Introduction to ELAU MC-4/11/05/230
Product Description
The ELAU MC-4/11/05/230 is a modular, high-performance motion controller engineered for complex multi-axis automation, tailored to industries including packaging, printing, material handling, and robotic assembly. As a key model in Schneider Electric’s ELAU portfolio (now integrated into the Lexium Motion range), this controller specializes in synchronizing multiple servo axes, executing precision motion profiles, and enabling seamless integration with diverse industrial networks—making it ideal for applications where reliable coordination between mechanical systems (e.g., conveyors, robotic arms, cutting tools) and enterprise-level data systems is critical.
The model designation “MC-4/11/05/230” encodes its core specifications: “MC-4” indicates a 4-axis base controller (expandable to 16 axes via add-on modules), “11” denotes a 110V AC power supply, “05” specifies advanced communication capabilities (including dual industrial protocols for flexible network integration), and “230” references compatibility with ELAU’s 230V-class servo drives (e.g., mid-range C-series variants). Unlike basic motion controllers, the MC-4/11/05/230 supports advanced motion modes such as electronic gearing (with dynamic ratio adjustment), fixed/dynamic cam profiling, and linear/circular/helical interpolation—enabling tasks like precision label alignment, multi-axis robotic pick-and-place, and synchronized printing. Its modular design 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, dynamic adjustment), electronic camming (up to 2000 cam points), linear/circular/helical interpolation
- Processor: Dual-core 32-bit DSP (400 MHz main core + 200 MHz communication core)
- Memory: 2 MB RAM (for real-time motion data); 8 MB flash memory (for program storage); expandable via microSD card (up to 64 GB)
- Power Supply: 110V AC (90–132V AC, 50/60 Hz); power consumption ≤40W
- Digital I/O (Built-in): 24 inputs (24V DC, PNP/NPN configurable, response time ≤5 µs); 12 outputs (24V DC, 1A max per output)
- Analog I/O (Built-in): 4 inputs (±10V, 16-bit); 2 outputs (±10V, 16-bit)
- Feedback Compatibility:
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- Incremental encoders (TTL/HTL, up to 4 MHz)
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- Absolute encoders (SSI, BiSS-C, Profinet IO, up to 2 Mbps)
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- Resolvers (4-wire, 5V/11V excitation, via internal converter)
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- Linear scales (Heidenhain, Fanuc, via optional interface)
- Communication Interfaces:
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- Primary Ethernet: 10/100/1000BASE-T (Modbus TCP/IP, ELAU Motion Link, Profinet IO)
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- Secondary Ethernet: 10/100BASE-T (for network redundancy or HMI/SCADA integration)
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- CANopen (DS 301/402, for servo drive communication, 2 channels)
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- RS485 (for legacy device integration, Modbus RTU)
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- Optional: EtherCAT or PROFINET via expansion cards
- Motion Performance:
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- Positioning accuracy: ±0.05 encoder counts
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- Axis synchronization error: ≤0.5 µs
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- Maximum interpolation speed: 15 m/s (linear); 1500 RPM (circular)
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- Cam table update rate: 0.5 ms
- Operating Temperature: 0°C to +60°C (32°F to +140°F)
- Storage Temperature: -20°C to +75°C (-4°F to +167°F)
- Relative Humidity: 5–95% RH (non-condensing)
- Vibration Resistance: 10–500 Hz, 2g peak (IEC 60068-2-6)
- Shock Resistance: 40g peak (11 ms duration, IEC 60068-2-27)
- Protection Rating: IP20 (module); IP54 when installed in a sealed enclosure
- Dimensions: 150mm × 190mm × 105mm (W × H × D)
- Weight: Approximately 2.1 kg
- Certifications: CE, UL 508, IEC 61131-2, RoHS, ISO 13485 (for medical equipment compatibility)
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 60mm above and below the module—critical for accommodating its higher power consumption and expanded I/O when using add-on 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). Use a metal cabinet with grounded shielding if operating near high-EMI equipment (e.g., welding machines).
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- Secure the controller with heavy-duty 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 1.5A fused circuit and twisted-pair cable (min. 1.5 mm² cross-section) to reduce electrical noise. Install a surge protector if the controller is used in regions with unstable power grids.
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- Wire digital inputs to sensors (e.g., photoelectric eyes, limit switches) and digital outputs to actuators (e.g., solenoids, contactors) using 24V DC wiring. Configure input type (PNP/NPN) via the controller’s web-based interface (accessible via Ethernet) or front-panel DIP switches.
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- Connect analog inputs to variable sensors (e.g., pressure transducers, temperature probes) and analog outputs to proportional valves or variable-speed drives, ensuring signal shielding to prevent drift.
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- Establish CANopen communication with 230V-class servo drives (e.g., ELAU C-series mid-range models) using shielded twisted-pair cable, with a 120Ω termination resistor at both ends of the bus. Use the secondary CANopen channel for redundant drive communication if needed.
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- Link the primary Ethernet port to the production network (for MES/ERP integration) and the secondary Ethernet port to a local HMI or programming PC, using Cat6 cable for gigabit speeds.
- Configuration and Programming:
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- Use Schneider Electric’s MotionWorks IEC software (v5.0+) to program motion logic, leveraging support for IEC 61131-3 languages (Structured Text, Function Block Diagram, Ladder Diagram) and ELAU-specific motion libraries.
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- Configure axis parameters via the “Advanced Axis Setup Wizard,” which includes pre-defined profiles for ELAU 230V servo motors (e.g., SM-series mid-torque models). Enable resolver-to-digital conversion via the internal converter to simplify wiring for resolver-equipped motors.
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- Define advanced motion profiles: For dynamic camming, use the software’s “Cam Designer” to import CAD-derived cam curves or create custom profiles with real-time adjustment triggers. For interpolation, program waypoints with jerk limitation to minimize mechanical stress.
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- Test motion sequences in “Dual-Mode Simulation”: Verify logic in virtual mode (without hardware) first, then use “Soft Start” mode to run the controller with drives in torque-limited state—ensuring safe testing before full-speed operation. Use the software’s real-time oscilloscope to monitor position error, velocity, and analog signal levels.
- Operation and Maintenance:
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- Power on the controller and verify the status LED (solid green = normal operation; steady blue = network connected; flashing red = fault). Use the web-based diagnostic tool (accessible via Ethernet) to troubleshoot faults (e.g., communication errors, overcurrent) with step-by-step resolution guides.
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- Monitor system performance via the HMI: Display key metrics (axis position, speed, analog sensor values) and set up conditional alarms (e.g., “trigger alert if pressure > 10 bar and axis speed < 500 RPM”).
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- Perform bi-monthly maintenance: Inspect wiring connections for tightness (paying special attention to analog and Ethernet cables), clean dust from ventilation slots with compressed air, and verify network integrity using the controller’s built-in network analyzer.
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- Back up program and configuration files to a network server (via Ethernet) daily, and to a local microSD card weekly. Update firmware quarterly via the primary Ethernet port to access new features (e.g., expanded drive compatibility, enhanced security) and bug fixes.
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- Replace the internal backup battery every 3 years to preserve program data during power outages. Calibrate analog inputs annually using a precision signal generator to maintain measurement accuracy.
System Introduction
The ELAU MC-4/11/05/230 acts as the central “brain” of 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, ensuring smooth acceleration/deceleration and minimal settling time—critical for high-speed applications like pharmaceutical packaging.
- Control Execution Layer: Executes real-time closed-loop control for each axis, adjusting servo drive commands based on feedback from encoders/resolvers/linear scales. It compensates for load variations (e.g., changing film thickness in packaging) by dynamically tuning PID gains, maintaining position accuracy even under variable conditions.
- I/O Integration Layer: Processes signals from digital/analog sensors and triggers actuators in lockstep with motion, enabling event-driven automation (e.g., “activate cutting tool when linear scale detects product position X and pressure reaches Y”). The expanded I/O count supports more complex sensor/actuator networks without external I/O modules.
- Network Communication Layer: Exchanges data across dual Ethernet ports and dual CANopen channels, enabling: (1) high-speed drive communication (via CANopen), (2) production data transfer to MES/ERP systems (via primary Ethernet), and (3) local HMI/programming access (via secondary Ethernet). Redundant communication ensures uptime in critical applications.
- Enterprise Integration Layer: Supports industry-standard protocols (Profinet IO, Modbus TCP/IP) to connect with factory-wide systems, enabling remote monitoring, predictive maintenance alerts, and production data logging for OEE (Overall Equipment Efficiency) analysis.
In a high-speed pharmaceutical blister packaging line example, the MC-4/11/05/230 controls four axes: two for film feeding, one for blister forming, and one for product insertion. It uses dynamic camming to synchronize blister forming with product insertion, adjusting the cam profile in real time based on analog input from a film thickness sensor. The controller communicates with 230V servo drives via CANopen, using the secondary CAN channel for redundancy. The primary Ethernet port sends production data (e.g., blister count, reject rate) to the plant’s MES system, while the secondary Ethernet port connects to a local HMI for operator control. Analog inputs monitor forming pressure and product temperature, triggering alerts if values exceed thresholds—ensuring compliance with pharmaceutical quality standards.
Related Models in the Series
- ELAU MC-4/21/05/230: 4-axis controller with 230V AC power supply, optimized for regions with 220–240V electrical grids (e.g., Europe, Asia) and 230V servo drives.
- ELAU MC-8/11/05/230: 8-axis base model, designed for larger systems like multi-station assembly lines or robotic palletizers requiring more simultaneous motion axes and expanded I/O.
- ELAU MC-4/11/05/400: 4-axis variant compatible with ELAU 400V-class servo drives, ideal for high-power applications (e.g., heavy-duty material handling) with 400V three-phase power.
- ELAU MC-4/11/06/230: 4-axis controller with built-in EtherCAT (instead of secondary Ethernet), supporting ultra-high-speed drive communication (up to 1 Gbps) for precision applications like semiconductor wafer handling.
- ELAU MC-4/11/05/230-EX: Explosion-proof variant (ATEX Zone 2, IECEx) with reinforced housing and isolated I/O, suitable for hazardous environments (e.g., chemical packaging, oil & gas equipment).
- ELAU MC-4/11/05/230-MED: Medical-grade variant (ISO 13485 certified) with enhanced EMC protection and sterile-compatible materials, designed for medical device manufacturing (e.g., syringe assembly lines).
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