Siemens SIMATIC FM 455 C User manual
Safety Guidelines
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.
Danger
indicates that death or severe personal injury will result if proper precautions are not taken.
Warning
indicates that death or severe personal injury may result if proper precautions are not taken.
Caution
with a safety alert symbol, indicates that minor personal injury can result if proper precautions are not taken.
Caution
without a safety alert symbol, indicates that property damage can result if proper precautions are not taken.
Notice
indicates that an unintended result or situation can occur if the corresponding information is not taken into
account.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will
be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to
property damage.
Qualified Personnel
The device/system may only be set up and used in conjunction with this documentation. Commissioning and
operation of a device/system may only be performed by qualified personnel. Within the context of the safety notes
in this documentation qualified persons are defined as persons who are authorized to commission, ground and
label devices, systems and circuits in accordance with established safety practices and standards.
Prescribed Usage
Note the following:
Warning
This device 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. Correct, reliable operation of the product requires proper transport, storage, positioning and
assembly as well as careful operation and maintenance.
Trademarks
All names identified by ® are registered trademarks of the Siemens AG. The remaining trademarks in this
publication may be trademarks whose use by third parties for their own purposes could violate the rights of the
owner.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software
described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the
information in this publication is reviewed regularly and any necessary corrections are included in subsequent
editions.
Siemens AG
Automation and Drives
Postfach 48 48
90437 NÜRNBERG
GERMANY
Order No.: A5E00059365-03
Edition02/2006
Copyright © Siemens AG 2006.
Technical data subject to change
Table of contents
1 Introduction............................................................................................................................................. 1-1
2 Preparations ........................................................................................................................................... 2-1
3 Learning units ......................................................................................................................................... 3-1
3.1 Installing the configuration package .......................................................................................... 3-1
3.2 FM 455 C, installing and wiring.................................................................................................. 3-1
3.3 Preparations for programming ................................................................................................... 3-3
3.4 Programming the analog input parameters ............................................................................... 3-4
3.5 Programming the error signal parameter................................................................................... 3-4
3.6 Programming the controller parameters .................................................................................... 3-5
3.7 Programming the controller output parameters ......................................................................... 3-5
3.8 Programming the analog output parameters ............................................................................. 3-6
3.9 Saving parameter data and transferring those to FM 455 ......................................................... 3-6
3.10 Integrating FM 455 C in the user program................................................................................. 3-7
3.11 Editing controller parameters of the user program .................................................................... 3-7
3.12 Download finished example program "SIMATIC 400 Station2 (C)"........................................... 3-8
3.13 Testing the controller test using the loop monitor and curve recorder functions ....................... 3-8
3.14 PID controller tuning .................................................................................................................. 3-9
4 Further Information ................................................................................................................................. 4-1
4.1 Tuning temperature controllers.................................................................................................. 4-1
4.2 Diagnostics................................................................................................................................. 4-1
4.3 Examples ................................................................................................................................... 4-1
FM 455 C
Getting Started, 02/2006, A5E00059365-03
iii
Table of contents
FM 455 C
iv
Getting Started, 02/2006, A5E00059365-03
Introduction
1
Purpose of this documentation
Based on a practical example, this manual leads you through the various steps in
commissioning a fully functional application, and thus introduces the basic functions of
FM 455 C hardware and software, and corresponding test features. The references to the
manual should give you an initial overview of the information it contains.
Wiring and tuning of the controller will take approx. one to two hours, depending on your
experience.
FM 455 C
Getting Started, 02/2006, A5E00059365-03
1-1
Introduction
FM 455 C
1-2
Getting Started, 02/2006, A5E00059365-03
Preparations
2
Requirements
Hardware and software requirements:
• An S7-400 station, consisting of a power supply module and a CPU.
• STEP 7 (≥V4.02) is properly installed on your PG.
• You have configured a project for the S7-400 station.
• The PG is connected to the CPU.
• You have an FM 455 C module and its configuration package, including all necessary
accessories, such as front connectors, encoders (sensors), switches, final control
elements (actuators), and wiring material.
FM 455 C
Getting Started, 02/2006, A5E00059365-03
2-1
Preparations
FM 455 C
2-2
Getting Started, 02/2006, A5E00059365-03
Learning units
3
3.1
3.1
Installing the configuration package
Procedure
The configuration package contains a configuration tool for FM 455 C, all function blocks
(FBs) you need to integrate your FM in the CPU user program, and various example
programs.
To install the software, place the CD into your drive, and then run SETUP.EXE from this CD.
Follow the setup instructions (see the
FM 455 Controller Module,
manual, chapter
"Assigning parameters to FM 455".)
3.2
3.2
FM 455 C, installing and wiring
Procedure
Before you install FM 455 C, set the coding key module for channels 1 and 2 to position B
(see the
FM 455 Controlle Moduler
r
manual, chapter "Setting the measurement type and the
measuring ranges of the analog input channels".)
Place the FM 455 C into its rack slot, then swivel it down, and screw-tighten it (refer to the
FM 455 Controller Module
, chapter "Installing and removing the FM 455".)
The wiring diagram below shows you the front connector wiring of a controller channel with
voltage input and current output. The wiring of other sensors and actuators is described in
the "Wiring the FM 455" and "Connecting measuring sensors and loads/actuators" chapters
of the
Controller Module FM 455
manual.
Always short-circuit any unused analog inputs and the reference junction by wiring these to
MANA and M, regardless whether or not you configured those inputs on the user interface.
You do not necessarily have to wire the digital inputs to operate a controller. The wiring of
digital inputs is also described in the "Wiring the FM 455" and "Connecting measuring
sensors and loads/actuators" chapters of the
Controlle Module FM 455
manual. The
possible usage of the digital inputs is described in the "Digital inputs" chapter of this manual.
FM 455 C
Getting Started, 02/2006, A5E00059365-03
3-1
Learning units
3.2 FM 455 C, installing and wiring
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Insert the wired front connectors into the FM 455 C. Make sure they engage with an audible
click.
FM 455 C
3-2
Getting Started, 02/2006, A5E00059365-03
Learning units
3.3 Preparations for programming
3.3
3.3
Preparations for programming
Procedure
1. Open your project in SIMATIC Manager (see the
Controller Module FM 455
manual,
chapter "Assigning parameters to FM 455".)
2. Open the "HW Config" configuration table In your project.
3. Select the FM 455 C with order no. 6ES7 455-0VS00-0AE0 from the hardware catalog,
then drag-and-drop it to the required slot (in our example: slot 5.)
4. Open the "Properties - FM 455 C PID Control" dialog box by double-clicking this
FM 455 C.
5. Note down the module address defined in the addresses tab (in this example:
512 = 200H.) You need this address in the next step to integrate the FM 455 C in the user
program.
6. Check out the "basic parameters":
– Interrupt generation: none
– Interrupt selection: none
This setting prevents the FM from outputting a diagnostics interrupt to the CPU after a
transducer error has been detected (see the
Controlle Module FM 455r
manual, chapter
"Faults and diagnostics".)
Click Parameters... to open the programming interface. The next sections will only deal with
parameters required for the sample project. We are not going to show and describe all
programming interfaces.
FM 455 C
Getting Started, 02/2006, A5E00059365-03
3-3
Learning units
3.4 Programming the analog input parameters
3.4
3.4
Programming the analog input parameters
Procedure
In the first step, select a sensor type to enable the module to process an analog input and
the corresponding controller.
1. Click of analog input 1.
– Click Sensor type.
Set the parameter "voltage 0 ... 10 V" as sensor type, then save and confirm your
settings by clicking OK. This also closes the dialog box.
– Click Normalize , then define the required physical range of values for the setpoint and
actual value.
Define a "high" limit which corresponds with 10 V at the input.
Define a "low" limit which corresponds with 0 V at the input. Save your settings by
clicking OK.
2. Close the "Analog input 1" dialog box by clicking Close.
For further information, refer to the Online Help.
3.5
3.5
Programming the error signal parameter
Procedure
Do not change the default controller type "Fixed setpoint or cascade controller."
1. Click Error signal.
– To see which sources are selected for the setpoint and actual value, click Setpoint und
Actual value A. Do not change the default "Setpoint: by function block", and "Actual
value A: conditioned analog input 1," and close both windows by clicking Cancel.
– Open the Switch Safety Setpoint window. There, you can define the module's reaction
to CPU failure, and its startup characteristics.
– On the Limit window, define the high and low limits of the setpoint. Save this setting by
clicking OK.
2. Close the Error signal window.
For further information, refer to the Online Help.
FM 455 C
3-4
Getting Started, 02/2006, A5E00059365-03
Learning units
3.6 Programming the controller parameters
3.6
3.6
Programming the controller parameters
Procedure
Click Control algorithm to view all optional settings.
The selection returns a fuzzy temperature control and a PID control option. PID action
control is set by default. Do not change this setting, and then close the "Controller 1" dialog
box. The tuning of relevant control parameters is described further down.
For further information, refer to the Online Help.
3.7
3.7
Programming the controller output parameters
Procedure
1. Click Controller output.
– There, you can define the signals or operating states triggering a transition at the
controller output - for example, to a safety manipulated value, tracking input or
external preset manipulated value. It is not required to edit those parameters.
– You can also define the limits of the manipulated value. Using the split-range function,
you can prepare the manipulated variable for output to two different analog outputs.
On this interface, too, you do not need to edit any parameters.
– Open the Switch Safety Manipulated Value window. There, you can define the
module's reaction to transducer errors, and its startup characteristics.
2. Close the "Controller Output" dialog box.
For further information, refer to the Online Help.
FM 455 C
Getting Started, 02/2006, A5E00059365-03
3-5
Learning units
3.8 Programming the analog output parameters
3.8
3.8
Programming the analog output parameters
Procedure
Click to define the signal to output at analog output 1: Do not modify the default
Manipulated value A, Controller 1.
Click to select the type of signal (actuator type) for the analog output 1. Do not change
the 0 ... 10 V default.
For further information, refer to the Online Help.
3.9
3.9
Saving parameter data and transferring those to FM 455
Procedure
You have successfully completed programming.
1. Save your settings by selecting File > Save, and then close the programming interface
with File > Exit.
2. Close the "Properties - FM455 C PID Control" dialog box by clicking OK.
3. Save your configuration data to the project by selecting Station > Save.
4. When the CPU is in STOP, select PLC > Download to module to download the
configuration data.
The data are now downloaded directly to the CPU, and transferred to FM 455 C. Provided
you backup configuration data on the CPU, the CPU always transfers those data to
FM 455 C at each STOP to RUN transition.
Test: Cycle the power supply to the CPU and FM 455 C off and on. Provided you have
properly programmed and wired the module, the red INTF and EXTF LEDs light up briefly,
and then go dark after the module has successfully completed its self-test. The yellow
backup LED is lit when the CPU is in STOP, and is switched off again when the CPU goes
into RUN.
FM 455 C
3-6
Getting Started, 02/2006, A5E00059365-03
Learning units
3.10 Integrating FM 455 C in the user program
3.10
3.10
Integrating FM 455 C in the user program
Procedure
1. In SIMATIC Manager, select File > Open... > Libraries to open the FM_PID library.
2. Copy FB 31 PID_FM from the FM 355, 455 PID Control / blocks container of the FM_PID
library to the "Blocks" container of your project.
At FB 31 PID_FM, you can
– edit operating parameters such as setpoints, or toggle from manual to auto mode
– read process values from the FM, such as the actual value, the manipulated variable,
or the current operating states
– edit controller parameters based on the process state.
3. Add a cyclic interrupt clock OB to your project such as OB 35. Open OB 35, call FB 31
PID_FM in OB 35, and the assign this FB call an instance DB, for example:
CALL "PID_FM", DB 50
4. Set the module address you noted down earlier on at parameter MOD_ADDR
(see "Programming FM 455 C").
5. At the CHANNEL parameter, set the channel number of the controller whose parameters
you want to read/write with this call.
6. You can define the setpoint at parameter SP_RE. You can toggle manual / auto mode,
and set default values at the LMN_REON and LMN_RE parameters.
7. Select File > Save to save OB 35.
8. Open the symbol editor to assign a symbolic name to the new instance DB, for example,
DB_cont1.
For further information, refer to the
FM 455 Controlle Moduler
r
manual.
3.11
3.11
Editing controller parameters of the user program
Procedure
To let you modify specific parameters while the system is in RUN, FB PID_FM first has to
read the FM 455 parameters at startup, as you do not only transfer the deltas, but rather all
parameters to the FM. Corresponding declaration at the COM_RST parameter of FB 31
PID_FM in OB 100:
SET
= "DB_cont1".COM_RST
FB 31 PID_FM will now read the FM 455 controller parameters at the first call of OB 35, and
then saves these to its instance DB. You can now edit specific values such as the controller
GAIN. Set parameter LOAD_PAR = TRUE in OB 35 to transfer the parameter data from the
instance DB to FM 455 C. Successful completion of this action is indicated by the reset of
COM_RST or LOAD_PAR (see the
FM 455 Controlle Module
manual, "The function block
PID_FM and "Assignment of the DBs".)
FM 455 C
Getting Started, 02/2006, A5E00059365-03
3-7
Learning units
3.12 Download finished example program "SIMATIC 400 Station2 (C)"
3.12
3.12
Download finished example program "SIMATIC 400 Station2 (C)"
Procedure
We recommend you use the example "SIMATIC 400 Station2 (C)" of the FM_PIDEx project
for the next tests. As a result you can try out the FM 455 C on a simulated control section
without using real processes (refer to the
FM 455 Controller Module
manual, chapter
"Application example for the FM 455 C").
1. In HW Config, replace your FM 455 C with the FM 455 C of the example.
2. In the HW Config, check the cyclic interrupt clock cycle of the OB 35. 100 ms must be set
as the execution time.
3. Safe, compile and download this configuration.
4. Copy all blocks, except system data and the SFCs 58 and 59, from the blocks container
of the sample project to the blocks container of the user program.
5. Check the module address setting at the MOD_ADDR parameter of DB 31. It must tally
with the FM 455 C address that is entered in the HW Config.
6. Download those blocks to the CPU.
3.13
3.13
Testing the controller test using the loop monitor and curve recorder
functions
Procedure
You open the loop display in the parameterization interface by opening online Test > Loop
display in the FM 455 C of the example program. The loop monitor lets you manually enter
setpoints and manipulated values to test the controller.
To open the curve recorder, call instance DB 31 of the example program by selecting
Test > Curve Recorder in the FM 455 C programming interface. You can use the curve
recorder to record the trend of a setpoint step, for example.
For further information on the loop monitor and curve recorder, refer to the Online Help (click
Help in the relevant view.)
Note
You toggle from PG setpoint mode to PG manipulated value mode by setting the
SP_OP_ON, SP_OP, LMNOP_ON and LMN_OP variables at FB 31 PID_FM. Those
variables are reserved for this specific function and should not be implemented in the user
program.
FM 455 C
3-8
Getting Started, 02/2006, A5E00059365-03
Learning units
3.14 PID controller tuning
3.14
3.14
PID controller tuning
Procedure
1. Open online in the parameterization interface with Test > Controller optimization of the
instance DB 31 of the example program.
2. Follow the instructions in the "Controller optimization" message windows:
3. Set the PG option "Manipulated value", and then click Send.
4. This opens the "Controller optimization: prepare data logging" window. Confirm the
defaults with OK.
The message box now requests you to set the manipulated value of the operating point.
Select Send to set a manipulated value at the operating point of 0%, for example. You
can then, after the actual value has settled, confirm your entries by clicking OK on the
"Controller optimization" message box.
5. Set a manipulated value of 30% in the loop monitor, and then click Send.
Data logging is now active. You now how to wait until the program detects that the
process value has reached a steady state. This detection period may seem rather long.
However, noise generated by the measured value is frequently superimposed on the
actual value. The data logging period was slightly extended in order to safely eliminate
any negative effects of this noise on the controller settings.
6. When the "reverse excitation" message is output in the "Controller optimization" message
box, click Close to close the loop monitor, and close the message "Close loop monitor"
box with OK.
7. Select the transient response, then confirm your entry with OK.
The following window shows the conveyed process and controller parameters and lets
you choose between a PID and PI controller, and for each process just one PI controller.
8. Click Load PID or Load PI. Click Yes on the next "Write parameters for controller
optimization" dialog box.
The controller parameters you determined are now saved to the offline data storage, and
to the instance DB of FB 31 PID_FM. You can now transfer those data to FM 455 C by
setting the LOAD_PAR parameter at this instance DB.
Note
Do not forget to download the modified parameters from the offline data storage to
system data of the CPU. You can only perform this operation in the HW Config
configuration table. If you forget to do so, the FM 455 C controller parameters will be
overwritten with the old data at the next CPU transition from STOP to RUN.
FM 455 C
Getting Started, 02/2006, A5E00059365-03
3-9
Learning units
3.14 PID controller tuning
FM 455 C
3-10
Getting Started, 02/2006, A5E00059365-03
Further Information
4
4.1
4.1
Tuning temperature controllers
Information
For further information, refer to the
Controller Module FM 455
manual, chapter "Parameter
optimization at a temperature controller" and to the Online Help.
4.2
4.2
Diagnostics
Error diagnostics
Errors may occur due to faulty parameters, incorrect wiring, or transducer failure. FM 455 C
indicates such errors at the EXTF LED.
For information on the analysis of such errors, refer to the
FM 455 Controller Module
manual, chapter "Faults and diagnostics."
4.3
4.3
Examples
Project FM_PIDEx
The FM_PIDEx project contains an additional set of examples for your orientation. You can
also adapt those examples to suit your application (see the
FM 455 Controller Module
manual, chapter "Examples").
FM 455 C
Getting Started, 02/2006, A5E00059365-03
4-1
Further Information
4.3 Examples
FM 455 C
4-2
Getting Started, 02/2006, A5E00059365-03
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