Beckhoff EP7402-0057 User manual

Documentation | EN
EP7402-0057
2-channel motor controller box for roller conveyor systems
2021-12-15 | Version: 1.3

Table of contents
EP7402-0057 3Version: 1.3
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 Overview.......................................................................................................................... 17
3.2.2 Supply voltages and EtherCAT........................................................................................ 18
3.2.3 Motors.............................................................................................................................. 23
3.2.4 Digital input/outputs ......................................................................................................... 25
3.3 Disposal...........................................................................................................................................26
4 Commissioning........................................................................................................................................27
4.1 Quick start........................................................................................................................................27
4.1.1 Step 1: Hardware Setup .................................................................................................. 27
4.1.2 Step 2: TwinCAT configuration ........................................................................................ 29
4.1.3 Step 3: Basic parameters ................................................................................................ 30
4.1.4 Step 4: Test run ............................................................................................................... 33
4.1.5 Step 5: Final steps ........................................................................................................... 35
4.2 Determining the “Mechanical to electrical ratio” experimentally ......................................................36
4.3 Fine-tuning parameters ...................................................................................................................37
4.3.1 Alignment phase and ramp-up phase.............................................................................. 37
4.3.2 Velocity controller ............................................................................................................ 37
4.4 Automatic restart after error.............................................................................................................38
4.5 Restoring the delivery state .............................................................................................................39
4.6 Decommissioning ............................................................................................................................40
5 Troubleshooting ......................................................................................................................................41
5.1 Diagnosis bits ..................................................................................................................................42
5.2 Acknowledging errors ......................................................................................................................44
6 Application Notes ....................................................................................................................................45
6.1 Motor Diagnosis...............................................................................................................................45
7 CoE objects..............................................................................................................................................46
7.1 Register ...........................................................................................................................................46
7.2 Object descriptions ..........................................................................................................................47
7.2.1 Parameterization objects ................................................................................................. 47

Table of contents
EP7402-00574 Version: 1.3
7.2.2 Information objects .......................................................................................................... 50
7.2.3 Standard objects.............................................................................................................. 51
8 Appendix ..................................................................................................................................................52
8.1 Example motor parameters .............................................................................................................52
8.2 General operating conditions...........................................................................................................53
8.3 Accessories .....................................................................................................................................54
8.4 Version identification of EtherCAT devices .....................................................................................55
8.4.1 General notes on marking ............................................................................................... 55
8.4.2 Version identification of EP/EPI/EPP/ER/ERI boxes ....................................................... 56
8.4.3 Beckhoff Identification Code (BIC)................................................................................... 57
8.4.4 Electronic access to the BIC (eBIC) ................................................................................ 59
8.5 Support and Service ........................................................................................................................61

Foreword
EP7402-0057 5Version: 1.3
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®, TwinCAT/BSD®, TC/BSD®, 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: 1.3
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: 1.3
1.3 Documentation issue status
Version Comment
1.3 • Structure update
1.2 • Technical data updated
• Chapter "Troubleshooting" updated
1.1 • Hardware change at supply voltage output X60
• Accessories added
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
1.3 01 03
1.2 01 03
1.1 01 03
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 [}55].

Product overview
EP7402-00578 Version: 1.3
2 Product overview
2.1 Introduction
2-channel motor controller box for roller conveyor systems
The EP7402-0057EtherCATBox offers two outputs with integrated MDR 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 IP67 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.
NOTE
Brake chopper required
Overvoltage peaks can occur on the supply voltage UP which can destroy the device.
The overvoltage peaks occur during braking operations of the motor or by manually moving objects on the
roller conveyor.
• Use a brake chopper to dissipate overvoltages.
E.g. EP9576-1032 or EL9576.
Quick links
Technical data [}9]
Process image [}11]
Dimensions [}15]
Connections [}17]
Quick start [}27]

Product overview
EP7402-0057 9Version: 1.3
2.2 Technical data
All values are typical values over the entire temperature range, unless stated otherwise.
EtherCAT
Connection Input and downstream connection: B23 ENP hybrid connector
EtherCAT junction: M8 socket, 4-pin, green
Electrical isolation 500V
Supply voltages
Connection B23 ENP hybrid connector
US nominal voltage 24VDC (-15%/ +20%)
US sum current: IS,sum max. 28A at 45°C 1)
Current consumption from US150mA
+ output currents of the digital outputs
+ sensor supply
+ output current from the output X60
Rated voltage UP24VDC (-15%/ +20%)
UP sum current: IP,sum max. 28A at 45°C 1)
Current consumption from UPOutput currents for the motors
+ output current for the motor brake
Undervoltage detection 18VDC
Overvoltage detection 30VDC
1) This value corresponds to the current carrying capacity of the connectors.
Motor channels
Number 2
Motor type 3-phase BLDC roller motors
Rotary encoder No rotary encoder needed
Connector 2x M8 socket, b-coded
Motor voltage 24VDC from peripheral voltage UP
Continuous current per channel max. 3.5A
Peak current per channel max. 5A (for approx. 1s)
Rotary field frequency max. 72000°/s = 12000 rpm 2)
2) Do not confuse the rotary field frequency with the motor speed or roller speed.
Digital inputs/outputs
Number 8
Connections 4x M8 socket
Sensor supply US1 24VDC from the control voltage US
max. 0.5A, short-circuit proof
Input specification
Characteristics Type 3 according to EN 61131-2, compatible with type 1
Input filter 10µs
Output specification
Nominal voltage 24VDC (-15% / +20%) from the control voltage US
Output current max. 0.5A per output, individually short-circuit proof

Product overview
EP7402-005710 Version: 1.3
Housing data
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60068-2-6/ EN60068-2-27
EMC immunity/ emission conforms to EN61000-6-2/ EN61000-6-4
Protection class IP65, IP66, IP67 conforms to EN60529
Approvals/markings
Approvals/markings*) CE, EAC, UKCA, UL under preparation
*) Real applicable approvals/markings see type plate on the side (product marking).

Product overview
EP7402-0057 11Version: 1.3
2.3 Process image
In the following sections, the letter n serves as a placeholder for the channel number.
Screenshots showing process data objects of channel1 are used as examples for both channels. The
process data objects of channel1 and channel2 have the same content structure.
DI Inputs
The input variables map the logic level of the digital
inputs/outputs in the process data.
Make sure that the corresponding output variable in
the process data object "DO Outputs" [}13] is set to
0 if you wish to use a digital input/output as an input.
Assignment of connectors to process data [}14]

Product overview
EP7402-005712 Version: 1.3
STM Status Channel n
The input variables "Status" contain the status bits of
the motor channels.
Ready to enable
• TRUE: all prerequisites for the activation of the
motor are fulfilled.
• FALSE: The motor channel cannot be enabled
(output variable "enable") because an error
message is pending.
Ready
• TRUE: The motor is being energized.
Warning
• TRUE: The motor channel is in a borderline state.
Error
• TRUE: The motor channel has been disabled due
to an error message. To determine the cause of
the error, refer to the chapter Diagnosis bits
[}42].
Moving positive
• TRUE: The motor speed is higher than zero.
Moving negative
• TRUE: The motor speed is lower than zero.
TxPDO Toggle
This bit is inverted each time the status bit is updated.
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 [}48].
• Select the measured values for Channel 2 in CoE
object 8032 [}48].

Product overview
EP7402-0057 13Version: 1.3
STM Inputs Device
"STM Inputs Device" contains diagnostic bits that you
can use to narrow down the cause of a warning or an
error. See chapter Diagnosis bits [}42].
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: 1.3
STM Target Velocity Channel n
Velocity
Target velocity.
This value is the setpoint for the velocity controller.
However, any value less than parameter 80n00:09
start velocity [}47], is interpreted as zero.
Unit: °/s
Acceleration
This value determines the maximum acceleration. If
this value is zero, the acceleration is not limited.
Unit: °/s2
Deceleration
This value determines the maximum deceleration. A
deceleration is not limited if this value is zero.
Unit: °/s2
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: 1.3
3 Mounting and cabling
3.1 Mounting
3.1.1 Dimensions
174
166
60 5236.5
13.6
Ø 4.5
All dimensions are given in millimeters.
The drawing is not true to scale.
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: 1.3
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.1: 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: 1.3
3.2 Cabling
3.2.1 Overview
X01
X02
X05
X06
X20
X21
X40
X60
X70 X71
X70
X71
Name Function Connector type Tightening
torque
X01 Digital input/outputs [}25] 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 channel 1 [}23] M8 socket, b-coded 0.4Nm
X21 Motor channel 2 [}23] M8 socket, b-coded 0.4Nm
X40 EtherCAT junction [}20] M8 socket 0.4Nm
X60 Supply voltage output [}21] M8 socket 0.4Nm
X70 Supply voltage and EtherCAT input [}18] B23 ENP -
X71 Supply voltage and EtherCAT downstream connection
[}18]
B23 ENP -
Suitable connection cables can be found in the chapter Accessories [}54].

Mounting and cabling
EP7402-005718 Version: 1.3
3.2.2 Supply voltages and EtherCAT
3.2.2.1 Input and forwarding
NOTE
Brake chopper required
Overvoltage peaks can occur on the supply voltage UP which can destroy the device.
The overvoltage peaks occur during braking operations of the motor or by manually moving objects on the
roller conveyor.
• Use a brake chopper to dissipate overvoltages.
E.g. EP9576-1032 or EL9576.
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
You can connect several EP7402-0057 in series by forwarding the supply voltages and EtherCAT via X71 to
the respective subsequent device.
NOTE
UP is not protected against inverse polarity
Defect possible through polarity reversal.
• Make sure that the supply voltage UP is connected correctly.
Input X70 Forwarding X71
female
male
male
female
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 [}54].

Mounting and cabling
EP7402-0057 19Version: 1.3
3.2.2.1.1 Status LEDs
LED Signal Meaning
24V Us off The supply voltage US is not available.
green illuminated The supply voltage US is available.
L/A off No connection to the connected EtherCAT device.
green illuminated LINK: connection to the connected EtherCAT device.
flashing green ACT: communication with the connected EtherCAT device.
24V Up off The supply voltage UP is not available.
green illuminated The supply voltage UP is available.
3.2.2.1.2 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: 1.3
3.2.2.2 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
3 1
24
Fig.2: 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 [}54].
3.2.2.2.1 Status LED
LED Signal Meaning
L/A off No connection to the connected EtherCAT device.
green illuminated LINK: connection to the connected EtherCAT device
flashing green ACT: communication with the connected EtherCAT device