ELAU PacDrive Distribution Box DB-5

The ELAU PacDrive Distribution Box DB-5 is a critical component within the PacDrive™ system, designed to facilitate the efficient distribution of power and control signals between the PacDrive Power Supply PS-5 and the Intelligent Servo Module (iSH). This modular and flexible solution is engineered for seamless integration into industrial automation systems, particularly in packaging and food processing machinery. The DB-5 ensures reliable power distribution while adhering to stringent safety and performance standards.

Key Features of the DB-5

1. Modular Design:
   The DB-5 supports the connection of 1 to 4 iSH motors, with the ability to expand the system by adding more DB-5 units as needed. This scalability makes it ideal for applications requiring multiple axes of motion control.

2. High Compatibility:
   It is fully compatible with the PacDrive PS-5 power supply and the iSH servo modules, ensuring a cohesive and efficient control system.

3. Diagnostic Capabilities:
   Equipped with LED indicators for DC bus voltage status and SERCOS communication, the DB-5 provides real-time feedback for troubleshooting and maintenance.

4. Robust Construction:
   With a protection class of IP65, the DB-5 is resistant to dust and water jets, making it suitable for harsh industrial environments.

5. Safety Compliance:
   The DB-5 meets CE and cULus standards, ensuring adherence to international safety and electromagnetic compatibility (EMC) regulations.

Technical Specifications

The DB-5 is designed to operate under specific electrical and environmental conditions. Below is a detailed table summarizing its technical data:

Electrical Connections

The DB-5 features multiple connectors for seamless integration into the PacDrive system:

1. Input (X1):

   • Connects to the PS-5 or another DB-5 using pre-fabricated ELAU cables.

   • Supports power and control signal transmission.

2. Outputs (X2 to X5):

   • Each output can connect to another DB-5 or an iSH motor.

   • Ensures distributed power and control signals to multiple axes.

Pin Configuration for DB-5 Connectors:

Safety and Installation Guidelines

1. Residual DC Bus Voltage:

   • The DB-5 includes an LED to indicate dangerous DC bus voltage (≥50 V).

   • Always verify the absence of voltage using a meter before servicing.

2. Inverter Enable Function:

   • The ie1/ie2 signals must be correctly wired to avoid damage to the iSH module.

   • Ensure proper grounding to maintain safety and EMC compliance.

3. Environmental Considerations:

   • Avoid operating in explosive atmospheres or mobile systems.

   • Maintain ambient temperature within the specified range to prevent overheating.

4. EMC Rules:

   • Use shielded cables and minimize cable loops to reduce electromagnetic interference.

   • Ensure proper grounding to avoid current loops.

Maintenance and Troubleshooting

1. Routine Checks:

   • Inspect LED indicators for errors (e.g., SERCOS ring breaks).

   • Verify cable connections for wear or damage.

2. Cleaning:

   • Use dry compressed air (max 1 bar) to remove dust.

   • Ensure the unit is de-energized before cleaning.

3. Fault Reporting:

   • Use the fault report form (Section 10.4 of the manual) to document issues.

   • Include details such as error codes, operating conditions, and machine specifications.

Applications

The DB-5 is widely used in:

• Packaging machinery requiring precise motion control.

• Food processing systems where hygiene and reliability are critical.

• Industrial automation with modular and scalable drive systems.

Conclusion

The ELAU PacDrive Distribution Box DB-5 is a versatile and robust component that enhances the flexibility and reliability of the PacDrive™ system. Its modular design, diagnostic features, and compliance with international standards make it an ideal choice for complex automation applications. By adhering to the installation and maintenance guidelines, users can ensure optimal performance and longevity of the DB-5 in their industrial systems.

ELAU PacDrive Power Supply PS-5:

Comprehensive Technical Overview

Introduction to PacDrive PS-5 Power Supply

The ELAU PacDrive Power Supply PS-5 is a sophisticated component designed for integration within the PacDrive™ automation system, specifically developed for modern packaging and food processing machinery. As a critical element in ELAU's modular drive concept, the PS-5 provides reliable power distribution and management for intelligent servo modules (iSH) within industrial automation environments.

Manufactured by ELAU AG, a Schneider Electric company based in Marktheidenfeld, Germany, the PS-5 represents state-of-the-art power supply technology with a compact, closed construction optimized for switch cabinet installation. Its design emphasizes ease of installation, comprehensive diagnostics, and seamless integration with other PacDrive system components.

Key Features and Technical Specifications

The PacDrive PS-5 power supply unit boasts several notable features that make it suitable for demanding industrial applications:

• Integrated mains filter and bleeder for clean power distribution

• Intermediate circuit power capacity for up to 25 iSH modules (application-dependent)

• Integrated SERCOS interface for high-speed communication

• Comprehensive diagnostic capabilities through its integrated controller

• Simplified assembly with single connection line design

Technical Data Table

Safety Features and Compliance

The PacDrive PS-5 incorporates multiple safety features to protect both equipment and personnel:

1. Residual DC Bus Voltage Display: An LED indicator warns when dangerous voltages (>50V DC) are present in the DC bus.

2. Leakage Current Protection: With leakage current greater than 3.5 mA, the unit requires a fixed connection to the power supply network in accordance with DIN EN 50178 standards.

3. Comprehensive Safety Standards Compliance:

   • EN 60204-1 (2007): Safety of machinery - Electrical equipment

   • EN 50081-2 (3/1994): Electromagnetic compatibility

   • EN 61000-6-2 (3/2000): Electromagnetic immunity

The manufacturer's declaration confirms that the PS-5 is intended for installation in machines and complies with EC machine guidelines 98/37/EC. Commissioning is prohibited until it's confirmed that the host machine meets all EC Directive requirements.

Installation and Wiring Considerations

Proper installation of the PacDrive PS-5 requires attention to several critical factors:

Power Supply Grounding Requirements

• Grounded Operation: May be operated without potential separation on AC networks with a grounded star point

• Ungrounded Mains: Requires an isolating transformer when operating on IT networks or mains without grounded neutral points

UL Conformity Requirements

• Use of a fuse (Type: maximum 40 A, 600 VAC) in the feed line

• Operation only on circuits capable of delivering ≤5000 rms symmetrical amperes

• For 24V supply, use a fuse with max. 15 A

Connection Overview

The PS-5 features multiple connection points with specific requirements:

Indicators and Diagnostic Capabilities

The PS-5 features a comprehensive LED indicator system for status monitoring and diagnostics:

Power (POW) LED

• OFF: Control voltage missing or too low

• Slow Flash (0.5 Hz): Bootloader active, firmware defective

• Brief Flash (3 Hz): Device identification active

• ON: Device ready, error diagnosis possible

Error (ERR) LED

• OFF: No error

• Slow Flash (0.25 Hz): SERCOS error

• Quick Flash (2 Hz): General error or device not configured

• Long Flash: SERCOS ring interruption

• ON: Fatal system error

SERCOS Bus Indicators

• BUS ERR: Indicates fiber-optic cable connection problems

• SINK: Shows SERCOS bus state (copper cable)

• SERR: Displays errors for copper cable SERCOS connection

Operational Considerations

EMC Rules

The PS-5 requires careful attention to electromagnetic compatibility:

• Use shielded cables only with proper grounding

• Implement star configuration grounding from central point

• Avoid cable loops in switch cabinets

• Maintain short motor cable lengths

• Isolate controller from interference sources when necessary

Maintenance Requirements

While largely maintenance-free when correctly installed, the PS-5 requires:

• Periodic cleaning with dried compressed air (max 1 bar)

• Annual checks of brake functions (if present)

• Regular verification of safety functions (EMERGENCY OFF, etc.)

• Maintenance logbook entries for all component replacements

System Integration

The PacDrive PS-5 serves as a central component in the PacDrive system architecture, which includes:

1. PacDrive Controllers: Microprocessor-based control hardware with VxWorks RTOS

2. PacDrive Servo Amplifiers (MC-4)

3. PacDrive Motors

4. Distribution Box DB-5: Links between PS-5 and iSH modules

The system supports various HMIs and can coordinate multiple drives depending on controller model (C200: 8 drives, C400: 16 drives, C600: 99 drives).

Conclusion

The ELAU PacDrive Power Supply PS-5 represents a robust, feature-rich solution for industrial automation power distribution. Its combination of safety features, diagnostic capabilities, and flexible integration options make it particularly suitable for packaging and food processing machinery where reliability and precision are paramount.

With proper installation and maintenance in accordance with the manufacturer's guidelines, the PS-5 provides a stable power foundation for PacDrive automation systems, contributing to reduced downtime and enhanced system performance in demanding industrial environments.