Introduction to ELAU MC-4/11/03/400
Product Description
The ELAU MC-4/11/03/400 is a modular, high-performance motion controller engineered for complex multi-axis automation systems, specifically optimized for integration with 400V-class servo drives and industrial networks. As a core model in Schneider Electric’s ELAU portfolio (now part of the Lexium Motion range), this controller excels at synchronizing precision motion across multiple axes, executing advanced motion profiles, and enabling seamless data exchange with factory-wide systems—making it ideal for industries including heavy-duty packaging, printing, material handling, and robotic assembly, where 400V three-phase power and robust communication are standard.
The model designation “MC-4/11/03/400” decodes its key specifications: “MC-4” indicates a 4-axis base controller (expandable to 16 axes via add-on modules), “11” denotes a 110V AC power supply for the controller itself, “03” specifies a dual-protocol communication setup (optimized for both real-time drive control and enterprise data integration), and “400” confirms compatibility with ELAU’s 400V servo drives (e.g., C400 series). Unlike entry-level motion controllers, the MC-4/11/03/400 supports advanced motion modes such as electronic gearing (with dynamic ratio adjustment), fixed/dynamic cam profiling, and linear/circular/helical interpolation—critical for tasks like high-speed bottle labeling, multi-axis conveyor synchronization, and precision robotic pick-and-place. 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 1500 cam points), linear/circular/helical interpolation, and flying shear
- Processor: Dual-core 32-bit DSP (400 MHz main motion core + 200 MHz communication core)
- Memory: 1.5 MB RAM (real-time motion data); 6 MB flash memory (program storage); expandable via microSD card (up to 32 GB)
- Power Supply: 110V AC (90–132V AC, 50/60 Hz); power consumption ≤38W
- Digital I/O (Built-in): 20 inputs (24V DC, PNP/NPN configurable, response time ≤8 µs); 10 outputs (24V DC, 0.8A max per output)
- Analog I/O (Built-in): 2 inputs (±10V, 14-bit); 1 output (±10V, 14-bit)
- Feedback Compatibility:
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- Incremental encoders (TTL/HTL, up to 3 MHz)
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- Absolute encoders (SSI, BiSS-C, up to 1.5 Mbps)
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- Resolvers (4-wire, 5V/11V excitation, via external converter)
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- Linear scales (Heidenhain, Fanuc, via optional interface module)
- Communication Interfaces:
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- Primary: CANopen (DS 301/402, 2 channels, for real-time 400V drive communication)
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- Secondary: Ethernet (10/100BASE-T, Modbus TCP/IP, for HMI/SCADA/MES integration)
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- Tertiary: RS485 (Modbus RTU, for legacy device integration)
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- Optional: Profinet IO or EtherCAT via expansion cards
- Motion Performance:
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- Positioning accuracy: ±0.08 encoder counts
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- Axis synchronization error: ≤0.8 µs
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- Maximum interpolation speed: 12 m/s (linear); 1200 RPM (circular)
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- Cam table update rate: 0.8 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, 1.5g peak (IEC 60068-2-6)
- Shock Resistance: 35g peak (11 ms duration, IEC 60068-2-27)
- Protection Rating: IP20 (module); IP54 when installed in a sealed enclosure
- Dimensions: 145mm × 185mm × 102mm (W × H × D)
- Weight: Approximately 1.9 kg
- Certifications: CE, UL 508, IEC 61131-2, RoHS, ISO 12100 (machine safety)
Usage Methods
- Installation:
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- Mounting: Secure the controller to a standard DIN rail in a control cabinet, ensuring vertical orientation to optimize heat dissipation. Maintain a minimum clearance of 55mm above and below the module—critical for accommodating 400V drive wiring and preventing overheating when using expansion cards.
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- Environmental Preparation: Install in a clean, dry environment away from direct sunlight, high-voltage 400V cables, and sources of electromagnetic interference (e.g., large motors, transformers). Use a grounded metal cabinet to shield against EMI, which can disrupt encoder feedback or drive communication.
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- Vibration Mitigation: Use heavy-duty DIN rail clips to secure the controller, especially in environments with high vibration (e.g., near industrial conveyors or stamping machines).
- Wiring and Connection:
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- Power Wiring: Connect the 110V AC power supply to the dedicated terminal block using a 1.25A fused circuit and twisted-pair cable (min. 1.0 mm² cross-section). Install a surge protector if the controller is used in regions with unstable power grids.
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- Drive Communication: Link the controller’s dual CANopen ports to 400V servo drives (e.g., ELAU C400/10/1/1/1/00) using shielded twisted-pair cable. Terminate each CAN bus with a 120Ω resistor at the first and last drive to ensure signal integrity.
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- I/O Wiring: Connect 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 front-panel DIP switches or Schneider Electric’s MotionWorks IEC software.
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- Ethernet Connection: Use Cat5e cable to link the Ethernet port to a local HMI (for operator control) or factory network (for MES integration). Assign a static IP address to the controller to ensure consistent communication.
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- Grounding: Securely ground the controller’s frame to the cabinet chassis using the dedicated ground terminal—this prevents electrical noise and ensures safety in case of insulation failure.
- Configuration and Programming:
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- Software Setup: Use Schneider Electric’s MotionWorks IEC software (v4.5+) to create a project, selecting the MC-4/11/03/400 as the target device. Leverage IEC 61131-3 languages (Structured Text, Function Block Diagram, Ladder Diagram) and ELAU’s pre-built motion libraries to simplify programming.
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- Drive Pairing: Load the 400V drive’s parameter set into the controller via CANopen. Use the “Drive Auto-Detection” function to automatically map drive addresses and verify communication.
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- Motion Profile Definition:
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- For electronic gearing: Program dynamic gear ratios (e.g., adjust feeder speed based on product size) using ST code.
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- For camming: Use the software’s “Cam Editor” to import CAD-derived cam curves or create custom profiles for applications like bottle labeling.
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- For interpolation: Define waypoints with acceleration/deceleration limits to minimize mechanical stress on 400V-driven loads (e.g., heavy conveyors).
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- Testing: Verify logic in “Simulation Mode” first, then run the controller in “Torque-Limited Test Mode” to validate motion without full load—critical for preventing damage to 400V drive systems. Use the software’s real-time oscilloscope to monitor position error, velocity, and CANopen bus traffic.
- Operation and Maintenance:
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- Startup Verification: Power on the controller and check the status LED (solid green = normal operation; flashing blue = CANopen communication active; red = fault). Use MotionWorks IEC’s diagnostic tool to troubleshoot faults (e.g., drive communication errors, overcurrent).
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- Real-Time Monitoring: Track key metrics via the HMI or MES system: axis position, speed, drive current, and I/O status. Set alarms for abnormal conditions (e.g., position error >0.5 encoder counts or drive current >80% of rated).
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- Routine Maintenance:
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- Monthly: Inspect wiring connections (especially CANopen and 400V drive cables) for tightness; clean dust from ventilation slots with compressed air.
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- Quarterly: Verify CANopen bus integrity using the controller’s built-in network analyzer; back up program and configuration files to a network server.
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- Annually: Update firmware via Ethernet to access new features (e.g., expanded 400V drive compatibility); replace the internal backup battery to preserve program data during power outages.
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System Introduction
The ELAU MC-4/11/03/400 acts as the central “brain” of 400V-based multi-axis automation systems, integrating five critical functional layers to deliver precise, synchronized motion with enterprise connectivity:
- Motion Planning Layer: The dual-core DSP calculates complex motion profiles (e.g., dynamic cam curves, jerk-limited interpolated paths) based on user-defined parameters and real-time sensor data. For 400V systems, this layer optimizes torque distribution to handle heavier loads (e.g., large conveyors) while maintaining precision.
- Drive Control Layer: Communicates with 400V servo drives via dual CANopen ports, sending real-time torque/speed/position commands and receiving feedback. The dual CAN channels enable redundant communication—critical for high-uptime applications like packaging lines, where drive failure can halt production.
- I/O Integration Layer: Processes signals from digital/analog sensors and triggers actuators in lockstep with motion. For example, a photoelectric sensor detecting a product can trigger the controller to adjust a 400V-driven conveyor’s speed, ensuring precise alignment with a labeling head.
- Network Communication Layer: Exchanges data across Ethernet and RS485, enabling: (1) operator control via HMI, (2) production data logging to MES (e.g., cycle counts, reject rates), and (3) remote monitoring for maintenance teams.
- Safety Integration Layer: Supports machine safety standards (ISO 12100) by integrating with safety relays or safety PLCs. For 400V systems, this layer can trigger emergency torque shutdowns via CANopen if a safety interlock is tripped, preventing injury or equipment damage.
In a high-speed beverage packaging line example, the MC-4/11/03/400 controls four 400V-driven axes: two for bottle conveyors, one for a labeling head, and one for a capping unit. It uses electronic gearing to synchronize conveyor speed with the labeling head, adjusting the gear ratio in real time based on bottle size (detected via a photoelectric sensor). The dual CANopen channels ensure redundant communication with the C400 drives, while Ethernet sends production data (bottles per minute, label accuracy) to the plant’s MES system. If a bottle jam is detected, the controller triggers a safety shutdown of the 400V drives, preventing damage to the labeling mechanism.
Related Models in the Series
- ELAU MC-4/21/03/400: 4-axis controller with 230V AC power supply, optimized for regions with 220–240V electrical grids (e.g., Europe, Asia) while retaining 400V drive compatibility.
- ELAU MC-8/11/03/400: 8-axis base model, designed for larger 400V systems like multi-station assembly lines or robotic palletizers requiring more simultaneous motion axes.
- ELAU MC-4/11/03/200: 4-axis variant compatible with ELAU 200V servo drives (e.g., C200 series), ideal for smaller 200V-based applications like light-duty packaging or laboratory automation.
- ELAU MC-4/11/04/400: 4-axis controller with built-in EtherCAT (instead of RS485), supporting ultra-high-speed drive communication (up to 100 Mbps) for precision 400V applications like semiconductor wafer handling.
- ELAU MC-4/11/03/400-EX: Explosion-proof variant (ATEX Zone 2, IECEx) with reinforced housing and isolated I/O, suitable for hazardous 400V environments (e.g., chemical packaging, oil & gas equipment).
- ELAU MC-4/11/03/400-MED: Medical-grade variant (ISO 13485 certified) with enhanced EMC protection, designed for 400V medical device manufacturing (e.g., large-scale syringe assembly lines).
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