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Key Technical Specifications
| Parameter | Value |
|---|---|
| Manufacturer | ELAU AG, now part of Schneider Electric |
| Product family | PacDrive |
| Model | MAx-4 |
| Processor | Intel Pentium II, 266 MHz |
| RAM | 32 MB |
| L2 cache | 512 kB |
| NVRAM | 32 kB |
| Internal storage | 16 MB CompactFlash |
| Operating system | VxWorks real-time operating system |
| Programming | IEC 61131-3: CFC, FBD, IL, LD, SFC, and ST |
| Motion bus | SERCOS interface, 4 Mbaud, terminals X7 and X8 |
| Axis capacity | Up to 8 axes or up to 99 axes, depending on configuration |
| Motion performance | 11 axes at 1 ms SERCOS cycle; 23 axes at 2 ms; 45 axes at 4 ms |
| Integrated digital inputs | 20 inputs at X3 |
| Integrated analog inputs | 2 differential inputs at X2 |
| Touch-probe inputs | 16 inputs at X4 |
| Digital outputs | 16 outputs at X4, 100 mA rated per output |
| Serial interfaces | RS-232 at X5 and RS-485 at X6 |
| Ethernet | 10Base-T at X10 |
| Optional fieldbus | PROFIBUS DP master/slave, CAN, CANopen, DeviceNet slave, Ethernet/IP slave |
| Supply voltage | 24 VDC, -15% to +25% |
| Maximum supply current | 3.15 A |
| Power consumption | 60 W maximum |
| Protection rating | IP20 |
| Operating temperature | +5 to +55 °C |
| Approvals | CE, UL, cUL |
Product Introduction
The ELAU MAx-4 is a PacDrive multi-axis motion controller for packaging, material-handling, printing, and other synchronized machinery. It combines an IEC 61131-3 soft PLC with real-time SERCOS motion control, allowing one controller to coordinate servo axes, machine logic, fieldbus I/O, and HMI communication.
The MAx-4 is available in 8-axis and 99-axis configurations and supports up to three option modules. Its integrated Ethernet, RS-232/RS-485 ports, trace recorder, and optional PROFIBUS DP, CANopen, DeviceNet, or Ethernet/IP interfaces make it suitable for legacy PacDrive systems where the original controller must be replaced like-for-like.
MAx-4
MAx-4
Troubleshooting Quick Reference
| Symptom | Possible Cause | Relevance to this Part | Quick Check Method | Recommendation |
|---|---|---|---|---|
| Controller will not power up | Missing 24 VDC, weak power supply, blown fuse, or wiring fault | ✅ High | Measure 24 VDC at X1 terminals 1/2 and 5/6; verify supply can deliver up to 3.15 A | Check PSU, fuses, and wiring before replacing the MAx-4 |
| Controller boots but axes do not enable | SERCOS cable fault, drive not initialized, or motion program fault | ✅ High | Inspect X7/X8 SERCOS cabling and check drive/controller diagnostic status | Verify SERCOS topology and drive errors before condemning the controller |
| SERCOS communication fault | Incorrect fiber routing, damaged fiber, missing termination, or drive firmware mismatch | ✅ High | Check optical power/path and confirm every SERCOS device is addressed and initialized | Replace damaged fiber and verify the SERCOS ring or line configuration |
| PLC program lost after power failure | CompactFlash failure or improper shutdown | ✅ High | Check boot behavior, CompactFlash status, and project backup availability | Restore from a verified project backup; replace the CompactFlash only with an approved compatible media |
| Ethernet will not communicate | Wrong IP address, subnet conflict, bad cable, or DHCP/network configuration issue | ❌ Medium | Ping the controller from a PC on the same subnet; inspect link LEDs at X10 | Correct IP settings and cable type before replacing hardware |
| PROFIBUS DP not communicating | Missing option module, wrong node address, termination, or GSD configuration mismatch | ✅ Medium | Verify the installed PROFIBUS option module, node address, bus termination, and master configuration | Match the project configuration and physical bus setup |
| Digital outputs do not switch | Missing +UL supply at X1, overloaded output, or controller output fault | ✅ Medium | Measure +UL at X1 terminal 3; check output load current and wiring | Restore +UL supply or reduce load; each output is rated 100 mA |
| Analog input reads incorrectly | Signal outside -7 to +10 V or 0-20 mA range, poor shielding, or wrong scaling | ❌ Medium | Measure input signal at X2 and compare with controller scaling | Correct signal range, shielding, and scaling; the MAx-4 has no analog outputs |
| Controller overheats or shuts down | Blocked ventilation, excessive ambient temperature, or excessive power draw | ✅ Medium | Measure cabinet temperature and verify the MAx-4 is within +5 to +55 °C | Improve enclosure cooling; do not operate above the rated temperature |
❗ Shutdown warning: Do not simply remove 24 VDC power. The MAx-4 documentation warns that disconnecting control voltage can cause data loss or CompactFlash damage; close files and use the proper shutdown sequence or UPS-supported procedure.
If the controller still will not operate, send the full model suffix, firmware version, PacDrive project backup status, SERCOS topology, and photos of the status LEDs before ordering a replacement.
Frequently Asked Questions
How many servo axes can an ELAU MAx-4 control?
The MAx-4 is available in configurations for up to 8 axes or up to 99 axes. The actual usable axis count also depends on the selected SERCOS cycle time and system configuration.
What motion bus does it use?
It uses a SERCOS interface at 4 Mbaud through terminals X7 and X8.
Can I program it like a PLC?
Yes. The MAx-4 supports IEC 61131-3 languages including Ladder Diagram, Function Block Diagram, Structured Text, Instruction List, Sequential Function Chart, and Continuous Function Chart.
What fieldbus options are available?
PROFIBUS DP master or slave, CAN, CANopen, DeviceNet slave, and Ethernet/IP slave are available through optional hardware modules. Only one CAN or CANopen option module can be installed per MAx-4.
Does it have analog outputs?
No. The MAx-4 has two integrated analog inputs but no integrated analog outputs. Additional analog I/O must be added through a fieldbus or compatible PacDrive I/O architecture.
Can I hot-swap the CompactFlash card?
No. Do not remove storage media or disconnect control power while the controller is running. Use the documented shutdown procedure to avoid file corruption or CompactFlash damage.
Is the MAx-4 still supported by Schneider Electric?
The MAx-4 is legacy PacDrive hardware, and current market listings generally offer refurbished or surplus controllers rather than new production units. Before purchasing, confirm the exact full suffix, firmware compatibility, CompactFlash/project backup, and available repair or exchange support.
