Introduction to ELAU MC-4/11/01/400
Product Description
The ELAU MC-4/11/01/400 is a modular, high-performance motion controller designed for complex multi-axis automation systems, tailored for industries such as packaging, printing, material handling, and robotic assembly. As a core component of Schneider Electric’s ELAU portfolio (now integrated into the Lexium Motion range), this controller excels at synchronizing multiple servo axes, executing precision motion profiles, and integrating with industrial networks—making it ideal for applications where tight coordination between mechanical systems (e.g., conveyors, robotic arms, cutting tools) is critical.
The model designation “MC-4/11/01/400” encodes key specifications: “MC-4” indicates a 4-axis base controller (expandable to 16 axes with add-on modules), “11” denotes a 110V AC power supply, “01” specifies a single Ethernet port for network communication, and “400” references compatibility with ELAU’s 400V-class servo drives (e.g., C400 series). Unlike entry-level motion controllers, the MC-4/11/01/400 supports advanced motion modes including electronic gearing, cam profiling (both fixed and dynamic), and interpolated motion (linear, circular, helical)—enabling tasks like precision label alignment, multi-axis robotic pick-and-place, and synchronized printing. Its modular architecture allows users to add I/O modules, communication cards, or axis expansions, adapting to evolving production needs without replacing the entire controller.
Technical Parameters
- Axis Capacity: 4 axes (expandable to 16 axes via ELAU axis expansion modules)
- Control Modes: Position, velocity, torque, electronic gearing (ratio 1:1000 to 1000:1), electronic camming (up to 1000 cam points), linear/circular/helical interpolation
- Processor: Dual-core 32-bit DSP (400 MHz main core + 200 MHz communication core)
- Memory: 1 MB RAM (for real-time motion data); 4 MB flash memory (for program storage); expandable via microSD card (up to 32 GB)
- Power Supply: 110V AC (90–132V AC, 50/60 Hz); power consumption ≤35W
- Digital I/O (Built-in): 16 inputs (24V DC, PNP/NPN configurable, response time ≤10 µs); 8 outputs (24V DC, 0.5A max per output)
- Feedback Compatibility:
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- Incremental encoders (TTL/HTL, up to 2 MHz)
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- Absolute encoders (SSI, BiSS-C, up to 1 Mbps)
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- Resolvers (4-wire, 5V/11V excitation, via external converter)
- Communication Interfaces:
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- Ethernet (10/100BASE-T, Modbus TCP/IP, ELAU Motion Link)
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- CANopen (DS 301/402, for servo drive communication)
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- RS232 (for programming, diagnostics, and HMI integration)
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- Optional: Profibus-DP or EtherCAT via expansion cards
- Motion Performance:
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- Positioning accuracy: ±0.1 encoder counts
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- Axis synchronization error: ≤1 µs
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- Maximum interpolation speed: 10 m/s (linear); 1000 RPM (circular)
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- Cam table update rate: 1 ms
- Operating Temperature: 0°C to +55°C (32°F to +131°F)
- Storage Temperature: -20°C to +70°C (-4°F to +158°F)
- Relative Humidity: 5–95% RH (non-condensing)
- Vibration Resistance: 10–500 Hz, 1g peak (IEC 60068-2-6)
- Shock Resistance: 30g peak (11 ms duration, IEC 60068-2-27)
- Protection Rating: IP20 (module); IP54 when installed in a sealed enclosure
- Dimensions: 140mm × 180mm × 100mm (W × H × D)
- Weight: Approximately 1.8 kg
- Certifications: CE, UL 508, IEC 61131-2, RoHS
Usage Methods
- Installation:
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- Mount the controller on a standard DIN rail in a control cabinet, ensuring vertical orientation to optimize heat dissipation. Maintain a minimum clearance of 50mm above and below the module to avoid overheating, especially when using expansion cards.
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- Install in a clean, dry environment away from direct sunlight, high-voltage cables, and sources of electromagnetic interference (e.g., motor drives, transformers) to preserve signal integrity.
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- Secure the controller with DIN rail clips to prevent movement in high-vibration environments (e.g., near industrial fans or heavy machinery).
- Wiring and Connection:
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- Connect the 110V AC power supply to the dedicated terminal block, using a 1A fused circuit and twisted-pair cable (min. 1.0 mm² cross-section) to reduce electrical noise.
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- Wire digital inputs to sensors (e.g., photoelectric eyes, limit switches) and digital outputs to actuators (e.g., solenoids, indicator lights) using 24V DC wiring. Configure input type (PNP/NPN) via DIP switches on the controller front panel.
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- Establish CANopen communication with servo drives (e.g., ELAU C400 series) using shielded twisted-pair cable, with a 120Ω termination resistor at both ends of the bus.
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- Connect encoders or resolvers to the feedback ports, using manufacturer-supplied shielded cables. Ground the cable shield at both the controller and sensor ends to minimize EMI.
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- Link the Ethernet port to a PC (for programming) or industrial network (for HMI/SCADA integration) using Cat5e/Cat6 cable.
- Configuration and Programming:
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- Use Schneider Electric’s MotionWorks IEC software (compliant with IEC 61131-3) to program motion logic. Support for Structured Text (ST), Function Block Diagram (FBD), and Ladder Diagram (LD) allows flexibility for both simple and complex applications.
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- Configure axis parameters (e.g., motor type, encoder resolution, acceleration/deceleration limits) via the software’s “Axis Setup Wizard.” Load pre-defined parameter sets for ELAU servo motors (e.g., SM070 series) to simplify setup.
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- Define motion profiles: For electronic camming, use the built-in cam editor to create custom cam curves; for interpolation, specify waypoints and speed constraints via ST code.
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- Test motion sequences in “Simulation Mode” to verify axis synchronization and I/O triggers without physical motor movement. Use the software’s real-time oscilloscope to monitor position error, velocity, and torque.
- Operation and Maintenance:
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- Power on the controller and verify the status LED (solid green = normal operation; flashing red = fault). Use MotionWorks IEC’s “Diagnostic Tool” to troubleshoot faults (e.g., communication errors, overcurrent).
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- Monitor system performance via the HMI: Display key metrics (axis position, speed, I/O status) and set up alarms for abnormal conditions (e.g., position error exceeding threshold).
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- Perform monthly maintenance: Inspect wiring connections for tightness, clean dust from ventilation slots with compressed air, and verify CANopen bus integrity using a network analyzer.
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- Back up program and configuration files to a PC or microSD card weekly. Update firmware annually via Ethernet to access new features (e.g., expanded drive compatibility) and security patches.
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- Replace the internal backup battery every 2 years to preserve program data during power outages.
System Introduction
The ELAU MC-4/11/01/400 acts as the “brain” of multi-axis automation systems, integrating four critical functional layers to deliver precise, synchronized motion:
- Motion Planning Layer: The dual-core DSP calculates complex motion profiles (e.g., cam curves, interpolated paths) based on user-defined parameters, ensuring smooth acceleration/deceleration and minimal settling time.
- Control Execution Layer: Executes real-time closed-loop control for each axis, adjusting servo drive commands based on feedback from encoders/resolvers to maintain position/velocity setpoints—even under variable load conditions.
- I/O Integration Layer: Processes signals from sensors (e.g., product detection) and triggers actuators (e.g., cutting tools) in lockstep with motion, enabling event-driven automation (e.g., “cut film when encoder reaches X position”).
- Network Communication Layer: Exchanges data with servo drives (via CANopen) and external systems (via Ethernet/RS232), enabling centralized monitoring, remote control, and integration with MES (Manufacturing Execution Systems) for production tracking.
In a high-speed packaging line example, the MC-4/11/01/400 controls four axes: two for film feeding, one for sealing, and one for labeling. It uses electronic gearing to synchronize film feed speed with the sealing axis, and dynamic camming to align labels with packages based on encoder feedback from a product detection sensor. The controller communicates with an ELAU C400 servo drive for each axis, adjusting torque in real time to handle variations in film thickness. An HMI connected via Ethernet displays production counts and alerts operators to jams, while data is sent to a SCADA system for OEE (Overall Equipment Efficiency) analysis.
Related Models in the Series
- ELAU MC-4/21/01/400: 4-axis controller with 230V AC power supply, optimized for regions with 220–240V electrical grids (e.g., Europe, Asia).
- ELAU MC-8/11/01/400: 8-axis base model, designed for larger systems like multi-station assembly lines or robotic palletizers requiring more simultaneous motion axes.
- ELAU MC-4/11/02/400: 4-axis controller with dual Ethernet ports, enabling redundant network connections for critical applications (e.g., pharmaceutical packaging).
- ELAU MC-4/11/01/200: 4-axis variant compatible with ELAU C200 (200V AC) servo drives, ideal for small to medium machinery with single-phase power.
- ELAU MC-4/11/01/400-EC: 4-axis controller with built-in EtherCAT interface, supporting faster drive communication (up to 100 Mbps) for high-speed applications (e.g., precision printing).
- ELAU MC-4/11/01/400-EX: Explosion-proof variant (ATEX Zone 2) with reinforced housing and isolated I/O, suitable for hazardous environments (e.g., chemical packaging, oil & gas equipment).
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