ELAU PacDrive C400/10/1/1/1/00 The Ultimate Control System for Precision Motion Control in Packaging Machinery

# ELAU PacDrive Controller C400/10/1/1/1/00:

Comprehensive Overview

## Introduction to ELAU and the PacDrive System

ELAU GmbH, a Schneider Electric company, is a leading manufacturer of automation solutions for packaging and other industrial applications. The PacDrive system represents ELAU's innovative approach to machine automation, combining PLC, motion control, and robotics functions in a single, integrated platform.

The PacDrive Controller C400/10/1/1/1/00 is part of this sophisticated control system family, designed specifically for demanding packaging applications that require high-speed, precision motion control with integrated PLC functionality. This microprocessor-based controller features the VxWorks real-time operating system and serves as the central intelligence for coordinating complex motion sequences in packaging machinery.

## Product Overview

The PacDrive C400 controller is a high-performance automation controller that synchronizes, coordinates, and executes motion control functions for up to 16 drives in a packaging machine environment. The specific model C400/10/1/1/1/00 features:

- Intel Pentium M 600 MHz processor
- 256 MB RAM
- 32 MB Flash memory
- CompactFlash card slot for permanent data storage (≥128 MB)

This industrial controller is designed for installation in machines or switching cabinets and complies with stringent European safety and EMC standards. The device combines the functions of a programmable logic controller (PLC) and motion controller in one unit, significantly simplifying system architecture compared to traditional solutions that require separate controllers for these functions.

## Key Features and Capabilities

### Motion Control Performance

The C400 controller stands out for its exceptional motion control capabilities:

- Controls up to 16 servo axes with all SERCOS cycle times
- Supports a maximum of 255 parallel motion profiles
- Cam sequential circuit functionality with up to 256 cams
- Dynamic sequential circuits with processing time of 250 μs

The controller achieves remarkable synchronization precision through its SERCOS (SErial Real-time COmmunication System) interface operating at 16 MBaud. This high-speed real-time bus ensures deterministic communication with connected servo drives.

### PLC Functionality

As a complete automation solution, the C400 provides full PLC functionality:

- Execution speed: 7 μs per 1000 bit instructions
- Supports all IEC 61131-3 programming languages:
- Instruction List (IL)
- Ladder Diagram (LD)
- Function Block Diagram (FBD)
- Sequential Function Chart (SFC)
- Structured Text (ST)
- Continuous Function Chart (CFC)
- Unlimited number of PLC processes (continuous, periodic, or event-controlled)
- Fast task cycle time: 250 μs
- Nominal I/O response time: 500 μs (read data, process, set output)

### Communication Interfaces

The controller offers comprehensive connectivity options:

## Technical Specifications

The C400 controller meets rigorous industrial standards with the following technical characteristics:

### Electrical Data

- Power supply: 24 V DC (-15%/+25%)
- Max. current: 3.0 A (without UPS), 4.0 A (with UPS option)
- Digital inputs: 20 channels (24 V DC / 5 mA)
- Digital outputs: 16 channels (24 V DC / 0.25 A per output)
- Analog inputs: 2 channels (-10...+10 V or 0...20 mA, 12-bit resolution)
- Analog outputs: 2 channels (-10...+10 V, 12-bit resolution)
- Interrupt inputs: 4 channels
- Touchprobe inputs: 16 channels (100 μs resolution)

### Mechanical and Environmental Specifications

- Dimensions: 300 x 130 x 400 mm (W x H x D)
- Weight: 3.5 kg (4.1 kg with packaging)
- Protection class: IP20
- Operating temperature: +5°C to +45°C (with UPS: +5°C to +40°C)
- Storage temperature: -25°C to +70°C
- Relative humidity: 5% to 85% (operation), 5% to 95% (storage)
- Shock resistance: 70 m/s² (operation), 100 m/s² (transport)
- Vibration resistance: 5 m/s² (operation), 15 m/s² (transport)

### Certifications and Standards Compliance

- CE marked
- cULus listed (Industrial Control Equipment)
- Complies with:
- EN 60204-1:2006 (Safety of machinery)
- EN 61800-3:2004 (EMC for adjustable speed drives)
- EN 50178:1997 (Electronic equipment for power installations)

## System Architecture and Integration

The PacDrive C400 serves as the central controller in a modular system architecture:

1. **Power Supply**: Typically paired with the PacDrive PS-5 power supply unit featuring integrated mains filter and bleeder, capable of supplying up to 25 iSH modules depending on application.

2. **Drive Components**:
- **iSH (Intelligent Servo Module)**: Combines motor, power amplifier, and digital servo controller in one housing (IP65 protection)
- **MC-4 Servo Amplifier**: Digital servo amplifier with global voltage range (34.5/69 kVA output)
- **SH Servo Motors**: Highly dynamic AC servo motors with single tooth winding technology

3. **Distribution**: The PacDrive DB-5 distribution box links power supply and drive components, supporting 1-4 iSH motors per unit with easy expandability.

4. **HMI Integration**: Supports various human-machine interfaces from simple text displays to industrial PCs.

## Diagnostic and Safety Features

The C400 controller includes comprehensive diagnostic capabilities:

### LED Indicators

Four vertically arranged LEDs provide status information:
- **pow**: Control voltage status (ON=normal, OFF=no power, FLASHES=UPS active)
- **wd**: Watchdog indicator (ON=fatal error requiring reset)
- **err**: Error display (various flash patterns indicate different error conditions)
- **bus err**: SERCOS real-time bus error (ON=bus error)

### Diagnostic System

The controller features a powerful diagnostic system with:
- Alphanumeric diagnostic display
- Message logger with 27 kB capacity
- Integrated trace recorder (8 channels, 1 ms resolution)
- Diagnostic messages categorized into classes (1-9) based on severity

### Safety Features

- Watchdog relay outputs (max. 60 V < 2 A)
- Safe separation of signal/control voltages (<33 V) as PELV circuits
- Compliance with machinery safety directives (98/37/EC)
- Integrated safety functions for drive monitoring

## Applications

The PacDrive C400 controller is particularly suited for:
- High-speed packaging machines
- Complex robotic packaging systems
- Machines requiring synchronized multi-axis motion
- Applications demanding both precise motion control and advanced PLC functionality
- Food and pharmaceutical packaging where hygiene and reliability are critical

## Conclusion

The ELAU PacDrive Controller C400/10/1/1/1/00 represents a sophisticated automation solution that combines motion control and PLC functionality in a single, integrated platform. Its high-performance processing capabilities, comprehensive I/O options, and robust construction make it ideal for demanding packaging applications requiring precision, speed, and reliability.

With its modular system architecture, the C400 controller can be seamlessly integrated with various ELAU drive components to create complete automation solutions tailored to specific machine requirements. The controller's extensive diagnostic features and safety compliance ensure reliable operation while simplifying maintenance and troubleshooting.

As part of Schneider Electric's automation portfolio, the PacDrive system benefits from global support and integration with broader industrial automation ecosystems, making the C400 controller a future-proof investment for packaging machine builders and end-users alike.