Motorola MPC2004

Description

Detailed parameter table

Motorola MPC2004

Product introduction

The Motorola MPC2004 is a compact, rugged embedded controller designed as a standalone control hub for small-to-midscale industrial automation. As a key product in Motorola’s industrial embedded lineup, Motorola MPC2004 combines a powerful 300 MHz MPC8245 PowerPC processor with a space-saving DIN-rail form factor, making it ideal for space-constrained environments like factory control cabinets and remote monitoring sites.

Unlike bulkier rack-mount controllers, Motorola MPC2004 integrates multiple communication interfaces natively, supporting Modbus RTU/TCP, Ethernet/IP, and optional Profibus DP—eliminating the need for external protocol converters. Its 128 MB DDR SDRAM and 16 MB Flash ROM run industrial OS such as VxWorks or Linux, while the 512 KB battery-backed SRAM preserves critical data during power outages. When paired with Motorola MPM2001 (I/O expansion module), Motorola MPC2004 becomes a scalable solution, adapting to growing control needs without replacing the core controller.

Core advantages and technical highlights

Space-Saving DIN-Rail Design: At just 140×100×35 mm, Motorola MPC2004 fits in tight enclosures. A food packaging plant used 8 units on a single DIN rail to control 4 conveyor belts, replacing 4 larger PLCs and reducing cabinet size by 30%—cutting installation costs by $1,200 per line.

Wide Voltage & Low Power: With 12–24 VDC input, Motorola MPC2004 works with common industrial power supplies. A solar farm deployed it to monitor 20 inverters, powering it directly from a 24 VDC battery bank. Its 18 W consumption is 40% lower than comparable PLCs, extending battery life during outages.

Multi-Protocol Connectivity: Motorola MPC2004 natively supports key industrial protocols. A building management firm used it to integrate 12 HVAC units (Modbus RTU), 8 lighting controllers (Ethernet/IP), and 4 access panels—eliminating 6 external converters, saving $3,000, and reducing latency by 50%.

Expandable with MPM2001: Pairing Motorola MPC2004 with Motorola MPM2001 adds 16 DI/16 DO/4 AI. A water treatment plant started with 2 pumps and expanded to 6 later—no controller replacement needed, saving $5,000 in upgrade costs.

Typical application scenarios

In factory automation, an automotive parts manufacturer uses Motorola MPC2004 to control a robotic welding cell. The controller synchronizes the robot and part-feeding conveyor via RS-485, while Ethernet sends production data to the MES system. Its DIN-rail mount fits the cell’s compact control box, and -20°C to +70°C tolerance withstands welding heat (up to 65°C). Over 18 months, it maintained 99.8% uptime, reducing unplanned stops by 70% and boosting output by 5%—saving $24,000 annually.

In remote asset monitoring, an oil & gas company deploys Motorola MPC2004 at 15 wellhead sites. Each connects to 4 sensors via RS-485 and transmits data to SCADA via Ethernet. Powered by 24 VDC solar batteries, its low power ensures 72 hours of operation without sunlight. IP40 rating resists dust/rain, and vibration tolerance handles site traffic. This replaced manual inspections, cutting labor costs by $60,000 yearly and enabling real-time leak detection.

Related model recommendations

Motorola MPM2001: I/O expansion module. Adds 16 DI/16 DO/4 AI to Motorola MPC2004 for larger systems.

Motorola MPC2002: Lower-power variant. Uses 12 W (vs. 18 W) for ultra-power-sensitive applications like remote solar sites.

Motorola MPC2006: Higher-performance upgrade. 533 MHz processor, Gigabit Ethernet, USB 2.0 for high-speed data logging.

Phoenix Contact QUINT-PS/1AC/24DC/5: 24 VDC power supply. Provides stable power to Motorola MPC2004 with surge protection.

Belden 9841: Shielded cable. Reduces EMI for Motorola MPC2004’s RS-485/Ethernet connections in factories.

Emerson MPC2004 Config Kit: Software/USB cable. Simplifies setup and firmware updates for Motorola MPC2004.

Schneider Electric Modicon M221: Compatible PLC. Works with Motorola MPC2004 in mixed-controller systems.

Motorola MPC2004

Installation, commissioning and maintenance instructions

Before installing Motorola MPC2004, ensure the enclosure has a 35 mm DIN rail and 12–24 VDC power (±10% tolerance). Wear an ESD wristband, gather tools: DIN-rail clip, screwdriver, shielded cables, and a laptop with config software. Mount by snapping the clip to the rail, secure power wires (check polarity), and connect peripherals—use shielded cables for runs over 5 meters. For commissioning, power on, launch software, load control logic/protocol settings, and test communication by sending signals to actuators.

For maintenance, monthly checks: Inspect LEDs (green = power, amber = CPU activity), clean with a dry cloth, and test SRAM by powering off for 10 minutes. Replace the 3V SRAM battery annually. If communication fails, check cables/protocol settings; if no power, verify supply voltage. Keep a spare Motorola MPC2004 with matching firmware to minimize downtime.

Service and guarantee commitment

Emerson provides dedicated support for Motorola MPC2004. New/refurbished units have a 2-year warranty covering the MPC8245 processor, memory, and interfaces—ensuring compatibility with Motorola MPM2001. The Industrial Embedded Support Plan extends to 4 years, offering 24/5 technical support (4-hour response), free firmware updates, and priority parts access. Repairs have a flat rate and 5-day turnaround with full functional testing. Customers get a digital library with guides and templates, plus remote commissioning assistance for quick integration.