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Micromaster 4 -- Commissioning and operation -- Using PI / PID controllers

Entry ID:26447106 Date:2007-01-08

Micromaster 4 -- Commissioning and operation -- Using PI / PID controllers

MICROMASTER 4 (MM4), SINAMICS G120 (CU2x0x): How is the feedback signal configured when using
PID control?
MICROMASTER 4 (MM4), SINAMICS G120 (CU2x0x): What is the reason for the loss of the PID controller
Output when driving an MM4 or G120?
MICROMASTER 4 (MM4), SINAMICS G120 (CU2x0x): Is there a difference in the mode of operation and in
the handling of PID controllers of the various drive inverters?
MICROMASTER 4 (MM420): Can I use the JOG function if PID control is enabled (P2200 = 1)?
MICROMASTER 4 (MM4): What information is available about the PI control of the MM420 and the PID
control of the MM440?

MICROMASTER 4 (MM4), SINAMICS G120 (CU2x0x): How is the feedback signal configured when using PID
control?

This FAQ applies only to the SINAMICS G120/G120D Control Units without “-2” in the product name and
MICROMASTER 4 inverters.

The PID control on MM4/G120 expects a feedback signal that will rise with motor speed, such as a pressure
transducer sensing the output of a pump. However, some transducers will operate in the reverse sense, such as
using a similar transducer as previously described, but measuring vacuum, or an NTC (Negative Temperature
Coefficient) resistor measuring temperature in a heating system.

In these cases, the PID control must be configured to reduce motor speed with a rising feedback signal.

The system is best understood with reference to the function diagram:

( 155 KB )

Example: Normal Operation

A positive setpoint is applied to the Setpoint path (P2253 = [for example] 755.0 analogue input 1).
A positive feedback is applied to the Feedback path (P2264 = [for example] 755.1 analogue input 2).

Both signals are processed such that, after the summing point (actually a subtracting point) a positive error is
generated when the setpoint is higher than the feedback, and this increases the motor speed to meet the demand.

By following the path using read parameters (for example r2260, r2262, r2266, r2272, r2273) all values are
observed to be positive under this condition. Clearly if the feedback signal later exceeds the setpoint, the error will
be negative, reducing motor speed.

Example: Reverse operation

In order to make the drive operate in the reverse sense, both the setpoint and feedback paths are inverted, so that

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two negative values are subtracted at the summing point, and the error is therefore negative.
In other words a negative setpoint is required, and the transducer type should be set in P2271 =1 to achieve the
inversion of the feedback signal.

Consider an arrangement similar to the above example, using both analogue inputs (MM440/G120 only)

In the setpoint path the inversion is achieved by scaling the analogue input so that the input value 0 to 10V (for
example) corresponds to 0 to - 100%. This requires only P0760.0 = -100%.

In the feedback path a similar scaling could be used, but is easily achieved by setting P2271 = 1.

Now when the signals are subtracted at the summing point, a setpoint which is higher in value compared with the
feedback (referring to the value at the input terminals) will now give a negative error, reducing the motor speed, and
a positive error when the feedback is higher.

For MM420 or MM440/G120 using only one analogue input, a negative fixed setpoint value or MOP should be
used.

Relevant parameter
Function Parameter Description Setting Description
enable PID p2200 enable/disable the PID controller 1 activated
controller
PID setpoint p2253 defines setpoint source for PID input 755.0 Analog input 1
PID feedback p2264 selects the source of the feedback signal 755.1 Analog input 2

PID transducer type p2271 selects the transducer type for the PID 0 disabled
feedback signal 1 Inversion of PID feedback
signal
Value y2 of ADC p0760.0 affects to reference values -100 in [%]
scaling

Information

Function description you find in the Operating Manual under chapter 3.11 "PID control"; Entry-ID: 24294529
further parameter information and function diagrams you find in the Parameter List; Entry-ID: 23708204
FAQ: "Is there a difference in the mode of operation and in the handling of PID controllers of the various
drive inverters?"; Entry-ID: 23997256

MICROMASTER 4 (MM4), SINAMICS G120 (CU2x0x): What is the reason for the loss of the PID controller Output
when driving an MM4 or G120?

This FAQ applies only to the SINAMICS G120/G120D Control Units without “-2” in the product name and
MICROMASTER 4 inverters.

It is possible when using the PID closed loop controller that under certain conditions the controller’s output can fall
from 100% to the PID output lower limit (P2292). This will occur if the PID setpoint (r2262) is at 100%, the P-Gain
(P2280) is greater than 13.107 and the feedback error (r2273) is greater than 98%.

Tested Software Versions

Product Software Version Affected?

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G120 – CU240 2.00 Yes

MM440 2.09 Yes
MM440 2.10 Yes
MM440 2.11 Yes
MM430 2.02 No
MM420 1.17 No

Solution:

There are three possible solutions shown below:

1. The PID controllers P-Gain should be kept below 13.108 (MM4) or 13.133 (G120).

2. The P-Gain can be altered proportionally to the required setpoint.

If the maximum setpoint to be used is 50% then the maximum PID proportional gain can be increased as
follows:

MICROMASTER 4

P2280 (Maximum) = (100 / setpoint) * 13.107

P2280 (Maximum) = (100 / 50%) * 13.107 = 26.214

SINAMICS G120 – CU240

P2280 (Maximum) = (100 / setpoint) * 13.132

P2280 (Maximum) = (100 / 50%) * 13.132 = 26.264

3. Alternatively, the setpoint can be rescaled (P2000) so that the PID set point percentage is reduced
accordingly. The P-Gain can then be increased as per point 2 above.

MICROMASTER 4 (MM4), SINAMICS G120 (CU2x0x): Is there a difference in the mode of operation and in the
handling of PID controllers of the various drive inverters?

This FAQ applies only to the SINAMICS G120/G120D Control Units without “-2” in the product name and
MICROMASTER 4 inverters.

MICROMASTER drives (MICROMASTER 420, 430 and 440) as well as SINAMICS G120 have a technology
controller with which process quantities such as pressure, temperature, filling level can be controlled.
As a function of the application, the technology controller can be parameterized as P, I, PI or PID controller

The differences at a glance:

The PID controllers of the two - the MM440 and the G120 - have an additional mode. This mode is the
dancer roll control. It is used in the paper and fiber industries as well as when manufacturing cables;
The PID controller of the MM440 and the G120 has an auto-tuning function, that allows the P, I and D
components of the controller to be automatically calculated;
The technology controller of the MM420 only has two components, P term proportional gain and I term –
integration time. On the other hand the technology controller of the MM430/MM440/G120 also has in
addition the D term – differentiating time constant;
The MM430 has three additional functions that expand the functionality of the PID controller:
Motor staging
Energy-saving function
Bypass

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aditional_Handhabung_PID-ReglerbeiMM4_G120_en_V1.pdfaditional_Handhabung_PID-
ReglerbeiMM4_G120_en_V1.pdf ( 397 KB )

Additional information is provided in the Attachment or the Operating Instructions and the parameter list for the
appropriate drives.

MICROMASTER 4 (MM420): Can I use the JOG function if PID control is enabled (P2200 = 1)?

Yes.
It functions independently of the PID controller.

Under PID control, the inverter output frequency after a RUN command is generated by the PID controller from the
difference between the PID setpoint and the feedback signal. The normal frequency setpoint and ramps are

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disabled.

When using JOG, the inverter always runs in frequency control with the frequency setpoint coming from P1058 and
P1059 and the ramp times set in P1060 and P0161. This can be very useful for "threading up" a machine or
removing material from a machine.

Note

The inverter must be stopped in order to switch between running under PID control and JOG under
frequency control.

Information

Further information of the particular function settings you find in the Operating Instructions; Entry-ID:
24523400
information about the parameters you find in the Parameter List; Entry-ID: 24525275

MICROMASTER 4 (MM4): What information is available about the PI control of the MM420 and the PID control of
the MM440?

MM420
A PI controller is integrated in the MM420. This can be activated by the user so that closed-loop control with
feedback can be used. If the PI controller was activated (P2200) it internally generates the motor frequency that
is necessary to minimize the difference (error) between the PI setpoint and the PI feedback. This is realized by
continuously comparing the feedback signal with the setpoint. The PI controller defines the required motor
frequency. The normal frequency setpoint (P1000) and the ramp times (P1120 & P1121) are automatically
deactivated; however, the settings for the minimum and maximum output frequencies (P1080 and P1082)
remain active.

MM440
A PID controller is integrated in the MM440; the same parameters and principles of operation are used as for the
MM20; this is the reason that the parameterization and operation of the MM420 and the MM440 are essentially
compatible with one another.

MM440 has a series of additional features and expanded functionality that can be useful for numerous
applications.

The attached document provides users with basic information about the PI controller implemented in the MM420;
as well as the PID controller implemented in the MM440.

PDF_Using_PI_Control_App_en_V1_1b_en.pdfPDF_Using_PI_Control_App_en_V1_1b_en.pdf
( 438 KB )

Written by: A&D SD CST

Entry ID:26447106 Date:2013-09-19

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