ECET-262 [LABORATORY 12B]

ECET-262 

FALL 2010 

[LABORATORY 12B] 

Motion Programming: Introduction to EPAS Software & Targetbased 

Positioning

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LAB 12B 

Introduction to EPAS Software & Target-based Positioning 

Objective: To learn and understand motion programming applications and concepts by working 

with ELAU PacDrive Systems and EPAS Software. 

Software Tool Required: Automation Toolkit EPAS-4 V24. 

Prerequisite Knowledge: Ladder Logic programming. 

Supplement Documents: EPAS-4 Programming Manual, PacDrive C-200 Controller Operating 

Manual, PacDrive iSH Motor Operating Manual, PacDrive MC-4 Servo Drive Operating 

Manual. 

Background 

This lab would be utilizing ELAU PacDrive MC-4 and ELAU PacDrive C200 Controller 

Hardware along with the ELAU iSH Motors. The system setup is being shown in the figure 

below: 

ECET 262-08-24-2010

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PacDrive Automation System 

The PacDrive automation system provides the optimal solution for electronic packaging 

machines, both in terms of technology and economy. PacDrive consists of a high performance 

controller run on a PC or controller-based architecture, the PacDrive controller and the digital 

servo amplifiers which contain the power supply unit, the final stages and the servo controller for 

the individual axes. The PacDrive controller is the intelligent head of the system and is based on 

an industrial PC. The PacDrive controller synchronizes and coordinates the motion functions of 

the packaging machine. Thanks to the use of an IEC 1131-3 soft PLC, areas of application that 

had previously been unavailable to a classical PLC have been opened up to the PacDrive 

controller family. The individual PLCs or motion tasks can thus be split up into various parallel 

tasks that can then be implemented with the programming environment EPAS-4 as per the IEC 

61131-3 standard. Up to 99 servo axes can be connected to one PacDrive controller and supplied 

with motion data. The circular, digital real-time bus SERCOS implements the secure data 

exchange with the MC-4 servo amplifiers. With the use of fiber optic technology, the data bus is 

insensitive to electromagnetic disturbances and cyclically supplies the decentralized 

MC-4 servo amplifiers with new set points at a data rate of up to 16 MBaud. All internal 

conditions of the axes can be called up via the real-time bus and processed by the PacDrive 

controller. 

In addition to digital and analog inputs and outputs, each PacDrive controller has two 

serial interfaces and one Ethernet interface available. Thanks to the integrated OPC 

interface, it is possible to connect various process visualization and control systems 

to PacDrive. Additional peripheral components can also be connected using the field 

bus interface module. A PacDrive controller can be the field bus master or the slave. 

The international field bus standards CANopen, PROFIBUS-DP and DeviceNet are 

supported. The built-in interfaces enable remote diagnosis via telephone modem or 

Internet. PCs can communicate via TCP/IP with the PacDrive controller and directly 

diagnose the conditions of the controller. 

C-200 Controller 

The PacDrive controller, microprocessor-based control hardware with the VxWorks real-time 

operating system, centrally implements the PLC and motion functions. PacDrive controller 

C200 synchronizes, coordinates and generates the motion functions for a maximum of 8 drives 

of a food and packaging machine. 


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PacDrive MC-4 servo amplifier 

The MC-4 digital servo amplifier features compact, closed, wall-mountable construction as well 

as state-of-the-art technology. The innovative MC-4 has a power supply unit, power amplifier, 

and a software servo controller for one axis all installed in a single space-saving housing. Since it 

communicates with the PacDrive controller exclusively via fiber optics, it is also suitable for 

decentralized structures. It does not require a user program, processes single or multi-turn 

encoders, and configures itself using the electronic type plate in the SH motor. 

Highlights of the PacDrive MC-4: 

▪ Broad voltage range 

▪ Integrated power supply unit 

▪ Max. 34.5 / 69 kVA power 

▪ Automatic motor identification 

▪ Minimal size 

▪ Inverter Enable safety input 

▪ 250% overload 

▪ Integrated SERCOS interface 

PacDrive iSH Motor 

The innovative iSH combines the motor, power amplifier, and the digital servo controller for an 

axis in a space-saving housing. Due to its compact construction with integrated controller it is 

perfectly suitable for peripheral set-up. It is available with single or multi-turn encoders and 

configures itself with the aid of the electronic type plate in the iSH itself. 

Highlights 

▪ Compact size 

▪ 3.5 times as much peak torque 

▪ Integrated SERCOS interface 

▪ High-resolution single or multi-turn encoder 

▪ Protection class IP65 

▪ Simple wiring 

▪ Superior reliability 


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Automation Toolkit EPAS-4 Software 

Due to the combination of comprehensive functions and fully developed tools, the Automation 

Toolkit EPAS-4 is a good example of a powerful programming tool that is as easy to use as a 

standard office program. 

Getting Started with EPAS-4 

EPAS-4 is a complete development environment for the PacDrive system. EPAS-4 puts a 

simple approach to the powerful IEC language at the disposal of the PLC programmer. Use of 

the editors and debugging functions is based upon the proven development program 

environments of advanced programming languages (such as Visual C++). 

EPAS-4 Quick Concepts 

Project 

A project contains all of the objects in a PLC program. A project is saved in a file named after 

the project. The following objects are included in a project: 

1. POUs (Program Organization Units) 

2. Data types 

3. Visualizations 

4. Resources and libraries. 

POU (Program Organization Unit) 

Functions blocks and programs are POUs. Each POU consists of a declaration part and a body. 

The body is written in one of the IEC programming languages, which include IL, ST, SFC, FBD, 

LD and CFC. EPAS-4 supports all IEC standard POUs. If you want to use these POUs in your 

project, you must include the library standard.lib in your project. POUs can call up other POUs. 

However, recursions are not allowed. 

Function block 

A function block is a POU which provides one or more values during the procedure. As opposed 

to a function, a function block provides no return value. As an example a function block is 

shown below 


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The above shown function block is a VarioPos function block. This function block performs the 

target –based positioning motion to the selected axis. 

Resources 

You need the resources for configuring and organizing your project and for tracing variable 

values: 

• Global Variables which can be used throughout the project 

• Message logger to show and archive system messages and diagnostic messages 

• PLC Configuration for configuring your hardware 

• Task Configuration for guiding your program through tasks 

• Sampling Trace for graphic display of variable values 

• VarioCam functions to execute motion tasks 

• Watch and Receipt Manager for displaying variable values and setting default variable values 

• Library manager 

• Log 

Libraries 

You can include in your project a series of libraries who’s POUs, data types, and global variables 

you can use just like user-defined variables. The library "Standard_V00XXXX.lib" and 

"MAX4_V00XXXX.lib" are a standard part of the program and are always at your disposal. 

Data types 

Along with the standard data types the user can define his own data types. Structures, 

enumeration types and references can be created. 

Visualization 


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EPAS-4 provides visualizations so that you can display your project variables. You can draw 

geometric elements off-line with the help of the visualization. They can then change their form 

online, depending upon certain variable values. 


Motion Profiles 

EPAS-4 supports and provides different motion profiles through different function blocks. The three main motion profiles available with 

EPAS-4 are: 

Motion 

Profiles 

Endless Feed 

based 

positioning 

CAM based 

positioning 

Vario Pos 

(Target-based 

positioning) 

EndlessFeed EndlessFeed2 EndlessFeed3 

VarioPos VarioPos2 VarioPos3 

VarioPos4 

Each of these motion profiles will be discussed in detailed one by one through Laboratory 7A-7C. 7C. This Lab would discuss the EndlessFeed 

motion profile in detail.

EndlessFeed Motion Profile 

EndlessFeed motion profile is the most common and basic motion profiles used frequently in 

packaging machines. The basic concept of this type of motion profile is to achieve a velocity in a 

given time. For Example: 

In the above figure where the curve goes flat in between the y-axis remains constant w.r.t time. 

Note that the above curve describes the motion profile for only one cycle. Note from the figure 

below: 

That the velocity starts de-accelerating as soon as start signal goes low. But if the start signal was 

present the motion would have been continued until the start signal is low. 

Endless motion is used for rotary systems and is performed using the function block. If the 

function block with the Enable input is released, the Active output is set. The axis with the 

acceleration ACC starts by a positive edge (FALSE -> TRUE) at the Start input until the 

velocity VEL is reached. If the start signal Start is removed, the axis stop at the set 

StopPosition with the deceleration DEC.

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Function Body Diagram of EndlessFeed Block 

OUTPUT VALUES 

INPUT PARAMETERS 

Input Parameters 

Enable: is the enable signal for this block. This signal needs to be high in order to start the 

motion through this block. 

Axis: The axis that is needed to perform motion through this block is specified in this field. 

Encoder: The logical encoder which is the drive itself is specified in this field. Remember the 

servo motor has a feedback to the MC-4 drive. This is the position feedback of the motor that is 

being listened by the drive all the time while the motor is in motion. 

Acceleration: Maximum acceleration is specified in this field. 

De-acceleration: Maximum de-acceleration is specified in this field. 

Emergency DEC: is the maximum de-acceleration that is applied when Enable signal goes to low 

during the motion. 

VEL: is the maximum velocity or the target velocity is specified in this field. 

Periode: is the number of times this motion will occur. One turn of the motor is takes 360 , 

therefore if we want 10 cycles the period would be 10 x 360 . 

Stopposition: is the position at which motion will stop with the specified de-acceleration if the 

start signal goes low. Usually it is specified as 0 (the angular position at which motion starts). 

Start: to start the motion through this block, start signal must be high along with the enable 

signal. The enable signal should be high first then only start signal go to high, otherwise motion 

will not start. 


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Output Parameters 

Active: An active signal tells of the block is active or not. If the signal is high that means motion 

for the selected axis is in progress. 

Position X & Position Y: are the real-time x and y coordinate positions of the axis. If the axis is 

in motion the values in this field will continuously change. 

Result: this field indicates the current status of the block. If there is an error executing the 

function block the equivalent result code will appear in this field. 

ResultText: this field will indicate result text equivalent to the result code in the result field. 

CamActive: this field will indicate if the Cam motion is active for the selected axis. 

Applications of EndlessFeed Motion Profile 

Each motion profile has a definite scope and application. Endless Feed motion profile as the 

name suggests is used to run industrial systems like conveyor belts endlessly where the target is 

to achieve a certain velocity. This motion is very basic to conveyor systems that move the 

objects on the conveyor belts and pass them on to the next conveyor belts. In a simpler way this 

motion profile is used thoroughly to move the objects on a conveyor belt at a constant velocity. 

For Example: In a packaging machine shown in the figure below, that is used to package photo 

print wallets. Endless feed motion can be used to drive exit conveyor which regularly moves the 

packaged product out of the line. 


Starting EPAS-4 

1. Double-click with the left mouse button on the EPAS-4 icon on your desktop. 

Goto Start -> All Programs/Programs-> ELAU->EPAS-4 V24-> Automation Toolkit 

EPAS-4 V24 

Starting New Project 

2. Click the icon in the top left corner of the EPAS-4, as shown below:

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Create New Project Step 1/3 

3. Enter the following fields one by one carefully into the “Create New Project” window: 

1. Project Name: 

C-200_Lab_7a_Target_Based_Positioning_YOUR_NAME_DATE 

2. Project Path: Choose a desired project path, your project related files will be saved in this 

path. 

3. Name of the POU(Program Organization Units): PLC_PRG 

4. Language of POU: LD= Ladder Programming 

5. Controller Type: Pac Drive C200 

6. Firmware Version: 00.24.20 


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Create New Project Step 2/3 (Selecting Controller Over the Network) 

In step 2 , click 

button to search for the controllers available over the network. 

Select Pac Drive C-200 Controller from the list obtained after search and click apply to select the 

controller, as shown below: 

Click next on the screen to proceed to step 3. 


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Create New Project Step 3/3 

Click Finish to start the project, as shown below: 


Familiarize with the EPAS Project Window and Tools: 

7. Cut, Copy Paste, Search and Zoom 

Tools 

6. Ladder Programming Tools 

5.Current Selected POU (Ladder 

8. Ladder Programming Workspace 

1. POUs- Program Organization Units associated with the current 

project. 

2. Data Types 

3. Visualizations 

4. Resources: shows the available resources for the current project.

Configuring Controller Configuration 

Before we start writing our ladder program we need to configure the controller configuration. In 

order to do so we need to understand what is the current hardware attached to the controller. For 

example- Currently C-200 Controller is serving two servo motors through two MC-4 drives. So 

in order to communicate or command these motors the MC-4 drives must be setup the following 

way: 

1. Goto Resources Tab Goto PLC Configuration 

Expand Controller Configuration Select SERCOS Interface RTB(Real-Time 

Bus)Right click and Goto Append Sub-element Select MC-4 

Append one more sub-element to the SERCOS Interface as told in the step above. 

2. After you have added the MC-4 sub-elements the controller configuration would look like 

this: 

3. Now since we have our hardware configured, we are ready to write a ladder-logic 

program. 

Writing a Ladder-Logic Program: 

As an example we are going to write a ladder-logic program that would provide motion to a iSH 

Motor.

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1. Goto POU Tab 

Double-click and select PLC_PRG 

Programming Window appears on the right that looks like: 

Ladder 

2. Familiarize yourself with the Ladder-Programming Toolbar: 

SET / RESET 

NEGATE 

TIMER ON (TON) 

FALLING EDGE DETECTION 

RISING EDGE DETECTION 

BOX with EN 

FUNCTION BLOCK 

Reset ‘Coil’ 

Set ‘Coil’ 

Coil 

Parallel Contact (Negated) 

Parallel Contact 

Contact (Negated) 

Contact 

Network After 

Network 

Before 

3. Start Programming: 

Start programming by selecting any of these tools from the Ladder Programming toolbar. 

For Example: 

Name each??? with a label that is appropriate to your program. 

Tips: Turn on the Auto Declaration feature in the EPAS-4 to quickly define new variables in 

your ladder program. This saves time and you won’t miss out to declare any variable that you 

created while programming. 

Steps to Turn-on Auto-Declaration 

Go to Project Go to Options Go to Editor Check the box before Auto-declaration 

Select OK 


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Downloading/Transferring Program to Controller: 

The steps below will guide you how to download your ladder program to the controller once you 

are finished programming. 

1. Compile 

Go to Project Build: 

If the build is successful, proceed to transfer the project files to the controller. 

2. Transferring Project 

Go to Project Tools Transfer Project Package to PacDrive Controller: 


ECET 262-08-24-2010 

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Make sure all the files types associated with the project are checked. Then go to 

to search for the available controllers on the network. 


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Note: Once the transfer is completed the controller will boot with the new program. Watch the 

front face of the controller when all the red lights dim out one by one the boot cycle is complete 

and you are ready to run your program. 

3. Testing 

The following steps will guide you how to test the program once the project is transferred to 

the controller. 

Step1. 

Go Online 

Go to Online Login: 

Step2. 

Run Mode 

Go to Online Run or F5: 

Step3. 

Writing Values 

Double-click the contact to which you wish to write the value, for a Boolean variable like 

shown below “enable controller” a filled blue square ( 

empty blue square ( 

) means “FALSE” 

) means “TRUE” and an 

To write the values: 

Go to Online Write Values or alternatively Press Ctrl+F7, you should see the impact 

on the ladder diagram right after you write values. Not that the program must be running 

in order to see the values change in the ladder diagram. 

After Writing Values: 


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Note: Notice that as soon as the enable controller signal is turned high the 

Conveyor_1.ControllerEnableSet coil turns blue (TRUE). You should also listen to a 

sound which would actually originate because the brakes are applied to the motor. This 

means that the motor is ready to move and waiting for the motion command. (Refer to the 

Axis State Flowchart on the next page for more details). 


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Axis State 

Understanding the axis state parameter is of utmost importance while writing motion programs. 

Axis state parameter makes available the current state of the axis. The flowchart below explains 

when an axis is considered to be Ready and what signals must be activated in order to reach 

Ready State. 


Example Ladder Program 

As an example you could refer to this ladder program. This Ladder program would demonstrate how to perform motion through 

EndlessFeed Block to a selected Axis. 

Rung 0001: The controller is needed to be enabled every time we seek to use controller. 

This is done by activating the ControllerEnableSet variable to true. 

Rung 0002: A ReadytoRun signal is generated TRUE if the Axis State of the 

first Axis which here is Conveyor_1 is GE (Greater Than or Equal to) 3. 3 is 

the Code for Axis state “Ready”. Note that ReadytoRun signal is an 

input/output variable. 

Rung 0003: A Start_Motor1 input contact is defined (Normally Open) which would 

drive an output coil named SM1 (Start Motor 1) 

Rung 0004: The ReadytoRun signal which was generated is used to drive or trigger The 

Enable of the Motion Block “EndlessFeed2”. The axis field of the block is fed as name 

of the axis which is needed to be in motion. In this case it is Conveyor_1. Other fields 

are filled anonymously such as Velocity, Acceleration, De-acceleration etc. Description 

of all these fields has been explained in the previous sections of this Lab.

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Ladder Programming Task 

Design a ladder-logic program that can drive two axes (2 Motors) at a time. Use EndlessFeed motion block to perform this task. Refer 

to the Example Ladder Program given in this Laboratory. Feed Following Motion Data into the EndlessFeed motion blocks. 

For 1 st Motor: For 2 nd Motor: 

Variable Value Variable Value 

VEL -800 VEL 1600 

ACC 1000 ACC 1000 

DEC 1000 DEC 1000 

Smooth 0 Smooth 0 

EmergencyDEC 10000 EmergencyDEC 10000 

Periode 7200 Periode 14400 

StopPosition 0 StopPosition 0 

Report: 

Include the Ladder Diagram for this Task and answers to the discussion questions in your report. 


Discussion 

1. What are the components of the C-200 Controller System? 

2. Suggest few other industrial applications where EndlessFeed motion profile is used or 

could be used. 

3. What is the basic difference between de-acceleration and EmergencyDEC? 

4. What is the basic difference between Enable and start signal in reference to the 

EndlessFeed Motion Block? 

5. In your Ladder Programming Task, what does a negative velocity suggests what 

difference do you observe in the motion between the two motors?

ECET-262 [LABORATORY 12B]

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