Preface, Contents

Product Overview
1
Information on the Controller
Settings
2
SIMATIC How Does the FM 455 Controller
Module Work?
3
Installing and Removing the
Controller Module FM 455 FM 455
4

Wiring the FM 455

5
Assigning Parameters to the
Manual FM 455
6
Integrating the FM 455 into the
User Program
7

Starting Up the FM 455

8
This manual is part of the documentation package Properties of Digital and Analog
with the order number: Inputs and Outputs
9
6ES7455-0VS00-8BA0 Connecting Measuring Sensors
and Loads/Actuators
10

Assignment of the Data Blocks

11

Faults and Diagnostics

12

Examples
13

Appendices

Data Sheet
A

Spare Parts
B

Literature List
C

Glossary, Index
03/2000
A5E00059359
Edition 02
 Safety guidelines
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connected equipment against damage. These notices are highlighted by the symbols shown below and
graded according to severity by the following texts:

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! indicates that death, severe personal injury or substantial property damage will result if proper precautions
are not taken.

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precautions are not taken.

Caution
! indicates that minor personal injury or property damage can result if proper precautions are not taken.

Note
draws your attention to particularly important information on the product, handling the product, or to a
particular part of the documentation.

Qualified Personnel
Only qualified personnel should be allowed to install and work on this equipment. Qualified persons are
defined as persons who are authorized to commission, to ground, and to tag circuits, equipment, and
systems in accordance with established safety practices and standards.

Correct Usage
Note the following:

Warning
! This device and its components may only be used for the applications described in the catalog or the
technical description, and only in connection with devices or components from other manufacturers which
have been approved or recommended by Siemens.
This product can only function correctly and safely if it is transported, stored, set up, and installed
correctly, and operated and maintained as recommended.

Trademarks
SIMATIC, SIMATIC HMI and SIMATIC NET are registered trademarks of SIEMENS AG.
Third parties using for their own purposes any other names in this document which refer to trademarks
might infringe upon the rights of the trademark owners.

Copyright
Siemens AG 1998 All rights reserved Disclaim of Liability

The reproduction, transmission or use of this document or its contents is not We have checked the contents of this manual for agreement with the hard-
permitted without express written authority. Offenders will be liable for ware and software described. Since deviations cannot be precluded entirely,
damages. All rights, including rights created by patent grant or registration of we cannot guarantee full agreement. However, the data in this manual are
a utility model or design, are reserved. reviewed regularly and any necessary corrections included in subsequent
editions. Suggestions for improvement are welcomed.

Siemens AG
Bereich Automatisierungs- und Antriebstechniktechnik
Geschaeftsgebiet Industrie-Automatisierungssysteme  Siemens AG 1998
Postfach 4848, D- 90327 Nuernberg Technical data subject to change.
Controller Module FM 455
SiemensIndex-2
Aktiengesellschaft A5E00059359 A5E00059359
Preface

Purpose of the Manual

This manual describes all the steps required to operate the FM 455 function
module. It introduces you quickly and effectively to the functions of the FM 455.

Contents of the Manual

This manual describes the hardware and software for the FM 455. It consists of an
instructional section and a reference section (appendices).
The manual contains sections on the following topics:
• Basic information on closed-loop control
• Installing and removing the FM 455
• Wiring the FM 455
• Assigning parameters to the FM 455
• Programming the FM 455
• Appendix

Users
This manual is aimed at the following readers:
• Installation engineers
• Programmers
• Operators
• Service and maintenance personnel

Validity of the Manual

This manual contains the description of the FM 455 function module valid at the
time the manual was printed. We reserve the right to describe any subsequent
changes to the functions of the FM 455 in a Product Information.

Controller Module FM 455

A5E00059359-02 iii
Preface

Approvals
The following approvals have been obtained for the S7-400 system:
UL Recognition Mark
Underwriters Laboratories (UL) to
Standard UL 508
CSA Certification Mark
Canadian Standard Association (CSA) to
Standard C 22.2 No.142
Factory Mutual (FM) Approval Standard Class Number 3611, Class I, Division 2,
Group A, B, C, D.

Warning
! Personal injury or property damage can result.
In hazardous areas, personal injury or damage to property can result if plug-in
connections are interrupted during operation of an S7-400.
The S7-400 must always be deenergized prior to separating plug-in connections in
hazardous areas.

Warning
! WARNING - DO NOT DISCONNECT WHILE CIRCUIT IS LIVE
UNLESS LOCATION IS KNOWN TO BE NON-HAZARDOUS.

CE Certification
Our products meet the requirements of EU Directive 89/336/EEC “Electromagnetic
Compatibility”.
In accordance with the above-mentioned EU Directive, Article 10, the EU
declarations of conformity are held at the disposal of the competent authorities at
the address below:

Siemens Aktiengesellschaft
Automation Group
A&D AS E48
P.O. Box 1963
D-92209 Amberg
Fed. Rep. of Germany

Controller Module FM 455

iv A5E00059359-02
 Preface

Where Does this Manual Fit in with the Rest of the Documentation?
This manual is part of the documentation on S7-400, M7-400 and ET 200M.

System Documentation
S7-400 • S7-400 Programmable Controller
Setting Up, CPU Data
• S7-400, M-400 Programmable Controllers; Module Specifications
• S7-400 Instruction List
M7-400 • M7-400 Programmable Controller;
Setting Up, CPU Data
• S7-400, M-400 Programmable Controllers; Module Specifications
ET 200M • ET 200M Distributed I/O Device
• S7-400, M-400 Programmable Controllers; Module Specifications

How to Find Your Way Around the Manual

The manual contains the following conventions to make it easier for you to find
specific information quickly:
• A complete table of contents is to be found at the front of the manual.
• At the end of the Appendix is a Glossary in which important technical terms
used in the manual are defined.
• At the end of the manual you will find a literature list and a detailed index which
also speeds up access to the information you seek.

Further Support
If you have any questions about using the products described in this manual and
cannot find an answer here, please contact the Siemens representative in your
area. You will find a list of addresses in the Appendix “SIEMENS Companies and
Representatives” in the S7-400 Programmable Controller, Hardware and
Installation Manual.
If you have any questions or comments on this manual, please fill out the remarks
form at the end of the manual and return it to the address shown on the form. We
would be grateful if you could also take the time to answer the questions giving
your personal opinion of the manual.
Siemens also offers a number of training courses to introduce you to the
SIMATIC S7 automation system. Please contact your regional training center or
the central training center in Nuremberg, Germany for details: D-90327
Nuremberg, Tel. 0911/895 3200.

Controller Module FM 455

A5E00059359-02 v
Preface

Constant Up-to-date Information

The SIMATIC Customer Support offers you externsive additional information on the
SIMATIC products via the online services:
• General up-to-date information can be obtained
– On the Internet under http://www.ad.siemens.de/simatic
• Up-to-date product information and downloads which can be of relevance for
the application:
– On the Internet under http://www.ad.siemens.de/simatic-cs
– Via the Bulletin Board System (BBS) in Nuremberg (SIMATIC Customer
Support Mailbox) under the number +49 (911) 895-7100.
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on the authorization hotline.

Controller Module FM 455

vi A5E00059359-02
Contents

1 Product Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.1 Functionality of the FM 455 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.2 Where to Use the FM 455 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.3 FM 455 Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.4 FM 455 Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
2 Information on the Controller Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1 Characteristic Values of the Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.2 Controller Type (Two-Step, Three-Step Controllers) . . . . . . . . . . . . . . . . . . 2-4
2.3 Control Response for Various Feedback Structures . . . . . . . . . . . . . . . . . . 2-7
2.4 Selection of the Controller Structures for a Specific Process . . . . . . . . . . . 2-15
2.5 Determining the Parameters by Trying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
3 How Does the FM 455 Controller Module Work? . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.1 Basic Structure of the FM 455 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.2 Basic Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.3 Inputs of the FM 455 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.3.1 Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.3.2 Digital Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3.4 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
3.5 Outputs of the FM 455 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
3.6 Control Action Mechanisms and Data Management in the FM 455 . . . . . 3-33
3.7 Properties of the FM 455 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
3.8 Parameter Optimization at the Temperature Controller . . . . . . . . . . . . . . . . 3-44
4 Inserting and removing the FM 455 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1 Preparing for Insertion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.2 How to Insert and Remove the FM 455 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Controller Module FM 455

A5E00059359-02 vii
Contents

5 Wiring the FM 455 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.1 Terminal Assignment of the Front Connector. . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.2 Wiring Front Connectors, Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5.2.1 Wiring Front Connectors, Crimp Snap-On Connection . . . . . . . . . . . . . . . . 5-18
5.2.2 Wiring Front Connectors, Screw-Type Terminals . . . . . . . . . . . . . . . . . . . . . 5-19
5.2.3 Wiring Front Connectors, Spring-Type Connectors . . . . . . . . . . . . . . . . . . . 5-20
5.3 Applying Strain Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
5.4 Labeling Front Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
5.5 Mounting the Front Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
6 Assigning Parameters to the FM 455 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
7 Integrating the FM 455 Into The User Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.1 The Function Block PID_FM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7.1.1 Operator Control Via the FB PID_FM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7.1.2 Monitoring Via the FB PID_FM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7.1.3 Changing Controller Parameters Via The FB PID_FM . . . . . . . . . . . . . . . . 7-5
7.1.4 Changing the Controller Parameters via The OP . . . . . . . . . . . . . . . . . . . . . 7-6
7.1.5 Saving the Parameters in the EEPROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7.1.6 Relationship Between FB Parameters and
Parameter Configuration Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7.2 The Function Block FUZ_455 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
7.3 The Function Block FORCE455 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
7.4 The Function Block READ_455 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
7.5 The Function Block CH_DIAG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
7.6 The Function Block PID_PAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24
7.7 The Function Block CJ_T_PAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30
8 Starting Up the FM455 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
9 Properties of Digital and Analog Inputs and Outputs . . . . . . . . . . . . . . . . . . . . . . 9-1
9.1 Properties of the Digital Inputs and Outputs . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
9.2 Properties of the Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
9.3 Setting the Measurement Type and the Measuring
Ranges of the Analog Input Channels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
9.4 Properties of the Analog Outputs (C Controllers) . . . . . . . . . . . . . . . . . . . . . 9-10
10 Connecting Measuring Sensors and Loads/Actuators . . . . . . . . . . . . . . . . . . . . . 10-1
10.1 Connecting Sensors to Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
10.2 Use of Thermoelements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
10.3 Connecting Voltage and Current Sensors and
Resistance Thermometers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
10.4 Connecting Loads/Actuators To Analog Outputs . . . . . . . . . . . . . . . . . . . . . 10-13
10.5 Connecting Loads/Actuators to Digital Outputs . . . . . . . . . . . . . . . . . . . . . . 10-15

Controller Module FM 455

viii A5E00059359-02
 Contents

11 Assignment of the Data Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1

11.1 Instance DB of the FB PID_FM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2
11.2 Instance DB of the FB FUZ_455 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-22
11.3 Instance DB of the FB FORCE455 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-24
11.4 Instance DB of the FB READ_455 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-26
11.5 Instance DB of the FB CH_DIAG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-28
11.6 Instance DB of the FB PID_PAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-30
11.7 Instance DB of the FB CJ_T_PAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-32
11.8 Allocation of the DBs for Operator Control and Monitoring via OP . . . . . . 11-34
12 Faults and Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1
12.1 Error Display via the Error LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2
12.2 Triggering of Diagnostics Interrupts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3
12.3 Faults in Measuring Transducers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-8
13 Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1
13.1 Application Example for the FM 455 S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-2
13.2 Application Example for the FM 455 C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-7
13.3 Application Example for the Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-11
13.4 Interconnection Example for a Cascade Control . . . . . . . . . . . . . . . . . . . . . 13-12
13.5 Interconnection Example for a Ratio Control . . . . . . . . . . . . . . . . . . . . . . . . 13-13
13.6 Interconnection Example for a Blending Control . . . . . . . . . . . . . . . . . . . . . 13-14
A Data Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
A.1 Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
A.2 Technical Specifications - Function Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . A-9
A.3 Technical Specifications - Parameter Assignment Software . . . . . . . . . . . A-10
B Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
C Literature List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Glossary-1
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index-1

Controller Module FM 455

A5E00059359-02 ix
Contents

Controller Module FM 455

x A5E00059359-02
Product Overview 1
What Does this Chapter Describe?
This chapter provides an overview of the FM 455 function module.
• You are familiarized with the functionality and some applications of the FM 455.
• You learn how the FM 455 is used in the S7-400 programmable controller and
get to know the most important components of the FM 455.

Chapter Overview

Section Description Page

1.1 Functionality of the FM 455 1-2
1.2 Where to Use the FM 455 1-4
1.3 FM 455 Hardware 1-5
1.4 FM 455 Software 1-9

Variants of the FM 455

The FM 455 has the following two variants:
• C controller (continuous-action controller with analog outputs)
• S controller (step-action and pulse controller with digital outputs)

Order Numbers

Product Scope of delivery Order number

FM 455 C • Module FM 455 C, Edition ≥ 4 6ES7455-0VS00-0AE0
(continuous controller)
• CD with project-planning package, manual
and Getting Started
FM 455 S • Module FM 455 S, Edition ≥ 4 6ES7455-1VS00-0AE0
(step and pulse controller)
• CD with project-planning package, manual
and Getting Started

Controller Module FM 455

A5E00059359-02 1-1
Product Overview

1.1 Functionality of the FM 455

Overview
The FM 455 function module is a closed-loop control module for use in the S7-400
programmable controller.

Control Processes
The FM 455 can perform two different types of control. Both types have methods
for optimizing the control process:

Control Process Optimized by...

Temperature controller (fuzzy ... the module (self–tuning controller)
controller)
PID controller ... Parameter configuration interface or PID Self Tuner

Control Structures
You can use the FM 455 for the following control structures:
• Fixed setpoint control
• Follow-up control
• Three-component control
• Cascade control
• Ratio control
• Blending control
• Split-range control

Operating Modes
The FM 455 recognizes the following operating modes:
• Automatic
• Manual
• Safety operation
• Follow-up mode (switching to preset safety value)
• Defined manipulated value DDC (Direct Digital Control)
• Follow-up/SPC controller (SPC = Setpoint Control)
• Back-up mode (when CPU in STOP or if CPU fails)

Controller Module FM 455

1-2 A5E00059359-02
 Product Overview

Number of Channels
There are 16 independent controllers in 16 channels on the FM 455.

Number of Inputs and Outputs

Table 1-1 shows an overview of the number of inputs and outputs on the FM 455.

Table 1-1 Inputs and Outputs of the FM 455

Inputs/Outputs FM 455 C FM 455 S

Analog inputs 16* 16*
Digital inputs 16 16
Analog outputs 16 –
Digital outputs – 32

* A Pt 100 occupies two analog inputs. A maximum of eight Pt 100s can

therefore be connected to one FM 455.

Diagnostic Interrupt
The FM 455 can trigger a diagnostic interrupt if any of the following events occur:
• Module parameter assignment faulty
• Module defective
• Overflow and underflow in analog inputs
• Break in load or short circuit in analog outputs
• Wire break at a measuring range of 4 to 20 mA, at a Pt 100 and at
thermocouples

Hardware Interrupts
No hardware interrupts are required to operate the FM 455.

Reference Junction
For use with thermocouples the FM 455 has an additional analog input for the
connection of a Pt 100 using 4-wire control. This input is used with thermocouples
and serves to measure the temperature of the reference junction and to
compensate it.

Parameter Assignment
Parameters can be assigned to the FM 455 by using the parameter assignment
interface.

Controller Module FM 455

A5E00059359-02 1-3
Product Overview

1.2 Where to Use the FM 455

Where Can You Use the FM 455?

The FM 455 is a closed-loop control module which can be used universally for the
following control tasks:
• Temperature control
• Level control
• Fill control
• Pressure control
• Flow control
• Concentration control

Fields of Application
The FM 455 can be used for control tasks in all of the following branches of
industry:
• General mechanical engineering
• System engineering
• Industrial furnaces
• Cooling and heating systems (HVAC)
• Food and beverages
• Process engineering
• Environmental engineering
• Glass and ceramic manufacturing
• Rubber and plastics machinery
• Wood and paper

Controller Module FM 455

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 Product Overview

1.3 FM 455 Hardware

View of Module
Figure 1-1 shows the module FM 455 with front connectors.

Release

5
67

Type plate
Order number

Diagnostics
and status LEDs

Slot labels

Coding key

Front connectors with

front connector coding

Figure 1-1 View of the FM 455 Module

Controller Module FM 455

A5E00059359-02 1-5
Product Overview

Front Connector
The FM 455 offers the following connections via the front connectors:
• 16 digital inputs
• 16 analog inputs
• 1 reference junction input
• 32 digital outputs (S controllers only)
• 16 analog outputs (C controllers only)
• Power supply DC 24 V between L+ and M to supply the module and the digital
and analog outputs
• Reference point of the analog loop MANA
The front connectors must be ordered separately (see Appendix B).

Front ConnectorCoding
Once you engage a front connector, the front connector coding snaps into place.
Once this is done, this front connector can then only be used on an FM 455.

Slot Labels
Enclosed with the module are two slot labels which you can use to label the
individual signal names.
The slot labels have the pinout of the FM 455.

Order Number and Release

The order number and release of the FM 455 are specified at the top next to the
left-hand mounting screw.

Coding Keys
There are eight coding keys on the FM 455. They can be plugged in at four
different positions and are used to adapt two adjacent analog inputs to a specified
sensor type.

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 Product Overview

Diagnostic and Status LEDs

The FM 455 has 19 LEDs that can be used both for diagnostic purposes and also
to indicate the status of the FM 455 and its digital inputs.
Table 1-2 lists the LEDs with their labeling, color and function.

Table 1-2 Diagnostics and status LEDs

Label Color Function

INTF Red Internal fault
EXTF Red External fault
Backup Yellow Indicates back-up operation
I1 Green Status of the digital input I1
I2 Green Status of the digital input I2
I3 Green Status of the digital input I3
I4 Green Status of the digital input I4
I5 Green Status of the digital input I5
I6 Green Status of the digital input I6
I7 Green Status of the digital input I7
I8 Green Status of the digital input I8
I9 Green Status of the digital input I9
I10 Green Status of the digital input I10
I11 Green Status of the digital input I11
I12 Green Status of the digital input I12
I13 Green Status of the digital input I13
I14 Green Status of the digital input I14
I15 Green Status of the digital input I15
I16 Green Status of the digital input I16

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Product Overview

The FM 455 S futhermore has 16 additional LEDs, which indicate the states of the
digital outputs:

Table 1-3 Additional LEDs of the FM 455 S

Label Color Function

Green Status of the digital output Open
Channel 1
Green Status of the digital output Close
Green Status of the digital output Open
Channel 2
Green Status of the digital output Close
Green Status of the digital output Open
Channel 3
Green Status of the digital output Close
Green Status of the digital output Open
Channel 4
Green Status of the digital output Close
Green Status of the digital output Open
Channel 5
Green Status of the digital output Close
Green Status of the digital output Open
Channel 6
Green Status of the digital output Close
Green Status of the digital output Open
Channel 7
Green Status of the digital output Close
Green Status of the digital output Open
Channel 8
Green Status of the digital output Close
Green Status of the digital output Open
Channel 9
Green Status of the digital output Close
Green Status of the digital output Open
Channel 10
Green Status of the digital output Close
Green Status of the digital output Open
Channel 11
Green Status of the digital output Close
Green Status of the digital output Open
Channel 12
Green Status of the digital output Close
Green Status of the digital output Open
Channel 13
Green Status of the digital output Close
Green Status of the digital output Open
Channel 14
Green Status of the digital output Close
Green Status of the digital output Open
Channel 15
Green Status of the digital output Close
Green Status of the digital output Open
Channel 16
Green Status of the digital output Close

Controller Module FM 455

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 Product Overview

1.4 FM 455 Software

Software Package of the FM 455

To integrate the FM 455 into the S7–400 you will require a software package with:
• Parameter assignment software
• Software for the CPU (function blocks)

Parameter Assignment Interface

Parameters are used to adapt the FM 455 to each task. These parameters are
stored in the system data and downloaded to the CPU from the programming
device or PC when the CPU is in STOP and then transferred to the FM 455. The
CPU also transfers these parameters to the module during every transition from
STOP to RUN.
You can enter the parameters via the parameter assignment software. The
parameter assignment application is installed on your programming device or PC
and called within STEP 7.

Online Help
You will find more information on assigning parameters in the integrated online
help.

Software for the S7-400 CPU (function blocks)

The software for the CPU consists of the following function blocks:
• PID_FM for changing parameters and operating modes (for example, setpoint
value, manual-automatic changeover) during running operation and for reading
process states (for example, process value).
• FORCE455 for forcing analog and digital inputs during the setup (force function
= specify simulation values).
• READ_455 for reading out the analog and digital input values during setting up.
• CH_DIAG for reading out channel–specific diagnostic values during setting up.
• FUZ_455 for reading out the parameters of the self–tuning temperature
controller (fuzzy controller) and for loading these parameters to the FM 455 (for
example, when replacing modules without repeated parameter identification of
the controller).
• PID_PAR for special applications for changing further parameters during
running operation.

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Product Overview

Figure 1-2 shows a S7-400 configuration with an FM 455 and a connected

programming device.

Power
supply
module

CPU FM 455
with user
program and
FBs for the
FM 455

Programming device (PG/PC)

with STEP 7 and the
parameter assignment screens

Figure 1-2 Configuration of a SIMATIC S7-400 with FM 455

Controller Module FM 455

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Information on the Controller Settings 2
What Does this Chapter Describe?
This chapter contains some basic rules of control technology which are applicable
to the use of a PID controller.

Section Description Page

2.1 Characteristic Values of the Process 2-2
2.2 Controller Type (Two-Step, Three-Step Controllers) 2-4
2.3 Control Response for Various Feedback Structures 2-7
2.4 Selection of the Controller Structures for a Specific Process 2-15
2.5 Determining the Parameters by Trying 2-17

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Information on the Controller Settings

2.1 Characteristic Values of the Process

The time response of the process can be determined by the time characteristics of
the controlled variable PV after an abrupt change in the manipulated variable LMN
from 0 to 100%.

LMN

100% ON
LMN_HLM
LMN = Manipulated variable
LMN_HLM = Manipulated range
Tu = Dead time
Tg = Delay time
Ks = Transfer coefficient
of the process

PVmax - PVcold
0% OFF Ks =
LMN_HLM

t
PV

Tg
PVmax

∆PV

PVcold ∆t

Tu t

Vmax = Max. rate of rise

of the process variable PVmax - PVcold ∆PV
PVmax= Maximum value of the process Vmax = =
Tg ∆t

Figure 2-1 Step response of a process

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Most of the processes are so-called processes with compensation (refer to

Figure 2-1). The time response can be approximated by means of the variables
Dead time Tu, Delay time Tg and Maximum value PVmax. The variables are
determined by applying tangents to the maximum value and to the point of
inflection of the step response. In many cases it is not possible to use the transient
function up to the maximum value since the process variable may not exceed
certain values. The rate of rise vmax is therefore used to recognize the process.

Tu Tu × vmax
The ratio or can be used to estimate
Tg PVmax - PVcold
the controllability of the process. The following applies:

Tu
Controllability of the Process
Tg
<0.1 Can be controlled well
0.1 to 0.3 Can still be controlled
>0.3 Is difficult to control

Processes can be judged in accordance with these values:

Tu < 0.5 min, Tg < 5 min = Fast process
Tu > 0.5 min, Tg > 5 min = Slow process

Characteristic Values of Important Temperature Processes

Process Type of Process Dead Time Delay Time Rate of Rise

Variable vmax
Tu Tg
Temperature Small, electrically heated furnace 0.5 to 1 min 5 to 15 min Up to 60 K/min
Large, electrically heated annealing 1 to 5 min 10 to 20 min Up to 20 K/min
furnace
Large, gas-heated annealing 0.2 to 5 min 3 to 60 min 1 to 30 K/min
furnace
Autoclaves 0.5 to 0.7 min 10 to 20 min
High-pressure autoclaves 12 to 15 min 200 to 300 min
Injection moulding machines 0.5 to 3 min 3 to 30 min 5 to 20 K/min
Extruder 1 to 6 min 5 to 60 min
Packaging machines 0.5 to 4 min 3 to 40min 2 to 35 K/min

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Information on the Controller Settings

2.2 Controller Type (Two-Step, Three-Step Controllers)

Two-Step Controllers Without Feedback

Two-step controllers have the states ”ON” and ”OFF” as switching functions. This
corresponds to 100% or 0% performance. This behavior causes a sustained
oscillation of the process variable PV around the setpoint value SP.
The amplitude and the duration of the oscillation increase with the ratio of the dead
time Tu to the delay time Tg of the process.These controllers are used mainly for
simple temperature control systems (for example, for directly electrically heated
furnaces) or as limit alarm monitors.

LMN LMN_HLM = Manipulated range

SP = Reference variable

LMN_HLM
ON

OFF

SP PV

Figure 2-2 Characteristics of a Two-Step Controller

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PV Tg

Tu = Dead time
Transient function Tg = Delay time
without controller PVSd = Differential gap

SP

PVSd

Tu t

LMN
100%

0%
t

Figure 2-3 Control Function of a Two-Step Controller without Feedback

Two-Step Controllers with Feedback

The performance of two-step controllers at processes with high dead times, for
example, furnaces in which the useful space of the furnace is separated from the
heating, can be improved by using electronic feedbacks.
The feedback is used to increase the switch rate of the controller, causing the
amplitude of the process variable to be reduced. In addition, the control results can
be improved notably in dynamic operation. The limit for the switch rate is set by the
output module. It should not exceed 1 to 5 switches per minute for mechanical final
controlling elements such as relays and contactors. High switch rates which lie far
above the critical frequency of the process can be selected in the case of binary
voltage and current outputs with downstream thyristor or Triac actuating elements .

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Information on the Controller Settings

Since the switching impulse at the output of the process can no longer be
determined, results which are comparable to continuous controllers are obtained.
In contrast to continuous controllers in which the amplitude of the output signal
represents the manipulated variable, the output variable of a two-step controller
with feedback is formed by the pulse width modulation.
Two-step controllers with feedback are used to control the temperature in furnaces,
processing machines in the plastics, textile, paper, rubber and foodstuffs industries
as well as for heating and cooling devices.

Three-Step Controllers
Three-step controllers are used for heating/cooling. These controllers have two
switching points as outputs. The controller results are optimized by means of
electronic feedback structures. Such controllers are used in heating, refrigerating
and climatic chambers and for heating tools for plastic processing machines.

LMN
LMN11

LMN12 = LMN21

LMN22

SP PV

PVSh

LMN = Manipulated variable SP = Setpoint

e.g. LMN11 = 100% Heating PVSh = Distance between Switching
LMN12 = 0% Heating Point 1 and Switching Point 2
LMN21 = 0% Cooling
LMN22 = 100% Cooling

PV= Process variable

for example temperature in °C

Figure 2-4 Characteristics of a Three-Step Controller

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2.3 Control Response for Various Feedback Structures

The controller has to be adapated to the transient response of the process in order
to achieve precision in a control system and optimal disturbance correction.
Feedback structures are used to this purpose. Depending on the structure the
feedback circuit has a proportional action (P), proportional-plus-derivative action
(PD), proportional-plus-integral action (PI) or
proportional-plus-integral-plus-derivate action (PID). If a jump function is applied to
the controller input, step responses arise provided that the dead times of the
controller are negligibly small and that the controller can react very fast (refer to
Figures 2-5 to 2-9).

P controller

PV
Jump function to
the controller input

Input variable
t

LMN

Step response of the

continuous controller

Output variable t

LMN

100%
Step response of the
pulse controller

0%
Output variable t

Figure 2-5 The Step Response of a P Controller

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Information on the Controller Settings

Equation for P controller

Output variable and input variable are directly proportional. This means:
Output variable change = Proportional gain × Input variable change

LMN = GAIN × ER

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 Information on the Controller Settings

PD Controller

ER

Jump function to the

controller input

Input variable t

LMN

TM_LAG Step response of the

continuous controller

Output variable t
LMN

100%

Step response of the

pulse controller

0%
Output variable t

Figure 2-6 Step Response of a PD Controller

D controller elements alone are not suitable for controlling, since they no longer
emit a control command when the input variable has readjusted to the static value.
In combination with P controller elements the derivative component is used to
generate a corresponding actuating pulse in dependency of the speed of change of
the process variable. If a disturbance variable z acts on the process, the
PD controller adjusts to a different system deviation on the basis of the changed
actuating degree. Disturbances are not compensated completely. The good
dynamic response is advantageous. A well damped non-oscillating transition is
achieved during the startup and when the setpoint changes. A controller with

Controller Module FM 455

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Information on the Controller Settings

derivative component is, however not appropriate when a process has oscillating
measured variables, for example in case of pressure or flow control systems.

Equation for PD Controller

The following applies for the step response of the PD controller in the time range:

-t
TD TM_LAG
LMN = GAIN × ER × 1 + × e
TM_LAG

t = Duration since the jump in the input variable

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 Information on the Controller Settings

PI Controller

ER

Jump function to the

controller input

Input variable t

LMN

Step response of the

continuous controller

Output variable t

LMN

100%

Step response of the

pulse controller

0%
Output variable t

Figure 2-7 Step Response of a PI Controller

I controller elements have the integral of the input variable as the output variable.
This means that the controller sums the derivation from the setpoint value across
the time. This means that the controller corrects are corrected until the derivation is
cleared by the setpoint variable. In reality a combination of the various timers is
ideal, depending on the requirements placed on the control response. The time

Controller Module FM 455

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Information on the Controller Settings

response of the individual elements can be described by the control parameters

proportional band GAIN, integral-action time TI (integral component) and
derivative-action time TD (derivative component).

Equation for PI Controller

The following applies for the step response of the PI controller in the time range:

t
LMN = GAIN × ER × 1 +
TI

t = Duration since the jump in the input variable

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 Information on the Controller Settings

PID Controller

ER

Jump function to the

controller input

Input variable t

LMN

TM_LAG
Step response of the
continuous controller

Output variable t

Tn

LMN

Step response of the

pulse controller

Output variable
t
Figure 2-8 Step Response of a PID Controller

Most of the control systems occurring in process engineering can be controlled

with a controller with PI action. In the case of processes with a large dead time, for

Controller Module FM 455

A5E00059359-02 2-13
Information on the Controller Settings

example temperature control systems, the control result can be improved by

means of a controller with PID action.

PV
100%

Transient function
without controller
PID

SP

PD

0%
t

Figure 2-9 Step Response for Various Control Responses

Controllers with PI and PID action have the advantage that the process variable
does not show a derivation from the setpoint value after the transient condition.
The process variable oscillates across the setpoint variable during starting up.

Equation for PID Controller

The following applies for the step response of the PI controller in the time range:

-t
t TD TM_LAG
LMN = GAIN × ER × 1 + + × e
TI TM_LAG

t = Duration since the jump in the input variable

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 Information on the Controller Settings

2.4 Selection of the Controller Structures for a Specific Process

The processes have a special position within the control loop elements. Their
properties are determined by the process-engineering applications and cannot be
modified afterwards. An optimal control result can therefore only be achieved by
selecting a suitable controller whose action can be adapted to the process data
within certain limits.

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Information on the Controller Settings

Selection of the Suitable Controller Structures

Controller Structure
Process
P PD PI PID

Control
Pure dead Unusable Unusable Unusable
+ disturbance
time

Dead time + delay Control

Unusable Unusable Somewhat
of the 1st order + disturbance
worse than
PID

Dead time Worse Control

+ delay of the Unsuitable Worse
than PID + disturbance
2nd order

1st. order + very

Control Control at Disturbance
small dead time Disturbance
dead time at dead time

Somewhat
Higher order Unsuitable Unsuitable Control
worse than
+ disturbance
PID

Without Control Control Disturbance Disturbance

compensation (without delay) (with delay) (without delay) (with delay)

Suitable Controller for the Most Important Process Variables

Controller P PD PI PID
Process
variable Steady-state deviation No steady-state deviation
For minor
requirements and The most suitable controller types for
Temperature for P processes Well suited heightened requirements
with T (except for specifically adapted
u special controllers)
< 0.1
Tg
Suitable, if no The most suitable controller types for
Pressure notable dead time Unsuitable heightened requirements
(except for specifically adapted
special controllers)
Less suitable, Usable
because required Hardly required
Flow Unsuitable but I controller for these process
GAIN range alone often
usually too large variables
better

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 Information on the Controller Settings

2.5 Determining the Parameters by Trying

Alternatively to calculating the parameters you can determine them by trying
specific values (refer to Figure 2-10 for information on the procedure).

Starting point: GAIN low; TD 0 or low TD = 0 means:

TI high Path is deactivated

Excitation: By abrupt
setpoint difference

GAIN

Damping bad? Yes

(controller oscillates)
No
TD

Yes
Damping too good?

No

No Does an increase in TD
result in marked
improvement of the
damping?
Yes
Reduce GAIN and TD until the transient
function has 5% overshooting

TI TD

Overshooting > 5%?

Yes

No

Overshooting ≈ 5%? Yes Aim

reached

No

Figure 2-10 Setting the Controller by Trying Specific Values

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Information on the Controller Settings

Optimal controller setting

TD = 0.5 TD opt
TD = 2 TD opt

TI= 2 TI opt
TI= 0.5 TI opt

GAIN = 0.5 GAIN opt GAIN = 2 GAIN opt

Figure 2-11 Effect on the Optimal Controller Setting of Changes in the Controller Parameters

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How Does the FM 455 Controller Module
Work? 3
What Does this Chapter Describe?
This chapter provides an overview of the basic structure of the FM 455, its mode of
operation in principle and its properties.

Chapter Overview

Section Description Page

3.1 Basic Structure of the FM 455 3-2
3.2 Basic Parameters 3-5
3.3 Inputs of the FM 455 3-6
3.4 Controller 3-10
3.5 Outputs of the FM 455 3-31
3.6 Mode of Operation and Data Management in the FM 455 3-33
3.7 Properties of the FM 455 3-38
3.8 Parameter Optimization at the Temperature Controller 3-44

Controller Module FM 455

A5E00059359-02 3-1
How Does the FM 455 Controller Module Work?

3.1 Basic Structure of the FM 455

Overview
In this section block diagrams are used to explain the basic structure and the
interconnection possibilities of the FM 455.

Basic Structure of the FM 455

FM 455 C and FM 455 S have a similar basic structure. It consists of the following
function blocks:
• Inputs of the FM 455
– 16 analog inputs with analog value conditioning
– 1 reference junction input for compensating thermoelements
– 16 digital inputs
• Controllers
– 16 controller channels independent of each other, each subdivided into the
units system error formation, control algorithm and controller output
• Outputs of the FM 455
– 16 analog outputs (only FM 455 C)
– 32 digital outputs (only FM 455 S)

Controller Module FM 455

3-2 A5E00059359-02
 How Does the FM 455 Controller Module Work?

Block Diagram of the FM 455 C

Figure 3-1 shows the block diagram of the FM 455 C (continuous controller) and
the interconnection possibilities between the individual function blocks.

Inputs of the FM 455 C Controlller Outputs of the

FM 455 C

Analog value
Analog input 1
conditioning

Analog output 1
Controller
channel 1
Analog value
Analog input 16
conditioning

Reference
junction for
analog input 1
Analog output
to 16
16
Controller
channel 16

Digital input 1

Assignment of the inputs and

Digital input 16 outputs to the controller channels
can be configured freely

Figure 3-1 Block Diagram of the FM 455 C (Continuous Controller)

Interconnection Possibilities of the FM 455 C

The function blocks of the FM 455 C do not have a fixed assignment to each other.
On the contrary, it is possible to interconnect them by means of configuration.
Each analog input has its own analog value conditioning (filtering, linearization,
normalization).
You can assign up to 4 analog inputs and up to 5 digital inputs to each controller
channel. Each controller channel can be interconnected to the conditioned analog
values, the digital inputs or also the output of another controller channel.
Every analog output can be interconnected to a controller output or to an analog
value conditioning. The possibility of interconnecting to an analog value
conditioning can be used, for example, to convert a non-linear temperature value
into a linear output signal.

Controller Module FM 455

A5E00059359-02 3-3
How Does the FM 455 Controller Module Work?

Block Diagram of the FM 455 S

Figure 3-2 shows the block diagram of the FM 455 S (step controller) and the
interconnection possibilities between the individual function blocks.

Inputs of the FM 455 S Controlller Outputs of the FM 455 S

Analog input 1 Analog value

conditioning
Controller Digital output 1
channel 1
Digital output 2

Analog input 16 Analog value

conditioning Digital output 3
Controller
channel 2
Digital output 4

Reference
junction for
analog input 1
to 16

Controller Digital output 31

Digital input 1 channel 16
Digital output 32

Digital input 16 Assignment of the inputs to

the controller channels can
be configured freely

Figure 3-2 Block Diagram of the FM 455 S (Step Controller)

Interconnection Possibilities of the FM 455 S

The function blocks of the FM 455 S do not have a fixed assignment to each other.
On the contrary, it is possible to interconnect them by means of configuration.
Each analog input has its own analog value conditioning (filtering, linearization,
normalization).
You can assign up to 4 analog inputs and up to 5 digital inputs to each controller
channel. Each controller channel can be interconnected to the conditioned analog
values, the digital inputs or also the output of another controller channel.
16 digital outputs each are assigned fixed to the 2 controller channels.

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 How Does the FM 455 Controller Module Work?

3.2 Basic Parameters

Overview
The FM 455 has basic parameters which deal with the interrupts and the reaction
to CPU STOP mode.

Basic Parameters
The basic parameters are contained in HW Config in the ”Basic parameters” tab of
the “Properties FM 455 ...” window.You have the following options:
Select interrupt - None
- Diagnostic interrupt

If ... Then ...

Select interrupt: None Generate interrupt: None

Select interrupt: Diagnostic Generate interrupt: Display of the interrupt line

interrupt

The reaction of the FM 455 to CPU STOP mode is: Continue processing

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How Does the FM 455 Controller Module Work?

3.3 Inputs of the FM 455

Overview
Various sensor types can be connected to the analog inputs. The input signals of
the sensors are then conditioned in accordance with the requirements.
The digital inputs can be used to switch the FM 455 to various operating modes.
Continuous controllers and step controllers have the same structure at analog and
digital inputs.

3.3.1 Analog Inputs

Sensor type

A
D
Conditioned
Filter Root Polyline Normalizing analog value
extraction

Reference
input

Configured

Figure 3-3 Analog Value Conditioning

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 How Does the FM 455 Controller Module Work?

The analog inputs can be adapted to various sensors by means of parameter

configuration. The following settings are possible:
• Analog input is not processed (for example, unused input)
• Current sensor 0 to 20 mA
• Current sensor 4 to 20 mA
• Voltage sensor 0 to 10 V
• Pt 100, -200 ... 850 °C
• Pt 100, -200 ... 556 °C (double resolution)
• Pt 100, -200 ... 130 °C (fourfold resolution)
• Thermocouples types B, J, K, R and S (analog input set to ±80 mV)
• Free thermocouple (analog input set to ±80 mV)
The analog inputs are configured in the ”Analog input” mask.

Adaptation to the Power Frequency

The input signal processing can be adapted to the power frequency in order to
suppress disturbances during the measurement of analog signals. The following
settings are possible:
• 50 Hz operation
• 60 Hz operation
This configuration is carried out in the parameter configuration interface:
Command button: Module parameters

Changeover Celsius/Fahrenheit
Temperatures can be measured both in °C and in °F.
This configuration is carried out in the parameter configuration interface:
Command button: Module parameters

Reference Junction
If you have set a thermoelement as a sensor at an analog input, you can connect a
Pt 100 at the reference junction input of the FM 455 in order compensate the
reference junction temperature at thermoelements.Alternatively a fixed reference
junction temperature can be configured to this purpose.
This configuration is carried out in the parameter configuration interface:
Command button: Module parameters
When the reference junction input is used, the sampling time of each controller is
increased by the conversion time for the reference junction input (refer to
Figure 3-32 on Page 3-38 and Figure 3-33 on Page 3-41).

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How Does the FM 455 Controller Module Work?

Analog Value Conditioning

The analog value conditioning offers various configurable possibilities of
conditioning input signals. The following table provides an overview of these
parameters and the adjustable values.

Parameter Adjustable Values Remarks

Resolution • 12 bits Conversion time 20 ms (50 Hz)
Conversion time 162/3 ms (60 Hz)
• 14 bits Conversion time 100 ms
Filter • On/Off First-order filter whose time
• Time constant in s response is specified by the time
constant
Square root • On/Off In order to linearize sensor signals
in which the process variable is
available as a physical variable
which have a quadratic relationship
to the measured process variable
Normalization • Bottom In order to convert the input signal
• Top into a different engineering unit by
linear interpolation between the
starting value (bottom) and the end
value (top)
Polyline • On/Off In order to linearize sensor
• 13 interpolation points characteristic curves
selectable in
– mA at current input
– mV at voltage input

Note
Normalization/Polyline: The conversion of the unit mA or mV into an engineering
unit is carried out via the polyline or - if it is not activated - via the normalization.
The polyline is used to linearize a free thermoelement or for any linearization.

Controller Module FM 455

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3.3.2 Digital Inputs

The digital inputs are used to change over operating modes of the individual
controller channels.
The direction of control action of the digital inputs can be configured. The following
settings are possible for each of the 16 digital inputs:
• High-active
• Low-active or open
This configuration is carried out in the parameter configuration interface:
Command button: Module parameters
The following operating modes can be selected:
• Changeover to manipulated value specification via the FB PID_FM
• Changeover to tracking operation (manipulated-value specification via an
analog input)
• Changeover to safety manipulated value
You can furthermore specify the following signals via digital inputs for a step
controller:
• Position feedback: Actuating device at the upper limit stop
• Position feedback: Actuating device at the lower limit stop

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3.4 Controller

Overview
The controllers of each channel of the FM 455 consist of the following blocks:
• Error signal formation
– Conditioning of the setpoint value and process variable
– Signal selection for setpoint value, process variable, differential input and
disturbance variable
• Control algorithm
– Temperature controller
– PID controller with dead band
• Controller output
– Manipulated value changeover
– Manipulated value conditioning
The configuration is carried out in the screens ”Error signal formation”, ”Control
algorithm” and ”Controller output”.
Figure 3-4 provides an overview of the structure of the controller.

Controller

Error signal Control algorithm Controller output

Figure 3-4 Structure of the Controller

Controller Type
You can set various controller types for each controller channel of an FM 455 C or
FM 455 S:
• Fixed setpoint or cascade controller
• Three-component controller
• Ratio/blending controller
You can select the following additional operating modes at the FM 455 S:
• Pulse controller
• Step controller with position feedback
• Step controller without position feedback

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Error Signal Formation

The same basic structure is used for the error signal formation at all the controller
types implemented in the FM 455 C and FM 455 S.
An effective setpoint value and an effective process variable are formed from the
setpoint value and process variable by corresponding conditioning. When the
effective setpoint value and the effective process variable are subtracted, the error
signal results, which is fed to the controller.
A signal selection can be carried out for the setpoint value and process variable.
This results in universal possibilities of application for the FM 455 (refer to
Table 3-1 on Page 3-15).
The structures of the error signal formation differ depending on the selected
controller type. The differences are shown in Figures 3-5 to 3-8.

Setpoint value conditioning

Setpoint Effective
value setpoint
Switch Ramp Limit
safety value
setpoint Error
value signal

Interrupt
Process variable A Effective
process
variable

Differential input

Disturbance variable
Figure 3-5 Error Signal Formation in a Fixed Setpoint or Cascade Controller

At the cascade controller the manipulated value of a master controller is selected

as the setpoint value. In the example in Figure 3-6 the manipulated value of
controller 1 is selected as the setpoint value at controller 2.
If a secondary controller configured as a fixed setpoint controller is switched to
manual mode (not closed-loop control), the module automatically also switches the
corresponding master controller to manual mode and holds it to the last
manipulated value. As soon as the secondary controller has returned to
closed-loop control the master controller is also switched over to closed-loop
control.
If the manipulated variable of a secondary controller enters the limitation or if the
setpoint-value slope of a secondary controller is limited by the ramp function in the
setpoint-value branch, the integral component of the master controller is blocked
direction-specifically until the cause for the limitation has been eliminated in the
secondary controller.

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SP LMN QLMNUP
Process Process
Controller 1 Controller 2 QLMNDN
segment 1 segment 2
PV PV

Figure 3-6 Two-Loop Cascade Control

Setpoint value conditioning

Setpoint Effective
value Switch Ramp Limit setpoint
safety value
setpoint Error
value signal
Total
(Factor for process variable B)
(Factor for process variable C)
(Offset) Interrupt

Process ∑ Effective
variable A process
variable
Process variable B

Differential input
Process variable C

Disturbance variable

Figure 3-7 Signal Error Formation at a Three-Component Controller

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Setpoint value conditioning Multiply

Setpoint Effective
value setpoint
Switch Ramp Limit/
safety normalize value
setpoint Error
value signal
Process variable D

Interrupt

Process variable A Effective

process
variable

Differential input

Disturbance variable

Figure 3-8 Error Signal Formation at a Ratio or Blending Controller

Figure 3-9 shows a blending control for three components:

The accumulated rate controller is implemented as a three-component
controller/pulse controller. The accumulated rate PV is calculated via its inputs
”process variable A, process variable B and process variable C”.
The secondary controllers are configured as ratio/blending controllers. The
manipulated variable of the master controller is interconnecte via the input process
variable D. The factor FAC1 to FAC3 is specified via the setpoint value of the
controller.
The manipulated variable LMN of the accumulated rate controller is specified in the
range of 0% to 100%. The secondary controller converts this variable at the
process variable input D into the range of the process variable A (the range of the
process variable A is the normalization values ”top” and ”bottom” of the selected
analog input).
If the manipulated variable of a secondary controller enters the limitation or if the
setpoint-value slope of a secondary controller is limited by the ramp function in the
setpoint-value branch, the integral component of the master controller is blocked
direction-specifically until the cause for the limitation has been eliminated in the
secondary controller.

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Accumulated rate Main component

SP LMN SP1 QLMNUP

- Controlller X - Controller 1 QLMNDN Process 1
PV
FAC1 PV1

SP2 QLMNUP
X - Controller 2 QLMNDN Process 2 +

FAC2 PV2

SP3 QLMNUP
X - Controller 3 QLMNDN Process 3 +

FAC3
PV3

Figure 3-9 Blending Control for Three Components

Figure 3-10 shows a ratio control with two control loops:

Control loop 1 is configured as a fixed setpoint or cascade controller.
Controller 2 is configured as a ratio/blending controller. The process variable D of
controller 1 is selected as the process variable of controller 2. The ratio factor FAC
is specified via the setpoint value input of controller 2. If a controller output is
selected as the ratio factor FAC, the setpoint value is normalized by means of the
lower and upper limitation ”0 .. 100%” to the range ”Lower limitation .. upper
limitation”.
If the manipulated variable of a secondary controller enters the limitation or if the
setpoint-value slope of a secondary controller is limited by the ramp function in the
setpoint-value branch, the integral component of the master controller is blocked
direction-specifically until the cause for the limitation has been eliminated in the
secondary controller.

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SP1
Controller 1 LMN1 Process
PV1 1

X
SP2
LMN2 Process 2
Controller 2
PV2

Figure 3-10 Ratio Control with Two Control Loops

Signal Selection for Setpoint Value, Process Variable, Differential Input and
Disturbance Variable
You can carry out a selection under various signal sources for the setpoint value,
the process variables, the value of the differential input and the disturbance
variable of each controller channel. The following table provides an overview of the
signal selection possibilities.

Table 3-1 Signal Selection for Setpoint Value, Process Variable, Differential Input and
Disturbance Variable

Affected Values Selected Signal Source

Setpoint value • A value specified by the user program through the function
block
• The conditioned analog value of an analog input
• The manipulated value of another controller channel (if
controllers are cascaded)
Process variables A, • The conditioned analog value of an analog input
B and C (the process variables B and C can also be deactivated)

Process variable D • Zero

(the process variable D can also be deactivated)
Value for differential • The error signal after the dead band of the own controller
input (only relevant channel
for PD or PID • The conditioned analog value of an analog input
controller)
• The negated effective process variable of the own controller
channel
Disturbance variable • The conditioned analog value of an analog input
(the value zero can also be specified for the disturbance
variable)

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Conditioning of the Setpoint Value

The conditioning of the setpoint value to the effective setpoint value can be
influenced by the following configuration possibilities:
• Switch safety setpoint
The following can be set here:
– A safety setpoint value
– The reaction of the FM 455 at a CPU failure
– The reaction of the FM 455 during the startup
The alternatives for the reaction of the FM 455 are:
- Setpoint value = Last setpoint value
- Setpoint value = Safety setpoint value
• Ramp
The rate of change of the setpoint value can be limited by selecting a ramp-up
time from the physical starting value to the end value.
• Limit/Normalize
If the setpoint value is specified by the function block or if it is the conditioned
analog value of an analog input, the setpoint value of a selectable lower and
upper limitation.
If a controller output is selected as the setpoint value at a ratio controller, this
value acts as a factor for the multiplication of the process variable D. The
setpoint value which exists as a % at the input, is normalized in this case by
using the lower and upper limitations.
If the manipulated value of another controller is to be used as the setpoint value
at a fixed-setpoint or cascade controller (for example, during cascade control), it
is normalized to a physical value by means of the normalizing constant of the
selected process variable channel.
• Multiplying
In the case of a ratio controller the process variable A is used as the process
variable, while the process variable D is used as the ratio variable. The setpoint
value input is used as the ratio factor. It is continioned to the effective setpoint
value by multiplying it with the process variable D and adding an adjustable
offset. If the process variable D is deactivated, only the offset is added to the
setpoint value.

Conditioning of the Process Variable

In the controlling structures of a fixed-setpoint or cascade controller and ratio
controller the effective process variable is identical to the process variable A.
In the controlling structure of a three-component controller the effective process
variable is formed by summing the three process variables A, B and C and by
adding an adjustable offset. The process variables B and C can be weighted
additionally by means of factors.

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Interrupt
A limit monitoring function is implemented in the FM 455. This allows
• Either the error signal
• Or the effective effective process variable
to be monitored to an upper and lower warning limit and to an upper and lower
alarm limit. In addition you can set a hysteresis for these limits (refer to
Figure 3-11).

Lower warning or Upper warning or

alarm limit Interrupt coming alarm limit
Interrupt going
Hysteresis

Figure 3-11 Hysteresis for Warning and Alarm Limit

Control Algorithm
The following operating modes can be selected at the control algorithm:
• Temperature controller (self-tuning fuzzy controller)
• PID controller
Continuous controllers and step controllers have the same controller algorithm
structure (refer to Figure 3-12).

Effective setpoint value

Effective process variable Temperature

controller Effective
manipulated
PID value

Error signal
Dead band

Differential input
Manipulated value
correction

Disturbance variable

Figure 3-12 Block Diagram of the Control Algorithm

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Temperature Controller
The temperature controller is a self-tuning fuzzy controller which operates with
self-determined control parameters after identification of the process.
The following settings are possible at a temperature controller:
• Cooling controller
• Heating controller
• Aggressivity
The aggresivity parameter can be used to influence the speed of the transient
response.
Possible values for the aggressivity:
• -1 ≤ Aggressivity < 0 : Slower transient response than determined via
identification
• Aggressivity = 0 : Transient response as determined via
identification
• 0 < Aggressivity ≤ 1 : Faster transient response than determined via
identification
For a more detailed description of the temperature controller please refer to
Section 3.8 “Temperature Controller of the FM 455”.

Control Algorithm and Controller Structure

In the cycle of the planned sampling time the manipulated variable of the
continuously operating controller is calculated from the error signal in the
PID positioning algorithm. The controller is implemented in a pure parallel structure
(Figure 3-13). The proportional, integral or differential components can each be
deactiavted individually. In the case of the integral and differential components this
is done by setting the respective parameter TI or TD to zero.

DISV_SEL
DISV

P_SEL
P
GAIN

ER X I + LMN

(linear combination)
D

Figure 3-13 Control Algorithm of the FM 455 (Parallel Structure)

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Feedforward Control:
A disturbance variable DISV can additionally be applied to the output signal of the
controller. Activation and deactivation is carried out in the “Error signal” window of
the configuration tool by means of the switch “Signal selection disturbance variable
controller”.
P/D Component in the Feedback:
In the parallel structure each component of the control algorithm receives the error
signal as the input signal. In this structure setpoint step changes act directly on the
controller. The manipulated variable is influenced directly via the proportional and
the derivative actions by means of setpoint step changes.
However, a different structure of the controller, in which the formation of the
proportional and the derivative action is laid into the feedback, ensures a smooth
course of the manipulated variable at step changes of the reference variable
(Figure 3-14). In this structure the Integral action processes the error signal as the
input signal. Only the negative process variable (factor = -1 is applied to the
proportional and the derivative action. At the derivative action to changeover is
carried out in the feedback in the “Error signal” window via the “Differential input
controller” switch by selecting the negated effective process variable as the input
signal. The input variable of the derivative action can also be selected via the
parameter D_EL_SEL of the function block PID_FM (also refer to Figure 7-2 on
Page 7-8).

GAIN

ER X I

-1 P + LMN
PV X X
D

Figure 3-14 Control Algorithm with Proportional and Derivative Action in the
Feedback Path

The proportional and derivative components can also be switched individually into
the feedback.

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Reversing the Controller Action

Reversing, meaning the changeover of the controller of the assignment
Rising process variable = Rising manipulated variable to
Rising process variable = Falling manipulated variable,
is achieved by setting a negative proportional gain at the parameter GAIN. The
sign of this parameter value determines the direction of control action of the
controller
Examples for the reversal of the controller action are cooling controllers or level
controllers.

Proportional Control
At a proportional controller the integral and derivative actions are deactivated. This
means that if the error signal ER = 0, the manipulated variable = 0 as well. If an
operating point is to be ≠ 0, meaning that a numerical value is to be set for the
manipulated variable at the error signal zero, this can be achieved via the
operating point:
• Operating point automatically: The operating point is set by the controller to the
current (manual) manipulated variable during the manual-automatic
changeover.
• Operating point not automatically: You can configure the operating point.
Example: Operating point OP = 5% results in a manipulated variable
of 5% at error signal ER = 0.

P_SEL
P
GAIN

ER X I Automatically
+ LMN
Not automatically

Operating point

Figure 3-15 Proportional Controller with Operating-Point Setting via the

Integral Action

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ER Manipulated variable (t)

Manipulated
variable

ER(t)

Figure 3-16 Step Response of the Proportional Controller

Proportional-Plus-Integral Control
The derivative action is deactivated at the PI controller. A PI controller adjusts the
output variable via the integral action until the error signal has become ER = 0.
However, this only applies if the output variable does not exceed the limits of the
manipulating range in the process. If the manipulated value limits are exceed, the
integral action retains the value reached at the limit (anti reset wind-up).

ER
Manipulated Manipulated
variable variable (t)

GAIN * ER0
GAIN * ER(t)
GAIN * ER0 ER(t)
t
TI

Figure 3-17 Step Response of the PI Controller

Smooth Manual-Automatic Changeover

In order to change over ”smoothly” from manual mode to automatic mode of the
PI/PID controller, the integrator is tracked in manual mode so that the manipulated
variable does not take a step through the proportional and derivative actions during
the manual-automatic changeover. An existing error signal is only compensated
slowly via the integral action. If a smooth manual-automatic changeover is not
selected, the manipulated variable takes a step which corresponds to the current
error signal from the current manual value during the manual-automatic
changeover. An existing error signal is thus compensated rapidly.

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Integral-Action Control
You can deactivate the proportional action in order to realize a pure integral-action
control. This is also possible via the parameter P_SEL of the function block
PID_FM.

Proportional-Plus-Derivative Control
The integral action is deactivated at the PD controller. This means that if the error
signal ER = 0, the output signal = 0 as well. If an operating point is to be ≠ 0,
meaning that a numerical value is to be set for the manipulated variable at the
error signal zero, this can be achieved via the operating point:
• Operating point automatically: The operating point is set by the controller to the
current (manual) manipulated variable during the manual-automatic
changeover.
• Operating point not automatically: You can configure the operating point.
The PD controller images the input variable ER(t) proportionally to the output
signal and adds the differential component formed by the differentiation of ER(t),
which is calculated with double precision according to the trapezoid rule (Padé
approximation). The time response is determined by the derivative action time
constant TD.
In order to smoothen the signal and to suppress noises a first-order delay
(adjustable time constant: TM_LAG) is integrated into the algorithm for forming the
derivative action . Usually a small value for TM_LAG is sufficient to achieve the
desired effect.

ER
Manipulated
variable

GAIN * TD ER0 Manipulated variable (t)

TM_LAG

ER(t)
GAIN * ER0

TM_LAG t

Figure 3-18 Step Response of the PD Controller

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PID Closed-Loop Control

At a PID closed-loop controller the proportional, integral and derivative actions are
activated. A PID controller adjusts the output variable via the integral action until
the error signal has become ER = 0. However, this only applies if the output
variable does not exceed the limits of the manipulating range in the process. If the
manipulated value limits are exceed, the integral action retains the value reached
at the limit (anti reset wind-up).
The PID controller images the input variable ER(t) proportionally to the output
signal and adds the components formed by the differentiation and integration of
ER(t), which are calculated with double precision according to the trapezoid rule
(Padé approximation). The time response is determined by the derivative-action
time constant TD and the integral-action time constant TI.
In order to smoothen the signal and to suppress noises a first-order delay
(adjustable time constant: TM_LAG) is integrated into the algorithm for forming the
derivative action. Usually a small value for TM_LAG is sufficient to achieve the
desired effect.

ER
Manipulated
variable

GAIN * TD  ER Manipulated variable (t)

0
TM_LAG

GAIN * ER0
ER(t)
GAIN * ER0
t
TM_LAG
TI

Figure 3-19 Step Response of the PID Controller

Use and Configuration of the PID Controller

The configuration of the PI/PID controller, i.e. finding the ”correct” setting values for
the controller parameters, is a great practical problem. The quality of this
configuration is of decisive importance for ensuring that the PID closed-loop control
functions in accordance with the task and requires either great practical
experience, special knowledge or a high degree of time.
The Optimize PID controller function included in the configuration tool allows
the initial setting of the controller parameter by means of adaptive starting up. In
this case the process model is determined after a process identification and then
the most favorable (optimal) setting values for the controller parameter are
calculated from it. This procedure, which is automatic to a great extent, makes it
unnecessary for the user to ”trim” the installed PID controller online manually.

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Dead Band
The PID controller is preceded by a dead band. In a steady controller state the
dead band suppresses the noise component in the signal of the error signal which
can arise by a higher-frequency noise being superimposed on the controlled or
reference variable, and can thus prevent undesired oscillating of the controller
output.
The dead band width can be set. If the error signal lies within the set dead band
width, the value 0 (error signal = 0) is output at the output of the dead band. Not
until the input variable leaves the sensitivity range does the output change by the
same value as the input variable (refer to Figure 3-20).
This results in a corruption the transferred signal - also outside the dead band.
However, this is put up with in order to avoid steps at the limits of the dead band.
The corruptiopn corresponds to the value of the dead band width and can therefore
be controlled easily.

Error signal at the

dead band output

Error signal at the

dead band input

Dead band
width

Figure 3-20 Dead Band

Controller Output
The controller output block of the control unit is structured differently at the
continuous controller and at the three operating modes of the step controller.
Various interconnection possibilities have been realized for the manipulated value,
the tracking input and the safety manipulated value at the controller output
(manipulated value changeover).
A limitation is provided in order to ensure that the manipulated value cannot
assume invalid values for the process.
The split-range function creates two different output signals manipulated value A

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and manipulated value B which can be normalized differently from the manipulated
value as the input signal. This allows, for example, two valves to be controlled with
one manipulated value.
The control output correction prevents a manipulated-variable step jump during the
changeover from manual to automatic mode. The manipulated variable remains
the same when switching between manual and automatic. The control output
correction is not active, if a pure P controller with fixed operating point has been
implemented (”automatic” is not checked in the PID controller screen).
Figures 3-21, 3-24, 3-27 and 3-28 show the block diagrams of the controller output
at the continuous controller and at the three operating modes of the step controller.

External
manipulated
value

Effective Switch
manipulated external
manipulated Manipulated
value
value value

Manipulated
Switch Switch Limit Split-range value A
correction safety
manipulated
value
Tracking input Manipulated
value B

Manipulated value correction

Figure 3-21 Continuous Controller Output

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Split Range
The splitrange function allows two control valves to be controlled with one
manipulated variable. The split-range function creates the two output signals
manipulated value A and manipulated value B from the manipulated value LMN as
the input signal.
Figure 3-22 shows the effect of the parameters for the output manipulated value A.

Output signal
manipulated value A

End of range
for output signal

Start of range for

output signal

Input signal
manipulated
value LMN
Start of range End of range
for input signal for input signal

Figure 3-22 Split-Range Function Manipulated value A

Figure 3-23 shows the effect of the parameters for the output manipulated value B.

Output signal
manipulated value B

Start of range for

output signal

End of range for

output signal

Input signal
manipulated
Start of range End of range value LMN
for input signal for input signal

Figure 3-23 Split-Range Function Manipulated Value B

The start of range of the input signal must be smaller that the end of range of the
end of range.

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Analog Output
At the analog output you can select for each channel which signal is to be output.
This is usually the manipulated value A of a controller. However, you can also
select the manipulated value B of a controller or also an analog input value. The
latter can be used to linearize an analog value. Thus, for example a signal supplied
by a thermoelement can be linearized and converted to 0 to 10 V.

Controller Output at the Pulse Controller

External
manipulated
value

Effective Switch
manipulated external
value manipulated Manipulated
value value

Switch Switch Limit Split-range/

correction safety pulse shaper
manipulated
value
Tracking input

Manipulated value correction

Figure 3-24 Step Controller Output (Pulse Controller Mode)

Split-Range/Pulse Shaper
The split-range function is the preparation of the analog signal for conversion to a
binary signal.
In the case of a two-step controller (for example, a heating controller) only the
manipulated value A is relevant. Figure 3-25 shows the conversion of the
manipulated value to the manipulated value A. The conversion to a binary output
signal is carried out so that the ratio of the pulse length to the period time
corresponds to the manipulated value A at the corresponding digital output.
For example, a manipulated value A of 40% at a period time of 60 seconds results
in a pulse length of 24 seconds and a pause length of 36 seconds.
The assignment of the digital outputs to the controller channels is shown in
Table 3-3 on Page 3-32.

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Output signal
manipulated value A

End of range
for output signal

Input signal
manipulated
Start of range for Start of range End of range value LMN
output signal for input signal for input signal

Figure 3-25 Split-Range Function Two-Step Controller

In the case of a three-step controller (for example, a heating and cooling

controller) the statements above also apply for the manipulated value A. The
second signal for controlling the cooling for formed via the manipulated value B.
Figure 3-26 shows the conversion of the manipulated value to the manipulated
values A and B. The conversion to a binary output signal is carried out so that the
ratio of the pulse length to the period time corresponds to the manipulated values A
or B at the corresponding digital outputs.
The assignment of the digital outputs to the controller channels is shown in
Table 3-3 on Page 3-32.

Output signals
Start of range output si- manipulated value A and B Manipulated
gnal manipulated value B value A
Manipulated
value B

Input signal
manipulated
Start of range input End of range input End of range output value LMN
signal manipulated signal manipulated signal manipulated
value B value B value B

Figure 3-26 Split-Range Function Three-Step Controller

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Controller Output at the Step Controller

External
manipulated
value

Effective Switch
manipulated external
value manipulated Manipulated
value value

Switch Switch Limit

correction safety Pulse
manipulated shaper
value
Tracking input

Manipulated value correction

Position feedback input

Figure 3-27 Step Controller Output (Step Controller with Position Feedback Mode)

External
manipulated value

Effective Switch Switch Pulse

manipulated external safety shaper
value manipulated manipulated
value value

Figure 3-28 Step Controller Output (Step Controller without Position Feedback Mode)

In the case of a step controller without analog position feedback the external
manipulated value and the safety manipulated value act as follows:
If a value between 40.0% and 60.0% is specified, no binary output is set and the
actuating element remains unchanged.
If a value >60.0% is specified, “Actuating signal high” is output as long as the
feedback ”Actuating device at upper stop” responds.
If a value <40.0% is specified, “Actuating signal low” is output as long as the
feedback ”Actuating device at lower stop” responds.
Table 3-2 lists the functions of the controller output and the setting possibilities.

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Table 3-2 Functions of the Controller Output and Setting Possibilities

Functions of the Adjustable Parameters
Controller Output
Switch external The changeover between the external manipulated value and the effective
manipulated value manipulated value from the controller can alternatively be carried out by
• A binary value from the function block
• A signal which results from the ORing of a binary value from the function
block and a digital input
Tracking input There are the following alternative settings:
• The tracking input has the value zero
• The tracking input is the conditioned analog value of an analog input
Position feedback input There are the following alternative settings:
(only step controller) • The position feedback input has the value zero
• The position feedback input is the conditioned analog value of analog I.
Switch tracking Changing over between the manipulated value and the tracking input is
carried out alternatively by
• A binary value from the function block
• A signal which results from the ORing of a binary value from the function
block and a digital input
Switch safety manipulated • Specifying the safety manipulated value
value • Alternative reaction of the FM 455 during the startup:
– The FM 455 changes to closed-loop control
– The safety manipulated value is output as the safety manipulated val.
• The changeover to the safety manipulated value is carried out
alternatively by
– A binary value from the function block
– A signal which results from the ORing of a binary value from the
function block and a digital input
• Reaction at a measuring transducer fault of the process variable A:
– At the setting ”Closed-loop control” the operating mode of the
controller remains unchanged
– At the setting ”Manipulated value = Safety manipulated value” the
system changes over to the safety manipulated value
• Reaction at a measuring transducer fault of an analog input:
– At the setting ”Closed-loop control” the operating mode of the
controller remains unchanged
– At the setting ”Manipulated value = Safety manipulated value” the
system changes over to the safety manipulated value
Manipulated value limiting Upper and lower limitation (cannot be deactivated)
Forming of the split-range • On/Off (only continuous controllers)
manipulated values • Starting and end value of the input signal
• Starting and end value of the output signal
Pulse shaper • Motor actuating time
(only step controller) • Minimum pulse time
• Minimum pause time

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3.5 Outputs of the FM 455

Analog Outputs of the FM 455 C

You can carry out the following specifications for each analog output of the
FM 455 C by means of configuration:
• Signal selection
• Signal type
The outputs are configured in the screens ”Signal selection analog output” and
”Signal type analog output”.

Signal Selection at the Analog Outputs

With the signal selection you can specify which signal value is output at the analog
output.
The following signal values can be configured:
• The value zero
• The conditioned analog value of one of the 16 analog inputs
• The manipulated value A of one of the 16 controller channels
• The manipulated value B of one of the 16 controller channels

Signal Type at the Analog Outputs

You can determine the signal type for each analog output.
The following signal types can be configured:
• Current output 0 to 20 mA
• Current output 4 to 20 mA
• Voltage output 0 to 10 V
• Voltage output -10 to 10 V

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Digital outputs of the FM 455 S

The digital outputs of the FM 455 S are used to control integrating or
non-integrating final controlling elements
Table 3-3 shows the assignment of the digital outputs to the controller channels
and their meaning:

Table 3-3 Assignment and Meaning of the Digital Outputs

Controller Digital Outputs Meaning of the Digital Assignment of the
Channel Assigned to the Outputs at the Step Digital Outputs at the
Controller Channel Controller Pulse Controller
1 Open Manipulated value A
1
2 Close Manipulated value B
3 Open Manipulated value A
2
4 Close Manipulated value B
5 Open Manipulated value A
3
6 Close Manipulated value B
7 Open Manipulated value A
4
8 Close Manipulated value B
9 Open Manipulated value A
5
10 Close Manipulated value B
11 Open Manipulated value A
6
12 Close Manipulated value B
13 Open Manipulated value A
7
14 Close Manipulated value B
15 Open Manipulated value A
8
16 Close Manipulated value B
17 Open Manipulated value A
9
18 Close Manipulated value B
19 Open Manipulated value A
10
20 Close Manipulated value B
21 Open Manipulated value A
11
22 Close Manipulated value B
23 Open Manipulated value A
12
24 Close Manipulated value B
25 Open Manipulated value A
13
26 Close Manipulated value B
27 Open Manipulated value A
14
28 Close Manipulated value B
29 Open Manipulated value A
15
30 Close Manipulated value B
31 Open Manipulated value A
16
32 Close Manipulated value B

Open = Open the actuating element

Close = Close the actuating element

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3.6 Control Action Mechanisms and Data Management in the

FM 455

Overview
This section describes important control action mechanisms and the data
management principle in the FM 455.
The parameter configuration interface on the programming device/personal
computer can be used to
• Configure,
• Optimize,
• Control and monitor the FM 455
The function block (FB) PID_FM included with the FM 455 can be used to
interconnect the module to a user program.

Parameter Configuration
The FM 455 is configured with the parameter configuration interface on the
programming device (refer to Chapter 5).All the parameter configuration data are
saved in an SDB on the programming device.

Note
You can only download the SDB parameter configuration data via an online
connection between the programming device and the CPU to the CPU and to the
FM 455 if the CPU is in STOP mode. This is only possible via the HW Config. The
parameter configuration interface must have been closed.

The parameters are transferred from the SDB in the CPU to the FM 455 during
every startup and during the transition of the CPU from STOP to RUN.

Downloading the Parameters Directly to the FM 455

You can also download the parameters via the parameter configuration interface
directly to the FM 455 so that you do not have to close the parameter configuration
interface and set the CPU to STOP mode several times consecutively while testing
your configuration during setting up. Please note that the downloaded parameters
are overwritten by the values from the SDB of the CPU when the CPU is started
up and during the CPU transition from STOP to RUN. An FB call can also
overwrite the parameters downloaded directly from the parameter configuration
interface.
Downloading to the FM 455 therefore only makes sense in order to test the
configuration during the setup.

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How Does the FM 455 Controller Module Work?

If you change parameters via the parameter configuration interface and then
download them directly to the FM 455, jumps can occur in the manipulated value
course. We recommend the following procedure in order to achieve a controlled
manipulation value course:
1. Switch to manual mode (for example via the loop display).
2. Change the parameters.
3. Download directly to the FM 455.
4. Switch to automatic mode (for example via the loop display).

Flow of Data when Configuring via the Parameter Configuration Interface

Figure 3-29 shows the path of the configuration data from the parameter
configuration interface to the FM 455.

Parameter
configuration
interface

HW Config

Programming
Offline device
data
management
Download directly to FM

Download
from
HW Config

CPU FM 455

System
data
Downloading of the
system data during
startup and
STOP → RUN of the CPU

Figure 3-29 Configuring the FM 455 via the Programming Device and via the CPU

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Connecting the FM 455 to the User Program

You have to use the FB PID_FM if you want to change the control parameters (for
example, controller gain, integration coefficient) of the FM 455 from the user
program or by operator control at the programming device. Assign an instance DB
to this FB for each controller channel which you want to use (refer to Chapters 7
and 11). If the parameter LOAD_PAR is set when the FB PID_FM is called by the
user program, all the controller parameters of the FB are transferred to the
FM 455. Controller parameters are all the parameters which lie in the instance data
block after the variable cont_par.
The parameters in the instance DB have a default setting. These default settings
can be changed with the STL/LAD Editor.

Note
You must first call the FB PID_FM once with COM_RST = TRUE in the CPU
startup so that the parameters which you do not want to change are not
overwritten with the default values from the instance DB. The FB PID_FB then
reads the parameters - which were transferred from the CPU to the FM
beforehand - from the FM 455 and saves them in its instance DB. You can now
change individual parameters and transfer all the parameters to the FM 455 with
LOAD_PAR = TRUE.
Please note that the parameters in the FM 455 are overwritten by the values from
the system data whenever the CPU is started up (transition from STOP to RUN).

CPU FM 455
System
data

Downloading of the
system data,
Startup,
STOP → RUN of CPU
Instance FB
DB of the PID_FM
FB PID_FM LOAD_PAR = TRUE

COM_RST = TRUE

Figure 3-30 Configuration of the FM 455 via the System Data and via the FB PID_FM

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The operating parameters (for example, setpoint value, manual manipulated value)
of the FM 455 are transferred cyclically from the FB PID_FM to the FM 455.
Operating parameters are all the parameters, which lie in the instance data block
between the variables op_par and cont_par. In order for the data transfer to be
possible without a high run time in the CPU, transferring is normally carried out via
direct I/O accesses, not via the SFC WR_REC. The data are multiplexed since
only four bytes per channel are available in the I/O address area of the module. It
can therefore take up to three cycles of the CPU or of the FM 455 until the
operating values have been transferred to the FM 455 - the respectively longer
cycle is decisive.
If you set the parameter LOAD_OP = TRUE, the operating parameters are then
transferred in one program cycle via the SFC WR_REC to the module. However,
this requires more run time (refer to technical specifications).
The process values (for example, process variable, manipulated value) can also be
read by the FB PID_FM via direct I/O accesses. This transmission does not
require much run time, however the following functional restrictions result. If the
parameter READ_VAR = TRUE is set, then the process values are read from the
FM 455 by means of the SFC RD_REC. However, this requires a higher run time
(refer to Section A.2, Page A-9, Technical Specifications of Function Blocks).
Functional restrictions when READ_VAR is not set:
• The variables SP (setpoint variable from the FM), ER (error signal), DISV
(disturbance variable), LMN_A and LMN_B (refer to Chapter ”Assignment of the
instance DBs) are not updated.
• The data are multiplexed. The process variable and manipulated value and the
binary displays are not updated again until after four calls of the block.
• If the setpoint value and the manual manipulated variable were operated via the
OP, these operating values are not updated (read out of the FM) by the FB
during the CPU startup.

Operator Control and Monitoring of the FM 455 by Means of the OP via the
FB PID_FM
Operator control and monitoring of the FM 455 is possible via the FB PID_FM.
If one of the following parameters ”Operating setpoint value SP_OP”, “Operating
manipulated variable LMN_OP” and the corresponding switches “SP_OP_ON” and
“LMNOP_ON” was changed by operation via the OP, the FB PID_FM takes over
these values from the FM after the CPU has been started up, if the parameter
READ_VAR = TRUE is set.
Operator Control and Monitoring of the FM 455 by Means of the OP via the MPI
A maximum of three connections from the FM 455 to the OPs can be implemented.
Operator control of the FM 455 with the OP is only possible in the STOP mode of
the CPU or at a CPU failure.
Monitoring of the FM 455 with the OP is always possible.
The variable interface of the FM 455 contains 16 data blocks with the block
numbers 101 to 116 for the controller channels 1 to 16 (refer to Figure 3-31).
These data blocks are described in Section 11.8 “Assignment of the DBs for
Operator Control and Monitoring via OP”.

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Note
The contents of the data blocks 101 to 116 do not automatically reflect the
parameter value effective at the FM 455. Parameters changed with the OP are
only transferred to the FM 455 after the operating bits LOAD_PAR or LOAD_OP
have been set.
If you use OP operator control to change a parameter without setting the
corresponding operating bit, the modified parameter value exists in the data block,
but the FM 455 continues to operate internally with the unchanged old value of the
parameter.
After the operating bits have been set and the parameters have been transferred
to the FM 455, the operating bits LOAD_PAR or LOAD_OP are reset by the
FM 455.

OP

Operation and monitoring in Operation only in STOP mode of

RUN mode of the CPU the CPU or at CPU failure;
Monitoring

CPU FM 455

DB 101
to 116

**
FB Max. of 16
PID_FM instance DBs
of the FB **
PID_FM Parameter
*

* Controlled by the parameter READ_VAR of the instance DB

** Controlled by the parameters LOAD_OP and LOAD_PAR

Figure 3-31 Operator Control and Monitoring of the FM 455

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3.7 Properties of the FM 455

Overview
This section provides information on
• Processing sequence and sampling time
• Controlling for operation
• Startup characteristics
• Back-up operation
• Firmware update

Processing Sequence
The analog inputs and the controller channels of the FM 455 are combined into two
groups of eight each:
Group 1: Analog input 1 to 8 and Controller Channel 1 to 8
Group 2: Analog input 9 to 16 and Controller Channel 9 to 16

Conversion time (example) Conversion time (example)

Startup Reference 100 ms

junction for
analog input 1
to 16

20 ms Controller 100 ms Controller

Analog input 1 channel 1 Analog input 9 channel 9

100 ms Controller Analog input 100 ms Controller

Analog input 2 channel 2 10 channel 10

Analog input 3 to Analog input 11 to

7 with 20 ms 15 with 20 ms
each conversion each conversion
time time

20 ms Controller 20 ms Controller
Analog input 8 Analog input 16
channel 8 channel 16

Group 1 Group 2

Figure 3-32 Processing Sequence of the FM 455

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Group 1 and group 2 are processed in parallel. Processing within each group is
sequential.
Within each group every controller channel is processed directly after the analog
input with the same number has been processed and conditioned. This is followed
by the processing of the analog input with the next higher number in the same
group, etc..
The reference junction is only processed in group 2 after controller channel 16.

Sampling Time
Within each group the common sampling time of all the controllers of the FM 455
results from the sum of the conversion time of the individual analog inputs. The
conversion time for the reference junction, if used, has to be added for the
controller channels of group 2 (Channels 9 to 16).
The conversion time of an analog input depends on the resolution, the power
frequency and controller type used (refer to Table 3-4):

Table 3-4 Conversion Time of an Analog Input

Resolution Power Controller Type Conversion Time of an

Frequency Analog Input
12 bits 60 Hz No temperature controller 16 2/3 ms
12 bits 50 Hz No temperature controller 20 ms
14 bits 50 or 60 Hz No temperature controller 100 ms
12 or 14 bits 50 or 60 Hz Temperature controller 100 ms

If an analog input is not processed, the controller channel with the same number is
not processed either (conversion time = 0).
No additional conversion times result for the analog outputs. The analog output
values of the FM 455 are output immediately after calculation of the corresponding
initial values.

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How Does the FM 455 Controller Module Work?

Table 3-5 contains further rules for the conversion time of the reference junctio
input.

Table 3-5 Rules for the Conversion Time

If ... Then ...

a resolution of 12 bits was selected at all the the reference junction requires the same
analog inputs, conversion time as an analog input.
the higher resolution of 14 bits was selected
at even only one analog input, the reference junction requires a conversion
One of the controllers was configured as a time of 100 ms.
temperature controller.

The sampling time in indicated in the parameter configuration interface:

Command button: Module parameters

In the example of Figure 3-32 the following sampling times result for each
controller (at 50 Hz power frequency):
For the controllers of group 1 (channel 1 to 8):
tsampling = 20 ms + 100 ms + 6
20 ms = 240 ms

For the controllers of group 2 (channel 9 to 16):

tsampling = 3
100 ms + 6
20 ms = 420 ms

Particularly short sampling times can be reached for controller channels 1 to 8,

since the conversion time of the reference junction does not have to be included.

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Figure 3-32 shows an example with five controller channels used from group 1 and
four controller channels used from group 2.

Conversion time (example) Conversion time (example)

Startup Reference 100 ms

junction for
Analog input 1
to 16

20 ms Controller 100 ms Controller

Analog input 1 Analog input 9
channel 1 channel 9

20 ms Controller Analog input Controller

Analog input 2
channel 2 10 channel 10

Analog input 10 is not processed (0 ms)

20 ms Controller Analog input 100 ms Controller

Analog input 3 channel 3 11 channel 11

20 ms Controller Analog input 11 to

Analog input 4
channel 4 14 is not
processed (0 ms)

Analog input 5 to Analog input 100 ms Controller

7 is not 15 channel 15
processed (0 ms)

20 ms Controller 20 ms Controller
Analog input 8 channel 8 Analog input 16 channel 16

Group 1 Group 2

Figure 3-33 Processing Sequence of the FM 455

In the example of Figure 3-33 the following sampling times result for each
controller (at 50 Hz power frequency):
For the controllers of group 1 (channel 1, 2, 3, 4 and 8):
tsampling = 5
20 ms = 100 ms

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How Does the FM 455 Controller Module Work?

For the controllers of group 2 (channel 9, 11, 15, and 16):

tsampling = 4
100 ms + 20 ms = 420 ms

Rules for Operating the FM 455

The following rules can be summarized for operation with the FM 455:
• The controllers of the FM 455 can be cascaded freely. This means that you can
switch the manipulated value of a controller channel to the setpoint value of
another controller channel.
• The processing of a controller channel is carried out immediately after the
conditioning of the analog input wth the same number.
If a controller uses several analog inputs, you should select the controller
channel whose number corresponds to the highest number of the analog inputs
used in order to reduce the dead times.
Example: A controller requires the signals of the analog inputs 1, 2 and 3. The
smallest dead time results if the controller No. 3 is selected.
• If you select the setting ”Analog input is not processed” at an analog input, the
controller channel with the same number is not processed either. No additional
sampoling time is thus required for this analog input.
• If the reference junction input is used, it requires the same conversion time as
the analog input with the highest conversion time.
• The sampling time of a controller is the sum of the conversion times of the
analog inputs in the same group. The conversion time for the reference
junction, if used, has to be added for controller channels 9 to 16 (group 2).

Startup Characteristics
During the startup the FM 455 first takes over the current parameters from your
EEPROM and begins to control with these parameters. These are overwritten by
the CPU with the parameters from the system data as soon as the P bus
connection between the CPU and the FM 455 has been established. If the system
data do not contain any parameters for the controller, the module continues to
control with the parameters contained in the EEPROM. The FM 455 does not know
a change to default parameters.
The following configurable possibilities exist for the manipulated value at a restart
after a failure of the power supply:
• The controller begins with the safety manipulated value.
This setting remains effective until it is reversed by the user program via the
function block.
• The controller changes over to closed-loop control

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The following configurable possibilities exist for the setpoint value at a restart
after a failure of the power supply:
• The last setpoint value valid remains effective.
• The system changes over to the safety setpoint value.
This changeover only remains effective until the setpoint value is specified by
the user program via the function block. Otherwise the setpoint value is
specified by an analog input or controller output depending on the configuration.

Characteristics of the FM 455 at an Own Power Supply

If the FM 455 has its own 24-V power supply, observe the following points:
• Startup without 24-V power supply at the FM 455:
– The CPU does not change to RUN if the run-time system error OB (OB 85)
does not exist.
• Failure of the 24-V power supply of the FM 455 during RUN mode:
– The CPU changes to STOP if the insert/remove-module interrupt OB
(OB 83) does not exist.
– The CPU changes to STOP, if the I/O access error OB (OB 122) does not
exist.
– The communication link of the CPU to the FM 455 is interrupted. In the
FB PID_FM the output parameter RET_VALU contains an error value.

Backup Operation
If the CPU goes into STOP mode or fails or the connection of the FM 455 to the
CPU fails, the FM 455 changes over to backup mode and continues to control with
the parameters applying at the time of the fault. The FM 455 uses either the last
setpoint value or the safety setpoint value depending on the configuration.
Backup operation is indicated by the yellow ”Backup” LED.
In backup operation the FM 455 can be operated directly via the OP. As soon as
the CPU returns to RUN mode, the FM 455 can no longer be operated via the OP
(refer to Section 3.6).

Firmware Update
In order extend functions and remedy faults it is possible to download firmware
updates to the operating system memory of the FM 455. This functionality is
described in the online help of the parameter configuration interface.

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3.8 Parameter Optimization at the Temperature Controller

Requirements to the Process at the Temperature Controller

The following requirements should be sufficient in order to achieve optimal
controlling by means of the temperature controller:
• In case of bath heatings the liquid to be heated must be mixed well.
• In the case of bath-to-bath control systems both liquids must be mixed well. At
the same time good heat transitions must be ensured between all the heat
exchanging media. In the case of materials with bad heat transfer properties
large transition surfaces should ensure good heat transferring.
• In the case of ambient-air temperature control systems thorough mixing (for
example, with fans) must be ensured.
• The process gain may not exceed the factor 3.
• The dead time may amount to a maximum of 3% of the delay time.
• The temperature to be controlled should not change by more than 1 ‰ of the
specified maximum temperature within the sampling time of the controller at the
maximum manipulated variable output.

Classification of the Processes

A process is characterized by parameters such as the heat output, the heating
mass or the thermal capacity of the medium to be heated. With regard to a fuzzy
controller ”critical” and ”non-critical” temperature processes are differentiated as
follows: The control system becomes more critical
• The higher the heat output,
• The higher the thermal capacity of the heating
• The lower the thermal capacity of the medium to be heated
• The higher the heat transfer resistance
• The smaller the heat transfer surface is.
After a manipulated value step has been applied to the process, it reacts with a
step response. The process can also be classified on the basis of this step
response: The control system becomes more critical the higher the ratio tu/ta is and
the higher the process gain is. If tu/ta < 1/10, the process is uncritical (refer to
Figure 3-34).

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Step response of the

process to a
manipulated value jump

ta t
tu
tu: Dead time
ta: Delay time

Figure 3-34 Step Response of the Process to a Manipulated Value Jump

Parameter Optimization at a Temperature Controller

Parameter optimization is based on a self-tuning fuzzy controller
In order for the temperature controller to operate optimally, an identification of the
process must take place. For this purpose the identification must be activated by
the parameter FUZID_ON = 1 in the instance DB of the function block PID_FM
and a setpoint value step of ≥12% of the setpoint value range must take place.
The identification of the process begins with a monitoring phase with no heat
output. The duration of the monitoring phase is as follows:
• Monitoring phase of the continuous controller: Approx. 1 min
• Monitoring phase of the step controller: Approx. 1 min + 1/2 × actuating
time
This period is used to establish the temperature trends in the heating medium.
Then the maximum heat output of 100% is output. This is indicated at the output
parameter LMN in the instance DB of the function block PID_FM.
The range of the first 4% temperature increase of the setpoint value range is used
for identification, whereby information on the process behavior is obtained on the
basis of the elapsed time at 1% and 4% of the temperature increase.

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The identification is completed when the heat output drops below 100%. This
behavior can be used in order, for example, to deactivate the identification via the
user program. After the identification phase the controller continues to operate with
the determined parameters.
At every further setpoint value step ≥12% a renewed identification is carried out,
unless the identification has been deactivated again with FUZID_ON = FALSE.
If the setpoint value step is not corrected and the heat output remains permanently
at zero, the identification is terminated unsuccessfully - meaning that the controller
cannot control the connected process.

Prerequisites for Identification

As far as possible you must ensure that the process has settled before
identification (no heating or cooling process) or is changing slowly and monotously.
The criterion can be that the temperature change approximates a straight line
during a period of one minute. In the case of faster processes this requirement is
of particular importance.
Since the controller outputs the manipulated variable zero for approximately one
minute at the beginning of identification, the temperature to be controlled must lie
near the ambient temperature.

How to Start Identification

In order to sart identification you must first change the controller over to
optimization mode. This is achieved by setting the bit FUZID_ON in the instance
DB of the FB PID_FM either from the user program or via the the parameter
configuration tool:
Call: Debug >Controller Optimization
The identification is started by a positive setpoint value step, whereby the following
conditions must be fulfilled:
• 1st. condition: The minimum step size: Setpoint value step > 5 degrees
• 2nd. condition: The setpoint value after the step:
Setpoint value after > Process variable + Setpoint value limitation * 0.12
with setpoint value limitation = Upper setpoint value limit of the controller
It is also possible to restart the identification by reducing and then increasing the
setpoint value. The setpoint value must fulfil condition 2 after the increase.

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Completing the Identification

As long as the bit FUZID_ON = TRUE, the next identification is started whenever
there is a sufficiently large setpoint value step. For this reason we recommend
deactivating the optimization mode (FUZID_ON = FALSE) immediately after
identification has been completed.
Information on the state of identification can be obtained by using the parameter
IDSTATUS of the FB CH_DIAG (refer to Page 3-48).

Aborting Identification
Identification can be aborted in the following cases:
• By the controller if a ”critical” process is identified. After aborting the controller is
in the fault state. This state is indicated by the fact that the manipulated variable
is set back permanently by the controller. This does not change either when
optimization is deactivated. The fault state is deleted when a new identification
is started.
Information on the state of identification can be obtained by using the
parameter IDSTATUS of the FB CH_DIAG (refer to Page 3-48).
• By the operator creating a negative setpoint value step which must lie below
condition 2 (see above, “How to Start Identification”).

Note
Deactivating the optimization mode FUZID_ON=0 before identification has been
completed, does not stop identification. An identification which has been started
continues to run - unless the setpoint value step is negative.

Process Behavior at Different Processes

In the case of an ”uncritical” process there are no problems, neither in the
identification nor in the control system.
The identification of a process which is ”too critical” is aborted. Controlling of an
identified ”critical” process is carried out very ”carefully” or slowly.

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Controller State Information

The parameter IDSTATUS of the function block FB CH_DIAG provides information
on the state of the identification.

X A I F
215 20

Figure 3-35 IDSTATUS Parameter of the FB CH_DIAG

The IDSTATUS parameter contains the four hexadecimal values X, A, I and F.

Their meanings are as follows:

X: Without any meaning (always 0)

A: Action number:
0 = Manual mode (or not closed-loop control respectively);
2 = Control
4 = Optimization activated (FUZID_ON = true)
6 = Transition state from manual mode to 2 or 4

I: Display “Identification running” and “Parameters determined but not saved in

EEPROM yet”
0 = Identification not running, but no new parameters determined
1 = Identification running, but no new parameters determined
2 = Identification not running, new parameters determined but not saved yet
in EEPROM
3 = Identification running, new parameters determined but not saved yet in
EEPROM

F: Error number:
0 = No error
4 = Process variable step too high during identification
5 = Ratio of dead time to system time constant too high or highly non-linear
behavior of the process.
6 = Temperature drop or rise to great at the start of the identification.
Process not settled sufficiently.

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Inserting and removing the FM 455 4
What Does this Chapter Describe?
This chapter contains information on inserting and removing the FM 455.
• You will learn what you must look out for when inserting. You will get notes and
hints on configuring an FM 455 and on where and how to insert an FM 455.
• You will learn step by step how to insert and remove an FM 455.

Chapter Overview

Section Description Page

4.1 Preparing for Insertion 4-2
4.2 Inserting and Removing the FM 455 4-3

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Inserting and removing the FM 455

4.1 Preparing for Insertion

Planning the Mechanical Structure

Manual /1/ describes the possibilities open to you for mechanical insertion and how
to proceed when configuring. The following paragraphs give only a few
supplementary tips.
1. The FM 455 function module occupies two slots. It can be inserted in an S7-400
central rack or expansion rack in all the slots which are not reserved for a
power supply module or for a receiver IM.
2. The maximum number is restricted only by the memory required by the
CPU software for communication with the FM 455.

Specifying the Starting Address

The starting address of the FM 455 is required for communications between the
CPU and the FM 455. The starting address must be entered in the instance DBs of
the required FBs (refer to Chapters 7 and 11).
The entry is made either with the help of the Statement List/Ladder Editor or from
the user program.
Enter the start address of the FM 455 under STEP 7.

Inportant Safety Regulations

There are important regulations you must observe for integrating an S7-400 with
an FM 455 into a plant or system. These rules and regulations are explained in
manual /1/.

Controller Module FM 455

4-2 A5E00059359-02
 Inserting and removing the FM 455

4.2 How to Insert and Remove the FM 455

Rules
No special protection measures (ESD guidelines) are required to insert an FM 455.

Required Tools
In order to insert and remove the FM 455 you require a cylindrical screwdriver with
a blade 3.5 mm wide.

Before Insertion
Before inserting the FM 455 you should check whether the coding keys at the side
of the module have to be repositioned. These coding keys can be used to adapt
the FM 455 to various sensors (refer to Section 9.3).

Procedure for Insertion

The following section describes how to insert the FM 455 into a rack. You will find
further information on inserting modules in Manual /1/
1. Remove the filler panels from the slot at which you want to plug in the FM 455.
2. Hang the FM 455 in and swivel it down.
3. If you notice any resistance while swiveling in the module, lift the module
slightly and then continue swiveling in.
4. Screw the FM 455 on by using both mounting screws (torque approx. 0.8 to
1.1 Nm).
5. Label the FM 455 with its slot number. For this purpose use the number wheel
which is supplied with the rack.
6. Manual /1/ describes the numbering scheme you must use and how to connect
the slot numbers.

Controller Module FM 455

A5E00059359-02 4-3
Inserting and removing the FM 455

Procedure for Removal/Module Replacement

The following section describes how to remove the FM 455. You will find further
information on removing modules in Manual /1/.
1. Switch off the supply voltage L+ at the front connector.
2. Loosen the mounting screw of the front connector and remove it.
3. Loosen the fixing screws of the module.
4. Swivel the module out.
5. Insert the new module if applicable.
6. If appropriate, replace the front connector and screw it on.
7. Switch on the supply voltage L+ at the front connector again.

Further Information
Manual /1/ contains further information on inserting and removing modules

Controller Module FM 455

4-4 A5E00059359-02
Wiring the FM 455 5
What Does this Chapter Describe?
This chapter contains information on wiring the FM 455.
• The terminal assignment of the front connector.
• The functions of the connections.
• Information on selecting the cables.
• Which steps have to be carried out when wiring the front connector.

Section Description Page

5.1 Terminal Assignment of the Front Connector. 5-2
5.2 Wiring Front Connectors Overview 5-12
5.3 Applying Strain Relief 5-22
5.4 Labeling the Front Connector 5-23
5.5 Mounting the Front Connector 5-25

Controller Module FM 455

A5E00059359-02 5-1
Wiring the FM 455

5.1 Terminal Assignment of the Front Connector.

Front Connector of the FM 455 C

The digital inputs, analog input and outputs and the power supply of the module
are connected via the two 48-pin front connectors of the FM 455 C.
Figures 5-1 and 5-2 show the wiring diagrams, Table 5-1 shows the connector
pinout of the front connectors.
Figure 5-2 shows an example of how the various sensors - current sensors,
voltage sensors, thermocouples and resistance thermometers (Pt100) - can be
connected to the analog inputs CH1 to CH16. A different assignment of the
sensors to the analog inputs is naturally also possible. However, you can only
connect sensors of the same type to two adjacent analog inputs (CH1 and CH2,
CH3 and CH4, etc.), since these analog inputs are adapted to the sensor type by
means of a common coding key (refer to Section 9.3).
Please note that resistance thermometers (Pt100) require two adjacent analog
inputs for their connection and that they can only be connected in the way shown
in Figure 5-2 to the analog inputs CH1, CH3, CH5, CH7, CH9, CH11, CH13 and
CH15.

Controller Module FM 455

5-2 A5E00059359-02
 Wiring the FM 455

INTF 1 1
EXTF 2 2
L+
IN 3 3 L+ Power supply 24 V
1 4 4 I1 Digital input
2 5 5 I2 Digital input
3 6 6 I3 Digital input
4 7 7 I4 Digital input
5 8 8 I5 Digital input
6 9 9 I6 Digital input
7 10 10 I7 Digital input
8 11 11 I8 Digital input
OUT 12 12
1 13 13 Q1 Analog output 1
14 14 MANA Reference point of the analog loop
2 15 15 Q2 Analog output 2
16 16 MANA Reference point of the analog loop
3 17 17 Q3 Analog output 3
18 18 MANA Reference point of the analog loop
4 19 19 Q4 Analog output 4
20 20 MANA Reference point of the analog loop
5 21 21 Q5 Analog output 5
22 22 MANA Reference point of the analog loop
6 23 23 Q6 Analog output 6
24 24 MANA Reference point of the analog loop
7 25 25 Q7 Analog output 7
26 26 MANA Reference point of the analog loop
8 27 27 Q8 Analog output 8
28 28 MANA Reference point of the analog loop
29 29
30 30
9 31 31 Q9 Analog output 9
32 32 MANA Reference point of the analog loop
10 33 33 Q10 Analog output 10
34 34 MANA Reference point of the analog loop
11 35 35 Q11 Analog output 11
36 36 MANA Reference point of the analog loop
12 37 37 Q12 Analog output 12
38 38 MANA Reference point of the analog loop
13 39 39 Q13 Analog output 13
40 40 MANA Reference point of the analog loop
14 41 41 Q14 Analog output 14
42 42 MANA Reference point of the analog loop
15 43 43 Q15 Analog output 15
44 44 MANA Reference point of the analog loop
16 45 45 Q16 Analog output 16
46 46 MANA Reference point of the analog loop
47 47
M
48 48 M Ground of the supply voltage

Figure 5-1 Wiring Diagram of the FM 455 C, Left-Hand Front Connector

Controller Module FM 455

A5E00059359-02 5-3
Wiring the FM 455

Current sensors Resistance thermometers

Voltage sensors (Pt 100)
Thermocouples
Backup 1 1
2 1) 2
L+
IN 3 3
9 4 4 I9 Digital input
10 5 5 I10 Digital input
11 6 6 I11 Digital input
12 7 7 I12 Digital input
13 8 8 I13 Digital input
14 9 9 I14 Digital input
15 10 10 I15 Digital input
16 11 11 I16 Digital input
1 12 V 12 M1+ IC1+
CH 1
13 13 M1- IC1-
CH 1
2 14 V
14 M2+ M1+
CH 2
15 15 M2- M1-
3 16 16 M3+ IC3+
CH 3
17 17 M3- IC3-
CH 3
4 18 18 M4+ M3+
CH 4
19 19 M4- M3-
5 20 20 M5+ IC5+
CH 5
21 21 M5- IC5-
CH 5
6 22 22 M6+ M5+
CH 6
23 23 M6- M5-
7 24 24 M7+ IC7+
A CH 7
25 25 M7- IC7-
CH 7
8 26 26 M8+ M7+
A CH 8
27 27 M8- M7-
28 28 IC+ IC+
COMP 29 29 IC- IC-
Reference Reference
30 30 COMP+ COMP+
junction junction
31 31 COMP- COMP-
9 32 A
32 M9+ IC9+
CH 9
33 33 M9- IC9-
CH 9
10 34 A 34 M10+ M9+
CH 10
35 35 M10- M9-
11 36 36 M11+ IC11+
37 37 M11- CH 11 IC11-
CH 11
12 38 38 M12+ M11+
CH 12
39 39 M12- M11-
13 40 40 M13+ IC13+
CH 13
41 41 M13- IC13-
CH 13
14 42 42 M14+ M13+
CH 14
43 43 M14- M13-
15 44 44 M15+ IC15+
Tr CH 15
45 45 M15- IC15-
CH 15
16 46 46 M16+ M15+
Tr CH 16
47 47 M16- M15-
48 MANA 48 MANA

1) Connection to L+ of the left-hand front

connector

Figure 5-2 Wiring Diagram of the FM 455 C, Right-Hand Front Connector

Controller Module FM 455

5-4 A5E00059359-02
 Wiring the FM 455

Table 5-1 Pinout of the Front Connector of the FM 455 C

Left-Hand Front Connector Right-Hand Front Connector

Con- Analog Name Function Con- Analog Name Function
nection Output nection Input
1 - - - 1 - - -
2 - - - 2 - - -
3 - L+ Power supply 24 V 3 - - -
4 - I1 Digital input 4 - I9 Digital input
5 - I2 Digital input 5 - I10 Digital input
6 - I3 Digital input 6 - I11 Digital input
7 - I4 Digital input 7 - I12 Digital input
8 - I5 Digital input 8 - I13 Digital input
9 - I6 Digital input 9 - I14 Digital input
10 - I7 Digital input 10 - I15 Digital input
11 - I8 Digital input 11 - I16 Digital input
12 - - - 12 M+ Measuring line (pos.)
1
13 Q1 Analog output 13 M- Measuring line (neg.)
14 1 MANA Reference point of the 14 M+ Measuring line (pos.)
analog loop 2
15 Q2 Analog output 15 M- Measuring line (neg.)
16 2 MANA Reference point of the 16 M+ Measuring line (pos.)
analog loop 3
17 Q3 Analog output 17 M- Measuring line (neg.)
18 3 MANA Reference point of the 18 M+ Measuring line (pos.)
analog loop 4
19 Q4 Analog output 19 M- Measuring line (neg.)
20 4 MANA Reference point of the 20 M+ Measuring line (pos.)
analog loop 5
21 Q5 Analog output 21 M- Measuring line (neg.)
22 5 MANA Reference point of the 22 M+ Measuring line (pos.)
analog loop 6
23 Q6 Analog output 23 M- Measuring line (neg.)
24 6 MANA Reference point of the 24 M+ Measuring line (pos.)
analog loop 7
25 Q7 Analog output 25 M- Measuring line (neg.)
26 7 MANA Reference point of the 26 M+ Measuring line (pos.)
analog loop 8
27 Q8 Analog output 27 M- Measuring line (neg.)
28 8 MANA Reference point of the 28 IC+ Constant-current line
-
analog loop (pos.)
29 - - 29 IC- Constant-current line
- -
(neg.)
30 - - 30 COMP+ Reference junction input
- -
(pos.)

Controller Module FM 455

A5E00059359-02 5-5
Wiring the FM 455

Table 5-1 Pinout of the Front Connector of the FM 455 C

Con- Analog Name Function Con- Analog Name Function

nection Output nection Input
31 Q9 Analog Output 31 COMP- Reference junction input
-
(neg.)
9
32 MANA Reference point of the 32 M+ Measuring line (pos.)
analog loop 9
33 Q10 Analog output 33 M- Measuring line (neg.)
34 10 MANA Reference point of the 34 M+ Measuring line (pos.)
analog loop 10
35 Q11 Analog output 35 M- Measuring line (neg.)
36 11 MANA Reference point of the 36 M+ Measuring line (pos.)
analog loop 11
37 Q12 Analog output 37 M- Measuring line (neg.)
38 12 MANA Reference point of the 38 M+ Measuring line (pos.)
analog loop 12
39 Q13 Analog output 39 M- Measuring line (neg.)
40 13 MANA Reference point of the 40 M+ Measuring line (pos.)
analog loop 13
41 Q14 Analog Output 41 M- Measuring line (neg.)
42 14 MANA Reference point of the 42 M+ Measuring line (pos.)
analog loop 14
43 Q15 Analog output 43 M- Measuring line (neg.)
44 15 MANA Reference point of the 44 M+ Measuring line (pos.)
analog loop 15
45 Q16 Analog output 45 M- Measuring line (neg.)
46 16 MANA Reference point of the 46 M+ Measuring line (pos.)
analog loop 16
47 - - - 47 M- Measuring line (neg.)
48 M Grounding of the supply 48 MANA Reference point of the
- -
voltage analog loop

Note
The connections MANA must be connected with low-impedance to the reference
point at the rack (CPU grounding (refer to Figure 5-8)

Controller Module FM 455

5-6 A5E00059359-02
 Wiring the FM 455

Front Connector of the FM 455 S

The analog inputs, digital inputs and outputs and the power supply of the module
are connected via the two 48-pin front connector of the FM 455 S.
Figures 5-3 and 5-4 show the wiring diagrams, Table 5-2 shows the connector
pinout of the front connectors.
Figure 5-4 shows an example of how the various sensors - current sensors,
voltage sensors, thermocouples and resistance thermometers (Pt 100) - can be
connected to the analog inputs CH1 to CH16. A different assignment of the
sensors to the analog inputs is naturally also possible. However, you can only
connect sensors of the same type to two adjacent analog inputs (CH1 and CH2,
CH3 and CH4, etc.), since these analog inputs are adapted to the sensor type by
means of a common coding key (refer to Section 9.3).
Please note that resistance thermometers (Pt 100) require two adjacent analog
inputs for their connection and that they can only be connected in the way shown
in Figure 5-4 to the analog inputs CH1, CH3, CH5, CH7, CH9, CH11, CH13 and
CH15.

Controller Module FM 455

A5E00059359-02 5-7
Wiring the FM 455

INTF 1 1
EXTF 2 2
L+
IN 3 3 L+ Power supply 24 V
1 4 4 I1 Digital input
2 5 5 I2 Digital input
3 6 6 I3 Digital input
4 7 7 I4 Digital input
5 8 8 I5 Digital input
6 9 9 I6 Digital input
7 10 10 I7 Digital input
8 11 11 I8 Digital input
L+
OUT 12 12 L+ Power supply 24 V
1 13 13 Digital output Open
Controller channel 1
14 14 Digital output Close
2 15 15 Digital output Open
Controller channel 2
16 16 Digital output Close
3 17 17 Digital output Open
18 18 Controller channel 3
Digital output Close
4 19 19 Digital output Open
Controller channel 4
20 20 Digital output Close
5 21 21 Digital output Open
Controller channel 5
22 22 Digital output Close
6 23 23 Digital output Open
24 L+ 24 L+ Power supply24 V Controller channel 6
25 25 Digital output Close
7 26 26 Digital output Open
27 27 Controller channel 7
Digital output Close
8 28 28 Digital output Open
Controller channel 8
29 29 Digital output Close
9 30 30 Digital output Open
31 Controller channel 9
31 Digital output Close
10 32 32 Digital output Open
33 33 Controller channel 10
Digital output Close
11 34 34 Digital output Open
35 35 Controller channel 11
Digital output Close
36 L+ 36 L+ Power supply 24 V
12 37 37 Digital output Open
Controller channel 12
38 38 Digital output Close
13 39 39 Digital output Open
40 40 Controller channel 13
Digital output Close
14 41 41 Digital output Open
Controller channel 14
42 42 Digital output Close
15 43 43 Digital output Open
Controller channel 15
44 44 Digital output Close
16 45 45 Digital output Open
46 46 Controller channel 16
Digital output Close
47 L+ 47 L+ Power supply 24 V
48 M 48 M Ground of the supply voltage

Figure 5-3 Wiring Diagram of the FM 455 S, Left-Hand Front Connector

Controller Module FM 455

5-8 A5E00059359-02
 Wiring the FM 455

Current sensors Resistance thermometers

Voltage sensors (Pt 100)
Thermocouples
Backup 1 1
2 1) 2
L+
IN 3 3
9 4 4 I9 Digital input
10 5 5 I10 Digital input
11 6 6 I11 Digital input
12 7 7 I12 Digital input
13 8 8 I13 Digital input
14 9 9 I14 Digital input
15 10 10 I15 Digital input
16 11 11 I16 Digital input
1 12 V
12 M1+ IC1+
CH 1
13 13 M1- IC1-
CH 1
2 14 V
14 M2+ M1+
CH 2
15 15 M2- M1-
3 16 16 M3+ IC3+
CH 3
17 17 M3- IC3-
CH 3
4 18 18 M4+ M3+
CH 4
19 19 M4- M3-
5 20 20 M5+ IC5+
CH 5
21 21 M5- IC5-
CH 5
6 22 22 M6+ M5+
CH 6
23 23 M6- M5-
7 24 24 M7+ IC7+
A CH 7
25 25 M7- IC7-
CH 7
8 26 26 M8+ M7+
A CH 8
27 27 M8- M7-
28 28 IC+ IC+
29 29 IC- IC-
COMP Reference Reference
30 30 COMP+ COMP+
junction junction
31 31 COMP- COMP-
9 32 A
32 M9+ IC9+
CH 9
33 33 M9- IC9-
CH 9
10 34 A 34 M10+ M9+
CH 10
35 35 M10- M9-
11 36 36 M11+ IC11+
37 37 M11- CH 11 IC11-
CH 11
12 38 38 M12+ M11+
CH 12
39 39 M12- M11-
13 40 40 M13+ IC13+
CH 13
41 41 M13- IC13-
CH 13
14 42 42 M14+ M13+
CH 14
43 43 M14- M13-
15 44 44 M15+ IC15+
Tr CH 15
45 45 M15- IC15-
CH 15
16 46 46 M16+ M15+
Tr CH 16
47 47 M16- M15-
48 MANA 48 MANA

1) Connection to L+ of the left-hand front

connector

Figure 5-4 Wiring Diagram of the FM 455 S, Right-Hand Front Connector

Controller Module FM 455

A5E00059359-02 5-9
Wiring the FM 455

Table 5-2 Pinout of the Front Connector of the FM 455 S

Left-Hand Front Connector Right-Hand Front Connector

Con- Controller Name Function Con- Analog Name Function
nection Channel nection Input
1 - - - 1 - - -
2 - - - 2 - - -
3 - L+ Power supply 24 V 3 - - -
4 - I1 Digital input 4 - I9 Digital input
5 - I2 Digital input 5 - I10 Digital input
6 - I3 Digital input 6 - I11 Digital input
7 - I4 Digital input 7 - I12 Digital input
8 - I5 Digital input 8 - I13 Digital input
9 - I6 Digital input 9 - I14 Digital input
10 - I7 Digital input 10 - I15 Digital input
11 - I8 Digital input 11 - I16 Digital input
12 - L+ Power supply 24 V 12 M+ Measuring line (pos.)
1
13 Digital output Open 13 M- Measuring line (neg.)
1
14 Digital output Close 14 M+ Measuring line (pos.)
2
15 Digital output Open 15 M- Measuring line (neg.)
2
16 Digital output Close 16 M+ Measuring line (pos.)
3
17 Digital output Open 17 M- Measuring line (neg.)
3
18 Digital output Close 18 M+ Measuring line (pos.)
4
19 Digital output Open 19 M- Measuring line (neg.)
4
20 Digital output Close 20 M+ Measuring line (pos.)
5
21 Digital output Open 21 M- Measuring line (neg.)
5
22 Digital output Close 22 M+ Measuring line (pos.)
6
23 6 Digital output Open 23 M- Measuring line (neg.)
24 - L+ Power supply 24 V 24 M+ Measuring line (pos.)
7
25 6 Digital output Close 25 M- Measuring line (neg.)
26 Digital output Open 26 M+ Measuring line (pos.)
7 8
27 Digital output Close 27 M- Measuring line (neg.)
28 Digital output Open 28 IC+ Constant-current line
-
(pos.)
8
29 Digital output Close 29 IC- Constant-current line
-
(neg.)
30 Digital output Open 30 COMP+ Reference junction input
-
(pos.)
9
31 Digital output Close 31 COMP- Reference junction input
-
(neg.)
32 Digital output Open 32 M+ Measuring line (pos.)
10 9
33 Digital output Close 33 M- Measuring line (neg.)
34 Digital output Open 34 M+ Measuring line (pos.)
11 10
35 Digital output Close 35 M- Measuring line (neg.)

Controller Module FM 455

5-10 A5E00059359-02
 Wiring the FM 455

Table 5-2 Pinout of the Front Connector of the FM 455 S

Con- Controller Name Function Con- Analog Name Function

nection Channel nection Input
36 - L+ Power supply 24 V 36 M+ Measuring line (pos.)
11
37 Digital output Open 37 M- Measuring line (neg.)
12
38 Digital output Close 38 M+ Measuring line (pos.)
12
39 Digital output Open 39 M- Measuring line (neg.)
13
40 Digital output Close 40 M+ Measuring line (pos.)
13
41 Digital output Open 41 M- Measuring line (neg.)
14
42 Digital output Close 42 M+ Measuring line (pos.)
14
43 Digital output Open 43 M- Measuring line (neg.)
15
44 Digital output Close 44 M+ Measuring line (pos.)
15
45 Digital output Open 45 M- Measuring line (neg.)
16
46 Digital output Close 46 M+ Measuring line (pos.)
16
47 - L+ Power supply 24 V 47 M- Measuring line (neg.)
48 M Grounding of the supply 48 MANA Reference point of the
- -
voltage analog loop

Note
The connection MANA must be connected with low impedance to the reference
point at the rack (CPU grounding (refer to Figure 5-8)

Controller Module FM 455

A5E00059359-02 5-11
Wiring the FM 455

5.2 Wiring Front Connectors, Overview

Overview
The 24 VDC power supply for the FM 455 and the connections between the
FM 455 and the sensors and actuators of your system are implemented in two
steps:
1. Wire the front connectors. The lines to the power supply and to the
sensors/actuators are connected to the front connectors.
2. Plug the front connector into the module.
Supply Voltage L+/M
Connect a direct voltage of 24 V to the connections L+ and M in order to supply
voltage to the module and the digital outputs (refer to Figure 5-8).

Caution
! Only an extra-low voltage ≤ 60 V DC which is isolated safely from the network may
be used for the 24 V DC power supply. Safe isolation can be implemented in
accordance with one of the following requirements:
• VDE 0100 Part 410/HD 384-4-41 / IEC 364-4-41 (as a functional extra-low
voltage with safe isolation)
• VDE 0805 / EN 60950 / IEC 950 (as a safety extra-low voltage SELV)
• VDE 0106 Part 101

An integrated diode protects the module against incorrect connection of the power
supply.

Input Filter for Digital Inputs

In order to suppress interferences the digital inputs I1 to I16 have an input filter
(RC elements) with a uniform filtering time of 1.5 ms.

Digital Outputs
In order to trigger control processes directly the FM 455 S disposes of 32 digital
outputs
The digital outputs are supplied via the power supply L+.
The digital outputs are current-sourcing switches and can carry a load current of
0.1 A. They are protected against overloading and short circuiting.

Controller Module FM 455

5-12 A5E00059359-02
 Wiring the FM 455

Connecting Inductors
Please observe the following points when connecting inductors to digital inputs of
the FM 455 S:

Note
The direct connection of inductors (for example, of relays and contactors) is
possible without external circuiting. If SIMATIC output circuits can be switched off
by means of additionally installed contacts (for example, relay contacts) you must
provide additional overvoltage protectors at inductors (refer to the following
example for overvoltage protection).

Example of Overvoltage Protection

Figure 5-5 shows an output circuit which requires additional overvoltage protectors.

SIMATIC-S7
control

Contact in the output circuit

Inductor requires
circuiting (refer to Fig. 5-6)

Figure 5-5 Relay Contact in the Output Circuit

Controller Module FM 455

A5E00059359-02 5-13
Wiring the FM 455

Circuiting of D.C.-Controlled Coils

D.C.-controlled coils are circuited with diodes or Zener diodes.

With diode With Zener diode

+ +

- -

Figure 5-6 Circuiting of d.c.-Controlled Coils

Circuiting with Diodes/Zener Diodes

The circuiting with diodes/Zener diodes has the following properties:
• Switching overvoltages can be avoided completely.
Zener diodes have a higher circuit interruption voltage.
• High interruption delay (6- to 9-fold higher than without suppression circuit).
Zener diodes interrupt faster than diode circuits.

Controller Module FM 455

5-14 A5E00059359-02
 Wiring the FM 455

Cables
Some rules have to be observed when selecting the cables:
• The cables for the digital inputs I1 to I16 have to be shielded if they are longer
than 600 m.
• The cables for the analog signals have to be shielded.
• You have to apply the shields of the cables of the analog signals both at the
sensor and directly near the module.
• Lay digital and analog signals in seperate cables in order to avoid crosstalk.
Fig. 5-7 shows details for connecting the analog signals.

Shielding on Shielding on
shield bus housing
Front connector
Pin

12
13
14
15
16
17
18
19

MANA
48
Twisted cables

Figure 5-7 Connection of Analog Signals

Potential Bonding
The reference point of the analog circle MANA (connector 48 of the right-hand front
connector) must be connected with low impedance to the reference point on the
rack (CPU grounding) (refer to Figure 5-8).
• Use flexible cables with cross-sections of
0.25 to 1.5 mm2.
• A core end sleeve is not required for the connection to the front connector. If
you do use core end sleeves, only use models with or without an insulating
collar conforming to DIN 46228 Form A, normal version!
• Use a cable lug for M4, a suitable spring lock washer (for example, conical
spring washer DIN 6796) and a pan head screw M4 x 6 for connection to the
reference point.

Controller Module FM 455

A5E00059359-02 5-15
Wiring the FM 455

Note
Unused analog inputs are to be short-circuited and connected to MANA.

Figure 5-8 shows how to implement the power supply to an FM 455 C or an

FM 455 S and how to wire the bonding to frame and the wire shieldings.

FM455C FM455S

Pin 3 Pin 3

Pin 12
Reference point
24 V DC (CPU grounding)
Pin 24
+ -

Pin 36

Pin 48 Pin 48
Pin 48 (MANA Pin 47 (MANA
) Pin 48 )

Grounding

Shield bus

Figure 5-8 Power Supply of the FM 455 and Potential Bonding

The 3 Types of Front Connectors

There are three different types of front connectors for the FM 455:
• Front connectors with crimp snap-on connector
• Front connectors with screw-type terminal
• Front connectors with spring-type connectors

Controller Module FM 455

5-16 A5E00059359-02
 Wiring the FM 455

Preparing the Wiring of the Front Connector

1. Insert a screwdriver at the marked point at the bottom left of the front connector
and lever the lower edge of the front-connector lid off.
2. Swivel the lid off completely.
3. Pull the opened lid at the lower end forward and swing it away upwards.
4. Cut the wires to length so that there is no loop in the front connector after wiring
has been completed.
Figure 5-9 shows how to open the lid and pull it away forwards.

Lever the lid off Swivel the lid away Pull the lid away

Figure 5-9 Opening the Lid and Pulling it away Forwards

Note
The front connector contains a jumper which is functionally necessary for some
signal modules. Do not remove this jumper.

Controller Module FM 455

A5E00059359-02 5-17
Wiring the FM 455

5.2.1 Wiring Front Connectors, Crimp Snap-On Connection

Procedure
Proceed as follows in order to wire the prepared front connectors:
1. Strip the wires to approx. 5 mm.
2. Crimp the crimp contacts to the cables. You can use a crimping tool, which you
can order as an accessory for your signal module, to do so.
3. Insert the crimp contacts into the cut-outs in the front connector. Begin at the
bottom of the front connector.
Please refer to the appendix for the order number of the crimp contacts.
Figure 5-10 shows how to wire a front connector with crimp snap-on connector.

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Figure 5-10 Wiring a Front Connector with Crimp Snap-On Connector

Controller Module FM 455

5-18 A5E00059359-02
 Wiring the FM 455

5.2.2 Wiring Front Connectors, Screw-Type Terminals

Procedure
Proceed as follows in order to wire the prepared front connectors:
1. Are you using core end sleeves?
If so: Strip the wires to 10 mm.
Crimp the core end sleeves to the cables.
If no: Strip the wires to 8 to 10 mm.
2. Insert the cores. Begin at the bottom of the front connector.
3. Screw the ends of the wires to the front connector, tightening torque: 0.6 to 0.8
Nm. Also screw any clamps which are not wired tight.
Figure 5-11 shows how to wire a front connector with screw-type terminal.

0.6 to 0.8 Nm.

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ÂÂÂ
ÂÂÂ

Figure 5-11 Wiring a Front Connector with Screw-Type Terminal

Controller Module FM 455

A5E00059359-02 5-19
Wiring the FM 455

5.2.3 Wiring Front Connectors, Spring-Type Connectors

Procedure
Proceed as follows in order to wire the prepared front connectors:
1. Are you using core end sleeves?
If so: Strip the wires to 10 mm.
Crimp the core end sleeves to the cables.
If no: Strip the wires to 8 to 10 mm.
2. Use a screwdriver (0.5 x 3.5 mm DIN 5264) to release the spring-type terminal
of the first connection. Begin at the bottom of the front connector.
You can release the individual spring-type terminals at three points, from the
front, from the side or from the rear (refer to Figure 5-12).
3. Slide the first core into the released spring-type terminal and retract the
screwdriver.
4. Repeat Steps 3 and 4 for all the other cores.
Figure 5-12 shows how to wire a front connector with spring-type terminal.

Releasing the spring-

ÂÂÂ type terminal from the

ÂÂÂ
rear.

ÂÂÂ
Releasing the spring-
type terminal from the
front.

Releasing the spring-

type terminal from the
side.

Figure 5-12 Wiring a Front Connector with Spring-Type Connection

Controller Module FM 455

5-20 A5E00059359-02
 Wiring the FM 455

Principle of the Spring-Type Terminal

Figure 5-13 shows the principle of a spring-type terminal. The actions of releasing
and locking from the front are shown.

1. Insert the screwdriver

2. Push the wire into the spring-type

terminal until it locks.

3. Remove the screwdriver The wire

is clamped to the contact

Figure 5-13 Principle of the Spring-Type Terminal

Controller Module FM 455

A5E00059359-02 5-21
Wiring the FM 455

5.3 Applying Strain Relief

Using Cable Binders for Strain Relief

After you have wired the front connector, attach the enclosed cable binders to the
bottom of the front connector as strain relief for the connected wires.
You can apply the strain relief in three variations, depending on how thick the wire
is. There are three openings at the underside of the front connector.
Figure 5-14 shows how you can attach a strain relief.

Figure 5-14 Attaching a Strain Relief (View from Below)

Controller Module FM 455

5-22 A5E00059359-02
 Wiring the FM 455

5.4 Labeling Front Connectors

Address Labels and Wiring Diagrams

Each FM 455 has three labels, namely 2 address labels and a printed label with
the wiring diagram of the inputs and outputs.
Figure 5-15 shows where the individual labels can be attached to the front
connector.

Address label Wiring diagram

in the front connector inside

Address label
outside

Figure 5-15 Attaching Labels to the Front Connector

Proceed as follows in order to label the front connector:

1. Enter the addresses of the individual channels on the two address labels. Note
the slot numbers on the address labels in order to record the assignment of the
front connector to the module.
2. Attach one address label on the left in the opened front connector. The address
label has a T-shaped recess by means of which the label can be fastened to the
front connector housing. Expand the recess slightly sideways and slide it behind
the corresponding cut-out at the front connector while sliding in the label (refer
to Figure 5-16).
3. Reattach the cover to the front connector.
4. Slide the label with the wiring diagram of the inputs or outputs into the inside of
the front connector cover.
5. Slide an address label into the outside of the front connector cover.

Controller Module FM 455

A5E00059359-02 5-23
Wiring the FM 455

Figure 5-16 shows in detail how to attach an address label on the inside of the
front connector.

Address label with

recess

Cut-out in the front

connector

Figure 5-16 Attaching an Address Label to the Front Connector

Controller Module FM 455

5-24 A5E00059359-02
 Wiring the FM 455

5.5 Mounting the Front Connector

Overview
The FM 455 is equipped with a coding element for front connectors in order to
reduce the risk of a wired front connector being plugged into an incorrect module
type after rewiring or after replacing a module.

How the Coding Element Functions

A coding element consists of two parts. One part has a fixed connection to the
module, the second part is still connected to the first part on delivery (refer to
Figure 5-17).
When you engage a front connector, the second part of the coding element snaps
into the connector. It detaches itself from the part which is connected to the signal
module. Both parts of the coding element form counterparts. It is therefore not
possible to engage a front connector with an incorrect counterpart onto this signal
module.

Engaging a Front Connector

The front connectors can only be engaged, if the module is inserted (the upper and
lower mounting screws must have been tightened).

Caution
! Modules can be damaged.
If, for example, you engage a front connector of a digital input module to a digital
output module, the module can be damaged. If, for example, you engage a front
connector of an analog input module to an analog output module, the module can
be damaged.
Ensure that the module and the front connector are compatible when you engage
the front connector.

Proceed as follows in order to engage the front connector:

1. Hold the front connector horizontally and engage the front connector into the
coding element. After an audible click the front connector engages into the
bearing point and can be swiveled upwards.
2. Swivel the front connector upwards. The two parts of the coding element are
separated from each other.
3. Screw the front connector on.

Controller Module FM 455

A5E00059359-02 5-25
Wiring the FM 455

Figure 5-17 shows how to mount the front connector.

Coding element

Figure 5-17 Mounting the Front Connector

FM 455 Front Connector Coding

Table 5-3 shows the assignment of the front connector coding elements to the front
connectors of the FM 455.

Controller Module FM 455

5-26 A5E00059359-02
 Wiring the FM 455

Table 5-3 Front Connector Coding

Module Front Connector Color of the Front Connector Coding

Element
Yellow Green
Left 
FM 455 C
Right 
Left 
FM 455 S
Right 

Screwing the Front Connector On

Figure 5-18 Screwing the Front Connector on

Controller Module FM 455

A5E00059359-02 5-27
Wiring the FM 455

Controller Module FM 455

5-28 A5E00059359-02
Assigning Parameters to the FM 455 6
What Does this Chapter Describe?
In this chapter you will learn how to install and start the parameter assignment user
interface.

Prerequisites
STEP 7 must have been installed correctly on your programming device or PC

Form of Supply
The software is supplied on a CD-ROM.

Installation
Proceed as follows to install the software:
1. Insert the CD into the CD drive of your programming device/PC.
2. Start the dialog box for installing software under Windows 95/NT by
double-clicking on the “Add/Remove Programs” icon in the Control Panel.
3. Select the CD drive and the SETUP.EXE file in the dialog box and start the
installation procedure.
4. Follow the step-by-step instructions which the installation program gives you.
The installation procedure installs the following items on your programming
device/PC:
• Parameter assignment interface
• Function blocks
• Program examples
• Online help

Program examples
The program examples are contained in the STEP 7 directory folder in the
”Examples” subdirectory im the project FM_PIDEx.

Controller Module FM 455

A5E00059359-02 6-1
Assigning Parameters to the FM 455

Reading Out the Readme File

Important up-to-date information on the software supplied may be contained in a
README file. You will find this file in the start window of the SIMATIC Manager.

Hardware Configuration
Configuring requires that you have already created a project in which you can save
the parameter assignments. You will find more information on configuring modules
in your Standard Software for S7 and M7, STEP 7 User Manual. The most
important steps are outlined below.
1. Start the SIMATIC Manager and open the configuration table in your project.
2. Select a rack and arrange it.
3. Open the rack.
4. Select the FM 455 in your module catalog.
5. Drag the FM 455 to the corresponding row in your configuration table.
6. Note the input address of the FM 455 from the configuration table,
for example, 512.
The value you read out will be in decimal format.

Parameter Assignment
You can now start assigning parameters.
Assigning parameters means setting the module parameters.
1. Double-click on the order number for the FM 455 in the configuration table or
select the FM 455 and use the menu command Edit > Object Properties.
Result: The “Properties” dialog box is opened.
2. Click on the “Basic Parameters” tab card.
Result: The “Basic Parameters” dialog box is opened.
3. Assign the basic parameters for the FM 455.
4. Click on the “Parameters...” command button.
Result: The parameter assignment interface is opened.
5. Assign parameters to the FM 455, and save the parameters with File > Save
command.
6. Close the parameter assignment interface.
7. Save your project in HWConfig by using Station > Save and Compile.

Controller Module FM 455

6-2 A5E00059359-02
 Assigning Parameters to the FM 455

8. Download the parameter data to the CPU in STOP mode by using the menu
command PLC > Download to Module.
Result: The data are then in the CPU memory and are transferred from there
directly to the FM 455.
9. Carry out a CPU startup.

Observe the Following Points during Parameter Assignment

The FM 455 checks parameters for limits only in as far as it is necessary to ensure
the module functionality. This applies, for example, to parameters which are used
for forming addresses and to time-dependent variables (for example, integration
time constant > half sampling time). When the FM 455 recognizes a parameter
assignment error, an entry is made in the DS0 and DS1 of the FM 455 (refer to
Chapter 12) and the red error LED EXT is activated. You can read out parameter
assignment errors on the FM 455 by using the menu PLC > Parameter
Assignment Error of the parameter assignment interface.
Further checks for any limits set or for plausibility (for example, upper limit > lower
limit) are not made.
In the parameter assignment software you can freely select both the assignment
between inputs and controller channels and between controller channels and
outputs. You should note the following:

Note
The parameter assignment software does not display an error message if you
assign an input or output more than once when assigning controller channels to
the inputs and outputs.

Integrated Help
There is an integrated help function for the parameter assignment software which
helps you in assigning parameters to the FM 455. You can call up the integrated
help in one of the following ways:
• By using the menu command Help > Contents...
• By pressing F1
• By clicking on the “Help” button in the parameter assignment dialog boxes
The integrated help describes the parameter assignment of the module in more
detail than the module.

Controller Module FM 455

A5E00059359-02 6-3
Assigning Parameters to the FM 455

Controller Module FM 455

6-4 A5E00059359-02
Integrating the FM 455 Into The User
Program 7
What Does this Chapter Describe?
This chapter contains all the information required to program the FM 455 in the
S7-400. Six STEP 7 blocks, which allows simple handling of the desired functions,
are provided for integrating the FM 455 into a user program.
This chapter describes the following blocks:
• FB PID_FM for operator control and monitoring via the CPU as well as for
changing the controller parameters online
• FB FUZ_455 for reading and writing the parameters of all the temperature
controllers of the FM 455. The block allows rapid adjustment of the controllers
to changes in the process and parameter assignment of the temperature
controllers after a module replacement without renewed identification.
• FB FORCE455 for simulating (forcing) the analog and digital inputs
(to support the setup).
• FB READ_455 for reading out the digital and analog input values
(to support the setup).
• An FB CH_DIAG for displaying further channel-specific parameters
(to support the setup)
• The FB PID_PAR for changing further parameters online.
• The FB CJ_T_PAR for changing the configured reference junction temperature
online.

Section Description Page

7.1 The Function Block PID_FM 7-2
7.2 The Function Block FUZ_455 7-15
7.3 The Function Block FORCE455 7-17
7.4 The Function Block READ_455 7-19
7.5 The Function Block CH_DIAG 7-21
7.6 The Function Block PID_PAR 7-24
7.7 The Function Block CJ_T_PAR 7-30

Controller Module FM 455

A5E00059359-02 7-1
Integrating the FM 455 Into The User Program

7.1 The Function Block PID_FM

The FM 455 is interconnected to the user program by means of the FB PID_FM.

This FB allows you to change operating parameters during operation. You can, for
example, specify a setpoint value and the manipulated value or switch to an
external manipulated-value specification.
The data required for the FM PID_FM are saved in an instance DB on the CPU.
The FB PID_FM reads data from the FM 455 program-controlled and writes data
to the FM 455 program-controlled.
The individual parameters are describe in the online help and in Chapter 11.

Creating and Supplying the Instance DB

Before you can use the user program to program the module you must first create
an instance DB for each controller channel and supply important data to it.
1. Create the instance DBs for the controller channels as data blocks with the
associated function block PID_FM under STEP 7.
2. Enter the module address in the parameter MOD_ADDR for each instance DB.
The module address of the FM 455 is specified while configuring the hardware.
Use the start address from HW Config.
3. Enter the channel number of the corresponding controller channel (1, 2, 3 to 16)
in the CHANNEL parameter for each instance DB.
4. Save the instance DBs.

Call
The FB PID_FM must be called in the same OB as all other FBs which access the
same FM 455.
The FB PID_FM is normally called in the watchdog interrupt OB 35. It requires an
initializing run which started by setting the parameter COM_RST = TRUE in the
startup of the CPU. It is possible to call the FB in the startup OB, but it is not
necessary. After the initialization run the FB PID_FM set the parameter COM_RST
to FALSE.

Controller Module FM 455

7-2 A5E00059359-02
 Integrating the FM 455 Into The User Program

7.1.1 Operator Control Via the FB PID_FM

The operating parameters (for example, setpoint value, manual manipulated value)
of the FM 455 are transferred cyclically from the FB PID_FM to the FM 455.
Operating parameters are all the in/out parameters, which lie in the instance DB of
the function block between the parameters op_par and cont_par.
In order for the data transmission to be possible without a high run time in the
CPU, transmission is normally (when LOAD_OP = FALSE) carried out direct I/O
accesses. The data are multiplexed since only four bytes per channel are available
in the I/O address area of the module. It can therefore take up to three cycles of
the CPU or of the FM 455 until the operating values have been transferred to the
FM 455 and become effective there - the respectively longer cycle is decisive.
If you want the operating values to be transferred immediately (within one cycle of
the CPU or of the FM 455) to the FM 455, you can then set the parameter
LOAD_OP to TRUE. The transmission is then carried out via the SFC WR_REC,
the FB then requires more run time (refer to the Technical Specifications Function
Blocks in Section A.2). After the data transmission has been carried out
successfully the LOAD_OP parameter is reset to FALSE by the FM PID_FM.

7.1.2 Monitoring Via the FB PID_FM

The FB PID_FM reads process values (for example, actual value, manipulated
value) cyclically from the FM 455. Process values are all the output parameters of
the function block of the parameter out_par.
The FB PID_FM also reads the process values via direct I/O accesses, if
READ_VAR = FALSE. This transmission does not require much run time, however
the following functional restrictions result.
If the parameter READ_VAR = TRUE is set, then the process values are read from
the FM 455 by means of the SFC RD_REC. However, this requires more run time
(refer to technical specifications). After the data transmission has been carried out
successfully, the READ_VAR parameter is reset to FALSE by the FM PID_FM.

Function At READ_VAR = TRUE

If one of the following parameters ”Operating setpoint value SP_OP”, “Operating
manipulated variable LMN_OP” and the corresponding switches “SP_OP_ON” and
“LMNOP_ON” was changed by operation via the OP, the FB PID_FM takes over
these values from the FM 455 after the CPU has been started up.

Controller Module FM 455

A5E00059359-02 7-3
Integrating the FM 455 Into The User Program

Functional restrictions for READ_VAR = FALSE

• The parameters SP (setpoint value from the FM), ER (error signal), DISV
(disturnance variable), LMN_A and LMN_B are not read from the FM (refer to
Chapter 11, Assignment of the DBs).
• The data are multiplexed. Actual value, manipulated value and the binary
displays are updated at every fourth call of the block.
• If the setpoint value and the manual manipulated variable were operated via
MPI, these operating values are not read out of the FM by the FB during the
CPU startup.

Note
Multiplexing of the data to be transferred is controlled by the FB PID_FM in the
case of access to the FM 455 via direct I/O accesses. This multiplex controlling
does not function if two instances of the FB PID_FM access the same channel
number of a module. This results in incorrect parameters in the FM 455 (for
example, setpoint value and manual manipulated variable) and incorrect display of
the FB PID_FM to its output parameters.

Error Displays
The output parameter RET_VALU contains the return value RET_VAL of the
SFCs 58 and 59. RET_VAL can be evaluated if the parameters READ_PAR and
LOAD_PAR are not reset. The values of RET_VALU are described in the
Reference Manual /2/.
When the FB PID_FM is called, an I/O access error (I/O AAE) can arise, if the
FM 455 is not plugged or if there is no power supply. In this case the CPU changes
over to STOP, if no OB 122 is loaded in the CPU.

Controller Module FM 455

7-4 A5E00059359-02
 Integrating the FM 455 Into The User Program

7.1.3 Changing Controller Parameters Via The FB PID_FM

Controller parameters (for example, controller gain, integration action factor) are all
the I/O parameters which lie in the instance DB of the function block after the
parameter cont_par. Controller parameters are initially configured via the
parameter assignment interface and are transferred via the system data to the
FM 455 (also refer to Section 3.6, “Working Mechanisms and Data Retention in the
FM 455”).
Changing the controller parameters via the FB PID_FM makes sense if you want
to change them during operation depending on the process states. To do so,
proceed as follows:
1. Set the parameter COM_RST of the FB PID_FM to TRUE in the CPU startup.
The FB then reads all the controller parameters from the FM 455 and stores
them in its instance DB. The instance DB of the FB PID_FM has now been
compared to the parameters of the parameter assignment interface (system
data). After the parameters have been read succesfully, the FB PID_FM sets
the parameter COM_RST to FALSE.
2. If COM_RST = FALSE, you can then change individual controller parameters in
the instance DB of the FB PID_FM in the user program.
To do so call the FB PID_FM with LOAD_PAR = TRUE. The FB PID_FM then
transfers all the controller parameters from the instance DB to the FM. After the
parameters have been transmitted successfully the FB PID_FM resets the
parameter LOAD_PAR.

Note
Please note that the parameters in the FM 455 are overwritten by the values from
the system data whenever the CPU is started up (transition from STOP to RUN).

Controller Module FM 455

A5E00059359-02 7-5
Integrating the FM 455 Into The User Program

7.1.4 Changing the Controller Parameters via The OP

Proceed as follows in order to change controller parameters of the FB PID_FM by
operation at the OP:
1. Write the parameters to be modified from the OP into an auxiliary DB (1).
2. Do not transfer the parameters which are to be changed from the auxiliary DB
to the instance DB of the FB PID_FM (3) until after the initializing run started by
COM_RST = TRUE (2).
3. Transfer the parameters to FM 455 by setting LOAD_PAR (4).
Storage of the parameters in an auxiliary DB is necessary because the FB
PID_FM reads those parameters from the FM 455 which the CPU transferred
beforehand from the system data to the FM after the CPU has been started up
with COM_RST = TRUE .

CPU OP
(1)

Auxiliary
DB

(3)
After initialization with
COM_RST = TRUE
FM 455

Instance DB FB (4)
of the PID_FM LOAD_PAR = TRUE
FB PID_FM
COM_RST = TRUE
(2)

System Downloading of the

data system data,
Startup,
STOP → RUN of CPU

Figure 7-1 Changing Controller Parameters via OP

If COM_RST = TRUE is set, the parameter CHANNEL is then also checked. In an

invalid channel number was assigned at the CHANNEL parameter, the output
QMOD_F and QCH_F is set, COM_RST remains set and no further action of the
FB is carried out.
If the check did not find any errors and the parameters were read succesfully from
the FM 455, the parameter COM_RST is reset by the FB PID_FM.

Controller Module FM 455

7-6 A5E00059359-02
 Integrating the FM 455 Into The User Program

Note
If the FB is called during the first call with COM_RST = FALSE and an invalid
channel number is assigned at the parameters MOD_ADDR or CHANNEL, the FB
accesses an incorrect I/O address without any further check.

7.1.5 Saving the Parameters in the EEPROM

During program-controlled reconfiguration (LOAD_PAR, LOAD_OP) of the FM 455

by the FB PID_FM its run time increases. The new parameters become effective
immediately and are saved additionally in an EEPROM.
Renewed saving is delayed by 30 minutes whenever the parameters have been
saved in the EEPROM. This ensures a high service life of the EEPROM.
After a power supply has returned saving of new parameters in the EEPROM is
possible immediately. Whether reconfiguration of the FM 455 by the FB PID_FM is
carried out smoothly depends on the parameter selection.

Controller Module FM 455

A5E00059359-02 7-7
Integrating the FM 455 Into The User Program

7.1.6 Relationship Between FB Parameters and Parameter

Configuration Interface

The following figures show the relationship between the FB PID_FM and the
parameter configuration interface of the controller module.
In the case of three-component controllers and ratio/blending controllers the
parameters act at the same point as for fixed setpoint or cascade controllers. This
also applies to the parameters which exist in continuous controllers, in controllers
with pulse outputs as well as in step controllers. This generally means that the
same command buttons also contain the same parameters. In order to ensure a
good overview we therefore do not show all the structure images and all the
parameters are not shown in all the figures.
The parameters of the FB PID_FM are, however, contained in all the figures - with
the exception of the parameters MOD_ADDR, CHANNEL, QMOD_F, QPARA_F,
QCH_F, QLMNR_ON, RET_VALU, COM_RST, LOAD_PAR, READ_VAR,
LOAD_OP.
Figures 7-2 to 7-7 show at which points in the module the parameters of the FB
PID_FM act.

SP_HLM
SP_OP
SP_LLM

SP_RE
Effective setpoint
Switch Ramp Limit
safety
Setpoint setpoint Error signal

SP_OP_ON H_ALM
MONERSEL H_WRN
L_WRN
Alarm L_ALM
HYS

Process variable A Effective process

variable

D input
D_EL_SEL

Disturbance variable

Figure 7-2 Error Signal Formation in a Fixed Setpoint or Cascade Controller

Controller Module FM 455

7-8 A5E00059359-02
 Integrating the FM 455 Into The User Program

FUZID_ON
Effective setpoint

Effective process Temperature

variable controller Effective manipulated
value

GAIN TM_LAG
TI P_SEL
DEADB_W TD PFDB_SEL

Error signal
Dead band

D input
Manipulated value
correction

Disturbance variable

Figure 7-3 Block Diagram of the Control Algorithm

LMN_RE LMN_REON
External LMNOP_ON
manipulated
value SAFE_ON LMN_HLM
LMN_OP LMN_SAFE LMN_LLM
Manipulated
Manipulated
value A
value
Effective
manipulated LMNTRKON
value Switch
external Switch Limit Split range
manipulated safety
value manipulated
Switch value
correction Manipulated
value B

Follow-up input

Manipulated value correction

Figure 7-4 Continuous Controller Output

Controller Module FM 455

A5E00059359-02 7-9
Integrating the FM 455 Into The User Program

LMN_RE LMN_REON
External LMNOP_ON
manipulated
value SAFE_ON LMN_HLM PULSE_TM
LMN_OP BREAK_TM
LMN_SAFE LMN_LLM
Manipulated
Effective Switch value
manipulated external LMNTRKON
value manipulated
value Switch Limit Split-range/
safety pulse shaper
manipulated
Switch value
correction

Follow-up input

Manipulated value correction

Figure 7-5 Step Controller Output (Pulse Controller Mode)

LMN_RE LMN_REON
External LMNOP_ON
manipulated
value LMN_OP SAFE_ON LMN_HLM
LMN_SAFE LMN_LLM MTR_TM
PULSE_TM
Manipulated
BREAK_TM
Effective Switch value
manipulated external LMNTRKON
value manipulated
value Limit
Switch
Pulse
safety manipulated
shaper
Switch value
correction

Follow-up input

Manipulated value correction

Position feedback input

Figure 7-6 Step Controller Output (Step Controller with Position Feedback Mode)

Controller Module FM 455

7-10 A5E00059359-02
 Integrating the FM 455 Into The User Program

LMNDN_OP
LMNUP_OP

LMNSOPON
LMNRS_ON
MTR_TM
Actuating signal
PULSE_TM
BREAK_TM
High
External manipulated LMNRSVAL
value

Low

Effective Switch Switch Pulse

manipulated external safety shaper
value manipulated manipulated
value value LMNRHSRE
LMNRLSRE

Figure 7-7 Step Controller Output (Step Controller without Position Feedback Mode)

Figures 7-8 to 7-13 show at which points in the module the output parameters of
the FB PID_FM are created.

Controller Module FM 455

A5E00059359-02 7-11
Integrating the FM 455 Into The User Program

QUPRLM QSPHLM
SP_OP
QDNRLM QSPLLM

Effective setpoint
SP_RE SP
Switch Ramp Limit ER
safety
Setpoint setpoint Error signal
PV

QH_ALM
QSPOPON QH_WRN
QL_WRN
Alarm QL_ALM

Process variable A Effective process

variable

D input

DISV

Disturbance variable

Figure 7-8 Error Signal Formation in a Fixed Setpoint or Cascade Controller

QSPLEPV QFUZZY
Effective setpoint

Effective process
variable Temperature
controller Effective manipulated
value

PID

Error signal
Dead band

D input
Manipulated value
correction

Disturbance variable

Figure 7-9 Block Diagram of the Control Algorithm

Controller Module FM 455

7-12 A5E00059359-02
 Integrating the FM 455 Into The User Program

External QLMNOPON
QLMNRE QLMN_HLM
manipulated
value QLMN_LLM
LMN_OP LMN QSPR
QLMNSAFE
Manipulated
value LMN_A
Effective Switch
manipulated external QLMNTRK
value Manipulated
manipulated
value Switch Limit Split-range value A
safety
manipulated LMN_B
Switch value
correction Manipulated
value B

Follow-up input

Manipulated value correction

Figure 7-10 Continuous Controller Output

External
manipulated
value

Effective Switch
manipulated external Manipulated
value manipulated value
value QLMNUP
QLMNDN

Switch Switch Limit Split-range/

correction safety pulse shaper
manipulated
value
Follow-up input

Manipulated value correction

Figure 7-11 Step Controller Output (Pulse Controller Mode)

Controller Module FM 455

A5E00059359-02 7-13
Integrating the FM 455 Into The User Program

External
manipulated
value

Effective Switch
manipulated external
Manipulated QLMNRHS
value manipulated
value QLMNRLS
value

Switch Switch Limit

correction safety Pulse
manipulated shaper
value
Follow-up input QLMNDN

QLMNUP

Manipulated value correction

LMN_A

Position feedback input

Figure 7-12 Step Controller Output (Step Controller with Position Feedback Mode)

QLMNRHS
QLMNRLS
External manipulated
value QLMNUP
QLMNDN

Effective Switch external Switch Pulse

manipulated manipulated safety shaper
value value manipulated
value

Figure 7-13 Step Controller Output (Step Controller without Position Feedback Mode)

Instance Data Block Allocation

The allocation of the instance DB of the FB PID_FM is shown in Section 11.1.

Controller Module FM 455

7-14 A5E00059359-02
 Integrating the FM 455 Into The User Program

7.2 The Function Block FUZ_455

The FB FUZ_455 is used for the temperature controller of the FM 455 (fuzzy
controller). With this FB you can read and write the parameters of all the
temperature controllers of the FM 455. This function is suitable for the following
applications:
• Transfer of the controller parameters determined by identification to the FM 455
after a module replacement
• Adapting the FM 455 to various processes

Note
You may not change the parameters determined through identification by the
FM 455 since they have been optimized for the process.

The FB FUZ_455 does not require an initializing run.

Creating and Supplying the Instance DB

Before you can use the user program to program the module you must first create
an instance DB and supply important data to it.
1. Create the instance DB as a data block with the associated function block FB
FUZ_455 under STEP 7.
2. Enter the module address in the parameter MOD_ADDR at the instance DB.
The module address of the FM 455 is specified while configuring the hardware.
Use the start address from HW Config.
3. Save the instance DB.

Call
The FB FUZ_455 must be called in the same OB as all other FBs which access
the same FM 455.

Controller Module FM 455

A5E00059359-02 7-15
Integrating the FM 455 Into The User Program

The FB FUZ_455 is Used as Follows:

After you have carried out an identification of the temperature controllers and the
controllers control satisfactorily, call the FB FUZ_455 and set the parameter
READ_PAR to TRUE.
The FB then reads the parameters of all four temperature controllers of the
FM 455 and stores them in the instance DB. After the temperature controller
parameters have been read out successfully, the FB FUZ_455 sets the parameter
READ_PAR to FALSE.
In the CPU startup you should set the parameter LOAD_PAR of the FB FUZ_455
and then call the block conditionally in the cyclic program as long as
LOAD_PAR = TRUE. When the parameter LOAD_PAR = TRUE is set, the FB
writes the parameters of all four temperature controllers of the FM 455 from the
instance DB to the FM 455. After the data transmission has been carried out
successfully the LOAD_PAR parameter is set to FALSE by the FM PID_FM.
When the temperature controller parameters are being read, a parameter
assignment error display of the temperature controller parameters in the
PARAFFUZ parameter is displayed as follows:
High byte of PARAFFUZ not equal to zero means that a parameter error is
present. The low byte contains the byte offset of the incorrect parameter, related to
the beginning of the static variable. Thus, for example, PARAFFUZ = W#16#0104
means that the second parameter is incorrect.
The error display can only be shown if you manipulate the temperature controller
parameters in the instance DB and write them to the FM 455. You can also read
out these parameter assignment errors by using the menu PLC > Parameter
Assignment Error of the parameter assignment interface.
The output parameter RET_VALU contains the return value RET_VAL of the
SFCs 58 and 59. RET_VALU can be evaluated if the parameters READ_PAR and
LOAD_PAR are not reset. The values of RET_VALU are described in the
Reference Manual /2/.

Instance Data Block Allocation

The allocation of the instance DB of the FB FUZ_455 is shown in Section 11.2.

Controller Module FM 455

7-16 A5E00059359-02
 Integrating the FM 455 Into The User Program

7.3 The Function Block FORCE455

The FB FORCE455 is used to simulate (force) the analog and digital input values
to support the setup.
The FB FORCE455 does not require an initializing run. It is normally called
cyclically.

Creating and Supplying the Instance DB

Before you can use the user program to program the module you must first create
an instance DB and supply important data to it.
1. Create the instance DB as a data block with the associated function block FB
FORCE455 under STEP 7.
2. Enter the module address in the parameter MOD_ADDR at the instance DB.
The module address of the FM 455 is specified while configuring the hardware.
Use the start address from HW Config.
3. Save the instance DB.

Call
The FB FORCE455 must be called in the same OB as all other FBs which access
the same FM 455.

Simulation Of The Analog Values

The simulation of the analog values for channels 1 to 4 is activated by using the
switch S_AION[ i ] or S_PVON[ i ], whereby 1 ≤ i ≤ 16. Figure 7-14 shows at which
point the simulated analog value is effective.
The simulation values for channels 1 to 16 are specified by means of the
parameter PV_SIM[ i ].
You can let the simulation values become effective at two points:
• S_AION[ i ] = TRUE (1 ≤ i ≤ 16)
The value PV_SIM[ i ] is used instead of the value of the analog input i of the
module.
• S_PVON[ i ] = TRUE (1 ≤ i ≤ 16)
The value PV_SIM[ i ] is used instead of the preprocessed value of the analog
input i of the module.

Controller Module FM 455

A5E00059359-02 7-17
Integrating the FM 455 Into The User Program

Simulation of the Digital Values

The simulation of the values for the digital inputs 1 to 16 is activated by using the
switch S_DION[ i ], whereby 1 ≤ i ≤ 16.
The simulation values are specified via the parameter DI_SIM[ i ].
• S_DION[ i ] = TRUE (1 ≤ i ≤ 16)
The value DI_SIM[ i ] is used instead of the value of the digital input i of the
module.

Note
The LEDs I1 to I16 always show the state of the corresponding digital input, also
during simulation.

Simulation value 1 ≤ i ≤ 16
PV_SIM [ i ]
Activate simulation: Activate simulation:
S_AION [ i ] S_PVON [ i ]

Sensor type

A
D
Preprocessed
Filter Root Polyline Normalizing analog value
extraction
Activate simulation:
Reference S_DION [ i ]
input
Simulation value
DI_SIM [ i ] 1
configured

Digital input Digital value

0

Figure 7-14 Action of the Simulation Values

After a restart of the FM 455 after a power off the simulation switch on the FM 455
is positioned again at FALSE.
The output parameter RET_VALU contains the return value RET_VAL of the
SFCs 58 and 59. The values of RET_VALU are described in the
Reference Manual /2/.

Note
Switching on and specification of the simulation values (force function) is not
carried out via the parameter configuration interface. The corresponding switches
and connecting lines are therefore drawn as dashed lines.

Instance Data Block Allocation

The allocation of the instance DB of the FB FORCE455 is shown in Section 11.3.

Controller Module FM 455

7-18 A5E00059359-02
 Integrating the FM 455 Into The User Program

7.4 The Function Block READ_455

The FB READ_455 is used to read out the digital and analog input values in order
to support the setup.
The FB READ_455 does not require an initializing run. It is normally called
cyclically.

Creating and Supplying the Instance DB

Before you can use the user program to program the module you must first create
an instance DB and supply important data to it.
1. Create the instance DB as a data block with the associated function block FB
READ_455 under STEP 7.
2. Enter the module address in the parameter MOD_ADDR at the instance DB.
The module address of the FM 455 is specified while configuring the hardware.
Use the start address from HW Config.
3. Save the instance DB.

Call
The FB READ_FM must be called in the same OB as all other FBs which access
the same FM 455.

Displayed Values
The following values are displayed:
• The reference junction temperature measured at the reference junction in
degrees C or in degrees F (depending on the temperature unit configured) is
shown at the parameter CJ_TEMP. If no sensor type ”Thermoelement” was
configured or if the configured reference junction temperature was selected at
all the analog inputs, 0.0 is displayed at the parameter CJ_TEMP.
• The actual state of the digital inputs 1 to 16 is displayed at the parameters
STAT_DI[1] to STAT_DI[16], also when these are simulated.
• The value of the analog inputs 1 to 16 is displayed in the unit mA or mV at the
parameters DIAG[1].PV_PER to DIAG[16].PV_PER. If the simulation of the
analog input value was activated via the FB FORCE455, the simulated value is
displayed.
• The value of the preprocessed analog inputs 1 to 16 is displayed in the physical
unit at the parameters DIAG[1].PV_PHY to DIAG[16].PV_PHY. If the simulation
of the preprocessed physical analog input value was activated via the
FB FORCE455, the simulated value is displayed.

Controller Module FM 455

A5E00059359-02 7-19
Integrating the FM 455 Into The User Program

DIAG [ i ].PV_PER 1 ≤ i ≤ 16 DIAG [ i ].PV_PHY

Sensor type

A
D Preprocessed
Filter Root Polyline Normalizing analog value
extraction

Reference CJ_TEMP
input

Cold junction
configured temperature

Figure 7-15 Displayed Input Values

The output parameter RET_VALU contains the return value RET_VAL of the
SFCs 58 and 59.
The values of RET_VALU are described in the Reference Manual /2/.

Instance Data Block Allocation

The allocation of the instance DB of the FB READ_455 is shown in Section 11.4.

Controller Module FM 455

7-20 A5E00059359-02
 Integrating the FM 455 Into The User Program

7.5 The Function Block CH_DIAG

The FB CH_DIAG reads further channel-specific parameters from the module (to
support the setup).
The FB CH_DIAG does not require an initializing run. It is normally called cyclically.

Creating and Supplying the Instance DB

Before you can use the user program to program the module you must first create
an Instance DB for each controller channel and supply important data to it.
1. Create the instance DBs for the controller channels as data blocks with the
associated function block FB CH_DIAG under STEP 7.
2. Enter the module address in the parameter MOD_ADDR for each instance DB.
The module address of the FM 455 is specified while configuring the hardware.
Use the start address from HW Config.
3. Enter the channel number of the corresponding controller channel (1, 2, 3 to 16)
in the CHANNEL parameter for each instance DB.
4. Save the instance DBs.

Call
The FB CH_DIAG must be called in the same OB as all other FBs which access
the same FM 455.

Displayed Values
The following values are displayed:
• The parameter SP_R is only relevant for ratio or blending controllers. It displays
the ratio factor specified via the setpoint input (refer to Figure 7-16).
• The parameter PV_R is only relevant for ratio controllers. It shows the effective
process variable ratio and is calculated as follows: PV_R = (PV – offset) / PV_D
(refer to Figure 7-16). Offset is the parameter which can be configured by the
”Multiply” command button.
• DIF_I is the input value of the derivative component of the PID controller, not
only at ratio or blending controllers (refer to Figure 7-16).
• TRACKPER is the tracking input value of the controller output (refer to
Figure 7-18).
• IDSTATUS is is the status display of the temperature controller if the controller
was configured (refer to Figure 7-17). The display IDSTATUS is described on
Page 3-48 of Section 3.8.
• LMN_P is the proportional component of the PID controller (refer to
Figure 7-17)
• LMN_I is the integral component of the PID controller (refer to Figure 7-17)
• LMN_D is the derivative component of the PID controller (refer to Figure 7-17)

Controller Module FM 455

A5E00059359-02 7-21
Integrating the FM 455 Into The User Program

SP_R SP
Multiply

Setpoint
Ramp Effective
Switch Limit/ setpoint
safety value normalize

Process variable D
Error signal
PV_D

Alarm
Process variable A
Effective
DIF_I process
PV variable

D input

Disturbance variable

Figure 7-16 Displayed Diagnostic Values of the Error Signal

Controller Module FM 455

7-22 A5E00059359-02
 Integrating the FM 455 Into The User Program

IDSTATUS

Effective setpoint

Effective process Temperature

variable controller Effective manipulated
value
LMN_P
LMN_I
LMN_D
PID

Error signal
Dead band

D input
Manipulated value
correction
Disturbance variable

Figure 7-17 Displayed Values of the Control Algorithm

External
manipulated
value

Switch
Effective external
manipulated manipulated Manipulated
value value value

Manipulated
Switch Switch Limit Split-range value A
correctionsafety
manipulated
value
TRACKPER Manipulated
value B
Follow-up input

Manipulated value correction

Figure 7-18 Displayed Values of the Continuous Controller or Step Controller

The output parameter RET_VALU contains the return value RET_VAL of the
SFCs 58 and 59.
The values of RET_VALU are described in the Reference Manual /2/.
Instance Data Block Allocation
The allocation of the instance DB of the FB CH_DIAG is shown in Section 11.5.

Controller Module FM 455

A5E00059359-02 7-23
Integrating the FM 455 Into The User Program

7.6 The Function Block PID_PAR

The FB PID_PAR is used to change further parameters online, which cannot be

specified via the FB PID_FM.
The FB PID_PAR requires an initializing run. For this purpose it must be called
once here in the startup by using the parameter COM_RST = TRUE. Othewise
calling the FB causes a parameter assignment error on the module. You can also
read out these parameter assignment errors by using the menu PLC > Parameter
Assignment Error of the parameter configuration interface.
In order to save run time the FB PID_PAR should not be called cyclically but only
when parameters are to be changed. COM_RST must then be FALSE.

Creating and Supplying the Instance DB

Before you can use the user program to program the module you must first create
an Instance DB for each controller channel and supply important data to it.
1. Create the instance DBs for the controller channels as data blocks with the
associated function block FB PID_PAR under STEP 7.
2. Enter the module address in the parameter MOD_ADDR for each instance DB.
The module address of the FM 455 is specified while configuring the hardware.
Use the start address from HW Config.
3. Enter the channel number of the corresponding controller channel (1, 2, 3 to 16)
in the CHANNEL parameter for each instance DB.
4. Save the instance DBs.

Call
The FB PID_PAR must be called in the same OB as all other FBs which access
the same FM 455.
The FB PID_PAR can be used to change one each of the REAL parameters and
one of the INT parameters listed in Table 7-1 for each call.
The assignment of the specified value to the parameter is carried out via the index
numbers of Table 7-1 which you can specify in the parameter INDEX_R or
INDEX_I in the instance DB of the FB PID_PAR.
If the input COM_RST = TRUE, the FB reads the parameters from the system
data and saves them in static variables. The parameters to be changed are
overwritten there and then the complete record is transferred to the FM. Since the
FB has its own data retention for the parameters in its static variables, further
parameters can also be changed. To this purpose you must call the same
instance DB several times consecutively with COM_RST = FALSE and with
different index numbers.

Controller Module FM 455

7-24 A5E00059359-02
 Integrating the FM 455 Into The User Program

The parameter COM_RST is an input parameter which cannot be reset by the

FB PID_PAR.
The output parameter RET_VALU contains the return value RET_VAL of the
SFCs 58 and 59.
The values of RET_VALU are described in the Reference Manual /2/.

Note
Please note that the parameters which you have changed by means of the
FB PID_PAR are overwritten with the parameters from the system data whenever
the CPU is started up.

Example
You want to change the ramp-up time of the ramp for the reference variable as well
as use different analog input values as the process variable depending on the
process state during operation.
• Call the FB PID_PAR with COM_RST = TRUE in the CPU startup.
• In order to configure the ramp-up time of the ramp for the reference variable to
10.0, call the FB PID_PAR during operation with INDEX_R = 30,
VALUE_R = 10.0 and INDEX_I = 0.
• In order to configure analog input value 4 of the module as the process value,
call the FB PID_PAR during operation with INDEX_R = 0, INDEX_I = 50 and
VALUE_I = 4.

Table 7-1 List of REAL and INT Parameters which Can Be Changed with the FB PID_PAR

Data Type Description Index Nummer

- No parameter selected 0
REAL Filter time constant for analog input 1
REAL Measuring end (100%) 2
REAL Measuring start (0%) 3
REAL Polyline, Interpolation value 1 input end 4
REAL Polyline, Interpolation value 2 input end 5
REAL Polyline, Interpolation value 3 input end 6
REAL Polyline, Interpolation value 4 input end 7
REAL Polyline, Interpolation value 5 input end 8
REAL Polyline, Interpolation value 6 input end 9
REAL Polyline, Interpolation value 7 input end 10
REAL Polyline, Interpolation value 8 input end 11
REAL Polyline, Interpolation value 9 input end 12
REAL Polyline, Interpolation value 10 input end 13
REAL Polyline, Interpolation value 11 input end 14

Controller Module FM 455

A5E00059359-02 7-25
Integrating the FM 455 Into The User Program

Table 7-1 List of REAL and INT Parameters which Can Be Changed with the FB PID_PAR, continued

Data Type Description Index Nummer

REAL Polyline, Interpolation value 12 input end 15
REAL Polyline, Interpolation value 13 input end 16
REAL Polyline, Interpolation value 1 output end 17
REAL Polyline, Interpolation value 2 output end 18
REAL Polyline, Interpolation value 3 output end 19
REAL Polyline, Interpolation value 4 output end 20
REAL Polyline, Interpolation value 5 output end 21
REAL Polyline, Interpolation value 6 output end 22
REAL Polyline, Interpolation value 7 output end 23
REAL Polyline, Interpolation value 8 output end 24
REAL Polyline, Interpolation value 9 output end 25
REAL Polyline, Interpolation value 10 output end 26
REAL Polyline, Interpolation value 11 output end 27
REAL Polyline, Interpolation value 12 output end 28
REAL Polyline, Interpolation value 13 output end 29
REAL Ramp-up time of the ramp for reference variable 30
REAL Safety reference variable or safety reference variable ratio 31
REAL Offset for setpoint value logic (ratio/blending controller) 32
REAL Factor for process variable B (three-component controller) 33
REAL Factor for process variable C (three-component controller) 34
REAL Offset for process variable logic (three-component controller) 35
REAL Factor for disturbance variable logic 36
REAL Operating point 37
REAL Aggressiviness at fuzzy controller 38
REAL Vertices for slit-range function: Start of range for input signal A 39
REAL Vertices for slit-range function: End of range for input signal A 40
REAL Vertices for slit-range function: Start of range for output signal A 41
REAL Vertices for slit-range function: End of range for output signal A 42
REAL Vertices for slit-range function: Start of range for input signal B 43
REAL Vertices for slit-range function: End of range for input signal B 44
REAL Vertices for slit-range function: Start of range for output signal B 45
REAL Vertices for slit-range function: End of range for output signal B 46
REAL Minimum pulse time 47
REAL Minimum pause time 48
INT Selection of the reference variable SP or SP_RE for the controller 49
0: Setpoint value SP_RE from function block
1 to 16: Analog input value 1 to 16
17 to 32: Manipulated variable from controllers 1 to 16
INT Selection of the main process variable, process variable A for the 50
controller
0: Process variable A = 0.0
1 to 16: Analog input value 1 to 16

Controller Module FM 455

7-26 A5E00059359-02
 Integrating the FM 455 Into The User Program

Table 7-1 List of REAL and INT Parameters which Can Be Changed with the FB PID_PAR, continued

Data Type Description Index Nummer

INT Selection of the auxilary process variable, process variable B for the 51
controller
0: Process variable B = 0.0
1 to 16: Analog input value 1 to 16
INT Selection of the auxilary process variable, process variable C for the 52
controller
0: Process variable C = 0.0
1 to 16: Analog input value 1 to 16
INT Selection of the auxilary process variable, process variable D for the 53
controller
0: Process variable D = 0.0
1 to 16: Analog input value 1 to 1c
17 to 32: Manipulated variable from Controllers 1 to 16
INT Selection of the disturbance variable DISV for the controller 54
0: Disturbance variable = 0.0
1 to 16: Analog input value 1 to 16
INT Selection of the status tracking TRACK_PER for the controller 55
0: Status tracking = 0.0
1 to 16: Analog input value 1 to 16
INT Selection of the status tracking LMNR_PER for the controller 56
0: Status tracking = 0.0
1 to 16: Analog input value 1 to 16
INT Selection of the signal for changing over to safety value for the 57
manipulated value of the controller
0: Only selection via SAFE_ON parameter of the FB PID_FM
1 to 16: Selection via SAFE_ON parameter of the FB PID_FM ORed
with digital input 1 to 16
INT Selection of the signal for changing over to tracking function of the 58
manipulated value of the controller
0: Only selection via LMNTRKON parameter of the FB PID_FM
1 to 16: Selection via LMNTRKON parameter of the FB PID_FM
ORed with digital input 1 to 16
INT Selection of the signal for changing over the manipulated value of the 59
controller to LMN_RE
0: Only selection via LMN_REON parameter of the FB PID_FM
1 to 16: Selection via LMN_REON parameter of the FB PID_FM
ORed with digital input 1 to 16

Controller Module FM 455

A5E00059359-02 7-27
Integrating the FM 455 Into The User Program

Table 7-1 List of REAL and INT Parameters which Can Be Changed with the FB PID_PAR, continued

Data Type Description Index Nummer

INT Selection of the upper stop signal of the position feedback 60
0: Only selection via LMNRHSRE parameter of the FB PID_FM
1 to 16: Selection via LMNRHSRE parameter of the FB PID_FM
ORed with digital input 1 to 16
INT Selection of the lower stop signal of the position feedback 61
0: Only selection via LMNRLSRE parameter of the FB PID_FM
1 to 16: Selection via LMNRLSRE parameter of the FB PID_FM
ORed with digital input 1 to 16

Controller Module FM 455

7-28 A5E00059359-02
 Integrating the FM 455 Into The User Program

Take Into Account

Note
The FB PID_PAR uses the SFC 54 RD_DPARM. You can therefore only use
FB PID_PAR in the CPUs listed in Table 7-2:

Table 7-2 List of CPUs in which the FB PID_PAR Can Be Used

CPU Order No.

CPU 412-1 6ES7 412-1XF02-0AB0
CPU 412-2 6ES7 412-2XG00-0AB0
CPU 413-1 6ES7 413-1XG02-0AB0
CPU 413-2 6ES7 413-2XG02-0AB0
CPU 414-1 6ES7 414-1XG02-0AB0
CPU 414-2 6ES7 414-2XG02-0AB0
CPU 414-2 6ES7 414-2XJ01-0AB0
CPU 414-3 6ES7 414-3XJ00-0AB0
CPU 414-3H 6ES7 414-3HJ00-0AB0
CPU 416-1 6ES7 416-1XJ02-0AB0
CPU 416-2 6ES7 416-2XK01-0AB0
CPU 416-2 6ES7 416-2XL01-0AB0
CPU 416-3 6ES7 416-3XL00-0AB0
CPU 417-4 6ES7 417-4XL00-0AB0
CPU 417-4H 6ES7 417-4HL00-0AB0
All future CPUs

Instance Data Block Allocation

The allocation of the instance DB of the FB PID_PAR is shown in Section 11.6.

Controller Module FM 455

A5E00059359-02 7-29
Integrating the FM 455 Into The User Program

7.7 The Function Block CJ_T_PAR

The FB CJ_T_PAR is used to change the configured reference junction

temperature online. This is necessary if a temperature control system with several
FM 455s with thermoelement inputs is to be operated without having to connect a
Pt 100 to each FM 455.
If, for example, the reference junction temperature is to be measured with an
FM 455 in an extruder control system with more than 16 heating zones (more than
8 heating zones for a Pt 100) then it can be read out via the FB READ_455 at the
parameter CJ_TEMP and configured via the FB CJ_T_PAR at the other FM 455s .
The FB CJ_T_PAR requires an initializing run. To this purpose it must be called
once here in the startup by using the parameter COM_RST = TRUE.
The FB CJ_T_PAR is normally called cyclically. COM_RST should be FALSE in
order to reduce the run time.
The parameter COM_RST is an input parameter which cannot be reset by the
FB CJ_T_PAR.

Creating and Supplying the Instance DB

Before you can use the user program to program the module you must first create
an instance DB and supply important data to it.
1. Create the instance DB as a data block with the associated function block
FB CJ_T_PAR under STEP 7.
2. Enter the module address in the parameter MOD_ADDR at the instance DB.
The module address of the FM 455 is specified while configuring the hardware.
Use the start address from HW Config.
3. Enter the channel number of the corresponding controller channel (1, 2, 3 to 4)
in the CHANNEL parameter for the instance DB.
4. Save the instance DB.
The reference junction temperature can be specified via the parameter CJ_T.
The output parameter RET_VALU contains the return value RET_VAL of the
SFCs 58 and 59. The values of RET_VALU are described in the
Reference Manual /2/.

Call
The FB PID_PAR must be called in the same OB as all other FBs which access
the same FM 455.

Controller Module FM 455

7-30 A5E00059359-02
 Integrating the FM 455 Into The User Program

Take Into Account

Note
The FB CJ_T_PAR uses the SFC 54 RD_DPARM. You can therefore only use
FB CJ_T_PAR in the CPUs listed in Table 7-2:

Instance Data Block Allocation

The allocation of the instance DB of the FB CJ_T_PAR is shown in Section 11.7.

Controller Module FM 455

A5E00059359-02 7-31
Integrating the FM 455 Into The User Program

Controller Module FM 455

7-32 A5E00059359-02
Starting Up the FM455 8
Overview
This chapter shows you how to start up the FM 455 using only a few steps.

Hardware Installation and Wiring

In order to achieve a clearer structure the process of starting up has been
subdivided into several smaller steps. In this first section you install the FM 455 in
your S7-400 and wire up the external I/O elements.

Step Options/Procedure 
1 Determining the slot
Select the slot for the FM 455. 
2 Setting the coding key (refer to Section 9.3)
Key for Channel 1 and 2: Position ..... 
Key for Channel 3 and 4: Position ..... 
Key for Channel 5 and 6: Position ..... 
Key for Channel 7 and 8: Position ..... 
Key for Channel 9 and 10: Position ..... 
Key for Channel 11 and 12: Position ..... 
Key for Channel 13 and 14: Position ..... 
Key for Channel 15 and 16: Position ..... 
3 Installing the FM 455 (refer to Chapter 4)
• Switch the CPU to STOP mode. 
• Insert the FM 455 and screw it on. 
• Label the module with its slot number. 

Controller Module FM 455

A5E00059359-02 8-1
Starting Up the FM455

Step Options/Procedure 
4 Wiring the FM 455 (refer to Chapter5)
• Analog inputs (right front connector) 
• Digital inputs (both front connectors) 
• Analog outputs (C controller only, left front connector) 
• Digital outputs (S controller only, left front connector) 
• Wire up the supply voltage
- 24 V supply voltage L+: 
C controller Left front connector Pin 3 
S controller Left front connector Pin 3, 12, 24, 36 and 47
- Ground supply voltage M: Left front connector Pin 48 
• Wire up the reference potential of the analog measurement circuits
- MANA: Right front connector Pin 20
5 Front connectors
Insert the front connector and screw it on. 
6 Shielding
Check the shielding of the individual cables. 
7 Switching on the voltage supply
Switch on the 24 V supply for the FM 455. 

Module State after First Switching On

The state of the module after the power supply has first been switched on and
when no data have been transferred yet (delivery state) has the following
characteristics:
• Analog inputs: No processing
• Analog outputs (C controllers): 0 mA
• Digital outputs (S controllers): Zero (switched off)
• No controller active
• Diagnostic interrupt disabled

Controller Module FM 455

8-2 A5E00059359-02
 Starting Up the FM455

Creating a New Project

If you want to insert the FM 455 in an existing project, skip this section and move
to the next section.
If you have not yet created a project, create a new project under STEP 7 so that
you can assign parameters with the parameter assignment software:

Step Options/Procedure 
1 Create a new project under STEP 7. 
2 Configure a new rack. 
3 Enter your hardware structure in the rack using the HW Config

application.
4 Select the FM 455 from the module catalog and drag it to the selected

slot.
5 Note the module address which is now displayed.
This value will be required later to prepare the instance DB.
____
6 Now call the parameter assignment software for the FM 455 by

double-clicking on the order number of the FM 455.

Now go to the section labeled Assigning Parameters.

Inserting FM 455 into an Existing Project

If you want to insert the FM 455 into a SIMATIC 400 station of an existing project,
proceed as follows:

Step Options/Procedure 
1 Open the SIMATIC 400 station for your existing project. 
2 Select the FM 455 from the module catalog and drag it to the selected

slot.
3 Note the module address which is now displayed.
This value will be required later to prepare the instance DB. ____

4 Now call the parameter assignment software for the FM 455 by


double-clicking on the order number of the FM 455.

Controller Module FM 455

A5E00059359-02 8-3
Starting Up the FM455

Parameter Assignment
Assign parameters to the module.

Step Options/Procedure 
1 Fill out the dialog boxes for the basic parameters:
• For interrupt selection, determine whether the FM 455 should trigger 
interrupts.
2 Click on the button Parameters... 
3 Fill out the dialog boxes. 
4 Save the parameter assignments by using the menu command

File > Save.

Saving Parameter Configuration Data and Transferring Them to the FM 455

When you have finished assigning parameters, you have to save the data and
prepare the plant for operation.

Step Options/Procedure 
1 Close the parameter assignment interface. 
2 Save the project by using File > Save and Compile. 
3 Switch the CPU to STOP mode. 
4 Download the data to the CPU in STOP mode with Download PLC...

The data are transferred directly to the CPU and the FM 455.

Creating an Instance DB
You must create an instance DB for each controller channel in order to use the
functions of the module.

Step Options/Procedure 
1 Create the instance DBs for the controller channels as data blocks with

the associated function block FB31 PID_FM.
2 Enter the module address in the parameter MOD_ADDR for each
instance DB.

This is the address you noted when you were configuring your hardware
under STEP 7.
3 In every instance DB, enter the channel number in the CHANNEL

parameter.

Controller Module FM 455

8-4 A5E00059359-02
 Starting Up the FM455

Starting Up the FM 455

You can now optimize and debug your process.

Step Options/Procedure 
1 Switch the CPU to RUN mode. 
2 Open the parameter assignment interface and measure the motor
actuating time: 
Debug > Measure Motor Actuating Time (S controllers only)
3 Call the controller optimization:
Debug > Controller Optimization 
4 Execute the steps for controller optimization. 
5 Monitor and modify the control loop with the loop monitor function:

Debug > Loop Monitor
6 Monitor the control loop with the curve recorder function:

Debug > Curve Recorder

Saving a Project
Once you have completed all the tests successfully and the parameters for the
FM 455 have been optimized, you must save the data again.

Step Options/Procedure 
1 Save all the data in the parameter assignment with File > Save. 
2 Close the parameter assignment interface. 
3 Save the project with File > Save. 
4 Transfer the data to the CPU in STOP mode by using the menu

command Download PLC...
5 Switch the CPU to RUN mode. 

Particular Points to Observe

The FM 455 is supplied with voltage exclusively via the left front connector. The
CPU therefore recognizes the state ”Module removed/not addressable” in the
following cases:
• If the left front connector of the FM 455 is not plugged
• If there is no 24-V power supply at the left front connector

Note
If the entry ”Module removed/not addressable” is entered in the diagnostic buffer
of the CPU, check whether the left front connector is plugged and whether the
24-V power supply is available at the FM 455.

Controller Module FM 455

A5E00059359-02 8-5
Starting Up the FM455

Controller Module FM 455

8-6 A5E00059359-02
Properties of Digital and Analog Inputs
and Outputs 9
What Does this Chapter Describe?
This chapter describes the properties of the digital and analog inputs and outputs.

Chapter Overview

Section Description Page

9.1 Properties of the Digital Inputs and Outputs (S Controllers) 9-2
9.2 Properties of the Analog Inputs 9-4
9.3 Setting the Measuring Type and Measuring Ranges of the 9-6
Analog Input Channels
9.4 Properties of the Analog Outputs (C Controllers) 9-10

Controller Module FM 455

A5E00059359-02 9-1
Properties of Digital and Analog Inputs and Outputs

9.1 Properties of the Digital Inputs and Outputs

Digital inputs
The FM 455 C and the FM 455 S have 16 digital inputs each (I1 to I16). They are
suitable for connecting switches and 2-/3-/4-wire BEROs.
The assignment of the digital inputs to the controller channels is described in
Section 3.1.

Input Filter for Digital Inputs

In order to suppress interferences the digital inputs I1 to I16 have an input filter
(RC elements) with a uniform filtering time of 1.5 ms.

Digital Outputs
In order to trigger control processes directly the FM 455 S disposes of 32 digital
outputs Two digital outputs each are assigned fixed to a controller channel. The
assignment is described in Section 3.1.
The digital outputs have the following properties:
• Power supply via L+ (24 V DC)
• Current-sourcing switch with a maximum load current of 0.1 A
• Suitable for connecting solenoid valves, d.c. contactors an signal lamps
• Isolated against the S7-400 bus
• Protection against overloading and short circuiting

Note
When connecting the 24 V supply voltage to the system via a mechanical contact,
as a result of the switching, the outputs of the FM have a “1” signal for
approximately 50 µs. You should remember this if you use the FM 455 in
conjunction with fast counters!

Controller Module FM 455

9-2 A5E00059359-02
 Properties of Digital and Analog Inputs and Outputs

Block diagram

Inputs L+

Backplane
bus

Minternal

Outputs L+
Backplane
bus

Minternal

Figure 9-1 Block Diagram of the Digital Inputs and Outputs

Controller Module FM 455

A5E00059359-02 9-3
Properties of Digital and Analog Inputs and Outputs

9.2 Properties of the Analog Inputs

Properties
The analog inputs of the FM 455 have the following properties:
• 16 inputs
• Measured-value resolution
– 12 bits
– 14 bits
• Measurement type, selectable for each analog input:
– Voltage
– Current
– Resistance
– Temperature
• Selectable measurement range for each analog input
• Diagnostics that can have parameters set
• Diagnostic interrupt that can have parameters set
• Limit-value monitoring
• Limit-value alarm that can have parameters set
The assignment of the analog inputs to the controller channels is described in
Section 3.1.

Resolution
The reset time results from the selected resolution of the measured value. The
preciser the resolution of the measured value, the longer the reset time for the
analog input channel (refer to Appendix A.1, Technical Data of the Analog Inputs).

Controller Module FM 455

9-4 A5E00059359-02
 Properties of Digital and Analog Inputs and Outputs

Block diagram
Figure 9-2 shows the block diagram of the analog inputs. The input resistances
depend on the measuring range set (refer to Appendix A.1, Technical Data of the
Analog Inputs).

Channel activation
Current source
CH 1

CH 2
•
ADC
• Processing in
• +
the FM 455
External
compensation
•
•
•
Configured
CH 15 compensation

CH 16

L+
Internal
24 V VDC
supply
M

Figure 9-2 Block Diagram of the Analog Inputs

Controller Module FM 455

A5E00059359-02 9-5
Properties of Digital and Analog Inputs and Outputs

9.3 Setting the Measurement Type and the Measuring Ranges of the
Analog Input Channels

Overview
You can set various measurement types and measuring ranges at the analog input
channels of the FM 455, thus adapting them to various sensors. This adaptation is
carried out by means of pluggable coding keys and by parameter assignment
under STEP 7.

Setting the Measurement Type and the Measuring Ranges via Coding Keys
The FM 455 is supplied with eight plugged coding keys. These coding keys may
have to be replugged to suit the measurement type and the measuring range.
Please take into account that the coding keys may not be accessible when the
FM 455 is installed. Therefore check before installing the FM 455 whether the
coding keys have to be set to a different measurement type and a different
measuring range!

Marks for the Coding Keys

Use the marking points on the FM 455 when replugging the coding key.
Figure 9-3 shows the coding keys and the marking points on the FM 455.

Marking points on
the FM 455
B
A
C

B
A
C

B
A
C

Marks on the
coding keys

Figure 9-3 Marking Points for the Coding Keys

Controller Module FM 455

9-6 A5E00059359-02
 Properties of Digital and Analog Inputs and Outputs

A coding key is in the position ”A”, ”B”, ”C” or ”D” when the corresponding letter
points in the direction of the marking point on the FM 455.

Adaptation to Different Sensors

You can use the supplied coding keys to adapt two adjacent analog input channels
to a common sensor type.
Both the assignment of the keys to the analog input channels and the assignment
of the key position to the measuring ranges are printed next to the coding keys on
the FM 455.
The assignment of the keys to the channels is shown in Figure 9-4.
The assignment of the individual positions of a coding key to the corresponding
sensor types is shown in the following table:

Table 9-1 Position of the Coding Key

Position Sensor Types

A Thermocouples
Resistance-type sensors in 4-wire technique
Resistance thermometers (RTDs) in 4-wire technique
B Voltage sensors 10 V
C Current sensors
4-wire measuring transducers with current output
D 2-wire measuring transducers

Warning
! The module can be damaged.
The shunt resistor of a input channel can be destroyed if you connect a voltage
sensor to the channel by mistake while the coding key is plugged into position C
(current sensor/4-wire measuring transducer).
Ensure that the coding key is in the correct position before you connect a sensor
to the module.

The FM 455 is adapted to different sensors by means of two steps:

1. Plug the coding key in the correct position into the module.
2. When assigning parameters to the module set the corresponding measuring
range for the channels of the module.

Controller Module FM 455

A5E00059359-02 9-7
Properties of Digital and Analog Inputs and Outputs

Proceed as follows in order to reset a coding key:

1. Use a screwdriver to lever the coding key out of the FM 455.

1 = Key for channels 1 and 2

2 = Key for channels 3 and 4
3 = Key for channels 5 and 6
4 = Key for channels 7 and 8
5 = Key for channels 9 and 10
6 = Key for channels 11 and 12:
7 = Key for channels 13 and 14
8 = Key for channels 15 and 16

1 2 3 4 5 6 7 8

Figure 9-4 Levering the Coding Key out of the FM 455

Controller Module FM 455

9-8 A5E00059359-02
 Properties of Digital and Analog Inputs and Outputs

2. Plug the coding key in the desired setting (1) into the FM 455.
3. The measuring range which points to the marking point (2) is selected.

Figure 9-5 Plugging the Coding Key into the FM 455

4. Use the same procedure for all the coding keys.

Controller Module FM 455

A5E00059359-02 9-9
Properties of Digital and Analog Inputs and Outputs

9.4 Properties of the Analog Outputs (C Controllers)

Properties
The 16 analog outputs of the FM 455 C have the following properties:
• The outputs can be selected for each channel as
– Voltage output
– Current output
• 12 bit resolution
• Diagnostics that can have parameters set
The assignment of the analog outputs to the controller channels is described in
Section 3.1.

Note
When switching the supply voltage (L+) on and off, incorrect intermediate values
may occur at the output for approximately 10 ms.

Block diagram

DAC
Q1
CH 1
MANA

Q2
Processing in CH 2
MANA
the FM 455
Q3
CH 3
MANA

Q4
CH
MANA 16

L+
Internal 24 V VDC
supply M

MANA of all channels are connected internally

Figure 9-6 Block Diagram for the Analog Outputs (C Controller)

Controller Module FM 455

9-10 A5E00059359-02
Connecting Measuring Sensors and
Loads/Actuators 10
What Does this Chapter Describe?
This chapter describes
• Basic information on connecting measuring sensors
• A description of thermoelements
– Design and method of operation of thermoelements
– Compensation of the reference junction temperature
• The description of how thermoelements are connected to analog inputs
• The description of how other measuring sensors are connected to analog inputs
– Connection of voltage sensors
– Connection of current sensors
– Connection of resistance sensors
• The description of how loads/actuators are connected to analog outputs

Chapter Overview

Section Description Page

10.1 Connecting Measuring Sensors to Analog Inputs 10-2
10.2 Use of Thermoelements 10-5
10.3 Connecting Voltage and Current Sensors and Resistance 10-10
Thermometers
10.4 Connecting Loads/Actuators to Analog Outputs 10-13
10.5 Connecting Loads/Actuators to Digital Outputs 10-15

Controller Module FM 455

A5E00059359-02 10-1
Connecting Measuring Sensors and Loads/Actuators

10.1 Connecting Sensors to Analog Inputs

Overview
Depending on the measuring type used you can connect various measuring
sensors to the analog inputs of the FM 455:
• Voltage sensors
• Current sensors as 4-wire measuring transducers and 2-wire measuring
transducers
• Resistors
This chapter describes how you connect the sensors and what you have to
observe when connecting the sensors.

Cables for Analog Signals

You should use screened and twisted-pair cables for the analog signals. This
reduces the disturbing influences. You should ground the screen of the analog
cables at both cable ends. If there are potential differences between the cable
ends, a potential compensating current could flow across the screen possibly
causing the analog signals to be disturbed. In this case you should only ground the
shield at one cable end or lay an equalizing conductor >16 mm2.

Reference Point MANA

You must create a connection between the reference point of the analog loop
MANA and the reference point on the subrack in order to operate the FM 455 (refer
to Figure 5-8). A potential difference between MANA and the reference point on the
subrack could lead to invalidation of the analog signal.

Abbreviations Used
The abbreviations used in Figures 10-1 and 10-2 have the following meaning:
M+: Measuring lead (positive)
M-: Measuring lead (negative)
MANA: Reference potential of the analog measuring circuit
M: Electrical bonding
L+: Voltage supply connection 24 V DC
UCM: Potential difference between inputs and reference potential of the
measuring circuit MANA

Controller Module FM 455

10-2 A5E00059359-02
 Connecting Measuring Sensors and Loads/Actuators

Connecting Sensors to Analog Inputs

No potential difference ≥CM (common mode voltage) may arise between the
measuring leads M- of the input channels and the reference point of the measuring
circuit MANA. In order for the permitted value not to be exceeded, you have to carry
out different measures depending on the potential connection of the sensor
(isolated, non-isolated). These measures are explained in this chapter.

Isolated Measuring Sensors

The isolated sensors are not connected to the local potential to ground. They can
be operated potential-free. Local conditions or disturbances can cause potential
differences UCM (static or dynamic) between the measuring leads M- of the input
channels and the reference point of the measuring circuit MANA.

Note
You must connect M- to MANA in order for the permitted value (UCM) not to be
exceeded.
But: When connecting resistance-type sensors and 2-wire measuring
transducers you may not establish a connection from M- to MANA.

Figure 10-1 shows the connection in principle of isolated sensors to an FM 455.

L+ FM 455
M

M+
Isolated M-
measuring ADC Logic
M+
sensor
M-

MANA

Without these connections

at resistance-type sensors!

Reference point at subrack (CPU grounding)

Figure 10-1 Block Diagram of the Connection of Isolated Measuring Sensors

Controller Module FM 455

A5E00059359-02 10-3
Connecting Measuring Sensors and Loads/Actuators

Non-Isolated Measuring Sensors

The non-isolated sensors are connected to the local potential to ground. You have
to connect MANA to the potential to ground. Local conditions or disturbances can
cause potential differences UCM (static or dynamic) to arise between the locally
distributed measuring points.
Equipotential bonding lines must be provided between the measuring points if the
permitted value for UCM may be exceeded.
Figure 10-2 shows the connection in principle of non-isolated sensors to an
FM 455.

L+ FM 455
M

M+
Non-isolated M-
measuring Logic
M+ ADC
sensor
M-

UCM MANA

Equipotential
Reference point at
bonding line
subrack (CPU
grounding) Jumper at
subrack

Grounding point

Figure 10-2 Block Diagram of the Connection of Non-Isolated Measuring Sensors

Controller Module FM 455

10-4 A5E00059359-02
 Connecting Measuring Sensors and Loads/Actuators

10.2 Use of Thermoelements

Overview
This chapter describes the design of thermoelements and the points to be
observed when connecting thermoelements.

Design of Thermoelements
A thermoelement consists of
• The thermocouple (detecting elements) and
• The respective built-in and connection parts.
The thermocouple consists of two wires which are made of different metals or
alloys and whose ends are soldered or welded to each other. The various types of
thermoelements are named after the different material compositions, for example
B, J, K. The measuring principle of all the thermoelements is the same,
irrespective of the thermoelement type.

Measuring point
Thermocouple with plus and minus
thermal legs
Connecting point
Equalizing line

Reference
junction
Lead wire

Trimming resistor

Detection point of the thermal e.m.f.

°C

Figure 10-3 Design of Thermoelements

Controller Module FM 455

A5E00059359-02 10-5
Connecting Measuring Sensors and Loads/Actuators

Operating Principle of Thermoelements

When a measuring junction is subject to a different temperature than the free ends
of the thermocouple, a voltage, called the thermal e.m.f., arises between the free
ends.
The height of the thermal e.m.f. depends on the difference between the
temperature of the measuring junction and the temperature at the free ends as well
as on the material combination of the thermocouple. Since a thermocouple always
detects a temperature difference the free ends of a reference junction have to be
kept to a known temperature in order to determine the temperature at the
measuring junction.
If this is not possible, the reference junction temperature has to be detected and
equalized via the additional input with a Pt 100.

Extension To A Reference Junction

The thermocouples can be extended from their connecting point by means of
equalizing lines to a point with a temperature which remains constant as far as
possible (reference junction).
The equalizing lines are made of the same material as the wires of the
thermoelement. The lead wires are made of copper. Ensure that the polarity of the
equalizing lines is not reversed since large measuring errors will otherwise arise.

Compensation of the Reference Junction Temperature

The influence of temperature fluctuations at the reference junction can be
compensated by measuring the reference junction temperature outside the
module.

Measuring the Reference Junction Temperature

The influence of the temperature on the reference junction of a thermoelement (for
example the terminal box) can be equalized by measuring the reference junction
temperature with a Pt 100.
If the actual reference temperature differs from the comparison temperature, the
temperature-dependent resistance changes. A positive or negative compensation
voltage arises which is added to the thermal e.m.f.

Controller Module FM 455

10-6 A5E00059359-02
 Connecting Measuring Sensors and Loads/Actuators

Use of Thermoelements
The following points must be observed when connecting thermoelements:
Depending on where the reference junction is required, either configured or
external compensation can be used.
In case of configured compensation a configurable reference junction temperature
of the module is used for comparison.
In the case of external compensation the temperature of the reference junction of
the thermoelements is taken into consideration by means of a Pt 100.
The following restrictions apply:
• External compensation with connection of the Pt 100 to Connections 28 to 31 of
the module can only be implemented for one thermoelement type. This means
that all the channels which operate with external compensation must use the
same type.

Abbreviations Used
The abbreviations used in Figures 10-4 and 10-5 have the following meaning:
M+: Measuring lead (positive)
M-: Measuring lead (negative)
COMP+: Compensation connection (positive)
COMP-: Compensation connection (negative)
M: Electrical bonding
L+: Voltage supply connection 24 V DC

Possibilities of Connecting Thermoelements

Figures 10-4 and 10-5 show the various possibilities of connecting thermoelements
to external and configured compensation.
In addition to the information below the information contained in Section 10.1 on
connecting sensors to analog inputs applies. The subsequent figures do not show
the required connecting lines between MANA and the reference point at the subrack
which result from the potential connection of the FM 455 and the sensor (isolated,
non-isolated). This means that the information given in Section 10.1 have to be
observed and implemented.

Controller Module FM 455

A5E00059359-02 10-7
Connecting Measuring Sensors and Loads/Actuators

Thermoelements With External Compensation of the Reference Junction

If all the thermoelements which are connected to the inputs of the FM 455 have the
same reference junction, carry out compensation as shown in Figure 10-4. The
thermoelements which use a reference junction must be of the same type.

Lead wire L+ FM 455

(made of Cu)
M

M+
M- Processing
Thermoelements M+ in the
Logic
M- FM 455

Equalizing line ADC

(same material as IC+
thermoelement) COMP+

COMP-
IC-

Reference junction

Figure 10-4 Block Diagram for Connecting Thermoelements with External Compensation

The grounding of thermoelements is shown in Figure 10-1 and Figure 10-2.

Controller Module FM 455

10-8 A5E00059359-02
 Connecting Measuring Sensors and Loads/Actuators

Thermoelements With Configured Compensation Of The Reference Junction

The configured temperature compensation can be used when thermoelements are
connected directly or via equalizing lines to the inputs of the module.

Lead wire L+ FM 455

(made of Cu) M

M+
M- Processing
Thermoelements M+ Logic in the
M- FM 455

Equalizing line ADC

(same material as IC+
thermoelement) COMP+

COMP-
IC-

MANA
Reference junction
Compensation can be specified by the configuration interface

Figure 10-5 Block Diagram for Connecting Thermoelements with Configured Compensation

The grounding of thermoelements is shown in Figure 10-1 and Figure 10-2.

Controller Module FM 455

A5E00059359-02 10-9
Connecting Measuring Sensors and Loads/Actuators

10.3 Connecting Voltage and Current Sensors and Resistance

Thermometers

Abbreviations Used
The abbreviations used in Figures 10-6 to 10-9 have the following meaning:
IC+: Constant-current line (positive)
IC-: Constant-current line (negative)
M+: Measuring lead (positive)
M-: Measuring lead (negative)
MANA: Reference potential of the analog measuring circuit
M: Electrical bonding
L+: Voltage supply connection 24 V DC
In addition to the information below the information contained in Section 10.1 on
connecting sensors to analog inputs applies. The subsequent figures do not show
the required connecting lines between the reference point at the subrack, M-,
MANA and grounding potential, which result from the potential connection of the
FM 455 and the sensor (isolated, non-isolated. This means that the information
given in Section 10.1 have to be observed and implemented.

Connection of Voltage Sensors

Figure 10-6 shows the connection of voltage sensors to an FM 455.

L+ FM 455
M

+ M+
U M-
-
+ M+ ADC Logic Processing in
U M- the FM 455
-

MANA

Figure 10-6 Connection of Voltage Sensors

Controller Module FM 455

10-10 A5E00059359-02
 Connecting Measuring Sensors and Loads/Actuators

Connection of Current Sensors as 4-Wire Measuring Transducers

4-wire measuring transducers have a separate operating voltage.
Figure 10-7 shows the connection of current sensors as 4-wire measuring
transducers to an FM 455.

L+ FM 455
Sensor, M
for example

4-wire measuring
manometer
M+
+

transducer
P ADC Processing in
Logic
the FM 455
- M-

MANA
L+ M

Figure 10-7 Connecting 4-Wire Measuring Transducers

Connection of Current Sensors as 2-Wire Measuring Transducers

The 2-wire measuring transducer converts the supplied measured quantities into
current.
2-wire measuring transducers must be isolated sensors.
Figure 10-8 shows the connection of current sensors as 2-wire measuring
transducers.

L+ FM 455
Sensor, M
for example
2-wire measuring

manometer
M+
+
transducer

P ADC Logic Processing in

the FM 455
- M-

MANA
M

Figure 10-8 Connecting 2-Wire Measuring Transducers

Controller Module FM 455

A5E00059359-02 10-11
Connecting Measuring Sensors and Loads/Actuators

Connection of Resistance Thermometers (For Example, Pt 100) and Resistors

The resistance thermometers/resistors are measured in a 4-wire connection. A
constant current is supplied to the resistance thermometers/resistors via the
connections IC + and IC - . The voltage arising at the resistance
thermometer/resistor is measured at the connection M+ and M- . This means that
a high degree of precision of the measuring results is attained at a 4-wire
connection.
Figure 10-9 shows the connection of resistance thermometers to an FM 455.

L+ FM 455
M

M+
M-
ADC Logic Processing in
IC+ the FM 455
IC IC-

MANA
M

Figure 10-9 Connection of Resistance Sensors

In the case of a 2- or 3-wire connection you must apply corresponding jumpers to

the module between M+ and IC + or M- and IC -. However, you must then accept
losses in the precision of the measuring results.

Controller Module FM 455

10-12 A5E00059359-02
 Connecting Measuring Sensors and Loads/Actuators

10.4 Connecting Loads/Actuators To Analog Outputs

Overview
Current or voltage can be supplied to loads/actuators by means of the FM 455 C.

Cables for Analog Signals

You should use screened and twisted-pair cables for the analog signals.This
reduces the disturbing influences.You should ground the screen of the analog
cables at both cable ends. If there are potential differences between the cable
ends, a potential compensating current could flow across the screen possibly
causing the analog signals to be disturbed. In this case you should only ground the
shield at one cable end or lay an equalizing conductor >16 mm2.

Reference Point MANA

You must create a connection between the reference point of the analog loop
MANA and the reference point on the subrack in order to operate the FM 455 C. To
do so connect the connector MANA to the reference point at the subrack (refer to
Figure 5-8). A potential difference between MANA and the reference point on the
subrack could lead to invalidation of the analog signal.

Abbreviations Used
The abbreviations used in Figure 10-10 have the following meaning:
Q: Analog output (current or voltage, depending on the configuration)
MANA: Reference potential of the analog measuring circuit
RL: Load/Actuator
L+: Voltage supply connection 24 V DC
M: Electrical bonding

Controller Module FM 455

A5E00059359-02 10-13
Connecting Measuring Sensors and Loads/Actuators

Connecting Loads To An Analog Output

Loads at an analog output have to be connected to Q and the reference point of
the analog circuit MANA.
Loads can only be connected to an analog output with a 2-wire connection.
Figure 10-10 shows the connection in principle of loads to an analog output of an
FM 455 C.

FM 455 L+
M

Q
Processing in Logic DAC
the FM 455
RL

MANA

Reference point at subrack (CPU grounding)

Figure 10-10 Connecting a Load to an FM 455 C

Controller Module FM 455

10-14 A5E00059359-02
 Connecting Measuring Sensors and Loads/Actuators

10.5 Connecting Loads/Actuators to Digital Outputs

Overview
Voltage can be supplied to loads/actuators by means of the FM 455 S.

Abbreviations Used
The abbreviations used in Figure 10-11 have the following meaning:
Q: Digital output
RL: Load/Actuator
L+: Voltage supply connection 24 V DC
M: Electrical bonding

Connecting Loads/Actuators To An Analog Output

Figure 10-11 shows the connection in principle of loads/actuators to a digital output
of an FM 455 S.

FM 455 L+

Q
Processing in Logic
the FM 455
RL

Figure 10-11 Connection of Loads/Actuators to an FM 455 S

Controller Module FM 455

A5E00059359-02 10-15
Connecting Measuring Sensors and Loads/Actuators

Controller Module FM 455

10-16 A5E00059359-02
Assignment of the Data Blocks 11
Chapter Overview

Section Description Page

11.1 Instance DB of the FB PID_FM 11-2
11.2 Instance DB of the FB FUZ_455 11-22
11.3 Instance DB of the FORCE455 11-24
11.4 Instance DB of the FB READ_455 11-26
11.5 Instance DB of the FB CH_DIAG 11-28
11.6 Instance DB of the FB PID_PAR 11-30
11.7 Instance DB of the FB CJ_T_PAR 11-32
11.8 Assignment of the DBs for Operator Control and Monitoring via 11-34
the OP

Controller Module FM 455

A5E00059359-02 11-1
Assignment of the Data Blocks

11.1 Instance DB of the FB PID_FM

You require the FB PID_FM in order to communicate with the FM 455 while you
are in the user program. You must also create an instance data block (DB) that is
assigned to the function block for each controller channel used.

Note
After you have created an instance DB all the in/out parameters are set to FALSE.
In order to transfer the parameters from the FM 455 to the instance DB you have
to carry out an initialization run in which the in/out parameter COM_RST = TRUE
is set.

The following tables list the parameters of this instance DB:

• Input parameters (Table 11-1)
• Output parameters (Table 11-2 on Page 11-3)
• In/out parameters (Table 11-3 on Page 11-12)

Table 11-1 Input Parameters of the Instance DB for the FB PID_FM

Add. Parameter Data Comment Permitted Default Explanation Param.

Type Value Range Dialog
Box
0.0 MOD_ADDR INT Module address 256 This input contains -
FM 355/455 the module address
that resulted from the
configuration set
under STEP 7.
2.0 CHANNEL INT Channel number 1 to 16 1 At the input “channel -
number” you can set
the number of the
controller channel to
which the instance
DB is to refer.
4.0 PHASE INT Phase of the PID Is not configured 0 The parameter -
self tuner PHASE can be
interconnected to the
output parameter
PHASE of a PID self
tuners (program for
self-tuning of
controller
parameters). The
phase state of the
PID self tuner can
then be displayed in
clear text in the loop
display. This
parameter is without
meaning for the OP.

Controller Module FM 455

11-2 A5E00059359-02
 Assignment of the Data Blocks

Table 11-2 Output Parameters of the Instance DB for the FB PID_FM

Add. Parameter Data Comment Permitted Default Explanation Param.

Type Value Range Dialog
Box
6.0 RET_VALU INT Return value 0 RET_VALU contains -
SFC 58/59 the return value
RET_VAL of the
SFC58/59.
RET_VALU can be
evaluated if an error
is reported via
QMOD_F (see
Reference Manual
/2/).
8.0 out_par WORD Beginning of W#16#3130 W#16#3 The parameter -
output 130 out_par may not be
parameters changed by the user.
It identifies the
beginning of the
output parameters
which are read from
the module when
READ_VAR = TRUE
is set.
10.0 SP REAL Setpoint value Technical range of 0.0 The effective -
values setpoint is output at
(physical variable) the “Setpoint” output.

14.0 PV REAL Process variable Technical range of 0.0 The effective actual -
values value is output at the
(physical variable) “Process variable”
output .
18.0 ER REAL Error signal Technical range of 0.0 The effective error -
values signal is output at the
(physical variable) “Error signal” output.

22.0 DISV REAL Disturbance -100.0...100.0 (%) 0.0 The effective -

variable disturbance variable
is output at the
“Disturbance
variable” output.
26.0 LMN REAL Manipulated -100.0...100.0 (%) 0.0 The effective -
value manipulated value is
output at the
“Manipulated value”
output. At a step
controller without
analog position
feedback the
unlimited P- +
D-component is
output at the
parameter LMN.

Controller Module FM 455

A5E00059359-02 11-3
Assignment of the Data Blocks

Table 11-2 Output Parameters of the Instance DB for the FB PID_FM, continued

Add. Parameter Data Comment Permitted Default Explanation Param.

Type Value Range Dialog
Box
30.0 LMN_A REAL Manipulated -100.0...100.0 (%) 0.0 At the output -
value A of split “Manipulated value A
range function / of split-range
position feedback function / position
feedback” the
manipulated value A
of the split-range
function for a
continuous controller
and the position
feedback for a step
controller with analog
position feedback
are displayed.
The output LMN_A
can only be used for
approximate display
of a corresponding
simulated
manipulated variable.
The starting
value LMNRSVAL of
the simulated
position feedback
must be configured
correspondingly and
becomes effective
when LMNRS_ON is
set.
34.0 LMN_B REAL Manipulated -100.0...100.0 (%) 0.0 At the output -
value B of split “Manipulated value B
range function of split-range
function” the
manipulated value B
of the split-range
function is displayed
for a continuous
controller.
38.0 QH_ALM BOOL High limit alarm FALSE The actual value or -
reached process variable is
monitored for four
limit values. If the
limit H_ALM is
violated, this is
indicated at the
output “High limit
alarm reached”.

Controller Module FM 455

11-4 A5E00059359-02
 Assignment of the Data Blocks

Table 11-2 Output Parameters of the Instance DB for the FB PID_FM, continued

Add. Parameter Data Comment Permitted Default Explanation Param.

Type Value Range Dialog
Box
38.1 QH_WRN BOOL High limit warning FALSE The actual value or -
reached process variable is
monitored for four
limit values. If the
limit H_WRN is
violated, this is
indicated at the
output “High limit
warning reached”.
38.2 QL_WRN BOOL Low limit warning FALSE The actual value or -
reached process variable is
monitored for four
limit values. If the
limit L_WRN is
violated, this is
indicated at the
output “Low limit
warning reached”.
38.3 QL_ALM BOOL Low limit alarm FALSE The actual value or -
reached process variable is
monitored for four
limit values. If the
limit L_ALM is
violated, this is
indicated at the
output “Low limit
alarm reached”.
38.4 QLMN_HLM BOOL High limit of FALSE The manipulated -
manipulated value is always
value reached limited to an upper
and a lower limit. The
output “High limit of
manipulated value
reached” indicates
that the upper limit
has been exceeded.
(Not for step
controllers without
analog position
feedback)

Controller Module FM 455

A5E00059359-02 11-5
Assignment of the Data Blocks

Table 11-2 Output Parameters of the Instance DB for the FB PID_FM, continued

Add. Parameter Data Comment Permitted Default Explanation Param.

Type Value Range Dialog
Box
38.5 QLMN_LLM BOOL Low limit of FALSE The manipulated -
manipulated value is always
value reached limited to an upper
and a lower limit. The
output “Low limit of
manipulated value
reached” indicates
that the lower limit
has been undershot.
(Not for step
controllers without
analog position
feedback)
38.6 QPARA_F BOOL Parameter FALSE The module checks -
assignment error parameters for
validity. A parameter
assignment error is
indicated at the
output “Parameter
assignment error”.
You can also read
out these parameter
assignment errors by
using the menu PLC
> Parameter
Assignment Error
of the parameter
assignment
interface.

38.7 QCH_F BOOL Channel error FALSE The output “Channel -

error” is set if the
controller channel
cannot supply any
valid results.
“Channel error” (e.g.
wire break) is also
set if QPARA_F = 1
or QMOD_F = 1. If
QCH_F=TRUE, the
exact error
information can be
read out in the
diagnostics data
record DS1 of the
module (refer to
Chapter 12).

Controller Module FM 455

11-6 A5E00059359-02
 Assignment of the Data Blocks

Table 11-2 Output Parameters of the Instance DB for the FB PID_FM, continued

Add. Parameter Data Comment Permitted Default Explanation Param.

Type Value Range Dialog
Box
39.0 QUPRLM BOOL Limit of positive FALSE The setpoint is -
setpoint limited in positive
inclination and negative
reached inclination. If the
output “Limit of
positive setpoint
inclination reached”
is set, the positive
setpoint inclination is
limited.
39.1 QDNRLM BOOL Limit of negative FALSE The setpoint is -
setpoint limited in positive
inclination and negative
reached inclination. If the
output “Limit of
negative setpoint
inclination reached”
is set, the negative
setpoint inclination is
limited.
39.2 QSP_HLM BOOL High limit of FALSE The setpoint is -
setpoint reached always limited to an
upper and a lower
limit. The output
“High limit of setpoint
reached” indicates
that the upper limit
has been exceeded.
39.3 QSP_LLM BOOL Low limit of FALSE The setpoint is -
setpoint reached always limited to an
upper and a lower
limit. The output
“Low limit of setpoint
reached” indicates
that the lower limit
has been undershot.
39.4 QLMNUP BOOL Manipulated FALSE This is the output -
signal up ”Manipulated signal
up”.
(For step controllers
or pulse controllers
only)
39.5 QLMNDN BOOL Manipulated FALSE This is the output -
signal down ”Manipulated signal
down”.
(For step controllers
or pulse controllers
only)

Controller Module FM 455

A5E00059359-02 11-7
Assignment of the Data Blocks

Table 11-2 Output Parameters of the Instance DB for the FB PID_FM, continued

Add. Parameter Data Comment Permitted Default Explanation Param.

Type Value Range Dialog
Box
39.6 QID BOOL Identification FALSE QID = TRUE shows -
running that an identification
is running (not that it
is switched on). After
the end of
identification the
identification result
can be read out via
the parameter
IDSTATUS of the
FB CH_DIAG (refer
to Section 3.8,
Page 3-48 and
Section 7.5,
Page 7-21).

40.0 QSPOPON BOOL Setpoint FALSE The output “Setpoint -

operation on operation on”
indicates whether the
setpoint is being
operated via the
configuration tool. If
the bit is set, the
value SP_OP is
used as the setpoint.
40.1 QLMNSAFE BOOL Safety operation FALSE If the output “Safety -
operation” is set, the
safety manipulated
value is output as the
manipulated value.
40.2 QLMNOPON BOOL Manipulated FALSE The output -
value operation “Manipulated value
on operation on”
indicates whether the
manipulated value is
being operated via
the configuration
tool. If the bit is set,
the value LMN_OP
is used as the
manipulated value.
40.3 QLMNTRK BOOL Follow-up FALSE The output “follow-up -
operation operation” indicates
whether the
manipulated value is
matched via an
analog input.

Controller Module FM 455

11-8 A5E00059359-02
 Assignment of the Data Blocks

Table 11-2 Output Parameters of the Instance DB for the FB PID_FM, continued

Add. Parameter Data Comment Permitted Default Explanation Param.

Type Value Range Dialog
Box
40.4 QLMN_RE BOOL Manual = 1 FALSE The output -
Automatic = 0 “Manual = 1;
Automatic = 0”
indicates whether the
manipulated value is
set to the external
manipulated value
LMN_RE
(manual = 1) or not.
40.5 QLMNR_HS BOOL High limit signal FALSE The output “High limit -
of repeated signal of position
manipulated feedback” indicates
value whether the control
valve is at its upper
limit.
QLMNR_HS = TRU
E means: the control
valve is at the upper
end stop.
(For step controllers
only)
40.6 QLMNR_LS BOOL Low limit signal of FALSE The output “Low limit -
repeated signal of position
manipulated feedback” indicates
value whether the control
valve is at its lower
limit.
QLMNR_LS = TRUE
means: the control
valve is at the lower
end stop.
(For step controllers
only)
40.7 QLMNR_ON BOOL Repeated FALSE The output “Position -
manipulated feedback on”
value on indicates the set
mode as either “Step
controller with
position feedback” or
“Step controller
without position
feedback”.
41.0 QFUZZY BOOL PID algorithm = 0 FALSE If the output -
Fuzzy = 1 parameter
QFUZZY =1, the
controller operates
with the fuzzy
algorithm.

Controller Module FM 455

A5E00059359-02 11-9
Assignment of the Data Blocks

Table 11-2 Output Parameters of the Instance DB for the FB PID_FM, continued

Add. Parameter Data Comment Permitted Default Explanation Param.

Type Value Range Dialog
Box
41.1 QSPLEPV BOOL Fuzzy display: FALSE The output “Fuzzy -
Setpoint < display: Setpoint <
Process variable actual value” is set
when the fuzzy
controller is switched
on if the setpoint is
smaller than the
effective process
variable.
41.2 QSPR BOOL Split range FALSE If the output -
operation “Split-range
operation” is set, the
continuous controller
operates in
split-range mode.
41.4 QMAN_FC BOOL Follow-up FALSE The output -
operation or “QMAN_FC” is set in
anti-reset-windup the following two
by secondary cases:
controller • The secondary
controller is in
manual
operation and
the master
controller is
tracked to the
process variable
of the secondary
controller.
• The integral
component of
the master
controller is
halted because
the setpoint
value or
manipulated
variable of the
secondary
controller is in
the limitation or
because the
secondary
controller is in
manual mode.

Controller Module FM 455

11-10 A5E00059359-02
 Assignment of the Data Blocks

Table 11-2 Output Parameters of the Instance DB for the FB PID_FM, continued

Add. Parameter Data Comment Permitted Default Explanation Param.

Type Value Range Dialog
Box
41.7 QPARABUB BOOL Internal value FALSE This parameter is set -
by the FM when
operating
parameters are
changed via the OP.
If READ_VAR =
TRUE and if this
display is set by the
FM, the FB PID_FM
reads the
parameters
SP_OP_ON,
LMNOP_ON,
SP_OP and
LMN_OP out of the
FM and saves them
in the instance DB.
The FB thus takes
over the operating
state of the FM. After
the reading process
the parameter is set
to FALSE.
42.0 QMOD_F BOOL Module error FALSE The function block -
checks that a data
record is read and
written correctly. If
an error is detected,
the output “Module
error” is set. The
error cause can be:
An incorrect module
address at the
parameter
MOD_ADDR, an
incorrect channel
number at the
parameter
CHANNEL or a
defective module.

Controller Module FM 455

A5E00059359-02 11-11
Assignment of the Data Blocks

Table 11-3 In/Out Parameters of the Instance DB for the FB PID_FM

Add. Parameter Data Comment Permitted Default Explanation Param.

Type Value Range Dialog
Box
44.0 COM_RST BOOL Read control FALSE If the parameter -
parameters from COM_RST = TRUE,
FM 355/455 the FB PID_FM
carries out an
initialization run. In
the process the
controller parameters
(all the parameters
after cont_par) are
read from the FM
and saved in the
instance DB. In
addition the
parameters
MOD_ADDR and
CHANNEL are
checked for their
validity. After the
initialization run the
parameter is set to
FALSE.

44.1 LOAD_OP BOOL Load operator FALSE If the in/out -

parameter to parameter “Load
FM 355/455 operator parameters
to FM 355/455” is
set, the operator
parameters are
downloaded to the
module and the
in/out parameter
reset.
44.2 READ_VAR BOOL Read variables FALSE If the in/out -
from FM 355/455 parameter “Read
variables from
FM 355/455” is set,
the output
parameters are read
from the module and
the in/out parameter
is reset.
44.3 LOAD_PAR BOOL Load control FALSE If the in/out -
parameter to parameter “Load
FM 355/455 control parameters to
FM 355/455” is set,
the control
parameters are
downloaded to the
module and the
in/out parameter
reset.

Controller Module FM 455

11-12 A5E00059359-02
 Assignment of the Data Blocks

Table 11-3 In/Out Parameters of the Instance DB for the FB PID_FM, continued

Add. Parameter Data Comment Permitted Default Explanation Param.

Type Value Range Dialog
Box
46.0 op_par WORD Beginning of W#16#3130 W#16#3 The parameter -
operation 130 op_par may not be
parameters changed by the user.
It identifies the
2) beginning of the
operating
parameters which
transferred to the
module when
LOAD_OP = TRUE
is set. The end of the
operating
parameters is
identified by
cont_par.

48.0 SP_RE REAL External setpoint Technical range of 0.0 An external setpoint -
values is connected to the
(physical variable) controller at the input
“External setpoint”.
52.0 LMN_RE REAL External -100.0...100.0 (%) 0.0 An external -
manipulated manipulated value is
value interconnected to the
controller at the input
“External
manipulated value”.
56.0 SP_OP_ON BOOL Setpoint operation FALSE The configuration -
on tool has access to
the in/out parameter
1) “Setpoint operation
on”. If the bit is set,
the value SP_OP is
used as the setpoint.
56.1 SAFE_ON BOOL Setpoint FALSE If the input “safety -
operation on position on” is set, a
safety value is used
as the manipulated
value.
56.2 LMNOP_ON BOOL Manipulated FALSE The configuration -
value operation tool has access to
on the in/out parameter
1) “Manipulated value
operation on”. If the
bit is set, the value
LMN_OP is used as
the manipulated
value.

Controller Module FM 455

A5E00059359-02 11-13
Assignment of the Data Blocks

Table 11-3 In/Out Parameters of the Instance DB for the FB PID_FM, continued

Add. Parameter Data Comment Permitted Default Explanation Param.

Type Value Range Dialog
Box
56.3 LMNTRKON BOOL Track (LMN from FALSE If the input “Track -
analog input) (LMN from analog
input)” is set, the
manipulated value is
tracked to an analog
input (AI).
(Not for step
controllers without
analog position
feedback)
56.4 LMN_REON BOOL External FALSE If the input “External -
manipulated manipulated value
value on on” is set, the
external manipulated
value LMN_RE is
used as the
manipulated value.
56.5 LMNRHSRE BOOL High limit signal FALSE The signal “Control -
of repeated valve at upper end
manipulated stop” is
value interconnected at the
input “High limit
signal of position
feedback”.
LMNRHSRE =
TRUE means: the
control valve is at the
upper end stop.
(For step controllers
only)
56.6 LMNRLSRE BOOL Low limit signal of FALSE The signal “Control -
repeated valve at lower end
manipulated stop” is connected at
value the input “Low limit
signal of position
feedback”.
LMNRLSRE = TRUE
means: the control
valve is at the lower
end stop.
(For step controllers
only)
56.7 LMNSOPON BOOL Manipulated FALSE If the bit at the input -
signal operation “Manipulated value
on signal operation on”
1) is set, the signals
LMNUP_OP and
LMNDN_OP are
used as manipulated
value signals.
(For step controllers
only)

Controller Module FM 455

11-14 A5E00059359-02
 Assignment of the Data Blocks

Table 11-3 In/Out Parameters of the Instance DB for the FB PID_FM, continued

Add. Parameter Data Comment Permitted Default Explanation Param.

Type Value Range Dialog
Box
57.0 LMNUP_OP BOOL Manipulated FALSE If LMNSOPON is -
signal up set, the value at the
operation input “Manipulated
1) value signal up
operation” is used as
the manipulated
value signal.
(For step controllers
only)
57.1 LMNDN_OP BOOL Manipulated FALSE If LMNSOPON is -
signal down set, the value at the
operation input “Manipulated
1) value signal down
operation” is used as
the manipulated
value signal.
(For step controllers
only)

Controller Module FM 455

A5E00059359-02 11-15
Assignment of the Data Blocks

Table 11-3 In/Out Parameters of the Instance DB for the FB PID_FM, continued

Add. Parameter Data Comment Permitted Default Explanation Param.

Type Value Range Dialog
Box
57.3 LMNRS_ON BOOL Simulation of the FALSE If there is no position -
repeated feedback, this can
manipulated be simulated. The
value on function is switched
on at the input
“Simulation of the
position feedback
on”. The
configuration tool
(controller
optimization) has
access to this
parameter since at
least one simulated
manipulated value is
required for
optimization if a step
controller was
configured without
position feedback.
The simulated value
is displayed at
parameter LMN_A.
When the simulation
is activated the value
of the parameter
LMNRSVAL is set as
the starting value.
CAUTION: The
simulation deviates
increasingly from the
real position
feedback as time
passes.
(For step controllers
without analog
position feedback
only)
57.4 FUZID_ON BOOL Fuzzy FALSE Identification of the -
identification on fuzzy algorithm is
switched on at the
input “Fuzzy
identification on”.
58.0 SP_OP REAL Setpoint Technical range of 0.0 The configuration -
operation values tool (controller
(physical variable) optimization) has
1) access to the in/out
parameter “Setpoint
operation”. If the bit
SP_OP_ON is set,
the value “Setpoint
operation” is used as
the setpoint.

Controller Module FM 455

11-16 A5E00059359-02
 Assignment of the Data Blocks

Table 11-3 In/Out Parameters of the Instance DB for the FB PID_FM, continued

Add. Parameter Data Comment Permitted Default Explanation Param.

Type Value Range Dialog
Box
62.0 LMN_OP REAL Manipulated -100.0...100.0 (%) 0.0 The configuration -
value operation tool has access to
the in/out parameter
1) “Manipulated value
operation”. If the bit
LMNOP_ON is set,
the value
“Manipulated value
operation” is used as
the manipulated
value.
66.0 LMNRSVAL REAL Start value of the -100.0...100.0 (%) 0.0 The configuration -
repeated tool (controller
manipulated optimization) has
value in access to the input
simulation “Start value of the
position feedback in
simulation”. The start
value for the
simulation is entered
in the parameter.
(For step controllers
without analog
position feedback
only)
70.0 cont_par WORD Beginning of W#16#3130 W#16#3 The parameter -
control 130 cont_par may not be
parameters changed by the user.
It identifies the
2) beginning of the
controller parameters
which are read from
the FM and saved in
the instance DB if
COM_RST = TRUE
and which are
transferred to the FM
if LOAD_PAR =
TRUE is set. The
end of the controller
parameters is the
end of the instance
DB.
72.0 P_SEL BOOL P action on TRUE In the PID algorithm PID
the PID components Controller
can be switched on
2) and off separately.
The proportional
component is
switched on if the
input “P action on” is
set.

Controller Module FM 455

A5E00059359-02 11-17
Assignment of the Data Blocks

Table 11-3 In/Out Parameters of the Instance DB for the FB PID_FM, continued

Add. Parameter Data Comment Permitted Default Explanation Param.

Type Value Range Dialog
Box
72.1 PFDB_SEL BOOL P action in FALSE In the PID algorithm PID
feedback path the P and D actions Controller
can be placed in the
2) feedback path. The P
action is in the
feedback path if the
input “P action in
feedback path” is set.
72.2 MONERSEL BOOL Monitoring: FALSE The controller has a Alarm
Process limit value alarm that controller
variable = 0 Error can either be used
signal = 1 2) for the process
variable or the error
signal. If the input
“Monitoring: Process
variable = 0, Error
signal = 1” is set, the
error signal is
monitored.
74.0 D_EL_SEL INT D-element input 0 to 17 0 The D element in the Error
for the controller PID algorithm can be Signal
applied at a separate (...)
2) input. This is Controller
selected via the input
“D element input for
the controller”.

0: Error signal
1 to 16: Analog input
1 to 16
17: Negative
process
value,
derivative
component
in feedback
76.0 SP_HLM REAL Setpoint high limit > SP_LLM 100.0 The setpoint is Limit
(physical variable) always limited to an Setpoint
upper and a lower Controller
2) limit. The input
“setpoint high limit”
determines the upper
limit.
80.0 SP_LLM REAL Setpoint low limit < SP_HLM 0.0 The setpoint is Limit
(physical variable) always limited to an Setpoint
upper and a lower Controller
2) limit. The input
“Setpoint low limit”
determines the lower
limit.

Controller Module FM 455

11-18 A5E00059359-02
 Assignment of the Data Blocks

Table 11-3 In/Out Parameters of the Instance DB for the FB PID_FM, continued

Add. Parameter Data Comment Permitted Default Explanation Param.

Type Value Range Dialog
Box
84.0 H_ALM REAL High limit alarm > H_WRN 100.0 Four limits can be Alarm
(physical variable) set for monitoring the controller
actual value or the
2) error signal. The
input “High limit
alarm” determines
the upper limit.
88.0 H_WRN REAL High limit warning H_ALM...L_WRN 90.0 Four limits can be Alarm
(physical variable) set for monitoring the controller
actual value or the
2) error signal. The
input “High limit
warning” determines
the secondary upper
limit.
92.0 L_WRN REAL Low limit warning H_WRN...L_ALM 10.0 Four limits can be Alarm
(physical variable) set for monitoring the controller
actual value or the
2) error signal. The
input “Low limit
warning” determines
the secondary lower
limit.
96.0 L_ALM REAL Low limit alarm < L_WRN 0.0 Four limits can be set Alarm
(physical variable) for monitoring the controller
actual value or the
2) error signal. The
input “Low limit
alarm” determines
the lower limit.
100.0 HYS REAL Hysteresis ≥ 0.0 1.0 To avoid flickering of Alarm
(physical variable) the watchdog LEDs, controller
a hysteresis can be
2) set at the input
“hysteresis”.
104.0 DEADB_W REAL Dead band width ≥ 0.0 0.0 The error signal is Dead
(physical variable) fed via a dead band. Band
The input “dead band Controller
2) width” determines
the width of the dead
band.
108.0 GAIN REAL Proportional gain Entire range of 1.0 The input PID
values “Proportional gain” Controller
(no dimension) determines the
2) controller gain.

Controller Module FM 455

A5E00059359-02 11-19
Assignment of the Data Blocks

Table 11-3 In/Out Parameters of the Instance DB for the FB PID_FM, continued

Add. Parameter Data Comment Permitted Default Explanation Param.

Type Value Range Dialog
Box
112.0 TI REAL Reset time (s) = 0.0 or ≥ 0.5 3000.0 The input “Reset PID
Integration time time” determines the Controller
time response of the
2) integrating action
element.
If TI = 0, the
integrating action
element is
deactivated
116.0 TD REAL Derivative action = 0.0 or ≥ 1.0 0.0 The input “Derivative PID
time (s) action time” Controller
determines the time
2) response of the
derivative action
element. If TD = 0
the D element is
switched off.
120.0 TM_LAG REAL Time lag of the TM_LAG≥ 0.5 5.0 The algorithm of the PID
derivative action D component Controller
(s) contains a time lag
2) that can be set at the
input “Time lag of the
derivative action”.
124.0 LMN_SAFE REAL Safety -100.0...100.0 (%) 0.0 A safety value can Switch
manipulated be set for the Safety
value manipulated value at Manipulat
2) the input “Safety ed Value
manipulated value”. Controller
128.0 LMN_HLM REAL Manipulated LMN_LLM...100,0 100.0 The manipulated Limit
value high limit (%) value is always Manipulat
limited to an upper ed Value
2) and a lower limit. The Controller
input “Manipulated
value high limit”
determines the upper
limit.
(Not for step
controllers without
analog position
feedback)
132.0 LMN_LLM REAL Manipulated -100,0..LMN_HLM 0.0 The manipulated Limit
value low limit (%) value is always Manipulat
limited to an upper ed Value
2) and a lower limit. The Controller
input “Manipulated
value low limit”
determines the lower
limit.
(Not for step
controllers without
analog position
feedback)

Controller Module FM 455

11-20 A5E00059359-02
 Assignment of the Data Blocks

Table 11-3 In/Out Parameters of the Instance DB for the FB PID_FM, continued

Add. Parameter Data Comment Permitted Default Explanation Param.

Type Value Range Dialog
Box
136.0 MTR_TM REAL Motor actuating MTR_TM≥ 0.001 60.0 The run time of the Pulse
time (s) control valve from Shaper
end stop to end stop Controller
2) is entered at the
parameter “Motor
actuating time”.
(For step controllers
only)
140.0 PULSE_TM REAL Minimum pulse ≥ 0.0 0.2 A minimum pulse Pulse
time (s) duration can be set Shaper
with the parameter Controller
2) “Minimum pulse Split-rang
time”. e/Pulse
(For step controllers Shaper
or pulse controllers Controller
only)
144.0 BREAK_TM REAL Minimum break ≥ 0.0 0.2 A minimum pulse Pulse
time (s) pause duration can Shaper
be set with the Controller
2) parameter “Minimum Split-rang
pause time”. e/Pulse
(For step controllers Shaper
or pulse controllers Controller
only)

1) You can also change these parameters via the loop display.
2) Initial value of the module after the first startup of the FB PID_FM with COM_RST = TRUE

Note
If LOAD_PAR = TRUE is set, all the control parameters are loaded permanently to
the EEPROM of the FM 455.
If LOAD_OP = TRUE is set, only the setpoint SP_RE of the operator parameters
is loaded permanently to the EEPROM of the FM 455. All the other operator
parameters have the values 0 or FALSE pre-assigned during the FM 455 startup.:
The EEPROM of the module could be destroyed by excessive writing processes.
In order to prevent this the module delays renewed writing to the EEPROM by
30 minutes.

Controller Module FM 455

A5E00059359-02 11-21
Assignment of the Data Blocks

11.2 Instance DB of the FB FUZ_455

The FB FUZ_455 is used to read out the controller parameters of the fuzzy
temperature controller from the FM 455. You can then, for example, transfer these
parameters back to the module after you have replaced the FM 455.

Note
You may not change the parameters determined through identification by the
FM 455 since they have been optimized for the process.

The following tables list the input parameters (Table 11-4) and the output
parameters (Table 11-5) of the instance DB.

Table 11-4 Input Parameters of the Instance DB for the FB FUZ_455

Add. Parameter Data Comment Permitted Default Explanation Param.

Type Value Range Dialog
Box
0.0 MOD_ADDR INT Module address 512 This input contains -
FM 355/455 the module address
that resulted from the
configuration set
under STEP 7.

Table 11-5 Output Parameters of the Instance DB for the FB FUZ_455

Add. Parameter Data Comment Permitted Default Explanation Param.

Type Value Range Dialog
Box
2.0 RET_VALU WORD Return value 0 RET_VALU contains -
SFC 58/59 the return value
RET_VAL of the
SFC58/59.
RET_VALU can be
evaluated if an error
is reported via
QMOD_F (see
Reference Manual
/2/).

Controller Module FM 455

11-22 A5E00059359-02
 Assignment of the Data Blocks

Table 11-5 Output Parameters of the Instance DB for the FB FUZ_455, continued

Add. Parameter Data Comment Permitted Default Explanation Param.

Type Value Range Dialog
Box
4.0 PARAFFUZ WORD Parameter fault 0 A parameter -
display assignment error
created by the FB
FUZ_455 is
displayed at the
parameter
PARAFFUZ as
follows:
High byte of
PARAFFUZ = 01:
There is a parameter
assignment error.
High byte of
PARAFFUZ= 00:
There is no
parameter
assignment error.
The low byte
contains the offset of
the parameter which
caused the
parameter
assignment error,
calculated from the
static variables
FUZ_PAR[1].

6.0 READ_PAR BOOL Read fuzzy FALSE If the parameter -

parameters READ_PAR is set,
the fuzzy parameters
are read from the
module and saved in
the static variable of
the instance DB.
6.1 LOAD_PAR BOOL Write fuzzy FALSE If the parameter -
parameters LOAD_PAR is set,
the fuzzy parameters
are read from the
static variable of the
instance DBs and
transferred to the
module.

Controller Module FM 455

A5E00059359-02 11-23
Assignment of the Data Blocks

11.3 Instance DB of the FB FORCE455

The FB FORCE455 is required to simulate analog or digital input values of the

FM 455.
The following tables list the input parameters (Table 11-6) and the output
parameters (Table 11-7) of the instance DB.

Table 11-6 Input Parameters of the Instance DB for the FB FORCE455

Add. Parameter Data Comment Permitted Default Explanation Param.

Type Value Range Dialog
Box
0.0 S_AION ARRAY Switch: FALSE If, e.g., the switch -
[1..16] Simulation of the S_AION[1] is set to
of analog input by TRUE, the value
BOOL PV_SIM PV_SIM[1] is used
instead of the analog
input value 1 of the
module (refer to
Figure 7-14 on
Page 7-18).
2.0 S_PVON ARRAY Switch: FALSE If, e.g., the switch -
[1..16] Simulation of S_PVON[1] is set to
of linearized analog TRUE, the value
BOOL input by PV_SIM PV_SIM[1] is used
instead of the
conditioned analog
input value 1 of the
module (refer to
Figure 7-14 on
Page 7-18).
4.0 PV_SIM ARRAY Simulated analog 0.0 to 20.0 [mA] or 0.0 The simulation value -
[1..16] input value -1500 to for the analog input 1
of +10000 [mV] or is, for example
REAL technical range of specified at the input
values PV_SIM[1]. If
S_PVON = TRUE
ist, the conditioned
analog input value is
specified here. If
S_PVON = FALSE
and S_AION =
TRUE, the analog
input value is
specified in mA or
mV here. This is then
still converted to a
conditioned value by
the conditioning
functions.

Controller Module FM 455

11-24 A5E00059359-02
 Assignment of the Data Blocks

Table 11-6 Input Parameters of the Instance DB for the FB FORCE455, continued

Add. Parameter Data Comment Permitted Default Explanation Param.

Type Value Range Dialog
Box
68.0 S_DION ARRAY Switch: FALSE If, for example, -
[1..16] Simulation of S_DION[1] is set to
of digital input by true, the value
BOOL DI_SIM DI_SIM[1] is used as
the digital value
70.0 DI_SIM ARRAY Simulated digital FALSE instead of the digital -
[1..16] input value input 1.
of (refer to Figure 7-14
BOOL on Page 7-18).

72.0 MOD_ADDR INT Module address 256 This input contains -

FM 355/455 the module address
that resulted from the
configuration set
under STEP 7.

Table 11-7 Output parameters of the instance DB for the FB FORCE455

Add. Parameter Data Comment Permitted Default Explanation Param.

Type Value Range Dialog
Box
74.0 RET_VALU WORD Return value 0 RET_VALU contains -
SFC 58/59 the return value
RET_VAL of the
SFC58/59.
RET_VALU can be
evaluated if an error
is reported via
QMOD_F (see
Reference Manual
/2/).

Controller Module FM 455

A5E00059359-02 11-25
Assignment of the Data Blocks

11.4 Instance DB of the FB READ_455

The FB READ_455 is required to read analog or digital input values from the
FM 455.
The following tables list the input parameters (Table 11-8) and the output
parameters (Table 11-9) of the instance DB.

Table 11-8 Input Parameters of the Instance DB for the FB READ_455

Add. Parameter Data Comment Permitted Default Explanation Param.

Type Value Range Dialog
Box
0.0 MOD_ADDR INT Module address 512 This input contains -
FM 355/455 the module address
that resulted from the
configuration set
under STEP 7.

Table 11-9 Output Parameters of the Instance DB for the FB READ_455

Add. Parameter Data Comment Permitted Default Explanation Param.

Type Value Range Dialog
Box
2.0 CJ_TEMP REAL Reference 0.0 The reference -
junction junction temperature
temperature measured by the
Cold junction module is displayed
temperature at the output
CJ_TEMP if a
thermoelement input
was configured and
the reference
junction temperature
was not specified
configured.
6.0 STAT_DI ARRAY Status of digital FALSE The states of the -
[1..16] inputs 1 to 8 digital inputs 1 to 8
of are displayed at the
BOOL STAT_DI
parameters.
(Chan DIAG[x].PV_ ARRAY Analog input 0.0 The analog input -
nel PER [1..16] (0 to 20mA, -1500 value of the module
numbe of to 10000 mV) is displayed in the
r)× 8 STRUCT unit mA or mV at the
parameter
DIAG[1].PV_PER.

Controller Module FM 455

11-26 A5E00059359-02
 Assignment of the Data Blocks

Table 11-9 Output Parameters of the Instance DB for the FB READ_455, continued

Add. Parameter Data Comment Permitted Default Explanation Param.

Type Value Range Dialog
Box
(Chan DIAG[x].PV_ ARRAY Linearized analog 0.0 The conditioned -
nel PHY [1..16] input as a analog input value of
numbe of physical unit the module is, for
r) × 8 STRUCT example, displayed
+4 as an engineering
unit at the parameter
DIAG[1].PV_PHY.
136.0 RET_VALU WORD Return value 0 RET_VALU contains -
SFC 58/59 the return value
RET_VAL of the
SFC58/59.
RET_VALU can be
evaluated if an error
is reported via
QMOD_F (see
Reference Manual
/2/).

Controller Module FM 455

A5E00059359-02 11-27
Assignment of the Data Blocks

11.5 Instance DB of the FB CH_DIAG

The FB CH_DIAG is needed to read out additional channel-specific diagnostic

variables from the module.
The following tables list the input parameters (Table 11-10) and the output
parameters (Table 11-11) of the instance DB.

Table 11-10 Input Parameters of the Instance DB for the FB CH_DIAG

Add. Parameter Data Comment Permitted Default Explanation Param.

Type Value Range Dialog
Box
0.0 MOD_ADDR INT Module address 256 This input contains -
FM 355/455 the module address
that resulted from the
configuration set
under STEP 7.
2.0 CHANNEL INT Channel number 1 to 16 1 At the input “channel -
number” you can set
the number of the
controller channel to
which the instance
DB is to refer.
4.0 SP_R REAL Setpoint ratio 0.0 The input value of -
the setpoint value is
assigned to the
parameter when the
ratio controller is set.
8.0 PV_R REAL Process variable 0.0 The following value -
ratio is only assigned to
the parameter value
if the ratio controller
is set. (Process
variable A – Setpoint
value offset) /
Process variable D
12.0 DIF_I REAL Derivative unit 0.0 The input variable of -
input the derivative
component is
displayed at the
parameter DIF_I.
This is, for example,
of interest if an
analog input is
configured as the
input variable of the
derivative
component.

Controller Module FM 455

11-28 A5E00059359-02
 Assignment of the Data Blocks

Table 11-10 Input Parameters of the Instance DB for the FB CH_DIAG, continued

Add. Parameter Data Comment Permitted Default Explanation Param.

Type Value Range Dialog
Box
16.0 TRACKPER REAL Input value for 0.0 The parameter -
LMN tracking TRACKPER displays
the input variable to
which the
manipulated variable
is tracked when the
controller is switched
to manipulated
variable tracking.
20.0 IDSTATUS WORD Status of 0.0 This parameter is -
identification described on
Page 3-48 of
Section 3.8
22.0 LMN_P REAL Proportional 0.0 The proportional -
component component of the
manipulated variable
is displayed at the
parameter LMN_P.
26.0 LMN_I REAL Integral 0.0 The integral -
component component of the
manipulated variable
is displayed at the
parameter LMN_I.
30.0 LMN_D REAL Derivative 0.0 The derivative -
component component of the
manipulated variable
is displayed at the
parameter LMN_D.

Table 11-11 Output Parameters of the Instance DB for the FB CH_DIAG

Add. Parameter Data Comment Permitted Default Explanation Param.

Type Value Range Dialog
Box
34.0 RET_VALU WORD Return value 0 RET_VALU contains -
SFC 58/59 the return value
RET_VAL of the
SFC58/59.
RET_VALU can be
evaluated if an error
is reported via
QMOD_F (see
Reference Manual
/2/).

Controller Module FM 455

A5E00059359-02 11-29
Assignment of the Data Blocks

11.6 Instance DB of the FB PID_PAR

The FB PID_PAR is used to change parameters online which are not contained in
FB PID_FM.
The following tables list the input parameters (Table 11-12) and the output
parameters (Table 11-13) of the instance DB.

Table 11-12 Input Parameters of the Instance DB for the FB PID_PAR

Add. Parameter Data Comment Permitted Default Explanation Param.

Type Value Range Dialog
Box
0.0 COM_RST BOOL Read parameters TRUE If the parameter -
from system data COM_RST = TRUE,
the FB PID_PAR
carries out an
initialization run. In
the process the
parameters are read
from the system data
of the CPU and
saved in the
Instance DB.
2.0 MOD_ADDR INT Module address 256 This input contains -
FM 355/455 the module address
that resulted from the
configuration set
under STEP 7.
4.0 CHANNEL INT Channel number 1 to 16 1 At the input “channel -
number” you can set
the number of the
controller channel to
which the instance
DB is to refer.
6.0 INDEX_R INT Index for REAL 0 to 48 0.0 Refer to Section 7.6 -
parameter
8.0 VALUE_R REAL Value for REAL Depending on the 0.0 Refer to Section 7.6 -
parameter respective
parameter

12.0 INDEX_I INT Index for INT 0, 49 to 61 0.0 Refer to Section 7.6 -
parameter
14.0 VALUE_I INT Value for INT Depending on the 0.0 Refer to Section 7.6 -
parameter respective
parameter

Controller Module FM 455

11-30 A5E00059359-02
 Assignment of the Data Blocks

Table 11-13 Output Parameters of the Instance DB for the FB PID_PAR

Add. Parameter Data Comment Permitted Default Explanation Param.

Type Value Range Dialog
Box
16.0 RET_VALU WORD Return value 0 RET_VALU contains -
SFC 58/59 the return value
RET_VAL of the
SFC58/59.
RET_VALU can be
evaluated if an error
is reported via
QMOD_F (see
Reference Manual
/2/).
18.0 BUSY BOOL BUSY value of FALSE If BUSY = TRUE, the -
SFC WR_REC parameters have not
yet been taken over
by the module.
Calling the FB
PID_PAR should
then be repeated in
the next cycle.

Controller Module FM 455

A5E00059359-02 11-31
Assignment of the Data Blocks

11.7 Instance DB of the FB CJ_T_PAR

The FB JC_T_PAR is used to change the configured reference junction
temperature on the module on-line.
The following tables list the input parameters (Table 11-14) and the output
parameters (Table 11-15) of the instance DB.

Table 11-14 Input Parameters of the Instance DB for the FB CJT_T_PAR

Add. Parameter Data Comment Permitted Default Explanation Param.

Type Value Range Dialog
Box
0.0 COM_RST BOOL Read parameters - If the parameter -
from system data COM_RST = TRUE,
the FB CJ_T_PAR
carries out an
initialization run. In
the process the
parameters are read
from the system data
of the CPU and
saved in the
Instance DB.
2.0 MOD_ADDR INT Module address 256 This input contains -
FM 355/455 the module address
that resulted from the
configuration set
under STEP 7.
4.0 CJ_T REAL Reference Depending on the 0.0 The reference -
junction sensor type junction temperature
temperature can be specified via
Cold junction the parameter CJ_T.
temperature

Controller Module FM 455

11-32 A5E00059359-02
 Assignment of the Data Blocks

Table 11-15 Output Parameters of the Instance DB for the FB CJ_T_PAR

Add. Parameter Data Comment Permitted Default Explanation Param.

Type Value Range Dialog
Box
8.0 RET_VALU WORD Return value 0 RET_VALU contains -
SFC 58/59 the return value
RET_VAL of the
SFC58/59.
RET_VALU can be
evaluated if an error
is reported via
QMOD_F (see
Reference Manual
/2/).
10.0 BUSY BOOL BUSY value of FALSE If BUSY = TRUE, the -
SFC WR_REC parameters have not
yet been taken over
by the module.
Calling the FB
PID_PAR should
then be repeated in
the next cycle.

Controller Module FM 455

A5E00059359-02 11-33
Assignment of the Data Blocks

11.8 Allocation of the DBs for Operator Control and Monitoring via
OP

In order to allow operator control and monitoring of the FM 455 via an OP the
variable interface of the FM 455 contains four data blocks with the block
numbers 101 to 116 for the controller channels 1 to 16.
The following tables list the parameters of these data blocks:
• Input parameters (Table 11-16)
• Output parameters (Table 11-17 on Page 11-42)
• In/out parameters (Table 11-18 on Page 11-50)

Table 11-16 Input Parameters of the DBs for Operator Control and Monitoring

Add. Parameter Data Comment Permitted Default Explanation Param.

Type Value Range Dialog
Box
0.0 SP_HLM REAL Setpoint high limit > SP_LLM 100.0 The setpoint is Limit
(physical variable) always limited to an Setpoint
upper and a lower Controller
1) limit. The input
“setpoint high limit”
determines the upper
limit.
4.0 SP_LLM REAL Setpoint low limit < SP_HLM 0.0 The setpoint is Limit
(physical variable) always limited to an Setpoint
upper and a lower Controller
1) limit. The input
“Setpoint low limit”
determines the lower
limit.
8.0 H_ALM REAL High limit alarm > H_WRN 100.0 Four limits can be Alarm
(physical variable) set for monitoring the controller
actual value or the
1) error signal. The
input “High limit
alarm” determines
the upper limit.
12.0 H_WRN REAL High limit warning H_ALM...L_WRN 90.0 Four limits can be Alarm
(physical variable) set for monitoring the controller
actual value or the
1) error signal. The
input “High limit
warning” determines
the secondary upper
limit.

Controller Module FM 455

11-34 A5E00059359-02
 Assignment of the Data Blocks

Table 11-16 Input Parameters of the DBs for Operator Control and Monitoring, continued

Add. Parameter Data Comment Permitted Default Explanation Param.

Type Value Range Dialog
Box
16.0 L_WRN REAL Low limit warning H_WRN...L_ALM 10.0 Four limits can be Alarm
(physical variable) set for monitoring the controller
actual value or the
1) error signal. The
input “Low limit
warning” determines
the secondary lower
limit.
20.0 L_ALM REAL Low limit alarm < L_WRN 0.0 Four limits can be Alarm
(physical variable) set for monitoring the controller
actual value or the
1) error signal. The
input “Low limit
alarm” determines
the lower limit.
24.0 HYS REAL Hysteresis ≥ 0.0 1.0 To avoid flickering of Alarm
(physical variable) the watchdog LEDs, controller
a hysteresis can be
1) set at the input
“hysteresis”.
28.0 DEADB_W REAL Dead band width ≥ 0.0 0.0 The error signal is Dead
(physical variable) fed via a dead band. Band
The input “dead band Controller
1) width” determines
the width of the dead
band.
32.0 GAIN REAL Proportional gain Entire range of 1.0 The input PID
values “Proportional gain” Controller
(no dimension) determines the
1) controller gain.
36.0 TI REAL Reset time (s) = 0.0 or ≥ 0.5 3000.0 The input “Reset PID
Integration time time” determines the Controller
time response of the
1) integrating action
element. If TI = 0, the
integrating action
element is
de-activated
40.0 TD REAL Derivative action = 0.0 or ≥ 1.0 0.0 The input “Derivative PID
time (s) action time” Controller
determines the time
1) response of the
derivative action
element. If TD = 0
the D element is
switched off.

Controller Module FM 455

A5E00059359-02 11-35
Assignment of the Data Blocks

Table 11-16 Input Parameters of the DBs for Operator Control and Monitoring, continued

Add. Parameter Data Comment Permitted Default Explanation Param.

Type Value Range Dialog
Box
44.0 TM_LAG REAL Time lag of the TM_LAG≥ 0.5 5.0 The algorithm of the PID
derivative action D component Controller
(s) contains a time lag
1) that can be set at the
input “Time lag of the
derivative action”.
48.0 LMN_SAFE REAL Safety -100.0...100.0 (%) 0.0 A safety value can Switch
manipulated be set for the Safety
value manipulated value at Manipu-
1) the input “Safety lated
manipulated value”. Value
Controller
52.0 LMN_HLM REAL Manipulated LMN_LLM...100,0 100.0 The manipulated Limit Ma-
value high limit (%) value is always nipulated
limited to an upper Value
1) and a lower limit. The Controller
input “Manipulated
value high limit”
determines the upper
limit.
(Not for step
controllers without
analog position
feedback)
56.0 LMN_LLM REAL Manipulated -100,0..LMN_HLM 0.0 The manipulated Limit Ma-
value low limit (%) value is always nipulated
limited to an upper Value
1) and a lower limit. The Controller
input “Manipulated
value low limit”
determines the lower
limit.
(Not for step
controllers without
analog position
feedback)
60.0 MTR_TM REAL Motor actuating MTR_TM≥ 0.001 60.0 The run time of the Pulse
time (s) control valve from Shaper
end stop to end stop Controller
1) is entered at the
parameter “Motor
actuating time”.
(For step controllers
only)

Controller Module FM 455

11-36 A5E00059359-02
 Assignment of the Data Blocks

Table 11-16 Input Parameters of the DBs for Operator Control and Monitoring, continued

Add. Parameter Data Comment Permitted Default Explanation Param.

Type Value Range Dialog
Box
64.0 PULSE_TM REAL Minimum pulse ≥ 0.0 0.2 A minimum pulse Pulse
time (s) duration can be set Shaper
with the parameter Controller
1) “Minimum pulse
time”.
Split-
(For step controllers range/
or pulse controllers Pulse
only) Shaper
Controller
68.0 BREAK_TM REAL Minimum break ≥ 0.0 0.2 A minimum pulse Pulse
time (s) pause duration can Shaper
be set with the Controller
1) parameter “Minimum
pause time”.
Split-
(For step controllers range/
or pulse controllers Pulse
only) Shaper
Controller
72.0 SP_RE REAL External setpoint Technical range of 0.0 An external setpoint -
values is connected to the
(physical variable) controller at the input
2) “External setpoint”.
76.0 LMN_RE REAL External -100.0...100.0 (%) 0.0 An external -
manipulated manipulated value is
value interconnected to the
2) controller at the input
“External
manipulated value”.
80.0 LMNRSVAL REAL Start value of the -100.0...100.0 (%) 0.0 The configuration -
repeated tool has access to
manipulated the input “Start value
2) value in of the position
simulation feedback in
simulation”. The start
value for the
simulation is entered
in the parameter.
(For step controllers
without analog
position feedback
only)
84.0 SAFE_ON BOOL Safety position on FALSE If the input “safety -
position on” is set, a
safety value is used
2) as the manipulated
value.

Controller Module FM 455

A5E00059359-02 11-37
Assignment of the Data Blocks

Table 11-16 Input Parameters of the DBs for Operator Control and Monitoring, continued

Add. Parameter Data Comment Permitted Default Explanation Param.

Type Value Range Dialog
Box
84.1 LMNTRKON BOOL Track (LMN from FALSE If the input “Track -
analog input) (LMN from analog
input)” is set, the
2) manipulated value is
tracked to an analog
input.
(Not for step
controllers without
analog position
feedback)
84.2 LMN_REON BOOL External FALSE If the input “External -
manipulated manipulated value
value on on” is set, the
2) external manipulated
value LMN_RE is
used as the
manipulated value.
84.3 LMNRHSRE BOOL High limit signal FALSE The signal “Control -
of repeated valve at upper end
manipulated stop” is
2) value interconnected at the
input “High limit
signal of position
feedback”.
LMNRHSRE =
TRUE means: the
control valve is at the
upper end stop.
(For step controllers
only)
84.4 LMNRLSRE BOOL Low limit signal of FALSE The signal “Control -
repeated valve at lower end
manipulated stop” is connected at
2) value the input “Low limit
signal of position
feedback”.
LMNRLSRE = TRUE
means: the control
valve is at the lower
end stop.
(For step controllers
only)
84.5 LMNSOPON BOOL Manipulated FALSE If the bit at the input -
signal operation “Manipulated value
on signal operation on”
2) is set, the signals
LMNUP_OP and
LMNDN_OP are
used as manipulated
value signals.
(For step controllers
only)

Controller Module FM 455

11-38 A5E00059359-02
 Assignment of the Data Blocks

Table 11-16 Input Parameters of the DBs for Operator Control and Monitoring, continued

Add. Parameter Data Comment Permitted Default Explanation Param.

Type Value Range Dialog
Box
84.6 LMNUP_OP BOOL Manipulated FALSE If LMNSOPON is -
signal up set, the value at the
operation input “Manipulated
2) value signal up
operation” is used as
the manipulated
value signal.
(For step controllers
only)
84.7 LMNDN_OP BOOL Manipulated FALSE If LMNSOPON is -
signal down set, the value at the
operation input “Manipulated
2) value signal down
operation” is used as
the manipulated
value signal.
(For step controllers
only)
85.0 MONERSEL BOOL Monitoring: FALSE The controller has a Alarm
Process limit value alarm that controller
variable = 0 can either be used
1) Error signal = 1 for the process
variable or the error
signal. If the input
“Monitoring: Process
variable = 0, Error
signal = 1” is set, the
error signal is
monitored.
85.1 LMNRS_ON BOOL Simulation of the FALSE If there is no position -
repeated feedback, this can
manipulated be simulated. The
2) value on function is switched
on at the input
“Simulation of the
position feedback
on”.
CAUTION: The
simulation deviates
increasingly from the
real position
feedback as time
passes.
(For step controllers
without analog
position feedback
only)

85.2 FUZID_ON BOOL Fuzzy FALSE Identification of the -

identification on fuzzy algorithm is
switched on at the
2) input “Fuzzy
identification on”.

Controller Module FM 455

A5E00059359-02 11-39
Assignment of the Data Blocks

Table 11-16 Input Parameters of the DBs for Operator Control and Monitoring, continued

Add. Parameter Data Comment Permitted Default Explanation Param.

Type Value Range Dialog
Box
85.3 SPINT_EN BOOL Operator input: FALSE The input “Operator -
External = 0 input: External = 0,
Internal = 1 Internal = 1”
2) determines the input
that is transferred to
the module as the
setpoint.
SPINT_EN = TRUE:
SP_INT is
transferred.
SPINT_EN =
FALSE: SP_RE is
transferred.
85.4 P_SEL BOOL P action on TRUE In the PID algorithm PID
the PID components Controller
can be switched on
1) and off separately.
The proportional
component is
switched on if the
input “P action on” is
set.
85.5 PFDB_SEL BOOL P action in FALSE In the PID algorithm PID
feedback path the P and D actions Controller
can be placed in the
1) feedback path. The
P action is in the
feedback path if the
input “P action in
feedback path” is
set.
86.0 D_EL_SEL INT D element input 0 to 17 0 The D element in the Error
for the controller PID algorithm can be Signal
applied at a separate (...)
1) input. This is Controller
selected via the input
“D element input for
the controller”.

0: Error signal
1 to 16: Analog input
1 to 16
17: Negative
process
variable

1) Control parameters: Control parameters are downloaded to the module if the in/out parameter
LOAD_PAR is set.
All control parameters are loaded permanently into the EEPROM of the FM 455.
2) Operator parameters: Operator parameters are downloaded to the module if the in/out parameter
LOAD_OP is set.

Controller Module FM 455

11-40 A5E00059359-02
 Assignment of the Data Blocks

Of the operator parameters only the setpoint SP_RE is loaded permanently into the
EEPROM. All the other operator parameters have the values 0 or FALSE
preassigned during the FM 455 startup.

Note
The EEPROM of the module could be destroyed by excessive writing processes.
In order to prevent this the module delays renewed writing to the EEPROM by 30
minutes.

Controller Module FM 455

A5E00059359-02 11-41
Assignment of the Data Blocks

Table 11-17 Output Parameters of the DBs for Operator Control and Monitoring

Add. Parameter Data Comment Permitted Default Explanation Param.

Type Value Range Dialog
Box
94.0 SP REAL Setpoint value Technical range of 0.0 The effective -
values setpoint is output at
(physical variable) the “Setpoint” output.

98.0 PV REAL Process variable Technical range of 0.0 The effective actual -
values value is output at the
(physical variable) “Process variable”
output.
102.0 ER REAL Error signal Technical range of 0.0 The effective error -
values signal is output at the
(physical variable) “Error signal” output.

106.0 DISV REAL Disturbance -100.0...100.0 (%) 0.0 The effective -

variable disturbance variable
is output at the
“Disturbance
variable” output.
110.0 LMN REAL Manipulated -100.0...100.0 (%) 0.0 The effective -
value manipulated value is
output at the
“Manipulated value”
output. At a step
controller without
analog position
feedback the
unlimited P- +
D-component is
output at the
parameter LMN.
114.0 LMN_A REAL Manipulated -100.0...100.0 (%) 0.0 At the output -
value A of split “Manipulated value A
range function / of split-range
position feedback function / position
feedback” the
manipulated value A
of the split-range
function for a
continuous controller
and the position
feedback for a step
controller with analog
position feedback
are displayed.
The simulated
position feedback is
displayed for a step
controller without
analog position
feedback.

Controller Module FM 455

11-42 A5E00059359-02
 Assignment of the Data Blocks

Table 11-17 Output Parameters of the DBs for Operator Control and Monitoring, continued

Add. Parameter Data Comment Permitted Default Explanation Param.

Type Value Range Dialog
Box
118.0 LMN_B REAL Manipulated -100.0...100.0 (%) 0.0 At the output -
value B of split “Manipulated value B
range function of split-range
function” the
manipulated value B
of the split-range
function is displayed
for a continuous
controller.
122.0 QH_ALM BOOL High limit alarm FALSE The actual value or -
reached process variable is
monitored for four
limit values. If the
limit H_ALM is
violated, this is
indicated at the
output “High limit
alarm reached”.
122.1 QH_WRN BOOL High limit warning FALSE The actual value or -
reached process variable is
monitored for four
limit values. If the
limit H_WRN is
violated, this is
indicated at the
output “High limit
warning reached”.
122.2 QL_WRN BOOL Low limit warning FALSE The actual value or -
reached process variable is
monitored for four
limit values. If the
limit L_WRN is
violated, this is
indicated at the
output “Low limit
warning reached”.
122.3 QL_ALM BOOL Low limit alarm FALSE The actual value or -
reached process variable is
monitored for four
limit values. If the
limit L_ALM is
violated, this is
indicated at the
output “Low limit
alarm reached”.

Controller Module FM 455

A5E00059359-02 11-43
Assignment of the Data Blocks

Table 11-17 Output Parameters of the DBs for Operator Control and Monitoring, continued

Add. Parameter Data Comment Permitted Default Explanation Param.

Type Value Range Dialog
Box
122.4 QLMN_HLM BOOL High limit of FALSE The manipulated -
manipulated value is always
value reached limited to an upper
and a lower limit. The
output “High limit of
manipulated value
reached” indicates
that the upper limit
has been exceeded.
(Not for step
controllers without
analog position
feedback)
122.5 QLMN_LLM BOOL Low limit of FALSE The manipulated -
manipulated value is always
value reached limited to an upper
and a lower limit. The
output “Low limit of
manipulated value
reached” indicates
that the lower limit
has been undershot.
(Not for step
controllers without
analog position
feedback)
122.6 QSPINTON BOOL Internal setpoint FALSE The output “Internal -
on setpoint on” indicates
that SP_INT was
transferred to the
module.
123.0 QPARA_F BOOL Parameter FALSE The module checks -
assignment error parameters for
validity. A parameter
assignment error is
indicated at the
output “Parameter
assignment error”.
You can also read
out these parameter
assignment errors by
using the menu PLC
> Parameter
Assignment Error
of the parameter
assignment
interface.

Controller Module FM 455

11-44 A5E00059359-02
 Assignment of the Data Blocks

Table 11-17 Output Parameters of the DBs for Operator Control and Monitoring, continued

Add. Parameter Data Comment Permitted Default Explanation Param.

Type Value Range Dialog
Box
123.1 QCH_F BOOL Channel error FALSE The output “Channel -
error” is set if the
controller channel
cannot supply any
valid results.
“Channel error” (e.g.
wire break) is also
set if QPARA_F = 1
or QMOD_F = 1. If
QCH_F = TRUE, the
exact error
information can be
read out in the
diagnostics data
record DS1 of the
module.
(refer to Chapter 12)

123.2 QUPRLM BOOL Limit of positive FALSE The setpoint is -

setpoint limited in positive
inclination and negative
reached inclination. If the
output “Limit of
positive setpoint
inclination reached”
is set, the positive
setpoint inclination is
limited.
123.3 QDNRLM BOOL Limit of negative FALSE The setpoint is -
setpoint limited in positive
inclination and negative
reached inclination. If the
output “Limit of
negative setpoint
inclination reached”
is set, the negative
setpoint inclination is
limited.
123.4 QSP_HLM BOOL High limit of FALSE The setpoint is -
setpoint reached always limited to an
upper and a lower
limit. The output
“High limit of setpoint
reached” indicates
that the upper limit
has been exceeded.
123.5 QSP_LLM BOOL Low limit of FALSE The setpoint is -
setpoint reached always limited to an
upper and a lower
limit. The output
“Low limit of setpoint
reached” indicates
that the lower limit
has been undershot.

Controller Module FM 455

A5E00059359-02 11-45
Assignment of the Data Blocks

Table 11-17 Output Parameters of the DBs for Operator Control and Monitoring, continued

Add. Parameter Data Comment Permitted Default Explanation Param.

Type Value Range Dialog
Box
123.6 QSPOPON BOOL Setpoint FALSE The output “Setpoint -
operation on operation on”
indicates whether the
setpoint is being
operated via the
configuration tool
(loop monitor). If the
bit is set, the value
SP_OP is used as
the setpoint.
123.7 QLMNSAFE BOOL Safety operation FALSE If the output “Safety -
operation” is set, the
safety manipulated
value is output as the
manipulated value.
124.0 QLMNOPON BOOL Manipulated FALSE The output -
value operation “Manipulated value
on operation on”
indicates whether the
manipulated value is
being operated via
the configuration tool
(loop monitor). If the
bit is set, the value
LMN_OP is used as
the manipulated
value.
124.1 QLMNTRK BOOL Track FALSE The output “follow-up -
Follow-up operation” indicates
operation whether the
manipulated value is
matched via an
analog input.
124.2 QLMN_RE BOOL Manual = 1 FALSE The output -
Automatic = 0 “Manual = 1;
Automatic = 0”
indicates whether the
manipulated value is
set to the external
manipulated value
LMN_RE
(manual = 1) or not.

Controller Module FM 455

11-46 A5E00059359-02
 Assignment of the Data Blocks

Table 11-17 Output Parameters of the DBs for Operator Control and Monitoring, continued

Add. Parameter Data Comment Permitted Default Explanation Param.

Type Value Range Dialog
Box
124.3 QLMNR_HS BOOL High limit signal FALSE The output “High limit -
of repeated signal of position
manipulated feedback” indicates
value whether the control
valve is at its upper
limit. QLMNR_HS =
TRUE means: the
control valve is at the
upper end stop.
(For step controllers
only)
124.4 QLMNR_LS BOOL Low limit signal of FALSE The output “Low limit -
repeated signal of position
manipulated feedback” indicates
value whether the control
valve is at its lower
limit.
QLMNR_LS = TRUE
means: the control
valve is at the lower
end stop.
(For step controllers
only)
124.5 QLMNR_ON BOOL Repeated FALSE The output “Position -
manipulated feedback on”
value on indicates the set
Position feedback mode as either “Step
on controller with
position feedback” or
“Step controller
without position
feedback”.
124.6 QFUZZY BOOL PID algorithm = 0 FALSE If the output “PID -
Fuzzy = 1 algorithm = 0;
Fuzzy =1” is set, the
controller works with
the fuzzy algorithm.
124.7 QSPLEPV BOOL FUZZY-controller FALSE The output “Fuzzy -
display: Setpoint display: Setpoint <
value < Process actual value” is set
variable when the fuzzy
controller is switched
on if the setpoint is
smaller than the
effective process
variable.
125.0 QSPR BOOL Split range FALSE If the output -
operation “Split-range
operation” is set, the
continuous controller
operates in
split-range mode.

Controller Module FM 455

A5E00059359-02 11-47
Assignment of the Data Blocks

Table 11-17 Output Parameters of the DBs for Operator Control and Monitoring, continued

Add. Parameter Data Comment Permitted Default Explanation Param.

Type Value Range Dialog
Box
125.1 QLMNUP BOOL Manipulated FALSE This is the output -
signal up ”Manipulated signal
up”.
(For step controllers
or pulse controllers
only)
125.2 QLMNDN BOOL Manipulated FALSE This is the output -
signal down ”Manipulated signal
down”.
(For step controllers
or pulse controllers
only)
125.4 QBACKUP BOOL Back-up FALSE 0= No backup state -
operation (CPU in RUN)
1= Backup state
(CPU in STOP or
failed)

125.5 QID BOOL Identification FALSE QID = TRUE shows -

running that an identification
is running (not that it
is switched on). After
the end of
identification the
identification result
can be read out via
the parameter
IDSTATUS of the FB
CH_DIAG (refer to
Page 3-48 of
Section 3.8).

Controller Module FM 455

11-48 A5E00059359-02
 Assignment of the Data Blocks

Table 11-17 Output Parameters of the DBs for Operator Control and Monitoring, continued

Add. Parameter Data Comment Permitted Default Explanation Param.

Type Value Range Dialog
Box
125.6 QMAN_FC BOOL Follow-up FALSE The controller is a -
operation or master controller
anti-reset-windup which is tracked by
by secondary manual operation of
controller a secondary
controller is tracked
to its process
variable or whose
integral component
is halted because the
setpoint value or
manipulated variable
of the secondary
controller is in the
limitation.

126.0 RET_VALU INT Return value 0 RET_VALU contains -

SFC 58/59 the return value
RET_VAL of the
SFC58/59.
RET_VALU can be
evaluated if an error
is reported via
QMOD_F (see
Reference Manual
/2/).

Controller Module FM 455

A5E00059359-02 11-49
Assignment of the Data Blocks

Table 11-18 In/out Parameters of the DBs for Operator Control and Monitoring

Add. Parameter Data Comment Permitted Default Explanation Param.

Type Value Range Dialog
Box
128.0 SP_INT REAL Internal setpoint Technical range of 0.0 The in/out parameter -
values “Internal setpoint” is
(physical variable) used to assign a
setpoint using
operator interface
functions.
132.0 SP_OP REAL Setpoint Technical range of 0.0 The configuration -
operation values tool (loop monitor)
(physical variable) has access to the
2) in/out parameter
“Setpoint operation”.
If the bit SP_OP_ON
is set, the value
“Setpoint operation”
is used as the
setpoint.
136.0 LMN_OP REAL Manipulated -100.0...100.0 (%) 0.0 The configuration -
value operation tool (loop monitor)
has access to the
2) in/out parameter
“Manipulated value
operation”. If the bit
LMNOP_ON is set,
the value
“Manipulated value
operation” is used as
the manipulated
value.
140.0 SP_OP_ON BOOL Setpoint FALSE The configuration -
operation on tool (loop monitor)
has access to the
2) in/out parameter
“Setpoint operation
on”. If the bit is set,
the value SP_OP is
used as the setpoint.
140.1 LMNOP_ON BOOL Manipulated FALSE The configuration -
value operation tool (loop monitor)
on has access to the
2) in/out parameter
“Manipulated value
operation on”. If the
bit is set, the value
LMN_OP is used as
the manipulated
value.

Controller Module FM 455

11-50 A5E00059359-02
 Assignment of the Data Blocks

Table 11-18 In/out Parameters of the DBs for Operator Control and Monitoring, continued

Add. Parameter Data Comment Permitted Default Explanation Param.

Type Value Range Dialog
Box
140.2 LOAD_PAR BOOL Load control FALSE If the in/out -
parameter to parameter “Load
FM 355/455 control parameters to
FM 355/455” is set,
the control
parameters are
downloaded to the
module and the in/out
parameter reset.
140.3 LOAD_OP BOOL Load operator FALSE If the in/out -
parameter to parameter “Load
FM 355/455 operator parameters
to FM 355/455” is
set, the operator
parameters are
downloaded to the
module and the
in/out parameter
reset.

1) Control parameters: Control parameters become effective in the module if the in/out
parameter LOAD_PAR is set.

2) Operator parameters: Operator parameters become effective in the module if the in/out
parameter LOAD_OP is set.

Controller Module FM 455

A5E00059359-02 11-51
Assignment of the Data Blocks

Controller Module FM 455

11-52 A5E00059359-02
Faults and Diagnostics 12
What Does this Chapter Describe?
Operator errors, incorrect wiring or parameter assignment errors can cause faults
that the module has to indicate to the user.
You will find the following described in this chapter:
• Which faults can occur
• Where these faults are indicated
• How you acknowledge the faults
• The diagnostics interrupt on the FM 455

Chapter Overview

Section Description Page

12.1 Error Display via the Error LEDs 12-2
12.2 Triggering of Diagnostics Interrupts 12-3
12.3 Faults in Measuring Transducers 12-8

Controller Module FM 455

A5E00059359-02 12-1
Faults and Diagnostics

12.1 Error Display via the Error LEDs

Where are Faults Displayed?

The red LED INTF indicates an internal fault on the module.
The red LED EXTF indicates an external fault, for example fault at the connections.
If the yellow LED flashes, the firmware has been deleted. This state can only occur
if the hardware is defective or if the loading process for the firmware was aborted.

Which Faults are Indicated?

The following faults are indicated by the error LEDs lighting up:

Type of Diagnostics Message Possible Cause of Fault Remedy

Fault
Internal Module defective Hardware fault Exchange module
f lt
fault
Time-out responded (watch Hardware fault Exchange module
dog)
EEPROM content invalid Supply voltage failed during Assign new module parameters
parameter assignment
External Wrong parameter in module Incorrect parameters were Assign new module parameters
fault entered at the module
Error at analog inputs or Analog input Exchange module
analog outputs hardware fault
Analog input Repair wire break
wire break
Analog input Check measurement signal
measurement range
underflow
Analog input Check measurement signal
measurement range overflow
Analog output Repair wire break
wire break
Analog output Repair short circuit
short circuit
External auxiliary supply Left-hand front connector not Plug in the left-hand front
not present plugged connector
24-V supply failed Restore the 24-V supply

Diagnostics Interrupt at Faults

All faults can trigger a diagnostics interrupt provided you have enabled the
diagnostics interrupt in the relevant parameter assignment dialog box. You can see
which faults have caused the LED to light up from the diagnostics
data records DS0 and DS1. The assignments of the diagnostics data records DS0
and DS1 are described in the next section.

Controller Module FM 455

12-2 A5E00059359-02
 Faults and Diagnostics

12.2 Triggering of Diagnostics Interrupts

What is a Diagnostics Interrupt?

If a user program is to respond to an internal or external fault, you can set a
diagnostics interrupt parameter that interrupts the cyclic progam of the CPU and
calls the diagnostics interrupt OB, OB8 82.

Which Events Can Trigger a Diagnostics Interrupt?

The following list shows you which events can trigger a diagnostics interrupt:
• Module parameter assignment missing or faulty
• Module defective
• Wire break in analog inputs (4 to 20 mA)
• Overflow and underflow in analog inputs
• Break in load or short circuit in analog outputs
• Wire break at thermocouples and Pt 100

Default Setting
The default setting for the diagnostics interrupt is disabled.

Enabling the Diagnostics Interrupt

You disable or enable the diagnostics interrupt for the module in the “Basic
parameters” dialog box.

Reactions to an Event Triggering an Interrupt

The following occurs when an event occurs which can trigger a diagnostics
interrupt:
• The diagnostics information is stored in the diagnostics data records DS0 and
DS1 on the module.
• One or both error LEDs light up.
• The diagnostics interrupt OB is called (OB 82).
• The diagnostics data record DS0 is entered in the start information of the
diagnostics interrupt OB.
• If no hardware defect is found, the module continues with its control task.
If an OB 82 has not been programmed, the CPU goes into STOP.

Controller Module FM 455

A5E00059359-02 12-3
Faults and Diagnostics

Diagnostics Data Record DS0 and DS1

The information as to which event has triggered a diagnostics interrupt is stored in
the diagnostics data records DS0 and DS1. The diagnostics data record DS0
comprises four bytes. DS1 comprises 27 bytes with the first four bytes being
identical to DS0.

Reading the Data Record from the Module

The diagnostics data record DS0 is automatically transferred to the start
information when the diagnostics OB is called. These four bytes are stored there in
the local data area (bytes 8 through 11) of OB 82.
You can read out the diagnostics data record DS1 (and so also the contents of
DS0) from the module with the system function SFC59 “RD_REC”. It only makes
sense to do this if a fault in a channel is reported in DS0.

How Is the Diagnostics Text Displayed in the Diagnostics Buffer?

If you want to enter the diagnostics message in the diagnostics buffer, you must
call the system function SFC52 “Enter user-specific message in diagnostics buffer”
in the user program. The event number of the diagnostics message in each case is
specified in the input parameter EVENTN. The interrupt is entered in the
diagnostics buffer with x=1 as incoming and with x=0 as outgoing. The diagnostics
buffer contains the relevant diagnostics text in the “Meaning” column as well as the
time of the entry.

Assignment of the Diagnostics Data Record DS0 and the Start Information
Table 12-1 shows the assignment of the diagnostics data record DS0 in the start
information. All unlisted bits are insignificant and take the value zero.

Controller Module FM 455

12-4 A5E00059359-02
 Faults and Diagnostics

Table 12-1 Asignment of the Diagnostics Data Record DS0

Byte Bit Meaning Remarks Event No.

0 0 Module in fault Set for every diagnostics event 8:x:00
1 Internal fault Set for all internal faults: 8:x:01
• Time-out responded
• EEPROM contents invalid. Module starts up without
controlling and waits for renewed parameter
assignment by the CPU
• EPROM fault
• ADC/DAC fault
• Analog input hardware fault
2 External fault Set for all external faults: 8:x:02
• External auxiliary supply not present
• Parameter assignment incorrect
• Analog input wire break
• Analog input measurement range underflow
• Analog input measurement range overflow
• Analog output wire break
• Analog output short circuit
3 Fault in a channel See DS 1, from Byte 7 for further breakdown 8:x:03
4 External auxiliary 24-V supply of the FM 455 failed 8:x:04
supply not present
6 EEPROM content Failure of the supply voltage during a write process to 8:x:03
invalid the EEPROM. The module starts up with default
parameters.
7 Parameter The module cannot evaluate a parameter. 8:x:07
assignment Reason:
incorrect Parameter unknown or illegal combination of
parameters.
Refer to menu PLC > Parameter Assignment Error
Display
1 0 ... 3 Module class 8 always assigned -
4 Channel-specific Is set if the module can provide additional channel -
diagnostics information and a channel fault is present (see DS1,
bytes 7 to 12)
2 0 Use data module The position (A, B, C, D) of the coding key does not 8:x:30
false/missing agree with the parameter assignment in the FM 455
2 3 Time-out Hardware fault 8:x:33
responded
(watch dog)
3 2 EPROM fault Module defective 8:x:42
4 ADC/DAC fault Module defective 8:x:44

Controller Module FM 455

A5E00059359-02 12-5
Faults and Diagnostics

Diagnostics Data Record DS1

The diagnostics data record DS1 consists of 27 bytes. The first 4 bytes are
identical to the diagnostics data record DS0. Table 12-2 shows the assignments of
the remaining bytes. All unlisted bits are insignificant and take the value zero.

Diagnostics Data Record DS 1 of the FM 455

Table 12-2 Assignment of the Bytes 4 to 12 of the Diagnostics Data Record DS1 of the FM 455

Byte Bit Meaning Remarks Event No.

4 0 ... 7 Channel type 75H always assigned -
5 0 ... 7 Length of the diagnostics 8 always assigned -
information
6 0 ... 7 Number of channels 17 always assigned -
(16 controllers + 1 reference channel)
7 0 ... 7 Channel fault vector One bit each is assigned to channels 1 to -
8
8 0 ... 7 Channel fault vector One bit each is assigned to channels 9 to -
16
9 0 Error at reference channel -
10 0 Analog input hardware fault 8:x:B0
1 Parameter assignment error The position (A, B, C, D) of 8:x:B1
the coding key does not
agree with the parameter
assignment in the FM 455
2 Analog input wire break (4 to 8:x:B2
20 mA only)
3 Unused Channel- 8:x:B3
specific
4 Analog input diagnostics 8:x:B4
measurement range channel 1
underflow1)
5 Analog input 8:x:B5
measurement range overflow1)
6 Analog output wire break Only for current output of 8:x:B6
continuous controller
7 Analog output short circuit Only for voltage output of 8:x:B7
continuous controller
11 0 ... 7 See byte 10 Channel-specific diagnostics channel 2 See above
12 0 ... 7 See byte 10 Channel-specific diagnostics channel 3 See above
13 0 ... 7 See byte 10 Channel-specific diagnostics channel 4 See above
14 0 ... 7 See byte 10 Channel-specific diagnostics channel 5 See above
15 0 ... 7 See byte 10 Channel-specific diagnostics channel 6 See above

Controller Module FM 455

12-6 A5E00059359-02
 Faults and Diagnostics

Table 12-2 Assignment of the Bytes 4 to 12 of the Diagnostics Data Record DS1 of the FM 455

Byte Bit Meaning Remarks Event No.

16 0 ... 7 See byte 10 Channel-specific diagnostics channel 7 See above
17 0 ... 7 See byte 10 Channel-specific diagnostics channel 8 See above
18 0 ... 7 See byte 10 Channel-specific diagnostics channel 9 See above
19 0 ... 7 See byte 10 Channel-specific diagnostics channel 10 See above
20 0 ... 7 See byte 10 Channel-specific diagnostics channel 11 See above
21 0 ... 7 See byte 10 Channel-specific diagnostics channel 12 See above
22 0 ... 7 See byte 10 Channel-specific diagnostics channel 13 See above
23 0 ... 7 See byte 10 Channel-specific diagnostics channel 14 See above
24 0 ... 7 See byte 10 Channel-specific diagnostics channel 15 See above
25 0 ... 7 See byte 10 Channel-specific diagnostics channel 16 See above
26 0 ... 5 See byte 10 Diagnostics for reference channel See above
1) Refer to Section 12.3

Particular Points to Observe

The FM 455 is supplied with voltage exclusively via the left front connector.
The CPU therefore recognizes the state ”Module removed/not addressable” in the
following cases:
• If the left front connector of the FM 455 is not plugged
• If there is no 24-V power supply at the left front connector

Note
If the entry ”Module removed/not addressable” is entered in the diagnostic buffer
of the CPU, check whether the left front connector is plugged and whether the
24-V power supply is available at the FM 455.

Controller Module FM 455

A5E00059359-02 12-7
Faults and Diagnostics

12.3 Faults in Measuring Transducers

Faults in Measuring Transducers

The following faults in measuring transducers can be recognized by the FM 455:
• Measurement range underflow
• Measurement range overflow
• Wire break (not for all measuring ranges)
Whenever one of these faults occurs, the group error ”External error” is set in the
diagnostics data record DS0 and channel-specific error bits are set in the
diagnostics data record DS1 (refer to Tables 12-1 and 12-2). The corresponding
bits are reset when these faults have been eliminated.
The subsequent table shows at which limits in the individual measuring ranges the
error bits are set or reset:

Measuring Error Bit Measuring Error Bit Measuring Error Bit Wire Break
Range Range Underflow at ... Range Overflow at ... Display
DS1: Byte 10 to 26, Bit 4 DS1: Byte 10 to 26, Bit 5 DS1: Byte 10 to 26, Bit 2
0 to 20 mA < - 3.5 mA > 23.5 mA -
4 to 20 mA Error bit = 1 at < 3.6 mA > 22.8 mA Error bit = 1 at < 3.6 mA
Error bit = 0 at > 3.8 mA Error bit = 0 at > 3.8 mA
0 to 10 V < - 1.175 V > 11.75 V -
Pt 100 < 30.82 mV > 650.46 mV Yes, parameter can be set
(-200 to 850 °C) Display: 650.46 mV
(-328 to 1562 °F)
Pt 100 < 30.82 mV > 499.06 mV Yes, parameter can be set
(-200 to 556 °C) Display: 499.06 mV
(-328 to 1032 °F)
Pt 100 < 30.82 mV > 254.12 mV Yes, parameter can be set
(-200 to 130 °C) Display: 254.12 mV
(-328 to 264 °F)
Thermocouple < 0 mV > 13.81 mV -
Type B
Thermocouple < - 8.1 mV > 69.54 mV -
Type J
Thermocouple < - 6.45 mV > 54.88 mV -
Type K
Thermocouple < - 0.23 mV > 21.11 mV -
Type R
Thermocouple < - 0.24 mV > 18.7 mV -
Type S
Free < Lower input value of the < Upper input value of the -
thermocouple polygon polygon

Controller Module FM 455

12-8 A5E00059359-02
Examples 13
Chapter Overview

Section Description Page

13.1 Application Example for the FM 455 S 13-2
13.2 Application Example for the FM 455 C 13-7
13.3 Application Example for the Diagnostics 13-11
13.4 Interconnection Example for a Cascade Control 13-12
13.5 Interconnection Example for a Ratio Control 13-13
13.6 Interconnection Example for a Blending Control 13-14

Controller Module FM 455

A5E00059359-02 13-1
Examples

13.1 Application Example for the FM 455 S

Overview
The example “SIMATIC 400 Station1 (S)” is included in the project FM_PIDEx
which allows you to operate the FM 455 S on a process simulated in the CPU. This
means you can test the module without a real process.

Requirements
The following prerequisites must be fulfilled for you to be able to work with the
example program:
• CPU 414 is inserted in slot 2
• FM 455 S is inserted in slot 4
• CPU and FM 455 S are supplied with power
• Online connection between the programming device/PC and CPU available
If you want to use a different CPU or FM 455, you have to adapt the example
under the hardware configuration.

Downloading the Example Program

Proceed as follows to download the example program:
1. Download the “Blocks” user program from Example 455 S to the CPU.
2. Start the parameter assignment application for the FM 455 in the “HW Config:
Hardware Configuration” software.
3. Use the menu item Debug > ... > Open Instance DB to open the DB 31.
You can now work with the loop display, the curve recorder and the controller
optimization.

Controller Module FM 455

13-2 A5E00059359-02
 Examples

Using the Example Program

The example (Example 455 S) contains a step controller in connection with a
simulated process which consists of a third-order time delay (PT3).
The example program is a simple method of creating a step controller and of
configuring and debugging it in all its properties in an offline interaction with a
typical process.
The example program provides an opportunity to easily learn how controllers with a
discontinuous output - as they are often used in controlling processes with
motor-driven actuating elements - operate and how to configure them. This means
the example is suitable for introduction and training purposes.
By selecting appropriate parameters, you can adjust the process to approximate
the characteristics of a real process. By using the configuration tool you can find a
set of suitable controller data by identifying the model process.

Controller Module FM 455

A5E00059359-02 13-3
Examples

Functions of the Example Program

The example ”Example 455 S” consists mainly of the two function blocks PID_FM
(FB 31) and PROC_S (FB 100). PID_FM acts as the step controller while
PROC_S simulates a process with the function elements ”Valve” and PT3
(Figure 13-1). Apart from the process variable, the controller also receives
information about the position of the actuator and limit position signals if limit stops
are reached.

DISV

Setpoint Step
Controller
-
Process
variable (Actuator) Pt 3

Limit Stop Signals

Position Feedback

Controlller Process

Figure 13-1 Example of a Control Loop (Example 455 S)

The function block PROC_S simulates a cascade connection which consists of the
integrating actuating element and three first order time-delay elements
(Figure 13-2). The disturbance variable DISV is always added to the output signal
of the actuator so that process disturbances can be fed in manually at this point.
The static process gain can be determined by using the factor GAIN.
The parameter for the motor actuating time MTR_TM defines the time required by
the actuator to move from one limit stop to the other.

QLMNR_HS
QLMNR_LS

DISV GAIN
INV_UP
OUTV
INV_DOWN + X

MTR_TM LMNR_HLM TM_LAG1 TM_LAG2 TM_LAG3

LMNR_LLM

Figure 13-2 Structure and Parameters of the Process Block PROC_S

Controller Module FM 455

13-4 A5E00059359-02
 Examples

Block Structure
Example 1 is made up of the APP_1 function with the blocks for the controller and
simulated process as well as the call blocks for a complete restart (OB 100) and a
watchdog interrupt class (OB 35 with a 100 ms time base).

Table 13-1 Blocks for Example 1

Block Name Description

(in the symbol table)
OB 100 Complete restart OB
OB 35 Time-driven OB: 100 ms
FC 100 APP_1 Example 1
FC 101 SIM_455 Process value transfer in FM 455 S
FB 31 PID_FM Step controller FM 455 S
FB 100 PROC_S Process for step controller
DB 100 PROCESS Instance DB for PROC_S
DB 31 DB_PID_FM Instance DB for PID_FM

Parameters of the Model Process for Step Controllers

Figure 13-3 shows the function chart and the parameters of the process.

Input Parameters Output Parameters

PROC_S (FB 100)
Parameter Type *) Signal Type *)
COM_RST BOOL FALSE
CYCLE TIME T#1s
GAIN REAL 0.0
DISV REAL 0.0
INV_UP BOOL FALSE QLMNR_HS BOOL FALSE
INV_DOWN BOOL FALSE + OUTV REAL 0.0
QLMNR_LS BOOL FALSE
LMNR REAL 0.0
LMNR_HLM REAL 100.0
LMNR_LLM REAL 0.0
MTR_TM TIME T#30s
TM_LAG1 TIME T#10s
TM_LAG2 TIME T#10s
TM_LAG3 TIME T#10s
*) Default when new instance DB is created

Figure 13-3 Function Scheme and Parameters of the PROC_S Process Model

Controller Module FM 455

A5E00059359-02 13-5
Examples

Parameters and Step Response

The reaction of a control loop with a simulated third-order PT process is shown on
the basis of a concrete parameter assignment of the step controller with PI effect
and activated dead band. The process parameters selected with a 10 sec. time lag
approximate the response of a fast temperature process or a level controlling
system.
Setting one of the time lags TM_LAGx = 0 sec. reduces the process by one order.
The curve (configuration tool) shows the transient and settling response of the
closed loop after a setpoint change of 60% (Figure 13-4). The table contains the
values set for the relevant parameters of the controller and process.

Parameter Type Parameter Value Description

Controller:
GAIN REAL 0.31 Proportional gain
TI TIME 19.190 s Reset time
MTR_TM TIME 20 s Motor actuating time
PULSE_TM TIME 100 ms Minimum pulse time
BREAK_TM TIME 100 ms Minimum pause time
DEADB_ON BOOL TRUE Dead band on
DEADB_W REAL 0.5 Dead band width
Process:
CYCLE TIME 100 ms Sampling time
GAIN REAL 1.5 Process gain
MTR_TM TIME 20 s Motor actuating time
TM_LAG1 TIME 10 s Time lag 1
TM_LAG2 TIME 10 s Time lag 2
TM_LAG3 TIME 10 s Time lag 3

100
Setpoint Process variable
50

0
Position feedback
signal
-50

-100
15:53 15:54 15:55 15:56 15:57 15:58 15:59 16:00 16:01

Figure 13-4 Control Loop with Step Controller after a Step Change in the Setpoint

Controller Module FM 455

13-6 A5E00059359-02
 Examples

13.2 Application Example for the FM 455 C

Overview
The example “SIMATIC 400 Station2 (C)” is included in the project FM_PIDEx
which allows you to operate the FM 455 C on a process simulated in the CPU.
This means you can test the module without a real process.

Prerequisites
The following prerequisites must be fulfilled for you to be able to work with the
example program:
• CPU 414-2 DP is inserted in slot 2
• FM 455 C is inserted in slot 4
• CPU and FM 455 C with voltage supplied
• Online connection between the programming device/PC and CPU available
If you want to use a different CPU or FM 455, you have to adapt the example
under the hardware configuration.

Downloading the Example Program

Proceed as follows to download the example program:
1. Download the “Blocks” user program from Example 455 C to the CPU.
2. Start the parameter assignment application for the FM 455 in the “HW Config:
Hardware Configuration” software.
3. Use the menu item Debug > ...> Open Instance DB to open the DB 31.
You can now work with the loop display, the curve recorder and the controller
optimization.

Using the Example Program

The example (Example 455 C) contains a continuous controller in connection with
a simulated process which consists of a third-order time-delay element (PT3).
Using the sample program it is possible to create a continuous PID controller easily
and to assign parameters and test all its characteristics in offline interaction with a
typical process arrangement.
The example will help inexperienced users to understand how controllers work and
how to configure controllers with an analog output signal, just as they are very
often used to control systems involving processes with proportional actuators. This
means the example is suitable for introduction and training purposes.

Controller Module FM 455

A5E00059359-02 13-7
Examples

By selecting appropriate parameters, you can adjust the process to approximate

the characteristics of a real process. By using the configuration tool you can find a
set of suitable controller data by identifying the model process.

Functions of the Example Program

The example ”Example 455 C” consists mainly of the two function blocks PID_FM
(FB 31) and PROC_S (FB 100). PID_FM represents the controller and PROC_C
simulates a third-order self-regulating process (Figure 13-5).

DISV

SP Continuous LMN
controller
PV -
Pt 3

Controlller Process

Figure 13-5 Example of a Control Loop (Example 455 C)

The function block PROC_C simulates a series connection comprising three

first-order time lag elements (Figure 13-6). The disturbance variable DISV is
always added to the output signal of the actuator so that process disturbances can
be fed in manually at this point. The static process gain can be determined by
using the factor GAIN.

DISV GAIN

INV OUTV
+ X

TM_LAG1 TM_LAG2 TM_LAG3

Figure 13-6 Structure and Parameters of the Process Block PROC_C

Controller Module FM 455

13-8 A5E00059359-02
 Examples

Block Structure
Example 2 is made up of the APP_2 function with the blocks for the controller and
simulated process as well as the call blocks for a complete restart (OB 100) and a
watchdog interrupt class (OB 35 with a 100 ms time base).

Table 13-2 Blocks for Example 2

Block Name Description

(in the symbol table)
OB 100 Complete restart OB
OB 35 Time-driven OB: 100 ms
FC 100 APP_2 Example 2
FC 101 SIM_455 Process value transfer in FM 455 C
FB 31 PID_FM Continuous controller FM 455 C
FB 100 PROC_C Process for continuous controller
DB 100 PROCESS Instance DB for PROC_C
DB 31 DB_PID_FM Instance DB for PID_FM

Parameters of the Model Process for Continuous Controllers

Figure 13-7 shows the function chart and the parameters of the process.

Input Parameters Output Parameters

PROC_C (FB 100)
Parameter Type *) Signal Type *)
COM_RST BOOL FALSE
CYCLE TIME T#1s
GAIN REAL 0.0
DISV REAL 0.0

INV REAL 0.0 + OUTV REAL 0.0

TM_LAG1 TIME T#10s

TM_LAG2 TIME T#10s
TM_LAG3 TIME T#10s

*) Default when new instance DB is created

Figure 13-7 Functions and Parameters of the PROC_C Process Model

Controller Module FM 455

A5E00059359-02 13-9
Examples

Parameters and Step Response

The reaction of a control loop with a simulated third-order PT process is shown on
the basis of a concrete parameter assignment of a continuous controller with
PID effect. The process parameters selected with a 10 sec. time lag approximate
the response of a pressure control or a level control.
Setting one of the time lags TM_LAGx = 0 sec. reduces the process by one order.
The curve (configuration tool) illustrates the transient and settling response of the
closed loop after a series of setpoint changes of 20% of the measuring range
(Figure 13-8). The table contains the values set for the relevant parameters of the
controller and process.

Parameter Type Parameter Description

Value
Controller:
GAIN REAL 1.535 Proportional gain
TI TIME 22.720 s Reset time
TD TIME 5.974 s Derivative action time
TM_LAG TIME 1.195 s Time lag of the D action
Process:
CYCLE TIME 100 ms Sampling time
GAIN REAL 1.5 Process gain
TM_LAG1 TIME 10 s Time lag 1
TM_LAG2 TIME 10 s Time lag 2
TM_LAG3 TIME 10 s Time lag 3

100
Manipulated
variable
50

Setpoint
-50
Process variable

-100
17:15 17:16 17:17 17:18 17:19 17:20 1/:21 17:22 17:23

Figure 13-8 Controlling with a Continuous Controller and Setpoint Step Changes over the
Entire Measuring Range

Controller Module FM 455

13-10 A5E00059359-02
 Examples

13.3 Application Example for the Diagnostics

Overview
The project FM_PIDEx contains the example “SIMATIC 400 Station3 (C)” which
shows the application and the evaluation of the diagnostics in the DS1 of the
controller module.

Prerequisites
The following prerequisites must be fulfilled for you to be able to work with the
example:
• CPU414 inserted in slot 2
• FM455C inserted in slot 4
• CPU and FM 455 C with voltage supplied
• Online connection between the programming device/PC and CPU available
If you want to use a different CPU or FM 455, you have to adapt the example
under the hardware configuration.

Note
Diagnostics interrupts are only triggered in the CPU if you have selected the
following setting at the ”Basic parameters” tab card in the ”Properties - FM 455 C
PID Control” in HW Config:
• Select interrupt Diagnostics

Downloading the Example Program

Download the “Blocks” user program with the system data to the CPU.

Using the Example Program

If a diagnostics interrupt occurs, the parameter DIAG_ON of the
FB 1 FM_DIAG_355 is set in the OB 82. The FM_DIAG_455 is called in the
OB 35. It reads the diagnostics data record DS1 of the module (refer to
Section 12.2, Triggering Diagnostics Interrupts).

Controller Module FM 455

A5E00059359-02 13-11
Examples

13.4 Interconnection Example for a Cascade Control

The following figure shows a two-loop cascade control:

Controller Controller
SP 1 LMN 2 QLMNUP
Process Process
- (Pulse - (Step QLMNDN
controller) section 1 section 2
controller)
PV PV

Figure 13-9 Two-Loop Cascade Control

This controller interconnection is implemented with a FM 455 S by configuring a

pulse controller as a master controller and by selecting the manipulated variable of
the master controller at the setpoint value input of the secondary controller.
You can also implement a controller cascade by means of a FM 455 C. The master
controller is then not a pulse controller and the secondary controller is not a step
controller. The interconnection can be implemented identically.
In the secondary controller the manipulated value of the master controller is
normalized from the range of 0 to 100% to the range of the process variable A and
is then processed further as a setpoint variable.

Manipulated value Setpoint preprocessing

LMN of the master
controller

Setpoint Effective
Switch Ramp Limit setpoint
safety setpoint
Error signal

Alarm

Process variable A Effective process variable

D input

Disturbance variable

Figure 13-10 Implementation of the Cascade Control with FM 455

Controller Module FM 455

13-12 A5E00059359-02
 Examples

13.5 Interconnection Example for a Ratio Control

Figure 13-11 shows a ratio control with two control loops:

SP1 LMN1
Controller 1 Process 1
PV1

FAC
X
SP2
LMN2 Process 2
Controller 2
PV2

Figure 13-11 Ratio Control with Two Control Loops

Controller 1 is configured as a fixed setpoint controller. Controller 2 is configured

as a ratio/blending controller. Its interconnection is shown in Figure 13-12.
The ratio factor FAC is specified via the setpoint input of the FB PID_FM (SP_RE
or SP_OP).

Setpoint preprocessing Multiply

FAC
Setpoint Effective
Switch Ramp Limit setpoint
safety setpoint
Error signal
Process
variable PV 1
Process variable D
Process Alarm
variable PV 2
Process variable A Effective
process
variable

D input

Disturbance variable

Figure 13-12 Implementation of the Ratio Control with FM 455

Controller Module FM 455

A5E00059359-02 13-13
Examples

13.6 Interconnection Example for a Blending Control

Figure 13-13 shows a blending control with three components:

Main component

Total quantity
Controller
SP Controlller LMN SP1 1 QLMNUP
PV1
- (Pulse X - (Step Process 1
QLMNDN
controller) controller)
PV
FAC1

Controller
SP2 QLMNUP
2 PV2
X - (Step QLMNDN Process 2 X +
controller)
FAC2 FAC4

Controller
SP3 QLMNUP
3 PV3
X - (Step QLMNDN Process 3 X +
controller)
FAC3 FAC5

Figure 13-13 Blending Control for Three Components

Controller Module FM 455

13-14 A5E00059359-02
 Examples

The master controller is configured as a three-component controller and pulse

controller. Controllers 1, 2 and 3 are configured as ratio/blending controllers.
Figure 13-14 shows the interconnection for the master controller. You can use the
”Totalize” command button zo configure the blending factors for the components
PV2 and PV3. If you have to change these factors during running operation, you
can use the FB PID_PAR to do so (refer to Section 7.6 on Page 7-24).

Setpoint preprocessing

Setpoint Effective
Switch Ramp Limit setpoint
safety setpoint
Error
signal
Total
(Factor for process variable B)
Process (Factor for process variable C)
variable (Offset) Alarm

∑
PV 1
Process Process Effective
variable variable A process
PV 2
variable
Process Process
variable variable B
PV 3
Process variable C D input

Disturbance variable

Figure 13-14 Implementation of the Total Quantity Controller (Master Controller)

Controller Module FM 455

A5E00059359-02 13-15
Examples

The secondary controllers are configured as ratio/blending controllers.

Component PV1 shows an example of their interconnection in Figure 13-15. The
blending factor FAC is specified via the setpoint input of the FB PID_FM (SP_RE
or SP_OP).
In the secondary controller (blending controller) the manipulated variable of the
master controller is normalized from the range of 0 to 100 % to the range of the
process variable A and is then processed further as the process variable D.

Setpoint preprocessing Multiply

FAC
Setpoint Effective
Switch Ramp Limit/nor- setpoint
Manipulated
variable LMN of safety set- malize
the master point Error signal
controller
Process variable D
Process
variable Alarm
PV 1
Process variable A Effective
process
variable

D input

Disturbance variable

Figure 13-15 Implementation of the Component Controller (Secondary Controller)

Controller Module FM 455

13-16 A5E00059359-02
Data Sheet A
Chapter Overview

Section Description Page

A.1 Technical Specifications A-3
A.2 Technical Specifications - Function Blocks A-9
A.3 Technical Specifications - Parameter Assignment Software A-10

General Technical Specifications

General technical specifications are
• Electromagnetic compatibility
• Transportation and storage conditions
• Mechanical and climatic ambient conditions
• Information on dielectric tests, class of protection and degree of protection
These general technical specifications are described in manual /1/ .
They contain the standards and test values fulfilled by S7-400 and the test criteria
in accordance with which S7-400 was tested.

UL/CSA Approvals
The following approvals have been obtained for the S7-400 system:
UL Recognition Mark
Underwriters Laboratories (UL) to
Standard UL 508
CSA Certification Mark
Canadian Standard Association (CSA) to
Standard C 22.2 No. 142

FM Approvals
The following approval has been obtained for the S7-400 system:
FM approval to Factory Mutual Approval Standard Class Number 3611, Class I,
Division 2, Group A, B, C, D.

Controller Module FM 455

A5E00059359-02 A-1
Data Sheet

Warning
! Personal injury or property damage can result.
In hazardous areas, personal injury or damage to property can result if plug-in
connections are interrupted during operation of an S7-400.
The S7-400 must always be deenergized prior to separating plug-in connections in
hazardous areas.

Warning
! DO NOT DISCONNECT WHILE CIRCUIT IS LIVE UNLESS LOCATION IS
KNOWN TO BE NONHAZARDOUS

CE Certification
Our products meet the requirements of EU Directive 89/336/EEC
“Electromagnetic Compatibility”.
In accordance with the above-mentioned EU Directive, Article 10, the EU
declarations of conformity are held at the disposal of the competent authorities at
the address below:

Siemens Aktiengesellschaft
Automation Group
A&D AS E48
P.O. Box 1963
D-92209 Amberg
Fed. Rep. of Germany

Area of Use
SIMATIC products have been designed for use in industry.
They can also be used in the domestic environment (household, business and
trade, small plants) with individual approval.

Area of Use Requirements

Emitted Interference Immunity
Industry EN 50081-2 : 1993 EN 50082-2 : 1995

Observing the Installation Guidelines

SIMATIC products meet the requirements if you observe the installation guidelines
described in the manuals when installing and operating the equipment.

Controller Module FM 455

A-2 A5E00059359-02
 Data Sheet

A.1 Technical Specifications

Dimensions and Weight Galvanic isolation
Dimensions • From backplane bus Yes (optocoupler)
W × H × D (mm) 50 × 290 × 210 • Between channels No
Weight approx. 1370 g Permissible difference in
potential
Module-Specific Data
• Between input (ground 75 VDC
No. of digital inputs 16 connection) and central 60 VAC
No. of digital outputs 32 (S controllers grounding point
only) • Between analog inputs 2.5 VDC
No. of analog inputs 16 and MANA (UCM)
No. of analog outputs 16 (C controllers – If signal = 0 V
only) • Isolation tested with
Cable length 500 VDC
• Digital signals max. 600 m Current consumption
unshielded • From backplane bus typ. 100 mA
• Digital signals shielded max. 1000 m • From L+ (without load)
• Analog signals shielded 200 m – C controller typ. 370 mA
50 m with 80 mV max. 440 mA
and thermocouples
– S controller typ. 330 mA
Voltages, Currents, Potentials max. 400 mA
Rated load voltage L+ 24 VDC
Power loss
• Permitted range 20.4 to 28.8 V
– C controller typ. 12 W
• Reverse polarity Yes
max. 17.3 W
protection for input
supply – S controller typ. 10.7 W
• Reverse polarity Yes max. 16.2 W
protection for output Status, Interrupts,
supply Diagnostics
No. of digital inputs that can Status indication One green LED
be controlled at one time each per digital input
• Horizontal position 16 channel (step
to 60 °C controllers and
continuous
Residual current of the
controllers)
digital outputs
One green LED
• Horizontal position max. 1.6 A
each per digital
to 60 °C
output channel (only
step controllers)

Controller Module FM 455

A5E00059359-02 A-3
Data Sheet

Interrupts Interference Suppression, Fault Limits (Inputs)

• Limit value interrupt Yes, param. can be Interference voltage
set suppression for f = n ×
• Diagnostic interrupt Yes, param. can be (f1 ± 1 %),
set (f1 = interference)
Diagnostics functions Yes, param. can be • Common mode > 70 dB
set interference
(Uss < 2.5 V)
• Fault indication on the Yes, red LED
module for internal • Series mode > 40 dB
errors interference (peak value
of the
• Fault indication on the Yes, red LED
interference < rated
module for external
value of the input range)
errors
• Diagnostics information Yes Crosstalk between the
read out inputs

Back-up operation Yes, indicated by

• At 50 Hz 50 dB
orange LED • At 60 Hz 50 dB
Operational limit (in whole
temperature range, with
reference to input area)
• 80 mV ± 1%
• From 250 to 1000 mV ± 0.6%
• From 2.5 to 10 V ± 0.8%
• From 3.2 to 20 mA ± 0.7%

Basic error limit (operational

limit at 25 °C, with reference
to input area)
• 80 mV ± 0.6%
• From 250 to 1000 mV ± 0.4%
• From 2.5 to 10 V ± 0.6%
• From 3.2 to 20 mA ± 0.5%
Temperature sensitivity ± 0.005%/K
(with reference to input
area)
Linearity error (with ± 0.05%
reference to input area)
Repeat accuracy (in ± 0.05%
steady-state condition at
25°C, with reference to
input area)

Controller Module FM 455

A-4 A5E00059359-02
 Data Sheet

Interference Suppression, Fault Limits Input characteristic curve To IEC1131, type 2

(Outputs)
Connection of 2-wire Possible
Crosstalk between the 40 dB BEROs
outputs • Permitted closed-circuit ≤ 1.5 mA
Operational limit (in whole current
temperature range, with
reference to output area)
• Voltage ± 0.5%
• Current ± 0.6%
Basic error limit (operational
limit at 25 °C, with reference
to output area)
• Voltage ± 0.2%
• Current ± 0.3%
Temperature sensitivity ± 0.02%/K
(with reference to output
area)
Linearity error (with ± 0.05%
reference to output area)
Repeat accuracy (in ± 0.05%
steady-state condition at
25 °C, with reference to
output area)
Output ripple; range ± 0.05%
0 to 50 kHz (with reference
to output area)

Data for Selecting a Sensor

(Digital Inputs)
Input voltage
• Rated value 24 VDC
• For signal “1” From 13 to 30 V
• For signal “0” From -3 to 5 V
Input current
• When signal “1” typ. 7 mA
Input delay time
• Can be set No
• From “0” to “1” From 1.2 to 4.8 ms
• From “1” to “0” From 1.2 to 4.8 ms

Controller Module FM 455

A5E00059359-02 A-5
Data Sheet

Data for Selecting a Sensor Data for Selecting a Sensor

(Analog Inputs) (Analog Inputs)
Input ranges (nominal values)/input resistance Permissible input voltage 30 V
for voltage input (for a maximum of
• Voltage ** ± 80 mV /10 MΩ
(destruction limit) 2 inputs)
(-80 to +80 mV)***
Permissible input current for 40 mA
0 to 10 V /100 kΩ current input (destruction
(-1.175 to 11.75 V) limit)
• Current** 0 to 20 mA /50 Ω Connection of signal
(-3.5 to 23.5 mA) sensors
4 to 20 mA /50 Ω • For measuring voltage Possible
(0 to 23.5 mA) • For measuring current Possible
as a 4-wire measuring
• Thermo- B (0...13.81 mV) /10 MΩ transducer
couple J (-8.1...69.54 mV) /10 MΩ
types ** Characteristic curve Yes, param. can be
K (-6.45..54.88 mV) /10 MΩ linearization set
R (-0.23..21.11 mV) /10 MΩ • For thermocouples Types B, J, K, R, S
S (-0.24..18.7 mV) /10 MΩ
• For resistance Pt 100
For Type B: 42.15 °C to thermometers (standard range)
1820.01°C
Temperature compensation Yes, param. can be
For Type J: -210.02°C
set
to 1200.02 °C
• Internal temperature Possible
For Type K: -265.40 °C
compensation
to 1372.11°C
• External temperature Possible
For Type R: - 51.37 °C
compensation with
to 1767.77°C
Pt 100
For Type S: - 50.40 °C
to 1767.98 °C
• Resistance Pt 100 /10 MΩ
thermomet Current 1.667 mA
ers ** impulse-commutated:

(30.82 ...650.46 mV)

-200.01 ... 850.05 °C
(simple resolution)

(30.82...499.06 mV)
-200.01 ... 556.26 °C
(double resolution)

(30.82...254.12 mV)
-200.01 ... 129.20 °C
(four-fold resolution)

** The same limits apply for underflow and overflow indication as for the display range. Exception: underflow
indication for 4 to 20 mA: 1 for <3.6 mA
0 for > 3.8 mA
For the range of 4 to 20 mA the underflow report is displayed for a wire break.

*** or the lower or upper input value of the polygon. The value with the smaller amount applies.

Controller Module FM 455

A-6 A5E00059359-02
 Data Sheet

Data for Selecting an Actuator Data for Selecting an Actuator

(Digital Outputs) (Analog Outputs)
Output voltage Output ranges ± 10 V
• When signal “1” min. L+ (- 2.5 V) (nominal values) from 0 to 10 V
± 20 mA
Output current from 0 to 20 mA
• For signal “1” from 4 to 20 mA
Nominal value 0.1 A
Load resistance
Permissible range from 5 mA to 0.15 A
• For signal “0” • With voltage outputs min. 1 k

Residual current max. 0.5 mA – Capacitive load max. 1 F

Load resistance range 240
to 4 k

• With current outputs max. 500

– Inductive load max. 1 mH
Power output
Voltage output
• Lamp load max. 5 W
• Short-circuit protection Yes
Parallel switching of 2
• Short-circuit current max. 25 mA
outputs
• For logic operation Possible Current output
• To increase power Not possible • Open-circuit voltage max. 18 V
Connection of actuators
Controlling a digital input Possible
• For voltage output Possible
Switching frequency 2-wire connection
• For resistive load/lamp max. 100 Hz • For current output
load 2-wire connection Possible
• For inductive load max. 0.5 Hz
Limit (internal) of the typ. L+ (- 1.5 V)
inductive cut-off voltage on
Short-circuit protection of Yes, electronic
the output

Controller Module FM 455

A5E00059359-02 A-7
Data Sheet

Analog Value Formation

Measuring principle Integrating

Resolution (incl. overrange) Can have parameters set:

• 12 bits
• 14 bits
Conversion time
(per analog input)
• With 12 bit resolution 162 /3ms (at 60 Hz)
• With 12 bit resolution 20 ms (at 50 Hz)
• With 14 bit resolution 100 ms (at 50 and 60 Hz)
Settling time
• For resistive load 0.1 ms
• For capacitive load 3.3 ms
• For inductive load 0.5 ms
Can substitute values be Yes, param. can be set
applied
Integration/conversion
time/resolution (per
channel)
• Can be set
• Integration time in ms 162/3 20 100
• Basic conversion time 17 22 102
incl. processing time in
ms
• Additional 1 1 1
conversion time for
resistance
measurement in ms
or
additional 162/3 20 100 *
conversion time for
reference junction
input in ms
• Resolution in bits 12 12 14
(incl. overrange)
Measuring range
• Interference voltage 60 50 50, 60
suppression for
interference
frequency f1 in Hz

* Valid when a resolution of 14 bits is set at at least

one input.

Controller Module FM 455

A-8 A5E00059359-02
 Data Sheet

A.2 Technical Specifications - Function Blocks

Table A-1 Technical Specifications of the Function Blocks

Function Assignment in Processing Time in

Bl k
Blocks
Working Load Local Data CPU 414
Memory Memory Area
PID_FM 1592 bytes 1976 bytes 40 bytes Refer to Table A-2
FORCE455 498 bytes 658 bytes 100 bytes 2.8 ms
READ_455 526 bytes 644 bytes 162 bytes 3.5 ms
CH_DIAG 302 bytes 420 bytes 64 bytes 2.1 ms
FUZ_455 356 bytes 464 bytes 22 bytes 2.6 ms
PID_PAR 918 bytes 1074 bytes 24 bytes 3.8 to 7.2 ms
dependingg on whether
INDEX_R and INDEX_I are
both ≠ 0
CJ_T_PAR 274 bytes 354 bytes 22 bytes 1.6 ms

Table A-2 Processing Time of the PID_FM under Various Marginal Conditions

Marginal Conditions Processing Time in

READ_VAR LOAD_OP LOAD_PAR CPU 414-2DP
FALSE FALSE FALSE 0,077 ms
TRUE FALSE FALSE 2.36 ms
*) TRUE FALSE 4.48 ms
FALSE FALSE TRUE 2.59 ms
TRUE FALSE TRUE 5.15 ms
*) TRUE TRUE 7.1 ms

*) If LOAD_OP = TRUE, READ_VAR is also set to TRUE by FB PID_FM.

Table A-3 Technical Specifications of the Instance DBs

Instance DBs of the Assignment in

F
Function
ti Bl
Blocks
k ...
Working Memory Load Memory
PID_FM 190 bytes 490 bytes
FORCE455 112 bytes 262 bytes
READ_455 174 bytes 280 bytes
CH_DIAG 72 bytes 178 bytes
FUZ_455 176 bytes 268 bytes
PID PAR
PID_PAR 290 bytes 410 bytes
CJ_T_PAR 58 bytes 130 bytes

Controller Module FM 455

A5E00059359-02 A-9
Data Sheet

A.3 Technical Specifications - Parameter Assignment Software

Technical Specifications Parameter Assignment Software

Memory requirement (hard disk) 4 Mbytes

Technical Specifications System data

Memory requirement in the CPU 5430 bytes

Controller Module FM 455

A-10 A5E00059359-02
Spare Parts B
Spare Parts

Spare Parts Order No.

For FM 455
Coding key for analog modules 6ES7 974-0AA00-0AA0
Front connector, screw-type terminals 6ES7 492-1AL00-0AA0
Front connector, spring-type connector 6ES7 492-1BL00-0AA0
Front connector, crimp snap-on connector 6ES7 492-1CL00-0AA0
Crimping tool for crimping the crimp snap-on contacts 6XX3 071
Crimp snap-on contacts (unit package of 250 pieces) 6XX3 070
Extracting tool for crimp snap-on contacts 6ES5 497-4UC11
Cover sheet (10x) for slot labels 6ES7 492-2XX00-0AA0
For Subracks
Number wheel for slot labeling C79165-Z1523-A22
Replacement slot covers (10 piece) 6ES7 490-1AA00-0AA0

Controller Module FM 455

A5E00059359-02 B-1
Spare Parts
Spare

Controller Module FM 455

B-2 A5E00059359-02
Literature List C
Supplementary Literature
The following table lists the manuals referred to in this manual.

No. Title Order No.

/1/ SIMATIC S7; S7-400 Programmable Controller; 6ES7 498-8AA03-8BA0
Setting Up
/2/ SIMATIC; System Software for S7-300 and Part of the package
S7-400; System and Standard Functions 6ES7 810-4CA04-8BR0

You will also find the basics on closed-loop control explained (in German) in the
following books:

Title Author Order No.

“From a Process to Gißler/Schmid A19100-L531-F196
Controlling” ISBN 3-8009-1551-0
“Controlling on the Basis of Siemens E80850-C331-X-A2
SIMATIC S5”

Controller Module FM 455

A5E00059359-02 C-1
LiteratureList
Literature List

Controller Module FM 455

C-2 A5E00059359-02
Glossary

Actual Value The actual value of the process variable PV.

Blending Control Blending control involves a controller structure in which the setpoint for
the total amount SP is converted to percentages of the individual
components. The total of the blending factors FAC must be 1 (= 100%).

SP SP1 LMN1 PV1

FAC1 Controller 1 Process 1
–

SP4 LMN4 PV4

FAC4 Controller 4 Process 4
–

Cascade Control Cascade control involves a series of interconnected controllers, in

which the master controller adjusts the setpoint for the secondary
(slave) controllers according to the instantaneous error signal of the
main process variable.
A cascade control system can be improved by including additional
process variables. A secondary process variable PV2 is measured at a
suitable point and controlled to the reference setpoint (output of the
master controller SP2). The master controller controls the process
variable PV1 to the fixed setpoint SP1 and sets SP2 so that the target
is achieved as quickly as possible without overshoot.

Disturbance
Master controller variable
SP1 Slave controller
SP2
Controller 1 LMN PV2
Controller 2 Process 2 Process 1

Secondary loop

Main loop PV1

Control Process

Controller Module FM 455

A5E00059359-02 Glossary-1
Glossary

Closed-Loop A closed-loop controller is a device in which the error signal is

Controller continuously calculated (comparator) and an actuating signal (output
variable) generated with the aim of eliminating the error signal quickly
and without overshoot.

Configuration A software tool for creating and assigning parameters to a standard

controller and optimizing the controller settings using the data from a
process identification procedure.

Control Device The control device comprises the controller, actuator and sensor
(measuring device) for the process variables.

Controller Controller parameters are characteristic values for the static and
Parameter dynamic adaptation of the controller response to the given loop or
process characteristics.

Control Loop The control loop is the connection between the process output (process
variable) and the controller input and the controller output (manipulated
variable) with the process input, so that the controller and process form
a closed loop.

Control Output The control output correction prevents a manipulated-variable step

Correction jump during the changeover from manual to automatic mode. The
manipulated variable remains the same when switching between
manual and automatic.

Dead Time Dead time is the time lag in the process variable reaction to
disturbances or manipulated variable changes in processes involving
transport. The input variable of a dead time element is displaced by the
value of the dead time 1 : 1 at the output.

Derivative The derivative action component is the differentiating component of the

Component controller.
D elements alone are unsuitable for control since they do not produce
an output signal if the input signal remains at a constant value.

Controller Module FM 455

Glossary-2 A5E00059359-02
 Glossary

Digital Control A controller that acquires a new value for the controlled variable
(process variable) at constant intervals→ sampling time) and then
calculates a new value for the manipulated variable as a function for
the value of the current error signal.

wk yk = A(wk – xk)
yk Pulse y (t) Actuator
Memory
A = control shaper

Process
xk
algorithm

x (t)
ADC Sampling Sensor

Error Signal The error signal function forms the error signal ER = SP-PV. At the
point at which the comparison is made the difference between the
desired value (setpoint) and the actual process value is calculated. This
value is applied to the input of the control algorithm. Old designation:
System deviation

Fixed Setpoint A fixed setpoint controller is a controller with a fixed setpoint that is only
Control changed occasionally. This controller is used to compensate for
disturbances occurring in the process.

Feedforward Feedforward control is a technique for reducing or eliminating the

Control influence of a dominant (measurable) disturbance (for example,
ambient temperature) in the control loop. The measured disturbance
variable DISV is compensated before it affects the process. Ideally, the
influence can be fully compensated so that the controller itself does not
need to take corrective action itself (with the I action).

DISV (disturbance
DISV variable)
feedforward

SP – LMN PV
Controller Process
–
Control loop

Controller Module FM 455

A5E00059359-02 Glossary-3
Glossary

Follow-Up Control Follow-up control involves a controller in which the setpoint is

constantly influenced externally (secondary controller of a multiple-loop
control system). The task of the secondary controller is to correct the
local process variable as quickly and accurately as possible so that it
matches the setpoint.

Integral (I) Integral action component of the controller.

Component After a step change in the process variable (or error signal) the output
variable changes with a ramp function over time at a rate of change
proportional to the integral-action factor KI (= 1/TI). The integral
component in a closed control loop has the effect of correcting the
controller output variable until the error signal becomes zero.

1
INV OUTV(t) = INV0 * t
OUTV TI
INV0

t
TI

Limit Alarm An algorithm (function) for monitoring four selectable limits of an analog
Monitor value. When these limits are reached or exceeded, a corresponding
warning (first limit) or alarm (second limit) signal is generated. To avoid
signal flickering, the off threshold of the limit signals can be selected
with a hysteresis parameter.

Limiter An algorithm (function) for restricting the range of values of constant

variable to selectable upper or lower limit values.

Manipulated The manipulated variable is the output variable of the controller or input
Variable variable of the process. The actuating signal can take the form of an
analog percentage or a pulse duration value. With integrating actuators
(for example, motor-driven) binary up/down or forwards/backwards
signals are adequate.

Normalization Normalization is a technique (algorithm) for converting (normalizing) the

physical values of a process to the internal percentages used by the
controller and converting the percentages to physical values at the
output. The normalization curve is determined by the start value and
the end value.

Controller Module FM 455

Glossary-4 A5E00059359-02
 Glossary

P Algorithm Algorithm for calculating an output signal in which there is a

proportional relationship between the error signal and manipulated
variable change. Characteristics: steady-state error signal, not to be
used with processes including dead time.

Parallel Structure The parallel structure is a special type of signal processing in the
controller (mathematical processing). The P, I and D components are
calculated parallel to each other with no interaction and then totalled.

LMN_P Linear
GAIN combination
GAIN = 0
SP INT LMN_I
X +
– TI = 0 PID_OUTV
PV
DIF LMN_D
TD = 0

Physical → Normalization
Normalization

PI Algorithm Algorithm for calculating an output signal in which the change in the
manipulated variable is made up of a component proportional to the
error signal and an integral component proportional to the error signal
and time. Characteristics: no steady-state error signal, faster
compensation that with an I algorithm, suitable for all processes.

PID Algorithm Algorithm for calculating an output signal formed by multiplication,

integration and differentiation of the error signal. The PID algortithm is
carried out in a pure → parallel structure. Characteristics: high degree
of control quality can be achieved providing the dead time of the
process is not greater than the sum of the other time constants.

Process The process is the part of the system in which the process variable is
influenced by the manipulated variable (by changing the level of energy
or mass). The process can be divided into the actuator and the actual
process being controlled.

LMN PV

t t
LMN Process (e.g. PT 3) PV

Controller Module FM 455

A5E00059359-02 Glossary-5
Glossary

Process Control The process control unit is the part of the process which is used to
Unit influence the manipulated variable at the process input. Generally
comprises an actuator and a final controlling element.

Process Process identification is a function of the configuration tool which

Identification provides information about the transfer function and the structure of the
process. The result is a device-independent process model that
describes the static and dynamic response of the process. The
optimum settings and design of the controller are calculated based on
this model.

Adaptation

Controller Process
design model
GAIN, TI, TD Identification

SP LMN
Controller Process
–
PV
Control loop

Process Variable Process variable (output variable of the process) that is compared with
the instantaneous value of the setpoint (the actual value). Its
instantaneous value is called the actual value.

Controller Module FM 455

Glossary-6 A5E00059359-02
 Glossary

Ratio Control
• Single loop ratio controller. A single loop ratio controller is used (for
example, in speed control) when the ratio of two process variables is
more important than the absolute values of the variables.

SP LMN
Controller Process
– +
Ratio
PV1
PV2
Quotient

• Multiple loop ratio controller.

In a multiple loop ratio controller, the ratio of the two process variables
PV1 and PV2 must be kept constant. To this purpose the setpoint value
of the second control loop is calculated from the process variable of the
first control loop. Even if the process variable PV1 changes
dynamically, the ratio is maintained.

SP LMN1 PV1
Controller 1 Process 1
–

Factor
LMN2 PV2
Controller 2 Process 2
–

Root extraction → Square root

Setpoint The setpoint is the instantaneous reference input that specifies the
desired value or course of the process variable being controlled. The
momentary value is called the → Setpoint value (SP).

Setpoint Value The setpoint value is the value that the process variable should adopt
under the influence of the controller.

Square Root The square root function SQRT linearizes quadratic relationships.

Controller Module FM 455

A5E00059359-02 Glossary-7
Glossary

Step and Pulse The step and pulse controller is a quasi-continuous controller with two
Controller binary output signals. The step-action controller serves to control
integrating actuators (for example, stepper motor to open and close a
valve). The pulse controller serves to control non-integrating actuators
(for example, switching heating on and off, or controlling a burner).

Three-Step Controller in which the output variable can only have three discrete
Controller states: For example: ”Heating – Off – Cooling” or ”Right – Standstill –
Left”.

Controller Module FM 455

Glossary-8 A5E00059359-02
Index

A C
Actual value, Glossary-1 C controller, 1-1
Actuators Cables, 5-15
connecting to analog output, 10-13 cross-section, 5-15
connecting to digital output, 10-15 for analog signals, 10-2, 10-13
Address, starting address, 4-2 Cascade control, 3-12, 3-16, Glossary-1
Analog inputs example, 13-12
adaptation to sensors, 3-6 CE, Certification, iv, A-2
block diagram, 9-5 Certification, CE, iv, A-2
connecting to measuring sensors, 10-3 CH_DIAG, 7-21
number, 1-3 Changeover, manual-automatic, 3-21
Properties, 9-4 Changing controller parameters, 7-2
Analog output, connecting loads/actuators, via the PID_FM, 7-5
10-13 Changing controllers, via the OP, 7-6
Analog outputs Channel number, entering in DB, 7-2, 7-21,
block diagram, 9-10 7-24, 7-30
number, 1-3 Channels, number of, 1-3
of the FM 455 C, 3-31 CJ_T_PAR, 7-30
properties, 9-10 Closed-loop controller, Glossary-2
signal selection, 3-31 Coding key, 9-6
signal type, 3-31 plugging in, 9-9
Analog signal removing, 9-8
cable for, 5-15 setting, 9-7, 9-8
invalidation, 10-2 Coding of the front connectors, 1-6, 5-26
shielding, 5-15 Compensation
Analog signals, cable for, 10-2, 10-13 configured, 10-7
Analog value conditioning, 3-8 external, 10-7
Anti reset wind-up, 3-21 reference junction temperature, 3-7, 10-6
Application example Configuration, 4-2, Glossary-2
for FM 455 C, 13-7 flow of data, 3-34
for FM 455 S, 13-2 Connecting to analog output, loads/actuators,
Application example , diagnostics, 13-11 10-13
Approval Connecting to digital output, loads/actuators,
CSA, A-1 10-15
FM, A-1 Continuous-action controller, 1-1
Approvals, iv Control algorithm, block diagram, 3-17
UL, A-1 Control loop, Glossary-2
Control output correction, 3-25, Glossary-2
Control parameter, 11-21, 11-40, 11-51
B Control processes, 1-2
Control structures of the FM 455, 1-2
Backup operation, 3-43
Control tasks, 1-4
Basic parameters, 3-5
Blending control, 3-13, Glossary-1
example, 13-14

Controller Module FM 455

A5E00059359-02 Index-1
Index

Controller, 3-2 Digital outputs, 3-32, 5-12, 9-2

continuous, 1-1 block diagram, 9-3
self-tuning, 1-2 number, 1-3
step and pulse, 1-1 Direction of control action, 3-20
structure, 3-10 Disturbance variable, 3-15
Controller output, 3-24
functions, 3-30
Controller output of C controller, 3-25, 7-9, E
7-13
Error display, 12-2
Controller output of S controller, 3-29, 7-10,
Error LEDs, 12-2
7-11, 7-13, 7-14
Error signal (ER), Glossary-3
Controller output of step controller, 3-27, 3-29
Error signal formation, 3-11
Controller parameter, Glossary-2
fixed setpoint/cascade controller, 3-11, 7-8,
Controller state IDSTATUS, 3-48
7-12
Controller type, 3-10
ratio controller, 3-13
Controllers, cascadability, 3-42
Example
Core end sleeve, 5-15
application for the FM 455 C, 13-7
Creating an instance DB, 8-4
application for the FM 455 S, 13-2
CSA, A-1
blending control, 13-14
cascade control, 13-12
ratio control, 13-13
D Example APP_1
D component in the feedback, 3-19 block structure, 13-5
Data management in the FM 455, 3-33 functionality, 13-4
Dead band, 3-24 parameters of the model process, 13-5
Dead time, 3-42, Glossary-2 step response of the control loop, 13-6
Delay of the derivative action (TM_LAG), 3-22 Example APP_2
Derivative (D) component, Glossary-2 block structure, 13-9
Diagnostic interrupt, 1-3 functionality, 13-8
Diagnostic LEDs, 1-7 parameters of the model process, 13-9
Diagnostics data record, 12-4 step response of the control loop, 13-10
Diagnostics data record DS0, assignment, Example program, using, 13-3, 13-7
12-5 External fault, 12-2
Diagnostics data record DS1, assignment,
12-6
Diagnostics interrupt F
default setting, 12-3
Fault
enable, 12-3
external, 12-2
OB 82, 12-3
internal, 12-2
trigger events, 12-3
Faults in measuring transducers, 3-30
triggering, 12-2, 12-3
FB CH_DIAG, 7-21
what is a diagnostics interrupt?, 12-3
FB CJ_T_PAR, 7-30
Diagnostics text, 12-4
FB FORCE455, 7-17
Digital control, Glossary-3
FB FUZ_455, 7-15
Digital inputs, 3-9, 9-2
FB PID_FM, 7-2
block diagram, 9-3
FB PID_PAR, 7-24
cables, 5-15
FB READ_455, 7-19
input filters, 5-12, 9-2
Feedforward control, 3-19, Glossary-3
number, 1-3
Fields of application for the FM 455, 1-4
shielding, 5-15
Filter, 3-8
Digital output, connecting loads/actuators,
Firmware update, 3-43
10-15

Controller Module FM 455

Index-2 A5E00059359-02
 Index

Fixed Setpoint Control, Glossary-3 Function blocks, technical specifications, A-9

FM 455 FUZ_455, 7-15
basic structure, 3-2 Fuzzy controller, 1-2
configuring, 3-33
control action mechanisms, 3-33
data management, 3-33 H
fields of application, 1-4
Hardware, FM 455, 1-5
in the S7-400 configuration, 1-10
Hardware configuration, 6-2
inserting, 4-3
Hardware installation and wiring, 8-1
inserting into project, 8-3
Hardware interrupts, 1-3
order numbers, 1-1
Hysteresis for warning and alarm limit, 3-17
properties, 3-38
removing, 4-4
rules for operating, 3-42
technical specifications, A-3 I
variants, 1-1 Identification
where to use, 1-4 aborting , 3-47
FM 455 C completing, 3-47
application example , 13-7 of process, 3-45
block diagram, 3-3 prerequisites, 3-46
interconnection possibilities, 3-3 starting, 3-46
FM 455 hardware, 1-5 state, 3-48
FM 455 S IDSTATUS, 3-48
application example , 13-2 Input delay, 5-12, 9-2
block diagram, 3-4 Input filter, 5-12, 9-2
interconenction possibilities, 3-4 Inputs of the FM 455, 3-2, 3-6
FM 455 software, 1-9 Inserting and removing the FM 455, 4-3
FM approval, A-1 Installation, 6-1
Follow-up control, Glossary-4 parameter assignment interface, 6-1
FORCE455, 7-17 Instance DB
Four-wire measuring transducer, 10-2 creating and supplying, 7-2, 7-15, 7-17,
connecting, 10-11 7-19, 7-21, 7-24, 7-30
Front connector of the FB CH_DIAG, 11-28
coding element for, 5-25 of the FB CJ_T_PAR, 11-32
connection possibilities, 1-6 of the FB FORCE_455, 11-24
engaging, 5-25 of the FB FUZ_455, 11-22
labeling, 5-23 of the FB PID_PAR, 11-30
ordering, 1-6 of the FB READ_455, 11-26
terminal assignment, 5-2, 5-7 Integral (I) component, Glossary-4
wiring, 5-12, 5-18 Integral-action control, 3-22
with crimp snap-on connector, 5-16 Internal fault, 12-2
with screw-type terminal, 5-16 Interrupt, 3-17
with spring-type connector, 5-16
Front connector coding, 1-6, 5-26
Front connector of the FM 455 C L
left-hand front connector, 5-3
LEDs, meaning, 1-7
right-hand front connector, 5-4
Limit alarm monitor, Glossary-4
Front connector of the FM 455 S
Limit/Normalize, 3-16
left-hand front connector, 5-8
Limiter, Glossary-4
right-hand front connector, 5-9
Function block, create instance DB, 7-15, 7-17,
7-19, 7-21, 7-24, 7-30

Controller Module FM 455

A5E00059359-02 Index-3
Index

Loads P
connecting to an analog output, 10-14
P algorithm, Glossary-5
connecting to analog output, 10-13
P component in the feedback, 3-19
connecting to digital output, 10-15
P controller, 2-7
Parallel structure (PID), Glossary-5
Parameter
M control parameter, 11-21, 11-40, 11-51
Manipulated value operator, 11-21
at restart, 3-42 Parameter assignment, 6-2, 8-4
limiting, 3-30 what to observe, 6-3
switch external, 3-30 Parameter assignment interface, 1-9, 3-33
Manipulated value limiting, 3-30 Parameter assignment masks, integrated help,
Manipulated variable (LMN), Glossary-4 6-3
Measured value resolution, 9-4 Parameter assignment software, technical
Measurement range overflow, 12-8 specifications, A-10
Measurement range underflow, 12-8 Parameter configuration, 3-33
Measurement type, analog input channels, 9-6 Parameter data
Measuring ranges, analog input channels, 9-6 saving, 8-4
Measuring sensor transferring, 8-4
connecting, 10-2 Parameter optimization, temperature controller,
isolated, 10-3 3-45
non-isolated, 10-4 Parameters
Measuring sensors, to analog input, 10-3 downloading directly, 3-33
Measuring transducer fault, 12-8 in/out parameters, 11-34
Module address, entering in DB, 7-2, 7-15, input parameters, 11-34
7-17, 7-19, 7-21, 7-24, 7-30 operator parameters, 11-40, 11-51
Multiplying, 3-16 output parameters, 11-34
saving in the EEPROM, 7-7
PD controller, 2-9
N delay of the the derivative action, 3-22
step response, 3-22
Normalization, 3-8, Glossary-4
PI algorithm, Glossary-5
Normalize/Limit, 3-16
PI controller, 2-11
step response, 3-21
PID algorithm, Glossary-5
O PID closed-loop control, 3-23
OB 82, diagnostics interrupt, 12-3 PID controller, 2-13
Online help, 1-9 configuration, 3-23
Operating mode of the FM 455, 1-2 control algorithm, 3-18
Operating point for P(D) controller, 3-25 controller structure, 3-19
Operator control and monitoring step response, 3-23
allocation of the DBs, 11-34 PID_FM, 7-2
of the FM 455, 3-37 PID_PAR, 7-24
via FB PID_FM, 3-36, 7-3 Polyline, 3-8
via the OP, 3-36 Position feedback input, 3-30
Operator parameters, 11-21, 11-40, 11-51 Potential bonding, 5-15
Order numbers, 1-1, 1-6 Power frequency, adaptation, 3-7
Outputs of the FM 455, 3-2, 3-31 Power supply, of the sensors, 5-12

Controller Module FM 455

Index-4 A5E00059359-02
 Index

Power supply L+, M, 5-12 Setpoint, Glossary-7

Process, Glossary-5 Setpoint value, 3-15
characteristic values, 2-2 at restart, 3-43
optimizing, 8-5 conditioning, 3-16
Process control unit, Glossary-6 Setpoint value (SV), Glossary-7
Process identification, Glossary-6 Signal error formation, three-component
Process simulation (APP_1), 13-4 controller, 3-12
Process simulation (APP_2), 13-8 Simulation
Process variable, 3-15 of the analog values, 7-17
conditioning, 3-16 of the digital values, 7-18
Process variable (PV), Glossary-6 Slot label, 1-6
Processing sequence, 3-38, 3-41, 3-42 Slots, permitted, 4-2
Program examples, 6-1 Smooth changeover, 3-21
Projekt, creating, 8-3 Software, FM 455, 1-9
Proportional control, 3-20 Split range, 3-26
Proportional-plus-derivative control, 3-22 Split-range, 3-27
Proportional-plus-integral control, 3-21 Split-range function, 3-24
Pulse shaper, 3-30 Split-range function three-step controller, 3-28
Split-range function two-step controller, 3-28
Split-range manipulated values, 3-30
R Square root, 3-8, Glossary-7
Startup characteristics, general, 3-42
Ramp, 3-16
Starting address, 4-2
Ratio control, 3-14, Glossary-7
Starting up
example, 13-13
creating a new project, 8-3
READ_455, 7-19
hardware installation and wiring, 8-1
README file, 6-2
inserting FM in project, 8-3
Reference junction, 1-3, 3-7, 3-39, 10-7
Saving a project, 8-5
for a thermoelement, 10-6
Status LEDs, 1-7
Reference junction input, 3-42
Step and pulse controller, 1-1, Glossary-8
Reference junction temperature, 10-6
Switch safety setpoint, 3-16
compensation, 10-6
measuring, 10-6
Reference point, 5-6, 5-11, 5-15, 10-2, 10-13
Release, 1-6 T
Removing the FM 45, 4-3 Technical specifications
Removing the FM 455, 4-4 FM 455, A-3
Reset time, 9-4 function blocks, A-9
Resistance thermometer, connecting, 10-12 parameter assignment software, A-10
Resolution, 3-8 Temperature, Celsius/Fahrenheit, 3-7
measured value, 9-4 Temperature controller, 3-18
Reversing the controller action, 3-20 parameter optimization, 3-45
Rules for operating the FM 455, 3-42 requirements to the process, 3-44
Terminal assignments, 1-6

S
S controller, 1-1
Safety manipulated value, 3-30
Safety regulations, 4-2
Sampling time, 3-7, 3-39, 3-42
Self-tuning controller, 1-2
Sensor, adaptation, 9-7

Controller Module FM 455

A5E00059359-02 Index-5
Index

Thermoelement, 10-5 U
connecting, 10-7
UL, A-1
design, 10-5
User program, interconnection, 7-2
operating principle, 10-6
possibilities of connecting, 10-7
reference junction, 10-6
types, 10-5 V
with configured compensation, 10-9 Variants of the FM 455, 1-1
with external compensation, 10-8 View of module, 1-5
Three-step controller, 3-28, Glossary-8 Voltage sensor, 10-2
Three-step controllers, 2-6 connecting, 10-10
Tracking, 3-30
Tracking input, 3-30
Two-position controller, 3-27 W
Two-step controller
Wire break, 12-8
with feedback, 2-5
without feedback, 2-4
Two-wire measuring transducer, 10-2
connecting, 10-11

Controller Module FM 455

Index-6 A5E00059359-02
 Siemens AG
A&D AS E 81

Oestliche Rheinbrueckenstr. 50
D-76181 Karlsruhe
Federal Republic of Germany

From:
Your Name: _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
Your Title: _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
Company Name: _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
Street: _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
City, Zip Code_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
Country: _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
Phone: _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

Please check any industry that applies to you:

Automotive
Pharmaceutical

Chemical
Plastic

Electrical Machinery
Pulp and Paper

Food
Textiles

Instrument and Control
Transportation

Nonelectrical Machinery
Other _ _ _ _ _ _ _ _ _ _ _

Petrochemical

Controller Module FM 455

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A5E00059359-02
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Controller Module FM 455

2 A5E00059359-02