Beckhoff EPP7041-x002 User Manual
Documentation | EN
EPP7041-x002
Stepper motor module 48 V DC with incremental encoder
2021-01-20 | Version: 1.0
Table of contents
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 group: EtherCATP Box modules ..............................................................................................8
3 Product overview.......................................................................................................................................9
3.1 Module overview................................................................................................................................9
3.2 Introduction......................................................................................................................................10
3.3 Technical data .................................................................................................................................11
3.3.1 Additional checks............................................................................................................. 12
3.4 Scope of supply ...............................................................................................................................13
3.5 Process image.................................................................................................................................14
3.5.1 "Predefined PDO Assignments" ...................................................................................... 14
3.5.2 Process data objects ....................................................................................................... 16
3.6 Technology ......................................................................................................................................21
3.6.1 Stepper motor parameters............................................................................................... 21
3.6.2 Selecting a stepper motor................................................................................................ 23
4 Mounting and connections.....................................................................................................................24
4.1 Mounting..........................................................................................................................................24
4.1.1 Dimensions ...................................................................................................................... 24
4.1.2 Fixing ............................................................................................................................... 25
4.2 Functional earth (FE).......................................................................................................................25
4.3 Connections.....................................................................................................................................26
4.3.1 Overview.......................................................................................................................... 26
4.3.2 EtherCATP...................................................................................................................... 27
4.3.3 Stepper motor connection: X01 ....................................................................................... 30
4.3.4 DC link voltage input: X02 ............................................................................................... 32
4.3.5 Digital inputs and outputs: X03 ........................................................................................ 33
4.3.6 Incremental encoders: X04.............................................................................................. 34
4.3.7 Status LEDs..................................................................................................................... 35
5 Commissioning and configuration ........................................................................................................36
5.1 Integrating EPP7041 into a TwinCAT project ..................................................................................36
5.2 Parameterizing EPP7041 ................................................................................................................37
5.2.1 Open the parameter directory (CoE) ............................................................................... 37
5.2.2 Setting important motor parameters ................................................................................ 38
5.2.3 Setting other important parameters ................................................................................. 40
5.3 Setting the operating mode .............................................................................................................41
5.3.1 Operating modes ............................................................................................................. 42
5.4 Parameterizing the NC axis.............................................................................................................43
5.4.1 Parameterizing the encoder............................................................................................. 45
5.4.2 Parameterizing the controller........................................................................................... 47
5.5 Performing a test run .......................................................................................................................49
5.5.1 Test run with TwinCAT NC .............................................................................................. 49
EPP7041-x002 3Version: 1.0
Table of contents
5.5.2 Test run without the TwinCAT NC ................................................................................... 50
5.6 Further applications .........................................................................................................................51
5.6.1 Using the "Positioning Interface" ..................................................................................... 51
5.6.2 Linking an NC axis with EPP7041-x002 .......................................................................... 66
5.6.3 Restoring the delivery state ............................................................................................. 67
5.7 Decommissioning ............................................................................................................................68
6 Diagnosis..................................................................................................................................................69
6.1 Diagnostics – basic principles of diag messages ............................................................................69
6.2 Diag Messages of EtherCAT devices for drive technology .............................................................78
7 CoE parameters .......................................................................................................................................79
7.1 Object directory ...............................................................................................................................79
7.2 Data format of CoE parameters.......................................................................................................81
7.3 Object description............................................................................................................................82
7.3.1 Objects for parameterization............................................................................................ 82
7.3.2 Standard objects.............................................................................................................. 86
8 Appendix ..................................................................................................................................................88
8.1 General operating conditions...........................................................................................................88
8.2 Accessories .....................................................................................................................................89
8.3 Version identification of EtherCAT devices .....................................................................................90
8.3.1 Beckhoff Identification Code (BIC)................................................................................... 94
8.4 Support and Service ........................................................................................................................96
EPP7041-x0024 Version: 1.0
Foreword
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®, EtherCATG®, EtherCATG10®, EtherCATP®, SafetyoverEtherCAT®,
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.
EPP7041-x002 5Version: 1.0
Foreword
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.
EPP7041-x0026 Version: 1.0
Foreword
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.
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
Further information on this topic: Version identification of EtherCAT devices [}90].
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
EPP7041-x002 7Version: 1.0
Product group: EtherCATP Box modules
2 Product group: EtherCATP Box modules
EtherCATP
EtherCATP supplements the EtherCAT technology with a process in which communication and supply
voltages are transmitted on a common line. All EtherCAT properties are retained with this process.
Two supply voltages are transmitted per EtherCATP line. The supply voltages are electrically isolated from
each other and can therefore be switched individually. The nominal supply voltage for both is 24 VDC.
EtherCAT P uses the same cable structure as EtherCAT: a 4-core Ethernet cable with M8 connectors. The
connectors are mechanically coded so that EtherCAT connectors and EtherCATP connectors cannot be
interchanged.
EtherCATP Box modules
EtherCATP Box modules are EtherCATP slaves with IP67 protection. They are designed for operation in
wet, dirty or dusty industrial environments.
Fig.1: EtherCATP
EtherCAT basics
A detailed description of the EtherCAT system can be found in the EtherCAT system documentation.
EPP7041-x0028 Version: 1.0
Product overview
3 Product overview
3.1 Module overview
Module Rated current per phase Peak current per phase Microstepping
EPP7041-1002 1.0A 1.5A up to 64-fold
EPP7041-3002 3.5A 5.0A up to 256-fold
EPP7041-x002 9Version: 1.0
Product overview
Tx+ / GNDs
Rx+ / GNDp
Rx- / Up
Tx- / Us
1 |
2 |
3 |
4 |
EtherCAT P
downstream connection
Stepper motor
Encoder
EtherCAT P
input
Limit switch, motor brake
DC link input
1 |
2 |
3 |
4 |
5 |
A1
A2
B1
B2
n.c.
1,2 |
3,4 |
5 |
Motor supply
GND_Motor
n.c.
1 |
2 |
3 |
4 |
5 |
GND
V Enc
A Enc
B Enc
C Enc
1 |
2 |
3 |
4 |
5 |
+24 V Us
Input B
GND
Input A
OUT
Tx+ / GNDs
Rx+ / GNDp
Rx- / Up
Tx- / Us
1 |
2 |
3 |
4 |
EtherCAT P
downstream connection
Stepper motor
Encoder
EtherCAT P
input
Limit switch, motor brake
DC link input
1 |
2 |
3 |
4 |
5 |
A1
A2
B1
B2
n.c.
1,2 |
3,4 |
5 |
Motor supply
GND_Motor
n.c.
1 |
2 |
3 |
4 |
5 |
GND
V Enc
A Enc
B Enc
C Enc
1 |
2 |
3 |
4 |
5 |
+24 V Us
Input B
GND
Input A
OUT
3.2 Introduction
EPP7041-1002
EPP7041-3002
Schrittmotormodul 48VDC mit Inkremental-Encoder
The EPP7041-1002 EtherCAT P Box is intended for the direct connection of different Stepper Motors. The
PWM output stages for two motor coils with compact design are located in the module together with two
inputs for limit switches and cover a wide voltage and current range. The EPP7041-1002 can be adjusted to
the motor and the application by changing just a few parameters. 64-fold micro-stepping ensures particularly
quiet and precise motor operation. Connection of an incremental encoder enables a simple servo axis to be
realised. Two digital inputs and a digital 0.5 A output enable connection of end switches and a motor brake.
The -3002 variant is particularly suitable for applications that are subject to unsteady motor operation due to
natural resonance of the motor and the moved mass.
Quick links
Technical data [}11]
Connections [}26]
Commissioning [}36]
EPP7041-x00210 Version: 1.0
3.3 Technical data
All values are typical values over the entire temperature range, unless stated otherwise.
EtherCATP
Connection 2xM8 socket, 4-pin, P-coded, red
Distributed Clocks Yes
Supply voltages
Connection See EtherCAT P connection
US rated voltage 24VDC (-15%/ +20%)
US sum current: I
S,sum
Current consumption from U
Rated voltage U
UP sum current: I
P
P,sum
Current consumption from U
S
P
max. 3A
100mA
+ current consumption of the encoder
+ current consumption of the motor brake
+ auxiliary voltage for the limit switches
24VDC (-15%/ +20%)
max. 3A
None. UP is only forwarded.
Product overview
Stepper motor EPP7041-1002 EPP7041-3002
Motor type 2-phase stepper motor, unipolar or bipolar
Connection 1x M12 socket
DC link voltage 8…48V
DC
Connection for the DC link voltage M12 socket M12 plug
Rated current per phase 1.0A 3.5A
Peak current per phase 1.5A 5.0A at 50°C
Step frequency max. 32,000 full steps per second
Microstepping up to 64-fold up to 256-fold
Current controller frequency approx. 30kHz
Resolution approx. 5000 positions per revolution in typical applications
Protective functions Overload protection, short-circuit protection
Encoder input
Number 1
encoder type Incremental encoder with single-ended output drivers
Connection 1x M12 socket, 5-pin
Encoder supply 24VDC from the control voltage U
S
max. 0.5A, not short-circuit proof
signals A, B, C; single-ended
(C = reference pulse / zero pulse)
Signal voltage "0" -3…2V
Signal voltage "1" 3.5…28V
Pulse frequency max. 400,000 increments per second (quadruple evaluation)
EPP7041-x002 11Version: 1.0
Product overview
Digital inputs for limit switches
Number 2
Connection M12 socket
Nominal voltage high level 24V
DC
Signal voltage "0" -3…2V
Signal voltage "1" 3.5…28V
Input current 5mA
Digital output for the motor brake
Connection M12 socket
Output voltage high level 24VDC from the control voltage U
S
Output current max. 0.5A
Housing data
Dimensions WxHxD 30mmx 126mmx 26.5mm (without connectors)
Weight approx. 165 g
Installation position variable
Material PA6 (polyamide)
Environmental conditions
Ambient temperature during operation -25…+60°C
Ambient temperature during storage -40…+85°C
Vibration/ shock resistance conforms to EN60068-2-6/ EN60068-2-27
EMC immunity/ emission conforms to EN61000-6-2/ EN61000-6-4
Protection class IP65, IP66, IP67 conforms to EN60529
Approvals
Approvals CE, UL in preparation
3.3.1 Additional checks
The boxes have undergone the following additional tests:
Verification Explanation
Vibration 10 frequency runs in 3 axes
5Hz < f < 60Hz displacement 0.35mm, constant amplitude
60.1Hz < f < 500Hz acceleration 5g, constant amplitude
Shocks 1000 shocks in each direction, in 3 axes
35g, 11ms
EPP7041-x00212 Version: 1.0
3.4 Scope of supply
Make sure that the following components are included in the scope of delivery:
• 1x EPP7041-x002
• 2x protective cap for EtherCATP socket, M8, red (pre-assembled)
• 10x labels, blank (1 strip of 10)
Pre-assembled protective caps do not ensure IP67 protection
Protective caps are pre-assembled at the factory to protect connectors during transport. They may
not be tight enough to ensure IP67 protection.
Ensure that the protective caps are correctly seated to ensure IP67 protection.
Product overview
EPP7041-x002 13Version: 1.0
Product overview
3.5 Process image
The scope of the process image is adjustable.
EP7047-1032 has several predefined variants of the process image: "Predefined PDO Assignments". Select
the "Predefined PDO Assignment" according to the operating mode.
The factory default setting is "Velocity control compact" [}15].
3.5.1 "Predefined PDO Assignments"
Name Process image Process data objects
Position control
ENC Status [}16]
STM Status [}18]
ENC Control [}19]
STM Control [}20]
STM Position [}20]
Positioning interface
Positioning interface (Auto
start)
Positioning interface (Auto
start) with info data
ENC Status [}16]
STM Status [}18]
POS Status [}17]
ENC Control [}19]
STM Control [}20]
POS Control [}19]
ENC Status [}16]
STM Status [}18]
POS Status [}17]
ENC Control [}19]
STM Control [}20]
POS Control [}19]
POS Control 2 [}19]
ENC Status [}16]
STM Status [}18]
STM Synchron info data [}18]
POS Status [}17]
ENC Control [}19]
STM Control [}20]
POS Control [}19]
POS Control 2 [}19]
EPP7041-x00214 Version: 1.0
Product overview
Name Process image Process data objects
Positioning interface compact
ENC Status [}16]
STM Status [}18]
POS Status compact [}17]
ENC Control [}19]
STM Control [}20]
POS Control compact [}19]
Positioning interface with info
data
Velocity control
Velocity control compact
(Factory setting)
ENC Status [}16]
STM Status [}18]
STM Synchron info data [}18]
POS Status [}17]
ENC Control [}19]
STM Control [}20]
POS Control [}19]
ENC Status [}16]
STM Status [}18]
ENC Control [}19]
STM Control [}20]
STM Velocity [}20]
ENC Status compact [}16]
STM Status [}18]
Velocity control compact with
info data
EPP7041-x002 15Version: 1.0
ENC Control compact [}19]
STM Control [}20]
STM Velocity [}20]
ENC Status compact [}16]
STM Status [}18]
STM Synchron info data [}18]
ENC Control compact [}19]
STM Control [}20]
STM Velocity [}20]
Product overview
3.5.2 Process data objects
3.5.2.1 "ENC status"
"ENC Status" contains the status variables of the encoder input. "ENC" is the abbreviation for "Encoder".
State
• Latch C valid: A signal edge has been detected at
encoder signal "C". As a result, the "Counter value"
was written to the variable "Latch value" at the time of
the signal edge.
• Latch extern valid: A signal edge was detected at the
latch input. As a result, the counter value was written
to the variable "Latch value" at the time of the signal
1)
edge.
• Set counter done: The value from "Set counter
value" was written to the variable "Counter value" after
setting of "Set counter" (ENC Control).
• Counter underflow: The counter value "Counter
value" has fallen below the value 0.
• Counter overflow: The counter value "Counter value"
has exceeded the maximum value.
• Extrapolation stall: The extrapolated part of the
counter is invalid ("Micro increments").
• Status of input A: current signal level of encoder
signal "A"
• Status of input B: current signal level of encoder
signal "B"
• Status of input C: current signal level of encoder
signal "C"
• Status of extern latch: current signal level at the
latch input
• Sync error: Distributed Clocks synchronization error
in the previous cycle.
• TxPDO Toggle: This bit is inverted each time an input
data update occurs.
1)
Counter value: The current counter value.
Latch value: Counter value stored at the time of the last
signal edge at latch input or encoder signal "C".
1)
The latch function is deactivated in the factory setting. You may activate and configure the latch function in
1)
process data object "ENC Control" [}19] or "ENC Control compact" [}19].
3.5.2.2 "ENC Status compact"
This process data object is identical with "ENC status" [}16], see there.
EPP7041-x00216 Version: 1.0
3.5.2.3 "POS Status"
"POS Status" contains the status variables of the Positioning Interface [}51].
Status
• Busy: A motion command is active.
• In-Target: The target position of the motion command
has been reached.
• Warning: Warning message.
• Error: Error message.
• Calibrated: The motor is calibrated.
• Accelerate: The motor accelerates.
• Decelerate: The motor brakes.
• Ready to execute: Ready for a motion command.
Actual position: current set position
Actual velocity: current set velocity
Actual drive time: the elapsed time of the motion
command.
Product overview
3.5.2.4 "POS Status compact"
"POS Status compact" contains the status variables of the Positioning Interface [}51].
Status
This variable is identical to the "Status" variable in the
process data object "POS Status [}17]". See there.
EPP7041-x002 17Version: 1.0
Product overview
3.5.2.5 "STM Status"
„STM Status" contains the status bits of the stepper motor output stage. "STM" is the abbreviation for
"Stepper Motor".
Ready to enable: The output stage can be enabled. See
output variable "Enable" in the process data object STM
Control [}20].
Ready: The output stage is enabled.
Warning: Warning message.
Error: Error message. The output stage was switched
off due to an error. You can acknowledge the error
message with the output variable "Reset" in the process
data object STM Control [}20]
Moving positive: The speed is greater than 0.
Moving negative: The speed is less than 0.
Motor stall: A loss of step has occurred.
3.5.2.6 "STM Synchronous info data"
"STM" is the abbreviation for "Stepper Motor".
Info data n: Additional information from the box.
You can select what information these variables should
contain:
• Parameter 8012:11
• Parameter 8012:19
Select info data 1 [}84]
hex
Select info data 2 [}84]
hex
EPP7041-x00218 Version: 1.0
3.5.2.7 "ENC Control"
Enable latch C: Activate edge trigger for encoder input
"C".
Enable latch extern on positive edge: Activate edge
trigger for positive signal edges at latch input.
Set counter: Accept the value of the variable "Set
counter value" as the current counter value.
Enable latch extern on negative edge: Activate edge
trigger for negative signal edges at latch input.
Set counter value: Default value for "Set counter".
3.5.2.8 "ENC Control compact"
This process data object is identical with "ENC Control" [}19].
3.5.2.9 "POS Control"
This process data object contains variables for controlling the Positioning Interface [}51].
Product overview
3.5.2.10 "POS Control 2"
This process data object contains variables for controlling the Positioning Interface [}51].
3.5.2.11 "POS Control compact"
This process data object contains variables for controlling the Positioning Interface [}51].
EPP7041-x002 19Version: 1.0
Product overview
3.5.2.12 "STM Control"
Enable: Enable output stage.
Reset: Acknowledge error message, reset error status.
See input variable "Error" in the process data object STM
Status [}18]
3.5.2.13 "STM Position"
Position: Position setpoint.
Specify the position setpoint in increments.
Conversion from degrees (°) to increments: See below.
Conversion of position setpoints
The formula for converting a position setpoint from degrees (°) to increments depends on whether you are
using an encoder.
• If you are not using an encoder (feedback type [}84] = "Internal counter" ), use this formula:
Position: Setpoint [increments]
Θ
: Setpoint [°]
set
φ: Step angle of the motor [°]
(for AS10xx stepper motors: φ=1.8°)
• If you are using an encoder (feedback type [}84] = "Encoder" ), use this formula:
Position: Setpoint [increments]
Θ
: Setpoint [°]
set
PPR: Resolution of the encoder [increments/revolution]
(for AS10xx stepper motors: inc = 1024)
3.5.2.14 "STM Velocity"
Velocity: Speed setpoint in % of the parameter "Speed
range" [}40].
32767
-100%.
Conversion of speed setpoints
corresponds to 100%, -32767
dec
Velocity: Setpoint [increments/s]
n
: Setpoint [rpm]
set
φ: Step angle of the motor [°]
(for AS10xx stepper motors: φ=1.8°)
f
: "Speed range" [}40] [full steps/s]
max
corresponds to
dec
The speed setpoint can be positive or negative, depending on the desired direction of rotation of the motor.
EPP7041-x00220 Version: 1.0
Product overview
3.6 Technology
Stepper motors are electric motors and are comparable with synchronous motors. The rotor is designed as a
permanent magnet, while the stator consists of a coil package. In contrast to synchronous motors, stepper
motors have a large number of pole pairs. In a minimum control configuration, the stepper motor is moved
from pole to pole, or from step to step.
Stepper motors have been around for many years. They are robust, easy to control, and provide high torque.
In many applications, the step counting facility saves expensive feedback systems. Even with the
increasingly widespread use of synchronous servomotors, stepper motors are by no means "getting long in
the tooth". They are considered to represent mature technology and continue to be developed further in
order to reduce costs and physical size, increase torque and improve reliability.
3.6.1 Stepper motor parameters
Torque
Refers to the maximum motor torque at different speeds. This parameter is usually represented by a
characteristic curve. Stepper motors have comparatively high torque in the lower speed range. In many
applications, this enables them to be used directly without gearing. Compared with other motors, stepper
motors can quite easily provide a holding moment of the same order of magnitude as the torque.
Speed
Stepper motors have low maximum speed, which is usually specified as a maximum step frequency.
Nominal voltage, supply voltage and winding resistance
In steady state, the rated current flows at rated voltage, depending on the winding resistance. This voltage
should not be confused with the supply voltage of the power output stage.
If the supply voltage falls below the nominal voltage, the power output stage can no longer apply the full
current, resulting in a loss of torque. It is desirable to aim for systems with small winding resistance and high
supply voltage in order to limit warming and achieve high torque at high speeds.
Number of phases
Motors with 2 to 5 phases are common. EPP7041-x002 supports 2-phase motors. 4-phase motors are
basically 2-phase motors with separately fed out winding ends. They can be connected directly to EPP7041x002.
Resonance
At certain speeds, stepper motors run less smoothly. This phenomenon is particularly pronounced if the
motor runs without load. Under certain circumstances, it may even stop. This is caused by resonance. A
distinction can roughly be made between
• resonances in the lower frequency range up to approx. 250Hz and
• resonances in the medium to upper frequency range.
Resonances in the medium to upper frequency range essentially result from electrical parameters such as
inductance of the motor winding and supply line capacity. They can be controlled relatively easily through
high pulsing of the control system.
Resonances in the lower range essentially result from the mechanical motor parameters. Apart from their
impact on smooth running, such resonances can lead to significant loss of torque, or even loss of step of the
motor, and are therefore particularly undesirable.
In principle, the stepper motor represents an oscillatory system (comparable to a mass/spring system),
consisting of the moving rotor with a moment of inertia and a magnetic field that creates a restoring force that
acts on the rotor. Moving and releasing the rotor creates a damped oscillation. If the control frequency
corresponds to the resonance frequency, the oscillation is amplified, so that in the worst case the rotor will
no longer follow the steps, but oscillate between two positions.
EPP7041-x002 21Version: 1.0
Product overview
EPP7041-x002 prevents this effect by means of a SinCos-shaped current profile for almost all standard
motors. The rotor is not switched from step to step, i.e. it no longer jumps to the next position, but instead
passes through intermediate steps (microsteps), i.e. the rotor is gently guided from one step to the next. The
usual loss of torque at certain speeds is avoided, and operation can be optimized for the particular
application. This means that the lower speed range, where particularly high torque is available, can be fully
utilized.
Step angle
The step angle indicates the angle travelled during each step. Typical values are 3.6°, 1.8° and 0.9°. This
corresponds to 100, 200 and 400 steps per motor revolution. Together with the downstream transmission
ratio, this value is a measure for the positioning accuracy. For technical reasons, the step angle cannot be
reduced below a certain value. Positioning accuracy can only be improved further by mechanical means
(transmission). An elegant solution for improving positioning accuracy is the microstepping function. It
enables up to 64 intermediate steps. The smaller "artificial" step angle has a further positive effect: The drive
can be operated at higher speed, yet with the same precision. The maximum speed is unchanged, despite
the fact that the drive operates at the limit of mechanical resolution.
EPP7041-x00222 Version: 1.0
Product overview
3.6.2 Selecting a stepper motor
Specifying the stepper motor
1. Determine the required positioning accuracy and hence the step resolution. The first task is to determine the maximum resolution that can be achieved. The resolution can be increased via mechanical
gear reduction devices such as spindles, gearing or toothed racks. Microstepping also has to be taken
into account.
2. Determine mass m and moment of inertia (J) of all parts to be moved
3. Calculate the acceleration resulting from the temporal requirements of the moved mass.
4. Calculate the forces from mass, moment of inertia, and the respective accelerations.
5. Convert the forces and velocities to the rotor axis, taking account of efficiencies, moments of friction
and mechanical parameters such as gear ratio. It is often best to start the calculation from the last
component, usually the load. Each further element transfers a force and velocity and leads to further
forces or torques due to friction. During positioning, the sum of all forces and torques acts on the motor shaft. The result is a velocity/torque curve that the motor has to provide.
6. Using the characteristic torque curve, select a motor that meets these minimum requirements. The
moment of inertia of the motor has to be added to the complete drive. Verify your selection. In order to
provide an adequate safety margin, the torque should be oversized by 20% to 30%. The optimisation
is different if the acceleration is mainly required for the rotor inertia. In this case, the motor should be
as small as possible.
7. Test the motor under actual application conditions: Monitor the housing temperatures during continuous operation. If the test results do not confirm the calculations, check the assumed parameters and
boundary conditions. It is important to also check side effects such as resonance, mechanical play,
settings for the maximum operation frequency and the ramp slope.
8. Different measures are available for optimising the performance of the drive: using lighter materials or
hollow instead of solid body, reducing mechanical mass. The control system can also have significant
influence on the behaviour of the drive. EPP7041-x002 enables operation with different supply voltages. The characteristic torque curve can be extended by increasing the voltage. In this case, a current increase factor can supply a higher torque at the crucial moment, while a general reduction of the
current can significantly reduce the motor temperature. For specific applications, it may be advisable
to use a specially adapted motor winding.
EPP7041-x002 23Version: 1.0
Mounting and connections
119
126
23
3026.5
14
Ø 3.5
13.5
4 Mounting and connections
4.1 Mounting
4.1.1 Dimensions
Fig.2: Dimensions
All dimensions are given in millimeters.
Housing features
Housing material PA6 (polyamide)
Sealing compound polyurethane
Mounting two fastening holes Ø 3.5 mm for M3
Metal parts brass, nickel-plated
Contacts CuZn, gold-plated
Installation position variable
Protection class IP65, IP66, IP67 (conforms to EN 60529) when screwed together
Dimensions (H x W x D) approx. 126 x 30 x 26.5 mm (without connectors)
Weight approx. 165g
EPP7041-x00224 Version: 1.0
Mounting and connections
FE
4.1.2 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 M3 screws on the fastening holes in the corners of the module. The fastening
holes have no thread.
4.2 Functional earth (FE)
The upper fastening hole also serves as a connection for functional earth (FE).
Make sure that the box is grounded to low impedance via the functional earth (FE) connection. You can
achieve this, for example, by mounting the box on a grounded machine bed.
Fig.3: Connection for functional earth (FE)
EPP7041-x002 25Version: 1.0
Mounting and connections
X50 X51
X01
X02
X03
X04
X50 X51
X01
X02
X03
X04
EPP7041-1002 EPP7041-3002
4.3 Connections
4.3.1 Overview
Name Function Connector
type
X01
X02
Stepper motor connection [}30]
DC link voltage input [}32]
M12 socket 0.6Nm
M12 socket (EPP7041-1002)
Tightening
torque
0.6Nm
M12 plug (EPP7041-3002)
X03
Digital inputs for limit switches [}33]
M12 socket 0.6Nm
Digital output for the motor brake [}33]
X04
X50
X51
1)
Mount plugs on these connectors using a torque wrench, e.g. ZB8801 from Beckhoff.
Encoder connection [}34]
EtherCAT P input [}27]
EtherCAT P downstream connection [}27]
M12 socket 0.6Nm
M8 socket 0.4Nm
M8 socket 0.4Nm
Protective caps
• Seal unused connectors with protective caps.
• Ensure the correct seating of pre-assembled protective caps.
Protective caps are pre-assembled at the factory to protect connectors during transport. They may not
be tight enough to ensure IP67 protection.
1)
1)
1)
1)
1)
1)
EPP7041-x00226 Version: 1.0
Mounting and connections
1 2
1
2
3
4
4.3.2 EtherCATP
NOTE
Risk of damage to the device!
Bring the EtherCAT/EtherCATP system into a safe, powered down state before starting installation, disassembly or wiring of the modules!
NOTE
Pay attention to the maximum permissible current!
Pay attention also for the redirection of EtherCATP, the maximum permissible current for M8 connectors of
3A must not be exceeded!
4.3.2.1 Connectors
Fig.4: Plug connectors for EtherCAT P
1 - input
2 - downstream connection
Connection
Fig.5: M8 socket, P-coded
Contact Signal Voltage Core color
1 Tx + GND
2 Rx + GND
S
P
3 Rx - UP: Peripheral voltage, +24V
4 Tx - US: Control voltage, +24V
DC
DC
yellow
white
blue
orange
Housing Shield Shield Shield
1)
The core colors apply to EtherCAT P cables and ECP cables from Beckhoff.
1)
EPP7041-x002 27Version: 1.0
Mounting and connections
4.3.2.2 Status LEDs
4.3.2.2.1 Supply voltages
Fig.6: Status LEDs for the supply voltages
EtherCAT P Box Modules have two LEDs that display the status of the supply voltages. The status LEDs are
labelled with the designations of the supply voltages: Us and Up.
A status LED lights up green when the respective supply voltage is present.
A Status LED lights up red if the respective supply voltage is short-circuited.
4.3.2.2.2 EtherCAT
Fig.7: Status LEDs for EtherCAT
L/A (Link/Act)
A green LED labelled "L/A" or “Link/Act” is located next to each EtherCAT/EtherCATP socket. The LED
indicates the communication state of the respective socket:
LED Meaning
off no connection to the connected EtherCAT device
lit LINK: connection to the connected EtherCAT device
flashes ACT: communication with the connected EtherCAT device
Run
Each EtherCAT slave has a green LED labelled "Run". The LED signals the status of the slave in the
EtherCAT network:
LED Meaning
off Slave is in "Init" state
flashes uniformly Slave is in "Pre-Operational“ state
flashes sporadically Slave is in "Safe-Operational" state
lit Slave is in "Operational" state
Description of the EtherCAT slave states
EPP7041-x00228 Version: 1.0
Mounting and connections
I = 3 A
10 20
5
10
15
20
300
0
25
40
Vert. Faktor: 0,22 cm / V
Voltage drop (V)
Cable length (m)
0.14 mm²
0.22 mm²
0.34 mm²
4.3.2.3 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.
Use the planning tool for EtherCAT P in TwinCAT.
Voltage drop on the supply line
Fig.8: Voltage drop on the supply line
EPP7041-x002 29Version: 1.0
Mounting and connections
1
2
3
4
5
A2
A1
B1
5
4
3
2
1
B2
M
A2
A1
B1
5
4
3
2
1
B2
M
4.3.3 Stepper motor connection: X01
Pin assignment
M12 socket Pin Function Symbol Core color
1 Motor winding A A1 brown
2 A2 white
3 Motor winding B B1 blue
4 B2 black
5 n.c. n.c. gray
1)
The core colors apply to M12 cables from Beckhoff: ZK2000-5xxx, ZK2000-6xxx, ZK2000-7xxx
Connection example: Bipolar stepper motor, serial connection
1)
Connection example: Bipolar stepper motor, parallel connection
EPP7041-x00230 Version: 1.0
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