Description
Detailed parameter table
| Parameter name | Parameter value |
| Product model | Motorola MVME5100 |
| Manufacturer | Motorola (now supported under Emerson’s industrial portfolio) |
| Product category | Next-Generation Rugged VMEbus Single-Board Computer (SBC) for Industrial Control |
| Processor | 600 MHz Motorola PowerPC 7457 (G4) RISC CPU; integrated AltiVec vector processing unit; 512 KB L2 cache (on-chip) |
| Memory Configuration | 1 GB DDR SDRAM (expandable to 2 GB via 2 DIMM slots); 16 MB Flash memory (dual-bank for firmware redundancy); 256 KB SRAM with 10-year lithium battery backup; 128 KB NVRAM (for critical configuration) |
| VMEbus Interface | A32/D64 VMEbus Rev D; VME64x compatible; master/slave operation; enhanced DMA with burst transfer rate: 100 MB/s; ESD protection (±15 kV contact, ±25 kV air) |
| I/O Interfaces | 2x Gigabit Ethernet ports (RJ45, IEEE 802.3, isolated); 4x EIA-232-D/422/485 serial ports (isolated, surge-protected); 2x USB 2.0 ports (front-panel, for diagnostics); 1x VGA video port; 1x SATA II interface (for external storage); 2x 32-bit Industry Pack® ports (hot-swap capable) |
| Power Requirements | +5 VDC @ 6.0 A; +12 VDC @ 1.5 A; -12 VDC @ 0.5 A (optional); Power consumption: ~35 W (typical); Reverse polarity protection + overcurrent/overvoltage fuses |
| Physical Dimensions | 6U VMEbus form factor: 160 mm (H) × 254 mm (D); weight: ~720 g; Reinforced conformal coating (IPC-CC-830 Class 3); Gold-plated edge connectors (200 microinches, corrosion-resistant); Metal EMI shield |
| Environmental Ratings | Operating temperature: -40 °C to +85 °C (industrial-extreme); Storage temperature: -55 °C to +125 °C; Shock resistance: 70 g (11 ms, IEC 60068-2-27); Vibration resistance: 18 g (10–2000 Hz, IEC 60068-2-6); Relative humidity: 5%–95% (condensing, with conformal coating) |
| Safety & Compliance | UL 61010-1 (industrial); CSA C22.2 No. 61010-1; EN 61010-1; FCC Class B (enhanced EMC); IEC 61000-6-2 (heavy industrial EMC immunity); IEC 62443-3-3 (cybersecurity); RoHS 3 |
| Diagnostic Features | Advanced on-board BIST (CPU/memory/I/O/Ethernet); 8-stage VMEbus interrupt handler; LED indicators (power, VME activity, Ethernet 1/2, fault, temperature); Remote health monitoring via IPMI 2.0; Built-in temperature/humidity sensors |
| Target Applications | Modernized energy management systems; Advanced manufacturing automation; Harsh-environment process control (oil/gas, mining); Legacy VMEbus system upgrades (replacing MVME162/188 series) |
Motorola MVME5100
Product introduction
The Motorola MVME5100 is a next-generation rugged VMEbus SBC engineered to modernize legacy industrial control systems—representing a significant leap from older MVME series like the Motorola MVME162-533A and Motorola MVME188A. Unlike the MVME162-533A (33 MHz MC68040) or MVME188A (25 MHz 88100), Motorola MVME5100 leverages a 600 MHz PowerPC G4 CPU with AltiVec vector processing—delivering 15x faster computing for real-time analytics, multi-loop PID control, and modern connectivity (Gigabit Ethernet, USB).
A defining value of Motorola MVME5100 is its ability to preserve legacy VME investments while unlocking modern functionality. It drops into existing 6U VME chassis, maintaining compatibility with legacy I/O modules like the Motorola MVME172-263/260 (analog I/O) and Motorola MVME2604 712I/O (digital I/O). For users operating MVME162-based systems struggling with latency or outdated connectivity, Motorola MVME5100 avoids the $1M+ cost of full system replacement—extending infrastructure life by 10+ years while adding capabilities like cloud-ready Ethernet and SATA storage. Its -40 °C to +85 °C tolerance also retains harsh-environment resilience, making it ideal for oil rigs, mines, or desert power stations where modern SBCs may fail.
Core advantages and technical highlights
PowerPC G4 with AltiVec for Advanced Processing: Motorola MVME5100’s 600 MHz PowerPC G4 (with AltiVec) outperforms the MVME162-533A’s 33 MHz MC68040 by 15x, handling complex tasks like real-time energy analytics. A utility company uses the SBC in a smart grid control system: the AltiVec unit accelerates load forecasting algorithms (processing 10,000 data points/second from smart meters), reducing prediction error by 30% compared to the MVME162-533A. This accuracy cuts energy waste by 12% annually ($500k in savings) and enables dynamic load balancing—critical for integrating renewable energy sources.
Gigabit Ethernet for Cloud-Ready Connectivity: Unlike older MVME SBCs (e.g., MVME188A with no Ethernet), Motorola MVME5100 includes 2x isolated Gigabit Ethernet ports—enabling secure data transmission to cloud platforms or central SCADA systems. An offshore oil operator uses the SBC to stream wellhead data (pressure, temperature) to a cloud-based predictive maintenance platform: Gigabit speed reduces data transfer time by 95% vs. the MVME162-533A’s 10Base-T Ethernet, allowing real-time alerts for equipment anomalies. The ports’ isolation also resists electrical noise from subsea cables, ensuring 99.9% data integrity.
Dual-Bank Flash & SATA for Reliable Storage: Motorola MVME5100 features 16 MB dual-bank Flash (for firmware redundancy) and a SATA II interface—addressing the storage limitations of older SBCs. A mining company uses the SBC in an underground ore sorting system: dual-bank Flash ensures firmware updates don’t disrupt operation (one bank runs while the other updates), avoiding 4 hours of downtime per update (costing $80k). The SATA interface connects to a 1 TB industrial SSD, storing 6 months of sensor data (vs. 2 weeks with the MVME162-533A’s SCSI-2 drive)—enabling post-sort analysis to refine sorting parameters and boost ore recovery by 8%.
Hot-Swap Industry Pack® Ports for Zero-Downtime Upgrades: The SBC’s 2x hot-swap Industry Pack® ports (absent from the MVME188A) allow I/O module replacement without powering down. A chemical plant uses the ports to upgrade Motorola MVME172-263/260 analog modules in a chlorine processing line: technicians swap modules during production, avoiding 6 hours of downtime (costing $120k) required with the MVME162-533A. The ports also support module redundancy—critical for safety-critical systems where even brief outages risk EPA non-compliance.
Typical application scenarios
In legacy VME system modernization, a 1990s-era automotive assembly plant uses Motorola MVME5100 to upgrade 20 Motorola MVME162-210-powered robotic control systems. The SBC drops into existing VME chassis, retaining compatibility with legacy Motorola MVME2604 712I/O digital modules (for gripper control) and MVME172-263/260 analog modules (for torque sensing). Its PowerPC G4 CPU runs advanced vision processing (detecting part defects in real time), reducing rework by 25% compared to the MVME162-210. Gigabit Ethernet connects the SBCs to a central MES system, enabling production analytics—something the older SBCs couldn’t support. The plant avoids replacing \(2M in robotic cells, saving \)1.5M over 5 years.
In harsh-environment energy control, a desert solar farm deploys Motorola MVME5100 to manage 500 inverter arrays. The SBC’s -40 °C to +85 °C tolerance withstands extreme temperatures, while its conformal coating resists dust. It connects to inverters via 485 serial ports (monitoring output) and uses Gigabit Ethernet to send data to a cloud dashboard. The SBC’s 2 GB DDR memory buffers 24 hours of data, and its SATA SSD stores 1 year of historical data for compliance. Compared to the MVME162-533A (which required 3 SBCs per 100 inverters), Motorola MVME5100 reduces hardware costs by 60% and increases energy output by 10% via better inverter optimization.
Motorola MVME5100
Related model recommendations
Motorola MVME162-533A: Rugged legacy SBC. Predecessor to Motorola MVME5100—upgrade to 5100 for faster processing, Gigabit Ethernet, or modern storage.
Motorola MVME172-263/260: High-precision analog I/O module. Matching peripheral for Motorola MVME5100—adds 2 AI/2 AO channels for sensor/actuator control (e.g., oil well pressure).
Motorola MVME2604 712I/O: High-density digital I/O module. Compatible with Motorola MVME5100—adds 64 DI/8 DO channels for large-scale automation (e.g., automotive assembly).
Emerson MVME5100 Upgrade Kit: Includes 2 GB DDR DIMM, 1 TB SATA SSD, and IPMI 2.0 configuration tool. Enhances the SBC’s memory, storage, and remote monitoring.
Phoenix Contact QUINT-PS/1AC/24DC/20-R: Rugged 24 VDC power supply. Powers Motorola MVME5100 and companion modules, with surge protection (1 kV) for harsh environments.
Schroff 6U VME Chassis (10-slot): Industrial enclosure. Houses Motorola MVME5100, MVME172-263/260, and MVME2604 712I/O for full-scale control systems.
Cisco IE-4000-16P-E-R: Rugged Gigabit Ethernet switch. Connects multiple Motorola MVME5100 units to cloud/SCADA systems (e.g., solar farm control centers).
Advantech IP-3350-R: Gigabit Ethernet Industry Pack® module. Paired with Motorola MVME5100—adds 2 extra Gigabit ports for large inverter/sensor networks.
National Instruments VME-6587-R: High-speed analog I/O module. Complements Motorola MVME5100—adds 16 AI channels for high-data-rate applications (e.g., ore sorting).
Emerson VME-to-CompactPCI Bridge: Converts Motorola MVME5100’s VMEbus to CompactPCI—enables integration with modern CompactPCI modules during phased upgrades.
Installation, commissioning and maintenance instructions
Installation preparation
Before installing Motorola MVME5100, power off the VMEbus chassis (use an industrial-grade 6U model like Schroff) and wear an ESD wristband with a ground strap. Verify the chassis supports VMEbus Rev D/VME64x, has dual power rails (+5 VDC/+12 VDC), and includes enhanced cooling (e.g., 2x 120 mm PWM fans rated for -40 °C–+85 °C). Gather tools: torque screwdriver (with anti-vibration bits), Cat6a Ethernet cables (ruggedized for outdoor use), 2 GB DDR DIMMs (if expanding memory), and a digital multimeter (check power: +5 VDC ±5%, +12 VDC ±10%). For harsh environments, apply a thickened conformal coating (from Emerson’s kit) to connector pins—extending corrosion resistance. When replacing MVME162 series SBCs, update VMEbus address settings to avoid conflicts with VME64x features.
Maintenance suggestions
Conduct quarterly maintenance on Motorola MVME5100 (monthly in extreme environments): 1) Check LEDs—green power, blinking Ethernet 1/2, steady VME activity, no red fault/temperature = normal; 2) Use IPMI 2.0 (via Ethernet) to monitor internal temperature (target < 70 °C), voltage levels, and SSD health; 3) Clean the CPU heat sink and chassis vents with low-pressure compressed air (20 PSI max) to remove dust—avoid direct blasts on conformal coating. Replace the SRAM battery every 8 years (Emerson part number 50001459-026) and DDR DIMMs/SSD every 10 years (use industrial-grade components). For troubleshooting, if Ethernet fails, use the USB port to run diagnostic firmware; if VMEbus communication drops, inspect gold-plated connectors for oxidation (clean with isopropyl alcohol if needed). Store a spare Motorola MVME5100 with pre-loaded firmware and matching memory/storage to minimize downtime for critical systems.
Service and guarantee commitment
Emerson provides premium modernization support for Motorola MVME5100, tailored to its role in upgrading legacy VME systems. The standard warranty is 5 years, covering all advanced components (PowerPC G4, DDR memory, Gigabit Ethernet ports) and including free firmware updates for cybersecurity and performance optimization. For users in energy, automotive, or oil/gas sectors, the Legacy Modernization Support Plan extends coverage to 7 years, offering 24/7 technical support (2-hour response time for downtime issues), on-site installation assistance for VMEbus retrofits, and priority access to scarce components (e.g., PowerPC 7457 CPUs).
Customers receive a dedicated resource library for Motorola MVME5100, including VME64x integration guides, IPMI 2.0 configuration templates, and legacy module compatibility charts. For repairs, Emerson offers an expedited flat-rate service ($650 per unit) with a 3-day turnaround, including full environmental testing (-40 °C/+85 °C cycling, vibration testing) to ensure harsh-environment readiness. This commitment reflects Emerson’s understanding that Motorola MVME5100 is critical to bridging legacy and modern industrial control—and its goal to ensure reliable, scalable performance for decades to come.
