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Documentation | EN

EP7402-0057

2-channel motor controller box for roller conveyor systems

2021-12-15 | Version: 1.3

Summary of Contents for EP7402-0057

Page 1: ...Documentation EN EP7402 0057 2 channel motor controller box for roller conveyor systems 2021 12 15 Version 1 3...

Page 2: ......

Page 3: ...l 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...

Page 4: ...tor 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...

Page 5: ...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 EtherCA...

Page 6: ...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...

Page 7: ...e 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 Ha...

Page 8: ...x 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 P...

Page 9: ...e 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...

Page 10: ...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...

Page 11: ...s 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...

Page 12: ...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 Mov...

Page 13: ...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...

Page 14: ...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...

Page 15: ...e to scale Housing features Housing material PA66 polyamide Sealing compound polyurethane Mounting two fastening holes 4 5 mm for M4 Metal parts brass nickel plated Contacts CuZn gold plated Power fee...

Page 16: ...oles 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 s...

Page 17: ...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 Su...

Page 18: ...ectrically 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...

Page 19: ...ice 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 plannin...

Page 20: ...hite 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 th...

Page 21: ...with analog inputs or outputs may not be met under certain circumstances 3 1 2 4 Fig 3 M8 socket Contact Symbol Description Wire color 1 24V Us Control voltage Brown 2 24V Up Peripheral voltage 1 Whi...

Page 22: ...3 3 2 2 3 1 Status LEDs LED Signal Meaning 24V Us X60 off The supply voltage US is not output green illuminated The supply voltage US is output 24V Up X60 off The supply voltage UP is not output gree...

Page 23: ...4 2 1 3 5 Fig 4 M8 socket b coded Pin Wire color Function 1 brown Motor phase U 2 white Motor phase V 3 blue Brake output 4 black Motor phase W 5 grey GNDP Connection example M 3 W Pin 4 U Pin 1 V Pi...

Page 24: ...led due to an error Check the diagnostic bits 42 to determine the cause of the error Warning orange illuminated Warning message Check the diagnostic bits 42 to determine the cause of the warning messa...

Page 25: ...S 4 black Input output A 2 1 The core colors apply to cables of the type ZK2000 3xxx See chapter Accessories 54 2 Assignment to process data 14 3 2 4 1 Connection examples Digital sensor 2 wire connec...

Page 26: ...ts 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 disp...

Page 27: ...A L A EP7402 0057 D 46210 10 3 S No777777 Made in Germ any Auto m ation Gm bH Co KG D 33415 Verl H lshorstw eg 20 www beckhoff com 2 Connect the supply voltages and EtherCAT to socket X70 The pin assi...

Page 28: ...0 L A L A EP7402 0057 D 46210 10 3 S No777777 Made in Germ any Auto m ation Gm bH Co KG D 33415 Verl H lshorstw eg 20 www beckhoff com X21 X20 X70 X01 X05 X02 DIO1 DIO2 DIO3 DIO4 LC1 LC2 L Motor CH1 W...

Page 29: ...Step 2 TwinCAT configuration 1 Integrating EP7402 0057 into a TwinCAT project see quick start guide A dialog box appears 2 Click Cancel to close the dialog box 3 Reset EP7402 0057 to factory settings...

Page 30: ...020 01 Peak current Unit mA The peak current which may only flow for a short time 8020 02 Rated current Unit mA The rated current is the current that the motor draws when it is operated at the rated s...

Page 31: ...0 13 Mechanical to electrical ratio You can calculate or experimentally determine the value for this parameter If the number of poles of the roller motor is known use this formula p value for paramete...

Page 32: ...isables the velocity controller Reenable it after Step 4 Test run 33 has been successfully completed 8023 13 Velocity feed forward Unit Set this parameter to 100 This makes the target velocity value b...

Page 33: ...ease the holding brake set Brake output to 1 4 Set Velocity to 50 of the nominal speed of the motor including gear unit Formula for calculating 50 of the nominal speed n value for the Velocity output...

Page 34: ...Check the calculations Channel 1 motor overload I2T error The output current is too high Reduce the value of parameter 8023 14 Sensorless offset scaling 49 Channel 1 commutation error The conveyor ro...

Page 35: ...to 0 2 Set parameter 8023 12 Velocity loop proportional gain to 100dec Any value above zero activates the velocity controller You can now control the motor with the variables Enable and Velocity 3 Dur...

Page 36: ...ocity to 0 3 Set Enable to 1 A motor phase is powered You may hear a click noise from the roller motor 4 Rotate the conveyor roller by hand Do you feel defined snap steps Yes Continue below No Increas...

Page 37: ...warnings or errors Try again if necessary 80n3 19 Rampup velocity Variable Velocity time velocity time Enable 1 0 80n3 18 Rampup duration 80n3 18 Align duration Velocity controller operation Motor cha...

Page 38: ...motor restarted In the factory setting the automatic restart is switched off Configuring automatic restart There are two parameters with which the automatic restart can be configured Object Parameter...

Page 39: ...lt parameters PDO Double click on SubIndex 001 to enter the Set Value dialog Enter the value 1684107116 in field Dec or the value 0x64616F6C in field Hex and confirm with OK All backup objects are res...

Page 40: ...he devices 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...

Page 41: ...ble Velocity is smaller than the parameter Start velocity Increase Velocity or decrease parameter 80n00 09hex Start velocity The motor does not react to changes in the output variable Velocity It rota...

Page 42: ...ervoltage detection Make sure that UP lies within the nominal voltage range Check the measured value of the voltage UP in the CoE pa rameter F900 05hex Motor sup ply voltage Device overvoltage The sup...

Page 43: ...t the specifications is usually much lower than the thermal limit of the amplifier Check the motor parameters CoE index 80n0 47 Channel n amplifier over load I2T error The calculated I2 T value has ex...

Page 44: ...le It is not sufficient to acknowledge the error on only one motor channel The module error and the disablement of both motor channels are only canceled when the error has been acknowledged on both mo...

Page 45: ...r long term diagnosis and wear detection of the motor and attached mechanics 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...

Page 46: ...p Synchron info data Ch 1 1A03 STM TxPDO Map Status Ch 1 1A04 STM TxPDO Map Synchron info data Ch 1 1A05 STM TxPDO Map Inputs Device 1C00 Sync manager type 1C12 RxPDO assign 1C13 TxPDO assign 1C32 SM...

Page 47: ...tance between two motor phases 0 01 UINT 100dec 09 Start velocity Threshold value the motor is kept in align state if the value of the output variable velocity is lower than this value If this value i...

Page 48: ...o data 1 Define the measured values to be mapped to the input vari ables in STM Synchron info data Channel n Enum Motor velocity 7 Motor load I2 T value 11dec Motor amplifier I2 T load 12dec Motor dc...

Page 49: ...ts the output current during alignment and rampup phase The output current is specified in percent of the nominal cur rent CoE index 80n0 02 47 USINT 50dec 15 Align duration Duration of the alignment...

Page 50: ...age mA UINT 4500dec 0A Amplifier maximal cur rent If the output current exceeds the value of this parameter the output stage is switched off mA UINT 18000dec 0B Amplifier minimal volt age Threshold va...

Page 51: ...8 Device name Access rights read only Subindex hex Name Description Unit Data type Value Device Name Device Name String EP7402 0 057 Index 1009 Hardware version Access rights read only Subindex hex Na...

Page 52: ...y 666 8020 13hex Mechanical to electrical ratio 3 8020 19hex Motor thermal time constant 15 8023 11hex Velocity loop integral time 300 8023 12hex Velocity loop proportional gain 100 8023 14hex Align p...

Page 53: ...on Definition 0 Non protected 1 Protected against water drops 2 Protected against water drops when enclosure tilted up to 15 3 Protected against spraying water Water sprayed at an angle up to 60 on ei...

Page 54: ...n B coded field assembly Data sheet Protective caps for connectors Ordering information Description ZS5000 0010 Protective cap for M8 sockets IP67 50 pieces ZS7300 B001 Protective cap for B23 plastic...

Page 55: ...ntifier in the case of 0000 usually abbreviated to EL3314 0016 is the EtherCAT revision The order identifier is made up of family key EL EP CU ES KL CX etc type 3314 version 0000 The revision 0016 sho...

Page 56: ...06 production year 2006 3A firmware version 3A 02 hardware version 02 Exceptions can occur in the IP67 area where the following syntax can be used see respective device documentation Syntax D ww yy x...

Page 57: ...t it can be found in the following places on the packaging unit directly on the product if space suffices on the packaging unit and the product The BIC is machine readable and contains information tha...

Page 58: ...of composite information from positions 1 to 4 and with the above given example value on position 6 The data identifiers are highlighted in bold font 1P072222SBTNk4p562d71KEL1809 Q1 51S678294 Accordi...

Page 59: ...erCAT system manual Link for the relationships The eBIC is also stored in the ESI EEPROM The eBIC was introduced into the Beckhoff I O production terminals boxes from 2020 widespread implementation is...

Page 60: ...therCAT masters that they must not overwrite these data in case of an update or restore the data after an ESI update The structure follows the content of the BIC see there This results in a memory req...

Page 61: ...there Beckhoff Support Support offers you comprehensive technical assistance helping you not only with the application of individual Beckhoff products but also with other wide ranging services suppor...

Page 62: ......

Page 63: ...Beckhoff Automation GmbH Co KG H lshorstweg 20 33415 Verl Germany Phone 49 5246 9630 info beckhoff com www beckhoff com More Information www beckhoff com ep7402 0057...

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