Page 1 Preface, Contents Part 1: User Information Product Summary Basic Principles of Positioning SIMATIC Installing and Removing the FM 453 FM 453 Servo Drive / Wiring the FM 453 Step Drive Positioning Module Defining Parameters of the FM 453 Manual Programming the FM 453 Starting up the FM 453 Human-Machine Interface for the OP 17...
Page 2: C79000-G7076-C453
This device and its components may only be used for the applications described in the catalog or the technical description, and only in connection with devices or components from other manufacturers which have been approved or recommended by Siemens. This product can only function correctly and safely if it is transported, stored, set up, and installed correctly, and operated and maintained as recommended.
Page 3 Preface Purpose of this This manual contains all information about the FM 453 module: Document Hardware and functions Parameter definition Man-machine interface S7 function blocks Safe setup Information Blocks The following information blocks describe the purpose and uses of this in this Manual manual: Product overview of the module (Chapter 1)
Page 4 Preface Reference information and appendices for finding factual information (module functions, programming guide, interface signals, error handling, technical specifications, standard HMI user interface) List of abbreviations and index for looking up information. User Requirements The present manual describes the hardware and functions of the FM 453. To set up, program and start up a SIMATIC S7-400 with the FM 453, you will need a knowledge of: The SIMATIC S7...
Page 5 The EC Declarations of Conformity are held at the address below, where they can be obtained if and when required by the respective authorities in accor- dance with Article 10 of the EC Guideline referenced above: SIEMENS Aktiengesellschaft Bereich Automatisierungstechnik AUT E 148 Postfach 1963 D–92209 Amberg...
Page 6 Preface FM 453 Servo Drive / Step Drive Positioning Module C79000-G7076-C453-01...
Page 7: Table Of Contents
Table of Contents Product Summary ............The FM 453 in the S7-400 Programmable Controller .
Page 8 Table of Contents FC RD_COM (FC 3) – Process Read Jobs Cyclically ....6-13 Reading Diagnostic Information ........6-17 6.4.1 FC DIAG_RD (FC 4) –...
Page 9 Table of Contents 9.3.2 Single Functions (Job No. 10) ........9-39 9.3.3 Single Commands (Job No.
Page 10 Table of Contents 11.2.5 Viewing the Diagnostic Buffer (PG/PC) ......11-8 11.3 Error Lists .
Page 11 Table of Contents Fig. 5-3 Overview Display for Parameterization ......Fig. 5-4 Entering Values for Machine Data .
Page 12 Table of Contents Fig. 10-1 Reference-Measure Input G90 ........10-8 Fig.
Page 13 Table of Contents Table 8-1 Analysis of the User DB by the User Program ..... . . Table 8-2 Variables for user DB .
Page 14 Table of Contents FM 453 Servo Drive / Step Drive Positioning Module C79000-G7076-C453-01...
Page 15: Product Summary
Product Summary What Can the The FM 453 is a microprocessor-controlled positioning module for control- FM 453 Do? ling servo and/or stepper motors. The module has three mutually independent channels (axes). The control mode for each channel is specified by the parameterization. The FM 453 is a high-performance module for servo-controlled positioning and for positioning with step drives.
Page 16: The Fm 453 In The S7-400 Programmable Controller
Product Summary Chapter In Section You Will Find On Page Overview The FM 453 in the S7-400 Programmable Controller Module Description Overview of Module Functions The FM 453 in the S7-400 Programmable Controller How Is the FM 453 The FM 453 is designed as a function module of the SIMATIC S7-400 con- Linked Up with the troller.
Page 17 Product Summary System Overview A positioning controller using the FM 453 consists of a variety of individual components, which are shown in Figure 1-1. Operator panel (OP) Programming device (PG) (e.g. OP 05) Configuration package SIMATIC S7-400 Rack PS CPU SMs FM 453 e.g.
Page 18: Table 1-1 Components Of A Positioning Controller
Product Summary Components The most important components and their functions are listed in Table 1-1 . Table 1-1 Components of a Positioning Controller Component Function Rack ... establish the mechanical and electrical connections between the S7-400 modules. FM 453 ... the positioning module. It is controlled by the S7-400 CPU.
Page 19: Fig. 1-2 Data Storage Concept
Product Summary System Overview The following figure gives you an overview of the data storage concept. of Data Handling FM 453 Module data Load memory Module data Diagnostic data P bus User program, in- cluding FCs User DBx Diagnostic/ process inter- Online data rupt DBx pa-...
Page 20: Module Description
Product Summary Module Description View of the FM 453 Figure 1-3 shows the FM 453 module, its interfaces and front-panel elements (including fault and status displays). Rack Module identifier FM 453 453-3AH00-0AE0 Product status Short order No. (6ES7 453-3AH00-0AE0) Cover Type plate Bus connector - SIMATIC port...
Page 21: Table 1-2 Ports
Product Summary Ports A description of the ports is provided in Table 1-2 . Table 1-2 Ports Ports Description Bus connector - Rear connectors to continue the S7 buses (P and K SIMATIC port buses) to each module Drive port 50-pin male Sub-D connector (X5) to connect the power sections for up to three analog or step drives Measurement system port...
Page 22 Product Summary Type Plate of the Figure 1-4 describes all the information contained in the type plate of the FM 453 FM 453. SIEMENS The SIMATIC S7 6ES7 453-3AH00- 0AE0 FM 453 SVP JM123456 APPROVED CLASS 1 DIV 2 LISTED 69B1...
Page 23: Overview Of Module Functions For Each Channel
Product Summary Overview of Module Functions for Each Channel Summary The FM 453 module performs the following functions: Mode control Actual-value capture Servo position control Parameterizing the control mode Digital inputs and outputs Settings and functions that do not depend on operating mode Software limit switches Process interrupts Block sequence control...
Page 24 Product Summary Parameterization In the parameterization, the following control modes can be set: of the Control Servomotor with servo position control Modes Stepper motor with servo position control Stepper motor without servo position control Digital Inputs/ Four digital inputs and four digital outputs for each channel can be used spe- Outputs cifically to a given application.
Page 25: Basic Principles Of Positioning
Basic Principles of Positioning What Is Position- Positioning means moving a load to a defined position within a defined time, ing? taking all influencing forces and torques into account. Position A Position B F = driving force x = distance to be traversed s = path Fig.
Page 26: Fig. 2-2 Setup For Positioning (Example)
Basic Principles of Positioning Arrangement of Figure 2-2 shows the structure of a position control circuit with the FM 453 the Positioning for one channel. Equipment FM 453 Power EMERG. grid STOP Actuating signal Power Safety section device Actual position Parameteriz- ing/Program- ming...
Page 27 Basic Principles of Positioning Motor The motor is actuated by the power section and drives the axis. The motor can be: A servo motor, e.g. 1FT5 A stepper motor, e.g. SIMOSTEP Encoder The encoder detects movement of the axis. It supplies pulses to the FM 453. The number of pulses is proportional to the distance traversed.
Page 28 Basic Principles of Positioning FM 453 Servo Drive / Step Drive Positioning Module C79000-G7076-C453-01...
Page 29: Installing And Removing The Fm 453
Installing and Removing the FM 453 Overview The FM 453 positioning module can be installed, in the same manner as a signal module, in a central controller or in an expansion unit (EUs 1 to 6). Mechanical Set-Up The options for the mechanical set-up and its configuration are described in the manual S7-400/M7-400 Programmable Controller;...
Page 30: Installing The Fm
Installing and Removing the FM 453 Installing the FM 453 Rules No particular protective measures (EGB Guidelines) are necessary for the installation of the FM 453. Note Please refer to Appendix B in the manual S7-400/M7-400 Programmable Controller, Hardware and Installation. Tools Required A 4.5 mm (0.18 inch) screwdriver.
Page 31: Removing The Fm 453
Installing and Removing the FM 453 Removing the FM 453 Rules No particular protective measures (EGB Guidelines) are necessary for the removal of the FM 453. Note Please refer to Appendix B in the manual S7-400/M7-400 Programmable Controller, Hardware and Installation. Tools Required A 4.5 mm (0.18 inch) screwdriver.
Page 32: Fig. 3-1 Replacing The Fm 453 With The System Switched Off
Installing and Removing the FM 453 Replacing an To replace a parameterized but defective FM 453: FM 453 1. Replacing the FM 453 with the system switched off Remove the FM 453 acc. to Section 3.2 Install the FM 453 acc. to Section 3.1 Switch on the system Appropriate SDB 1 000 in...
Page 33: Wiring The Fm 453
Wiring the FM 453 Safety Rules In order to ensure the safe operation of your plant, you should introduce the following additional measures, and adjust them appropriately to your sys- tem’s conditions: An EMERGENCY STOP concept meeting appropriate safety regulations (e.g.
Page 34: Wiring Diagram For A Fm 453
1FT5 motor) Drive unit, e.g. e.g. absolute SIMODRIVE 611-A encoder (SSI) e.g. linear scale SIEMENS with EXE SIMODRIVE Fig. 4-1 Overview of Connecting Cables for a FM 453 with Servo Drive (example) FM 453 Servo Drive / Step Drive Positioning Module...
Page 35: Fig. 4-2 Overview Of Connecting Cables For An Fm 453 With Step Drive (Example)
FM 453 and a step drive are linked together. PG/PC FM 453 SIMATIC S7-400 MPI connecting cable Drive unit e.g. FM STEPDRIVE SIEMENS SIEMENS Front connector X1 Dig. outputs, e.g. direction of rota- tion Dig. inputs, e.g. touch probe Setpoint cable Fig.
Page 36: Table 4-1 Connecting Cables For A Positioning Controller Withfm
Wiring the FM 453 Connecting Cables Table 4-1 lists the connecting cables for a positioning controller with the FM 453. Table 4-1 Connecting Cables for a Positioning Controller with FM 453 Type Order No. Description MPI connecting see Catalog ST 70, Order No. Connection between OP, cable E86060-K4670-A101-A2...
Page 37: Description Of The Drive Interface
Wiring the FM 453 Description of the Drive Interface Connector for Power sections with analog interfaces ( 10 V) or stepper motor power sec- the Drive Unit tions which have at least one clock generator and direction input can be con- nected to the 50-pin male sub-D connector X5 of the FM 453.
Page 38: Table 4-2 Pinout Of Connector X5
Wiring the FM 453 Connector Pinout Connector identifier: X5 ANALOG OUT / STEP. CONTR. / (1...3) Connector type: 50-pin sub-D plug connector Table 4-2 Pinout of Connector X5 Name Type Name Type Name Type not assigned ENABLE1 not assigned ENABLE1_N ENABLE2 ENABLE2_N PULSE1...
Page 39: Table 4-3 Electrical Parameters Of The Setpoint Signal
Wiring the FM 453 Note The active level of each signal can be defined in MD37 (see Section 5.3.1, ). Check the technical documentation for your drive device regarding assign- ment of signal levels to direction of rotation. The following signal descriptions refer to: SIMODRIVE 611-A servo drive FM STEPDRIVE step drive Servo Drives...
Page 40 Wiring the FM 453 Step Drives Output signals: One pulse, one directional and one enable signal are provided for each chan- nel as true and negated signals. In addition, one additional signal per channel can be parameterized for current generation. PULSE The clock pulses control the motor.
Page 41: Table 4-5 Electrical Parameters Of The Step Drive Signal Outputs
Wiring the FM 453 Signal parameters of the outputs All output signals are output by way of differential-signal line drivers in com- pliance with Standard RS422 . To ensure optimum noise immunity, the power section should feature differ- ential signal receivers or optical coupler inputs to permit balanced signal transfer.
Page 42: Fig. 4-4 Connection Options For Drive Port Output Signals
Wiring the FM 453 Signal Wiring (Out- Figure 4-4 shows various ways to wire the signals. put Signals) Balanced transfer with RS422-compliant floating differential input FM 453 Power section 35 m Balanced transfer with floating optocoupler input 35 m Non-balanced transfer with floating optocoupler input 10 m Fig.
Page 43 Wiring the FM 453 Signal Connection Figure 4-5 shows you different signal connection options for the for the “READY1_N” input. “READY1_N” Input Actuation of the “READY1_N” input by floating contact FM 453 Power section 35 m Actuation of the “READY1_N” input by floating optocoupler 35 m Fig.
Page 44: Connecting The Drive Unit
Wiring the FM 453 Connecting the Drive Unit Danger The only drives permitted are those with safe isolation. To Connect the Please note: Connecting Cables Note Use only shielded twisted pairs for lines. The shielding must be connected to the metallic or metallized connector jacket on the controller side. To pro- tect the analog setpoint signal against low-frequency interference, we recom- mend that you not ground the shielding on the drive-unit side.
Page 45: Fig. 4-6 Connecting A Simodrive 611-A Drive Unit
The following Figure shows you how to connect an FM 453 with a SIMODRIVE 611-A drive unit. Connecting cable FM 453 READY2 (channels 1 to 3) Drive unit, e.g. SIMODRIVE 611-A SIEMENS SIMODRIVE Fig. 4-6 Connecting a SIMODRIVE 611-A Drive Unit FM 453 Servo Drive / Step Drive Positioning Module 4-13...
Page 46: Fig. 4-7 Connecting To Fm Stepdrive Drive Units
The connecting cable is available in a variety of lengths. For length code, see Order No.: E86060-K4490-A001-A4 The following Figure shows you how to connect an FM 453 to FM STEP- DRIVE drive units. Drive unit e.g. FM STEPDRIVE SIEMENS SIEMENS SIEMENS READY2 (channels 1 to 3) FM 453 Connecting cable Fig.
Page 47: Fig. 4-8 Connecting To Fm Stepdrive And Simodrive Drive Units
Two step drives and one servo drive – Order No.: 6FX2 002-3AB03-1 The connecting cable is available in a variety of lengths. For length code, see Order No.: E86060-K4490-A001-A4 Drive unit e.g. FM STEPDRIVE SIEMENS SIEMENS READY2 (channels 1 to 3) FM 453 Connecting cable SIMODRIVE 611-A Fig.
Page 48: Description Of The Measuring System Interface
Wiring the FM 453 Description of the Measuring System Interface Connectors for For each channel, a 15-pin female sub D connector is provided for the con- Encoders nection of incremental encoders or absolute encoders (serial port). Location of Figure 4-9 shows where the connector is installed on the module, and how it Connectors is identified.
Page 49 Wiring the FM 453 Signal Names A, A_N Track A true / negated (incremental encoder) B, B_N Track B true / negated (incremental encoder) N, N_N Zero mark true / negated (incremental encoder) CLS, CLS_N SSI sliding pulse true / negated (absolute encoder) DATA, DATA_N SSI data true / negated (absolute encoder) P5EXT...
Page 50 The maximum cable length depends on the specifications of the encoder to Encoder power supply, and on the transfer frequency. For trouble-free operation, you should not exceed the following values when using SIEMENS cable sets: Table 4-9 Cable Length as a Function of Encoder Power Supply...
Page 51: Connecting The Encoders
Wiring the FM 453 Connecting the Encoders To Connect the Please note: Connecting Cables Note Use only shielded cables. The shielding must be connected to the metallic or metallized connector jacket. The cable sets supplied as an accessory offer excellent immunity from inter- ference, as well as cross-sections large enough for the power supply to the encoders.
Page 52: Cable Set For Built-In Rod 320 Encoders With 17-Pin Round Plugs
Wiring the FM 453 Procedure for To connect the encoders: Connecting En- 1. Connect the connecting cables to the encoders. coders For absolute encoders (SSI) it may be necessary to cut and add connectors to the cable (end of the cable to the encoder) according to the manufactur- er’s instructions.
Page 53: Description Of The I/O Port
Wiring the FM 453 Description of the I/O Port Front Connector Four digital input/outputs per channel, the zero position signal and the standby signal (READY2) may be connected to the 48-pin front connector X1 with its single-wire terminals. LEDs The current status of the I/O port is indicated by the LEDs next to the front connector: One LED each for INTF, EXTF and STAT 3 LEDs for zero position signal input, channels 1 to 3...
Page 54: Fig. 4-12 Labels Of The Fm 453
Wiring the FM 453 Labels Figure 4-12 shows the labels of the FM 453. Internal con- Label in front External indicators label nection connector diagram INTF EXTF STAT 1READY2 2READY2 3READY2 READY2 Rack No. Slot No. Fig. 4-12 Labels of the FM 453 FM 453 Servo Drive / Step Drive Positioning Module 4-22 C79000-G7076-C453-01...
Page 55: Table 4-11Pinout Of The Front Connector
Wiring the FM 453 Connector Pinout Connector identifier: Connector type: 48-pin S7 front connector with single-wire terminals Table 4-11 Pinout of the Front Connector Termi- Name Significance Contains cable bridge for detection of the plugged in con- nector nector FE_X1 24 V DC auxiliary voltage for sensor supply Terminals 3, 4 and 5 are connected together on the module.
Page 56 Wiring the FM 453 Table 4-11 Pinout of the Front Connector, continued Termi- Name Significance 24 V DC auxiliary voltage for digital outputs, channel 1 Terminals 29 and 30 are connected together on the module. Digital output 0 from channel 1 Digital output 1 from channel 1 Digital output 2 from channel 1 Digital output 2 from channel 2...
Page 57 Wiring the FM 453 See Section 5.3.1 for further applications. NL Input The zero position signal of the drive power section can be connected for each channel to a further input. The zero position signal is specified in MD37 (see Section 5.3.1) and can be one of the following (see Section 9.7): Current-sourcing pattern zero signal for reference point approach Zero pulse, external (e.g.
Page 58: Fig. 4-13 Connection Of Standby Signal, Power From Auxiliary Voltage L
Wiring the FM 453 Connection of the The procedure for connecting the input signals to the FM 453 is explained for Input Signals the READY2 signal by way of example. There are two methods for connecting the input signals: with power supplied from the auxiliary voltage L+ with power supplied from the external signal source Power from Figure 4-13 shows how to connect the standby signal to connector X1 of the...
Page 59 Wiring the FM 453 Digital Outputs The FM 453 provides four digital outputs per channel. (Q0 to Q3) All outputs have equal priority. Switching functions are allocated to an output number by way of machine data. These four outputs are intended for wiring of application-specific signals. Possible uses include: Position reached and stopped Switching function M command...
Page 60: Wiring Up The Front Connector
Wiring the FM 453 Wiring Up the Front Connector Wiring the Front Figure 4-15 shows how to lay the lines to the front connector. Connector FM 453 Shielding bus Front connector with screw-type terminals without Digital out- cover puts Digital in- puts e.g.
Page 61 Wiring the FM 453 Connecting Cables Flexible conductor, cross-sectional area: 0.5 to 1.5 mm for front connector with crimp terminals 0.25 to 2.5 mm for front connector with screw-type terminals 0.08 to 2.5 mm for front connector with spring-loaded terminals Ferrules are not necessary.
Page 62 Wiring the FM 453 Tools Required A 3.5 mm (0.13 inches) screwdriver or power screwdriver. Procedure for Wir- To wire the front connector (with screw-type terminals): ing the Front Con- 1. Remove the cover from the front connector. nector 2. Strip the insulation from the lines (8 to 10 mm). 3.
Page 63: Defining Parameters Of The Fm 453
Defining Parameters of the FM 453 Summary This chapter gives you an overview of how to define the parameters of the FM 453 with the “Parameterize FM 453” tool. S7-400 FM 453 P bus Data blocks (DB) User data block DB-MD Online (editing in the DB-SM...
Page 64: Installation Of "Parameterize Fm
– Technology functions: SIEMENS\STEP7\S7LIBS\FMST_SRV – User interface for OPs: SIEMENS\STEP7\EXAMPLES\S7OP_BSP – Example applications: SIEMENS\STEP7\EXAMPLE1\FMSTSVEX Note If you chose a directory other than SIEMENS/STEP7 when you installed STEP 7, this directory is entered instead. FM 453 Servo Drive / Step Drive Positioning Module C79000-G7076-C453-01...
Page 65: Fig. 5-2 Getting Started With "Parameterize Fm
Defining Parameters of the FM 453 Getting Started with “Parameterize FM 453” Prerequisites You have installed the software on your programming device/PC, as de- scribed in Section 5.1. Configuration Before you can configure your system, you must create a project in which to save the parameters.
Page 66 Defining Parameters of the FM 453 7. By clicking the tabs in this window (General, Addresses and Basic Pa- rameters), you can – Name the FM 353 – Change the address of the FM 353 – configure the interrupts. Note: Further operation of the FM 453 is not possible with the CPU in the STOP state.
Page 67 Defining Parameters of the FM 453 Proceed as follows: 1. Position the mouse pointer on the top border of the window, so that it changes into an arrow. 2. Press the left mouse button, and drag the pointer downwards by moving the mouse.
Page 68 Defining Parameters of the FM 453 Parameter Data What Can I Para- You can parameterize the following data storage areas: meterize? Machine data (MD) Increment sizes (SM) Tool offset data (TO) Traversing programs (NC) User data (user data blocks) This data is stored in data blocks (DBs) within the numerical range (not includ- ing user data): from 1001 to 1239 for channel 1 from 1301 to 1539 for channel 2...
Page 69: Table 5-1 Data Blocks Of The Fm
Defining Parameters of the FM 453 Data blocks (DB) Table 5-1 gives you an overview of the data blocks in the FM 453 and their of the FM 453 meaning. Table 5-1 Data Blocks of the FM 453 Data Block Significance DB-MD Machine data...
Page 70 Defining Parameters of the FM 453 Table 5-1 Data Blocks of the FM 453, continued Data Block Significance DB-NC Traversing programs Program No. + 1000 = DB No. = 1001...1199 for channel 1 Program No. + 1300 = DB No. = 1301...1499 for channel 2 Program No.
Page 71: Table 5-2 User Db
Defining Parameters of the FM 453 User Data Block Chapter 6 describes how to generate a user data block. You can use “Parameterize FM 453” to fill the user DB with the data de- scribed in Table 5-2. The menu Target system Online editing User data allows you to select and edit your user DB.
Page 72: Table 5-4 Db Structure - Machine Data
Defining Parameters of the FM 453 Data Bloc Table 5-3 gives a rough picture of data block structure. Structure Table 5-3 Data Block Structure Addresses/ Comment Contents Offset System information, not rele- DB header (36 bytes) vant for user Information for labeling of data 0 and above User data area / structure header block within the system...
Page 73 Defining Parameters of the FM 453 Entering Values In “Parameterize FM 453” select the menu File New Machine Data to call up the following display. Fig. 5-4 Entering Values for Machine Data Enter the machine data in the tab windows. You can also enter your values in a table by selecting View Table form.
Page 74: Table 5-5 Machine Data List
Defining Parameters of the FM 453 Machine Data List All machine data of the FM 453 are listed in Table 5-5. Notes to the machine data list: K stands for configuration data: see Section 9.3.3 E stands for user-definable machine data settings for readjustment (startup optimization) and technology;...
Page 75 Defining Parameters of the FM 453 Table 5-5 Machine Data List, continued Default Data Type/ Designation Value/Meaning Values Unit/Comments Section 15 K Baud rate - 2 = 156 000 DWORD 9.6.1 absolute encoder 3 = 312 000 9.6.2 4 = 625 000 5 = 1 250 000 6 = 2 500 000 (no liability assumed) 16 K Reference-...
Page 76 Defining Parameters of the FM 453 Table 5-5 Machine Data List, continued Default Data Type/ Designation Value/Meaning Values Unit/Comments Section 9.2.3 27 E Reference- -1,000,000,000 - +1,000,000,000 DINT (MSR) point shift DWORD 28 E Referencing veloc- 6 10 10 - 500 000 000 (MSR/min) 29 E Reducing velocity...
Page 77 Defining Parameters of the FM 453 Table 5-5 Machine Data List, continued Default Data Type/ Designation Value/Meaning Values Unit/Comments Section 37 K Control signals 0 = Controller enable active BITFIELD32 2 = Controller ready active 3 = Controller ready inverted 4 = Controller ready via connector X5 (if Bits 24...27 active) 7 = Time override active...
Page 78 Defining Parameters of the FM 453 Table 5-5 Machine Data List, continued Default Data Type/ Designation Value/Meaning Values Unit/Comments Section 53 K Increment number 0 – 400 DWORD per current-sourcing cycle 54 E Start/Stop frequency 1 000 10 – 100 000 DWORD [Hz] 55 E Frequency value for...
Page 79 Defining Parameters of the FM 453 MD10 MD61 Measured Value Factor – MWFAKTOR = UMWEG / (4 MD13) 3, 4, 13, 14 – MWFAKTOR = UMWEG / MD13 Generation of minimum acceleration for stepper motor SMAMIN MD61 SMAMIN as required, not used in checks 1, 7 SMAMIN = 1000 MD52 / UMWEG Activation of software limit switches SEAKT...
Page 80 Defining Parameters of the FM 453 MD13 check MD10 Increments per Encoder Revolution 0, 1 – 3, 4, 13, 14 x = 1, 2, 3, ... MD14 check MD10 No. of Revolutions 0, 1, 3, 13 – 4, 14 x = 1, 2, 3, ... MD21, MD22 check SEAKT MD8 Permissible Software Limit Switches...
Page 81 Defining Parameters of the FM 453 MD35 check Permissible: BYTE0(MD35)&0x7F BYTE1(MD35)&0x7F BYTE2(MD35)&0x7F BYTE3(MD35)&0x7F Checks for stepper motor only (MD61.0 == 1): MD52 check (checked via input limit) Permissible increment number:4 MD52 Permissible pulse evaluation factor: –14 < UMWEG/MD52 < 2 MD53 check MD53 Permissible Increment Number Per Current-Sourcing Cycle...
Page 82 Defining Parameters of the FM 453 Zero Reference Figure 5-5 shows the relationship between the zero reference mark in your Mark application and the relevant machine data. Machine data Zero reference mark Encoder connection via connectors X2 to X4 = 1 (incremental encoder) >...
Page 83: Table 5-6 Db Structure - Increments
Defining Parameters of the FM 453 5.3.2 Increments DB Structure Table 5-6 gives you a general view of the structure of the “Increments” data block (DB-SM). DB No.: 1230 for channel 1 DB No.: 1530 for channel 2 DB No.: 1830 for channel 3 Table 5-6 DB Structure –...
Page 84: Table 5-7 Db Structure - Tool Offset Data
Defining Parameters of the FM 453 5.3.3 Tool Offset Data DB Structure Table 5-7 gives you a general view of the structure of the “tool offset data” data block (DB-WK). DB No.: 1220 for channel 1 DB No.: 1520 for channel 2 DB No.: 1820 for channel 3 Table 5-7 DB Structure –...
Page 85 Defining Parameters of the FM 453 Input of Values Values are input in the tool offset data menu of the “Parameterize FM 453” parameterization tool. If the additive wear value is changed online, the FM calculates the new wear parameter as an absolute value and the additive tool wear is reset to 0. Fig.
Page 86: Table 5-8 Db Structure - Traversing Programs
Defining Parameters of the FM 453 5.3.4 Traversing Programs DB Structure Table 5-8 gives you a general view of the structure of the “traversing pro- grams” data block (DB-NC). DB No.: 1001...1199 for channel 1 DB No.: 1301...1499 for channel 2 DB No.: 1601...1799 for channel 3 Table 5-8 DB Structure –...
Page 87 Defining Parameters of the FM 453 Input of Traversing An empty window is provided for the input of NC traversing programs . Here Programs you can input your traversing program as follows: Fig. 5-8 Entry for Traversing Programs 1. % Program number Program name The “%”...
Page 88: Table 5-9 Menus Of "Parameterize Fm
Defining Parameters of the FM 453 Parameterization with “Parameterize FM 453” Entering the You have a variety of options for entering your parameterization data. Values 1. User data You can input values or select texts in a table. Select input fields with the cursor and enter the values.
Page 89 Defining Parameters of the FM 453 Table 5-9 Menus of “Parameterize FM 453”, continued Menu Title or Entry Shortcut Significance (With Single Command) Channel 2 – for channel 2 Channel 3 – for channel 3 Traversing program > – Creates a new DB-NC Channel1 –...
Page 90 Defining Parameters of the FM 453 Table 5-9 Menus of “Parameterize FM 453”, continued Menu Title or Entry Shortcut Significance (With Single Command) 1 <Name of – Opens the DB which was last opened DB last opened> 2 <Name of –...
Page 91 Defining Parameters of the FM 453 Table 5-9 Menus of “Parameterize FM 453”, continued Menu Title or Entry Shortcut Significance (With Single Command) Tool offset data > – Edits the tool offset data on the FM 453 Channel 1 – for channel 1 Channel 2 –...
Page 92 Defining Parameters of the FM 453 Table 5-9 Menus of “Parameterize FM 453”, continued Menu Title or Entry Shortcut Significance (With Single Command) Status line – Switches the status line on/off Overview – The overview display for parameterization appears Extras –...
Page 93 Defining Parameters of the FM 453 Storing the Parameter Data in SDB 1 000 Overview The FM 453 stores its parameter data internally. In order to ensure that the parameter data are available if there is a fault on the FM 453 and no programming device/PC is at hand, the data can be stored in a system data block in the CPU (SDB 1 000).
Page 94 Defining Parameters of the FM 453 Display/Delete SDB in the S7 Select menu File Display SDB Project All SDBs for FM 453 of the project are displayed Close the Delete SDB? window Select SDB and delete Fig. 5-10 Displaying/Deleting SDB 1 000 Loading the SDB When you have created the SDB, you must load the “system data”...
Page 95 Defining Parameters of the FM 453 Deleting SDBs in To delete the SDBs in the CPU: the CPU 1. Select “Parameterize FM 453”. 2. Select menu File Display SDB. Delete the SDB(s). 3. Close “Parameterize FM 453” and in the SIMATIC Manager in Online Project select CPU\S7-Program\System data .
Page 96 Defining Parameters of the FM 453 FM 453 Servo Drive / Step Drive Positioning Module 5-34 C79000-G7076-C453-01...
Page 97 Programming the FM 453 Summary The present programming instructions describe the functions (FCs) that allow you to establish communications between the CPU and the FM 453 function module in the SIMATIC S7-400. Note The procedure is only described here for one channel. It must also be fol- lowed for each additional channel.
Page 98: Table 6-1 Technology Functions For The Fm
Programming the FM 453 Prerequisites The following prerequisites must be fulfilled in order to control the FM 453 from your user program: You have installed the software on your programming device/PC, as de- scribed in Section 5.1. The link between the programming device/PC and the S7-400 CPU must already be set up (see Figure 4-1).
Page 99 Programming the FM 453 Linking the The following figure shows you how the FM 453, the user data block (user FM 453 into the DB) and technology functions communicate. User program FM 453 OB 40 OB 82 4 bytes of OB startup information Diagnostic in- (Process inter- (Diagnostics)
Page 100 Programming the FM 453 Chapter In Section You Will Find On Page Overview FC INIT_DB – Initialize User DB FC MODE_WR – Control Operating Modes and Process Write Jobs FC RD_COM – Process Read Jobs Cyclically 6-14 Reading Diagnostic Information 6-18 FC MSRMENT –...
Page 101 Programming the FM 453 Description of The following table describes the parameters of this FC. Parameters Name Data Meaning Type Type DB_NO WORD Data block number CH_NO BYTE Number of axis: – Only one channel on the module – First channel on the module –...
Page 102 Programming the FM 453 FC MODE_WR (FC 2) – Control Operating Modes and Process Write Jobs Task You can use FC MODE_WR to: Control modes Process write jobs You must call FC MODE_WR once per channel in the OB 1 cycle. The FC performs the following actions: 1.
Page 103 Programming the FM 453 Principle of This function works together with a user DB. The structure of the user DB Operation can be found in the library FMSTSVLI in data type UDT 1. You need one user DB for each channel which contains entries for addressing the FM 453 and the data for the individual functions of the FM 453.
Page 104 Programming the FM 453 Example Call An example call is shown below for FC MODE_WR Explanation DB_FM.JOB_WR.BUSY; // Write job busy DB_FM.JOB_WR.IMPOSS; // Write job processing impossible DAWR; // Jump to call AT02: U G_STUFE_SETZEN; SPEN STRS; B#16#1; // Write job no. 1 for velocity level EINT;...
Page 105 Programming the FM 453 Operating Modes Job no. Addr. in System Data A/AE Sec- user DB tion Reference data is data/parameters for the corresponding mode. VLEVEL_1_2 – 90.0 9.2.1 Velocity levels 1, 2 CLEVEL_1_2 – 98.0 9.2.2 Voltage/Frequency levels 1, 2 TARGET_254 –...
Page 106: Table 6-2 Write Job Status
Programming the FM 453 Write Job Status The status of a write job is indicated in the user DB (in data byte DBB1). Table 6-2 Write Job Status Bit in JOB_WR Significance (DBX1.) .BUSY, 0 = 1, write job busy This bit is set by FC MODE_WR as soon as it starts processing a write job (JOB_WR.NO >...
Page 107 Programming the FM 453 6.2.2 Control Modes Overview Control/checkback signals are required in order to control the axis in the indi- vidual operating modes. The operating modes are described in Section 9.2. The control/checkback signals and their handling are described in Section 9.1. The user must enter the control signals in the user DB.
Page 108 Programming the FM 453 Troubleshooting Checkback Signals [BF/FS] and [DF] (group error messages) Error specification in user program (if necessary) Read out (on BF/FS) DS 162 (channel 1), DS 197 (channel 2), DS 232 (channel 3) or read out (on DF) DS 163 (channel 1), DS 198 (channel 2), DS 233 (channel 3) see example application 2 Error acknowledgment Set/clear control signal [BFQ/FSQ]...
Page 109 Programming the FM 453 Table 6-3 Control/Checkback Signals, continued German English Significance BF/FS OT_ERR Operator control and guidance errors MODE Active operating mode STR_MF Modify M function PR_BACK Program scanning backward DT_RUN Dwell time running POS_ROD Position reached and stopped GO_P Go_plus FR–...
Page 110 Programming the FM 453 FC RD_COM (FC 3) – Process Read Jobs Cyclically Task You can use FC RD_COM to execute read jobs. You must call FC RD_COM once per channel in the OB 1 cycle. The last read job must have finished processing, i.e. JOB_RD.NO in the user DB (data byte DBB2) must have been cleared and status bit JOB_RD.DONE enabled.
Page 111 Programming the FM 453 What does the user have to do? What is done by the FC 3? FM 453 User DB User program Write job no. Status of FC 2 according to job no. Scan/clear Read job no. Evaluate status Set/clear Status of FC 3 e.g.
Page 112 Programming the FM 453 Operating Modes Job no. Addr. in System Data A/AE Sec- user DB tion Display data is data/parameters returned by the FM. OP_DAT1 – additional operating data 354.0 9.3.16 PAR_READ – parameters/data 366.0 9.3.17 Data is accepted and only processed in the corresponding mode. Data is accepted or processed, as applicable.
Page 113 Programming the FM 453 Example call An example call is shown below for FC RD_COM Explanation DB_FM.JOB_RD.BUSY; // Read job busy DB_FM.JOB_RD.IMPOSS; // Read job processing impossible DARD; // Jump to call B#16#66; // Read job 102 for basic operating data DB_FM.JOB_RD.NO;...
Page 114 Programming the FM 453 Reading Diagnostic Information Overview FC DIAG_RD (FC 4) and FC DIAG_INF (FC 6) are used to read the diag- nostic interrupt information for all three channels in the user DB. FC 4 and FC 6 are intended as alternatives which you can use according to your needs.
Page 115: Table 6-4 Diagnostic Information
Programming the FM 453 The in/out parameter remains set while the job is running. Data transfer is complete when the in/out parameter is reset (IN_DIAG = FALSE). Error Evaluation Errors which occur are indicated in the binary result (BIE = 0). Possible errors are: Data transfer error during communication with SFC 59 “RD_REC”.
Page 116 Programming the FM 453 Table 6-4 Diagnostic Information, continued Data Byte.Bit Significance Format 12-byte FM Pos identifier (74H) Length of diagnostic information (16) No. of channels (3) 7.0...2 Channel error vector (1...3) Cable break (incremental encoder) for channel 1 Absolute encoder error for 1 Error pulse incr.
Page 117 Programming the FM 453 Byte.Bit: 0.0 Module distur- bance Byte.Bit: 0.2 Byte.Bit: 0.1 Byte.Bit: 0.3 External External internal error channel error errors Byte.Bit: 2.1 – 4 Byte.Bit: Byte.Bit: Byte.Bit: 8.0...7 10.0...7 12.0...7 Byte.Bit: 3.2 – 6 Channel 1 Channel 2 Channel 3 Fig.
Page 118 Programming the FM 453 6.4.2 FC DIAG_INF (FC 6) – Read Diagnostic Interrupt Data in OB 1 Task You can call FC DIAG_INF in OB 1 (or at another cyclical program level). For call options, parameters and evaluation, see Section 6.4.1. Principle of This function works together with a user DB.
Page 119 Programming the FM 453 FC MSRMENT (FC 5) – Read Measured Values Task You use FC MSRMENT to read the measured values into the user DB (start- ing at address 60). You can call FC MSRMENT in OB 40, if the process in- terrupt was activated (see Section 5.2 ), or in OB 1.
Page 120 Programming the FM 453 Error Evaluation Errors which occur are indicated in the binary result (BIE = 0). Possible errors are: Data transfer error during communication with SFC 59 “RD_REC”. The er- ror is returned in the output parameter RET_VAL (see reference manual Sys- tem Software for S7-300/400;...
Page 121 Programming the FM 453 User Data Block Overview The following table provides you with a description of the user data block structure. One of these user DBs must exist for each channel that is used. Table 6-5 User DB for the FM 453 Abso- Relative Decla-...
Page 122: Table 6-5 User Db For The Fm 453
Programming the FM 453 Table 6-5 User DB for the FM 453, continued Abso- Relative Decla- Initial Variable Data Type Comments lute Ad- Address ration Value dress 19.0 +19.0 stat RESERV_2 BYTE B#16#0 Reserved Control signals: FC MODE_WR 20.0 stat CONTROL_ STRUCT Control signals...
Page 123 Programming the FM 453 Table 6-5 User DB for the FM 453, continued Abso- Relative Decla- Initial Variable Data Type Comments lute Ad- Address ration Value dress 28.3 +0.3 OT_ERR BOOL FALSE Operator control and guidance errors 28.4 +0.4 DATA_ERR BOOL FALSE Data error...
Page 124 Programming the FM 453 Table 6-5 User DB for the FM 453, continued Abso- Relative Decla- Initial Variable Data Type Comments lute Ad- Address ration Value dress 36.0 +8.0 DWORD8 DWORD DW#16#0 Reserved =12.0 END_STRUCT Single functions: FC MODE_WR, job no. 10 40.0 stat SINGLE...
Page 125 Programming the FM 453 Table 6-5 User DB for the FM 453, continued Abso- Relative Decla- Initial Variable Data Type Comments lute Ad- Address ration Value dress 43.1 +1.1 DEL_DIST BOOL FALSE Delete residual distance 43.2 +1.2 SEARCH_F BOOL FALSE Automatic block search for- ward 43.3...
Page 126 Programming the FM 453 Table 6-5 User DB for the FM 453, continued Abso- Relative Decla- Initial Variable Data Type Comments lute Ad- Address ration Value dress 76.0 +4.0 BYTE4 BYTE B#16#0 Channel type 77.0 +5.0 BYTE5 BYTE B#16#0 Info length per channel 78.0 +6.0 BYTE6...
Page 127 Programming the FM 453 Table 6-5 User DB for the FM 453, continued Abso- Relative Decla- Initial Variable Data Type Comments lute Ad- Address ration Value dress 108.7 +2.7 BIT2_7 BOOL FALSE Reserved 109.0 +3.0 V_EN BOOL FALSE Speed 109.1 +3.1 M_1_EN BOOL...
Page 128 Programming the FM 453 Table 6-5 User DB for the FM 453, continued Abso- Relative Decla- Initial Variable Data Type Comments lute Ad- Address ration Value dress 139.0 +13.0 BYTE13 B#16#0 140.0 +14.0 BYTE14 B#16#0 141.0 +15.0 BYTE15 B#16#0 142.0 +16.0 BYTE16 B#16#0...
Page 129 Programming the FM 453 Table 6-5 User DB for the FM 453, continued Abso- Relative Decla- Initial Variable Data Type Comments lute Ad- Address ration Value dress 154.0 +2.0 G_1_EN BOOL FALSE G function group 1 154.1 +2.1 G_2_EN BOOL FALSE G function group 2 154.2...
Page 130 Programming the FM 453 Table 6-5 User DB for the FM 453, continued Abso- Relative Decla- Initial Variable Data Type Comments lute Ad- Address ration Value dress Request application data: FC MODE_WR, job no. 18 176.0 stat REQ_APP STRUCT Request application data 176.0 +0.0 CODE_AP1...
Page 131 Programming the FM 453 Table 6-5 User DB for the FM 453, continued Abso- Relative Decla- Initial Variable Data Type Comments lute Ad- Address ration Value dress 232.0 +2.0 G_1_EN BOOL FALSE G function group 1 232.1 +2.1 G_2_EN BOOL FALSE G function group 2 232.2...
Page 132 Programming the FM 453 Table 6-5 User DB for the FM 453, continued Abso- Relative Decla- Initial Variable Data Type Comments lute Ad- Address ration Value dress 252.4 +2.4 X_T_EN BOOL FALSE Position/dwell 252.5 +2.5 SR_L_EN BOOL FALSE Subroutine call counter 252.6 +2.6 SR_N_EN...
Page 133 Programming the FM 453 Table 6-5 User DB for the FM 453, continued Abso- Relative Decla- Initial Variable Data Type Comments lute Ad- Address ration Value dress 290.0 +0.0 OUT_VAL DINT DAC output value or frequency output value 294.0 +4.0 ENC_VAL DINT Actual encoder value or...
Page 134 Programming the FM 453 Table 6-5 User DB for the FM 453, continued Abso- Relative Decla- Initial Variable Data Type Comments lute Ad- Address ration Value dress 362.1 +8.1 LIM_SP BOOL FALSE Velocity limitation 362.2 +8.2 LIM_10 BOOL FALSE Limitation to 10 V 362.3 +8.3...
Page 135 Programming the FM 453 Table 6-5 User DB for the FM 453, continued Abso- Relative Decla- Initial Variable Data Type Comments lute Ad- Address ration Value dress 380.0 +14.0 BYTE14 BYTE B#16#0 381.0 +15.0 BYTE15 BYTE B#16#0 382.0 +16.0 BYTE16 BYTE B#16#0 383.0...
Page 136 Programming the FM 453 Table 6-5 User DB for the FM 453, continued Abso- Relative Decla- Initial Variable Data Type Comments lute Ad- Address ration Value dress 400.0 400.0 stat PICT_NO WORD W#16#0 Display number 402.0 402.0 stat KEY_CODE WORD W#16#0 Keycode 404.0...
Page 137: Table 6-6 Memories: Example Application
Programming the FM 453 Example Applications Example 1 see STEP 7 example application FMSTSVEX\EXAMPLE1 The following blocks are required, in addition to the technology functions, in order to run this example application: DB 1 (user DB), FC 100 (example call) OB 1 (cycle) and OB 100 (cold restart) The following operating modes are supported in example 1: Jogging...
Page 138 Programming the FM 453 Example 2 see STEP 7 example application FMSTSVEX\EXAMPLE2 The following blocks are required, in addition to the technology functions, in order to run this example application: DB 1 (user DB), FC 100 (example call), OB 1 (cycle), OB 40 (process interrupt), OB 82 (diagnostic interrupt) and OB 100 (cold restart).
Page 139: Table 6-7 Memories: Example Application 2
Programming the FM 453 Table 6-7 Memories: Example Application 2, continued Input Memories Used Output Memories Used M17.3 Read data M21.3 Travel minus M17.4 Transfer velocity levels M21.4 Travel plus M17.5 Transfer MDI block M21.5 Not used M17.6 Transfer single functions M21.6 Position reached, stop M17.7 Transfer program selection M21.7 Free...
Page 140 Programming the FM 453 The call for data sets 163 and 164 is programmed in the same way as the DS 162 call. The data sets are channel-specific, so when the data set is called, it must be ensured that the channel number is entered correctly. The data set number to be read on calling the SFC is calculated as the channel-specific data set offset plus the absolute data set number.
Page 141: Table 6-8 Memory: Example Application
Programming the FM 453 Example 3 See STEP 7 example application FMSTSVEX\EXAMPLE3 The following blocks are required, in addition to the technology functions, in order to run this example application: DB 1 (user DB), FC 100 (example call), OB 1 (cycle), OB 100 (cold restart). When you set memory M16.0 (P bus interface switchover), the job is transferred to the FM by means of control signals.
Page 142: Table 6-9 Memory Allocated To Fcs
Programming the FM 453 Technical Specifications Memory Allocation The following table gives you an overview of the memory allocated to FCs. Table 6-9 Memory Allocated to FCs Block in Bytes MC7 Code in Local Data in Bytes Bytes INIT_DB MODE_WR 1226 RD_COM DIAG_RD...
Page 143 Starting up the FM 453 Overview This Chapter introduces you to the user interface for testing and start-up, and provides check lists for starting up the positioning module. The checklists will help you: Check all steps until the module is running. Prevent malfunctions of the module once it is in operation.
Page 144: Table 7-1 Installation And Wiring Checklist
Starting up the FM 453 Installation and Wiring Installation You can find information about how to install your module: Information In Chapter 3 of this manual In the manual S7-400/M7-400 Programmable Controller, Hardware and Installation Wiring Information You can find information about how to wire your module: In Chapter 4 of this manual In the manual S7-400/M7-400 Programmable Controller, Hardware and Installation...
Page 145 Starting up the FM 453 Initial Values for Testing and Optimization Parameterization You can find information about parameterization: Information In Chapter 5 of this manual In the on-line help in “Parameterize FM 453” Overview The following opening display appears in the “Parameterize FM 453” tool: Fig.
Page 146: Table 7-2 Parameterization Checklist
Initial machine data assignments for FM STEPDRIVE To help you start up your machine axis with FM STEPDRIVE and the SIMOS- TEP motors, you will find the MD DBs for open-loop control mode in the di- rectory SIEMENS\STEP7\EXAMPLES\FM_UPOS : SIMOSTEP 2 si02_453.md SIMOSTEP 4 si04_453.md...
Page 147: Table 7-3 Initial Contents Of Machine Data
Starting up the FM 453 Table 7-2 Parameterization Checklist, continued Step Check What to Do: Traversing pro- Traversing programs are needed only for the “Automatic” mode and are not grams necessary for the startup described here. Generally, it is not needed until you start up the user program on the S7-400 CPU.
Page 148 Starting up the FM 453 Table 7-3 Initial Contents of Machine Data, continued MD (E) MD (E) Value/Meaning Value/Meaning Explanation Explanation MD61 1 000 000 [MSR] Zero speed range monitoring set to maximum +/– – value Reference-point shift (incremental encoders only), readjustment value (see Section 7.3.7) 0.2 v 20 % of maximum speed...
Page 149 Starting up the FM 453 Table 7-3 Initial Contents of Machine Data, continued MD (E) MD (E) Value/Meaning Value/Meaning Explanation Explanation MD61 Maximum frequency from drive configuration – Acceleration values for power-up and braking – – 1) This pair of values corresponds in the case of servomotors to the speed category of the drive. It serves as a basis for calculating the K factor in the servo, and must therefore be entered correctly.
Page 150 Starting up the FM 453 Testing and Optimization Testing and opti- Once you have installed, wired and parameterized the unit, you can test and mization informa- optimize your FM 453 positioning module. Testing and optimization can be tion performed with the aid of the testing and start-up interface with or without the user program.
Page 151 Starting up the FM 453 When you call up this menu the following screen appears: 1 – Error field 2 – Status field (e.g. actual values, check-back signals) 3 – Field for mode-specific inputs 4 – Field for input of values/settings/commands and start/stop for movement The abbreviations for the checkback signals are described in Section 6.2.2.
Page 152 Starting up the FM 453 Note To start a movement, we recommend the following input sequence: Select a mode Turn simulation on (if you want an operating case) Servo enable Enable axis Override 1...100% You can operate the “R+” and “R–” buttons in the “jogging” mode as fol- lows: 1.
Page 153 Starting up the FM 453 You can also call up the following screens: The following display appears when you select Test Troubleshooting: Fig. 7-3 Troubleshooting The following display appears when you select Test Service data: Fig. 7-4 Service Data FM 453 Servo Drive / Step Drive Positioning Module 7-11 C79000-G7076-C453-01...
Page 154: Table 7-4 Checklist - Startup Of Machine Axis
Starting up the FM 453 Checklist When starting up the machine axis, it is important to proceed step by step in a specified sequence. Depending on the parameterized control mode (MD16) and depending on your own application, certain steps have to be carried out as listed in the following table.
Page 155 Starting up the FM 453 7.3.1 Activation of the Machine Data Overview The checkback signal PARA notifies you that a DB-MD has been retained. This machine data is automatically activated at power-up. The module’s posi- tioning functions are ready to operate. If no DB-MD is present as yet on the FM 453 when the control is switched on, the module can only communicate by way of the MPI interface.
Page 156 Starting up the FM 453 7.3.2 Evaluating the Characteristics of the Stepper Motor Overview Basically, the stepper motor is a highly dynamic drive motor which is capa- ble of following setpoint assignments more or less free of following error. It is also capable of handling the transition between idle time and movement (and back) by way of the start/stop frequency at a high rate of acceleration.
Page 157 Starting up the FM 453 Operating Charac- Example of the operating characteristic curve of a stepper motor: teristic Curve Torque increase from boost [Nm] Maximum permissible Torque drop from PWM operating torque Start/Stop SS (J = 0) Load [1/min] 100 f1 f0 1 000 10 000 f [Hz]...
Page 158 Starting up the FM 453 MD54: Start/stop frequency f 1. Enter J into J diagram (e.g. 3 kg 4. Enter M in M diagram (e.g. 0.6 Nm) Load Load 2. Determine f0 (e.g. 150 Hz) from intersection 5. Determine f1 (e.g. 130 Hz) from intersection with J curve with SS curve 3.
Page 159 Starting up the FM 453 Notes Notes regarding special boundary conditions: It is evident from the above example that the acceleration torque within the lower speed range is approximately twice the value of the same value at maximum speed. This results in optimally-timed positioning cycles. Of course, the acceleration switchover is freely selectable in accordance within certain technological criteria.
Page 160 Starting up the FM 453 7.3.3 Basic Startup of Stepper Motor Actuation Overview The first step in the startup procedure for the drive is conducted to verify that the stepper motor will traverse as a matter of course in response to actuation by the FM 453 and therefore that the previously specified machine data are set correctly.
Page 161 Starting up the FM 453 Select Mode = open-loop control Frequency level 1 Frequency level 1 = f Frequency level 2 = f Servo = ON Start axis Plus or minus direction Travel test using Start/Stop frequency (execute several times) (make sure travel area is clear!) Axis movement completed? Step drive active?
Page 162 Starting up the FM 453 7.3.4 Basic Startup of Servomotor Actuation Overview With the following startup actions, you verify that the servo motor will tra- verse as a matter of course in response to actuation by the FM 453. You also determine the time constants of the servo drive that are required in later opti- mization steps for the servo position control.
Page 163 Starting up the FM 453 Select Mode = Control Voltage level 1 = 0 Voltage level 2 = 0.1 Select Voltage level 1 Servo enable = ON Zeroing for Start axis actuating signal Plus or minus direction Axis idle? Parameterization MD44 –...
Page 164 Starting up the FM 453 Drive Transition For the following position-controller optimization, it is important to know the Time and Maxi- drive time constant (transition time). In open-loop control mode and on errors mum Voltage Rise with the response “Everything Off” (see Section 11) the voltage value is fed to the drive by way of a ramp defined in MD45.
Page 165 Starting up the FM 453 7.3.5 Checking the Encoder Actuation Overview You can use the following flowchart to check the encoder actuation. Select Mode = Control Voltage level 2 Voltage level 1 = 0 Voltage level 2 = 0.1 Servo = ON Start axis Plus or minus direction (be sure there is enough room!)
Page 166 Starting up the FM 453 7.3.6 Startup of the Position Controller Overview By feeding back the measured displacement, a position controller closes the outermost loop of a controller cascade with the following structure: Motor and Drive FM 453 Machine Speed Current Ref.
Page 167 Starting up the FM 453 Non-release This test is only necessary when an encoder is used. Control You can use the following flow chart to check the non-release control. Select Mode = jogging Speed level 1 OVER = 100 % Speed level 1 = 0.1 Speed level 2 = 0.5 Servo = ON...
Page 168 Starting up the FM 453 Speed Assignment This test is only necessary in the case of servo drives (MD61 = 0). of the Drive Use the following flow chart to check that the speed assignment of the drive corresponds to the parameterization in the machine data. If you have carried out the “Check encoder actuation”...
Page 169 Starting up the FM 453 Positioning Use the following flow chart to check axis travel to a target position. Select Mode = Relative incremental Increment = 4 DB increments, Value 4 = e.g. 1,000 MSR OVER = 10 % Speed level 1 = 0.5 Speed level 2 = 0.5 Set reference point with value 0 Check check-back signal SYN...
Page 170 Starting up the FM 453 7.3.7 Optimizing the Position Control Overview In principle, the dynamic response of an axis is essentially determined by the dynamic response of the step drive or variable-speed servo drive; there is not sufficient space to discuss this topic here. But this latter dynamic response, in turn, is influenced by the design characteristics of the machinery, such as friction, backlash, torsion and the like.
Page 171 Starting up the FM 453 To Trigger Test You can trigger test movements as follows as you perform optimization: Movements Select Mode = jogging Speed level 2 OVER = various values Speed level 1 = 0.1 Speed level 2 = 0.5 Servo = ON Start axis Plus or minus direction...
Page 172 Starting up the FM 453 Step drive Set the following machine data to initial values for the following optimiza- tion steps: Acceleration, delay MD40 = MD41 = according to operating characteristic curve, see Section 7.3.2 “Procedure” Jolt time MD42 = 0 Positioning loop amplification MD38 [1/min] = 1 000 = default value Minimum standstill time, minimum traversing time...
Page 173 Starting up the FM 453 Note The values of MD40/MD41 can only be increased for step drives during op- timization and then only to a limited extent when the frequency ramp (MD45) is parameterized with the correct values in accordance with the op- erating characteristic curve.
Page 174 Starting up the FM 453 Optimization for especially soft travel (super-soft) For particular applications, especially soft travel response of the axis is desir- able. By choosing the following output values for the machine data affecting the dynamic response you can produce a very soft movement where the ac- celeration is controlled exclusively by the jolt filter.
Page 175 Starting up the FM 453 Compromise When optimizing for several of the above criteria, you can determine the ma- Optimization chine data from the results of the individual optimizations by a variety of methods: Guarantee of all partial results – Least determined value of MD38 –...
Page 176 Starting up the FM 453 7.3.8 Startup of Stepper Motor Control Overview The motor axis driven by the FM 453 is driven by pure, direct control. It fea- tures the following structure: Motor and FM 453 Drive Phase current control Machine PULS Current-...
Page 177 Starting up the FM 453 Positioning Use the following flow chart to check axis travel to a target position. Select BA = relative incremental Increment = 254 254 = Setpoint value for increment OVER = 10% Speed level 1 = 0.5 Speed level 2 = 0.5 Set reference point with value 0 Check check-back signal “SYN”...
Page 178 Starting up the FM 453 Optimization of The following table shows you how to make parameter quality selection for Dynamic Re- any given axis dynamic response desired. The time values MD46 and MD47 sponse are added to the previously documented machine data from basic startup. These times are essentially needed on a step drive-specific basis.
Page 179 Starting up the FM 453 7.3.9 Realigning the Reference Point Coordinates Axis with Incre- To ensure distinct reproducibility of reference recordings, it is necessary for mental Encoder the synchronizing zero pulse (SYNI) to be a distinct distance away from the reference point switch (RPS) (see Section9.6.4 for details of generating the zero reference mark).
Page 180 Starting up the FM 453 7.3.10 Activating Position Controller Diagnostics Overview Once the position controller has been optimized, activate the position con- troller diagnostics. If position control is performing improperly or the axis is responding abnormally, this function will trigger error messages. You can use the following flow chart to start the position controller diagnos- tics: FM 453 Servo Drive / Step Drive Positioning Module...
Page 181: Error Message
Starting up the FM 453 Select Mode = jogging Speed level 2 OVER = 10...20 % Speed level 1 = 0.1 Speed level 2 = 0.5 Test: “Swerve” the axis on deactivation of the controller Servo = ON Servo enable = OFF Read the following error from the servicing data Is maximum value for following error...
Page 182 Starting up the FM 453 7.3.11 Activating Stepper Motor Diagnostics Overview Once optimization of stepper motor control is completed, activate the stepper motor diagnostics as needed. Boost The boost signal is monitored in terms of its active time. This is in order to protect the drive motor against overheating.
Page 183 Starting up the FM 453 7.3.12 Activation of Software Limit Switches Overview Move the axis carefully to the end positions defined for normal machining. Enter these position actual values into the machine data MD21/MD22 as soft- ware limit switches, and activate them. Note If you change the reference-point coordinate later or use Set reference point for the absolute encoder, you must redefine the positioning values of the...
Page 184 Starting up the FM 453 Parameterization Initial backlash value MD30 = 0 (see Table 7-3) MD31 – Set directional reference of backlash Activate machine data Speed level 1 = 0.1 Speed level 2 = 0.5 Servo = ON Select Mode = Relative incremental DB increments, value 3 = e.g.
Page 185 Man-Machine Interface Summary In this chapter you’ll find an overview of the operator-control and monitoring capabilities offered by the FM 453. For operator control and monitoring of the FM 453, a control panel can be connected to the CPU via the MPI interface (see Figure 1-1). The module uses the SIMATIC interface (backplane bus) to communicate with the control panel.
Page 186 Man-Machine Interface What Can I Control Using the keyboard of the operator panel, you can change the data/signals in on the FM 453? the data blocks: Machine data DB No. 1205 for channel 1 DB No. 1505 for channel 2 DB No.
Page 187 You can print out the entire configuration using “ProTool/Lite” V3.0. This provides you with detailed screen descriptions. You will find the preconfigured user interface in the following directory: SIEMENS\STEP7\EXAMPLES\S7OP_BSP\01743_1a.pdb DB-SS The data block for status messages contains the control/checkback signals, as well as the system data of the FM 453.
Page 188 Man-Machine Interface User Program Your user program must analyze the signals (only those which are relevant to its applications). User-specific interlocks can be incorporated and the data/ signals are to be transmitted to the FM 453 by way of the FCs. User Interface of The following illustration provides you with an overview of the configuration the OP 17...
Page 189 Man-Machine Interface PIC7 Actual value display PIC71a PIC71 PIC71a1 subprogr. Overview subprogr. Edit version screen Z_SYSTEM_MEN PIC7112 system screens test screen 1) subprogr. = traversing program for FM 453 Fig. 8-3 Menu Tree of the OP 17 User Interface, continued Figure 8-2 describes the functions of the global function keys for the user interface of the OP 17.
Page 190 Man-Machine Interface Note The screens of the user interface (see Figure 8-2 and description of the indi- vidual screens) contain display fields and input/output fields. These fields contain values of configured variables. The display fields are addressed to the data blocks for status messages (“Steuerung_453”;...
Page 191 Man-Machine Interface Analysis of the User DB by the User Program for Operator Control Overview The following table describes for you which functions must be executed by the user program. Execution of these functions is triggered by setting/deleting of certain memory bits of the operator panel or by certain events within the FM 453 (e.g.
Page 192 Man-Machine Interface Table 8-1 Analysis of the User DB by the User Program, continued User Program OP 17 PIC... Triggered by Triggered by – – Byte.Bit Set in User DB Delete Function OP 17 Event (Byte.Bit) Byte.Bit 406.6 = 1 SK “Tipp”...
Page 193 Man-Machine Interface Variables in the The following table contains the variables which are entered into the user User DB See Section 6.6 for the structure of the user DB. Table 8-2 Variables for user DB Absolute Variable Significance address type BYTE Velocity or voltage/frequency level 1, 2 [BP] –...
Page 194 Man-Machine Interface Table 8-2 Variables for user DB, continued Absolute Variable Significance address type 16 BOOL Function bits for the user program – 390.0 Write MD 390.1 Read MD 390.2 Transfer MDI block 390.3 Transfer program selection 390.4 Transfer Teach In 390.5 Transfer increment 390.6...
Page 195 Man-Machine Interface Data Block for Status Messages (DB-SS) Overview The following table contains the parameters/data which are readable during operation. Table 8-3 Parameters/Data of DB-SS Byte Variable Type Value Significance of the Variables Comment 0 – 35 DB header 36 – 59 Internal header information Offset Variable Type...
Page 196 Man-Machine Interface Table 8-3 Parameters/Data of DB-SS, continued Offset Variable Type Value Significance of the Variables Comment STRUCT MDI block struc- MDI block on the fly ture BYTE Program selection Program number BYTE Program selection Block number 2 x BYTE Program selection Direction, free 4 x BYTE...
Page 197 Man-Machine Interface Table 8-3 Parameters/Data of DB-SS, continued Offset Variable Type Value Significance of the Variables Comment DINT factor (position control loop gain) Servicing data (for servo drive) DINT Following error (for servo drive) or dif- Servicing data ference between setpoint and actual positions (for step drive) DINT Following error limit (for drives with...
Page 198 Man-Machine Interface Table 8-3 Parameters/Data of DB-SS, continued Offset Variable Type Value Significance of the Variables Comment 2 x BYTE Data error BYTE Free BYTE Free 2 x BYTE Operator control error BYTE Free BYTE Free 32 x BOOL Process interrupt 1) A variable in the S7 protocol is addressed by the DB No.
Page 199 Man-Machine Interface The following table describes the control and checkback signals in German and English. Table 8-4 Control and Checkback Signals German English Significance Control signals MODE PA- Operating mode parameters RAMETER Velocity levels 1 and 2 Voltage/frequency levels 1 and 2 Increment selection 1...100, 254 Operating MODE...
Page 200 Man-Machine Interface Table 8-4 Control and Checkback Signals, continued German English Significance SYNC Synchronized DATA_ERR Data error FIWS FAVEL Flying actual value done TFGS TST_STAT Switchover, P-BUS port done WAIT_EN Wait for external enable PARA PARA Parameterized FM 453 Servo Drive / Step Drive Positioning Module 8-16 C79000-G7076-C453-01...
Page 201: Description Of Functions
Description of Functions Summary This chapter describes the functions of the FM 453. By calling up the appropriate functions (FCs) you can activate these func- tions by way of the user program. Note The procedure is only described here for one channel. It must also be fol- lowed for each additional channel.
Page 202 Description of Functions Control and Checkback signals Overview FC MODE_WR transfers the control signals from the user DB to the FM and transfers the checkback signals from the FM to the user DB. Byte Control signals: BFQ/FSQ R– operating mode OVERR Response signals: PARA...
Page 203 Description of Functions 9.1.1 Control Signals Overview The axis is operated and controlled by means of control signals. Table 9-1 describes the control signals and their functions. Table 9-1 Control Signals Symbol Name Name Function Function English German TEST_EN Sw./over Interrupts communication with the user program, and switches over the P bus P-bus in- interface for operation with the start-up user interface.
Page 204 Description of Functions Table 9-1 Control Signals, continued Symbol Name Name Function Function English German DRV_EN Drive en- ... enables movement. able When the signal is reset, a rapid deceleration of the movement takes place. On MD 37.15 = 0 program execution, or the movement, is canceled and the residual distance is deleted.
Page 205 Description of Functions Table 9-1 Control Signals, continued Symbol Name Name Function Function English German OVERRIDE OVERR Override Time override If you parameterize the “time override” function in MD37, there are two ranges: – range 100-255%: speed override operates as described above –...
Page 206 Description of Functions 9.1.2 Checkback Signals Overview The checkback signals indicate the processing status of the axis and report it to the user program. Table 9-2 describes the checkback signals and their functions. Table 9-2 Checkback Signals Symbol Significance Significance Function Function English...
Page 207 Description of Functions Table 9-2 Checkback Signals, continued Symbol Significance Significance Function Function English German WORKING Processing in ... indicates that a function has been started with Start or Travel Plus/Mi- progress nus, and is active. “Processing in progress” is set with: –...
Page 208 Description of Functions Table 9-2 Checkback Signals, continued Symbol Significance Significance Function Function English German FAVEL FIWS Set actual ... set Actual value on-the-fly is executed. value on-the- The signal is reset when “Set actual value on-the-fly” is activated (see fly complete Section 9.3.6).
Page 209 Description of Functions 9.1.3 General Handling Information Overview Before data/settings can be transferred to the FM 453, an operating mode must be active (e.g. “Jogging” mode = 1 and MODE = 1). That means that communication with the FM 453 has been initiated and the FM 453 has ac- cess to valid machine data.
Page 210 Description of Functions It is only possible to start the movement when the start enable is set and the enable input is set (if parameterized). Enable Start is set if: – No error occurred – Mode is active – No Stop is called –...
Page 211 Description of Functions Stat. Pending Start “Processing in progress” remains active after the end of machining and there Condition is no start enable as long as the start condition is not reset. Switching edge (e.g. R+, R–, Start, according to mode) Processing in progress Start enable Axis movement with...
Page 212 Description of Functions Operating Modes Overview The following operating modes are implemented on the FM 453: Jogging (T) Code 01 Open-loop control (STE) Code 02 Reference point approach (REF) Code 03 Incremental relative (SMR) Code 04 MDI (Manual Data Input) Code 06 Automatic (A) Code 08...
Page 213 Description of Functions 9.2.1 Jogging Overview In Jogging mode, axis traversing movements are specified by way of the direction keys (R+ or R–) and by speed. Velocity Before the axis can be moved, the velocities 1 and 2 must first be transferred to the FM 453 with job number 1.
Page 214 Description of Functions Table 9-3 Control Actions for “Jogging” Mode (examples) Signal Name Level Explanation Control action 1, enable “Jogging” mode Control signal: Mode [BA] The user initiates a [BA] command. Checkback signals: Active mode [BAR] The module returns [BAR] and [SFG]. Start enable [SFG] Control action 2, move axis –...
Page 215 Description of Functions Table 9-3 Control Actions for “Jogging” Mode (examples), continued Signal Name Level Explanation Control action 6, ambiguous direction command (special situation) Control signals: Direction plus [R+] [R+] is actuated while the axis is traversing with [R–]. Direction minus [R–] Checkback signals: The ambiguous direction command causes the axis to stop and [BF/FS] to be output.
Page 216 Description of Functions 9.2.2 Open-loop Control Overview In the “Control” mode, voltages of varying sizes or frequencies (if incre- ments are used) with selectable magnitudes are specified and then used to perform a controlled movement. The direction of movement is determined by way of direction keys (R+ or R–).
Page 217 Description of Functions 9.2.3 Reference Point Approach Overview In Reference-point approach mode, the direction keys (R+ or R–) or Start are used to position the axis to a point (reference-point coordinate MD16) speci- fied in the machine data. The axis is thus synchronized (see Section 9.6.4). The overrideis set to 100% for the reducing speed.
Page 218 Description of Functions With Reference It is necessary to connect the reference point switch (RPS) to a digital input Point Switch (RPS) and parameterize it in MD34. Sequence of Motions Triggering of Move- Type of Reference- (Reference Point Offset = 0) ment, Direction for Point Approach –...
Page 219 Description of Functions When crossing the RPS, a signal length of ∆t 2 FM cycle must be as- sured! The following table shows you the exact location of the synchronization point on the current-sourcing pattern zero or zero pulse external. Synchronization Point Applicable for Type (0 –...
Page 220 Description of Functions Note Please see also Section 9.1.3! Control Actions Preconditions: The FM 453 has been parameterized. The mode has been selected and confirmed Drive enable [AF] = 1 (control signal, FC MODE_WR) Stop [STP] = 0 (control signal, FC MODE_WR) Servo enable (RF) = 1 (FC MODE_WR, job no.
Page 221 Description of Functions Table 9-4 Control Actions for “Reference point approach” Mode (examples), continued Signal Name Level Explanation Control action 4, approach reference point Checkback signals: When reference point is reached. Travel minus [FR–] [FR–] is canceled. Position reached, stop [PEH] [PEH] is enabled.
Page 222 Description of Functions 9.2.4 Incremental Relative Overview In the Incremental Relative mode it is possible to execute single positionings over relative distances using user-definable increments. The traversing movement is triggered with the direction keys (R+ and R–). Defining the The options available for defining the increment with the mode parameter Position are: Via the user program,...
Page 223 Description of Functions Control Actions Preconditions: The FM 453 has been parameterized. The mode has been selected and confirmed Drive enable [AF] = 1 (control signal, FC MODE_WR) Stop [STP] = 0 (control signal, FC MODE_WR) Servo enable (RF) = 1 (FC MODE_WR, job no. 10) Velocity levels have been transferred (FC MODE_WR, job no.
Page 224 Description of Functions Table 9-5 Control Actions for “Incremental Relative” Mode (examples), continued Signal Name Level Explanation Control action 4, error during traversing movement Checkback signals: The axis moves. Travel plus [FR+] An error is output during the traversing movement. [FR+] and [BL] are canceled, and [BFQ/FSQ] is enabled.
Page 225 Description of Functions 9.2.5 MDI (Manual Data Input) Overview In the “MDI” mode, it is possible to execute single positionings via travers- ing blocks with relative or absolute path lengths. These traversing blocks are provided by the user program. The MDI block and MD block on-the-fly have an identical block structure. MDI Block The structure of the MDI block is identical to the traversing program block (see Chapter 10, however it does not have a program number or block num-...
Page 226 Description of Functions MDI block The MDI block currently being processed is canceled when the user program on-the-fly outputs an “MDI block on-the-fly” (job no. 16). Transfer of “MDI block on-the-fly” interrupts the active “MDI block”. The new block is executed immediately without “Start”. The MDI block on-the-fly is not saved in the FM 453.
Page 227 Description of Functions Handling by the The table below gives you an overview of how to handle this mode. User Triggering of Movement Type of Movement as defined by “MDI block” Start (job no. 6) “MDI block on-the-fly” transmitted as defined by “MDI block on-the- to the FM 453 fly”...
Page 228 Description of Functions Table 9-7 Control Actions for “MDI” mode (examples), continued Signal Name Level Explanation Control action 2, change position during positioning Transfer MDI block on-the- If a new “MDI block on-the-fly” is transferred during posi- fly (job no. 16) tioning, the current positioning operation is canceled immedi- ately, and the new positioning operation is started on-the-fly.
Page 229 Description of Functions 9.2.6 Automatic Overview In the Automatic mode (following-block mode), the FM 453 processes tra- versing programs . autonomously. These programs are created with “Parame- terize FM 453” (see Chapter 5, 5.3.4) and stored as a data block. The travers- ing programs contain information about movement sequences and outputs (see Chapter 10).
Page 230 Description of Functions User DB allocation Data Format Significance Byte 0 Program number Byte 1 Block number Byte 2 Direction of machining: 0 = process forward 1 = process in reverse Forward The program processes the block numbers in ascending order. Processing Processing begins at Start, with the first block (specified block number = 0).
Page 231 Description of Functions Block Search The program is processed to the end point of the target block, including tool Forward offset. M commands and dwell times are output and the traversing move- ments are suppressed. When processing traversing programs with a forward block search, there are a number of special cases: The external forward block search (G50) is not executed.
Page 232 Description of Functions Control Actions Preconditions: The FM 453 has been parameterized. The mode has been selected and confirmed Drive enable [AF] = 1 (control signal, FC MODE_WR) Stop [STP] = 0 (control signal, FC MODE_WR) Servo enable (RF) = 1 (FC MODE_WR, job no. 10) Axis is synchronized Table 9-8 Control Actions for “Automatic”...
Page 233 Description of Functions Table 9-8 Control Actions for “Automatic” Mode (examples), continued Signal Name Level Explanation Control action 5, traversing block with dwell Checkback signals: During processing of a traversing block with dwell, the dwell time t [T-L] and [PEH] are output. Travel plus [FR+] or Travel minus [FR–] Dwell time running [T-L]...
Page 234 Description of Functions Table 9-8 Control Actions for “Automatic” Mode (examples), continued Signal Name Level Explanation Control action 10, delete start signal and residual path (special situation) Control signal: If “delete residual path” is also preselected on [ST], the block interrupted by Stop is not executed up to the end, but the next Start [ST] block is started immediately.
Page 235 Description of Functions System Data Overview This chapter describes settings and functions that apply in multiple modes, and that are likewise necessary in order to control and operate the FM 453, and data of the FM available for checkback messages. These settings/functions, which you can activate by calling FC 2 or FC 3 (see Section 6) with the appropriate job no., are listed in the table below.
Page 236 Description of Functions 9.3.1 Change Parameters/Data (Job No. 8) Overview You can use this function to change parameters and data in the data function blocks of the FM 453, or to issue an order to read parameters or data from data function blocks.
Page 237 Description of Functions Notes Please note the following when changing the parameter data: Machine data Machine data can always be modified. Once you have modified the ma- chine data, the machine data have to be reactivated (for single command, see Section 9.3.3). Increments Modifications can be made in all operating modes (even in “Incremental relative”...
Page 238 Description of Functions Retentive Storage Please note the following when using the function “Write parameters and of Parameter Data with retentive storage” (byte 4, job type 4): Retentive writing must only occur on demand (not cyclically)! Modal data are stored on FEPROM (maintenance-free, no battery required). This memory has a physical limit for the possible number of delete/repro- gram cycles: minimum 10 , typically 10...
Page 239 Description of Functions 9.3.2 Single Functions (Job No. 10) Overview You can use this function to transfer single settings to the FM 453 and acti- vate the corresponding functions. These settings are: Length measurement Measurement on-the-fly Retrigger reference point Switch off enable output Follow-up mode (only for drives with encoders) Switch off software end position monitoring Rotation monitoring (only for step drive without encoder)
Page 240 Description of Functions Start Target – Zero pulse for Zero synchronization pulse Reference-point switch input of the FM 453 Hint to the user: You can use Retrigger Reference Point, for example, to compensate for slip- page of the trolley in a high-bay warehouse during operation, without having to resynchronize the axis with the Reference-Point Approach mode.
Page 241 Description of Functions Deactivate This function can be used to switch off the automatic drift compensation. Automatic Drift Automatic drift compensation means: Compensation The drift is balanced to zero by an automatic matching of the analog actuat- ing signal. The setting can be switched on or off if the axis is not in motion. Automatic drift compensation has no effect: –...
Page 242 Description of Functions 9.3.3 Single Commands (Job No. 11) Overview You can use this function to transfer single commands to the FM 453. These commands are: Activate machine data Delete residual distance Automatic block search in reverse Automatic block search forward Restart Istwert setzen rückgängig Callup of Single...
Page 243 Description of Functions Delete Residual You can use this command to delete a residual distance that remains after a Path job has been canceled. It is effective only in the “Incremental Relative”, “MDI”, and “Auto- matic” modes after a stop. If processing is not interrupted with a stop, the Delete Residual Distance requirement is suspended in the FM 453.
Page 244 Description of Functions 9.3.4 Zero Offset (Job No. 12) Overview You can use this function to shift the current zero point. Function of A selection, change or cancellation of a zero offset takes effect with the next Zero offset positioning action. With a zero offset, the instantaneous shift of a coordinate system is canceled, provided that a zero offset was already active and the specified shift was executed (relatively).
Page 245 Description of Functions Rotary Axis The following restriction applies to a rotary axis: Zero offset < Rotary-axis range. The actual value is normalized. Example: Range start/Range end 0/360 After shift value= –50 Actual value Actual value 350 Range start/ Range end 0/360 The Start and End of the Range Are Shifted –50 .
Page 246 Description of Functions 9.3.5 Set Actual Value (Job No. 13) Overview You can use this function to assign a new value to the current actual value. Function of By transmitting the coordinates, the actual value is set to this value when the Set Actual Value axis is not in motion (after selecting “Processing in progress”...
Page 247 Description of Functions 9.3.6 Set Actual Value On the Fly (Job No. 14) Overview You can use this function to assign a new value to the actual value by means of an external event. Function of Set By transmitting the coordinates (new actual value), set actual value on-the- Actual Value fly is activated.
Page 248 Description of Functions 9.3.7 Request Application Data (Job No. 18) Overview A selection of up to four display data items whose values can be read out with “read application data” (see Section 9.3.13). Code table: Code Significance No parameter request Actual position Actual velocity Residual distance...
Page 249 Description of Functions 9.3.8 Teach In (Job No. 19) Overview In a program block selected with the program number and block number, the current actual position is entered as a position setpoint (Caution: This is an absolute position). The Teach-in facility is possible only in the following modes: Jogging Incremental Relative and while the axis is not in motion, when “Processing in progress”...
Page 250 Description of Functions 9.3.10 Measured Values Activating the A “length measurement” or “inprocess measurement” can be activated by Measurement calling FC 2 and job no. 10 “single functions”. Function Since both functions use the same digital input of the FM 453, only one func- tion can be executed at a time.
Page 251: Troubleshooting
Description of Functions Length measurement The present actual position is captured at both the rising and the subsequent falling edge of the touch probe. In addition, the actually traveled distance (amount) is calculated. Length measurement On Measurement input Process interrupt Measurement taking place ∆S “Measured length value”...
Page 252 Description of Functions Measurement The checkback signal ME (see Section 9.1) signals the status of function Checkback Signals execution, as follows: “ME” Measurement On-the-fly Length Measurement the Length Measurement and Inprocess the Length Measurement and Inprocess Measurement functions are inactive Measurement functions are inactive with Start after a prior measurement with front edge of the touch probe signal...
Page 253 Description of Functions 9.3.12 Active NC Block (Job No. 103), Next NC Block (Job No. 104) Active NC Block ... are display data in “Automatic” mode Skipped block Subprogram callup (fills in UP number) Number of callups for subprogram (fills in UP callup number) Position/dwell time programmed (fills in value 1) G1-G3...
Page 254 Description of Functions 9.3.13 Application Data (Job No. 105) Overview The values passed with “request application data” job no. 18 (see Section 9.3.7) are returned from the FM 453. These values are always updated in the module cycle on the FM 453. 9.3.14 Actual Value Block Change (Job No.
Page 255 Description of Functions 9.3.16 Additional Operating Data (Job No. 110) Overview The following display data are additional operating data: Override (%) NC traversing program No. NC block No. UP callup counter G90/91 active, see Section 10.1 G60/64 active, see Section 10.1 G43/44 active, see Section 10.1 D No.
Page 256 Description of Functions System of Measurement Overview At the start of parameterization, you must fill in the basic machine data item system of measurement (MD7). This item governs the input of values. Variants of the You can set the system of measurement for the following three units: System of Measurement inches...
Page 257 Description of Functions Axis Type Overview You can select the axis type with machine data item MD8. Choose either of the following types: Linear axis Rotary axis Linear Axis A linear axis moves between two range limits (traversing range min –10 max 10 ).
Page 258 Description of Functions Rotary Axis End Machine data item MD9 defines the value by which the FM 453 recognizes the end of the rotary axis. This value is the theoretical maximum that the actual value can reach. At this value, display of the actual value switches back to 0. The theoretical maximum, however, is never displayed, because it is physi- cally located in the same position as the start of the rotary axis (i.e., 0).
Page 259 Description of Functions Encoders Overview One of the following encoders must be connected to the measuring-system interface of the FM 453 (see Fig. 1-1). Incremental encoder Absolute encoder (SSI) –3 –4 –4 Paths and positions are displayed in 10 mm, 10 inches or 10 degrees, as selected with machine data item MD7.
Page 260 Description of Functions The table below gives you an overview of the data used in this calculation and their meaning. You will find the machine data (MD) assignments under “Function parameters”. Sym- Significance Increments per encoder rotation (incremental encoder) Number of steps per encoder revolution (absolute encoder) Number of increments per stepper motor revolution MD52 Distance per spindle or rotary table revolution [mm/rev], [inches/rev], [degrees/ rev]...
Page 261 Description of Functions 9.6.1 Incremental Encoders Overview Incremental encoders serve to detect position values, supplying pulses that the FM 453 adds up to form an absolute value. After the FM 453 is switched on, there is an offset, which cannot be determined in advance, between the internal position value and the mechanical position of the axis.
Page 262 Description of Functions Function Table 9-9 shows you how to adapt the selected encoder to the Parameters FM 453. Table 9-9 Function Parameters – Incremental Encoders Designation Value/Meaning Comments/Unit Encoder type 1 = Incremental encoder (Code number) Displacement per 1...1 000 000 000 (MSR) encoder revolu- see Section 5.3.1, Dependencies...
Page 263 Description of Functions Monitoring/Error If MD20 = 0 is input, all monitoring functions are active. Diagnostics Individual monitoring functions can be inactivated by entering 0 in the desig- nated bit of MD20. You can deactivate the error messages using the single function “parking axis”...
Page 264 Description of Functions 9.6.2 Absolute Encoders (SSI) Overview Absolute encoders (SSI) have several significant advantages over incremental encoders: Longer cable lengths Reliable data capture by using a single-step GRAY code No encoder synchronization needed. Absolute Encoders You can use 13-bit single-turn encoders, or 25-bit multi-turn encoders with (SSI) the SSI protocol.
Page 265 Description of Functions Table 9-11 Function Parameters – Absolute Encoders (SSI), continued Designation Value/Meaning Comments/Unit Number of revo- 0/1 = Single-turn encoder Only powers of 2 al- lutions of ...2 for multi-turn encoder lowed SSI encoder SSI baud rate 2 = 156 000 Baud (Code number) 3 = 312 000 Baud The baud rate de-...
Page 266 Description of Functions Monitoring/Error If MD20 = 0 is input, all monitoring functions are active. Diagnostics Individual monitoring functions can be inactivated by entering 0 in the desig- nated bit of MD20. You can deactivate the error messages using the single function “parking axis”...
Page 267 Description of Functions 9.6.3 Stepper Motor Without Encoder Overview The FM 453 also operates with stepper motors without encoders. The position resolution of the axis is determined by the traversing distance of one motor increment. The control frequency pulses emitted by the FM 453 are added internally to form a position value.
Page 268 Description of Functions 9.6.4 Synchronization Overview When using incremental encoders, or stepper motors without encoders, at switch-on there is an offset, which cannot be determined in advance, between the internal position value in the FM and the mechanical position of the axis. To establish the position ref- erence, the value internal to the FM must be synchronized with the real posi- tion value of the axis.
Page 269 Description of Functions Synchronization is a defined point on the traversing path of the axis. It is defined by the me- Point chanical position of a reference-point switch or in association with a cyclic zero mark of an incremental encoder. Synchronization Creating the position reference between the internal FM position value and mechanical position of the axis.
Page 270 Description of Functions Setpoint Processing Overview Setpoint processing in the FM 453 is performed via the interpolation, servo position control or stepper motor control, actuating signal driver and drive actuation. Either the servo position control or stepper motor control function is active depending on the control mode (MD61).
Page 271 Description of Functions 9.7.1 Interpolation Overview In the interpolation function, a set position curve is generated as a function of time to present to the input of the position control loop or the stepper motor control. When the software limit switches are active, the traversing move- ment is limited in accordance with this range.
Page 272 Description of Functions Simple characteristic The machine data for acceleration (MD40) and deceleration (MD41) can be used to adapt the transition response of the command variable defined by the interpolator to the transition response of the controlled system. MD40 MD41 v –...
Page 273 Description of Functions The following illustrations provide you with examples of frequency profiles for selected traversing movements. Fig. 9-8 Maximum Speed Frequency Profile Stop Fig. 9-9 Frequency Profile for Stop or G60 The following table shows you which parameters to use in matching fre- quency generation to the selected step drive.
Page 274 Description of Functions Jolt Filter The jolt filter is effective in the case of a servo-controlled axis as well as for open-loop controlled operation of the step drive. In both cases, however, it is not effective in open-loop control mode due to the fact that in this operating mode, setpoint input takes place in the actuating signal driver.
Page 275 Description of Functions 9.7.2 Servo Position Control Overview In the servo position control function, the setpoint characteristic specified by the interpolation function is implemented in conjunction with the feed drive of the machine or installation in the form of a traverse movement of the axis . The following axis configurations are possible, depending on the parameter- ization: MD61...
Page 276 Description of Functions Position The following error is calculated by periodical comparison of the set position Comparitor defined by the interpolator with the actual position of the axis detected by the encoder. Following error = Set position – Actual position Position Controller The position controller generates an actuating signal that is required for cali- brating to the following error zero value from the following error of the posi-...
Page 277 Description of Functions The following relationship applies for these characteristics: The better the axis design, the greater the achievable K factor, and the better the axis parameters from the technological viewpoint. The size of the K fac- tor is especially affected by the time constants, backlash and spring compo- nents in the controlled system.
Page 278 Description of Functions Approach to the target position Target range (PEH) (MD24) Upper range Position to be approached Lower limit Actual Monitoring time (MD25) PEH – Position reached, stop s – path t – time On approach to a position, the monitoring time is activated: Time Position Monitoring After the interpolator reaches the target position, the monitoring time...
Page 279 Description of Functions The standstill zone is located symmetrically around the target approach posi- tion. Approach position Stationary range When the tolerance window for idle is exceeded, the FM 453 signals a “Sta- tionary Range” error (see Troubleshooting, Table 11-5, Class 1/No.
Page 280 Description of Functions Correction Drift compensation Functions Thermal conditions will shift the zero error in the control loop during opera- tion. This effect is called drift. In a closed control loop with a proportional- action controller, this results in a temperature-dependent positioning error. You can activate automatic drift compensation with MD37, under which con- tinuous balancing takes place in the positioning control loop.
Page 281 Description of Functions 9.7.3 Stepper Motor Control System Overview In open-loop controlled operation of the stepper motor, the axis is driven via the frequency output of the pulse/direction interface with “counted” distance increments and without following error. This results in the maximum dynam- ics possible for the movement, because when the target position is reached via interpolation, setpoint value output to the step drive is also terminated.
Page 282 Description of Functions Rotation monitoring The following prerequisites must be met for the “Rotation monitoring” func- tion: 1. External zero pulse (NIX) which is generated cyclically, precisely once per motor revolution Condition: At the maximum speed of the stepper motor, a signal length of ∆t 2 FM cycle must be assured for the external zero pulse! 2.
Page 283 Description of Functions Stepper motor rotation without a specified setpoint value likewise triggers a “Rotation monitoring” error in response to the NIX edges caused by the unwanted rotation. This occurs whenever the preceding target position falls within the range outside the allowable window for the NIX edges. If an unwanted rotation occurs outside the allowable window, there is no way of identifying whether oscillation on a NIX edge position caused by malfunction generated the error, or whether complete motor revolutions...
Page 284 Description of Functions 9.7.4 Actuating Signal Driver Overview In the actuating signal driver, the internal setpoint velocity value from the position controller is converted for output to the DAC (Digital to Analog Converter) for the servo drive to be actuated or to the DFC (Digital to Fre- quency Converter) for the stepper motor to be actuated.
Page 285 Description of Functions Velocity/voltage assignment The manipulated signal calculated by the position controller is available in- ternally on the FM as a velocity setpoint (see position loop gain). To convert this value to the analog actuating signal, a conversion factor (DAC factor) within the FM is necessary.
Page 286 Description of Functions Frequency (pulse/direction interface) Setpoint Output Direction Target speed Velocity/frequency DFC value assignment From – To drive servo position actuation control MD19 MD23 Frequency MD11 ramp MD12 MD52 MD45 MD54, MD55 Setpoint in MD56 Control mode MD57,MD58 MD59, MD60 MD61 (or) Fig.
Page 287 Description of Functions Velocity/frequency assignment An FM-internal conversion factor (DFC factor) is necessary for converting the internal setpoint velocity value to the setpoint required for programming the frequency output control for the purpose of generating the physical “Fre- quency” signal. This is determined by the pulse resolution of the step drive and is calculated from the parameterization of the distance assignment via the machine data MD11, MD12 and MD52.
Page 288 Description of Functions 9.7.5 Drive Actuation Overview In the interface between the FM 453 and the drive, apart from the actuating signal for the velocity setpoint for the traversing movement of the axis, other signals are exchanged. 10 V (DAC value) Pulse (DFC value) Direction Controller ready...
Page 289 Description of Functions In all operating modes except Control mode, the “servo enable” signal is re- quired for the duration of every traversing movement, irrespective of the pa- rameter definitions. If the controller enable is not detected or is deactivated during the movement, the “servo enable missing”...
Page 290 Description of Functions Effect: PWM The motor phase current can be changed between 0 % and 100 %. Current modification is possible at zero speed and during continuous travel. On accel- eration/deceleration, the current is always 100 % (max). pulse 100 % MD50 MD51...
Page 291 Description of Functions The following cases must be distinguished: Technical Implementation Signal Shape Parameter Definition Signal encoder on the motor axis Active phase over several motor incre- “Zero pulse external” (e.g. initiator) ments, one time per revolution Cyclical signal generated by the step drive Active phase over one motor increment, “Current-sourcing pattern one time per motor revolution (e.g.
Page 292 Description of Functions Digital Inputs/Outputs (Job No. 101) Overview Four digital inputs and four digital outputs of the FM 453 can be used specifi- cally to a given application. The conventions and parameterization for this purpose are defined in the ma- chine data MD34 to MD36.
Page 293 Description of Functions 9.8.1 Function Description for Digital Inputs External Start The control signals of the axis include the start signal which triggers a posi- tioning operation in “Reference point approach”, “MDI” and “Automatic” modes. A logical OR is established with the “External Start” digital input and the control signal (ST).
Page 294 Description of Functions External Block see Chapter 10 Change Set Actual Value see Chapter 10 and Section 9.3.6 On-the-fly Measurement see Section 9.3.10 Reference Point see Section 9.2.3 Switch for Reference Point Approach Reversal Switch see Section 9.2.3 For Reference Point approach 9.8.2 Function Description Digital outputs (Job No.
Page 295 Description of Functions Software Limit Switches Overview To limit the working range, entries in the machine data (MD21 and MD22) specify the start and stop limit switches. These limit switches are active at synchronization of the axis. If the limit switches are not needed, values lying outside the possible working range should be entered in the machine data (MD21 and M22), or monitoring should be switched off via the user program.
Page 296 Description of Functions Rotary Axis The end position of MD may be greater than MD start stop. When traveling into the working range (e.g. end position was previously switched off), the shortest path is always chosen. If both default values are parameterized the software limit switches are inac- tive.
Page 297 Writing Traversing Programs Overview To execute the desired operations of the machine axis (sequence, position, etc.) in “Automatic” mode, the FM 453 needs certain information. This in- formation is programmed with “Parameterize FM 453” (traversing program creation) in the form of a traversing program, based in principle on DIN 66025.
Page 298 Writing Traversing Programs N G1 G2 G3 M1 M2 M3 Start of 500 000 100 000 10 program = – – lowest block – number End of pro- gram = M2 or M30 Chapter In Section You Will Find On Page Overview 10.1 Traversing Blocks...
Page 299 Writing Traversing Programs Skip Block / Program blocks which are not to be executed every time the program runs can be identified as skippable blocks by an oblique “/ ”. When the program is being processed, the “Skip block” control signal can be used to decide whether skippable blocks are to be skipped.
Page 300 Writing Traversing Programs Dwell G04 A traversing block with dwell can only contain M functions and the time pa- rameter apart from this G function. The following applies for dwell time: Lower Input Upper Input Name Unit Limit Limit Dwell time 100,000 Odd input values are rounded upward.
Page 301 Writing Traversing Programs Notes to the The axis travels until a signal change from 0 to 1 takes place at the digital Example of input. This triggers two reactions: External Block A block change on-the-fly, and thus immediate processing of block N20. Change Storage of the actual position at the time of this signal change to “Actual value block change.”...
Page 302 Writing Traversing Programs Example of set The following figures show the program structure, program flow and actual- Actual Value value curve for an example of “Set actual value on-the-fly.” On-the-fly 400 000 89 (88) 200 000 400 000 400 000 Reversal of direction Í...
Page 303 Writing Traversing Programs Notes to the This changes blocks on-the-fly from N10 to N15, with G89 causing move- Example of Set ment in a positive direction and G88 causing movement in a negative direc- Actual Value tion at the speed programmed in N15. On-the-fly The axis now travels in the specified direction until a positive edge change occurs at the digital input.
Page 304 Writing Traversing Programs Dimensions G90, The traversing movement at a specific point can be described by Reference-measure input (absolute measure input) G90 or Incremental input (relative measure input) G91 You can switch back and forth at will between reference-measure and incre- mental input.
Page 305 Writing Traversing Programs Axis as Rotary If the axis is operated as a rotary axis, the measuring system must be adjusted Axis in such a way that the measurement scale refers to the full circle (e.g. 0 and 360 ). Reference-measure input G90 In a full circle with 360 , reference-measure programming (G90) has the peculiarity that there are always two options for reaching the set position.
Page 306 Writing Traversing Programs Acceleration Over- The acceleration override is used to control acceleration and deceleration ride G30...G39 during positioning movements. The acceleration and deceleration values are set by machine data. G30 through G39 in the traversing block can be used to achieve a percentage reduction in both values.
Page 307 Writing Traversing Programs Variants in Tool Tool offset is made up of two correction-value components: Offset Tool length offset The tool length offset is the actual tool length from tool zero to the tool tip. Tool length wear value The tool length wear value allows the change in tool length due to wear to be compensated in two ways: Absolutely: by specifying a fixed wear value...
Page 308 Writing Traversing Programs Direction of Tool The functions G44 (–) and G43 (+) correct the position value in such a way Offset that the tool tip reaches the programmed set position. Negative tool offset G44 As a rule, the tool points to the workpiece in a negative direction. With the infeed adjustment, the positioning value (traversing path) becomes smaller.
Page 309 Writing Traversing Programs M Functions Up to three M functions can be programmed in one traversing block, with any assignment of M1, M2 and M3. The output sequence of the M functions is always M1 M2 M3 (for information about output see Section 9.1). The following figure shows an example.
Page 310 Writing Traversing Programs Infinite Loop M18 M18 is always output as the last M function in the block. Two cases are distinguished: M function M18 is output like any other M function. Only after the block has been processed all the way to the end (including M18) does the axis skip back to the start of the program.
Page 311 Writing Traversing Programs 10.2 Program Execution and Direction of Machining Forward As a rule, programs are processed by ascending block number. Processing Reverse If programs are processed in reverse, the effects of commands must be taken Processing into account in the programming: Commands are self-maintaining (G90, G91, G60, G64, G30...G39) Active tool offset (G43, G44, D0...D20) Change of coordinate systems via G87, G88, G89.
Page 312 Writing Traversing Programs Output of Case 2 M Function During Positioning (“long block”) É É É É É É É É É É É É É É É É É É (“short block”) Output of Case 3 M Function After Positioning Target range É...
Page 313 Writing Traversing Programs Sample The following figure shows a sample program with the programming flow. Programming (Standard case) 10 000 100 00 20 000 30 000 200 00 40 000 150 00 30 000 100 00 1 – Block N10 is started at the point of deceleration of N5. 2 –...
Page 314 Writing Traversing Programs Change Block There are a number of conditions that may delay or prevent a block change On-the-fly - G64 on-the-fly. Here a distinction is necessary between the case in which this type (Deceleration) of block change is suppressed intentionally, and the case in which the se- lected function does not permit a block change on-the-fly.
Page 315 Writing Traversing Programs Influence of Machine data can specify the output time for M functions: M Function on M function is output before or after positioning with a block change Block Change On-the-fly M function output and positioning proceed in alternation. –...
Page 316 Writing Traversing Programs FM 453 Servo Drive / Step Drive Positioning Module 10-20 C79000-G7076-C453-01...
Page 317 Troubleshooting Overview The FM 453 provides diagnostics for the following: I/Os Module processes This “Troubleshooting” chapter describes the different types of errors, their cause, effect and elimination. Error Localization The FM 453 distinguishes between Errors which trigger a diagnostic interrupt in the CPU, and Errors which the module reports by way of checkback messages.
Page 318 Troubleshooting Programming The following manuals describe how to include diagnostics-capable modules Error Evaluation in your user program, and how to evaluate the diagnostic messages: Programming manual System Software for S7-300/400; Program Design (OB Types, Diagnostic Interrupt OB 82) Reference manual System Software for S7-300/400; System and Standard Functions A basic description of the diagnostic system of the S7-400 can be found in the Standard Software for S7 and M7, STEP 7 user manual.
Page 319 Troubleshooting 11.1 Error Classes and Module Responses Overview The FM 453 contains monitoring circuits which are active during startup or during continuous operation. Errors occurring during those times are reported to the system and to the user program. The table below lists the error classes and their meaning. Table 11-1 Error Classes, Overview Message...
Page 320 Troubleshooting 11.2 Error Messages Overview The following approaches to error localization are available for the FM 453: Error display by LEDs Error messages to the system and to the user program 11.2.1 Fault Indication by LED Status and Error The FM 453 features the following status and error displays: Displays INTF EXTF...
Page 321 Troubleshooting 11.2.2 Diagnostic Interrupts Overview Internal errors, external errors and external channel errors are indicated to an interrupt-capable system by means of diagnostic interrupts (see diagnostic interrupt data in Table 11-4, ). This presupposes that the diagnostic interrupt message was activated at the time of configuration (see Chapter 5.2). If the system is not interrupt-capable, the diagnostic interrupt information must be read out cyclically with FC 6.
Page 322 Troubleshooting 11.2.3 Error Messages in Checkback Signals Overview Operator/travel errors [BF/FS] and data errors/machine data errors/traversing program errors [DF], are communicated to the user by way of checkback sig- nals (FC 2 call). The error-specification is stored in the form of an error num- ber (see Error List in Table 11-6...11-8 in the corresponding data block (DS162/197/232 and DS163/198/233)
Page 323 Troubleshooting Error Number If a specific error analysis is called for in the user program, then the error Read-out numbers can be read out by calling up the corresponding system function (SFC 59, see Standard and System Functions Reference Manual). See also Section 6.7, user example 2.
Page 324: Viewing The Diagnostic Buffer (Pg/Pc)
Troubleshooting 11.2.4 Message in Data Block Overview Please note the following for direct access to DBs (e.g. using an OP). If data errors/machine data errors/traversing program errors are detected when the parameters are written to the data block (e.g. in the parameteriza- tion tool), an error message is stored in the data block.
Page 325: 11.3 Error Lists
Troubleshooting 11.3 Error Lists Note In the following tables, please note: The module response described under “Effect” refers to the error-specific module response. The error response described in Table 11-2 occurs in addi- tion. 11.3.1 Diagnostic Interrupts Overview The diagnostic interrupts are listed according to error class in Tables 11-4, 11-5.
Page 326 Troubleshooting Table 11-4 Diagnostic Interrupt, continued Byte. Error Message, Message/ Error Analysis and Elimination Display Internal errors Error response: “Everything OFF”, as in Table 11-2 Internal module power supply failure INTF (8034) (8034) EXTF EXTF Cause Drastic voltage dip. STAT FM 453 power supply faulty.
Page 327 Troubleshooting Table 11-4 Diagnostic Interrupt, continued Byte. Error Message, Message/ Error Analysis and Elimination Display 0.2, 0.3 External channel errors Error response: “Everything OFF”, as in Table 11-2 Cable break, incremental encoder INTF (8090) (8090) EXTF EXTF Cause Measurement system cable not plugged in or sheared off. STAT Encoder without internode signals.
Page 328 Troubleshooting Table 11-4 Diagnostic Interrupt, continued Byte. Error Message, Message/ Error Analysis and Elimination Display 0.2, 0.3 External channel errors Error response: “Everything OFF”, as in Table 11-2 Voltage monitoring, encoder INTF (8093) (8093) EXTF EXTF Cause Auxiliary 24 V DC voltage for encoder supply is not applied to front STAT connector X1.
Page 329 Troubleshooting Table 11-5 Operating Errors Error Message, Message/ Error Analysis and Elimination Display Operator control errors Error response: “Everything OFF”, as in Table 11-2 1 (01) 1 (01) Diagnostic Software limit switch beginning is passed interrupt interrupt. Cause Limit switch passed: in “Control” or “Correction” operating mode. Effect The limit switch position is passed by the necessary stopping distance.
Page 330 Troubleshooting Table 11-5 Operating Errors, continued Error Message, Message/ Error Analysis and Elimination Display Operator control errors Error response: “Everything OFF”, as in Table 11-2 1 (01) 11 (0B) Drive, direction of rotation Diagnostic interrupt interrupt. Cause Drive turns in wrong direction. Effect Elimina- Check drive.
Page 331 Troubleshooting 11.3.2 Error Message Overview The errors are listed in Tables 11-6...11-8 according to error class. Table 11-6 Operator Control Errors Error Message, Message/ Error Analysis and Elimination Display Operator control errors Error response : “Feed STOP” see Table 11-2 2 (02) 1 (01) Operating mode not allowed Cause...
Page 332 Troubleshooting Table 11-6 Operator Control Errors, continued Error Message, Message/ Error Analysis and Elimination Display Operator control errors Error response : “Feed STOP” see Table 11-2 2 (02) 12 (0C) Axis movement not possible Cause Due to an unacknowledged error, no drive enable or stop, a traverse command was triggered.
Page 333 Troubleshooting Table 11-7 Travel Errors Error Message, Message/ Error Analysis and Elimination Display Travel errors Error response : “Feed STOP” see Table 11-2 3 (03) 1 (01) Software limit switch, beginning Cause Limit switch approached in “Jog” operating mode, in “Automatic” operating mode if G88/89 without switching signal from the corresponding digital input.
Page 334 Troubleshooting Table 11-7 Travel Errors, continued Error Message, Message/ Error Analysis and Elimination Display Travel errors Error response : “Feed STOP” see Table 11-2 3 (03) 3 (03) Traversing range beginning approached Cause During traversing with soft limit switches disabled, the travers- ing range beginning was approached.
Page 335 Troubleshooting Table 11-7 Travel Errors, continued Error Message, Message/ Error Analysis and Elimination Display Travel errors Error response : “Feed STOP” see Table 11-2 3 (03) 28 (1C) M2/M30 missing Cause In the last program, block, no M2, M30 or M18 is pro- grammed.
Page 336 Troubleshooting Table 11-7 Travel Errors, continued Error Message, Message/ Error Analysis and Elimination Display Travel errors Error response : “Feed STOP” see Table 11-2 3 (03) 39 (27) MDI block on the fly, incorrect position or dwell time Cause Position or dwell time is outside allowable values. Position: Dwell time: >...
Page 337 Troubleshooting Table 11-7 Travel Errors, continued Error Message, Message/ Error Analysis and Elimination Display Travel errors Error response : “Feed STOP” see Table 11-2 3 (03) 65 (41) No drive movement Cause Axis standstill at maximum drive control signal ( 10 V). On violation of the defined following error limit.
Page 338 Troubleshooting Table 11-8 General Data Errors, Machine Data Errors, Traversing Program Errors Error Message, Message/ Error Analysis and Elimination Display General data errors Error response: ”Warning” see Table 11-2 4 (04) 1 (01) Data at time of transmission unacceptable Cause Data not transmitted in appropriate operating mode.
Page 339 Troubleshooting Table 11-8 General Data Errors, Machine Data Errors, Traversing Program Errors, continued Error Message, Message/ Error Analysis and Elimination Display General data errors Error response: ”Warning” see Table 11-2 4 (04) 7 (07) MDI block, incorrect syntax Cause Incorrect M or G commands or incorrect block structure. Effect Original MDI block is retained.
Page 340 Troubleshooting Table 11-8 General Data Errors, Machine Data Errors, Traversing Program Errors, continued Error Message, Message/ Error Analysis and Elimination Display General data errors Error response: ”Warning” see Table 11-2 4 (04) 13 (0D) Digital output not possible Cause Output not available for direct output of the user program. Effect Output is not executed.
Page 341 Troubleshooting Table 11-8 General Data Errors, Machine Data Errors, Traversing Program Errors, continued Error Message, Message/ Error Analysis and Elimination Display General data errors Error response: ”Warning” see Table 11-2 4 (04) 40 (28) Transmit non-relevant data Cause The data (data blocks) transmitted are unknown to the FM 453. Effect Data not accepted.
Page 342 Troubleshooting Table 11-8 General Data Errors, Machine Data Errors, Traversing Program Errors, continued Error Message, Message/ Error Analysis and Elimination Display General data errors Error response: ”Warning” see Table 11-2 4 (04) 124 (7C) “Save” parameter incorrect Cause Coding not 0 or 1. Effect DB does not become effective and is stored non-retentively.
Page 343 Troubleshooting Table 11-8 General Data Errors, Machine Data Errors, Traversing Program Errors, continued Error Message, Message/ Error Analysis and Elimination Display General data errors Error response: ”Warning” see Table 11-2 4 (04) 131 (83) Not possible to insert block Cause Memory full.
Page 344 Troubleshooting Table 11-8 General Data Errors, Machine Data Errors, Traversing Program Errors, continued Error Message, Message/ Error Analysis and Elimination Display Machine data errors Error response: “Warning” see Table 11-2 5 (05) 11 (0B) Travel per encoder revolution 12 (0C) Distance to go per encoder revolution 13 (0D) Increments per encoder revolution...
Page 345 Troubleshooting Table 11-8 General Data Errors, Machine Data Errors, Traversing Program Errors, continued Error Message, Message/ Error Analysis and Elimination Display Machine data errors Error response: “Warning” see Table 11-2 5 (05) 21 (15) Software limit switch, begin 22 (16) Software limit switch, end 23 (17) Maximum velocity...
Page 346 Troubleshooting Table 11-8 General Data Errors, Machine Data Errors, Traversing Program Errors, continued Error Message, Message/ Error Analysis and Elimination Display Machine data errors Error response: “Warning” see Table 11-2 5 (05) 35 (23) Digital outputs Cause Outputs undefined or defined more than once. Effect DB does not become effective and is stored non-retentively.
Page 347 Troubleshooting Table 11-8 General Data Errors, Machine Data Errors, Traversing Program Errors, continued Error Message, Message/ Error Analysis and Elimination Display Machine data errors Error response: “Warning” see Table 11-2 5 (05) 76(4C) Minimum stoppage time between two positioning operations 77(4D) Minimum traversing time at constant frequency 78(4E)
Page 348 Troubleshooting Table 11-8 General Data Errors, Machine Data Errors, Traversing Program Errors, continued Error Message, Message/ Error Analysis and Elimination Display Machine data errors Error response: “Warning” see Table 11-2 5 (05) 100 (64) Maximum velocity for drive too high Cause Based on the MD11, MD12 and MD52 machine data for the maxi- mum velocity MD23, a frequency would be generated that is...
Page 349 Troubleshooting Table 11-8 General Data Errors, Machine Data Errors, Traversing Program Errors, continued Error Message, Message/ Error Analysis and Elimination Display Traversing program errors Error response: “Warning” 8 (08) 1 (01) Program selection, subroutine error Cause The subroutine requested in the program is not in place on the FM 453.
Page 350 Troubleshooting Table 11-8 General Data Errors, Machine Data Errors, Traversing Program Errors, continued Error Message, Message/ Error Analysis and Elimination Display Traversing program errors Error response: “Warning” 8 (08) 20 (14) Error, program number Cause Program numbers in the blocks incorrect. Effect Program is not stored.
Page 351 Troubleshooting Table 11-8 General Data Errors, Machine Data Errors, Traversing Program Errors, continued Error Message, Message/ Error Analysis and Elimination Display Traversing program errors Error response: “Warning” 8 (08) 26 (1A) G function 3 unacceptable Cause The number programmed as G function 3 is not allowed. External block change (G50) was programmed in a block to- gether with continuous operation for setting actual value on the fly (G88/89).
Page 352 Troubleshooting Table 11-8 General Data Errors, Machine Data Errors, Traversing Program Errors, continued Error Message, Message/ Error Analysis and Elimination Display Traversing program errors Error response: “Warning” 8 (08) 31 (1F) Velocity missing Cause No velocity was programmed. Effect Program/block not stored. Elimina- Correct program, per cause.
Page 353 Technical Specifications Overview This chapter describes the technical data for the FM 453 positioning module. General technical data Dimensions and weight Load memory Encoder inputs Drive port Digital inputs Digital outputs General Technical General technical data include: Data Electromagnetic compatibility Shipping and storage conditions Ambient mechanical and climate conditions Data on insulation testing, protection class and degree of protection...
Page 354 Compatibility” EU Guideline and the harmonized European standards (EN) which it embodies. The EC Declarations of Conformity in accordance with Article 10 of the EU Guideline referenced above is available for the responsible authority from: SIEMENS Aktiengesellschaft Automation Group AUT E 148 PO Box 1963 D–92209 Amberg...
Page 355 Technical Specifications Power Ratings Technical data: Power ratings Power consumption from 5 V backplane bus Max. 1.6 A (nominal current) Power loss Auxiliary voltage 1L+...4L+ 24 V DC Dynamic range 18.5...30.2 V (incl. ripple) Static range 20.4 – 28.8 V Power consumption for 1L for nominal voltage Max.
Page 356 Technical Specifications Step drive Output signals, 5 V to RS422 standard = 100 Ω) Differential output voltage Min. 2 V (R Output voltage “1” Type 3.7 V (I = –30 mA) Output voltage “0” Type 1.1 V (I = 30 mA) Min.
Page 357 Technical Specifications Digital Inputs Technical data for digital inputs: Number of inputs 6 per channel Supply voltage 24 V DC (allowable range: 20.4 – 28.8 V) Electrical isolation Input voltage 0 signal: –3 – 5 V 1 signal: 11 – 30 V Input current 0 signal: Not more than 3 mA 1 signal: Not more than 7 mA...
Page 358 Technical Specifications FM 453 Servo Drive / Step Drive Positioning Module C79000-G7076-C453-01...
Page 359 Connecting Cables Overview This chapter provides an overview of the cable sets to the connectable encod- ers and drives. The encoder types that can be connected and the corresponding cable sets are listed in the following table. Table B-1 Connecting Cables for Encoders Encoder Connecting Cable Incremental encoder with RS 422...
Page 360: Cable Set For Incremental Encoders With Rs 422 Or Exes
View onto crimp ter- minal side 15-pin sub D connector, con- necting metallic 12-pin round con- housing side with nector, Siemens screw-locking connecting side 6FC9 341-1HC 6FX 2003-0CE12 Twisted pairs Order Notes The cable cross-sections have already been specified in the diagram. The maximum length of the connecting cable is given in Chapter A, Technical Specifications.
Page 361 Shield on housing Cable 4 0.38 + 4 0.5 mm View onto crimp terminal side 15-pin sub D 17-pin round connector, con- connector, Siemens necting metallic connecting side housing side with 6FC9 348-7AV01 screw-locking 6FC9 341-1HC Twisted pairs Order Notes The cable cross-sections have already been specified in the diagram.
Page 362 Connecting Cables Cable Set for Absolute Encoders (SSI) with a Free Cable End Connections The following figure shows the connecting cable between the FM 453 and the absolute encoder: FM 453 Encoder DATA Blue DATA DATA_N Violet DATA_N Black Brown CLS_N CLS_N White/red...
Page 363: Cable Set For Simodrive 611-A Servo Drive (3 Channels
Connecting Cables Cable Set for SIMODRIVE 611-A Servo Drive (3 channels) Connections The following figure shows the connecting cable between the FM 453 and the SIMODRIVE 611-A servo drive (3 channels): FM 453 SIMODRIVE 611-A Yellow 2/(9) Green 2/(65) Channel 1 Blue 2/(14) Violet...
Page 364: Cable Set For Fm Stepdrive Step Drive (3 Channels
Connecting Cables Cable Set for FM STEPDRIVE Step Drive (3 channels) Connections The following figure shows the connecting cable between the FM 453 and three FM STEPDRIVE step drives: FM 453 FM STEPDRIVES Black Brown Orange Yellow Green White/green Brown/black Blue Violet Green...
Page 365 Connecting Cables Order Notes The cable cross-sections have already been specified in the diagram. The maximum length of the connecting cable is: 35 m for symmetrical transmission 10 m for asymmetrical transmission The corresponding order number is: 6FX2 002-3AB04-1 : For length code, see Catalog NC Z Order No.
Page 366: Cable Set For One Fm Stepdrive Step Drive And Two Simodrive 611-A Servo Drives (3 Channels)
Connecting Cables Cable Set for One FM STEPDRIVE Step Drive and Two SIMODRIVE 611-A Servo Drives (3 channels) Connections The following figure shows the connecting cable between the FM 453, one FM STEPDRIVE step drive and two SIMODRIVE 611-A servo drives: FM 453 Black Brown...
Page 367: Cable Set For Two Fm Stepdrive Step Drives And One Simodrive 611-A Servo Drive (3 Channels)
Connecting Cables Cable Set for Two FM STEPDRIVE Step Drives and One SIMODRIVE 611-A Servo Drive (3 channels) Connections The following figure shows the connecting cable between the FM 453, two FM STEPDRIVE step drives and one SIMODRIVE 611-A servo drive: FM STEPDRIVES FM 453 Black...
Page 368 Connecting Cables Order Notes The cable cross-sections have already been specified in the diagram. The maximum length of the connecting cable is 35 m. The corresponding order number is: 6FX2 002 3AB03-1 : For length code, see Catalog NC Z Order No.
Page 369 List of Abbreviations Automation system Mode BA “A/AE” “Automatic/Automatic single block” mode BA “REF” “Reference point approach” mode BA “SM” “Incremental approach” mode BA “STE” “Open-loop control” mode BA “T” “Jogging” mode Binary result Mode parameter Central Processing Unit of the SIMATIC S7 Digital-analog converter Data block Data block byte...
Page 370 List of Abbreviations Electrostatic sensitive device External pulse shaper Function block Function FEPROM Flash EPROM: read/write memory Function module Hexadecimal Device for operating and monitoring of a process Input parameter Interface module (SIMATIC S7) In/out parameter (initialization parameter) Ladder program Light emitting diode Manual data input MLFB...
Page 371 List of Abbreviations System status list Technology function User program FM 453 Servo Drive / Step Drive Positioning Module C79000-G7076-C453-01...
Page 372: List Of Abbreviations
List of Abbreviations FM 453 Servo Drive / Step Drive Positioning Module C79000-G7076-C453-01...
Page 373: Index
Index connecting cables, 4-4, B-1 measurement system cable, 4-4, 4-20 absolute dimensioning, 10-8 MPI connecting cable, 4-4 absolute encoder alignment, 9-68 setpoint cable, 4-4 absolute encoders, 4-16 control signals, 6-6, 6-12, 8-15, 9-3 absolute encoders (SSI), 9-64 controller enable, 9-77 acceleration, 9-72, 9-90 COROS equipment (operator panel), 8-3 acceleration override, 10-10...
Page 374 Index dimensions, 10-8 front connector, 1-6, 4-21 dimensions of the FM 453, A-3 connecting cables, 4-29 direction alignment, 9-84, 9-86 wiring the front connector, 4-28 direction of machining, 9-30 front connectors, 4-4 drift compensation, 7-41, 9-80 front–panel elements, 1-7 deactivation, 9-41 LED indicators, 1-7 drive enable, 9-4 front-panel elements, 1-6...
Page 375 Index MDI (Manual Data Input), 9-9, 9-25 ports, 1-6, 1-7, 4-21 measured values, 9-50 drive port, 1-6, 1-7 inprocess measurement, 9-50 I/O port, 1-6, 1-7, 4-21 length measurement, 9-51 measurement system port, 1-6, 1-7 measurement, 9-50 SIMATIC bus connector port, 1-6, 1-7 memory for parameter data, A-3 position control, 7-24 mode parameter, 9-13, 9-16...
Page 376 Index reference point offset, 9-68 software limit switches, 7-41, 9-95 start enable, 9-6 reference point switch, 7-37, 9-18 switch alignment, 7-37 start-up, 7-8 reference point switch , 9-68 step drive, A-4 reference-point coordinate, 7-41 stepper motor control system, rotation monito- removing the FM 453, 3-3 ring, 9-82 restart, 9-43...
Page 377 Index troubleshooting , 7-11 weights, A-3 wiring diagram for a FM 453, 4-2 Wiring the FM 453, 4-1 UL certification, A-1 wiring up the front connector, 4-28 undo set actual value, 9-43 write data user data, 5-9, 8-1 request application data, 9-48 user data block, 5-9, 6-25 Teach in, 9-49 creating, 6-2...
Page 378 Index FM 453 Servo Drive / Step Drive Positioning Module Index-6 C79000-G7076-C453-01...
Page 379 Siemens AG AUT V240 P.O. Box 3180 D–91050 Erlangen Federal Republic of Germany From: Your Name: _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _...
Page 380 Please take the first available opportunity to fill out this questionnaire and return it to Siemens. Title of the manual: _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Order No.

Siemens SIMATIC FM 453 Manual

1 Product Summary

2 Basic Principles of Positioning

3 Installing and Removing the FM 453

4 Wiring the FM 453

5 Defining Parameters of the FM 453

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Summary of Contents for Siemens SIMATIC FM 453

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