 : MC403-X 2 axis servo + 1 encoder / 3
axis stepper

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MC403-X AXIS CONFIGURATION SUMMARY
CONFIGURATION
P867
P866
P865
AXIS 0
Extended+AS
Extended+AS*
Extended
AXIS 1
Extended+AS
Extended*
Extended
AXIS 2
Extended
Extended
AXES
# of axes (max)
3
3
2
# of virtual axes (max)
16
16
16
DRIVE INTERFACES
Stepper (Step & Direction)
Yes
Yes
Yes
Servo (±10V & Encoder)
Yes
Yes
No
ENCODER PORTS
Feedback input
Yes
Yes
Yes
Reference input
Yes
Yes
Yes
Pulse + direction output
Yes
Yes
Yes
Incremental (A+B) output
Yes
Yes
Yes
BUILT-IN I/0
Inputs 24Vdc
8
8
8
Bi-directional I/O 24Vdc
4
4
4
0-10V analogue inputs
2x12bit
2x12bit
2x12bit
±10V analogue outputs
2x12bit
2x12bit
2x12bit
# registration inputs
6
6
6
Registration input speed
20µs max
20µs max
20µs max
*For P866 –One Axis only can be configured as servo (AS), when Axis 0 is configured as Extended, Axis 1 can be configured as servo (AS), Vice Versa.
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.

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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 Trio Motion Technology
HARDWARE OVERVIEW Motion Coordinator MC403 2-54
76 Incremental encoder with Z input
78 Pulse and direction with VFF_GAIN and enable output 1
84 Quadrature encoder output with VFF_GAIN and enable output
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 can use the analogue output 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
79 Pulse and direction feedback with Z input
86 Tamagawa absolute encoder input
87 Endat absolute encoder input
88 SSI absolute encoder input
92 Analogue Servo with Biss absolute encoder
93 Biss absolute encoder input
35 Pulse and direction output with PWM output
36 Incremental encoder Servo with PWM output