ELAU

Data Sheet
ELAU On the best machines

No. ETIE 098-02 / 2006-03-08
PacDrive
TM
Controller C400
Controller-based architecture
The PacDrive Controller C400 is a Pentium M based
controller using the VxWorks real-time operating
system that provides logic and motion functions for a
production or packaging machine. A PacDrive
Controller synchronizes, coordinates and generates the
positioning functions for a maximum of 16 servo drives
which are connected through the motion bus SERCOS
interface.
Several standardized field bus interfaces are available,
PROFIBUS DP, CAN, CANopen or DeviceNet. For HMI
functions various standard HMI systems can be used.
Whether low-cost text display or IPC - no problem for
the flexible C400.
The technical data at a glance:
CPU: Intel Pentium M, 600 MHz, 256 MB RAM
Real-time operating system: VxWorks
IEC 61131-3 programming languages for PLC and
motion control
Motion bus: SERCOS interface
Field bus interface: Profibus DP, CAN, CANopen or
DeviceNet
Integrated IOs: digital inputs, digital outputs, analog
inputs, analog outputs, interrupt inputs,
fast touchprobe inputs
Communication interfaces: RS 232, RS 485,
Ethernet (TCP/IP)
CompactFlash
TM
Disk (32 MB)
OPC server for Windows based HMI available
Remote diagnosis over modem
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page 2 PacDrive Controller C400 ELAU AG
Contents
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Product information 1
Technical Data 3
Interfaces 7
Electrical Connections 9
Dimensions 17
All rights reserved to ELAU AG, also in case of patent right
applications.
No part of this documentation and the related software and firm-
ware may be reproduced, rewritten, stored on a retrieval system,
transmitted or translated into any other language or computer lan-
guage without the express written consent of ELAU AG.
Every possible measure was taken to ensure that this product
documentation is complete and correct. However, since hardware
and software are continuously improved, ELAU makes no repre-
sentations or warranties with respect to the contents of this product
documentation.
PacDrive is a registered trademark of ELAU AG.
All other trademarks mentioned are the exclusive property of their
manufacturers.
This Technical Data Sheet does not replace the Operating manual.
For a complete description of the PacDrive Controller see the
Operating manual PacDrive Controller
For planning and project activities see the
PacDrive Projecting manual
ELAU AG
Dillberg 12
D-97828 Marktheidenfeld
Phone: 09391/606-0
Fax: 09391/606-300
eMail: info@elau.de
Internet: http://www.elau.de
Contents
Trademark
Imprint
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ELAU AG PacDrive Controller C400 page 3
Technical Data
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Technical Data
Parameter Value
Product
configuration
Product ID code
- C400 up to 16 SERCOS devices
(SERCOS devices = MC-4, SCL, PS-4)
PacDrive C400 / 10 / 1 / 1 / 1 / 00
Order code
- C400 up to 16 SERCOS devices 13 13 02 61
Processor CPU Intel Pentium M 600 MHz
RAM 256 MB
L2 Cache 1 MB
NVRAM 128 kB
CompactFlash
TM
Disk 32 MB
Real time clock (RTC) yes (Battery, service intervall 5 years)
Watchdog yes (max. 60 V < 2 A)
Diagnostics alpha numeric diagnostic display, status LEDs
Operating
System
Real-time operating system VxWorks
Programming
languages
Programming languages
IEC 61131-3
Continuous Function Chart (CFC)
Function Block Diagram (FBD)
Instruction List (IL)
Ladder Diagram (LD)
Sequential Function Chart (SFC)
Structured Text (ST)
Interfaces Communication interfaces
COM1
COM2
RS232 (X17)
RS485 (X18)
Network interface Ethernet (10/100 Base-T) (X10)
Fieldbus interfaces PROFIBUS DP Master/Slave (12 MBaud) (X20)
or CAN (2.0A) resp. CANopen (X19)
DeviceNet Slave (cable adapter required)
Motion bus interface SERCOS interface (16 MBaud) (X14, X15)
PacNet interface 2 PacNet interfaces (X12, X13)
Encoder interface 1 SinCos encoder
or 1 incremental encoder (X11)
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Technical Data
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HMI interface Operator panels: RS485 using Modbus or
PROFIBUS DP
HMI software tools: OPC server (Windows NT/
2000/XP or Windows CE)
Remote Diagnostics interface Modem
Communication protocols http, ftp, SMTP (email)
Integrated trace recorder
(software oscilloscope)
8 channels
1 ms resolution
Integrated logger for
diagnostic messages
27 kB
Performance Motion performance 8 Servo axes @ 1 ms SERCOS cycle
12 Servo axes @ 2 ms SERCOS cycle
16 Servo axes @ 4 ms SERCOS cycle
max. 255 cam profiles running in parallel
PLC performance 7 s for 1000 Bit instructions
unlimited number of PLC tasks
PLC task types: continuous, periodic or event-
triggered
Cycle time Fast Task: 250 s
Nominal I/O response time: 500 s
(reading input, processing data, setting output)
PLS Programmable limit switches (PLS) max. 256
Type: dynamic
Outputs: memory or digital outputs
Inputs: external master encoder, virtual master
encoder, or axes position
Scan time: 250 s
I/Os Integrated digital inputs (X3) number: 20 (IEC61131-2)
range U
IN
0 state: DC 0 ... 6 V
range U
IN
1 state: DC 20 ... 33 V
input current: I
IN
= 5 mA on U
IN
= 24 V
pole safe: yes
input filter: 1or 5 ms programmable
Parameter Value
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Technical Data
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Integrated analog inputs (X5) number: 2
range U
IN
: -10 ... 10 V (impedance 100 k)
or
range I
IN
: 0 ... 20 mA (impedance 500 R)
Integrated interrupt inputs (X4) number: 4 (IEC61131-2)
range U
IN
0 state: DC 0 ... 6 V
range U
IN
1 state: DC 20 ... 33 V
input current: I
IN
= 5 mA on U
IN
= 24 V
pole safe: yes
input filter: 0.1 or 1 ms programmable
Integrated touchprobe inputs (X4) number: 16 (IEC61131-2)
range U
IN
0 state: DC 0 ... 6 V
range U
IN
1 state: DC 20 ... 33 V
input current: I
IN
= 5 mA on U
IN
= 24 V
pole safe: yes
input filter TP0 to TP15: 100 s
resolution time TP0 to TP15: 10 s
Integrated digital outputs (X2) number: 16 (IEC61131-2)
output voltage: (+UL-3 V) < U
OUT
< +UL
rated current: I
e
= 250 mA per output
switch current: I
emax
< 2 A for 1 s
leakage current 0 signal: < 0.4 mA
transmission time: 100 s
short-circuit-proof: yes
supply output: DC 24 V (-15%/+25%) / 3A
Integrated analog outputs (X5) number: 2
range U
OUT
: -10 ... 10 V (impendance 100 k)
Additional digital and analog I/Os via fieldbus
max. 3.584 Bytes digital/analog inputs and
max. 3.584 Bytes digital/analog outputs
max. number of stations: 126 (PROFIBUS)
Additional fast digital I/Os via PacNet
max. 128 inputs and 128 outputs
Additional touchprobe inputs via PacNet
max. 128 touchprobe inputs
Power supply Power supply DC 24 V (-15% / +25%) /
max. 2.5 A without UPS and 4.0 A with UPS
Power consumption max. 85 W
Uninterruptable power supply UPS yes (optional), (service interval 3 years)
Parameter Value
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Technical Data
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Environment Product size
Box size
see chapter Dimensions
width: 130 mm
height: 400 mm
depth: 300 mm
Product weight
Boxed weight
3.5 kg
4.1 kg
Ambient conditions
- protection class
- ambient temp.
- insulation class
- rel. humidity
IP20
+5...+55 C (in operation without UPS)
+5...+40 C (in operation with UPS)
-25...+70 C (for storage and transport without UPS)
-25...+50 C (for storage and transport with UPS)
degree of pollution 2 ..., no dewing allowed
5% ... 85% climatic category 3K3 EN 60 721
Approval Approvals CE, UL , cUL
Parameter Value
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Interfaces
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Interfaces
Fig. 2-1: Overview of the PacDrive Controller C400
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X15
X14
X1
2
4
V
/
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d
X4
t
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X5
X2
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X17
X10
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2
X18
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2

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8
5
X11
X19
X12 X13
X20
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X3
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1

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-
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enter
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bus
err
wd
pow
err
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X18 COM 2 serial
interface RS485
X10 ethernet
X14 motion bus SERCOS *)
IN
X15 motion bus SERCOS *)
OUT
X19 CAN
X11 master encoder
SinCos or incremental
PD_Anschlussbersicht_C400_us.FH8
shield connection
X17 COM 1 serial
interface RS232
X12 pacnet 0
X13 pacnet 1
X20 profibus dp
power supply X1
and watchdog
digital outputs X2
digital inputs X3
touchprobe X4
and fast inputs
analog in-/outputs X5
*) max. stud torque 0,8 Nm
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Interfaces
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Electrical Connections
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X1 - control voltage and watchdog
Table 3-1: Electrical connections of C400/ X1
Fig. 3-1: Electrical connections of C400 / X1 input connection
CAUTION!
Disconnection of control voltage!
Risk of data loss or damage to flash disk!
Use UPS, and the control voltage of the PacDrive Controller
may only be switched off if all files are closed. See also
Programming Manual -Reference- Function SysShutdown().
Pin
Desig-
nation
Meaning Range
Max.
cross
section
1 DC +24 V supply voltage - 15% / +25% 1.5 mm
2
2 0 V supply voltage 1.5 mm
2
3 +UL for digital outputs DC +24V
-15% / +25%
1.5 mm
2
4 L0 for digital inputs /
outputs
1.5 mm
2
5 DC +24 V supply voltage -15% / +25% 1.5 mm
2
6 0 V supply voltage 1.5 mm
2
7 WD watchdog relay 1.5 mm
2
8 WD watchdog relay 1.5 mm
2
1 5
4 8
supply voltage
internal
supply voltage
for digital outputs/inputs
input connection of power supply (simplified)
X1:1 24V
X1:5 24V
X1:2 0V
X1:6 0V
X1:3 +UL
X1:4 0VL
X1
PD_C4_600_P600_X1_us.fh8
fuse
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X2 - digital outputs
Table 3-2: Electrical connections of C400 / X2
X3 - digital inputs
Pin
Desig-
nation
Meaning Range
Max.
cross
section *)
1 O.00 digital Output 1 1.0 mm
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
*) Stripping length l=9mm; by the wire-end ferrule is the length of the
metal ferrule l=10mm
Pin
Desig-
nation
Meaning Range
Max.
cross
section *)
1 I.00 digital input 0 DC 0 ... 33 V 1.0 mm
2
2
2
2
2
2
2
2
2
2
2
2
1 9
8 16
1 11
10 20
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X4 - touchprobe and fast digital inputs
2
2
2
2
2
2
19 I.18 digital input 18 DC 0... 33 V 1.0 mm
2
2
Pin
Desig-
nation
Meaning Range
Max.
cross
section *)
1 T.00 touchprobe input 0 DC 0 ... 33 V 1.0 mm
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
17 F.00 fast input 0 DC 0 ... 33 V 1.0 mm
2
2
2
2
Pin
Desig-
nation
Meaning Range
Max.
cross
section *)
1 11
10 20
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X5 - analog in- /outputs
Fig. 3-2: Electrical connections of C400 / X5
Fig. 3-3: Electrical connections of C400 / X5 input connection
Pin
Desig-
nation
Meaning Range
Max.
cross
section *)
1 AI.0 + analog input 0 1.0 mm
2
2 J.0 + Br. current input 0 + 1.0 mm
2
3 AI.0 - analog input 0 - 1.0 mm
2
4 A.GND analog ground 1.0 mm
2
5 12 V Out 0 output voltage 0 12 V 1.0 mm
2
6 PE shield 1.0 mm
2
7 AO.0 analog output 0 -10 ... +10 V 1.0 mm
2
2
9 PE shield 1.0 mm
2
10 AI.1 + analog input 1 1.0 mm
2
11 J.1 + Br. current input 1 + 1.0 mm
2
12 AI.1 - analog input 1 - 1.0 mm
2
2
14 12 V Out 1 output voltage 1 12 V 1.0 mm
2
15 PE shield 1.0 mm
2
16 AO.1 analog output 1 -10 ... +10 V 1.0 mm
2
2
18 PE shield 1.0 mm
2
1 10
9 18
X5
input connection of analog inputs (simplified)
channel 1
X5:3 AI.0-
X5:12 AI.1-
X5:1 AI.0+
X5:10 AI.1+
X5:4
X5:5
X5:6
X5:2 J.0+
X5:11 J.1+
X5:8
X5:14
X5:9
PE (shield)
+12V
+
-
+
-
+12V
R1
R1, R2 = 500R
R3 - R8 = 1k
R4
R3
R5
R2
j1
j2
R7
AGND
R8
channel 2
PD_C4_600_X5_AnaIn_us.fh8
R6
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X10 - ethernet
NOTE
Depending on the application, different cables are required for the
connection to the PacDrive Controller via the RJ-45 connector plug.
Connection PacDrive Controller <-> corporate network mit RJ-45
-> straight twisted-pair cable
Connection PacDrive Controller <-> Hub
-> straight twisted-pair cable
Connection PacDrive Controller <-> PC
-> crossover twisted-pair cable
In doubt, please contact your network administrator.
X11 - master encoder (SinCos)
1
8
Pin
Desig-
nation
Meaning Range
Max. cross
section
1 Tx+ OutputTransmitData+
2 Tx- OutputTransmitData-
3 Rx+ InputReceiveData +
4 - reserved
5 - reserved
6 Rx- InputReceiveData -
7 - reserved
8 - reserved
LED yellow:link (light on) / Aktivity (flash or flicker)
LED green: type of connection 10MBit (light off) / 100MBit (light on)
1
5
6
9
Pin
Desig-
nation
Meaning Range
Max. cross
section
1 REFSIN sinus reference signal 0.25 mm
2
2 SIN sinus trace 0.25 mm
2
3 REFCOS cosine reference signal 0.25 mm
2
4 COS cosine trace 0.25 mm
2
5 +9 V supply voltage 0.25 mm
2
6 RS485- parameter channel - 0.25 mm
2
7 RS485+ parameter channel + 0.25 mm
2
8 SC_SEL encoder connected
(bridge to GND)
0.25 mm
2
9 GND supply voltage 0.25 mm
2
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X11 - master encoder (incremental)
CAUTION!
Disconnection of master encoder plug while unit is powered on!
Master encoder may be damaged!
Disconnect and connect the master encoder plug only in voltage-
free state (disconnect MotorController from 24 V power supply!).
X12/13 - PacNet
Table 3-8: Electrical connections of C400 / X12, X13
NOTE
Only use permitted PacNet cables with the PacNet interface to
avoid malfunction.
1
5
6
9
Pin
Desig-
nation
Meaning Range
Max. cross
section
1 _UA track A 0.25 mm
2
2 UA track A 0.25 mm
2
3 _UB track B 0.25 mm
2
4 UB track B 0.25 mm
2
5 + 5 V supply voltage 0.25 mm
2
6 _UO track O 0.25 mm
2
7 UO track O 0.25 mm
2
8 - reserved 0.25 mm
2
9 GND ground 0.25 mm
2
1 8
8 1
Pin Desig-nation Meaning Range
Max. cross
section
1 TxD+ OutputTransmitData+
2 TxD- OutputTransmitData-
3 RxD+ InputReceiveData+
4 TxC- OutputTransmitClock-
5 TXC+ OutputTransmitClock+
6 RxD- InputReceiveData-
7 RxC+ InputReceiveClock+
8 RxC- InputReceiveClock-
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X17 - Com 1 (RS 232)
X18 - Com 2 (RS485)
X19 - CAN
1
5
6
9
Pin
Desig-
nation
Meaning Range
Max. cross
section
1 DCD Data Carrier Detect 0.25 mm
2
2 RxD Receive Data 0.25 mm
2
3 TxD Transmit Data 0.25 mm
2
4 DTR Data Terminal Ready 0.25 mm
2
5 GND Signal Ground 0.25 mm
2
6 DSR Data Set Ready
Clear To Send
0.25 mm
2
7 RTS Request To Send 0.25 mm
2
8 CTS Clear To Send 0.25 mm
2
9 RI Ring Indicator 0.25 mm
2
1
5
6
9
Pin
Desig-
nation
Meaning Range
Max. cross
section
1 +5 VM supply voltage 0.25 mm
2
2 TxD- RS485 Transmit - 0.25 mm
2
3 TxD+ RS485 Transmit+ 0.25 mm
2
4 RxD+ RS485 Receive + 0.25 mm
2
5 RxD- RS485 Receive - 0.25 mm
2
6 GNDR GND receive RS485 0.25 mm
2
2
8 GNDM supply voltage 0.25 mm
2
9 GNDR GND receive RS485 0.25 mm
2
1
5
6
9
Pin
Desig-
nation
Meaning Range
Max. cross
section
2
2 CAN_L bus line (low) 0.25 mm
2
3 GND ground 0.25 mm
2
2
2
2
7 CAN_H bus line (high) 0.25 mm
2
2
2
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X20 - profibus db
1
5
6
9
Pin
Desig-
nation
Meaning Range
Max. cross
section
1 PE shield 0.25 mm
2
2
3 RxD / TxD -P data -P 0.25 mm
2
4 CNTR-P control signal P 0.25 mm
2
5 DGND signal ground 0.25 mm
2
6 VP control voltage 0.25 mm
2
2
8 RxD / TxD -N data -N 0.25 mm
2
9 reserved 0.25 mm
2
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Dimensions
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Dimensions
Fig. 4-1: Dimensions of the PacDrive C400
ca. 235 (9.25)
ca. 260 (10.23) max. depth incl. connectors!
PDM_C400_Masszeichnung_us.FH8
X17
c
o
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1

r
s
2
3
2
X18
c
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2

r
s
4
8
5
X19
X20
c
a
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d
p
3
1
0

(
1
2
.
2
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2
6
8

(
1
0
.
5
5
)
2
4

(
0
.
9
5
)
1
8

(
0
.
7
1
)
16.6 (0.65) 70 (2.76)
103.2+2 (4.06)
2
9
6

(
1
0
.
6
)
7

(
0
.
2
8
)
6.5 (0.26)
12 (0.47)
16.6 (0.65)
7

(
0
.
2
8
)
7

(
0
.
2
8
)
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Data Sheet

ELAU On the best machines

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