Beckhoff EP7402-0057 Manual
  1. Manuals
  2. Brands
  3. Beckhoff Manuals
  4. Controller
  5. EP7402-0057
  6. Manual

Beckhoff EP7402-0057 Manual

2-channel motor controller box for roller conveyor systems
Hide thumbs Also See for EP7402-0057:
Table of Contents

Advertisement

Quick Links

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

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the EP7402-0057 and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Beckhoff EP7402-0057

Summary of Contents for Beckhoff EP7402-0057

  • Page 1 Documentation | EN EP7402-0057 2-channel motor controller box for roller conveyor systems 2021-12-15 | Version: 1.3...

  • Page 3: Table Of Contents

    Automatic restart after error...................... 38 Restoring the delivery state ...................... 39 Decommissioning .......................... 40 5 Troubleshooting ............................ 41 Diagnosis bits .......................... 42 Acknowledging errors ........................ 44 6 Application Notes ............................ 45 Motor Diagnosis.......................... 45 7 CoE objects .............................. 46 Register ............................ 46 Object descriptions .......................... 47 7.2.1 Parameterization objects .................... 47 EP7402-0057 Version: 1.3...
  • Page 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 Support and Service ........................ 61 Version: 1.3 EP7402-0057...

  • Page 5: Foreword

    , 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...

  • Page 6: Safety Instructions

    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.

  • Page 7: Documentation Issue Status

    YY - year of production 10 - year of production 2010 FF - firmware version 02 - firmware version 02 HH - hardware version 01 - hardware version 01 Further information on this topic: Version identification of EtherCAT devices [} 55]. EP7402-0057 Version: 1.3...

  • Page 8: Product Overview

    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.

  • Page 9: Technical Data

    Input specification Characteristics Type 3 according to EN 61131-2, compatible with type 1 Input filter 10 µs Output specification Nominal voltage 24 V (-15 % / +20 %) from the control voltage U Output current max. 0.5 A per output, individually short-circuit proof EP7402-0057 Version: 1.3...
  • Page 10 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). Version: 1.3 EP7402-0057...

  • Page 11: Process Image

    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] EP7402-0057 Version: 1.3...
  • Page 12 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]. Version: 1.3 EP7402-0057...
  • Page 13 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. EP7402-0057 Version: 1.3...

  • Page 14: Assignment Of Connectors To Process Data

    STM Status Channel 1 STM Control Channel 1 STM Synchron info data Channel 1 STM Target Velocity Channel 1 Motor STM Status Channel 2 STM Control Channel 2 STM Synchron info data Channel 2 STM Target Velocity Channel 2 Version: 1.3 EP7402-0057...

  • Page 15: Mounting And Cabling

    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) EP7402-0057 Version: 1.3...

  • Page 16: Fixing

    FE core of the first supply line needs to be earthed. supply line supply line supply line EP7402-0057 EP7402-0057 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.

  • Page 17: Cabling

    EtherCAT junction [} 20] M8 socket 0.4 Nm Supply voltage output [} 21] B23 ENP Supply voltage and EtherCAT input [} 18] B23 ENP Supply voltage and EtherCAT downstream connection [} 18] Suitable connection cables can be found in the chapter Accessories [} 54]. EP7402-0057 Version: 1.3...

  • Page 18: 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 U • Peripheral voltage U You can connect several EP7402-0057 in series by forwarding the supply voltages and EtherCAT via X71 to the respective subsequent device. NOTE is not protected against inverse polarity Defect possible through polarity reversal.
  • Page 19 Variations in the voltage of the power supply unit must also be taken into account. Voltage drop on the supply line Conductor cross-section: 4 mm² 25 A 20 A 15 A Vert. Faktor: 0,8 cm / V 10 A Cable length (m) EP7402-0057 Version: 1.3...
  • Page 20 Suitable connection cables can be found in the chapter Accessories [} 54]. 3.2.2.2.1 Status LED Signal Meaning 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 Version: 1.3 EP7402-0057...
  • Page 21 Up to and including hardware version 02: GND is connected to pin 3, GND to pin 4. Starting with hardware version 03, both pins are connected to the same ground potential GND Suitable connection cables can be found in the chapter Accessories [} 54]. EP7402-0057 Version: 1.3...
  • Page 22 The supply voltage U ' is not output. green illuminated The supply voltage U ' is output. 24V Up‘ (X60) The supply voltage U ' is not output. green illuminated The supply voltage U ' is output. Version: 1.3 EP7402-0057...

  • Page 23: Motors

    Wire color Function brown Motor phase U white Motor phase V blue Brake output black Motor phase W grey Connection example Pin 1 Pin 2 Pin 4 Brake Brake Pin 3 Pin 5 Fig. 5: Motor connection example EP7402-0057 Version: 1.3...
  • Page 24 You can enable it by setting "Enable" to 1 in the process data object STM Control Channel 2 [} 13]. green illuminated Motor channel 2 is enabled. red illuminated Motor channel 2 has been disabled due to an error. Check the diagnostic bits [} 42] to determine the cause of the error. Version: 1.3 EP7402-0057...

  • Page 25: Digital Input/Outputs

    Digital sensor, 2-wire connection to channel A 24 V Pin 1 DIO A Pin 4 Fig. 7: Digital sensor, 2-wire connection Digital sensor, 3-wire connection to channel A 24 V Pin 1 DIO A Pin 4 Pin 3 Fig. 8: Digital sensor, 3-wire connection EP7402-0057 Version: 1.3...

  • Page 26: Disposal

    Products marked with a crossed-out wheeled bin shall not be discarded with the normal waste stream. The device is considered as waste electrical and electronic equipment. The national regulations for the disposal of waste electrical and electronic equipment must be observed. Version: 1.3 EP7402-0057...

  • Page 27: Commissioning

    1. Connect a roller motor to socket X20. The pin assignment can be found in the chapter Motors [} 23]. 2. Connect the supply voltages and EtherCAT to socket X70. The pin assignment can be found in the chapter Supply voltages and EtherCAT [} 18]. EP7402-0057 Version: 1.3...
  • Page 28 Commissioning 3. Check the correct connection using the status LEDs: Target state: • "24V Us" lights up green. • "24V Up" lights up green. • "L/A" shows the LINK/ACT status of the EtherCAT communication. Version: 1.3 EP7402-0057...

  • Page 29: Step 2: Twincat Configuration

    Commissioning 4.1.2 Step 2: TwinCAT configuration 1. Integrating EP7402-0057 into a TwinCAT project. (see quick start guide) ð A dialog box appears: 2. Click "Cancel" to close the dialog box. 3. Reset EP7402-0057 to factory settings: Set parameter 1011:01 to value 1684107116 EP7402-0057 Version: 1.3...

  • Page 30: Step 3: Basic Parameters

    Commissioning 4.1.3 Step 3: Basic parameters Example parameters for a servomotor from Beckhoff: AM8111-0F20-0000 [} 52] Open the "CoE – Online" tab. Set the parameters as described below. Leave all other parameters in the factory setting. 4.1.3.1 Index 8020 “STM Motor Settings Ch. 1”...
  • Page 31 • If the number of poles of the roller motor is not known: Determine the "Mechanical to electrical ratio" experimentally [} 36]. 8020:14 "Rated velocity" Unit: °/s Rated speed of the roller motor. 8020:19 “Motor thermal time constant” Unit: 1/10 s (1/10 of a second) EP7402-0057 Version: 1.3...
  • Page 32 8023:14 „Sensorless offset scaling“ Set this parameter to 80. 8023:19 “Rampup velocity” Unit: °/s (degrees per second) Set this parameter to the same value as parameter 8020:09 “Start velocity” [} 30]. 8023:21 "Rampup needed switchover events" Set this parameter to 1. Version: 1.3 EP7402-0057...

  • Page 33: Step 4: Test Run

    (i = 1 if no gear unit    is used) 5. Set "Enable" to 1. ð The rotor is aligned for 1 second. ð The box then attempts to turn the motor. 6. Assess the result. [} 34] EP7402-0057 Version: 1.3...
  • Page 34 8023:21 "Rampup needed switchover events" [} 32]. Incorrect motor parameters Check the motor parameters [} 30] The motor is too weak Insert a gear unit and recalculate all parameters. Especially likely when the motor makes a sound with ascending pitch. Version: 1.3 EP7402-0057...

  • Page 35: Step 5: Final Steps

    2. Set parameter 8023:12 "Velocity loop proportional gain" to 100 (Any value above zero activates the velocity controller) ð You can now control the motor with the variables "Enable" and "Velocity". 3. During operation, monitor the diagnostic bits [} 42]. 4. Fine-tuning of the parameters [} 37] EP7402-0057 Version: 1.3...

  • Page 36: Determining The "Mechanical To Electrical Ratio" Experimentally

    The parameter 8020:13 “Mechanical to electrical ratio“ [} 47] is an essential parameter for the operation of EP7402-0057. You can calculate the parameter [} 31], if the number of poles and the gear ratio are known. Otherwise you must determine the parameter experimentally: 1.

  • Page 37: Fine-Tuning Parameters

    : parameter 80n3:11 “Velocity loop integral time” • Integral time T : CoE parameter 80n3:12 “Velocity loop proportional gain” • Parameter 80n3:13 “Feed forward gain” You can disable the velocity controller by setting the proportional gain K to zero. EP7402-0057 Version: 1.3...

  • Page 38: Automatic Restart After Error

    STM Controller Settings 4 Ch. n Restart after error number of repetition 80n3 STM Controller Settings 4 Ch. n Restart after error delay • n = 2 for motor channel 1 (socket X20) • n = 3 for motor channel 2 (socket X21) Version: 1.3 EP7402-0057...

  • Page 39: Restoring The Delivery State

    Fig. 11: Entering a restore value in the Set Value dialog Alternative restore value In some older terminals / boxes the backup objects can be switched with an alternative restore value: Decimal value: 1819238756 Hexadecimal value: 0x6C6F6164 An incorrect entry for the restore value has no effect. EP7402-0057 Version: 1.3...

  • Page 40: Decommissioning

    Disposal In order to dispose of the device, it must be removed. In accordance with the WEEE Directive 2012/19/EU, Beckhoff takes back old devices and accessories in Germany for proper disposal. Transport costs will be borne by the sender. Return the old devices with the note "for disposal" to: Beckhoff Automation GmbH &...

  • Page 41: Troubleshooting

    It rotates at a constant speed. Unexplained failure of Overvoltages on the supply Use a brake chopper to prevent EP7402-0057 or other device voltage U , caused by energy overvoltages on the supply powered from the same supply recovery, e.g.

  • Page 42: Diagnosis Bits

    At least one phase current has • A motor phase is short-cir- Channel n short circuit exceeded the value of the pa- cuited. rameter "Maximum current": CoE • The motor is defective. index 80n0:01 [} 47]. The motor channel has been dis- abled. Version: 1.3 EP7402-0057...
  • Page 43 The speed (output variable "Ve- eter "Start velocity" (CoE index locity") is too low. 80n0:09 [} 47]) to ensure that the motor does not start with too low a speed preset. Especially likely when the motor makes a sound with ascending pitch. EP7402-0057 Version: 1.3...

  • Page 44: Acknowledging Errors

    "STM Control Channel n" (n = 1...2). Troubleshooting • If an error message persists after acknowledgement, the error has probably not yet been eliminated. • To successfully acknowledge the error "Open Load", you must first set "Enable" to 0. Version: 1.3 EP7402-0057...

  • Page 45: Application Notes

    1. Map the I2T value to one of the “Info data” variables in “STM Synchron info data Channel n”. CoE index 80n2 “STM Features“ [} 48]. 2. Monitor the “Info data” variable in a scope project. ð This enables to recognize irregularities. Example scope recording EP7402-0057 Version: 1.3...

  • Page 46: Coe Objects

    8033 STM Controller Settings 4 Ch. 2 [} 49] F000 Modular Device Profile F008 Code word F010 Module Profile List F081 Download revision F600 STM Device Diag data F80F STM Vendor data [} 50] F900 STM Info data [} 50] Version: 1.3 EP7402-0057...

  • Page 47: Object Descriptions

    T value exceeds this threshold, the “Channel n overload I2T error” bit is set. The motor is switched torqueless. Motor thermal time T limit monitoring: Thermal time constant. 0.1 s UINT constant The thermal time constant can be found in the motor datasheet. EP7402-0057 Version: 1.3...
  • Page 48 • “Motor amplifier I T load” = 12 • “Motor dc current” = 13 • “Motor back EMF” = 17 • “Motor restart counter” = 18 • “Internal temperature” = 101 • “Motor supply voltage” = 104 Version: 1.3 EP7402-0057...
  • Page 49 If this parameter is zero, the motor will be switched off immediately after a commutation error in nominal operation. Restart after error de- This parameter determines the time span between a commuta- UINT 1000 tion error and the automatic restart. See also subindex 25. EP7402-0057 Version: 1.3...

  • Page 50: Information Objects

    Index F900: STM Info data Access rights: read only Subindex Name Description Unit Data type Default (hex) value Internal temperature Internal temperature °C SINT Motor supply voltage Current value of the peripheral voltage U 0.01 V UINT Version: 1.3 EP7402-0057...

  • Page 51: Standard Objects

    Hardware revision String Refer to Firmware and hardware versions [} 7]. Index 100A Software version Access rights: read only Subindex Name Description Unit Data type Value (hex) Software Version Firmware revision Refer to Firmware and hardware versions [} 7]. EP7402-0057 Version: 1.3...

  • Page 52: Appendix

    Motor thermal time constant 8023:11 Velocity loop integral time 8023:12 Velocity loop proportional gain 8023:14 Align power 8023:15 Align duration 1000 8023:16 Rampup power 8023:18 Rampup duration 8023:19 Rampup velocity 2000 8023:21 Rampup needed switchover events 8023:22 Commutation threshold Version: 1.3 EP7402-0057...

  • Page 53: General Operating Conditions

    (ph-Value > 12) > 40°C: not resistant Acetic acid not resistant Argon (technical clean) resistant • resistant: Lifetime several months • non inherently resistant: Lifetime several weeks • not resistant: Lifetime several hours resp. early decomposition EP7402-0057 Version: 1.3...

  • Page 54: Accessories

    ZB8801-0001 Torque cable key for M8 / wrench size 9 for ZB8801-0000 ZB8802-0003 Assembly tool for B23 connectors Further accessories Further accessories can be found in the price list for fieldbus components from Beckhoff and online at https://www.beckhoff.com. Version: 1.3 EP7402-0057...

  • Page 55: Version Identification Of Ethercat Devices

    Associated and synonymous with each revision there is usually a description (ESI, EtherCAT Slave Information) in the form of an XML file, which is available for download from the Beckhoff web site. From 2014/01 the revision is shown on the outside of the IP20 terminals, see Fig. “EL5021 EL terminal, standard IP20 IO device with batch number and revision ID (since 2014/01)”.

  • Page 56: Version Identification Of Ep/Epi/Epp/Er/Eri Boxes

    Version identification of EP/EPI/EPP/ER/ERI boxes The serial number/ data code for Beckhoff IO devices is usually the 8-digit number printed on the device or on a sticker. The serial number indicates the configuration in delivery state and therefore refers to a whole production batch, without distinguishing the individual modules of a batch.

  • Page 57: Beckhoff Identification Code (Bic)

    8.4.3 Beckhoff Identification Code (BIC) The Beckhoff Identification Code (BIC) is increasingly being applied to Beckhoff products to uniquely identify the product. The BIC is represented as a Data Matrix Code (DMC, code scheme ECC200), the content is based on the ANSI standard MH10.8.2-2016.
  • Page 58 Fig. 14: Example DMC 1P072222SBTNk4p562d71KEL1809 Q1 51S678294 An important component of the BIC is the Beckhoff Traceability Number (BTN, position 2). The BTN is a unique serial number consisting of eight characters that will replace all other serial number systems at Beckhoff in the long term (e.g.

  • Page 59: Electronic Access To The Bic (Ebic)

    Electronic access to the BIC (eBIC) Electronic BIC (eBIC) The Beckhoff Identification Code (BIC) is applied to the outside of Beckhoff products in a visible place. If possible, it should also be electronically readable. Decisive for the electronic readout is the interface via which the product can be electronically addressed.
  • Page 60 EtherCAT, the eBIC of the top-level device is located in the CoE object directory 0x10E2:01 and the eBICs of the sub-devices follow in 0x10E2:nn. Profibus/Profinet/DeviceNet… Devices Currently, no electronic storage and readout is planned for these devices. Version: 1.3 EP7402-0057...

  • Page 61: Support And Service

    Please contact your Beckhoff branch office or representative for local support and service on Beckhoff products! The addresses of Beckhoff's branch offices and representatives round the world can be found on her internet pages: https://www.beckhoff.com You will also find further documentation for Beckhoff components there.
  • Page 63 More Information: www.beckhoff.com/ep7402-0057/ Beckhoff Automation GmbH & Co. KG Hülshorstweg 20 33415 Verl Germany Phone: +49 5246 9630 info@beckhoff.com www.beckhoff.com...

Table of Contents