ELAU PacDrive™ Controller C600/10/1/1/1/00: Advanced Motion Control for Industrial Automation

Introduction to the PacDrive™ C600 Controller

The ELAU PacDrive™ Controller C600/10/1/1/1/00 represents the high-performance tier in ELAU's industrial automation controller lineup, specifically designed for complex motion control applications in packaging machinery and other demanding industrial environments. As part of the comprehensive PacDrive™ System, the C600 model distinguishes itself through its exceptional processing power, extensive I/O capabilities, and ability to coordinate up to 99 servo axes simultaneously—far surpassing the capacity of its C200 and C400 counterparts.

This advanced controller combines PLC functionality with sophisticated motion control capabilities in a single hardware platform, running on the VxWorks real-time operating system to ensure deterministic performance for time-critical applications. The C600/10/1/1/1/00 variant features specific hardware configurations that make it particularly suitable for large-scale automation systems requiring precise synchronization of multiple axes.

Key Features and Technical Specifications

The PacDrive C600 controller offers an impressive array of features that set it apart in industrial automation:

Processing Power:

• Intel Pentium M 1.6 GHz processor

• 256 MB RAM with 1 MB L2 cache

• 256 kB NVRAM for critical parameter storage

• ≥128 MB CompactFlash™ card for program and data storage

Motion Control Capabilities:

• Controls up to 99 servo axes via SERCOS interface (16 MBaud)

• Supports maximum of 255 parallel motion profiles

• Advanced cam switch functionality (up to 256 cam switches)

• Integrated trace recorder (8 channels, 1 ms resolution)

Programming and Configuration:

• Full IEC 61131-3 programming support (IL, LD, FBD, SFC, ST, CFC)

• Fast PLC cycle times (4 µs for 1000 bit instructions)

• Multiple task types (continuous, periodic, event-controlled)

• Nominal I/O response time of 500 µs

Communication Interfaces:

• Dual Ethernet ports (10/100 Base-T)

• PROFIBUS DP Master/Slave (12 MBaud)

• CAN/CANopen interface

• Optional modules for EtherNet/IP, additional PROFIBUS, or CAN

• Serial interfaces (RS232 and RS485)

The C600's technical superiority becomes evident when examining its ability to handle complex motion sequences across numerous axes while maintaining precise synchronization—a capability that makes it indispensable in high-speed packaging lines and other demanding automation scenarios.

Hardware Architecture and Design

The PacDrive C600 controller features a robust industrial design with careful attention to reliability and serviceability:

Physical Characteristics:

• Dimensions: 130 mm (W) × 400 mm (H) × 300 mm (D)

• Weight: 3.5 kg (4.1 kg with packaging)

• Protection class: IP20

• Operating temperature: +5°C to +55°C (without UPS), +5°C to +40°C (with UPS)

Power Supply:

• 24 V DC control voltage (-15% to +25% range)

• Maximum current: 3.0 A (without UPS), 4.5 A (with UPS)

• Power consumption: max. 85 W

• Optional internal UPS (12V/2000mAh battery)

I/O Capabilities:

The C600's modular design allows for expansion through optional modules, enabling customization for specific application requirements while maintaining system integrity.

System Integration and Communication

The C600 controller serves as the central intelligence in the PacDrive System, which includes:

Integrated System Components:

• PacDrive Servo Amplifier MC-4

• PacDrive Intelligent Servo Module (iSH)

• PacDrive Power Supply PS-5

• PacDrive Distribution Box DB-5

• SH-Motor series servo motors

Network Capabilities:

• Real-time communication via SERCOS interface

• Fieldbus connectivity (PROFIBUS DP, CANopen)

• Ethernet for upper-level communication

• Support for industrial protocols (EtherNet/IP with optional modules)

Diagnostic Features:

• Comprehensive LED status indicators (power, watchdog, error, bus status)

• 4-line LCD display for firmware version and IP information

• Integrated data logger for diagnostic messages (27 kB capacity)

• Detailed error classification system

The controller's ability to handle up to 99 SERCOS nodes makes it uniquely capable in large-scale automation systems where coordination between numerous axes is critical for operational efficiency.

Application Areas and Industry Solutions

The PacDrive C600 controller excels in applications requiring:

High-Axis-Count Motion Control:

• Complex packaging machinery with multiple servo axes

• Printing and converting equipment

• Automated assembly systems

Precision Motion Applications:

• Robotics integration

• Pick-and-place systems

• High-speed labeling machines

Demanding Industrial Environments:

• Food and beverage packaging

• Pharmaceutical production

• Consumer goods manufacturing

The C600's advanced features like its 10 µs resolution touchprobe inputs and ability to manage 255 parallel motion profiles make it particularly valuable in applications requiring precise position synchronization and high-speed event capture.

Maintenance and Service Considerations

ELAU has designed the C600 controller with maintenance and serviceability in mind:

Preventive Maintenance:

• Battery replacement every 6 years (3 years for UPS battery)

• CompactFlash™ card maintenance

• Regular cleaning with dry compressed air (max. 1 bar)

Diagnostic Capabilities:

• Detailed error messages with classification

• Last error memory

• System status monitoring through LEDs and display

Safety Features:

• Watchdog monitoring

• Safe separation of signal voltages (PELV system)

• Compliance with EN 60204-1 safety standards

The controller's modular design facilitates quick replacement of components, while its comprehensive diagnostic system minimizes downtime by enabling rapid fault identification and resolution.

Technical Comparison with Other Models

While sharing the PacDrive system architecture with C200 and C400 models, the C600 distinguishes itself through:

Enhanced Processing Capabilities:

• Higher axis count (99 vs. 8 for C200 and 16 for C400)

• Greater motion profile capacity

• Expanded memory and processing power

Superior I/O Options:

• More touchprobe inputs (16 vs. fewer in other models)

• Additional fast inputs

• Greater expansion capabilities through optional modules

Advanced Features:

• Support for more complex network configurations

• Enhanced diagnostic capabilities

• Greater flexibility in large-system integration

These differences make the C600 the preferred choice for applications where scale, complexity, and precision are paramount considerations.

Conclusion

The ELAU PacDrive™ Controller C600/10/1/1/1/00 represents the pinnacle of ELAU's motion control technology, offering unparalleled performance for large-scale, high-precision automation applications. Its ability to coordinate up to 99 servo axes while maintaining precise synchronization makes it an ideal solution for the most demanding packaging and industrial automation challenges.

With its robust construction, comprehensive communication options, and advanced diagnostic features, the C600 controller provides system integrators and machine builders with a powerful tool for creating efficient, reliable automation solutions. The controller's flexibility through optional modules ensures it can be tailored to specific application requirements while maintaining the high performance and reliability expected from ELAU's PacDrive™ System.

For industries requiring the highest levels of motion control sophistication, the PacDrive C600 stands as a testament to ELAU's innovation in industrial automation technology, delivering the performance, precision, and reliability needed in today's competitive manufacturing environment.