Beckhoff EP7402 Operator's manual

Documentation | EN
EP7402
2-channel motor controller box for roller conveyor systems
2023-01-09 | Version: 1.6

Table of contents
EP7402 3Version: 1.6
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 Module overview ...............................................................................................................................8
2.2 EP7402-0057 ....................................................................................................................................9
2.2.1 Introduction ........................................................................................................................9
2.2.2 Technical data EP7402-0057...........................................................................................10
2.3 EP7402-0167 ..................................................................................................................................12
2.3.1 Introduction ......................................................................................................................12
2.3.2 Technical data EP7402-0167...........................................................................................13
2.4 Process image ................................................................................................................................15
2.4.1 Process image "PLC control" ...........................................................................................15
2.4.2 Process image "Local control...........................................................................................19
3 Selection of a motor................................................................................................................................21
4 Mounting and cabling .............................................................................................................................22
4.1 Mounting .........................................................................................................................................22
4.1.1 Dimensions ......................................................................................................................22
4.1.2 Fixing................................................................................................................................ 23
4.1.3 Functional earth (FE) ....................................................................................................... 23
4.2 Cabling ............................................................................................................................................24
4.2.1 EP7402-0057 - Overview ................................................................................................. 24
4.2.2 EP7402-0167 - Overview ................................................................................................. 25
4.2.3 FE connection (EP7402-0167 only) ................................................................................. 26
4.2.4 Supply voltages and EtherCAT ........................................................................................ 27
4.2.5 Motor connections of EP7402-0057.................................................................................32
4.2.6 Motor connections of EP7402-0167.................................................................................34
4.2.7 Digital input/outputs.......................................................................................................... 36
4.3 Disposal ..........................................................................................................................................38
5 Commissioning .......................................................................................................................................39
5.1 Quick start .......................................................................................................................................39
5.1.1 Step 1: Hardware Setup...................................................................................................39
5.1.2 Step 2: TwinCAT configuration ........................................................................................ 41
5.1.3 Step 3: parameterization .................................................................................................. 42
5.1.4 Step 4: Test run................................................................................................................ 47
5.1.5 Step 5: Final steps ........................................................................................................... 49
5.2 Determining the “Mechanical to electrical ratio” experimentally......................................................50
5.2.1 Firmware 04 and higher ................................................................................................... 50
5.2.2 Firmware 03 and lower..................................................................................................... 50
5.3 Fine-tuning parameters ...................................................................................................................51
5.3.1 Alignment phase and ramp-up phase .............................................................................. 51
5.3.2 Velocity controller.............................................................................................................51

Table of contents
EP74024 Version: 1.6
5.4 Automatic restart after error ............................................................................................................52
5.5 ZPA: Zero Pressure Accumulation..................................................................................................53
5.5.1 Requirements...................................................................................................................53
5.5.2 Basic principles ................................................................................................................ 53
5.5.3 Cabling .............................................................................................................................56
5.5.4 Commissioning................................................................................................................. 58
5.5.5 State machine .................................................................................................................. 60
5.6 Restore the delivery state ...............................................................................................................62
6 Troubleshooting......................................................................................................................................63
6.1 Diagnosis bits..................................................................................................................................64
6.2 Acknowledging errors......................................................................................................................66
7 Decommissioning ...................................................................................................................................67
8 Application Notes....................................................................................................................................68
8.1 Motor Diagnosis ..............................................................................................................................68
9 CoE objects .............................................................................................................................................69
9.1 Register...........................................................................................................................................69
9.2 Object descriptions..........................................................................................................................71
9.2.1 Parameterization objects.................................................................................................. 71
9.2.2 Information objects...........................................................................................................77
9.2.3 Standard objects .............................................................................................................. 78
10 Appendix..................................................................................................................................................79
10.1 Example motor parameters.............................................................................................................79
10.2 General operating conditions ..........................................................................................................80
10.3 Accessories.....................................................................................................................................81
10.4 Version identification of EtherCAT devices .....................................................................................82
10.4.1 General notes on marking................................................................................................82
10.4.2 Version identification of EP/EPI/EPP/ER/ERI boxes........................................................83
10.4.3 Beckhoff Identification Code (BIC)...................................................................................84
10.4.4 Electronic access to the BIC (eBIC).................................................................................86
10.5 Support and Service........................................................................................................................88

Foreword
EP7402 5Version: 1.6
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
EP74026 Version: 1.6
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 7Version: 1.6
1.3 Documentation issue status
Version Comment
1.6 • New functions of firmware04 added.
1.5 • EP7402-0167 added
1.4 • New functions from firmware03 added, e.g. ZPA
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 EP7402-0057 EP7402-0167
Firmware Hardware Firmware Hardware
1.6 04 03 04 00
1.5 03 03 03 00
1.4 03 03 - -
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 [}82].

Product overview
EP74028 Version: 1.6
2 Product overview
2.1 Module overview
The following table shows the products described in this documentation and the main distinguishing features.
Module Motor
nominal voltage
Motor
connections
Additional functions
EP7402-0057 [}9] 18 … 24VDC M8 sockets,
b-coded
• EtherCAT junction
• Supply voltage output
• Motor brake outputs
EP7402-0167 [}12] 18 … 48VDC M8 sockets,
a-coded
• Additional FE connection

Product overview
EP7402 9Version: 1.6
2.2 EP7402-0057
2.2.1 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 EP7402-0057 [}10]
Process image [}15]
Dimensions [}22]
Connections [}24]
Quick start [}39]

Product overview
EP740210 Version: 1.6
2.2.2 Technical data EP7402-0057
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
UP nominal voltage 18 … 24VDC
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
Motor inductance min. 200µH
Rotary encoder No rotary encoder needed
Connector 2x M8 socket, b-coded
Cable length max. 30m from the box to the motor
Motor voltage 18 … 24VDC from the peripheral voltage UP
Continuous current per channel max. 3.5Arms
Peak current per channel • Firmware03 and higher:
max. 12.0Arms for approx. 1s
• Firmware02 and lower:
max. 5.0Arms for approx. 1s
Rotating field velocity • Firmware03 and higher:
max. 599Hz = 215640°/s = 35940rpm2)
• Firmware 02 and lower:
max. 72000°/s = 12000rpm2)
PWM clock frequency 16kHz
Current controller frequency 32kHz
2) Do not confuse the rotating field velocity with the motor speed or the roller speed.

Product overview
EP7402 11Version: 1.6
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
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, UL under preparation
*) Real applicable approvals/markings see type plate on the side (product marking).

Product overview
EP740212 Version: 1.6
2.3 EP7402-0167
2.3.1 Introduction
2-channel motor controller box for roller conveyor systems
The EP7402-0167 EtherCAT Box provides two outputs with integrated MDR controller for direct connection
of 48VDC roller motors or other BLDC motors with max. 3.5A. Eight additional digital inputs/outputs allow the
connection of e.g. light barriers and the communication between the modules in PLC-less operation.
The EP7402-0167 takes over the complete control of the roller motor irrespective of the manufacturer of the
conveyor or the motor. The connection is made directly to the three phases of the motor. Maximum nominal
current, start-up or deceleration ramps as well as various other parameters can be configured, which allows
wide adaptation to different applications. The motors are controlled without sensors.
Measuring just 174mm x 60mm x 36.5mm, the IP67-rated EtherCAT Box can be easily mounted in
standard side profiles on the conveyor frame. It does not require an additional protective cover. Power
supply and EtherCAT communication are done via a B23 ENP connector with a current carrying capacity of
28A/45°C. In pure conveying mode, the EP7402-0167 can also be operated without a PLC and provides
functions such as ZPA (Zero Pressure Accumulation), singulated or train release.
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 [}13]
Process image [}15]
Dimensions [}22]
Connections [}25]
Quick start [}39]

Product overview
EP7402 13Version: 1.6
2.3.2 Technical data EP7402-0167
All values are typical values over the entire temperature range, unless stated otherwise.
EtherCAT
Connection B23 ENP hybrid connector
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 power supply
UP nominal voltage range 18 … 48VDC
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
UP undervoltage detection 18V
UP overvoltage detection 60V
1) This value corresponds to the current carrying capacity of the connectors.
Motor channels
Number 2
Motor type 3-phase BLDC roller motors
Motor inductance min. 200µH
Rotary encoder No rotary encoder needed
Connector 2x M8 socket, b-coded
Cable length max. 30m from the box to the motor
Motor voltage 18 … 48VDC from the supply voltage UP
Continuous current per channel 3.5Arms
Peak current per channel 12.0Arms for approx. 1s
Rotating field velocity 599Hz2)
PWM clock frequency 16kHz
Current controller frequency 32kHz
2) Do not confuse the rotating field velocity with the motor speed or the roller speed.

Product overview
EP740214 Version: 1.6
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
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, UL under preparation
*) Real applicable approvals/markings see type plate on the side (product marking).

Product overview
EP7402 15Version: 1.6
2.4 Process image
The scope of the process image is adjustable.
The EP7402 has two predefined variants of the process image, called "Predefined PDO Assignments".
The factory default setting is "PLC control".
Predefined PDO Assignment Use
"PLC control" [}15] Operation with a controller as central intelligence
"Local control [}19] ZPA operation
2.4.1 Process image "PLC control"
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" [}17] is set to
0 if you wish to use a digital input/output as an input.
Assignment of connectors to process data [}18]

Product overview
EP740216 Version: 1.6
STM Status Channel n
The input variables "Status" contain the status bits of
the motor channels.
Ready to enable
• TRUE: all prerequisites for enabling 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, see chapter Diagnosis bits [}64].
Moving positive
• TRUE: the motor velocity is higher than zero.
Moving negative
• TRUE: the motor velocity 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 [}72].
• Select the measured values for Channel 2 in CoE
object 8032 [}72].

Product overview
EP7402 17Version: 1.6
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 [}64].
DO Outputs
Output variables for the digital inputs/outputs.
STM Control Channel n
Enable
This bit enables the motor channel. The bit has no
effect if the variable Ready to enable [}16] is FALSE.
Reset
Apply a rising signal edge to this bit to acknowledge
an error.
Invert direction
If this bit is set, the setpoint velocity [}18] is
multiplied by "-1" to change the direction.
Brake output (EP7402-0057 only)
Output variable for switching the motor brake output.

Product overview
EP740218 Version: 1.6
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 [}71], 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
2.4.1.1 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

Product overview
EP7402 19Version: 1.6
2.4.2 Process image "Local control
In the factory setting, "Local control" is disabled. It is enabled when the ZPA operation is put into operation.
See chapter Commissioning [}58].
If the Predefined PDO Assignment "Local control" is enabled, the process image contains variables for
monitoring and controlling the ZPA operation.
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.
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 [}64].

Product overview
EP740220 Version: 1.6
ZNCTRL Inputs Channeln
Moving
EP7402 currently drives the motor. The zone is
conveying.
Zone sensor input
The current state of the zone sensor.
Upstream control input value
The current state of the control signal received by the
controller from the upstream zone.
With the value1, the preceding zone announces a
package.
See chapter ZPA operation with EP7402 [}55].
Upstream control output value
The current signal level of the control signal that the
controller sends to the upstream zone.
The value1 means that the zone is free.
See chapter ZPA operation with EP7402 [}55].
Downstream control input value
The current signal level of the control signal received
by the controller from the downstream zone.
The value1 means that the following zone is free.
See chapter ZPA operation with EP7402 [}55].
Downstream control output value
The current signal level of the control signal that the
controller sends to the downstream zone.
With the value1 the controller announces a package.
See chapter ZPA operation with EP7402 [}55].
Reset input value
The current state of the external reset input.
Zone state
The current state of the ZPA state machine. See
chapter State machine [}60].
ZNCTRL Outputs Channeln
Reset
Apply a rising signal edge to this bit to acknowledge
an error.
Disable
Disable ZPA operation for this zone.