Beckhoff EP7402-0057 Operator's manual

Documentation | EN
EP7402-0057
2-channel motor controller box for roller conveyor systems
2020-11-02 | Version: 1.0

Table of contents
EP7402-0057 3Version: 1.0
Table of contents
1 Foreword ....................................................................................................................................................5
1.1 Notes on the documentation..............................................................................................................5
1.2 Safety instructions .............................................................................................................................6
1.3 Documentation issue status ..............................................................................................................7
2 Product overview.......................................................................................................................................8
2.1 Introduction........................................................................................................................................8
2.2 Technical data ...................................................................................................................................9
2.3 Process image.................................................................................................................................11
2.3.1 Assignment of connectors to process data...................................................................... 14
3 Mounting and cabling..............................................................................................................................15
3.1 Mounting..........................................................................................................................................15
3.1.1 Dimensions ...................................................................................................................... 15
3.1.2 Fixing ............................................................................................................................... 16
3.1.3 Functional earth (FE) ....................................................................................................... 16
3.2 Cabling ............................................................................................................................................17
3.2.1 Connector overview ......................................................................................................... 17
3.2.2 Supply voltages and EtherCAT........................................................................................ 18
3.2.3 Motors.............................................................................................................................. 21
3.2.4 Digital input/outputs ......................................................................................................... 22
4 Commissioning........................................................................................................................................23
4.1 Quick start........................................................................................................................................23
4.1.1 Step 1: Hardware Setup .................................................................................................. 23
4.1.2 Step 2: TwinCAT configuration ........................................................................................ 24
4.1.3 Step 3: Basic parameters ................................................................................................ 25
4.1.4 Step 4: Test run ............................................................................................................... 27
4.1.5 Step 5: Final steps ........................................................................................................... 29
4.2 Determining the “Mechanical to electrical ratio” experimentally ......................................................30
4.3 Fine-tuning parameters ...................................................................................................................31
4.3.1 Alignment phase and ramp-up phase.............................................................................. 31
4.3.2 Velocity controller ............................................................................................................ 31
4.4 Automatic restart after error.............................................................................................................32
4.5 Restoring the delivery state .............................................................................................................33
4.6 Decommissioning ............................................................................................................................34
5 Troubleshooting ......................................................................................................................................35
5.1 Common problems ..........................................................................................................................35
5.2 Warnings and errors ........................................................................................................................35
5.3 Diagnosis bits ..................................................................................................................................36
6 Application Notes ....................................................................................................................................38
6.1 Motor Diagnosis...............................................................................................................................38
7 CoE objects..............................................................................................................................................39
7.1 Register ...........................................................................................................................................39
7.2 Object descriptions ..........................................................................................................................40
7.2.1 Parameterization objects ................................................................................................. 40

Table of contents
EP7402-00574 Version: 1.0
7.2.2 Information objects .......................................................................................................... 43
7.2.3 Standard objects.............................................................................................................. 44
8 Appendix ..................................................................................................................................................45
8.1 Example motor parameters .............................................................................................................45
8.2 General operating conditions...........................................................................................................46
8.3 Accessories .....................................................................................................................................47
8.4 Version identification of EtherCAT devices .....................................................................................48
8.4.1 Beckhoff Identification Code (BIC)................................................................................... 52
8.5 Support and Service ........................................................................................................................54

Foreword
EP7402-0057 5Version: 1.0
1 Foreword
1.1 Notes on the documentation
Intended audience
This description is only intended for the use of trained specialists in control and automation engineering who
are familiar with the applicable national standards.
It is essential that the documentation and the following notes and explanations are followed when installing
and commissioning these components.
It is the duty of the technical personnel to use the documentation published at the respective time of each
installation and commissioning.
The responsible staff must ensure that the application or use of the products described satisfy all the
requirements for safety, including all the relevant laws, regulations, guidelines and standards.
Disclaimer
The documentation has been prepared with care. The products described are, however, constantly under
development.
We reserve the right to revise and change the documentation at any time and without prior announcement.
No claims for the modification of products that have already been supplied may be made on the basis of the
data, diagrams and descriptions in this documentation.
Trademarks
Beckhoff®, TwinCAT®, EtherCAT®, EtherCATG®, EtherCATG10®, EtherCATP®, SafetyoverEtherCAT®,
TwinSAFE®, XFC®, XTS® and XPlanar® are registered trademarks of and licensed by Beckhoff Automation
GmbH. Other designations used in this publication may be trademarks whose use by third parties for their
own purposes could violate the rights of the owners.
Patent Pending
The EtherCAT Technology is covered, including but not limited to the following patent applications and
patents: EP1590927, EP1789857, EP1456722, EP2137893, DE102015105702 with corresponding
applications or registrations in various other countries.
EtherCAT® is registered trademark and patented technology, licensed by Beckhoff Automation GmbH,
Germany.
Copyright
© Beckhoff Automation GmbH & Co. KG, Germany.
The reproduction, distribution and utilization of this document as well as the communication of its contents to
others without express authorization are prohibited.
Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a
patent, utility model or design.

Foreword
EP7402-00576 Version: 1.0
1.2 Safety instructions
Safety regulations
Please note the following safety instructions and explanations!
Product-specific safety instructions can be found on following pages or in the areas mounting, wiring,
commissioning etc.
Exclusion of liability
All the components are supplied in particular hardware and software configurations appropriate for the
application. Modifications to hardware or software configurations other than those described in the
documentation are not permitted, and nullify the liability of Beckhoff Automation GmbH & Co. KG.
Personnel qualification
This description is only intended for trained specialists in control, automation and drive engineering who are
familiar with the applicable national standards.
Description of instructions
In this documentation the following instructions are used.
These instructions must be read carefully and followed without fail!
DANGER
Serious risk of injury!
Failure to follow this safety instruction directly endangers the life and health of persons.
WARNING
Risk of injury!
Failure to follow this safety instruction endangers the life and health of persons.
CAUTION
Personal injuries!
Failure to follow this safety instruction can lead to injuries to persons.
NOTE
Damage to environment/equipment or data loss
Failure to follow this instruction can lead to environmental damage, equipment damage or data loss.
Tip or pointer
This symbol indicates information that contributes to better understanding.

Foreword
EP7402-0057 7Version: 1.0
1.3 Documentation issue status
Version Comment
1.0 • First release
Firmware and hardware versions
This documentation refers to the firmware and hardware version that was applicable at the time the
documentation was written.
The module features are continuously improved and developed further. Modules having earlier production
statuses cannot have the same properties as modules with the latest status. However, existing properties
are retained and are not changed, so that older modules can always be replaced with new ones.
Documentation version Firmware Hardware
1.0 01 02
The firmware and hardware version (delivery state) can be found in the batch number (D-number) printed on
the side of the EtherCAT Box.
Syntax of the batch number (D-number)
D: WW YY FF HH
WW - week of production (calendar week)
YY - year of production
FF - firmware version
HH - hardware version
Example with D no. 29 10 02 01:
29 - week of production 29
10 - year of production 2010
02 - firmware version 02
01 - hardware version 01
Further information on this topic: Version identification of EtherCAT devices [}48].

Product overview
EP7402-00578 Version: 1.0
2 Product overview
2.1 Introduction
Fig.1: EP7402-0057
2-channel motor controller box for roller conveyor systems
The EP7402-0057 EtherCAT Box offers two outputs with integrated controller for the direct connection of 24
V DC conveyor roller motors or other BLDC motors with max. 3.5 A. Eight additional digital inputs/outputs
enable connection of e.g. photoelectric switches and communication between the box modules in operation
without PLC.
The EP7402-0057 takes over the complete control of a roller motor independently of the manufacturer of
conveyor or motor. Maximum rated current, acceleration or deceleration ramps and various other parameters
can be configured and allow for a wide range of adaptations to different applications. The control of the
motors is sensorless.
The EtherCAT Box with IP 67 protection rating measures only 174 mm x 60 mm x 36.5 mm and can be
easily mounted in standard C-channel or L-brackets on the conveyor frame. It requires no additional
protective covering. Power supply and EtherCAT communication are realized via a B23 ENP connector with
a current carrying capacity of 28 A/45 °C. In conveyor operation the EP7402-0057 can also be operated
without PLC and provides functions such as ZPA (Zero Pressure Accumulation), single or block discharge.
Further EtherCAT devices such as digital and analog I/Os, barcode readers or safety devices can be
connected to the additional EtherCAT junction.
Quick links
Technical data [}9]
Process image [}11]
Dimensions [}15]
Quick start [}23]

Product overview
EP7402-0057 9Version: 1.0
2.2 Technical data
All values are typical values over the entire temperature range, unless stated otherwise.
Technical data EP7402-0057
Fieldbus
Fieldbus EtherCAT
Electrical isolation 500V (fieldbus/ IO)
Connectors Input and forwarding: B23 hybrid connectors
Junction: M8 socket, green
Distributed Clocks yes
Supply voltages
Connectors B23 hybrid connectors
Control voltage US
Nominal voltage 24VDC (-15%/ +20%)
Sum current max. 28A at 45°C 1)
Current consumption from US150mA at 24VDC
Additional consumers Loads on digital outputs
Peripheral voltage UP
Nominal voltage 24VDC (-15%/ +20%)
Sum current max. 28A at 45°C 1)
Consumers • Motors
• Motor brake
Undervoltage detection threshold 18VDC
Overvoltage detection threshold 30VDC
Motor output stage
Number of channels 2
Motor type 3-phase BLDC roller motors
Encoder Encoder not required
Connectors 2x M8 socket, b-coded
Motor voltage 24VDC from the peripheral voltage UP
Continuous current per channel max. 3.5A
Peak current per channel max. 5A (approx. 1s)
Rotary field frequency max. 72000°/s = 12000 rpm 2)
Motor brake (digital output)
Rated voltage 24VDC from peripheral voltage UP
Output current max. 1A
1) Sum current of consumers and power forwarding. This value corresponds to the
current carrying capacity of the connectors for the supply voltages.
2) Do not confuse the rotary field frequency with motor speed or roller speed.

Product overview
EP7402-005710 Version: 1.0
Technical data EP7402-0057
Digital in-/outputs
Number of inputs / outputs 8
Connectors 4x M8 socket
Input specification
Characteristics Type 3 according to EN 61131-2, compatible with type 1
Input filter 10µs
Output specification
Nominal output voltage 24VDC (-15% / +20%) from control voltage US
Output current max. 0.5A per channel, short-circuit proof
Supply voltage output: US1 24VDC from control voltage US
max. 0.5A, short-circuit protected
Mechanics
Weight 750g
Installation position variable
Environmental conditions
Ambient temperature during operation -25 .. +60°C
Ambient temperature during storage -40.. +85°C
Vibration / shock resistance conforms to EN 600068-2-6 / EN600068-2-27
EMC immunity/emission conforms to EN 61000-6-2 / EN 61000-6-4
Protection class IP65, IP66, IP67 (conforms to EN 60529)
Approvals and conformity
Approvals CE, UL in preparation

Product overview
EP7402-0057 11Version: 1.0
2.3 Process image
Fig.2: Process image
In the following the letter n serves as a placeholder for the channel number.
Screenshots that display process data objects of channel 1 are representative for both channels. The
process data objects of channel 1 and 2 have the same structure.
DI Inputs
The input variables represent the logic level of the
digital in/outputs.
Make sure that the value of the corresponding output
variable [}13] is set to 0 (default) if you want to use
a digital in/output as an input.
Assignment of connectors to process data [}14]

Product overview
EP7402-005712 Version: 1.0
STM Status Channel n
The input variables “Status” contain the status bits of
the motor channels.
Ready to enable
• TRUE: all requirements are met for enabling the
motor.
• FALSE: The motor can not be enabled by the
output variable “enable” due to an error [}35].
Ready
• TRUE: the motor is energized.
Warning
• TRUE: The motor channel is in a borderline
condition.
Error
• TRUE: The motor was switched off due to an error.
[}35]
Moving positive
• TRUE: The motor velocity is above zero.
Moving negative
• TRUE: The motor velocity is below zero.
TxPDO Toggle
This bit is inverted on each update of the status bits.
STM Synchron info data Channel n
The input variables “Info data x” contain measured
values. You can choose which measured values are
mapped to these variables in the CoE directory:
• Select the measured values for Channel 1 in CoE
object 8022 [}41].
• Select the measured values for Channel 2 in CoE
object 8032 [}41].

Product overview
EP7402-0057 13Version: 1.0
STM Inputs Device
The input variable „STM Inputs Device“ contains the
Diagnosis bits [}36] that you can evaluate to isolate
the reasons for warnings and errors.
DO Outputs
Output values for the digital in-/outputs.
STM Control Channel n
Enable
This bit activates the motor channel. It is without
effect if the variable Ready to enable [}12] is FALSE.
Reset
Apply a rising egde to this bit to acknowledge an
error.
Invert direction
If this bit is set, the target velocity [}14] is multiplied
with "-1" to change the direction.

Product overview
EP7402-005714 Version: 1.0
STM Target Velocity Channel n
Velocity
This is the target velocity for the velocity controller.
However, any value below parameter 80n0:09 start
velocity [}40] is interpreted as zero.
Acceleration
This value specifies the maximum positive change in
velocity. If the value is zero, acceleration is not
limited.
Deceleration
This value specifies the maximum negative change in
velocity. If the value is zero, deceleration is not
limited.
2.3.1 Assignment of connectors to process data
Connector Process data
Name Pin Function Input Output
X01 2 Digital
in-/output DI Inputs
Input 2
DO Outputs
Output 2
4 DI Inputs
Input 1
DO Outputs
Output 1
X02 2 Digital
in-/output DI Inputs
Control input 2
DO Outputs
Control output 2
4 DI Inputs
Control input 1
DO Outputs
Control input 1
X05 2 Digital
in-/output DI Inputs
Input 4
DO Outputs
Output 4
4 DI Inputs
Input 3
DO Outputs
Output 3
X06 2 Digital
in-/output DI Inputs
Control input 4
DO Outputs
Control output 4
4 DI Inputs
Control input 3
DO Outputs
Control input 3
X20 Motor STM Status Channel 1
STM Synchron info data Channel 1
STM Control Channel 1
STM Target Velocity Channel 1
X21 Motor STM Status Channel 2
STM Synchron info data Channel 2
STM Control Channel 2
STM Target Velocity Channel 2

Mounting and cabling
EP7402-0057 15Version: 1.0
3 Mounting and cabling
3.1 Mounting
3.1.1 Dimensions
60
166
174
Ø 4.5
52
36.5
13.5
fastening holes
Fig.3: Dimensions
All dimensions are given in millimeters.
Housing features
Housing material PA66 (polyamide)
Sealing compound polyurethane
Mounting two fastening holes Ø 4.5 mm for M4
Metal parts brass, nickel-plated
Contacts CuZn, gold-plated
Power feed through max. 30A
Installation position variable
Protection class IP65, IP66, IP67 (conforms to EN 60529) when screwed together
Dimensions (HxWxD) approx. 174 x 60 x 36.5mm (without connectors)

Mounting and cabling
EP7402-005716 Version: 1.0
3.1.2 Fixing
NOTE
Dirt during assembly
Dirty connectors can lead to malfunctions. Protection class IP67 can only be guaranteed if all cables and
connectors are connected.
• Protect the plug connectors against dirt during the assembly.
Mount the module with two M4 screws on the fastening holes in the corners of the module. The fastening
holes have no thread.
3.1.3 Functional earth (FE)
Earth the FE core of the supply line connected to X70 [}18].
The FE potential is passed through to the FE pin of X71. So if multiple devices are connected in series, only
the FE core of the first supply line needs to be earthed.
X70
FE
X71
supply line supply line supply line
EP7402-0057
X70 X71
EP7402-0057
X70 X71
EP7402-0057
Fig.4: Functional earth connection example
You can tap the FE potential at the housings of X70 and X71: use the nuts of X70 and X71 to screw on a
sheet metal. So you can earth the machine part where the box is mounted.

Mounting and cabling
EP7402-0057 17Version: 1.0
3.2 Cabling
3.2.1 Connector overview
X01 X05
X02
X21
X20
X71
X70
X06
X70
X60
X40
X71
Fig.5: EP7402-0057 Connectors
Name Function Connector type Tightening
torque
X01 Digital input/outputs [}22] M8 socket 0.4Nm
X02 M8 socket 0.4Nm
X05 M8 socket 0.4Nm
X06 M8 socket 0.4Nm
X20 Motor connection [}21] M8 socket, b-coded 0.4Nm
X21 M8 socket, b-coded 0.4Nm
X40 EtherCAT junction [}20] M8 socket 0.4Nm
X60 Supply voltage output [}20] M8 socket 0.4Nm
X70 Supply voltage and EtherCAT input [}18] B23 ENP -
X71 Supply voltage and EtherCAT input [}18] B23 ENP -
Suitable connection cables can be found in the chapter Accessories [}47].

Mounting and cabling
EP7402-005718 Version: 1.0
3.2.2 Supply voltages and EtherCAT
The EtherCAT Box is supplied with two supply voltages. The supply voltages are electrically isolated in the
EtherCAT Box.
• Control voltage US
• Peripheral voltage UP
3.2.2.1 Input and forwarding
Multiple devices can be connected in series by forwarding the supply voltages and EtherCAT via X71.
NOTE
UP is not protected against reverse polarity
Defect possible through polarity reversal.
• Make sure that the supply voltage UP is connected correctly.
Input
X70
Forwarding
X71
Fig.6: B23 connectors
Pin Core color 1) Function
1 yellow EtherCAT Tx +
2 white EtherCAT Rx +
3 blue EtherCAT Rx -
4 orange EtherCAT Tx -
5 green/yellow FE
6 grey GNDP
7 black UP: 24VDC
8 blue GNDS
9 brown US: 24VDC
1) The wire colors apply to cables of the type ZK7314-3xxx-Axxx. See chapter Accessories [}47].

Mounting and cabling
EP7402-0057 19Version: 1.0
3.2.2.2 Conductor losses
Take into account the voltage drop on the supply line when planning a system. Avoid the voltage drop being
so high that the supply voltage at the box lies below the minimum nominal voltage.
Variations in the voltage of the power supply unit must also be taken into account.
Voltage drop on the supply line
5 10 15 20
1
2
3
6
250
0
7
30
Vert. Faktor: 0,8 cm / V
Voltage drop (V)
Cable length (m)
35
4
5
Conductor cross-section: 4 mm²
5 A
10 A
15 A
20 A
25 A

Mounting and cabling
EP7402-005720 Version: 1.0
3.2.2.3 Output
NOTE
Risk of confusion
M8 connectors for supply voltages have the same design as M8 connectors for EtherCAT. Observe the
color coding of the connectors in order to avoid incorrect insertion:
black: Supply voltages
green: EtherCAT
EtherCAT junction X40
3 1
24
Fig.7: M8 socket
EtherCAT M8
connector
Core colors
Signal Contact ZB9010, ZB9020, ZB9030, ZB9032,
ZK1090-6292,
ZK1090-3xxx-xxxx
ZB9031 and old versions of
ZB9030, ZB9032, ZK1090-3xxx-
xxxx
TIA-568B
Tx + 1 yellow1) orange/white white/orange
Tx - 4 orange1) orange orange
Rx + 2 white1) blue/white white/green
Rx - 3 blue1) blue green
Shield Housing Shield Shield Shield
1) Core colors according to EN61918
Adaptation of core colors for cables ZB9030, ZB9032 and ZK1090-3xxxx-xxxx
For standardization, the core colors of the ZB9030, ZB9032 and ZK1090-3xxx-xxxx cables have
been changed to the EN61918 core colors: yellow, orange, white, blue. So there are different color
codes in circulation. The electrical properties of the cables have been retained when the core colors
were changed.
Suitable connection cables can be found in the chapter Accessories [}47].
Power output X60
3 1
24
Fig.8: M8 socket
Contact Function Description Core color 1)
1 USControl voltage Brown
2 UPPeripheral voltage White
3 GNDSGND to USBlue
4 GNDPGND to UPBlack
1) The core colors apply to cables of the type ZK2020-3xxx. See chapter Accessories [}47].