ELAU MAX-4

Product Introduction:​ The ELAU MAX-4 (now under Schneider Electric) is a Pentium II-based controller platform that unifies logic control (PLC) and motion control into a single architecture. It serves as the central brain for the PacDrive system, synchronizing up to 47 (or more depending on config) servo drives via SERCOS interface, widely used in high-speed packaging and converting machinery.

Category:
Description
Technical Specifications & Performance Parameters:
  • CPU:​ Intel Pentium II, 266 MHz
  • Memory:​ 32 MB RAM, 512 KB L2 Cache, 32 kB NVRAM, 16 MB Internal CompactFlash Disk
  • Operating System:​ VxWorks (Real-Time OS)
  • Programming:​ IEC 61131-3 (LD, FBD, SFC, ST, IL, CFC)
  • Motion Bus:​ SERCOS Interface (4 Mbaud, up to 2 channels X7/X8)
  • Fieldbus Options:​ PROFIBUS DP (Master/Slave), CAN, CANopen, DeviceNet Slave, Ethernet/IP Slave (via optional modules)
  • Ethernet:​ 10 Base-T (TCP/IP) for programming/HMI/diagnostics
  • Serial:​ RS-232 (COM1), RS-485 (COM2)
  • Integrated I/O:​ Digital inputs/outputs, analog inputs, fast touch-probe inputs, interrupt inputs
  • Axes Support:​ Configurable for up to 8 axes base, expandable to 99+ axes via distributed architecture
  • Power Supply:​ 24 V DC (typical for Schneider/ELAU PAC units, approx 1.5 A)
  • Weight:​ Approx. 2.2 kg (depending on modules)
  • Status:​ Many variants are Obsolete / Discontinued, available via spares/refurbished markets
Material Composition & Structure:
  • Enclosure:​ Metal housing (likely aluminum/steel with coating) for EMC shielding and DIN rail/rack mounting
  • Backplane:​ High-speed bus connecting CPU module, power supply, fieldbus modules, I/O modules
  • Connectors:​ Sub-D (SERCOS, Serial), RJ45 (Ethernet), Screw terminals (I/O, Power)
  • Storage:​ CompactFlash slot for program/data logging
Functional Features & Working Principle:
  • Working Principle:​ Executes deterministic real-time control loops for logic and motion. The CPU processes IEC 61131-3 code and motion profiles, sending synchronized setpoints to SERCOS-connected drives. Feedback from encoders is processed to close the loop.
  • Integrated Logic & Motion:​ Eliminates need for separate PLC and Motion Controller; single development environment (PacDrive Workbench / IPS).
  • Electronic Camming/Gearing:​ High-precision virtual cam profiles and axis synchronization without mechanical linkages.
  • OPC Server:​ Included for Windows-based HMI integration.
  • Web Server/Modem:​ Supports remote diagnosis over network or telephone line.
  • Modularity:​ Expandable via option modules for increased I/O or different fieldbus protocols.
Application Scenarios:
  • High-speed flow wrapping and primary packaging machines
  • Cartoning, case packing, palletizing systems
  • Pharmaceutical blister/liquid filling lines
  • Printing and converting machinery (labelers, slitters)
  • Food processing machinery requiring washdown-compatible distributed I/O (with remote stations)
Installation Requirements & Usage Notes:
  • Requires 24 V DC regulated power supply with sufficient current margin for all connected I/O and processor load.
  • SERCOS fiber optic cables must be correctly terminated (ring topology) and cleaned; bending radius should not be exceeded to avoid signal loss.
  • Ground the controller chassis to the control panel ground bus; separate power and signal cabling to minimize EMI.
  • Backup CompactFlash cards regularly; these aging components can fail and are critical for system recovery.
  • Since the product is largely obsolete, ensure spare parts availability and consider migration paths (e.g., to PacDrive 3 or Lexium) for new designs.
  • Use proper ESD when handling the CompactFlash card or installing modules.
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