Data Sheet PacDrive C400 / A8 Controller

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Any possible measure was taken to ensure that this product documentation is com‐

plete and correct. However, since hardware and software are continuously improved,

ELAU makes no representations or warranties with respect to the contents of this

documentation.

All information on our products in this manual are given purely for the purpose of prod‐

uct description and is not binding. Misprints, errors and modifications -without prior

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manual are explicitly a part of an agreement made with ELAU GmbH, then the details

of the agreements in this manual are exclusively to determine the agreed condition of

the object of agreement, on behalf of the § 434 BGB (condition guarantee on behalf

of legal regulations).

Trademark

PacDrive is a registered trademark of ELAU GmbH.

All other trademarks mentioned in this documentation are the exclusive property of

their manufacturers.

ELAU GmbH

Dillberg 12-16

97828 Marktheidenfeld, Germany

Tel.: +49 (0) 9391 / 606 - 0

Fax: +49 (0) 9391 / 606 - 300

E-mail: info@elau.de

Internet: www.elau.de

Imprint

Page 2 PacDrive Controller C400 ELAU GmbH

1 Overview

Figure 1-1: PacDrive System Overview

C400 / C400 A8 Controller

Controller based architecture

The PacDrive C400 Controller is based on an Intel module processor. It uses the real-

time operating system VxWorks. VxWorks provides logic and motion functions for a

production or packaging machine. A PacDrive Controller synchronizes, coordinates

and generates the positioning functions for up to 16 servo drives, which are connected

via the SERCOS bus interface.

Several standardized field bus interfaces are available: PROFIBUS DP, CAN, CAN‐

open or DeviceNet. A variety of standard HMI systems, ranging from low-cost text

displays to industrial PCs, can be used for the HMI functions.

•CPU: Intel Module, 600 MHz, 256 MB RAM

•Real-Time operating system: VxWorks

•IEC 61131-3 programming languages for PLC and Motion Control

•SERCOS interface

•Profibus DP, CAN, CANopen, DeviceNet, or Ethernet/IP

•Digital inputs, digital outputs, analog, interrupt and Touchprobe inputs

•Communication interfaces: RS 232, RS 485, Ethernet (TCP/IP)

•CompactFlash™ card (≥128 MB)

•Includes OPC server for Windows-based HMIs

•Teleservice via web server or modem

1

ELAU GmbH PacDrive Controller C400 Page 3

2 Technical data

2.1 Ambient conditions

Procedure Parameters Value Basis

Operation Class 3K3 IEC/EN 60721-3-3

Ambient temperature +5°C...+45°C

Condensation Prohibited

Icing Prohibited

Another water Prohibited

Relative humidity 5% ... 85%

Transport Class 2K3 IEC/EN 60721-3-2

Ambient temperature -25°C...+70°C

Condensation Prohibited

Icing Prohibited

Another water Prohibited

Relative humidity 5% ... 95%

Long time storage in

transport packaging

Class 1K4 IEC/EN 60721-3-1

Ambient temperature -25°C...+55°C

Condensation Prohibited

Icing Prohibited

Another water Prohibited

Relative humidity 5% ... 95%

Table 2-1: Ambient conditions PacDrive C400 Controller

Procedure Parameters Value Basis

Operation Class 3K3 IEC/EN 60721-3-3

Ambient temperature +5°C...+40°C

Condensation Prohibited

Icing Prohibited

Another water Prohibited

Relative humidity 5% ... 85%

Transport Class 2K3 IEC/EN 60721-3-2

Ambient temperature -25°C...+50°C

Condensation Prohibited

Icing Prohibited

Another water Prohibited

Relative humidity 5% ... 95%

Long time storage in

transport packaging

Class 1K3 IEC/EN 60721-3-1

Ambient temperature -5°C...+45°C

Condensation Prohibited

Icing Prohibited

Another water Prohibited

Relative humidity 5% ... 95%

Table 2-2: Ambient conditions PacDrive C400 Controller (with UPS)

2 Technical data

Page 4 PacDrive Controller C400 ELAU GmbH

2.2 Standards and regulations

Certifications CE, UL , cUL

Table 2-3: Standards and regulations PacDrive C400 Controller

2.3 Mechanical and electrical data

Category Parameters Value

Product

configuration

Type key C400 up to 16 SER‐

COS slaves

(SERCOS slaves = MC-4, SCL,

iSH)

PacDrive C400 / 10 / 1 / 1 / 1 / 00

Type key C400 up to 8 SERCOS

slaves

PacDrive C400 / A8 / 1 / 1 / 1 / 00

Order number- C400 up to 16

SERCOS slaves

13 13 02 61

Order numbers C400 up to 8

SERCOS slaves

13 13 02 61-001

Processor

CPU C400 up to 16 SERCOS slaves: Intel Pentium M 600 MHz

C400 up to 8 SERCOS slaves: Celeron M 600 MHz

RAM 256 MB

L2 Cache C400 up to 16 SERCOS slaves: 1 MB

C400 up to 8 SERCOS slaves: 512 kB

NVRAM 128 kB

CompactFlashTM card ≥128 MB

Real time clock (RTC) Yes (battery maintenance interval: 5 years)

Watchdog Yes (max. 60 V < 2 A)

Diagnosis Alphanumeric diagnostic display, Status LEDs

Operating system Real-time operating system VxWorks

Programming

languages

Programming languages IEC

61131-3

Instruction list (IL)

Ladder diagram (LD)

Function block diagram (FBD)

Sequential function chart (SFC)

Structured text (ST)

Continuous function chart (CFC)

2.2 Standards and regulations

ELAU GmbH PacDrive Controller C400 Page 5

Category Parameters Value

Interfaces

Serial interfaces COM1: RS232 (X17)

COM2: RS485 (X18)

Network connection Ethernet (10/100 Base-T) (X10)

Field bus connections PROFIBUS DP Master/Slave (12 MBaud) (X20) or

CAN (2.0A) or CANopen (X19)

DeviceNet Slave (cable adapter required)

EtherNet/IP Slave (projected) (optional hardware module required)

Real-time bus interface SERCOS interface (16 MBaud) (X14, X15)

PacNet interface 2 PacNet interfaces (X12, X13)

Master encoder interfaces 1 SinCos master encoder or

1 incremental master encoder (X11)

HMI Interfaces RS485 (Modbus or PROFIBUS DP)

HMI software tools: OPC server (for Windows NT/2000/XP or Win‐

dows CE)

Diagnostic interface for remote

maintenance

Modem

Communications protocols Http

Ftp

SMTP (E-Mail)

Integrated trace recorder (soft‐

ware oscilloscope)

8 channels, resolution 1 ms

Integrated data logger for diag‐

nostic messages

27 kB

Output

C400 16 servo axes with all SERCOS cycle times

C400 / A8 8 servo axes with all SERCOS cycle times

Max. of 255 parallel motion profiles possible

SPS output

Time for 1000 Bit instructions 7 µs

Number of PLC processes Unlimited

Type of PLC processes Continuous,

periodic or

event-controlled

Cycle time fast task 250 µs

nominal I/O response time 500 µs (read in data, process, set output)

Cam Switch

Group

Number of cams Max. 256

Sequential circuit Dynamic

Outputs Memory or

Digital outputs

Inputs External master encoder

Virtual master encoder

Axis position

Processing time 250 µs

Digital inputs (X3)

Number 20 (IEC61131-2)

Range UIN 0 Voltage DC 0 ... 6 V

Range UIN 1 Voltage DC 20 ... 33 V

Input data IIN = 5 mA by UIN = 24 V

Polarized Yes

Input filter 1 or 5 ms can be parameterized

2 Technical data

Page 6 PacDrive Controller C400 ELAU GmbH

Category Parameters Value

Analog inputs (X5)

Number 2

Range UIN -10 ... 10 V

Resolution 12 Bit (5 mV)

Resistor 100 kOhm

Range IIN -20 ... 20 mA

Resolution 12 Bit, (5 μA)

Resistor 500 Ohm

Interrupt inputs

(X4)

Number: 4 (IEC61131-2)

Range UIN 0 Voltage DC 0 ... 6 V

Range UIN 1 Voltage DC 20 ... 33 V

Input data IIN = 5 mA by UIN = 24 V

Polarized Yes

Input filter 0.1 or 1 ms can be parameterized

Touchprobe inputs

(X4)

Number 16 (IEC61131-2)

Range UIN 0 Voltage DC 0 ... 6 V

Range UIN 1 Voltage DC 20 ... 33 V

Input data IIN = 5 mA by UIN = 24 V

Polarized Yes

Input filter TP0 to TP15 100 µs resolution

TP0 to TP15 10 µs at a cycle time of 1, 2, 4 ms

Digital outputs (X2)

Number 16 (IEC61131-2)

Output voltage (+UL-3 V) < UOUT < +UL

Rated current Ie = 250 mA per output

Inrush current Iemax < 2 A for 1 s

Leakage current with 0 signal < 0.4 mA

Transmission time 100 µs

short circuit proof Yes

Digital outputs (X5)

Number 2

Range UOUT -10 ... 10 V

Resolution 12 Bit (5 mV)

Load > 5 kOhm (max. Offset < +/- 75mV)

Additional digital

and analog I/Os

Via field bus Max. 3,584 bytes digital/analog inputs and

Max. 3,584 bytes digital/analog outputs

Max. number of stations: 126 (PROFIBUS)

Additional fast digi‐

tal I/Os

Via PacNet Max. 128 inputs and 128 outputs

Additional Touchp‐

robe inputs

Via PacNet Max. 128 Touchprobe inputs

Power supply

Power supply unit DC 24 V (-15% / +25%)

max. 3,0 A without UPS

max. 4,5 A without UPS

Power consumption Max. 85 W

Uninterruptible Power Supply

(UPS)

Internal, optional (maintenance interval 3 years)

Dimensions Dimensions packaging DxWxH (mm): 300x130x400

Weight Weight (with packaging) 3.5 kg (4.1 kg)

Protection class Housing IP 20

2.3 Mechanical and electrical data

ELAU GmbH PacDrive Controller C400 Page 7

Category Parameters Value

Isolation class Degree of pollution 2

Table 2-4: Technical data PacDrive C400 Controller

2 Technical data

Page 8 PacDrive Controller C400 ELAU GmbH

2.4 Electrical connections

battery

battery

battery

X21 cf-card

battery

X21 cf-card

15

14

X1

24V/wd

X4

tp/fast

X5

X2

digital out

analog in/out

X17

10

com1 rs232

X18

com2 rs485

X11 19

12 13

20

pacnet

phys enc

can

profibus dp

eth

X3

digital in

Made in Germany

battery

battery

X21 cf-card

X21 cf-card

enter

PacDrive

bus

err

wd

pow

err

C400

X17

X18

X10

X19

X11

X13

X12

X1

X2

X3

X4

X5 X14

X20

X15

Figure 2-1: Connection overview PacDrive C400 Controller

Connection Meaning max. terminal cross-section [mm2]/

[AWG]

X1 Control voltage/

Watchdog

1.50 mm228 - 16

X2 Digital outputs 1.50 mm228 - 16

X3 Digital inputs 1.50 mm228 - 16

X4 Touchprobe and fast digital inputs 1.50 mm228 - 16

X5 Analog inputs/outputs 1.50 mm228 - 16

X10 Ethernet connection - -

X11 Master encoder (SinCos) 0.25 mm2-

X11 Master encoder (incremental) 0.25 mm2-

X12/X13 PacNet - -

X17 Com 1 (RS232) 0.25 mm2-

X18 Com 2 (RS485) 0.25 mm2-

X19 CAN 0.25 mm2-

X20 PROFIBUS db 0.25 mm2-

Shielded connector - -

Table 2-5: Connection overview PacDrive C400 Controller

2.4 Electrical connections

ELAU GmbH PacDrive Controller C400 Page 9

X1 - Control voltage and watchdog

1 5

4 8

Pin Designation Meaning Range

1 DC +24 V Supply voltage - 15 % / +25 %

2 DC 0 V Supply voltage

3+UL For digital outputs DC +24 V

-15 % / +25 %

4 L0 For digital inputs/outputs

5

DC +24 V Supply voltage

(with pin 1 bridged, max. ampacity

4A)

-15 % / +25 %

6

DC 0 V Supply voltage

(with pin 2 bridged, max. ampacity

4A)

7 WD Watchdog relay

8 WD Watchdog relay

Table 2-6: Connection X1

2

X1

3

1

Pin1

Pin5

Pin2

Pin6

Pin3

Pin4

Figure 2-2: Connection X1 - Input connection

1Internal wiring diagram - input connection of power supply (simplified)

2Internal supply voltage

3Supply voltage for digital outputs/inputs

2 Technical data

Page 10 PacDrive Controller C400 ELAU GmbH

X2 - Digital outputs

1 9

8 16

Pin Designation Meaning Range

1 O.00 Digital output 1 DC 20 ... 30 V

2 O.01 Digital output 2 DC 20 ... 30 V

3 O.02 Digital output 3 DC 20 ... 30 V

4 O.03 Digital output 4 DC 20 ... 30 V

5 O.04 Digital output 5 DC 20 ... 30 V

6 O.05 Digital output 6 DC 20 ... 30 V

7 O.06 Digital output 7 DC 20 ... 30 V

8 O.07 Digital output 8 DC 20 ... 30 V

9 O.08 Digital output 9 DC 20 ... 30 V

10 O.09 Digital output 10 DC 20 ... 30 V

11 O.10 Digital output 11 DC 20 ... 30 V

12 O.11 Digital output 12 DC 20 ... 30 V

13 O.12 Digital output 13 DC 20 ... 30 V

14 O.13 Digital output 14 DC 20 ... 30 V

15 O.14 Digital output 15 DC 20 ... 30 V

16 O.15 Digital output 16 DC 20 ... 30 V

Table 2-7: Connection X2

X3 - Digital inputs

1 11

10 20

Pin Designation Meaning Range

1 l.00 Digital input 0 DC 20 ... 30 V

2 l.01 Digital input 1 DC 20 ... 30 V

3 l.02 Digital input 2 DC 20 ... 30 V

4 l.03 Digital input 3 DC 20 ... 30 V

5 l.04 Digital input 4 DC 20 ... 30 V

6 l.05 Digital input 5 DC 20 ... 30 V

7 l.06 Digital input 6 DC 20 ... 30 V

8 l.07 Digital input 7 DC 20 ... 30 V

9 l.08 Digital input 8 DC 20 ... 30 V

10 l.09 Digital input 9 DC 20 ... 30 V

11 l.10 Digital input 10 DC 20 ... 30 V

12 l.11 Digital input 11 DC 20 ... 30 V

13 l.12 Digital input 12 DC 20 ... 30 V

14 l.13 Digital input 13 DC 20 ... 30 V

15 l.14 Digital input 14 DC 20 ... 30 V

16 l.15 Digital input 15 DC 20 ... 30 V

17 l.16 Digital input 16 DC 20 ... 30 V

18 l.17 Digital input 17 DC 20 ... 30 V

19 l.18 Digital input 18 DC 20 ... 30 V

20 l.19 Digital input 19 DC 20 ... 30 V

Table 2-8: Connection X3

2.4 Electrical connections

ELAU GmbH PacDrive Controller C400 Page 11

X4 - Touchprobe and fast digital inputs

1 11

10 20

Pin Designation Meaning Range

1 T.00 Touchprobe input 0 DC 20 ... 30 V

2 T.01 Touchprobe input 1 DC 20 ... 30 V

3 T.02 Touchprobe input 2 DC 20 ... 30 V

4 T.03 Touchprobe input 3 DC 20 ... 30 V

5 T.04 Touchprobe input 4 DC 20 ... 30 V

6 T.05 Touchprobe input 5 DC 20 ... 30 V

7 T.06 Touchprobe input 6 DC 20 ... 30 V

8 T.07 Touchprobe input 7 DC 20 ... 30 V

9 T.08 Touchprobe input 8 DC 20 ... 30 V

10 T.09 Touchprobe input 9 DC 20 ... 30 V

11 T.10 Touchprobe input 10 DC 20 ... 30 V

12 T.11 Touchprobe input 11 DC 20 ... 30 V

13 T.12 Touchprobe input 12 DC 20 ... 30 V

14 T.13 Touchprobe input 13 DC 20 ... 30 V

15 T.14 Touchprobe input 14 DC 20 ... 30 V

16 T.15 Touchprobe input 15 DC 20 ... 30 V

17 F.00 Fast input 1 DC 20 ... 30 V

18 F.01 Fast input 2 DC 20 ... 30 V

19 F.02 Fast input 3 DC 20 ... 30 V

20 F.03 Fast input 4 DC 20 ... 30 V

Table 2-9: Connection X4

X5 - Analog inputs/outputs

1 10

9 18

Pin Designation Meaning Range

1 AI.0 + Analog input 0+ -10 ... +10 V (*) 0 ... 20 mA (**)

2 J.0 + Br. current input 0 +

3 AI.0 - Analog input 0-

4 A.GND 0 Analog ground 0

5 12 V Out 0 Output voltage 0 12 V

6 PE Shield

7 AO.0 Analog output 0 -10 ... +10 V

8 A.GND AO.0 Analog ground 0

9 PE Shield

10 AI.1 + Analog input 1+ -10 ... +10 V (*) 0 ... 20 mA (**)

11 J.1 + Br. current input 1 +

12 AI.1 - Analog input 1-

13 A.GND 1 Analog ground

14 12 V Out 1 Output voltage 1 12 V

15 PE Shield

16 AO.1 Analog output 1 -10 ... +10 V

17 A.GND AO.1 Analog ground

18 PE Shield

(*) Voltage metering and (**)current measurement on AI.0+ / AI.0- (Pin 1 / Pin 3) and AI.1+ / AI.1- (Pin 10 /

Pin 12)

(**)Current measurement by bridging to J.0+ (Pin 2) or. J.1+ (Pin 11).

Table 2-10: Connection X5

2 Technical data

Page 12 PacDrive Controller C400 ELAU GmbH

Pin1

Pin3

Pin10

Pin11

Pin4

Pin6

X5

PE

+12V

+

-

+

-

+12V

R1

R1, R2 = 500R

R3 - R8 = 1k

R4

R3

R5

R2

R7

AGND

R8

R6

Pin2

Pin12

Pin8

Pin5

Pin14

Pin9

2

3

1

Figure 2-3: Connection X5 - Input connection

1Internal wiring diagram - input connections for analog inputs (simplified)

2Analog Input 1

3Analog Input 2

X10 - Ethernet

1

8

Pin Designation Meaning Range

1 Tx+ OutputTransmitData+

2 Tx- OutputTransmitData-

3 Rx+ InputReceiveData+

4 - (PE)

5 - (PE)

6 Rx- InputReceiveData-

7 - (PE)

8 - (PE)

Table 2-11: Connection X10

Depending on the application, you will need different cables to connect the controller

via the RJ-45 outlet.

Component A Component B required cable

PacDrive Controller "Firm network" with RJ-45 Commercially available patch ca‐

ble

PacDrive Controller Hub Commercially available patch ca‐

ble

PacDrive Controller PC Crossed RJ-45 network cable

▶In case of doubt, ask your network administrator.

2.4 Electrical connections

ELAU GmbH PacDrive Controller C400 Page 13

X11 - Master encoder (SinCos)

1

5

6

9

Pin Designation Meaning Range

1 REFSIN Reference Signal Sinus

2 SIN Sinus trace

3 REFCOS Reference Signal Cosinus

4 COS Cosinus trace

5 +9 V Supply voltage

6 RS485- Parameter channel -

7 RS485+ Parameter channel +

8SC_SEL Master encoder plugged in

(bridge to GND)

9 GND Supply voltage

Table 2-12: Connection X11 - Master encoder (SinCos)

X11 - Master encoder (incremental)

1

5

6

9

Pin Designation Meaning Range

1 _UA Track A

2 UA Track A

3 _UB Track B

4 UB Track B

5 +5 V Supply voltage

6 _UO Track O

7 UO Track O

8 - -

9 GND Ground

Table 2-13: Connection X11 - Master encoder (incremental)

CAUTION

PLUGGING IN/UNPLUGGING THE MASTER ENCODER PLUG WHEN SWITCHED

ON

•Only unplug or plug in master encoder when off-circuit.

•Disconnect controller from the 24 V supply voltage.

Failure to follow these instructions can result in equipment damage.

X12/13 - PacNet

1 8

8 1

Pin Designation Meaning Range

1 TxD+ OutputTransmitData+

2 TxD- OutputTransmitData-

3 RxD+ InputReceiveData+

4 TxC- OutputTransmitClock-

5 TXC+ OutputTransmitClock+

6 RxD- InputReceiveData-

7 RxC+ InputReceiveClock+

8 RxC- InputReceiveClock-

2 Technical data

Page 14 PacDrive Controller C400 ELAU GmbH

Table 2-14: Connection X12, X13

Use only approved PacNet cables at the PacNet connection to avoid malfunction.

X17 - Com 1 (RS 232)

1

5

6

9

Pin Designation Meaning Range

1 DCD Data Carrier Detect

2 RxD Receive Data

3 TxD Transmit Data

4 DTR Data Terminal Ready

5 GND Signal Ground

6 DSR Data Set Ready Clear To Send

7 RTS Request To Send

8 CTS Clear To Send

9 RI Ring Indicator

Table 2-15: Connection X17

X18 - Com 2 (RS485)

1

5

6

9

Pin Designation Meaning Range

1 +5 VM Supply voltage

2 TxD- RS485 Transmit -

3 TxD+ RS485 Transmit+

4 RxD+ RS485 Receive +

5 RxD- RS485 Receive -

6 GNDR GND receive RS485

7 - Reserved

8 GNDM Supply voltage

9 GNDR GND receive RS485

Table 2-16: Connection X18

X19 - CAN

1

5

6

9

Pin Designation Meaning Range

1 - Reserved

2 CAN_L Bus line (low)

3 GND Ground

4 - Reserved

5 - Reserved

6 - Reserved

7 CAN_H Bus line (high)

8 - Reserved

9 - Reserved

Table 2-17: Connection X19

An adapter is available for the connection to DeviceNet.

2.4 Electrical connections

ELAU GmbH PacDrive Controller C400 Page 15

X20 - profibus db

1

5

6

9

Pin Designation Meaning Range

1 PE Shield

2 - Reserved

3 RxD / TxD -P Data -P

4 CNTR-P Control signal P

5 DGND Signal ground

6 VP Supply voltage

7 - Reserved

8 RxD / TxD -N Data -N

9 Reserved

Table 2-18: Connection X20

Connector

A PROFIBUS connector must be used to connect to the 9 pole PROFIBUS outlet

because the bus terminal resistors are in this connector. The possible PROFIBUS

connectors with different cable outlets are illustrated below.

Figure 2-4: PROFIBUS connector

Bus terminal resistors

For the first and last bus nodes, the terminal resistors must be switched on. Otherwise

data transmission will not function properly.

The shielding must be applied generously and on both sides.

3

4

2

1

Figure 2-5: Position of the bus terminal resistors

1Last bus slave

2Nth bus slave

3First bus slave

4Bus terminator

2 Technical data

Page 16 PacDrive Controller C400 ELAU GmbH

2.5 Dimensions

ca. 235 (9.25)

ca. 260 (10.23)

max. Bautiefe inkl. Steckverbinder

!

PDM_C400_Masszeichnung_de.FH8

X17

com1 rs232

X18

com2 rs485

X19

X20

can

profibus dp

310 (12.2)

268 (10.55) 24 (0.95)

18 (0.71)

16.6 (0.65) 70 (2.76)

103.2+2 (4.06)

296 (10.6)

7 (0.28)

6.5 (0.26)

12 (0.47)

16.6 (0.65)

7 (0.28)

7 (0.28)

battery

battery

battery

X21 cf-card

battery

X21 cf-card

X15

X14

X1

24V/wd

X4

tp/fast

X5

X2

digital out

analog in/out

X17

X10

com1 rs232

X18

com2 rs485

X11 X19

X12 X13

X20

pacnet

phys enc

can

profibus dp

eth

X3

digital in

Made in Germany

battery

battery

X21 cf-card

X21 cf-card

enter

PacDrive

bus

err

wd

pow

err

C400

Figure 2-6: Dimensions PacDrive C400 Controller

2.5 Dimensions

ELAU GmbH PacDrive Controller C400 Page 17

3 Type code

Product ID code C400 / 10 / 1 / 1 / 1 / 00

HW-Variant

Processor

1 = Intel Pentium M 600 MHz

RAM

1 = 256 MB

Flash memory

1 = 32 MB

Optional functions

3 Type code

Page 18 PacDrive Controller C400 ELAU GmbH