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A-6

FM 453 Servo Drive / Step Drive Positioning Module

C79000-G7076-C453-01

Technical Specifications

Summary of Contents for SIMATIC FM 453

Page 1: ...53 7 Human Machine Interface for the OP 17 8 Part 2 Reference Information Description of Functions 9 Writing Traversing Programs 10 Troubleshooting 11 Appendices Technical Specifications A Connecting Cables B List of Abbreviations C Index C79000 G7076 C453 01 FM 453 Servo Drive Step Drive Positioning Module Manual This manual is a component part of the FM 453 configuration package with the order n...

Page 2: ...cal 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 SIMATICR and SINECR are registered trademarks of SIEMENS AG Third parties using for their own purposes a...

Page 3: ...ctory information on positioning methods and associated definitions of terms S Installing and removing the FM 453 Chapter 3 Explains the installation and removal of the FM 453 S Wiring the FM 453 Chapter 4 Describes the connection and wiring of drives encoders and digital input output modules S Defining parameters of the FM 453 Chapter 5 Describes the parameterization and functions of Parameterize...

Page 4: ... PG S How to perform programming with STEP 7 S How to configure an operator panel interface The structure and presentation of the information in the manual are oriented to the intended uses of the FM 453 and the user s own activity It distinguishes among the following S Installation These activities include installation and wiring of the FM 453 S Programming These activities include parameterizing...

Page 5: ... 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 Federal Republic of Germany If you should encounter any problems using this manual or if you have any questions please contact the office specified on the query form at the end of this manu...

Page 6: ...vi FM 453 Servo Drive Step Drive Positioning Module C79000 G7076 C453 01 Preface ...

Page 7: ...Drive Unit 4 12 4 4 Description of the Measuring System Interface 4 16 4 5 Connecting the Encoders 4 19 4 6 Description of the I O Port 4 21 4 7 Wiring Up the Front Connector 4 28 5 Defining Parameters of the FM 453 5 1 5 1 Installation of Parameterize FM 453 5 2 5 2 Getting Started with Parameterize FM 453 5 3 5 3 Parameter Data 5 6 5 3 1 Machine Data 5 10 5 3 2 Increments 5 21 5 3 3 Tool Offset ...

Page 8: ... 7 24 7 3 7 Optimizing the Position Control 7 28 7 3 8 Startup of Stepper Motor Control 7 34 7 3 9 Realigning the Reference Point Coordinates 7 37 7 3 10 Activating Position Controller Diagnostics 7 38 7 3 11 Activating Stepper Motor Diagnostics 7 40 7 3 12 Activation of Software Limit Switches 7 41 7 3 13 Activation of Drift Compensation 7 41 7 3 14 Activation of Backlash Compensation 7 41 8 Man ...

Page 9: ...Type 9 57 9 6 Encoders 9 59 9 6 1 Incremental Encoders 9 61 9 6 2 Absolute Encoders SSI 9 64 9 6 3 Stepper Motor Without Encoder 9 67 9 6 4 Synchronization 9 68 9 7 Setpoint Processing 9 70 9 7 1 Interpolation 9 71 9 7 2 Servo Position Control 9 75 9 7 3 Stepper Motor Control System 9 81 9 7 4 Actuating Signal Driver 9 84 9 7 5 Drive Actuation 9 88 9 8 Digital Inputs Outputs Job No 101 9 92 9 8 1 ...

Page 10: ...ig 1 4 Type Plate of the FM 453 1 8 Fig 2 1 Principle of a Positioning Action 2 1 Fig 2 2 Setup for Positioning example 2 2 Fig 3 1 Replacing the FM 453 with the System Switched Off 3 4 Fig 3 2 Replacing the FM 453 with the System Switched On 3 4 Fig 4 1 Overview of Connecting Cables for a FM 453 with Servo Drive example 4 2 Fig 4 2 Overview of Connecting Cables for an FM 453 with Step Drive examp...

Page 11: ... 27 Fig 7 15 Test Movements for Optimizing the Servo Control System 7 29 Fig 7 16 Transition Function of the Position Control Circuit 7 31 Fig 7 17 Response on Different Velocity Transitions Sum Effect of Jolt Filter and Posi tion Control 7 32 Fig 7 18 Structure of the Stepper Motor Axis 7 34 Fig 7 19 Positioning Verification 7 35 Fig 7 20 Test Movements for Optimizing the Stepper Motor Control Sy...

Page 12: ...2Electrical Parameters of NL and READY2 Digital Inputs 4 25 Table 4 13Electrical Parameters of Digital Outputs 4 27 Table 5 1Data Blocks of the FM 453 5 7 Table 5 2User DB 5 9 Table 5 3Data Block Structure 5 10 Table 5 4DB Structure Machine Data 5 10 Table 5 5Machine Data List 5 12 Table 5 6DB Structure Increments 5 21 Table 5 7DB Structure Tool Offset Data 5 22 Table 5 8DB Structure Traversing Pr...

Page 13: ...ons for Automatic Mode examples 9 32 Table 9 9Function Parameters Incremental Encoders 9 62 Table 9 10Error Diagnostics Incremental encoder 9 63 Table 9 11Function Parameters Absolute Encoders SSI 9 64 Table 9 12Error Diagnostics Absolute Encoder 9 66 Table 9 13Function Parameters for Digital I Os 9 92 Table 10 1 Functions 10 3 Table 10 2M Functions 10 13 Table 11 1Error Classes Overview 11 3 Tabl...

Page 14: ...xiv FM 453 Servo Drive Step Drive Positioning Module C79000 G7076 C453 01 Table of Contents ...

Page 15: ...dule has a non volatile data memory to store parameterization data S The FM 453 is low maintenance no battery S It can be linked and adapted to user circumstances by parameterizing it as required by the system The FM 453 can be used for both simple positioning and complex traversing profiles demanding superior dynamic response accuracy and speed It is also suitable for positioning tasks in machine...

Page 16: ...of a CPU and a variety of I O modules mounted in a rack Depending on requirements the configuration of the programmable control ler can comprise one central controller CC and up to 21 expansion units EUs The FM 453 however can only be operated in the central controller or in expansion units 1 to 6 The CPU is installed in the central controller For further details on the basic requirements for the ...

Page 17: ...ts which are shown in Figure 1 1 PS CPU SMs FM 453 Operator panel OP e g OP 05 Programming device PG Rack Configuration package Power section e g SIMODRIVE 611 A SIMODRIVE e g touch probe Encoder 3x Motor 3x e g 1FT5 SIMATIC S7 400 Power section e g FM STEPDRIVE and or Motor e g SIMOSTEP and or Fig 1 1 System Overview schematic System Overview Product Summary ...

Page 18: ...nal modules SM adapts various process signal levels to the S7 400 Programming device PG configures parameterizes programs and tests the S7 400 and the FM 453 Operator panel OP the interface to the machine It serves for operation and monitoring It is not an absolute prerequisite for operation of an FM 453 Power section actuates the motor Motor drives the axis Encoder the path measurement system tha...

Page 19: ...er ize FM 453 PG STEP 7 Creation of the user program P bus K bus Operating system DBx pa rame terization data e g S Machine data S Increments S Tool offset data S Traversing programs S Status messages Diagnostic process inter rupt S Module data S Diagnostic data Load memory RAM Human machine interface Parameterization testing and diag nostics DBx pa rame terization data MPI Fig 1 2 Data Storage Co...

Page 20: ...us displays Rack Bus connector SIMATIC port Type plate Front view without con nector cover Cover Measurement system ports X2 to X4 Drive port X5 Front connector Labeling plate Status and error displays I O port X1 Module identifier Product status 453 3AH00 0AE0 2 3 4 X FM 453 Short order No 6ES7 453 3AH00 0AE0 Fig 1 3 View of the Ports and Front Panel Elements View of the FM 453 Product Summary ...

Page 21: ...he FM 453 Table 1 3 describes these LEDs and what they mean Table 1 3 Status and Error Displays LED Significance INTF rot Internal errors This LED indicates an error condition in the FM 453 see Troubleshooting Chapter 11 EXTF rot External errors This LED indicates an error condition outside the FM 453 see Troubleshooting Chapter 11 STAT yellow Status This LED indicates various statuses flashing se...

Page 22: ...he FM 453 Order number Module identifier X 2 3 4 5 6 7 Product status APPROVED 8 Marks and approvals Serial number LISTED 69B1 IND CONT EQ 1P6ES7 453 3AH00 0AE0 SVP JM123456 Made in Germany FM 453 2 The SIMATIC S7 3 4 5 6 X FM APPROVED CLASS 1 DIV 2 Group A B C D T4A SIEMENS Fig 1 4 Type Plate of the FM 453 Type Plate of the FM 453 Product Summary ...

Page 23: ...stics and troubleshooting S Data storage on the FM 453 The user program passes the operating mode to the FM The FM 453 has the following modes available S Jogging S Open loop control S Reference point approach S Incremental mode relative S Manual data input MDI S Automatic S Automatic single block Incremental or absolute encoders SSI may be connected to the measuring system port Setpoint processin...

Page 24: ... is automatically monitored after synchronization is recorded Process interrupts are triggered by such events as S Position reached S Length measurement completed S On the fly block change S Measurement on the fly Process interrupts are selected by way of machine data Automatic processing of a traversing program including subprograms created during the parameterization process A number of traversi...

Page 25: ...true to target axis approach into pro grammed target position S Acquisition of the actual value at the connected encoder incremental or absolute S Maintaining the axis in position in the face of interfering factors S For servo motors the 10 V port is used S For stepper motors the pulse direction outputs are used Positioning with stepper motors is S Control of the drive at the right speed while a m...

Page 26: ...PG PC EMERG STOP Actuating signal Actual position Safety device Mo tor Hardware limit switch Fig 2 2 Setup for Positioning example Positioning with the output of an analog actuating signal for the servo drive or pulses for the step drive The power section processes the actuating signal and delivers the proper elec tric power to the motor The power section can be S A servo drive e g SIMODRIVE 611 A...

Page 27: ...operation is also possible without the encoder The CPU executes the user program These include not only the axis but also gear trains and clutch systems All other additional equipment is covered by the term peripherals Peripherals mainly include S Limit switches to limit the positioning range safety devices S The programming device PC is used for Assigning parameters using the software Parameteriz...

Page 28: ...2 4 FM 453 Servo Drive Step Drive Positioning Module C79000 G7076 C453 01 Basic Principles of Positioning ...

Page 29: ...ammable Controller Hardware and Instal lation There are important rules which you must follow when integrating an FM 453 in the S7 400 PLC in a plant or system These rules and specifications are described in the manual S7 400 M7 400 Programmable Controller Hardware and Installation A module can be replaced during operation of the programmable controller In Section You Will Find On Page 3 1 Install...

Page 30: ...to position 2 Screw the FM 453 down torque approx 0 8 to 1 1 Nm 3 Attach the sub D plugs to the encoder and drive unit 4 Attach the front connector 5 Fit the connector cover and lock it in place 6 After the modules have been mounted you can also assign each of them a slot number Slot labels for this purpose are enclosed with the rack The numbering scheme and how to plug in the slot labels are desc...

Page 31: ...nhook the module 3 3 Module Replacement If a defective FM 453 has to be replaced and no programming device PC is available for parameterization or the module is to be replaced while the sys tem is switched on please note the following start up requirements CPU FM S An SDB w 1 000 should be generated in order to complete the startup for storing the parameter data see Section 5 5 S In the user progr...

Page 32: ...acing the FM 453 with the System Switched Off 2 Replacing the FM 453 with the system switched on CPU is at STOP see 1 CPU remains in RUN Remove the FM 453 acc to Section 3 2 No 1 Install the FM 453 2 Attach the sub D connector 3 Attach the front connector FM 453 restart Yes FM 453 ready FM 453 has been inserted in user program of the OB 83 see Section 6 CPU switches to STOP continue see below Yes ...

Page 33: ...ne directive in order to identify sources of danger affecting the complete system Please refer also to the following chapters in the S7 400 M7 400 Program mable Controller Hardware and Installation manual S Guidelines for handling of electrostatic sensitive devices ESDs Appen dix B S Configuring the electrical installation Chapter 4 For further information about EMC guidelines we recommend the des...

Page 34: ...be MPI connecting cable Setpoint cable Measuring system cables Drive unit e g SIMODRIVE 611 A e g absolute encoder SSI e g linear scale with EXE CPU OP SIMATIC S7 400 X5 X2 to X4 e g incremental en coder with RS 422 e g ROD 320 built in encoder in 1FT5 motor Dig outputs e g direction of rotation Front connector X1 5 6 7 8 9 10 11 12 13 14 15 16 17 18 PS Channels 1 to 3 Fig 4 1 Overview of Connecti...

Page 35: ... are linked together PG PC FM 453 Dig inputs e g touch probe MPI connecting cable CPU OP SIMATIC S7 400 X5 Dig outputs e g direction of rota tion Front connector X1 5 6 7 8 9 10 11 12 13 14 15 16 17 18 PS SIEMENS SIEMENS Drive unit e g FM STEPDRIVE Setpoint cable Fig 4 2 Overview of Connecting Cables for an FM 453 with Step Drive example FM 453 with Step Drive Wiring the FM 453 ...

Page 36: ...ervo drives Setpoint cable 6FX2 002 3AB03 1VVV Connection between FM 453 two step drives and one servo drive Measuring system cable 6FX2 002 2CD01 1VV0 see Order No E86060 K4490 A001 A4 Incremental encoder with RS 422 and FM 453 EXE with linear scale Measuring system cable 6FX2 002 2CE01 1VV0 see Order No E86060 K4490 A001 A4 ROD 320 encoder with 1FT5 motor and FM 453 Measuring system cable 6FX2 0...

Page 37: ... input can be con nected to the 50 pin male sub D connector X5 of the FM 453 Mixed config urations for up to three drives are possible here Additionally the FM 453 provides one enable signal per channel Figure 4 3 shows the installation position and identification of the plug on the module FM 453 1 17 18 34 33 50 X5 ANALOG OUT STEP CONTR 1 3 Fig 4 3 Position of X5 Connector Connector for the Drive...

Page 38: ... BOOST1_N O 29 PWM2_N BOOST2_N O 45 PWM3_N BOOST3_N O 13 READY1_1_N I 30 READY1_2_N I 46 READY1_3_N I 14 not assigned 31 not assigned 47 not assigned 15 RF1_1 K 32 not assigned 48 RF1_2 K 16 RF2_1 K 33 not assigned 49 RF2_2 K 17 RF3_1 K 50 RF3_2 K For step drives PULSE 1 3 PULSE 1 3 _N Clock pulse true and negated DIR 1 3 DIR 1 3 _N Direction signal true and negated ENABLE 1 3 ENABLE 1 3 _N Enable...

Page 39: ... A reference potential analog ground for the setpoint signal internally connected with the logic ground S SERVO ENABLE RF A relay contact pair used to switch the axis specific enable of the power section The signal is activated via the user program of the CPU Signal parameters of the outputs The setpoint is output as an analog differential signal Table 4 3 Electrical Parameters of the Setpoint Sig...

Page 40: ...ng speed S DIRECTION The signal levels which are output determine the direction of rotation of the motor Signal ON Rotation to left Signal OFF Rotation to right S ENABLE The FM 453 activates this signal anytime the cyclical control operating mode is detected Signal ON Power activation is enabled Signal OFF Power activation is disabled motor is current free S PWM BOOST This signal is for purposes o...

Page 41: ...ance RL 55 Ω Output current IO 60 mA Pulse frequency fp 1 MHz Connecting cable Permissible length l for balanced transfer 35 m for unbalanced transfer 10 m READY1_N This input is non isolated and works with a 5V level A floating output switching contact or optical coupler may be connected The FM 453 inter prets this input as a Ready message from the power section An alternative connection option i...

Page 42: ...l v 10 m FM 453 VOD VOH RL IO GND GND GND IO VOL RL RL Balanced transfer with RS422 compliant floating differential input Balanced transfer with floating optocoupler input Non balanced transfer with floating optocoupler input Power section Fig 4 4 Connection Options for Drive Port Output Signals Signal Wiring Out put Signals Wiring the FM 453 ...

Page 43: ... connection options for the READY1_N input l v 35 m FM 453 GND Actuation of the READY1_N input by floating contact Actuation of the READY1_N input by floating optocoupler GND Power section l v 35 m 2 k 5 V 2 k 5 V Fig 4 5 Connection of the READY1_N Input Signal Connection for the READY1_N Input Wiring the FM 453 ...

Page 44: ... mend that you not ground the shielding on the drive unit side The cable set supplied as an accessory offers excellent immunity against interference For servo drives you use the 10 V interface Proceed as follows 1 Wire the free cable end of the connecting cable to the terminals of the drive unit The terminal identifiers on the cable ends indicate the proper terminals for SIMODRIVE units 2 Open the...

Page 45: ... for SIMODRIVE drive units Order No 6FX2 002 3AD01 1VVV The connecting cable is available in a variety of lengths see Order No E86060 K4490 A001 A4 The following Figure shows you how to connect an FM 453 with a SIMODRIVE 611 A drive unit FM 453 SIMODRIVE SIEMENS Connecting cable Drive unit e g SIMODRIVE 611 A X5 READY2 channels 1 to 3 Fig 4 6 Connecting a SIMODRIVE 611 A Drive Unit Wiring the FM 4...

Page 46: ...ont door Connecting cable The connecting cable is a cable set for three channels with a step drive Order No 6FX2 002 3AB04 1VVV 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 FM 453 Connecting cable X5 SIEMENS SIEMENS Drive unit e g FM STEPDRIVE READY2 c...

Page 47: ...rive on channel 2 Servo drive on channel 3 Connecting cable The connecting cables are a cable set for three channels with S One step drive and two servo drives Order No 6FX2 002 3AB02 1VVV S Two step drives and one servo drive Order No 6FX2 002 3AB03 1VVV The connecting cable is available in a variety of lengths For length code see Order No E86060 K4490 A001 A4 FM 453 Connecting cable X5 SIEMENS S...

Page 48: ...15 8 9 ENCODER 2 1 15 8 9 ENCODER 3 1 15 8 9 X2 X3 X4 Channel 1 Channel 2 Channel 3 Fig 4 9 Location of Connectors X2 to X4 Identifier X2 X3 X4 ENCODER 1 3 Type 15 pin female sub D plug connector Table 4 7 Pinout of Connectors X2 to X4 Pin Encoder Type Pin Encoder Type Pin Incremental Absolute Type Pin Incremental Absolute Type 1 not assigned 9 MEXT VO 2 CLS O 10 N I 3 CLS_N O 11 N_N I 4 P5EXT VO ...

Page 49: ... shaper EXE that converts the signals to 5 V levels Both encoders that can be connected directly and EXEs must meet the fol lowing requirements Incremental Encoders Transfer procedure Differential transfer with 5 V rectangular signals such as RS422 standard Output signals Track A as true and negated signal Ua1 Ua1 Track B as true and negated signal Ua2 Ua2 Zero signal N as true and negated signal ...

Page 50: ...ons of the 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 Supply Voltage Tolerance Power Consumption Max Cable Length 5 V DC 4 75 V to 5 25 V 300 mA 25 m 82 ft 5 V DC 4 75 V to 5 25 V 210 mA 35 m 115 ft 24 V DC 20 4 V to 28 8 V 300 mA ...

Page 51: ...e as well as cross sections large enough for the power supply to the encoders When cables are routed unprotected the cable shielding must be connected to a grounded shielding bus over a large contact area in the proximity of the FM 453 and the sensors e g absolute encoder SSI e g ROD 320 built in en coder in 1FT5 e g linear scale with EXE FM 453 Connecting cable X3 X3 X3 X3 e g incremen tal encode...

Page 52: ...e 3 Lock the connector in place with the knurled screws Close the connector cover Cable set for incremental encoders with RS 422 or EXEs for connection of linear scales Order No 6FX2 002 2CD01 1jj0 Cable set for built in ROD 320 encoders with 17 pin round plugs Order No 6FX2 002 2CE01 1jj0 Cable set for absolute encoders SSI with a free cable end Order No 6FX2 002 2CC01 1jj0 Connecting cables are ...

Page 53: ... to the front connector S One LED each for INTF EXTF and STAT S 3 LEDs for zero position signal input channels 1 to 3 S 3 LEDs for standby signal 2 input channels 1 to 3 S 12 LEDs for digital inputs 1 to 3 channels 1 to 3 S 12 LEDs for digital outputs 1 to 3 channels 1 to 3 Figure 4 11 shows the location of the front connector and the labels Front connector X1 FM 453 LED indicators External label ...

Page 54: ... 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 LED indicators 1L M2 4L 4L 3L 3L M2 2L 2L M2 M1 M1 M1 1NL 2NL 3NL 1READY2 2READY2 3READY2 1I0 1I1 1I2 1I3 2I0 2I1 2I2 2I3 3I0 3I1 3I2 3I3 1Q0 1Q1 1Q2 1Q3 2Q0 2Q1 2Q2 2Q3 3Q0 3Q1 3Q2 3Q3 NL 1 2 3 1 2 3 READY2 1I0 1I1 1I2 1I3 2I0 2I1 2I2 2I3 3I0 3I1 3I2 3I3 1Q0 1Q1 1Q2 1Q3 2Q0 2Q1 2Q2 2Q3 3Q0 3Q1 3Q2 3Q3 Rack No Slo...

Page 55: ... 1L 13 M1 Terminals 12 13 and 14 are connected together on the module 14 M1 module 15 1I0 Digital input 0 from channel 1 16 1I1 Digital input 1 from channel 1 17 1I2 Digital input 2 from channel 1 18 1I3 Digital input 3 from channel 1 19 M2 Reference potential for auxiliary voltage 2L to 4L 3 20 2I0 Digital input 0 from channel 2 21 2I1 Digital input 1 from channel 2 22 2I2 Digital input 2 from ch...

Page 56: ... from channel 3 44 3Q1 Digital output 1 from channel 3 45 3Q2 Digital output 2 from channel 3 46 3Q3 Digital output 3 from channel 3 47 M2 Reference potential for auxiliary voltage 2L to 4L 3 48 M2 1 In applications using encoders 1L with reference 1M must always be connected to a 24 V auxiliary voltage 2 If this channel is not utilized the associated auxiliary voltage must not be connected 3 Term...

Page 57: ...dy of the drive power section can be con nected for each channel to a further input The message signal is specified in MD37 see Section 5 3 1 Note The READY2 input is configured as an isolated optical coupler input See Section 4 7 for details about wiring Table 4 12 Electrical Parameters of NL and READY2 Digital Inputs Supply voltage 24 V DC permissible range 20 4 28 8 V Electrical isolation Yes I...

Page 58: ...rive on channel 1 of the FM 2L M2 30 9 29 48 X1 FM 73 74 Drive unit High side switch or relay contact Actuation of standby signal by high side switch or relay contact e g SIMODRIVE 611 READY2 channel 1 47 Fig 4 13 Connection of Standby Signal Power from Auxiliary Voltage L Figure 4 14 shows how to power the standby signal from the drive unit FM Actuation of standby signal by high side switch or re...

Page 59: ... value range Lamp load S at ambient temperature of 60_C Rated value Permissible value range 0 5 A 5 mA to 0 6 A over auxiliary voltage range max 5 W 0 1 A 5 mA to 0 12 A over auxiliary voltage Short circuit overload protection Yes for overtemperature switches for each output separately Switching rate S Resistive load max 100 Hz S Inductive load max 0 25 Hz with exter nal quenching Polarity reversa...

Page 60: ...nnector Figure 4 15 shows how to lay the lines to the front connector e g touch probe FM 453 Digital out puts Digital in puts ÂÂÂ ÂÂÂ ÂÂÂ Cable grip Shielding bus Front connector with screw type terminals without cover Fig 4 15 Wiring of the Front Connector Wiring the Front Connector Wiring the FM 453 ...

Page 61: ...essary You can use ferrules with or without insulated collars to DIN 46228 T 1 or T 4 Type A in the standard version for front connectors with screw type or spring loaded terminals You can connect two lines each measuring 1 0 mm2 In this case special fer rules must be used Please refer to the manual S7 400 M7 400 Programmable Controller Hard ware and Installation Note To provide optimum immunity t...

Page 62: ...0 8 Nm 6 Tighten the cable grip on the cable strand 7 Close the front connector 8 Label the connections on the supplied label 9 Plug front connector onto the module For further details on wiring up a front connector please refer to the manual S7 400 M7 400 Programmable Controller Hardware and Installation When using shielded cables the following additional steps are necessary 1 The cable shielding...

Page 63: ...processing option see Table 5 9 Offline editing in the File menu see Table 5 9 PG STEP 7 HW CONFIG Setup exe Parameter ization forms Rack parameterization Group selection Acti vate interrupts basic pa rameters S Parameterization tool Parameterize FM 453 S Function blocks S Preconfigured user interface for OPs User data block Data blocks DB S DB MD S DB SM S DB TO S DB NC FM 453 1 DB per channel 1 ...

Page 64: ...s and is installed complete Install the software as follows 1 Insert diskette 1 in the floppy disk drive of your programming device PC 2 In Windows 95 start the interactive routine for installing the software by double clicking the Software symbol in the Control Panel 3 Select the floppy disk drive and the file Setup exe in the dialog box and start the installation program 4 Follow the instruction...

Page 65: ...ion below outlines only the most important steps 1 Start the SIMATIC Manager and open your project 2 Insert a SIMATIC 400 station in the menu Insert Station 3 Select the SIMATIC 400 station Call up the S7 hardware configuration from the menu Edit Open Object 4 Select a rack and assign it 5 Select the FM 453 positioning module with the correct order number from the module catalog and insert it in t...

Page 66: ...eterization by select ing the menu View Overview The FM 453 module for universal positioning is parameterized in each chan nel by way of parameter DBs that reside in memory on the module Here a key function is performed by the Machine data data block DB MD since it is always needed regardless of what technological function the module performs All other parameter DBs are only needed as a function o...

Page 67: ...ou have moved the window to the correct position release the mouse button When you have configured your project you can call up the Properties screen in S7 Configuration by selecting the module and activating the menu command Edit Object Properties The parameterization user interface has an integrated help system to support you when you set the parameters of the positioning module To call up the i...

Page 68: ...ser data from 1001 to 1239 for channel 1 from 1301 to 1539 for channel 2 from 1601 to 1839 for channel 3 The MD SM TO and NC data blocks are transferred to the FM 453 and re side in memory there Parameterization of SM TO and NC may be omitted if the associated func tions are not used The user data block must be stored in the CPU Only then can it be filled with data online see Section 6 Parameteriz...

Page 69: ...hannel 2 DB No 1830 for channel 3 Block size rounded in bytes 460 Increments serve in the Relative incremental operating mode as user definable relative path distances for individual positioning You can define from 1 to 100 increment sizes see Section 5 3 2 Modifications can be made in all operating modes even in Incre mental relative mode during movement The modifications of the increments must a...

Page 70: ...luding the subprogram preselection of the program is canceled You must then select the program again A modification can be made to a program when BL 0 program call end of program and on Stop System data block SDB w 1 000 For module replacement without programming device All the parameter data of the FM 453 DB MD DB SM DB WK DB NC are stored in the SDB w 1 000 for channels 1 to 3 This SDB is loaded...

Page 71: ...ovided the DB itself has been loaded to the CPU S Module address1 S Channel address1 S Channel offset1 S Zero offset S Set actual value S Set actual value on the fly S Set reference point S Setpoint for increment S Speed level 1 S Speed level 2 S Voltage level 1 S Voltage level 2 S MDI block S MD block on the fly S Program selection program number S Program selection block number S Program selecti...

Page 72: ... in the following sections 5 3 1 Machine Data Table 5 4 gives you an overview of the structure of the machine data data block DB MD DB No 1205 for channel 1 DB No 1505 for channel 2 DB No 1805 for channel 3 Table 5 4 DB Structure Machine Data Address Variable Type Value Significance of the Variables Comment DB header 36 bytes 0 WORD Rack slot Module address 2 WORD DB No w 1000 As in DB header 4 DW...

Page 73: ...ctions in Section 7 Starting up the FM 453 Note The measurement system MD7 must match the measurement system speci fied in the other DBs The measurement system raster MSR is the smallest distance unit in the active system of measurement If at some point you have failed to take this precaution 1 Delete all data blocks of the relevant channel which do not match the measurement system or clear the me...

Page 74: ... of measurement 1 1 10 3 mm 2 10 4 inch 3 10 4 degrees 4 10 2 degrees DWORD 9 4 8 K Axis type 0 0 linear axis 1 rotary axis DWORD 9 5 9 K Rotary axis end2 36 105 0 1 000 000 000 DWORD MSR 10 K Encoder type 1 0 not present 1 incremental encoder 3 absolute encoder SSI 13 bit 4 absolute encoder SSI 25 bit 13 absolute encoder SSI 13 bit 14 absolute encoder SSI 25 bit DWORD GRAY Code GRAY Code Binary C...

Page 75: ... center 8 Direction RPS edge 9 Direction RPS edge DWORD Zero reference mark See zero reference mark selection Fig ure 5 5 9 2 3 19 K Direction adjustment 0 0 invert direction of measurement not for sensor type 0 1 invert direction of drive rotation BITFIELD32 9 7 20 K Hardwaremonitoring 0 0 encoder cable break 1 error absolute encoder 2 pulse monitoring incremental encoder 3 voltage monitoring enc...

Page 76: ...wledgment controlled after positioning 5 time controlled 6 acknowledgment controlled DWORD serial output of up to 3 M functions in NC block 10 3 9 1 33 K Output time M function 10 1 100 000 DWORD ms rounded to 2 ms steps 34 K Digital inputs2 0 0 external start 1 input for enable 2 external block change 3 set actual value on the fly 4 measure 5 RPS for search for reference 6 reversing switch for se...

Page 77: ...9 E Minimum following error dynamic 0 0 no monitoring 1 1 000 000 DWORD MSR 9 7 40 E Acceleration 1 000 0 without ramp 1 100 000 DWORD 103MSR s2 9 7 41 E Deceleration 1 000 1 100 000 s2 42 E Jolt time 0 0 10 000 DWORD ms 9 7 43 E Set voltage max 8 000 1 000 10 000 DWORD mV 9 7 44 E Offset compensation 0 5 000 5 000 DINT mV 9 7 45 E Actuating signal ramp 0 0 10 000 000 voltage ramp if MD61 0 freque...

Page 78: ...0 Servomotor with servo position control simple characteristic 1 Stepper motor with servo position control simple characteristic 7 Stepper motor without servo posi tion control stepped characteristic DWORD 9 7 With certain combinations of machine data restrictions in the value range arise for non processing of the machine data These dependencies are verified on acceptance of the MD DB or individua...

Page 79: ...09 109 109 1 active 109 109 Internal generation of absolute traversing range limits VFBABS MWFAKTOR VFBABS 1 109 w 1 109 MWFAKTOR Checks for servo motor and stepper motor MD9 check MD8 MD10 MD61 Permissible Rotary Axis End 0 any not used 1 0 0 0 1 7 MD18 MD23 60 000 1 1 7 w 4 MD23 60 000 Sampling time 1 0 4 MD9 mod UMWEG 0 p g vMD9v VFBABS 3 13 MD9 mod UMWEG 0 VFBABS 4 14 MD14 UMWEG mod MD9 0 Note...

Page 80: ...itches 0 MD21 109 MD22 109 1 0 MD21 VFBABS MD10 MD22 VFBABS 0 1 MD21 MD22 3 13 MD22 MD21 UMWEG 1 0 MD21 MD9 0 MD22 MD9 MD21 MD22 4 14 MD22 MD21 MD14 UMWEG MD28 check Permissible Velocity 10 MD28 MD23 MD29 check MD10 Permissible Velocity 3 4 13 14 any not used 0 1 10 MD29 MD23 MD31 check MD30 MD10 Permissible Directional Reference of Backlash 0 0 0 1 3 4 13 14 1 2 MD34 check Permissible BYTE0 MD34 ...

Page 81: ... factor 2 14 UMWEG MD52 214 MD53 check MD53 Permissible Increment Number Per Current Sourcing Cycle 0 0 MD53 4 MD55 check Permissible frequency MD54 MD55 MD56 MD56 check Permissible frequency MD56 MD23 MWFAKTOR 60 MD57 check Permissible Acceleration MD57 SMAMIN MD58 check MD58 Permissible Acceleration 0 0 SMAMIN MD58 MD57 MD59 check MD59 Permissible Acceleration 0 0 SMAMIN MD59 MD60 check MD60 MD5...

Page 82: ...ev MD37 24 control signal BMN active Zero pulse encoder motor internal incremental precision BMN 1 per rev Zero reference mark not defined 1 absolute encoder 1 incremental encoder 0 not encoder 0 servo motor 1 7 stepper motor 0 0 0 1 pulse per revolution Encoder connection via connectors X2 to X4 Connection of neutral conductor input via connector X1 1 zero pulse encoder n w 4 n pulses per current...

Page 83: ...DWORD Reserved 8 WORD Error No from FM With MMI services 10 WORD 1 Channel number 12 2 STRING SM DB identifier type 2 ASCII characters 16 DWORD 453 Module identifier FM 453 20 4 CHAR 0 Version number block number DB structure 24 DWORD 1 3 Measurement system grid per MD7 Unit of measurement 28 WORD 0 1 Parameter DB backup Job via MMI 30 WORD Reserved 32 DWORD 0 109 Increment 1 36 DWORD 0 109 Increm...

Page 84: ...With MMI services 10 WORD 1 Channel number 12 2 STRING TO DB identifier type 2 ASCII characters 16 DWORD 453 Module identifier FM 453 20 4 CHAR 0 Version number block number DB structure 24 DWORD 1 3 Measurement system grid per MD7 Unit of measurement 28 WORD 0 1 Parameter DB backup Job via MMI 30 WORD Reserved 32 DINT DINT DWORD 109 109 109 109 0 109 Tool length offset 1 Wear value 1 absolute Wea...

Page 85: ...ffset 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 5 7 Entering Values for Tool Offset Data Input of Values Defining Parameters of the FM 453 ...

Page 86: ... address 2 WORD DB No w 1000 As in DB header 4 DWORD Reserved 8 WORD Error No from FM With MMI services 10 WORD 1 Channel number 12 2 STRING NC DB identifier type 2 ASCII characters 16 DWORD 453 Module identifier FM 453 20 4 CHAR 0 Version number block number DB structure 24 DWORD 1 3 Measurement system grid per MD7 Unit of measurement 28 WORD Reserved 30 WORD Reserved 32 18 STRING ASCII char NC p...

Page 87: ... up to 18 characters 2 N block number G command G1 G2 G3 X value F value M command M1 M2 M3 D No tool offset number L No P No for NC programming see Chapter 10 You must enter the block number N first and in ascending order The rest of the inputs may be in any desired sequence Input separators as a blank You must enter characters in upper case letters You can also use the guided input area at the t...

Page 88: ...fields with the cursor and enter the values 4 Traversing programs Traversing programs are input in text format A comment column is included in the tables for MD SM and TO values This comment is not stored in the data block It can be printed out or stored with the data in the file on export The following table shows you an overview of the menus of Parameterize FM 453 Table 5 9 Menus of Parameterize...

Page 89: ... channel 2 Channel 3 for channel 3 Traversing program Opens one of the DB NC stored on the programming device PC Channel 1 for channel 1 Channel 2 for channel 2 Channel 3 for channel 3 Import Ctrl O Opens a data block which has been saved as a file Close Ctrl F4 Closes the window of the current DB Save Ctrl S Saves the current data block on the programming device PC Export Saves the current data b...

Page 90: ...rd Paste Ctrl V Inserts the clipboard contents at the cursor position Replace cells Overwrites the field in a table with the clipboard contents Copy channel Allows data blocks for a channel to be copied to another channel Search Ctrl F Searches for text the text may also be a number e g MD No Default values Fills the current data block with default values Destination system Transfers data and data...

Page 91: ...e Clear flash memory Clears the FLASH memory on the FM 453 Test Startup and troubleshooting pStartup Opens the startup window Module control and observation Channel 1 for channel 1 Channel 2 for channel 2 Channel 3 for channel 3 pTroubleshooting Opens the troubleshooting window Displays faults in the module Channel 1 for channel 1 Channel 2 for channel 2 Channel 3 for channel 3 pService data Opens...

Page 92: ...anges all parameterization windows Changes to a specified win dow Arrange Arranges all windows Overlapping Shift F5 Stacks all windows one behind the other Horizontal Spaces all windows uniformly top to bottom Vertical Spaces all windows uniformly left to right Arrange icons Arranges parameterization window icons Close all Closes all open windows p1 opened window 1 Changes to window window name n ...

Page 93: ...always match the parameter data on the FM 453 when start up is complete Note SDB w 1 000 should not be created until start up is finished If you need to modify the data subsequently you should generate SDB w 1 000 again and load it into the CPU You can delete the previous SDB before you load the new one however the new SDB automatically over writes the old one when it is generated The old SDB and ...

Page 94: ... open Copy the system data from the offline project in CPU S7 Pro gram Blocks System data into the online project drag with the mouse or select Copy Paste 2 Second method Select the system data in the SIMATIC Manager in CPU S7 Pro gram Blocks System data Activate the menu Target system Load or the right mouse button to load the system data into the CPU or Use the menu Target system Load in EPROM m...

Page 95: ...ct 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 Delete the system data 4 Transfer the system data to the CPU again see above Deleting SDBs in the CPU Defining Parameters of the FM 453 ...

Page 96: ...5 34 FM 453 Servo Drive Step Drive Positioning Module C79000 G7076 C453 01 Defining Parameters of the FM 453 ...

Page 97: ... channel P bus K bus CPU FM 453 S7 400 Online Offline PG STEP 7 STL LAD Editor Setup exe UDT 1 FC S Parameterize FM 453 parameter ization tool S Function blocks FCs UDT 1 and example programs S Preconfigured user interface for OPs User defined data type A DB is created in STEP7 User DB The source is UDT1 User DB 1 DB each per channel Data blocks The user DB can be edited on the CPU with Parameteri...

Page 98: ... use Parameterize FM 453 to fill the user DB in the CPU with data You must create a user DB for each channel The following table gives you a general view of the function block package FCs for the FM 453 Table 6 1 Technology Functions for the FM 453 Function Block No Function Block Name Significance FC 1 INIT_DB Initialize user DB FC 2 MODE_WR Control operating modes and process write jobs FC 3 RD_...

Page 99: ... and write job processing FC RD_COM for reading data is only required if the FM data are to be pro cessed in the user program e g for display purposes Regardless of which or how many technology functions you use you need a data block with a predefined structure UDT 1 to contain all the necessary data or data storage areas This data block is implemented as a user data block and one way to set its d...

Page 100: ...IT_DB FC 1 Initialize user DB You can use FC INIT_DB to initialize specific areas of your user DB For this purpose you can call FC INIT_DB in OB 100 or OB 83 Remove Insert interrupt once for each channel The FC performs the following actions 1 Enters addressing values in the user DB FM address Channel address Offset address 2 Deletes the following structures in the user DB CONTROL_SIGNALS CHECKBAC...

Page 101: ...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 The DB number is passed when you call the FC with the DB_NO parameter Errors which occur are indicated in the binary result BIE 0 Possible errors are Unknown channel number CH_NO the user DB is not initialized An example call is shown below for FC INIT_DB S...

Page 102: ... START CONTROL_SIGNALS DIR_P and CONTROL_SIGNALS DIR_M are cleared when a start is detected edge generation of signals for FM 3 Executes the write job from the user DB JOB_WR transfers the associated data from the user DB and displays the write job status 4 Generates the status bits JOB_WR MODE_BUSY operating mode busy i e started and JOB_WR POS_REACHED position reached Call in LAD Notation ladder...

Page 103: ...nsfer system data to FM according to job no FC 2 FM 453 Set mode and correspond ing control signals Evaluate mode and corre sponding checkback signals Enter system data 1 1 Before the appropriate write job no is set in the user DB the system data to be written must be entered e g write job possible Evaluate status 4 3 1 2 Errors which occur are indicated in the binary result BIE 0 Possible errors ...

Page 104: ...n user DB FC Write data Binary result Error on initialization 6 2 1 Process Write Jobs Before a write job is processed the data area belonging to the write job must be filled with the appropriate values The last write job must have finished processing i e JOB_WR NO in the user DB data byte DBB0 must have been cleared and status bit JOB_WR DONE enabled You initiate a write job by entering the write...

Page 105: ...INGLE_COMMANDS 11 42 0 x x x x x x 9 3 3 ZERO_OFFSET 12 44 0 x x x x x 9 3 4 SETTING_ACT_VALUE 13 48 0 x x x x x 9 3 5 FLYING_SETTING_ACT_VALUE 14 52 0 x x x x 9 3 6 DIG_IO digital outputs 15 150 0 x x x x x x 9 8 2 MDI_FLY 16 152 0 x 9 2 5 PROG_SEL program selection 17 172 0 V 9 2 6 REQ_APP request application data 18 176 0 x x x x x x 9 3 7 TEACH_IN 19 180 0 x x x 9 3 8 SETTING_REFERNCE_POINT 21...

Page 106: ...the axis is not parameterized because test mode is active because no mode is active because the selected mode is not yet active In this case you can leave the write job JOB_WR or delete it FC MODE_WR clears the bit when all the above conditions have been met UNKNOWN 3 1 Write job unknown The write job JOB_WR which you specified is not within the known range see error evaluation FC MODE_WR clears t...

Page 107: ...8 PARA DF BF FS TFGS 29 PBR T L WFG BL SFG 30 BAR 31 PEH FIWS FR FR ME SYN 32 MNR 33 AMF Single settings in the user DB starting at address 40 and single commands in user DB starting at address 42 are also required in order to control the FM 353 These are transferred by means of write jobs system data Single Settings Single Commands Length measurement Inprocess measurement Retrigger reference poin...

Page 108: ...ntrol Signals BP MODE PA RAMETER Operating mode parameters Velocity levels 1 and 2 Voltage frequency levels 1 and 2 Increment selection 1 100 254 operating mode MODE Operating mode Jogging 01 Open loop control 02 Reference point approach 03 Incremental relative 04 MDI 06 Automatic 08 Automatic single block 09 R DIR_P Direction plus R DIR_M Direction minus STP STOP Stop ST START Start OVERR OVERRID...

Page 109: ...mode AMF STR_MF Modify M function PBR PR_BACK Program scanning backward T L DT_RUN Dwell time running PEH POS_ROD Position reached and stopped FR GO_P Go_plus FR GO_M Go_minus ME MSR_DONE Measurement done SYN SYNC Channel synchronized DF DATA_ERR Data error FIWS FAVEL Flying actual value done TFGS TST_STAT Switchover P BUS port done WFG WAIT_EN Wait for external enable PARA PARA Channel parameteri...

Page 110: ...ted data into the user DB and displays the read job status Call in LAD Notation ladder diagram Call in STL Notation statement list EN ENO FC RD_COM DB_NO RET_VAL CALL RD_COM DB_NO RET_VAL The following table describes the parameters of this FC Name Data Type P Type Meaning DB_NO WORD I Data block number RET_VAL INT Q Return code of SFC 59 RD_REC Parameter types I input parameter Q output parameter...

Page 111: ...oach SM Incremental relative MDI MDI Manual Data Input A AE Automatic Automatic single block Operating Modes System Data Job no Addr in user DB T STE REF SM MDI A AE See Sec tion Display data is data parameters returned by the FM DIG_IO dig inputs outputs 101 150 0 x x x x x x 9 8 OP_DAT basic operating data 102 198 0 x x x x x x 9 3 11 ACT_BLCK active NC block 103 230 0 x 9 3 12 NXT_BLCK next NC ...

Page 112: ...by FC RD_COM as soon as it has finished a read job also with errors This bit is cleared by FC RD_COM when a new read job begins You can clear this bit manually IMPOSS 2 1 Read job not possible at the present time Read job processing is not possible because the axis is not parameterized because no mode is preselected because test mode is active In this case you can leave the read job JOB_RD NO or d...

Page 113: ..._FM JOB_RD IMPOSS SPB DARD L B 16 66 T DB_FM JOB_RD NO DARD CALL RD_COM DB_NO W 16 1 RET_VAL FEHLERCODE_LESEN UN BIE S FEHLER_LESEFKT Read job busy Read job processing impossible Jump to call Read job 102 for basic operating data Store in job box Call read data FC DB number Return value Binary result Error on initialization Example call Programming the FM 453 ...

Page 114: ..._DIAG The following table describes the parameters of the FC DIAG_RD Name Data Type P Type Meaning DB_NO WORD I Data block number RET_VAL INT Q Return code of SFC 59 RD_REC IN_DIAG BOOL I O Initiate reading of diagnostic data is cleared after execution of FC 4 Parameter types I input parameter Q output parameter I O in out parameter initiation parameter This function works together with a user DB ...

Page 115: ...on in the user DB starting at address 72 and calls FC 4 Calls FC 6 On operating error addr in user DB 80 7 82 7 84 7 For further error specification by reading out DS 164 channel 1 DS 199 channel 2 DS 234 channel 3 in OB 1 see example application 2 The following table contains the diagnostic information for channels 1 to 3 DIAGNOSTIC_INT_INFO in the user DB starting at address 72 Table 6 4 Diagnos...

Page 116: ...oubleshooting for channel 1 9 Free 10 Analog byte 8 for channel 2 11 Free 12 Analog byte 8 for channel 3 13 15 Free In a diagnostic event bytes 0 to 3 are automatically transmitted to the CPU and the diagnostic organization block OB82 is called up The diagnostic OB should be included in the user program otherwise the CPU will go to the Stop state Byte 0 contains group error messages that are set s...

Page 117: ...te Bit 12 0 7 Byte Bit 10 0 7 Channel 1 Channel 2 Channel 3 Fig 6 3 Evaluation of Diagnostic Information An example call is shown below for FC DIAG_RD STL Explanation S DIAG_READ CALL DIAG_INF DB_NO W 16 1 RET_VAL FEHLERCODE_LESEN IN_DIAG DIAG_READ UN BIE S FEHLER_LESEFKT Initiate read function Call diagnostic information FC DB number Return value Initiate reading Binary result Error on initializa...

Page 118: ...rameter When the FM 453 is used centrally the Read job is processed within a single function block callup When the FM 453 is used in a distributed configuration it may take several function block callups to process the Read job 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 An example call is shown below for FC D...

Page 119: ...ameter Q output parameter I O in out parameter initiation parameter This function works together with a user DB The DB number is passed when you call the function with the DB_NO parameter Reading of the measured values MEASUREMENT_VALUES in user DB starting at address 60 is started when you set the in out parameter IN_MSR to one The parameter is reset by the FC after the job is executed The FC mus...

Page 120: ...TOSS_LESEFKT U ANSTOSS_LESEFKT SPB NWE UN BIE S FEHLER_LESEFKT NWE NOP 0 Measurement completed checkback signal Edge flag for Measurement com pleted Set initiation parameters CALLUP OF FC MSRMENT Initiation bit is still set Communication error Indicate error in Read function An example call is shown below in OB 40 STL Explanation S MW_LESEN CALL MSRMENT DB_NO W 16 1 RET_VAL FEHLERCODE_LESEN IN_MSR...

Page 121: ...4 1 4 BIT1_4 BOOL FALSE Reserved 1 5 1 5 BIT1_5 BOOL FALSE Reserved 1 6 1 6 MODE_BUSY BOOL FALSE Start an operating mode 1 1 1 7 POS_REACHED BOOL FALSE Position reached 2 0 END_STRUCT Job box for FC RD_COM 2 0 JOB_RD STRUCT Read jobs 2 0 2 0 NO BYTE B 16 0 Read job number 3 0 3 0 BUSY BOOL FALSE Read job busy 3 1 3 1 DONE BOOL FALSE Read job finished 3 2 3 2 IMPOSS BOOL FALSE Read job impossible 3...

Page 122: ... 7 0 7 BIT0_7 BOOL FALSE Reserved 21 0 1 0 START BOOL FALSE Start 21 1 1 1 STOP BOOL FALSE Stop 21 2 1 2 DIR_M BOOL FALSE Direction minus 21 3 1 3 DIR_P BOOL FALSE Direction plus 21 4 1 4 ACK_MF BOOL FALSE Acknowledge M function 21 5 1 5 READ_EN BOOL FALSE Enable read in 21 6 1 6 SKIP_BLK BOOL FALSE Skip block 21 7 1 7 DRV_EN BOOL FALSE Drive enable 22 0 2 0 MODE BYTE B 16 0 Operating mode 23 0 3 ...

Page 123: ...e in progress 29 6 1 6 PR_BACK BOOL FALSE Program processing in reverse 29 7 1 7 BIT1_7 BOOL FALSE Reserved 30 0 2 0 MODE BYTE B 16 0 Active operating mode 31 0 3 0 SYNC BOOL FALSE Synchronized 31 1 3 1 MSR_DONE BOOL FALSE End measurement 31 2 3 2 GO_M BOOL FALSE Go_minus 31 3 3 3 GO_P BOOL FALSE Go_plus 31 4 3 4 BIT3_4 BOOL FALSE Reserved 31 5 3 5 FAVEL BOOL FALSE Flying actual value done 31 6 3 ...

Page 124: ...E Simulation on 41 0 1 0 BIT1_0 BOOL FALSE Reserved 41 1 1 1 BIT1_1 BOOL FALSE Reserved 41 2 1 2 MSR_EN BOOL FALSE Length measurement 41 3 1 3 REFTRIG BOOL FALSE Retrigger reference point 41 4 1 4 DI_EN BOOL FALSE Switch off enable output 41 5 1 5 FOLLOWUP BOOL FALSE Follow up mode 41 6 1 6 SSW_DIS BOOL FALSE Switch off software end posi tion monitoring 41 7 1 7 DRIFTOFF BOOL FALSE Switch off auto...

Page 125: ...no 13 48 0 48 0 stat SETTING_ ACT_VALUE DINT L 0 Set Actual value Set actual value on the fly FC MODE_WR job no 14 52 0 52 0 stat FLYING_ SETTING_ ACT_VALUE DINT L 0 Set actual value on the fly Set reference point FC MODE_WR job no 21 56 0 56 0 stat SETTING_ REFERENCE_ PIONT DINT L 0 Set reference point Measured values FC MSRMENT 60 0 stat MEASURE MENT_VALUES STRUCT Measured values 60 0 0 0 BEGIN_...

Page 126: ...254 DWORD DW 16 0 Setpoint for increment Velocity levels 1 and 2 FC MODE_WR job no 1 90 0 stat VLEVEL_1_2 STRUCT Velocity levels 1 and 2 90 0 0 0 VLEVEL_1 DWORD DW 16 0 Speed level 1 94 0 4 0 VLEVEL_2 DWORD DW 16 0 Speed level 2 8 0 END_STRUCT Voltage Frequency level 1 and 2 FC MODE_WR job no 2 98 0 stat CLEVEL_1_2 STRUCT Voltage Frequency level 1 and 2 98 0 0 0 CLEVEL_1 DWORD DW 16 0 Voltage Freq...

Page 127: ...2 0 6 0 BYTE6 BYTE B 16 0 Reserved 113 0 7 0 BYTE7 BYTE B 16 0 Reserved 114 0 8 0 X_T_VAL DINT L 0 Value position dwell 118 0 12 0 V_VAL DINT L 0 Value of velocity 122 0 16 0 M_1_VAL BYTE B 16 0 M function no of group 1 123 0 17 0 M_2_VAL BYTE B 16 0 M function no of group 2 124 0 18 0 M_3_VAL BYTE B 16 0 M function no of group 3 125 0 19 0 BYTE19 BYTE B 16 0 Reserved 20 0 END_STRUCT Change parame...

Page 128: ...L FALSE Digital input 0 150 1 0 1 D_IN1 BOOL FALSE Digital input 1 150 2 0 2 D_IN2 BOOL FALSE Digital input 2 150 3 0 3 D_IN3 BOOL FALSE Digital input 3 150 4 0 4 BIT0_4 BOOL FALSE Reserved 150 5 0 5 BIT0_5 BOOL FALSE Reserved 150 6 0 6 BIT0_6 BOOL FALSE Reserved 150 7 0 7 BIT0_7 BOOL FALSE Reserved 151 0 1 0 D_OUT0 BOOL FALSE Digital output 0 151 1 1 1 D_OUT1 BOOL FALSE Digital output 1 151 2 1 2...

Page 129: ...BIT3_4 BOOL FALSE Reserved 155 5 3 5 BIT3_5 BOOL FALSE Reserved 155 6 3 6 BIT3_6 BOOL FALSE Reserved 155 7 3 7 BIT3_7 BOOL FALSE Reserved 156 0 4 0 G_1_VAL BYTE B 16 0 G function no 1 157 0 5 0 G_2_VAL BYTE B 16 0 G function no 2 158 0 6 0 BYTE6 BYTE B 16 0 Reserved 159 0 7 0 BYTE7 BYTE B 16 0 Reserved 160 0 8 0 X_T_VAL DINT L 0 Value position dwell 164 0 12 0 V_VAL DINT L 0 Value of velocity 168 ...

Page 130: ... 0 END_STRUCT FC MODE_WR job no 22 182 0 stat SRV_IN STRUCT Reserved 182 0 0 0 SRV_IN1 DINT L 0 186 0 4 0 SRV_IN2 DINT L 0 190 0 8 0 SRV_IN3 DINT L 0 194 0 12 0 SRV_IN4 DINT L 0 16 0 END_STRUCT Basic operating data FC RD_COM job no 102 198 0 stat OP_DAT STRUCT Basic operating data 198 0 0 0 ACT_VAL DINT L 0 Actual position 202 0 4 0 SPEED DWORD DW 16 0 Actual speed 206 0 8 0 REM_DIST DINT L 0 Resi...

Page 131: ...fset 233 5 3 5 BIT3_5 BOOL FALSE Reserved 233 6 3 6 BIT3_6 BOOL FALSE Reserved 233 7 3 7 BIT3_7 BOOL FALSE Reserved 234 0 4 0 G_1_VAL BYTE B 16 0 G function no of group 1 235 0 5 0 G_2_VAL BYTE B 16 0 G function no of group 2 236 0 6 0 G_3_VAL BYTE B 16 0 G function no of group 3 237 0 7 0 BYTE7 BYTE B 16 0 Reserved 238 0 8 0 X_T_VAL DINT L 0 Value 242 0 12 0 V_VAL DINT L 0 Value 246 0 16 0 M_1_VA...

Page 132: ...nction no of group 1 255 0 5 0 G_2_VAL BYTE B 16 0 G function no of group 2 256 0 6 0 G_3_VAL BYTE B 16 0 G function no of group 3 257 0 7 0 BYTE7 BYTE B 16 0 Reserved 258 0 8 0 X_T_VAL DINT L 0 Value 262 0 12 0 V_VAL DINT L 0 Value 266 0 16 0 M_1_VAL BYTE B 16 0 M function no of group 1 267 0 17 0 M_2_VAL BYTE B 16 0 M function no of group 2 268 0 18 0 M_3_VAL BYTE B 16 0 M function no of group 3...

Page 133: ...Positioning time response time constant 32 0 END_STRUCT FC RD_COM job no 109 322 0 stat SRV_OUT STRUCT Reserved 322 0 0 0 SRV_OUT1 DINT L 0 326 0 4 0 SRV_OUT2 DINT L 0 330 0 8 0 SRV_OUT3 DINT L 0 334 0 12 0 SRV_OUT4 DINT L 0 338 0 16 0 SRV_OUT5 DINT L 0 342 0 20 0 SRV_OUT6 DINT L 0 346 0 24 0 SRV_OUT7 DINT L 0 350 0 28 0 SRV_OUT8 DINT L 0 32 0 END_STRUCT Additional operating data FC RD_COM job no ...

Page 134: ...eserved 363 3 9 3 LIM_FS BOOL FALSE Reserved 363 4 9 4 BIT9_4 BOOL FALSE Reserved 363 5 9 5 BIT9_5 BOOL FALSE Reserved 363 6 9 6 BIT9_6 BOOL FALSE Reserved 363 7 9 7 BIT9_7 BOOL FALSE Reserved 364 0 10 0 BYTE10 BYTE B 16 0 Reserved 365 0 11 0 BYTE11 BYTE B 16 0 Reserved 12 0 END_STRUCT Parameters data FC RD_COM job no 114 366 0 stat PAR_READ STRUCT Parameters data 366 0 0 0 PAR_TYP BYTE B 16 0 DB ...

Page 135: ...SE Transfer MDI block 390 3 0 3 BITC_3 BOOL FALSE Transfer program selection 390 4 0 4 BITC_4 BOOL FALSE Transfer teach in 390 5 0 5 BITC_5 BOOL FALSE Transfer incremental value 390 6 0 6 BITC_6 BOOL FALSE Transfer velocity levels 390 7 0 7 BITC_7 BOOL FALSE Transfer voltage frequency levels 391 0 1 0 BITC_8 BOOL FALSE Transfer MDI block on the fly 391 1 1 1 BITC_9 BOOL FALSE Transfer set actual v...

Page 136: ...BOOL FALSE Reference point approach 406 2 0 2 BITA_2 BOOL FALSE Incremental relative 406 3 0 3 BITA_3 BOOL FALSE MDI 406 4 0 4 BITA_4 BOOL FALSE Automatic single block 406 5 0 5 BITA_5 BOOL FALSE Automatic 406 6 0 6 BITA_6 BOOL FALSE Jogging 406 7 0 7 BITA_7 BOOL FALSE Reserved 407 0 1 0 BITA_8 BOOL FALSE Reserved 407 1 1 1 BITA_9 BOOL FALSE Reserved 407 2 1 2 BITA_10 BOOL FALSE Reserved 407 3 1 3...

Page 137: ...lues can be transferred again by setting the appropriate write memory M17 4 to M17 6 OB 100 contains certain default settings for velocity levels MDI block single functions servo enable simulation operating mode Jogging mode is active on start mode parameters and override however these can be changed according to the application Table 6 6 Memories Example Application 1 Input Memories Used M16 0 St...

Page 138: ...ing the memory RE START M17 0 An example for calling data set DS 162 evaluation of operator control guid ance errors is provided for special error evaluation at the end of FC 100 Data set 163 evaluation of data errors and data set 164 evaluation of oper ating errors are called similarly OB 100 contains certain default settings for velocity levels MDI block servo enable simulation operating mode Jo...

Page 139: ... 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 MB18 Operating mode encoded MB22 Active mode MB19 Override MB23 Not used Example call for DS 162 channel 1 Programming the FM 453 ...

Page 140: ...ALS OT_ERR SPB NW5E U R_DS162 SPB D162 INI1 L 1 DEC 1 L 35 I L 162 I T DSNR S R_DS162 D162 CALL SFC 59 REQ TRUE IOID B 16 54 LADDR DB1 DBW12 RECNUM DSNR RECORD P M30 0 BYTE 4 BUSY BUSY RET_VAL FEHLERCODE_LESEN UN BUSY R R_DS162 UN BIE S FEHLER_LESEFKT Auxiliary bit for data set Parameter for SFC 59 Only read DS162 if operating error otherwise jump to end of network If read job already active jump ...

Page 141: ...of control signals If memory M20 0 is enabled the job was executed successfully on the FM You can now start up test and optimize the FM with the Parameterize FM 453 tool Table 6 8 Memory Example Application 3 Input Memories Used Output Memories Used M16 0 Switch P bus interface to start up M20 0 Switchover to P bus interface done M16 1 Not used M20 1 Not used M16 2 Not used M20 2 Not used M16 3 No...

Page 142: ...G_RD 302 180 34 5 MSRMENT 288 172 26 6 DIAG_INF 282 166 26 The following average processing times for FCs were measured with a CPU 413 The specified times are rounded Table 6 10 Processing Times of FCs FC Transfer Cycle 1 Cycle 2 Cycle 3 INIT_DB MODE_WR Write control checkback sig nals without data job 0 0 8 ms Write control checkback sig nals with data job 1 0 9 ms 2 5 ms 0 9 ms RD_COM Read data ...

Page 143: ... starting up the positioning module The checklists will help you S Check all steps until the module is running S Prevent malfunctions of the module once it is in operation You are guided through start up of the machine axes In Section You Will Find On Page 7 1 Installation and Wiring 7 2 7 2 Initial Values for Testing and Optimization 7 3 7 3 Testing and Optimization 7 8 Overview Chapter Overview ...

Page 144: ...itable slots 2 Shielding Check the shielding of the FM 453 positioning module S To ensure proper shielding the module must be screwed down firmly on the rack S The shielding for shielded lines must be connected to the shielding termi nal element S The shielding for the setpoint cable should not be grounded on the drive unit end 3 Hardware limit switches Check the start stop hardware limit switches...

Page 145: ... 1 Overview Display for Parameterization and Start up You can return to this display at any point during parameterization by select ing the menu View Overview As it is written to the FM 453 the DB MD is checked for the input limits of the individual values and their interdependencies It is then stored only if all values are allowed Otherwise data error messages are displayed by way of the MPI A de...

Page 146: ...alues in Table 7 3 are recommended and sometimes necessary as initial settings 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 S SIMOSTEP 2 si02_453 md S SIMOSTEP 4 si04_453 md S SIMOSTEP 6 si06_453 md S SIMOSTEP 10...

Page 147: ...which do not match the measurement system or clear the memory of the FM 453 completely 2 Modify the other data blocks on the programming device 3 Reload the data blocks to the FM 453 The table below shows you what initial contents are recommended or re quired for the E machine data at startup of the machine axis Enter the machine data in the tab windows in accordance with the control mode MD61 as ...

Page 148: ...V Setpoint drive values for maximum velocity 1 44 0 Offset value for drive setpoint 45 0 Actuating signal ramp inactive 46 100 ms Minimum idle time between two positioning cycles 47 100 ms Minimum traversing time at constant frequency 48 100 Boost duration absolute 49 100 Boost duration relative 50 100 Phase current travel 51 100 Phase current idle 54 fSS Start Stop frequency 2 55 feg Frequency va...

Page 149: ...and braking 2 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 Kv factor in the servo and must therefore be entered correctly Recommendation So far as possible Umax should be set in the range between 8 and 9 V 2 Determined from the operating characteristic curve see Section 7 3 2 Machine data is required Machin...

Page 150: ...re are two ways of operating the FM S CPU is in STOP test without user program S CPU is in RUN test with user program You can monitor the interface between the FM and the user program You can also control the program from the start up user interface when control signal TFB TEST_EN is enabled in the user program Example ap plication 3 see Section 6 7 can be included in the user program for this pur...

Page 151: ... 4 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 Fig 7 2 Startup Interface e g for Reference point approach mode Starting up the FM 453 ...

Page 152: ...PU When you operate the following buttons you will get dialog windows S Set actual value S Set actual value on the fly S Set reference point S Zero offset Warning If you move the axis directly without simulation for safety s sake make sure you can switch off the hardware if a hazard arises Note If you use the start up user interface to operate the FM 453 when the CPU is in STOP and then switch the...

Page 153: ...000 G7076 C453 01 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 Starting up the FM 453 ...

Page 154: ... 3 Basic startup of stepper motor actuation 7 3 3 4 Basic startup of servomotor actuation 7 3 4 5 Monitoring of encoder actuation 7 3 5 6 Startup of position controller 7 3 6 7 Optimization of position controller 7 3 7 8 Startup of stepper motor control 7 3 8 9 Readjustment of reference point coordinates 7 3 9 10 Activation of position controller diagnostics 7 3 10 11 Activation of stepper motor d...

Page 155: ...module and if the entire DB MD is error free this new data can then be put into effect by way of the Activate machine data function The following approaches are possible S If only E data has been modified in the machine data record since the last activation the equipment is activated with module status Operation in progress 0 without interrupting the servo cycle SYN is retained S If K data has als...

Page 156: ...ed timing diagram as shown in Figure 9 8 is well defined You can determine the parameters for the speed profile as shown in the fol lowing parameterization example from the operating characteristic curves of the stepper motor you have in use Always be sure to allow a torque reserve of approx 20 Determining the available or necessary torque MMotor MLoad MAccelerations Determining the present moment...

Page 157: ...f1 f0 1 000 feg 10 000 12 120 1 200 n 1 min 1 min 3 0 Fig 7 5 Operating Characteristic Curve of the Stepper Motor When you evaluate this example characteristic in accordance with the algo rithm in Figure 7 6 you determine the following machine data MD54 100 Hz Start Stop frequency fss MD55 3 000 Hz Frequency value feg MD57 218 000 Hz s Acceleration 1 f v feg MD58 109 000 Hz s Acceleration 2 f feg ...

Page 158: ...actors may provide a torque which deviates from the acceleration case MD60 must be either be calculated along the lines of the formula used to calculate MD58 or some technologically desirable value must be verified Enter MD60 0 Should values for acceleration and delay be identical within the range f feg Yes No Equate acceleration element for all f fmax Mb1 Mb2 Enter MD55 MD56 MD58 0 MD60 0 MD40 Fr...

Page 159: ...s realized from the torque curve only within the lower rpm range of the motor e g Mb1 3 4 Nm 0 6 Nm 2 8 Nm Mb2 unchanged The following adjustments should be made electrical connection MD37 activation of the function MD48 49 for monitoring of boost duration see Section 7 3 9 S In case your step drive features the Current control through PWM func tion you can reduce the power loss converted in the m...

Page 160: ...cause undetectable positioning errors can re sult if increments are lost Use the following flow chart to verify the drive actuation and that the ma chine data determined so far are correct A subsequent test should be con ducted to verify that the stepper motor will traverse as a matter of course in response to actuation by the FM 453 A later test verifies that the positioning is correct see Sectio...

Page 161: ...xis movement completed Step drive active Motor torque present Select Frequency level 2 Check drive Check MD MD 37 0 RFG MD 37 17 bis MD 37 19 No Yes No Direction correct No Check MD MD54 MD37 19 Check MD MD19 1 rot dir Yes No Yes Restart test sequence Start axis Plus or minus direction execute several times make sure travel area is clear Axis movement completed including correct braking Travel at ...

Page 162: ...o determine the time constants of the servo drive that are required in later opti mization steps for the servo position control Note Always be sure to put MD modifications into effect with Activate machine data Caution Before triggering any traversing movement be sure to check that there is enough space for the axis to move in the desired direction You can use the following flow chart to check the...

Page 163: ...rrect drive actuation Axis travel direction correct No Yes Parameterization MD19 Invert analog value Set Activate machine data END No Yes Select Mode Control Set Voltage level 1 0 Voltage level 2 0 1 Umax Select Set Servo enable ON Start axis Plus or minus direction Axis idle Parameterization MD44 Adjust offset Set Activate machine data Voltage level 1 No Yes Zeroing for actuating signal Traverse ...

Page 164: ...nse occurs Select Mode Control Voltage level 2 Set Voltage level 1 0 Voltage level 2 Ua Umax Set Servo enable ON Start axis Plus or minus direction be sure there is enough room Axis acceleration too high Parameterization MD45 Voltage ramp lower Set Activate machine data No Yes No Yes END Axis acceleration too low Parameterization MD45 Voltage ramp higher Set Activate machine data Was voltage level...

Page 165: ...tage level 2 0 1 Umax Set Servo ON Start axis Plus or minus direction be sure there is enough room Is direction of position change correct Parameterization MD19 Reverse direction of measurement Set Activate machine data Parameterization MD11 13 Measured value resolution Set Activate machine data No Yes Is amount of change in ac tual position correct No Yes END Read actual position Fig 7 10 Encoder...

Page 166: ...ou verify the basic functional capability of the position control Optimization in accordance with your technological criteria is described in Section 7 3 7 First check the basic functions S Non release control S Speed assignment of servo drive S Positioning Special case In the control mode Step drive in position control circuit MD61 1 with out an encoder the position control circuit is closed with...

Page 167: ... Set Speed level 1 0 1 vmax Speed level 2 0 5 vmax Set Servo ON Is there a brief fast axis movement with Drive rotation direction error message No Yes END Read actual position Yes Is position control functioning Axis stays in position cannot be pushed and does not drift away Repeat Motor actua tion startup step No Repeat Motor actuation encoder actuation startup step Fig 7 12 Non release Control N...

Page 168: ... parameterized Kvfactor is implemented with the correct value in the position control circuit Fine calibration is then possible in the Optimize position control startup step with the aid of the Kv factor checkback signal in the service data Select Mode Control Voltage level 2 Set Voltage level 1 0 Voltage level 2 0 1 Umax Set Servo ON Start axis Plus or minus direction be sure there is enough room...

Page 169: ...vmax Speed level 2 0 5 vmax Set Servo ON Set Set reference point with value 0 Direction OK Yes END Check check back signal SYN Yes Start again with Motor actuation startup step No DB increments Value 4 e g 1 000 MSR Start axis Plus or minus direction be sure there is enough room Read actual position Amount OK Further testing desired Yes No No Select new OVER 1 200 Fig 7 14 Positioning Positioning ...

Page 170: ...ains the drive and if applicable the machine axis see Figure 7 11 The following instructions are intended as an aid for practical situations Position controllers must meet a variety of requirements for various techno logical applications Assessment criteria for the quality of the positioning process can include S Good uniformity of traversing movement S Little or no overshoot at the target point f...

Page 171: ...owing machine data in accordance with the drive time constant Ta Tareal determined in Section 7 3 2 to the initial values for the optimization steps below e g for an axis in MSR 10 3 mm S Acceleration delay MD40 MD41 mm s2 30 MD23 mm min Ta ms S Jolt time MD42 ms 0 S Positioning loop amplification MD38 1 min 100 000 Ta ms The acceleration value that actually acts on the system is reduced by the ti...

Page 172: ...escription of these param eters see Section 7 3 8 Optimization of dynamic response The qualitative effect of the parameters on the positioning procedure is illus trated by the following table Table 7 5 Effect of Machine Data that Defines Response in the Position Control Circuit MD38 MD40 41 MD42 Quiet running small Noise immunity great Soft movement reversal small great great Positioning without o...

Page 173: ...rably easier by analyzing the actuating signal or drive speed tachometer voltage with a storage oscillograph The resulting oscillograms for the transition functions U t and v t i e the oscillation pattern can be interpreted more easily see Figure 7 16 v t U Gain too high axis swing damping weak Amplification acceleration too small Amplification acceleration too great Optimum setting Effective rang...

Page 174: ...leration in movement reversal processes responds proportionally to the difference in speed and reaches its maximum in the transition from v 0 to maximum speed see Figure 7 17 S Acceleration delay MD40 MD41 mm s2 0 S Jolt time MD42 ms 0 5 Ta ms S Positioning loop amplification MD38 1 min 100 000 Ta ms The maximum value of the actual effective acceleration can be estimated as follows amax mm s2 16 M...

Page 175: ...ined value of MD38 Greatest value for each of MD40 MD41 and MD42 S Prioritization of one optimization criterion Set MD38 and MD40 MD42 to the values that match the highest priority optimization criterion for your application and again evaluate response as to the remaining criteria S Taking the mean of partial results Set MD38 and MD40 MD42 to the means of the individual partial results and again e...

Page 176: ...ubordinated to these factors as they bear on parameterization Following completion of basic startup as described in Section 7 3 3 optimization of parameterization should now be carried out geared to these factors as well as to the technology Different requirements are imposed on the axis dynamic response for differ ent technological applications Criteria for evaluating the quality of the posi tion...

Page 177: ... Plus or minus direction be sure there is enough room Depending on traversing speed of test movement select any travel distance in crement which is great enough to ensure that the set speed is reached within the speed profile of the test movement Pre liminary computation or evaluation of the frequency display in the service data Yes No Repeat basic startup see Figure 7 7 Direction OK Check check b...

Page 178: ...a that Defines Response for the Open loop Controlled Operation of the Step Drive MD54 MD55 MD57 60 MD46 MD47 Soft travel behavior small small great great Suppression of reso nance great great great great Short positioning time great great great small small By implementing test movements in accordance with 7 20 optimize the step per motor control to your requirements Check all speed ranges and if a...

Page 179: ...highest value compatible with your requirements It is important to be able to decelerate to the reducing velocity across the length of the reference point switch If this is not the case an additional repositioning to the RPS occurs before the search phase of the synchronizing zero pulse begins Compare the cycle of the executed travers ing movements with Section 9 2 3 and optimize the referencing s...

Page 180: ...e 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 Overview Starting up the FM 453 ...

Page 181: ...ates Drive movement without controller en able idle range error message Read the following error from the servicing data Parameterization MD39 Enter the following error at approx 5 10 vmax Enable Following error too great er ror message OVER 200 Parameterization MD24 Enter a PEH target range In the specified distance range the positioning op eration for the motion sequence is interpreted as comple...

Page 182: ...is exceeded Once parameterization is completed check the diagnostics function for effi cacy using a suitable test program with which particularly large proportions of acceleration and braking phases occur during execution This diagnostics function cannot be activated in the control mode MD61 1 with an encoder Activation is accomplished by way of the Rotation monitoring single set ting function ref...

Page 183: ... the drift compensation function in addition to the offset compensation already described in Section 7 3 2 activate it in the machine data please see the function description in Section 9 7 position control 7 3 14 Activation of Backlash Compensation With indirect position measurement for example with an encoder on the motor the free play of mechanical transmission elements during positioning may c...

Page 184: ...ine data Set Speed level 1 0 1 vmax Speed level 2 0 5 vmax Select Mode Relative incremental Increment 3 OVER 10 Direction as in MD31 Gauge e g dial gauge or laser gauge Start axis Direction opposite to MD31 Further testing for checking or to take mean Further testing at another position to take mean Select Mode jogging Speed level 2 OVER 100 Start axis Move to new measuring position Check for effi...

Page 185: ... Configured operator control screens User data user data block technology functions Section 6 CPU in data blocks S Machine data S Increments S Tool offset data S Traversing pro grams S Status messages FM 453 Backplane bus Operator panel OP e g Line oriented op erator panel OP Operator control and monitoring via the MPI interface Fig 8 1 Operator Control and Monitoring for the FM 453 The data and s...

Page 186: ...annel 1 DB No 1301 1499 for channel 2 DB No 1601 1799 for channel 3 The following data and signals can be displayed on the operator panel dis play S Machine data see above S Increments see above S Tool offset data see above S Traversing programs see above S Status messages DB No 1000 for channel 1 DB No 1300 for channel 2 DB No 1600 for channel 3 e g Operating data such as actual values Active NC ...

Page 187: ...han nels 1 2 and 3 in the FM 453 controller Steuerg_453 address 2 slot 8 or to the traversing program The OP 17 has been addressed in this example configuration to the MPI ad dress 9 The text field FM user name represented in the images can be renamed to a text of your choice You can print out the entire configuration using ProTool Lite V3 0 This provides you with detailed screen descriptions You ...

Page 188: ... F6 F7 F8 Main screen PIC7_G User specific screens PIC 78 with overview of as signment of global softkeys Diagnostics error message PIC77 SK1 Group signal SK2 Alarms Start up_Servo SK1 Start up settings SK3 Machine data Operating mode selection MDI block input SK1 MDI block on the fly Automatic main screen SK1 Current block SK2 Follow block SK4 Program selection SK5 Teach In Parameters PIC Z_MESS_...

Page 189: ...You can use this key to jump from any point on the menu tree to the main screen PIC7_G Function key You can use this key to jump from any point on the menu tree to the diagnos tics error message screen PIC77 Function key You can use this key to jump from any point on the menu tree to the operat ing mode selection screen PIC75 K5 K6 7 K Function key 14 K You can use this key to switch to channel 1 ...

Page 190: ...ed to the FM 453 by the user program If certain values or control signals can be written only under the right conditions e g if axis is necessary on HOLD or selection of a certain operating mode then the user program must ensure by analyzing the response signals that these conditions are met The pending errors are displayed in the Error line More detailed error information is provided on the scree...

Page 191: ...r data for set actual value from user DB to the FM Transfer data for Zero point offset from user DB to the FM Transfer Remove setting actual value flag to the FM 390 9 390 10 42 14 72 42 10 1 42 11 1 390 3 1 SK SAvor SK SArü SK set Transfer Automatic block search for ward memory bit to the FM Transfer the Automatic block search backward memory bit to the FM Transfer data for Program selection from...

Page 192: ...FM Transfer Automatic single block oper ating mode to the FM Transfer Automatic operating mode to the FM 406 6 406 0 406 1 406 2 406 3 406 4 406 5 75 40 14 42 13 1 42 9 1 TF software limit switch off TF Restart axis TF Delete distance to go In case of modification transfer Soft ware limit switch disable yes no to the FM Transfer Restart axis memory bit to the FM Transfer Delete distance to go memo...

Page 193: ...OOL Single commands Activate machine data Delete distance to go Automatic block search forward Automatic block search backward Restart Undo set actual value 11 44 DINT Zero offset 12 48 DINT Set Actual value 13 86 DWORD Increment for incremental dimensions 3 90 DWORD Speed level 1 1 94 DWORD Speed level 2 98 DWORD Voltage frequency level 1 2 102 DWORD Voltage frequency level 2 106 STRUCT NC Satz M...

Page 194: ...nsfer increment Transfer velocity levels Transfer voltage frequency levels Transfer MDI block on the fly Transfer set actual value Transfer zero offset Diagnostic interrupt Data error Operator control guidance error 392 WORD No 394 DINT MD value 398 BYTE SM no 406 0 406 1 406 2 406 3 406 4 406 5 406 6 407 6 407 7 16 BOOL Mode selection change input to corresponding mode Open loop control Reference...

Page 195: ...L Response signals Byte 0 33 8 x BOOL Response signals Byte 1 34 BYTE Response signals Byte 2 35 8 x BOOL Response signals Byte 3 36 BYTE Response signals Byte 4 37 8 x BOOL Response signals Byte 5 38 2 BYTE Free 40 32 x BYTE Reserved 72 DWORD Velocity level 1 76 DWORD Velocity level 2 80 DWORD Voltage frequency level 1 84 DWORD Voltage frequency level 2 88 DWORD Setpoint for incremental value 92 ...

Page 196: ...s Basic operating data 202 DINT Free 208 DINT Free 212 STRUCT NC block structure Active NC block 232 STRUCT NC block structure Next NC block 252 DINT Code application 1 Application data 256 DINT Code application 2 Application data 260 DINT Code application 3 Application data 264 DINT Code application 4 Application data 268 DINT Actual position on leading edge Length measurement in process measurem...

Page 197: ... BYTE No of callup subroutine loops Additional operating data 352 BYTE G90 91 Active Additional operating data 353 BYTE G60 64 Active Additional operating data 354 BYTE G43 44 Active Additional operating data 355 BYTE Active D No Additional operating data 356 356 1 356 2 356 3 8 x BOOL Status messages S Bit 1 Velocity limitation to limit value from MD S Limitation to 10 V for servo drive S Limitat...

Page 198: ...E Free 338 32 x BOOL Process interrupt 1 A variable in the S7 protocol is addressed by the DB No and depending on data format by the DBB DBW and DBD No offset in DB as well The control and checkback signals in Table 8 3 can be the following signals Bit Byte 7 6 5 4 3 2 1 0 Control signals 20 BFQ FSQ TFB 21 AF SA EFG QMF R R STP ST 22 operating mode 23 BP 24 OVERR 25 Response signals 28 PARA DF BF ...

Page 199: ...e block 09 R DIR_P Direction plus R DIR_M Direction minus STP STOP Stop ST START Start OVERR OVERRIDE Override AF DRV_EN Drive enable SA SKIP_BLK Enable bit for block skip EFG READ_EN Read enable QMF ACK_MF Acknowledgment M function BFQ FSQ OT_ERR_A Acknowledgment operator control and guidance error TFB TEST_EN Switchover P BUS port Checkback signals MNR NUM_MF M function number BL WORKING Program...

Page 200: ...le 8 4 Control and Checkback Signals continued German Significance English SYN SYNC Synchronized DF DATA_ERR Data error FIWS FAVEL Flying actual value done TFGS TST_STAT Switchover P BUS port done WFG WAIT_EN Wait for external enable PARA PARA Parameterized Man Machine Interface ...

Page 201: ...er program Note The procedure is only described here for one channel It must also be fol lowed for each additional channel In Section You Will Find On Page 9 1 Control and Checkback Signals 9 2 9 2 Operating Modes 9 12 9 3 System Data 9 35 9 4 System of Measurement 9 56 9 5 Axis Type 9 57 9 6 Encoder 9 59 9 7 Setpoint Processing 9 70 9 8 Digital I Os 9 92 9 9 Software Limit Switches 9 95 9 10 Proc...

Page 202: ...from the user DB to the FM and transfers the checkback signals from the FM to the user DB Bit Byte 7 6 5 4 3 2 1 0 Control signals 20 BFQ FSQ TFB 21 AF SA EFG QMF R R STP ST 22 operating mode 23 BP 24 OVERR 25 Response signals 28 PARA DF BF FS TFGS 29 PBR T L WFG BL SFG 30 BAR 31 PEH FIWS FR FR ME SYN 32 MNR 33 AMF Overview Description of Functions ...

Page 203: ... axis in negative direction level dependent S Starts movement in negative direction in Incremental relative and Refer ence point approach modes S Specifies direction of movement for rotary axes in MDI and Automatic modes DIR_P R Direction plus moves axis in positive direction S In Jogging and Control modes moves axis in positive direction level dependent S Starts movement in positive direction in ...

Page 204: ...if the user starts a movement without a start enable etc an error response is initiated e g the residual distance is deleted BL 0 a new path default must be defined MODE operating mode Operat ing mode Operating mode see Section 9 2 Code Jogging 01 Open loop control 02 Reference point approach 03 Incremental relative 04 MDI 06 Automatic 08 Automatic single block 09 MODE PA RAMETER BP Mode pa ramete...

Page 205: ...ffected only after the axis comes to a stop e g reversal of direction vact vprog Override 100 aact a Override2 1002 tact t 100 Override speed v is cut in half acceleration and deceleration are quartered Positioning time is doubled Example Cut override in half from 100 to 50 100 t vact vprog 50 v S Time override If you parameterize the time override function in MD37 there are two ranges range 100 2...

Page 206: ...user when a data error occurs see Chapter 11 PARA PARA Parameterize module parameterized All machine data applicable for control of an axis are present on the module START_EN SFG Start enable signals that the FM 453 is ready for positioning and output S Start enable is set if no static stop or error is pending and the drive enable is pend ing if the mode setting and mode checkback match after mode...

Page 207: ...well time has been processed T L is output during the programmed time period PR_BACK PBR Programmbear beitung rückwärts is set after a Start in Automatic mode if a program is being processed in reverse MODE BAR Active mode The selected mode is not fed back until it is internally active For a mode change for example a movement must be stopped before another mode can become active does not apply to ...

Page 208: ...ged for acknowledgment controlled M functions POS_ROD PEH Position reached Stop PEH S When the preset target position is reached correctly PEH is actu ated and remains in effect until the next axis movement S Target position reached correctly means that during approach of the actual value to target position a defined tolerance PEH toler ance must not be exceeded during a defined time PEH time watc...

Page 209: ...00 the appropriate increments must be parameterized MDI 06 ST STP AF QMF OVERR BL SFG FR FR WFG SYN PEH AMF MNR T L 6 10 servo enable Automatic 08 Automatic single block 09 ST S EFG STP AF QMF OVERR BL SFG FR FR WFG SYN PEH AMF T L PBR MNR 17 assuming the corre sponding traversing pro gram was parameter ized 10 servo enable Error condition S Message via BF FS acknowledgement with BFQ FSQ S Message...

Page 210: ...table lists the control signals used to start a movement Prerequisite Drive enable AF 1 Stop STP 0 Start enable SFG 1 Mode Parameters Command Signal State Activation of Movement Jogging mode 01 Velocity level BP 1 level 1 BP 2 level 2 R R Level R or R with Level 1 R and R simultaneously error Control mode 02 Voltage frequency level BP 1 level 1 BP 2 level 2 R R Level R or R with Level 1 R and R si...

Page 211: ...nge Drive enable 02 Reference point ap proach mode 03 Stop 0 1 or ref received or mode change or enable input1 0 Drive enable 02 Incremental relative mode 04 Stop 1 or Enable input1 0 Stop 0 or Enable input1 1 with R or R Position reached or mode change Drive enable 02 MDI mode 06 Stop 1 or Enable input1 0 Stop 0 or Enable input1 1 with Start 0 1 Position reached or block processed or mode change ...

Page 212: ... block to the FM 453 The axis is controlled by enabling and disabling appropriate control signals When the specification is allowed the FM 453 feeds back the specified mode to the user program If this checkback mode matches the specified one the mode is active Changing modes triggers an internal stop If a mode change is attempted while a traversing movement is in progress the modes are not switche...

Page 213: ...it Upper Input Limit Unit Speed 10 500 000 000 MSR min MSR stands for measurement system raster see Section 5 3 1 The table below gives you an overview of how to handle this mode Triggering of Move ment Direction R Level Selection Speed R or R BP 1 Value for speed level 1 level controlled BP 2 Value for speed level 2 Note Please see also Section 9 1 3 Preconditions S The FM 453 has been parameteri...

Page 214: ...ection Control signal Direction plus R Checkback signals Travel plus FR Start enable SFG Processing in progress BL R is canceled When the axis has come to a standstill by way of the decel eration ramp the BL and FR messages are canceled and SFG is activated Before the axis comes to a standstill it is possible to define a new direction through start Control action 4 move axis negative direction Con...

Page 215: ...7 cancel drive enable special situation Control signal Drive enable AF Checkback signals Travel minus FR Processing in progress BL AF is deactivated during the traversing movement The axis is stopped abruptly FR and BL are canceled Control action 8 reset during axis motion special situation Single command Restart job no 11 Checkback signals Travel plus FR Processing in progress BL Restart is defin...

Page 216: ...es to a stop if the controller enable is still active when the axis stops The voltage frequency is defined with job No 2 You can choose between two mutually independent voltage frequency values level 1 and level 2 with the mode parameter BP Name Lower Input Limit Upper Input Limit Unit Voltage levels 1 2 0 10 000 mV Frequency levels 1 2 0 1 000 000 Hz The values for the voltage levels can be chang...

Page 217: ... direction zero ref mark left 4 direction RPS center 5 direction RPS center 8 direction RPS edge 9 direction RPS edge Zero refer ence mark See zero ref erence mark selection Figure 5 5 27 Reference point shift 1 000 000 000 1 000 000 000 MSR 28 Referencing speed 10 500 000 000 see Section 5 3 1 Dependencies MSR min 29 Reducing speed 10 500 000 000 see Section 5 3 1 Dependencies MSR min 34 dig Inpu...

Page 218: ...ero reference mark to left of RPS Zero ref erence mark VA V R RPS R edge con trolled or Start 3rd situation RPS centered no zero pulse nec essary RPS VA V R 4th situation RPS edge no zero pulse nec essary RPS VA V R 1st situation zero reference mark to right of RPS equals R 2nd situation mirrored R edge con trolled or Start 2nd situation zero reference mark to left of RPS equals R 1st situation mi...

Page 219: ...at the end of the axis in the approach direction in order to reverse the axis in the direction of the reference point switch On axis movements with referencing feed a signal length of t w 2 FM cycle must be assured for the reversing switch Example Approach direction from MD18 Reversing switch Emer gency limit switch Reference point Axis position RPS The value for the reference point shift MD27 is ...

Page 220: ...and SFG Control action 2 move axis positive direction Control signal Direction plus R Checkback signals Travel plus FR Start enable SFG Processing in progress BL Synchronization SYN When SFG is active R or Start are actuated for exam ple The axis cancels SFG outputs the BL and FR mes sages and travels here in the positive direction defined in MD An existing synchronization is reset Control action ...

Page 221: ...ls Direction plus R Direction minus R Checkback signal Start enable SFG R is defined although R is active The ambiguous direction command causes the axis to stop FR and BL are canceled and an error is output The SFG does not reappear until R and R have been canceled Control action 6 cancel servo enable special situation Single function servo en able job no 10 Checkback signals Operator control tra...

Page 222: ...ow gives you an overview of how to handle this mode Triggering of Move ment Direction R Increment Selection Position Distance to Be Traveled R or R BP 254 in accordance with setpoint for increment job no 3 BP 1 100 as in SM table DB SM Position setting Name Lower Input Limit Upper Input Limit Unit Increment 0 1 000 000 000 MSR MSR stands for measurement system raster see Section 5 3 1 Note the fol...

Page 223: ...2 define position Transfer increment job no 3 Select increment 254 Control signal Direction plus R Checkback signals e g Travel plus FR Start enable SFG Processing in progress BL e g Travel plus FR Processing in progress BL Position reached stop PEH When the increment has been transferred and selected R can be initiated The axis cancels the SFG and outputs messages BL and FR When the defined posit...

Page 224: ...l Direction plus R Checkback signals Travel plus FR Processing in progress BL The axis moves An error is output during the traversing movement FR and BL are canceled and BFQ FSQ is enabled When the error has been acknowledged the start enable is activated The movement can be restarted with R FR and BL are activated SFG is canceled Control action 5 change mode Control signal Mode BA Checkback signa...

Page 225: ...ate is override dependent The MDI block remains in effect until it is overwritten with a new MDI block A new block can be transmitted while another block is being pro cessed Table 9 6 MDI Block Name Lower Input limit Upper Input Limit Unit Position X Dwell time t 1 000 000 000 2 1 000 000 000 100 000 MSR from MD7 ms Speed F 10 500 000 000 MSR from MD7 min G function group 1 G04 Dwell time G90 Abso...

Page 226: ...e of the MDI block X t Position dwell time programmed fills in value 1 G1 G2 G function group 1 2 M1 M3 M function group 1 3 F Speed programmed fills in value 2 Byte Data Format Bit 7 6 5 4 3 2 1 0 0 Byte 0 1 Byte 0 2 8 bits 0 0 0 X t 0 0 G2 G1 3 8 bits 0 0 0 0 M3 M2 M1 F 4 Byte G function 1 5 Byte G function 2 6 Byte 0 7 Byte 0 8 DINT 32 bit value 1 12 DINT 32 bit value 2 16 Byte M function 1 17 ...

Page 227: ...P 0 control signal FC MODE_WR S Servo enable RF 1 FC MODE_WR job no 10 S Axis is synchronized Table 9 7 Control Actions for MDI mode examples Signal Name Level Explanation Control action 1 define position Transfer MDI block job no 6 Control signal Start ST Checkback signals e g Travel plus FR Start enable SFG Processing in progress BL e g Travel plus FR Processing in progress BL Position reached s...

Page 228: ...ivated BL remains active and PEH is not output since positioning is not complete If ST is initiated again FR and SFG are reset and posi tioning is completed Before the axis comes to a standstill it is possible to restart through start Control action 4 stop during positioning with new start signal and new MDI block Control signal Stop STP Checkback signals Travel plus FR Start enable SFG Transfer M...

Page 229: ...select the pro gram again A modification can be made to a program when BL 0 start of program end of program and on Stop Triggering of Select Program Type of Movement According to Programmed Blocks of Movement Block No Processing Direction According to Programmed Blocks Start 0 0 e g 30 e g 30 forward reverse forward reverse Start at beginning of program process by ascending block number Start at e...

Page 230: ...mbers in descending order Processing begins at Start with the last block specified block number 0 If processing is to begin at some other point of the traversing program spec ify the desired block number Processing will take place by searching back to this block then processing in reverse until the program beginning is recog nized Note If reverse processing is to execute the same sequence of movem...

Page 231: ...backward means that after the interruption of an active automatic program by an operating mode change you can con tinue execution from this point of interruption in the appropriate direction of processing With forward block search the interrupted program must previously have been going in the forward direction With block search in reverse the interrupted program must previously have been going in ...

Page 232: ...R Start enable SFG Processing in progress BL When SFG appears the program can be activated by ST when EFG is active Processing commences e g with a positioning operation FR or FR and BL are activated SFG is reset Control action 3 M function output Checkback signals Change M function AMF M function number MNR Control signal Acknowledge M function QMF 2nd M command If M function output is acknowledg...

Page 233: ...cial situation Control signal Read in enable EFG Checkback signals Travel plus FR or Travel minus FR Position reached stop PEH The program resumes on EFG FR and FR are reset PEH is reset Control action 8 stop during positioning with new start signal for resumed positioning special situation Control signals Stop STP Start ST Checkback signals Position reached stop PEH Travel plus FR Start enable SF...

Page 234: ...be suppressed by specifying R or R Control action 12 deactivate operating mode during program execution special situation Control signal Mode BA Checkback signals Old mode BAR Travel plus FR or Travel minus FR Processing in progress BL New mode BAR If a new operating mode is selected during active program execution the axis is stopped by way of the deceleration ramp FR or FR and BL are reset 9 2 7...

Page 235: ...Page 9 3 1 Change Parameters Data Job No 8 9 36 9 3 2 Single Functions Job No 10 9 39 9 3 3 Single Commands Job No 11 9 42 9 3 4 Zero Offset Job No 12 9 44 9 3 5 Set Actual Value Job No 13 9 46 9 3 6 Set Actual Value On the fly Job No 14 9 47 9 3 7 Request Application Data Job No 18 9 48 9 3 8 Teach In Job No 19 9 49 9 3 9 Set Reference Point Job No 21 9 49 9 3 10 Measured Values 9 50 9 3 11 Basic...

Page 236: ...No 1 20 Progr No 1 199 128 Byte number of data Info 2 Number of MDs consec utive 1 5 Number of SMs consec utive 1 5 0 Tool offset complete 1 Tool length only 2 Wear value abs only 3 Wear value add only Block No 1 255 1 129 Byte job type 1 Read job parameters 2 Write parameters 4 Write parameters and save 130 149 depends on type data array Parameters data see data blocks Section 5 3 1 For block for...

Page 237: ...ifications are made during starting or at block transitions when the tool compensation is active internal access to offset values the error message tool offset value does not exist is output Cl 3 No 35 S Traversing programs Programs which are not selected can always be modified If modifications are made to a preselected program including the sub program preselection of the program is canceled You ...

Page 238: ... which param eter data are modified Block sizes DB Machine data approx 310 bytes DB Increments approx 460 bytes DB Tool offset data approx 310 bytes DB Traversing programs 110 20 x no of traversing blocks bytes Example Assuming a service life of 10 years and 24 hour operation a typical limit 106 Parameterization data DB size Number of possible de lete reprogram cycles Number of possible de lete re...

Page 239: ...ivations both functions are switched to inactive An error message is issued For function description see Section 9 3 10 A precondition for retrigger reference point is that the axis has been synchro nized by reference point approach With this setting the axis is synchronized at each positive edge of the zero mark after leaving the reference point switch RPS in the direction of the zero mark direct...

Page 240: ...ith the switch off enable input function you can switch off evaluation of the enable input see Section 9 8 1 The follow up mode function is used to cancel closed loop control of the axis S For external movement of the axis the actual value is tracked S This setting can be switched on or off only if Processing in progress 0 You can use this function to deactivate monitoring of the software limit sw...

Page 241: ...to change over the measurement system while the complete system is running With this setting S Encoder synchronization SYN 0 is deleted S Pending error messages are deleted and no new ones are triggered in cluding diagnostic interrupts S Digital outputs are inactive analog voltage 0 V The setting can be switched on or off if Processing in progress 0 You can use this function to S Test function seq...

Page 242: ...ed the machine data MD or the MD block from the programming device the machine data have to be activated At the first parameterization the machine data is transferred automatically In terms of effects the FM 453 distinguishes between K and E machine data MD Category Effect in FM 453 After Activation K Reset of the FM S As long as Reset is in progress it is not possible to transfer other data S For...

Page 243: ...lative and Automatic modes processing continues with the following block This command is described in Section 9 2 6 This command is described in Section 9 2 6 You can use this command to reset the axis S The setpoint output is interrupted S The instantaneous processing status is canceled and synchronization in incremental encoders is deleted S Active compensation values are deleted S An acknowledg...

Page 244: ...ly All coordinates and software limit switches the reference point and the actual value are updated accordingly Example of a zero offset Machine axis Working range Start 0 Target position 120 Working range End 200 Zero offset by 50 shift of reference point Actual position 150 Working range End 250 Working range Start 50 Target position 120 Zero point Actual position 100 50 Fig 9 1 Zero Offset The ...

Page 245: ... shift value 50 Actual value 350 Actual value 40 Range start Range end 0 360 The Start and End of the Range Are Shifted 50 Exceptions In the Incremental Relative MDI and Automatic modes a zero offset is not possible until the block has been processed position reached pro grammed stop set i e it is not possible when the axis is stationary after execution is interrupted with an abnormal stop Rotary ...

Page 246: ...software limit switches remain unchanged Example of setting actual value Machine axis Working range Start 0 Target position 120 Working range End 200 Set actual value to 150 Working range End 200 Working range Start 0 Target position 120 Machine axis Actual position 100 Actual position 150 Fig 9 2 Set Actual Value The coordinates can be reset to their original value by S Including synchronization ...

Page 247: ...Actual Value function is not triggered via the appropriate digital input until Processing in progress 1 Set actual value on the fly can be activated again by transmitting Set actual value on the fly again The coordinates can be reset to their original value by S Including synchronization in Reference Point Approach mode S Set reference point S Undo set actual value S Restart Note For set actual va...

Page 248: ...oder or pulse output counter 0 216 1 pulse for step drive without encoder 18 Pulse errors for drive with incremental encoder 19 Kv factor for servo drive 20 Following error for servo drive or difference between setpoint and actual positions MSR for step drive 21 Following error limit for drives with encoders 22 s Overshoot Switch readjustment in Reference Point Approach mode 23 Approach time Te ms...

Page 249: ...nction to synchronize the axis without reference point ap proach With Set Reference Point a position value at the instantaneous position of the axis indicated as a parameter is accepted as an actual value For axes with an absolute encoder the generated position reference is entered in MD17 At a known axis position the known actual position of the system of measurement is transmitted to the FM 453 ...

Page 250: ...tes must be fulfilled in order to execute the function measurement 1 Connect a bounce free switching signal encoder touch probe to a digital output of the FM 453 2 Parameterize Measurement for this input in MD34 Measurement functions can be executed in all modes An executed measure ment is signaled by the checkback signal ME and optionally also by a pro cess interrupt Inprocess measurement The pre...

Page 251: ...traversed distance Note The zero offset function does not change the actual position of the axis and is thus not relevant for the above observations regarding the Length Measure ment function The following table lists the errors that can occur in the execution of the Measurement function Error Significance Guidance er rors The Digital input not parameterized error is signaled when a measurement fu...

Page 252: ...lues 1 the Length Measurement and Inprocess Measure ment functions are inactive Actual position for rising touch probe edge in Inprocess Measurement and Length Measurement functions 2 S the Length Measurement and Inprocess Mea surement functions are inactive S always with the Inprocess Measurement function Actual position for falling touch probe edge in Length Measurement function 3 S the Length M...

Page 253: ...1 3 D Tool offset value number M1 M3 M function group 1 3 F Speed programmed fills in value 2 Byte Data Bit Byte Format 7 6 5 4 3 2 1 0 0 Byte NC program number 1 Byte NC block number 2 8 bit L P X t 0 G3 G2 G1 3 8 bit 0 0 0 D M3 M2 M1 F 4 Byte G function 1 5 Byte G function 2 6 Byte G function 3 7 Byte 0 8 DINT 32 bit value 1 UP number bytes 12 DINT 32 bit value 2 UP callup number bytes 16 Byte M...

Page 254: ...e servicing data S DAC output value mV for servo drive or frequency output value Hz for step drive S Actual encoder value MSR for drive with encoder or pulse output counter 0 216 1 pulse for drive without encoder S Pulse errors for drive with incremental encoder S Kv factor position control loop gain for servo drive S Following error MSR for servo drive or difference between setpoint and actual po...

Page 255: ...tion 10 1 S G43 44 active see Section 10 1 S D No active see Section 10 1 S Status messages 1 data type BOOL Speed limitation to limit value from MD23 Limitation to 10 V for servo drive Limitation of minimum acceleration or minimum deceleration in ef fect S Status messages 2 data type BOOL not assigned 9 3 17 Parameters Data Job No 114 The parameters and data requested for reading with the modify ...

Page 256: ...al values System of Measurement Internal Values Input at Interface mm 10 3 mm 10 995 10 3 mm 10 995 mm inches 10 4 inch 10 995 10 4 in ch 1 0995 inch degrees 10 4 degree 10 2 degree 3 600 000 10 4 de gree 36 000 10 2 degree 360 0000 degree 360 00 degree Note The measurement system MD7 must match the measurement system speci fied in the other DBs The measurement system raster MSR is the smallest di...

Page 257: ...MD22 to form the working range Linear axes have a limited traversing range The limits are imposed by the S Resolution of the numerical scale S The range covered by an absolute encoder M Movement Encoder G Motor Fig 9 3 Linear Axis With rotary axes the actual value is reset to 0 after one revolution Rotary axes thus have an infinite traversing range 0 5 000 9 999 Fig 9 4 Rotary Axis Before you star...

Page 258: ...m 9 999 to 0 If the direction of rotation is negative the display rolls over from 0 to 9 999 Rotary axes are subject to certain restrictions in the choice of encoder gear box motor as shown in Figure 9 5 These restrictions arise from the need to reproduce the actual position accurately over several revolutions when refer encing with incremental encoders or on POWER OFF ON with absolute encoders Se...

Page 259: ...accuracy is an n fold im provement in path resolution by the encoder Recommended Values for n Minimum Optimum Maximum 2 4 10 For that reason when configuring a given specific application select an en coder that meets the desired positioning accuracy requirements The known design data for the machine axis and the desired measurement resolution A A 1 n Positioning accuracy mm inches degrees yield a ...

Page 260: ...ary table revolution mm rev inches rev degrees rev A Required resolution mm inches degrees 4 Pulse multiplication constant iGS Ratio between encoder and mechanism Number of encoder revolutions number of encoder revolutions spindle revolution number of encoder revolutions rotary table revolution or If unusual numbers of pulses or steps result the encoder with the next higher number of pulses or ste...

Page 261: ...s Encoders with one zero pulse per revolution may be used The number of encoder pulses must be a multiple of ten or a power of two S Rotary incremental encoder on rotary axes Encoders with one zero pulse per revolution may be used The number of encoder pulses must be a multiple of ten or a power of two With indirect encoder mounting and reference point approach with a zero pulse MD18 4 you must en...

Page 262: ...asured value direc tion 20 20 0 20 2 20 3 Hardware moni toring 1 Cable break 1 Pulse monitoring 1 Voltage monitoring Entry for monitoring to be switched on MSR stands for measurement system raster see Section 5 3 1 Encoder Number of increments per revolution MD13 2 500 The FM 453 works by the principle of quadruple evaluation This yields an FM internal number of increments per revolution 10 000 Ma...

Page 263: ...external channel error is output see Troubleshooting Table 11 4 S The missing pulse memory is cleared with the control signal Restart Note For encoders with non cyclic zero pulse switch pulse monitoring in MD20 OFF In Reference Point Approach mode no zero pulse is recorded after leaving the reference point switch within the path as de fined in MD11 12 Effect S Encoder cannot be synchronized S On l...

Page 264: ...xis and that it encompasses at least one rotary axis revolution see Dependencies Section 5 3 1 and Figure 9 5 Table 9 11 shows you how to adapt the selected encoder to the FM 453 Table 9 11 Function Parameters Absolute Encoders SSI MD Designation Value Meaning Comments Unit 10 Encoder type 3 Absolute encoder SSI 13 Bit 4 Absolute encoder SSI 25 Bit 13 Absolute encoder SSI 13 Bit 14 Absolute encode...

Page 265: ...ing to be switched on MSR stands for measurement system raster see Section 5 3 1 Encoder Number of increments per revolution MD13 4096 212 Number of revolutions MD14 256 28 Machine axis design S Motor with 50 30 gear ratio on spindle with 10 mm pitch 10 000 MSR S Encoder on motor From this one can calculate the following traversing distance per encoder revolution Displacement per encoder revolutio...

Page 266: ...lute encoder S Error in protocol for data transfer be tween absolute encoder and FM 453 S Cable break Diagnostic interrupt external channel error see Troubleshooting 11 4 Warning Hardware monitoring functions should be skipped only for test purposes since positioning errors may destroy the machine When voltage monitoring is deactivated and the power supply to the encod ers or the FM is switched of...

Page 267: ...per motor revolution division period 0 232 1 see Section 5 3 1 Dependencies 2 32MSR fractional portion 52 Increments per motor revo lution division period 4 10 000 Entry per stepper mo tor data plate MSR stands for measurement system raster see Section 5 3 1 Stepper motor Number of increments per revolution MD52 10 000 Machine design Motor with 50 30 gear ratio on spindle with 10 mm pitch 10 000 M...

Page 268: ...ization point of the axis in some cases with refer ence to the reference point switch see Figure 5 5 Zero reference mark selection is an operating mode used to position the axis at the reference point is a fixed point on the axis It is S The target coordinate in the Reference Point Approach mode S Removed from the synchronization point by the amount of the reference point shift in axes with increm...

Page 269: ...witch This selection is made by the MD18 together with the approach direction Example RPS Axis direction Synchronization point Cyclical zero mark Measurement grid With reference to the synchronization point the reference point can be lo cated on the side of the lower or the higher position actual values In the ref erence point approach operating mode the machine axis additionally tra verses this d...

Page 270: ...ing on the control mode MD61 Figure 9 6 gives an over view of the interaction of the functions The separate functions are described in detail with reference to the relevant machine data in the following sec tions From encoder actual value Example Channel 1 X2 Drive actuation Actuating signal driver Stepper motor control MD61 7 MD61 or Position control MD61 or 1 Interpolation X5 To drive setpoint S...

Page 271: ... MD 55 MD56 MD57 MD58 MD59 MD60 MD61 or v t v t Fig 9 7 Overview of Interpolation Function The subfunctions of the interpolation function are described in detail here Software limit switches MD21 and MD22 see Section 9 9 are used to limit the working area MD Designation Value Meaning Unit 21 Software limit switch start 1 000 000 000 1 000 000 000 MSR 22 Software limit switch stop see Section 5 3 1...

Page 272: ...nds for measurement system grid see Section 5 3 1 Stepped characteristic The stepped characteristic is specially designed to comply with the demands of stepper motors on the frequency time function which result from the fall off in torque with increasing stepper motor speed A discontinuous traversing movement with a programmed speed is initiated or stopped below the Start Stop frequency For higher...

Page 273: ...re quency generation to the selected step drive MD Designation Value Meaning Unit 46 Minimum idle time between two positioning cycles tst 1 10 000 ms 47 Minimum traversing time at constant frequency tvk 1 10 000 ms 54 Start Stop frequency fss 10 100 000 Hz 55 Frequency value for accelera tion switchover feg 10 1 000 0001 Hz 56 Maximum frequency fmax 500 1 000 0001 Hz 57 Acceleration 1 ab1 10 10 00...

Page 274: ...lt limitation the acceleration and deceleration act as abrupt vari ables Jolt limitation allows the break points of a ramp like speed curve to be smoothed out for both acceleration and deceleration This yields particularly soft jolt free acceleration and braking for certain positioning tasks such as conveying of fluids Jolt time can be set in MD42 as the parameter for jolt limitation v a t MD42 t ...

Page 275: ...r with absolute encoder 1 0 Step drive in position controller without encoder with FM in ternal pulse feedback 1 Step drive in position controller with incremental encoder 3 4 13 14 Step drive in position controller with absolute encoder 7 Step drive in open loop control mode This function is subdivided into subfunctions as shown below which are then described in detail From encoder actual value E...

Page 276: ...n controller that operates according to the following principle Internal velocity setpoint Following error Positioning loop amplification Here the positioning loop amplification determines the effect of a specific following error on the generation of the actuating signal for the drive to be actuated Positioning loop amplification The positioning loop amplification Kv factor specifies at what speed...

Page 277: ...he possible maximum values 10 V or maximum frequency A violation of the maximum limit is interpreted as follows No axis movement No drive movement error message see Table 11 7 Class 3 No 65 Traverse in the opposite direction Direction of drive rotation error message see Table 11 5 Class 1 No 11 Correct travel direction Overrange message in status message 1 see Section 9 3 16 Additional operating d...

Page 278: ...tpoint side t2 b Before the monitoring time expires the actual position reaches the target range Positioning is completed A PEH is signaled and exact matching is performed by the CL controller t3 c After the monitoring time expires the actual position has not reached the target range PEH Error message PEH Target Range Monitoring see Troubleshooting Table 11 5 Class 3 No 64 MD Designation Value Mea...

Page 279: ...d Minimum following error dynamic a comparison is performed with the actual value for the following error MD39 vmax MD23 Idealized curve of fol lowing error Dynamic monitoring in effect Calculated curve of fol lowing error scalc s Actual curve of following error v s following error v speed MD Designation Value Meaning Unit 39 Minimum following error dy namic 0 no monitoring 0 1 000 000 MSR When th...

Page 280: ... positioning errors Backlash Spindle When the position encoder is situated on the machine part to be positioned e g on a saddle direct arrangement backlash adversely affects the achiev able Kv factor On the other hand if the position encoder is attached to the drive motor indirect arrangement a high Kv factor can be achieved but at the cost of position deviations that cannot be detected by the pos...

Page 281: ...er ready External zero reference mark MD37 From drive actuation v t Fig 9 11 Overview of stepper motor control system Basic diagnostics 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...

Page 282: ...g Table 11 7 Kl 3 Nr 30 Selecting function without parameterization for NIX S Rotation monitoring error see Troubleshooting Table 11 7 Cl 3 No 66 Motor turns too slowly during acceleration travel Motor turns too fast during acceleration travel External zero pulse failed Incorrect number of increments per motor revolution parameterized MD52 Function description The external zero pulse is used as de...

Page 283: ...nction generated the error or whether complete motor revolutions are involved S Rotation monitoring is automatically discontinued whenever the synchro nization mark is passed over in the Reference point approach operating mode and the function Retrigger reference point approach is executed X 45 45 B A NIX NIX Zero pulse external NIX center is synchronization point for rotation monitoring X Permiss...

Page 284: ...he voltage sign of the manipulated signal and the axis movement MD Designation Value Meaning Unit 19 1 Direction adjustment 1 Invert direction of drive rotation Offset compensation The analog modules in the positioning control loop D A converter of the FM453 and closed loop controller module of the drive cause a zero error because of operating voltage and component tolerances The result is that at...

Page 285: ... V Warning This assignment MUST be identical with the setting on the drive MD Designation Value Meaning Unit 23 Maximum speed 10 500 000 000 MSR min 43 Set voltage max 1 000 10 000 mV Voltage ramp A ramp shaped voltage rise drop can be defined in MD45 for the voltage out put to the drive when the position controller is inactive This serves to limit acceleration and thus power for the drive control...

Page 286: ...eed The pulse length is auto matically set by the FM 453 to a symmetrical 1 1 sampling ratio with re spect to the currently output frequency The direction information of the internal velocity setpoint value is converted into the direction signal for the step drive Direction alignment MD19 allows you to align the direction by defining an assignment between the signal level of the Direction signal a...

Page 287: ...23 but never one with values that are below this value MD Designation Value Meaning Unit 11 Displacement per encoder rev olution division period 1 1 000 000 0001 MSR 12 Residual distance per encoder revolution division period 0 232 11 2 32MSR 23 Maximum speed 10 500 000 000 MSR min 52 Increments per motor revolu tion division period 4 10 0001 56 Maximum frequency 500 1 000 0001 Hz 1 see Section 5 ...

Page 288: ...ion These signals are used to activate the drive The Controller ready signal can be connected to the FM 453 either via the X1 connector at TTL level or X2 with the 24 V level see Section 4 and can be parameterized with respect to its active level Control enable is output as a closed contact when active see Section 4 2 MD Designation Value Meaning 37 Control signals 37 0 Controller en able active 0...

Page 289: ...The FM 453 implements these two functions via an output This is done by alternate machine data selection The active level of the signal can be parameterized Signal response Movement status Output signal Boost Output signal PWM Idle inactive pulse duty factor per MD 51 Acceleration delay active static active Constant travel inactive pulse duty factor per MD 50 The following table shows you the avai...

Page 290: ... unit The amount of the increase is set on the drive unit At zero speed and during continuous travel the current is always 100 IBoost 100 fpulse t t Zero pulse generation To support stepper motor axis synchronization the FM 453 processes a cyclic input signal which is dependent on the axis movement as a zero marker see Section 4 6 This signal can be either the Current sourcing pattern zero signal ...

Page 291: ...t sourcing pattern number Current sourcing pattern external and MD53 n When the Zero pulse external signal is active the rotation monitoring func tion can be implemented see Section 9 7 3 The following table shows you the available machine data for parameterizing the function MD Designation Value Meaning 37 Control signals 37 24 Current sourcing pattern zero active 0 Current sourcing pattern zero ...

Page 292: ...0 I1 I2 I3 0 8 16 24 External start2 1 9 17 25 Enable input 2 10 18 26 External block change 3 11 19 27 Set actual value on the fly 4 12 20 28 Measurement inprocess mea surement length measurement2 5 13 21 29 Reference point switch for reference point approach2 6 14 22 30 Reversing switch for reference point approach2 35 Digital outputs1 Q0 Q1 Q2 Q3 0 8 16 24 Position reached stop 1 9 17 25 Axis m...

Page 293: ... input w 2 FM cycle The enable input signal must be set if defined in MD34 for a positioning operation movement output of the axis to take place A reset stops the move ment external movement enable S In the Jogging and Control modes the movement of the axis pro ceeds as long as the AND link continues between the control signal R R and the enable input Positioning R or R Enable 1 2 3 1 2 3 Example ...

Page 294: ...l output It allows these M functions switching signals to be applied without being delayed by the user cycle time Outputs Q0 Q3 D_OUT1 D_OUT4 which are defined in MD35 as di rect output can be used directly by the user program job no 15 and can also be controlled by the FM 453 Since the same memory is used in the user DB for job 15 and job 101 the jobs cannot be used simultaneously in the cycle No...

Page 295: ...e traveling movement is stopped and an error is signaled The limit switch position is overshot by the amount of the necessary deceleration distance Reference point approach mode No effect Incremental relative MDI Automatic mode Movement is stopped or not even started as soon as read in of the set posi tion reveals that the position lies outside the working range An error is sig naled The following...

Page 296: ...ogram The appropriate setting in the machine data MD5 specifies which signals are to be quickly communicated to the user program The process interrupt is generated by way of machine data item MD5 MD Designation Significance 5 Process interrupt generation data type bit field 0 Position reached 1 Length measurement completed 3 Change block on the fly 4 Measurement on the fly You must program the int...

Page 297: ...e Section 9 3 12 are stored in the appropriate data block and are transferred to the module where they are administered The possible number of programs depends on the amount of memory avail able max 16 Kbytes and on the length of the individual programs Program length in bytes 110 20 x no of traversing blocks Any program can be assigned a name optional The program name may have up to 18 characters...

Page 298: ...llowing Figure gives you an overview of the structure of traversing blocks Identifier for skipped block N Block number G1 G function of first function group G2 G function of second function group see Table 10 1 G3 G function of third function group X t Position dwell time F Speed M1 M function of first function group M2 M function of second function group see Table 10 2 M3 M function of third func...

Page 299: ... function groups Table 10 1 G Functions G No G Function G Function Group 041 Dwell time 87 Turn off measuring system shift for Set Actual Value On the Fly 881 Continuous travel for for Set Actual Value On the Fly 1 891 Continuous travel for for Set Actual Value On the Fly 90 Absolute measure 91 Incremental dimensions 30 31 32 39 100 override on acceleration deceleration 10 override on acceleration...

Page 300: ...int of deceleration is reached change block on the fly G60 and G64 are mutually exclusive and self maintaining M commands have no effect on G64 operation For a detailed description see Section 10 3 The external block change function causes a block change on the fly trig gered by a digital input The fast input must be parameterized with the Ex ternal block change function by way of machine data ite...

Page 301: ...d the functions programmed in N20 are executed and processing then moves on to the next block except if the block contains M0 M2 or M30 S If the programmed path in block N20 is less than the deceleration dis tance the programmed position is overshot and then positioned by a re versal of direction If no signal change occurs at the digital input the target position of N10 is approached with the foll...

Page 302: ...on the fly N G1 G2 G3 X t F M1 M2 M3 D 400 000 10 90 15 20 25 50 300 400 200 000 400 000 400 000 89 88 90 87 100 ÍÍ ÍÍ V t I N10 N15 N20 N25 t Reversal of direction 0 50 100 150 200 250 300 350 400 0 50 100 150 200 250 300 350 400 X X System of measure ment nor mal I N15 N10 N25 N20 System of measure ment shifted I digital input Example of set Actual Value On the fly Writing Traversing Programs ...

Page 303: ...7 cancels the shift of the coordinate system and causes reference measure programming to the block position of N25 The saved actual value can be read out with Actual value block change The shift of the coordinate system is maintained until it is canceled by G87 or by a mode change It is possible to use the existing shift of the coordinate system in different programs The coordinate system can be s...

Page 304: ... specify dimensions that gener ally refer to the coordinate system 90 20 N G1 G2 G3 X t F M1 M2 M3 D 100 0 10 20 30 40 50 mm Programmed position Actual position Fig 10 1 Reference Measure Input G90 Note To ensure precise reproduction of the program the first block should contain reference measure programming Incremental dimensioning is the method used to specify incremental dimen sions that refer ...

Page 305: ...tonomously always takes the shortest path to reach the set position of 45_ going via 0_ to 315_ Option 2 The control signals R or R force the respective direction of the axis in this example 45_ via 180_ to 315_ R or R must already be pending when positioning is activated START Note The direction R or R must be specified sufficiently in advance A tra versing direction cannot be forced on a travers...

Page 306: ... the axis with a Restart single command S Changing or ending the program Tool compensation allows you to continue using an existing machining pro gram even when the tool dimensions have changed Tool offset is selected with G43 or G44 as applicable and the tool offset number D1 D20 Tool offset is turned off with G43 or G44 as applicable and the tool offset number D0 A total of 20 tool offset storag...

Page 307: ... specifying a fixed wear value Additively by adding an offset value to the current tool length wear value contents Tool new Tool wear a Tool wear b Tool zero DL DVabs DVadd DV ÉÉ ÉÉ ÉÉ ÉÉ Fig 10 4 Tool Offset Notes to the figure The tool offset thus consists of the tool length offset and the tool length wear value D DL DV DV DVabs DVadd D Tool offset DL Tool length offset positive or negative DV T...

Page 308: ... offset in the traversing block at least the tool length offset must be input If no correction is to be applied even when the function has been selected the tool length offset and tool length wear value must be preset to 0 A tool length wear value can be deleted by an absolute input of 0 Positions may be input with a negative or positive sign The plus sign on pos itive values may be omitted Name L...

Page 309: ...as digital output 99 User functions M0 M2 M18 and M30 are always output at the end of the traversing move ment M0 M2 M18 and M30 are mutually exclusive within a single block If M no 0 is programmed in a traversing block the program stops at the end of the traversing block and M0 is output Only a new START edge causes the traversing program to be continued If M2 or M30 is programmed in a block then...

Page 310: ... M98 is programmed in a block the M function output proceeds via the digital outputs as defined in machine data item MD35 in the same way as the checkback signals Twenty tool offset numbers D1 D20 are available D0 in conjunction with G43 or G44 causes the tool offset to be switched off The offset values must previously have been loaded to the module Nonstandard offset values have a value 0 A block...

Page 311: ...reasons a distinction can be made between forward processing and reverse processing in terms of both geometry and block transition response 10 3 Block Transitions This chapter describes the influence of certain commands on block transi tions G60 mode is overlaid with G50 and G88 to G89 force block change on the fly The program advances to the next block when the target range is reached The influen...

Page 312: ...d rate is changed in such a way that a higher speed from a preceding block is never carried over into the next block and a higher speed from a following block never goes into effect while a given block is still traversing its own path This means that acceleration does not begin until the starting point of the block and deceleration to a lower speed for a following block is initiated as with G60 Wh...

Page 313: ...t a lower traversing speed at the braking point of N15 4 In a change of traversing direction the axis brakes until it comes to a standstill and waits until the actual value of the encoder has reached the target range 5 When the target range is reached the axis accelerates in the opposite direction up to the traversing speed of the new block To be able to approach a position correctly the axis must...

Page 314: ...d of block To continue the program the START control signal must be reset By a block with a dwell time By processing a program in the Automatic Single Block mode Each block must be activated individually By a change in the acceleration override S Functions that themselves prevent block change on the fly M functions during positioning 1 V t M ÉÉÉ ÉÉÉ ÉÉÉ t t 2 ÉÉÉÉ ÉÉÉÉ t t 3 M ÉÉÉÉ ÉÉÉÉ M V V t 1 ...

Page 315: ...0 90 40 97 5 15 20 60 20 000 30 000 40 000 200 00 150 00 20 30 V X N5 N10 N15 N20 10 000 20 000 30 000 40 000 10 20 30 40 97 M No 1 Output of M10 is not position dependent since no relevant position for a position dependent M function is present 2 At the block change from N5 to N10 output is prepared Output of the M function does not proceed until the actual position has reached the programmed pos...

Page 316: ...10 20 FM 453 Servo Drive Step Drive Positioning Module C79000 G7076 C453 01 Writing Traversing Programs ...

Page 317: ... of diagnostic interrupt STATUS LEDs light up in addition Diagnos tic backup error his tory FM 453 CPU callup in user program User DB MPI OP PG STEP 7 P bus K bus SSL Diagnostic interrupt binary diagnostic interrupt informa tion RAM DB SS Other errors op erating er rors External channel er rors External er rors OB 1 OB 82 Call SFC 52 FC RD_COM Diag nostic backup of CPU Write diagnost interrupt inf...

Page 318: ...7 300 400 Program Design OB Types Diagnostic Interrupt OB 82 S 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 In Section You Will find On Page 11 1 Error Classes and Module Responses 11 3 11 2 Error Messages 11 4 11 3 Error Lists 11 9 Prog...

Page 319: ... operation operating errors of the FM 453 e g cable break incremental value encoder See Section 6 4 for diagnostic interrupt data and error list Table 11 4 and 11 5 Checkback signals Operator control and travel errors Feed STOP are errors general operator control and guidance errors which can occur during operation of the FM 453 e g direction signals R and R set at the same time see Error List Tab...

Page 320: ...dition in the FM 453 Diagnostic interrupt internal error To eliminate the error see Error List Table 11 4 EXTF red LED ON Group errors for external errors This LED indicates an external channel error Diagnostic interrupt external error or external channel error To eliminate the error see Error List Table 11 4 STAT yellow LED ON LED blinking Diagnosis This LED indicates various statuses flashing Di...

Page 321: ... byte 8 The operator control errors in the external channel error class are specified again and are stored in data set 164 199 234 or in the diagnostic buffer The FM 453 signals a diagnostic interrupt incoming or outgoing Diagnostic Interrupt Message to the CPU precondition interrupt message activated see Section 5 2 Message in the trou bleshooting display f P t i FM Entry in diag nostic buffer No...

Page 322: ...lock DS162 197 232 and DS163 198 233 Checkback Signals BF FS and DF group error messages Error specification in user program if necessary programming device PC Read out DS 162 for channel 1 DS 197 for channel 2 DS 232 for chan nel 3 on BF FS or Read out DS 163 for channel 1 DS 198 for channel 2 DS 233 for chan nel 3 on DF Message in the trou bleshooting display of Parameterize FM 453 Menu Test Ala...

Page 323: ... 1 DS 199 for channel 2 DS 234 for channel 3 DS Data Block Structure Significance 162 163 2 byte error number DEKL DENR 163 164 2 x 1 byte free Free Free The errors are identified by the detail event class DEKL and by the detail event number DENR In the case of operating errors within the external channel errors error class the message is displayed using the bit combination 0 0 0 2 0 3 8 7 10 7 12...

Page 324: ... an error number in the corresponding data block see Error List in Table 11 8 The error message occurs each time the data block is written to until the cause has been eliminated We recommend scanning the error message after every write operation 11 2 5 Viewing the Diagnostic Buffer PG PC The last five error messages are stored in the diagnostic buffer Proceed as follows 1 Open your project in the ...

Page 325: ...NTF EXTF 8031 Cause MPI K bus communication fault caused by unknown event EXTF STAT Effect S Elimina tion S Check connection S Check programming device CPU S Switch module on off S Replace module 2 3 8033 Internal time monitoring circuit Watchdog 8033 Cause S Pronounced noise conditions on the FM 453 S Error in the FM 453 Effect S Deactivation of entire FM 453 S LED indicators STAT Flashing cycle ...

Page 326: ...3 3 3 8043 RAM error 8043 Cause S Faulty RAM data memory S Faulty flash EPROM data memory Effect Elimina tion Replace the FM 453 3 6 8046 Process interrupt lost 8046 Cause S A process interrupt event was detected by the FM 453 and cannot be reported because the same event has not yet been acknowledged by the user program CPU S Faults on backplane bus Effect Elimina tion S Incorporate OB40 into use...

Page 327: ...ncoder delivers erroneous values S Noise interference on measurement system cable S Baud rate set too high MD15 Effect Elimina tion S Check encoder and measurement system cable S Check telegram traffic between encoder and FM 453 S Using the MD20 monitoring can be temporarily skipped at the responsi bility of the owner operator 8 2 8092 Erroneous pulses incremental encoder or zero reference mark mi...

Page 328: ...er cable OK S Using the MD20 monitoring can be temporarily skipped at the responsi bility of the owner operator 8 4 8094 Voltage monitoring 15 V 8094 or 10 4 Cause Failure of module internal 15 V 10 4 80B4 Effect or 12 4 80D4 Elimina tion S Replace the FM 453 S Using the MD20 monitoring can be temporarily skipped at the responsi bility of the owner operator 8 5 8095 Voltage monitoring of digital o...

Page 329: ...sary stopping distance S Set actual value is not executed Elimina tion S Following acknowledgment of the error it is possible to tra verse to the working range S Alter value of software limit switch MD22 S Disable limit switch monitoring With the limit switches MD21 22 disabled the travel range limits are established by the maximum allowable values for the limit switches 1 01 3 03 Beginning of tra...

Page 330: ... the servo enable was deactivated or when an axis standstill was reached in the PEH target range interrupt Effect Elimina tion S Check electrical and mechanical drive disable terminals con necting cables control element functions S Match MD26 1 01 90 99 5A 63 System errors Diagnostic interrupt 5A 63 Cause Internal errors in the module interrupt STAT Effect Undefined effects possible STAT LED Elimi...

Page 331: ... is not allowed 1 100 and 254 permitted Effect Elimina tion Set operating mode parameters to an allowable value 2 02 5 05 Start enable missing CBS Cause A travel command was given in the absence of a start enable start external start R R Effect Elimina tion Restore travel command and wait for start enable 2 02 9 09 Axis is not synchronized CBS Cause Synchronization of the axes is necessary in the ...

Page 332: ...ize and read in setpoint parameters 2 02 14 0E No program preselected CBS Cause No program preselected at Start Effect Elimina tion First preselect program then start 2 02 15 0F Digital input not activated CBS Cause The programmed target was reached in a block with external block change G50 Effect Elimina tion Check programming MD34 and connection of digital input 2 02 16 10 Measurement function u...

Page 333: ...ng With the limit switches MD21 22 disabled the travel range limits are established by the maximum allowable values for the limit switches 3 03 2 02 Software limit switch end CBS Cause Limit switch approached in Jog operating mode in Automatic operating mode if G88 89 without switching signal from the corresponding digital input The axis is located to the right of the software limit switch because...

Page 334: ...se of actual value set Traversing range 109 or from range covered by absolute encoder Effect S Axis movement is stopped at the traversing range limit S Set actual value is not executed Elimina tion Travel in the opposite direction 3 03 5 05 Target position not within traversing range CBS Cause S The position to be approached is outside the working range limited by the software limit switches S The...

Page 335: ... MD34 3 03 35 23 Tool offset value not in place CBS Cause No tool offset values are available on the FM 453 or tool offsets are accessed and modified when an override is active Effect Elimina tion Parameterize and read in tool offset values 3 03 36 24 Set actual value on the fly incorrect value CBS Cause Value is no longer within the range 109 Effect Elimina tion Input a correct value 3 03 37 25 M...

Page 336: ...ffect No axis movement Axis stopped at same time con troller enable is held until axis comes to rest OR Elimina tion Set controller enable by way of user program 3 03 62 3E Controller not ready for operation CBS Cause Axis started without Controller ready mes sage Controller ready message can celed whilst processing in progress OR Effect No axis movement Axis is stopped with actual value transfer ...

Page 337: ... 453 and drive 3 03 66 42 Following error too great CBS Cause Excessive following error during axis movement Effect Elimina tion S Check drive S Check MD23 MD43 3 03 67 43 Boost duration absolute exceeded CBS Cause Acceleration phase too long Effect Elimina tion S Check MD48 S Change drive configuration S Change technology axis traversing cycle 3 03 68 44 Boost duration relative exceeded CBS Cause...

Page 338: ...between 0 and max allowable tra verse velocity 500 000 000 MSR min or DB Effect Velocity does not become effective Elimina tion Input an allowed velocity value 4 04 4 04 Voltage frequency level 1 is incorrect CBS Cause Voltage frequency specified does not fall within the range of 10 V or DB Effect Voltage frequency level does not become effective Elimina tion Input an allowed voltage frequency val...

Page 339: ...BS Cause Position or dwell time falls outside the allowable values Position 109 MSR Dwell time 100000 ms or DB Effect Original MDI block is retained Elimina tion Input a correct MDI block 4 04 10 0A Zero offset value offset value incorrect CBS Cause Value falls outside the range 109 MSR or DB Effect Does not become effective DB Elimina tion Input a correct value 4 04 11 0B Set actual value actual ...

Page 340: ...15 0F Teach In program number incorrect CBS Cause The program was not parameterized or read in or DB Effect Teach In is not executed DB Elimina tion Parameterize and read in program or correct program number 4 04 16 10 Teach In block number incorrect CBS Cause The block number in the program selected is not in place or DB Effect Teach In is not executed DB Elimina tion Specify correct block number...

Page 341: ...8 Measurement system grid deviates CBS Cause The measurement system in the DBs NC SM TO does not agree with MD7 or DB Effect DB does not become effective and is stored non retentively Elimina tion Correct and retransmit 4 04 121 79 Incorrect DB type in the module CBS Cause An incorrect type of DB has been transmitted into the FM 453 or DB Effect DB does not become effective and is stored non reten...

Page 342: ...B does not become effective and is stored non retentively DB Elimina tion Correct program and retransmit 4 04 127 7F Writing parameters data is not possible CBS Cause Axis does not come to a stop or DB Effect Parameters data do not become effective DB Elimina tion Stop axis 4 04 128 80 Incorrect module identification CBS Cause DBs which do not belong to the module were transmitted no identificatio...

Page 343: ...ent system grid MSR entered does not agree with the MSR in the other DBs of the module or DB Effect DB does not become effective and is stored non retentively Elimina tion S Check MSR and correct as necessary S When making correct input delete the other DBs on the mod ule before retransmitting 5 05 8 08 Type of axis CBS Cause No linear or rotary axis parameterized or DB Effect DB does not become e...

Page 344: ...na tion Correct and retransmit 5 05 16 10 17 11 Reference point coordinates absolute encoder adjustment CBS 17 11 Cause Unacceptable value range or DB Effect DB does not become effective and is stored non retentively DB Elimina tion Correct and retransmit 5 05 18 12 Type of reference point travel CBS Cause Unacceptable type of reference point travel or DB Effect DB does not become effective and is...

Page 345: ...a tion Correct and retransmit 5 05 31 1F Backlash vector reference CBS Cause Backlash vector reference undefined or DB Effect DB does not become effective and is stored non retentively DB Elimina tion Correct and retransmit 5 05 32 20 Type of output M function CBS Cause Type of output M function not defined or DB Effect DB does not become effective and is stored non retentively DB Elimina tion Cor...

Page 346: ...Speed up Slow down Jerk time Set voltage max Offset compensation Voltage ramp CBS or DB Cause Unacceptable value range Effect DB does not become effective and is stored non retentively Elimina tion Correct and retransmit 5 05 67 43 68 44 Control signals Number of increments per current sourcing cycle CBS or Cause Unacceptable value range DB Effect DB does not become effective and is stored non ret...

Page 347: ... limit switch end with rotary axes Software begin end limit switches not within rotary axis cycle and not at maximum input value or DB Effect DB does not become effective and is stored non retentively Elimina tion Correct and retransmit 5 05 97 61 Limitation software limit with absolute encoder CBS Cause Impermissible value range or dependency violation see Section 5 3 1 Travel distance between so...

Page 348: ... Impermissible increment evaluation factor for step drive CBS Cause Impermissible relationship in the assignments for distance per en coder revolution MD11 12 and steps per motor revolution MD52 or DB Effect DB does not become effective and is stored non retentively Elimina tion Correct and retransmit 5 05 102 66 Limitation software limit for linear axis CBS Cause For encoder resolutions step reso...

Page 349: ...program 8 08 9 09 Program selection block number missing CBS Cause The block number is missing in the program selected or DB Effect Program selection is not executed DB Elimina tion S Correct program S Select different block number 8 08 10 0A Program block number unacceptable CBS Cause Block number missing or outside of the number range or DB Effect Program is not stored DB Elimina tion Correct pr...

Page 350: ...alue range incorrect or DB Effect Program is not stored DB Elimina tion Correct program 8 08 23 17 Block number sequence incorrect CBS Cause Block number not in ascending order or DB Effect Program is not stored DB Elimina tion Correct program 8 08 24 18 G function 1 unacceptable CBS Cause S The number programmed as G function 1 is not allowed S In block other data besides M functions were program...

Page 351: ...s M function is not allowed S At least two of the M functions M0 M2 M18 M30 which cancel each other out are found in one block or DB Effect Program block not stored Elimina tion Correct program per cause 8 08 28 1C Position dwell time missing CBS Cause S No dwell time specified in block with G04 S Target position missing with external block change G50 S No new actual value programmed for the funct...

Page 352: ...Error callup subroutine CBS Cause Block syntax for callup subroutine is incorrect or DB Effect Program is not stored DB Elimina tion Correct program per cause 8 08 33 21 D function unacceptable CBS Cause Block syntax for invoking a D function is incorrect or DB Effect Program is not stored DB Elimina tion Correct program per cause 8 08 34 22 Incorrect program length CBS Cause Maximum block number ...

Page 353: ... climate conditions S Data on insulation testing protection class and degree of protection This information contains standards and test values with which the S7 400 complies or according to whose criteria the S7 400 was tested The general technical data are described in the manual Installing an S7 400 The following certifications are on record for the S7 400 UL Recognition Mark Underwriters Labora...

Page 354: ...Our products are in compliance with the 89 336 EWG Electromagnetic 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 SIMATIC products ...

Page 355: ...r consumption 2L 4L for nominal volt age for digital input channels 1 to 3 Max 2 A per channel Technical data for dimensions and weights Dimensions W H D mm 50 290 210 Weight g ca 1620 RAM memory 64 Kbytes in total for the parameter data of the three channels FEPROM for retentive storage of parameter data 3 ms Servo drive Setpoint signal Rated voltage range 10 10 V Output current 3 3 mA Relay cont...

Page 356: ...te SSI Signal voltages Inputs 5 V RS422 compliant Encoder supply voltage S 5 V 300 mA S 24 V 300 mA Input frequency and line length for incremental encoder S Max 1 MHz wih 10 m conductor length shielded S Max 500 kHz with 35 m conductor length shielded Data transmission rates and line length for absolute encoder SSI S Max 1 25 Mbit s with 10 m conductor length shielded S Max 156 kbit s with 250 m ...

Page 357: ...24 V DC allowable range 20 4 28 8 V Electrical isolation Yes Output voltage S 0 signal Residual current max 2 mA S 1 signal aux v 2L 4L 0 3 V Output current on signal 1 S at ambient temperature of 40_C Rated value Permissible value range Lamp load S at ambient temperature of 60_C Rated value Permissible value range 0 5 A 5 mA to 0 6 A over auxiliary voltage range Max 5 W 0 1 A 5 mA to 0 12 A over ...

Page 358: ...A 6 FM 453 Servo Drive Step Drive Positioning Module C79000 G7076 C453 01 Technical Specifications ...

Page 359: ...onnecting Cables for Drives Drive Configuration Connecting Cable 3 SIMODRIVE 611 A servo drives 6FX2 002 3AD01 1VVV 3 FM STEPDRIVE step drives 6FX2 002 3AB04 1VVV 1 FM STEPDRIVE step drive and 2 SIMODRIVE 611 A servo drives 6FX2 002 3AB02 1VVV 2 FM STEPDRIVE step drives and 1 SIMODRIVE 611 A servo drive 6FX2 002 3AB03 1VVV In Section You Will Find the Cable Sets For On Page B 1 incremental encoder...

Page 360: ...5 V Shield on housing Cable 4 2 0 38 4 0 5 mm2 Twisted pairs 15 pin sub D connector con necting metallic housing side with screw locking 6FC9 341 1HC 12 pin round con nector Siemens connecting side 6FX 2003 0CE12 1 2 3 4 5 6 7 8 9 10 12 9 15 1 8 11 View onto crimp ter minal side White red White blue 4 9 Ground 5 V Ground A_N The cable cross sections have already been specified in the diagram The m...

Page 361: ...using Cable 4 2 0 38 4 0 5 mm2 Twisted pairs 15 pin sub D connector con necting metallic housing side with screw locking 6FC9 341 1HC 17 pin round connector Siemens connecting side 6FC9 348 7AV01 9 15 1 8 View onto crimp terminal side White red White blue 4 9 Ground 5 V Ground A_N The cable cross sections have already been specified in the diagram The maximum length of the connecting cable is give...

Page 362: ...airs 15 pin sub D connector con necting metallic housing side with screw locking 6FC9 341 1HC 9 15 1 8 Ground DATA Cable sleeve stripped 100 mm DATA DATA_N CLS CLS_N Ground 24 V DATA_N CLS_N View onto crimp ter minal side White yellow 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 The cor...

Page 363: ...tallic housing side with screw locking 6FX2 003 0AA00 White black Wire end ferrules with designation 1 17 18 34 33 50 36 3 17 50 4 37 View onto crimp terminal side Shield Channel 1 Channel 2 Channel 3 Not assigned White red White orange White yellow White green 2 9 2 65 2 14 2 56 3 9 3 65 3 14 3 56 4 9 4 65 4 56 4 14 1 9 1 65 1 14 1 56 Black Brown Red Orange The cable cross sections have already b...

Page 364: ...w locking 6FX2 003 0AA00 1 17 18 34 33 50 11 12 40 7 41 8 View onto crimp terminal side Shield 20 21 28 29 9 42 10 26 43 27 44 45 15 8 9 1 15 pin female sub D connector connecting metallic housing side with screw locking 6FC9 348 7HX View onto crimp terminal side 1 9 2 10 3 11 4 12 1 9 2 10 3 11 4 12 1 9 2 10 3 11 4 12 Channel 1 Channel 2 Channel 3 Black Brown Red Orange Yellow Green White green B...

Page 365: ...fied in the diagram The maximum length of the connecting cable is S 35 m for symmetrical transmission S 10 m for asymmetrical transmission The corresponding order number is 6FX2 002 3AB04 1VVV VVV For length code see Catalog NC Z Order No E86060 K4490 A001 A4 1 1 Soon to be included in catalog Order Notes Connecting Cables ...

Page 366: ...3 17 50 4 37 15 8 9 1 15 pin female sub D connector connecting metallic housing side with screw locking 6FC9 348 7HX View onto crimp terminal side 1 9 2 10 3 11 4 12 2 9 2 65 2 14 2 56 3 9 3 65 3 14 3 56 Channel 1 Channel 2 Channel 3 SIMODRIVE 611 A FM STEPDRIVE Brown red Brown orange White yellow White green White blue White violet 24 13 14 15 Black Brown Red Orange Yellow Green White green Brown...

Page 367: ... side with screw locking 6FX2 003 0AA00 1 17 18 34 33 50 11 12 40 7 41 8 View onto crimp terminal side Shield 20 21 28 29 24 13 25 17 30 50 4 37 15 8 9 1 15 pin female sub D connector connecting metallic housing side with screw locking 6FC9 348 7HX View onto crimp terminal side 1 9 2 10 3 11 4 12 1 9 2 10 3 11 4 12 14 15 Channel 1 Channel 2 14 15 3 9 3 65 3 14 3 56 FM STEPDRIVE SIMODRIVE 611 A Cha...

Page 368: ...s 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 1VVV VVV For length code see Catalog NC Z Order No E86060 K4490 A001 A4 1 1 Soon to be included in catalog Order Notes Connecting Cables ...

Page 369: ...a block byte Data block for machine data Data block for traversing programs Data block for increments Data block for status messages Data block for tool offset data Data block bit Detail event class Detail event number Digital frequency converter Distributed I O Electromagnetic compatibility Enable input parameter in LAD representation Enable output output parameter in LAD representation Erasable ...

Page 370: ...Multi point interface Measurement system raster Organization block Operator panel Position reached stop Programming device Programmable controller Power Supply SIMATIC S7 Pulse width modulation Output parameter Controller enable Reference point switch PLC of medium performance range System data block System function call integrated functions Signal module SIMATIC S7 e g input output module Synchro...

Page 371: ...C 3 FM 453 Servo Drive Step Drive Positioning Module C79000 G7076 C453 01 System status list Technology function User program SZL TF UP List of Abbreviations ...

Page 372: ...C 4 FM 453 Servo Drive Step Drive Positioning Module C79000 G7076 C453 01 List of Abbreviations ...

Page 373: ...tion 5 3 configuring the interrupts 5 4 connecting cables 4 4 B 1 measurement system cable 4 4 4 20 MPI connecting cable 4 4 setpoint cable 4 4 control signals 6 6 6 12 8 15 9 3 controller enable 9 77 COROS equipment operator panel 8 3 CSA certification A 1 D data blocks 5 7 increments 5 7 5 21 machine data 5 7 5 10 status messages 8 3 8 11 tool offset data 5 7 5 22 traversing programs 5 8 5 24 us...

Page 374: ...ram errors 11 33 error messages 11 4 LED indicators 11 4 error response 11 3 external block change 10 4 F FM approval A 2 FM cycle 9 19 9 39 9 51 9 54 9 82 9 92 9 93 A 3 follow up mode 9 40 following error monitoring 9 78 frequency generation 9 73 frequency levels 9 16 front connector 1 6 4 21 connecting cables 4 29 wiring the front connector 4 28 front connectors 4 4 front panel elements 1 7 LED ...

Page 375: ...s 1 6 1 7 4 21 drive port 1 6 1 7 I O port 1 6 1 7 4 21 measurement system port 1 6 1 7 SIMATIC bus connector port 1 6 1 7 position control 7 24 approach to position 9 78 assessment criteria 7 28 backlash compensation 9 80 direction alignment 9 84 9 86 drift compensation 9 80 following error monitoring 9 78 offset compensation 9 84 position controller diagnostics 7 38 positioning loop amplificatio...

Page 376: ...9 parking axis 9 41 retrigger reference point 9 39 rotation monitoring 9 40 servo enable 9 41 simulation 9 41 switch off enable input 9 40 software limit switches 7 41 9 95 start enable 9 6 start up 7 8 step drive A 4 stepper motor control system rotation monito ring 9 82 Stepper motor without encoder 9 67 switch off enable input 9 40 synchronization 9 68 9 69 absolute encoder alignment 9 68 measu...

Page 377: ... creating 6 2 initialization 6 4 V velocity levels 9 13 velocity override 9 4 voltage levels 9 16 voltage ramp 9 85 9 87 W weights A 3 wiring diagram for a FM 453 4 2 Wiring the FM 453 4 1 wiring up the front connector 4 28 write data request application data 9 48 Teach in 9 49 write jobs 6 6 writing traversing programs 10 1 Z zero offset 9 44 zero pulse 7 37 zero reference mark 9 68 Index ...

Page 378: ...Index 6 FM 453 Servo Drive Step Drive Positioning Module C79000 G7076 C453 01 Index ...

Page 379: ..._ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Street _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ City Zip Code _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Country _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Phone _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Please tick any industry that applies to you Automotive Chemical Electrical Engineering Food Instrumentation and Co...

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