MOTOROLA MVME162-220

Description

Product Overview and Introduction

The MOTOROLA MVME162-220 is a classic, high-performance single-board computer (SBC) from the Motorola (now part of NXP Semiconductors) VMEbus product line. This board is not a traditional PLC module but a versatile embedded computer that has been extensively used as a powerful processor and control engine within industrial automation systems, particularly in VME-based chassis for demanding real-time applications. The MOTOROLA MVME162-220 integrates a CPU, memory, and essential I/O interfaces on a single VME board, enabling it to function as a central controller, data processor, or communication gateway in complex automation and military/aerospace systems.

Detailed Product Parameters and Specifications

The board’s architecture is defined by its advanced (for its era) integrated design:

• Core Processor: Features a Motorola MC68040 or MC68LC040 microprocessor, a high-performance 32-bit CPU with an integrated floating-point unit (FPU) in the 68040 variant, clocked at a speed such as 25 MHz or 33 MHz.
• Memory: Equipped with onboard DRAM (typically 4MB, 8MB, or 16MB, expandable via SIMM modules) and Flash memory (e.g., 512KB) for program storage.
• Bus Architecture: A 6U VMEbus (VERSAbus-Eurocard) board, acting as a master/slave on the VME backplane for communication with other I/O cards.
• Onboard I/O Interfaces:
  • Ethernet: Includes one or two 10BASE-T or 10BASE2 (BNC) Ethernet controllers for network connectivity.
  • Serial Ports: Multiple RS-232/422/485 serial ports (typically 2-4) for connecting terminals, modems, or other serial devices.
  • Parallel Port: A Centronics-type parallel port.
  • SCSI: An onboard SCSI-1 or SCSI-2 interface for connecting hard drives, tape drives, or other SCSI peripherals.
• Timers & Counters: Includes programmable timers and a real-time clock.
• Mechanical: Conforms to the standard 6U VME form factor (233.35 mm x 160 mm).

Key Advantages and Distinctive Features

The MOTOROLA MVME162-220 was distinguished by several powerful features that made it a favorite for embedded control:

• High Integrated Processing Power: By combining a powerful 68040 CPU, memory, and multiple communication ports on one board, it reduced system complexity and improved reliability compared to multi-board solutions, offering significant computational capability for real-time control algorithms.
• Versatile Connectivity: Its built-in Ethernet, SCSI, and multiple serial ports provided exceptional flexibility for system design, allowing easy integration into both local networks and legacy industrial device networks.
• Robust and Stable Platform: The VMEbus architecture is renowned for its robustness, deterministic data transfer, and suitability for harsh environments. The MVME162-220 leveraged this to create a stable and reliable computing core.
• Strong Real-Time OS Support: The board was widely supported by major real-time operating systems (RTOS) of the time, such as VxWorks, pSOS+, and LynxOS, which were essential for developing deterministic, mission-critical automation software.
• Industry Standard Form Factor: As a VME board, it could be integrated into a wide variety of existing VME chassis and systems, offering excellent scalability and interoperability with thousands of other VME I/O cards from various manufacturers. This flexibility cemented the role of the MOTOROLA MVME162-220 in many long-lifecycle systems.

Application Scenarios and Case Studies

This SBC was deployed in high-end, complex automation and control systems:

• Industrial Process Control: Acting as the main process controller in VME-based DCS or SCADA systems for industries like semiconductor manufacturing, where it ran custom real-time control applications.
• Military & Aerospace Test Rigs: Used in systems for testing avionics or weapon systems, where it coordinated data acquisition, stimulus generation, and real-time analysis.
• Telecommunications: Served in early telecom switching and transmission equipment that required robust, real-time performance.
• Scientific Research & Data Acquisition: Utilized in particle accelerators or large physics experiments to control equipment and gather data from VME-based instrumentation crates.

A typical legacy application case is in a continuous casting machine at a steel mill. The MOTOROLA MVME162-220, housed in a VME crate, executed the proprietary real-time control software that managed the spray cooling zone, coordinating analog and digital I/O cards to regulate water flow based on temperature models, ensuring steel quality.

Comparison with Competing Products

In its prime, the MVME162-220 competed with other VME SBCs from manufacturers like Force Computers (now part of Emerson), PEP Modular Computers, and Intel.

• Processor Leadership: The 68040 CPU offered a strong balance of integer, floating-point, and overall system performance, competing favorably with Intel i386/i486-based SBCs in many real-time and embedded contexts.
• Integration Level: Its high level of I/O integration (Ethernet, SCSI, serial) was a key differentiator, often reducing the need for additional communication cards in the chassis.
• Ecosystem and Support: Motorola’s dominance in the 68k ecosystem and the board’s long-term availability made it a conservative and safe choice for large projects requiring decades of support.

Modern equivalents would be advanced PLC CPUs (e.g., Siemens S7-1500, Beckhoff CX series) or ruggedized industrial PCs, which offer orders of magnitude more performance, modern connectivity (Gigabit Ethernet, USB), and support for contemporary software frameworks, but within different hardware architectures.

Selection Guidelines and Important Considerations

Selecting or supporting this board today is primarily about sustaining legacy systems:

1. Legacy System Compatibility: The MOTOROLA MVME162-220 is almost exclusively selected as a direct replacement for a failed unit in an existing VME system. Verify the exact model, CPU variant, memory size, and firmware revision to ensure compatibility.
2. Obsolescence Management: This is a discontinued product. Availability is from specialist surplus/refurbishment suppliers. Secure necessary spares for the lifecycle of your system and develop a migration plan.
3. Software and Firmware Dependencies: The application software and RTOS are almost certainly customized and compiled for this specific hardware. A replacement board must be functionally identical to avoid software issues.
4. Power and Cooling: Ensure the VME chassis provides the correct voltage and sufficient power on the VMEbus P1/P2 connectors. The 68040 CPU can generate significant heat; verify chassis cooling is adequate.
5. Handling and ESD: These are complex, static-sensitive electronic assemblies. Handle with proper ESD precautions.
6. Expertise Required: Troubleshooting and integration require knowledge of VMEbus systems, 68k assembly/C programming, and the specific RTOS used. For any technical details, always consult the original hardware manual for the MVME162-220, which may be found via the product link. Consider the long-term strategy: eventually, a system modernization to a contemporary platform will be necessary.

ICSA04B5 DCS
086329-003 PLC DCS
RELIANCE57C411 PLC
RELIANCE0-57407-4H PLC
CM400RGICH1ACB PLC DCS