Learning targets ...............................................................................................................................

2
Setpoint channel .............................................................................................................................. 3
Setpoint source ................................................................................................................................ 4
Limitations ....................................................................................................................................... 9
Ramp-function generator .................................................................................................................. 10
Control modes ................................................................................................................................. 11
Open-loop control modes ................................................................................................................. 13
Speed control / Vector control .......................................................................................................... 15
Induction motor ................................................................................................................................ 17
Exercises ......................................................................................................................................... 23
Exercise 1: Setpoint source .............................................................................................................. 24
Exercise 2: Setpoint channel ............................................................................................................ 27

SITRAIN Page Course DR-G12-PM

Training Document 5-1 Setpoint channel and Closed-loop control
SITRAIN Page Course DR-G12-PM
Training Document 5-2 Setpoint channel and Closed-loop control
Signal flow The signal flow in the setpoint channel is as follows::
• The signal source Is the origin (here analog input)
• In the “speed setpoint” the signal is edited
• The “speed limit” verifies if the setpoint is valid
• The “ramp-function generator” defines the dynamics of the movement
In the end the setpoint is handed over to the close-loop control.

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Training Document 5-3 Setpoint channel and Closed-loop control
Setpoint sources The inverter receives its main setpoint from the setpoint source. The main
setpoint generally specifies the motor speed.
The following options are available for the setpoint source of the main setpoint
and the supplementary setpoint:
• Inverter analog input.
• Inverter fieldbus interface.
• Motor potentiometer simulated in the inverter.
• Fixed setpoints saved in the inverter.

Macro P0015 Parameter P0015 serves to automate and thereby facilitate commissioning
through execution of a corresponding macro. When a selected macro is
executed, the programmed settings are applied and become effective.
The command sources, setpoint sources and outputs signals are pre-assigned
automatically. Different macros can be selected depending on the application
and requirements.

Note You can define the configuration of the command and setpoint sources either
manually or using parameter P0015. The I/O configuration is preassigned via
macros so that no further settings are necessary. A range of different settings
are possible depending on the Control Unit used. Detailed information is
provided in the Operating Instructions.

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Training Document 5-4 Setpoint channel and Closed-loop control
Description Here, you define the parameters of the analog inputs of the drive.
An analog input can be parameterized either as a voltage or a current input.

Scaling The scaling defines the percentage for the input signal, e.g. 0 to 10 V
corresponding to 0 to 100 %.
As a speed setpoint, the percentage refers to the reference speed (P2000) that
is defined automatically during commissioning as a function of the motor speed,
e.g. 4-pole motor => P2000 = 1500 rpm (synchronous speed)

Smoothing To smooth temporary variations in the measured value at the analog input, you
can specify a time constant. The larger the smoothing time constant, the slower
the response of the analog input to changes in the measured value.

SITRAIN Page Course DR-G12-PM

Training Document 5-5 Setpoint channel and Closed-loop control
Motor potentiometer This function simulates an electromechanical potentiometer for entering
setpoints. The value of the motor potentiometer (MOP) can be set by means of
the "up" and "down" control commands.

Setpoint higher You can connect the source for increasing the setpoint of the motor
potentiometer here.

Setpoint lower You can connect the source for reducing the setpoint of the motor
potentiometer here.

Maximum value Enter the maximum value of the drive speed here. Changing the maximum
value affects the ramp-function generator, the limits and the programmable V/f
characteristic.

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Training Document 5-6 Setpoint channel and Closed-loop control
Fixed setpoints The "Fixed setpoints" function allows a setpoint value for the drive to be
entered. This is an alternative selection option to entering a setpoint using
analog inputs, the serial data interface, the JOG function or the motor
potentiometer.

Parameters The fixed setpoints are defined by means of parameters P1001 to P1015 and
can be selected or combined by means of binector inputs P1020 to P1023.

Output value The effective fixed setpoint is available via the connector output r1024.
If this is to be used as the setpoint source, then macro parameter P0015 must
be changed, or the connector output r1024 must be connected to the main
setpoint P1070 or the additional setpoint P1075.

SITRAIN Page Course DR-G12-PM

Training Document 5-7 Setpoint channel and Closed-loop control
Main setpoint Defines the source of the main setpoint.

Scaling Defines the source from which the scaling of the main setpoint is read.

Additional setpoint Defines the source of the supplementary setpoint.

Scaling Defines the source from which the scaling of the additional setpoint is read.

Jog The function jog is used for example:

to check the motor and inverter after the commissioning (first movement, check
the direction, etc.), or to move the motor or the load after an interrupt.
The function can be started using the signals JOG 1or JOG 2. The values JOG
1 speed setpoint and JOG 2 speed setpoint defines the speed for the JOG-
mode.
technology controller
(PID controller) The SINAMICS G120 provides an integrated technological controller (PID-
controller) for closed-loop functions such as liquid level closed-loop control or
temperature control.
The P-,I- and the D- component can be set or switched off separately.
An application for the setpoint channel could be:
• as the main setpoint
• as fine adjustment

Direction reversal Defines the source to initiate a direction reversal in the setpoint channel after
reaching the end point.
Block negative
direction of rotation Defines the source to block a negative direction of rotation.

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Training Document 5-8 Setpoint channel and Closed-loop control
Skip frequency bands Suppression values can be used for example, to prevent mechanical resonance
effects. The setpoint speeds are suppressed by +/- bandwidth. Stationary
operation in the suppressed speed range is not possible. The suppression
range is skipped.

Minimum limitation Here you can enter the permissible minimum speed. This speed is not
undershot during operation. The parameter value is valid for both motor
directions of rotation. In exceptional cases, the motor can operate below this
value (e.g. when reversing).

Maximum limitation This value serves as limit for the controller. This is the maximum speed value
the motor should achieve. A modification of this value affects the settings for the
controller and the ramp-function generator.
There are other limitation variants, i.e. an individual fixed limit can be specified
for the negative and the positive direction of rotation.

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Training Document 5-9 Setpoint channel and Closed-loop control
Ramps The ramp-function generator is used to limit acceleration when abrupt setpoint
changes occur, which helps protect the mechanics of the connected machine.
The ramp-up time P1120 and ramp-down time P1121 can be used to set an
acceleration ramp and a deceleration ramp independently of each other. This
allows a controlled transition to be made in the event of setpoint changes.

Rounding Additional rounding times can be programmed in P1130 to P1133 to prevent

torque surges at the transitions between constant speed and ramp (low
stressing of the mechanic).
This is particularly important in applications that require smooth, jerk-free
acceleration and deceleration e.g.
• transport of liquids on a conveyor
• hoisting gear

Typical times Depending on the moment of inertia of the driven mechanics, the ramp-up and
ramp-down times may vary significantly. For large fan drives, for example, times
between 30 and 120 seconds must be provided.

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Training Document 5 - 10 Setpoint channel and Closed-loop control
Output voltage If the motor is operated via an inverter, the speed can be changed between
standstill and rated speed (and beyond).
Question: What voltage does the inverter output when the speed is increasing?
Answer: The voltage must rise in proportion to the speed.
Reason:

Resistance The motor primarily provides an inductive resistance. If the frequency of the
current is rising, the resistance increases too. A higher voltage is now called for,
even though the current flow is the same.

V/f characteristic Consequently, if the three-phase-current frequency is increasing, the inverter

output voltage must rise in proportion to it. When operating at rated speed, the
inverter outputs a voltage which is more or less the same as the supply voltage.
This relationship is referred to as the V/f characteristic or V/f control. (spoken
as: "V to f")

Ohmic resistance The ohmic resistance is also taken into account in the closed-loop control. It
only occurs distinctly at low output frequencies. This is reflected in the control,
by an increase in the V/f characteristic in the range from 0 to 5 Hz
approximately.

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Training Document 5 - 11 Setpoint channel and Closed-loop control
Differentiation Different open-loop and closed-loop control technologies are used for speed
and torque control for inverters with induction motors.
These technologies can be roughly classified as follows:

• Open-loop control with V/f-characteristic (so called V/f control)

• Field-oriented control technology (so called vector control)
Vector control can be further divided into two subgroups:
− Vector control without speed feedback (sensorless vector control (SLVC))
− Vector control with speed feedback (vector control (VC))

These open-loop and closed-loop control technologies differ from each other
both in their ability to control and regarding their technical complexity. Which
technology to use depends on the requirements relating to a specific
application.

Applications V/f control is generally used for simple applications (e.g. pumps and fans).
Vector control is preferred for demanding applications (e.g. winding machines)
where good control regarding speed and torque and good behavior in an
imperfect environment is required.
If these requirements also lie in the range from 0 Hz to around 1 Hz, then the
precision of the speed/torque is not sufficient without an encoder. In this case,
vector control with speed feedback must be used.

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Training Document 5 - 12 Setpoint channel and Closed-loop control
Linear characteristic The linear V/f relation is initially the standard case. The motor is always
sufficiently magnetized in this context and the inverter can react quickly to
setpoint changes or load surges.
Flux current control
FCC The flux current control (FCC) can provide a more efficient and better load
behavior than other V/f modes, because the FCC characteristic automatically
compensates voltage losses from the stator resistance at static or dynamic
loading.
This is particularly significant for small motors, as they have a relatively high
stator resistance.
Parabolic
characteristic This characteristic takes into account the torque characteristic of loads, such as
pumps or fans. More precisely one should speak of fans, pumps and
compressors here, because reciprocating pumps, for example do not have a
quadratic characteristic.
The advantage of a quadratic characteristic is an energy saving at partial load,
since the lower voltage causes a lower magnetization current and therefore
lower losses.
This restricts the control dynamics, which is, however, permissible for the
following reasons with pumps and fans:
• Setpoint changes normally take place over a period of seconds or minutes.
• The counter torque is so low at partial load that the motor always has
sufficient torque to accelerate .

Freely programmable The relationship between speed and voltage is defined by the user.

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Training Document 5 - 13 Setpoint channel and Closed-loop control
Slip For the V/f characteristic operating mode, the motor frequency is always smaller
than the inverter output frequency by the slip frequency ∆f. If the load is
increased at constant output frequency (increasing the load from M1 to M2), the
slip increases in the motor operation and the motor frequency decreases (from
f1 to f2).

Compensation The slip compensation can be used to compensate this behavior of the
induction motor. Here the load-related speed reduction is compensated by
increasing the inverter output frequency.

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Training Document 5 - 14 Setpoint channel and Closed-loop control
Principle Using a motor model, the speed or vector control calculates the load and the
slip of the motor. As a result of this calculation, the inverter controls its output
voltage and frequency so that the motor speed follows the setpoint, independent
of the motor load.

Sensorless Speed control is possible without directly measuring the motor speed and is
therefore also called sensorless vector control (SLVC).

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Training Document 5 - 15 Setpoint channel and Closed-loop control
Necessity The vector control only functions error-free if, during the basic commissioning,
you correctly parameterized the motor data and performed the motor data
identification with the motor in the cold state.

Sequence The sequence in which this is carried out is also important as basic
commissioning delivers output data for the motor model and the motor
identification specifies these.

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Training Document 5 - 16 Setpoint channel and Closed-loop control
Layout The most important components of the induction motor are:
• Stator
• Rotor

Stator The stator consists of punched sheet metal, layered to produce the round outer
shape of the motor. There are slots on the inside to accommodate the windings.

Rotor The rotor is also made of punched sheets. These sheets produce continuous,
rod-like hollow cavities when placed one on top of the other. These cavities are
cast in aluminum and then form the current-carrying rods.
For a short-circuit rotor, the short-circuit rings are also cast in aluminum at both
ends. Ultimately, current flows through the aluminum; the sheet serves to
conduct the magnetic field lines and for mechanical installation.
In the case of high-efficiency motors, the aluminum is partially or wholly
replaced by copper.

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Training Document 5 - 17 Setpoint channel and Closed-loop control
Equivalent
circuit diagram The currents in the stator and rotor come up against both ohmic and inductive
resistances, where inductances at high frequencies are significant.
The magnetic field generated by the stator is linked to the rotor's magnetic field.
This is referred to as main field inductance and is represented as a single
component.
In part, these values are largely dependent on the frequency and temperature,
meaning that a precise mathematical simulation of the motor can be difficult to
achieve.
Parameters
in the inverter Practically all modern inverters work internally with parameters which contain
equivalent circuit diagrams. The values are preassigned automatically during
commissioning:
• Calculated from the rating plate data
• Via automatic inverter measurements (motor identification), if required
The equivalent circuit diagram data are entered manually in special cases only.

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Training Document 5 - 18 Setpoint channel and Closed-loop control
Calculation Calculation of the motor parameters
The parameter P0340 is required during commissioning to optimize the
operating behavior of the inverter. For complete parameterization (P0340=1),
not only the motor and controller parameters are assigned in advance but also
the parameters which relate to the rated motor data (e.g. torque limit values and
reference quantities for interface signals). A list of the parameters which are
calculated depending on the setting of P0340 can be found in the Parameter list.
0: No calculation
1: Complete calculation
2: Calculation of equivalent circuit diagram parameters
3: Calculation of closed-loop control parameters
4: Calculation of controller parameters
5: Calculation of technological limits and threshold values

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Training Document 5 - 19 Setpoint channel and Closed-loop control
Motor identification SINAMICS G120 offers two measuring methods for determining the motor
parameters:
• Equivalent circuit diagram data
• Magnetization characteristic

Benefit For control-related reasons, you are strongly advised to carry out motor data
identification because the equivalent circuit diagram data, motor cable
resistance, IGBT forward voltage and compensation for the IGBT lockout times
can only be estimated if the data on the type plate is used.
The stator resistance, for example is very important for the stability of vector
control and for the voltage boost in the V/f characteristic.
Motor data identification is essential if long supply cables or third-party motors
are used.

Note Basic commissioning must have been completed before the motor data
identification is selected.

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Training Document 5 - 20 Setpoint channel and Closed-loop control
Description The identification/optimization helps with determining the motor data. It should
be carried out to improve the close loop control. In particular for vector control
w/o sensor, at least the stator resistance (including the supply cable resistance)
must be determined. This is required so that the observer model can operate
correctly even at very small speeds.

Requirements The following steps should be performed in the specified order.

1. Enter motor data using details from the data sheet/type plate.
2. Calculate the motor and control parameters using Startdrive or p0340. When
the drive wizard is used, this will be performed after the download. You will
find a description of parameter p340 in the online help.
3. Perform the motor identification with a cold motor or adapt the temperature.
4. Perform the stationary measurement first and then the turning measurement.
5. Perform the rotational measurement (only in Vector control) for a motor
running without load.
For the rotational measurement, the motor should be disconnected from the
machine to prevent damage to the mechanical system.
Performing
measurement The "Measurement type" list shows the available measurement types. A check
is made to determine whether a measurement is already active and, if so, it will
be displayed. After executing the drive wizard, the selection is set to "Stationary
measurement", because the "Complete calculation ..." has already been
performed.

Selecting measurements
yourself You should only select the measurement in the list manually if you are an
experienced user. This allows you to repeat a measurement, for example.

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Training Document 5 - 21 Setpoint channel and Closed-loop control
Starting the
measurement Open the screen form in ONLINE mode
1. Enter the cable resistance (p352) and the motor ambient temperature.
2. If it is not already active, click "Activate measurement", to initiate the motor
data identification.
3. With the next ON command, e.g. via the drive control panel the
measurement will start.
The motor identification finishes automatically and then the message appears
that the drive is in the "Switching On Inhibited" state.
After measurement, the new parameter values are shown in the results
table. You can view and check the new values.

Next measurement Carry out further measurements:

1. Click on "Next measurement".
The next measurement will be suggested by Startdrive and the
corresponding entry displayed in the "Measurement type" list.
2. Perform the measurement as described above.
3. Continue to perform "Next measurement" until the entry "None" appears in
the "Measurement type" list. You have then performed all required
measurements.
4. Select the measurements yourself

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Training Document 5 - 22 Setpoint channel and Closed-loop control
SITRAIN Page Course DR-G12-PM
Training Document 5 - 23 Setpoint channel and Closed-loop control
Requirements You have completed exercise 5, chapter 3 (basic commissioning).

Task Test the diverse options for adjusting the analog input to the system!

1. The entire speed setting rate range should be controlled with setpoint of 2 to
5 V. For this, adjust the scaling of the analog input used
>> G120_ > Parameter > Input/outputs > Analog inputs
2. Test the behavior.

3. The setpoint is present as a 10 to 0 V signal. For this, readapt the scaling to

invert the setpoint
>> G120_ > Parameter > Input/outputs > Analog inputs
4. Test the behavior.
Then restore the original state.

5. There is a current signal of 4 to 20 mA. What settings are necessary?

Since the training device does not deliver such an input signal, please
just provide the theoretical answer:

PPPPPPPPPPPPPPPPPPPPPPPPPPPPPP

PPPPPPPPPPPPPPPPPPPPPPPPPPPPPP

PPPPPPPPPPPPPPPPPPPPPPPPPPPPPP

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Training Document 5 - 24 Setpoint channel and Closed-loop control
Task The motor potentiometer function requires two signals: faster and slower.
Test this function!

1. Select the motor potentiometer as the setpoint source:

>> G120_ > > Setpoint channel > Motor potentiometer
2. Assign the digital inputs DIN the following functions:
• Setpoint higher = DIN3 (r722.3)
• Setpoint lower = DIN4 (r722.4)
3. Interconnect the output with the main setpoint (p1070).
4. Test your parameter assignments
5. Shorten the ramp-up time of the motor potentiometer to 3 s:
> Motor potentiometer > Ramp-function generator
6. Make the motor rotate at medium speed.
Use ON/OFF1 to switch off and back on again.
At which speed does the motor restart?

PPPPPPPPPPPPPPPPPPPPPPPPPPPPPP
7. Now the drive should restart with the previous speed.
What setting is required?

PPPPPPPPPPPPPPPPPPPPPPPPPPPPPP
8. Test this saving of the motor potentiometer setpoint.

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Training Document 5 - 25 Setpoint channel and Closed-loop control
Task The drive should normally work with a fixed setpoint of 1000 rpm. An additional
change of up to 150 rpm should be possible with the analog input!

1. Select Fixed setpoints as the setpoint source:

>> G120_ > > Setpoint channel > Fixed setpoints:
2. Enter the speed 1000 rpm for the fixed setpoint 1.
Activate the fixed setpoint permanently with a logical "1“.
Interconnect the fixed setpoint with the main setpoint (p1070).
3. Connect the analog input as a additional setpoint (p1075):
>> G120_ > > Setpoint channel > Speed setpoint
4. Scale the analog input to 10 % (150 rpm of 1500 rpm reference speed):
> Additional setpoint scaling > Fixed setpoint + 10% (p2902.2)
Check the settings at the analog input again if necessary
>> G120_ > Inputs/outputs > Analog inputs
5. Use ON/OFF1 to switch on and test the setpoints.
6. Observe the actual speed value in BOP-2, IOP-2 or on the status display in
Startdrive

AI 0 = min:PPPPPPPPPPPPPPPPPrpm

AI 0 = max:PPPPPPPPPPPPPPPPPrpm

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Training Document 5 - 26 Setpoint channel and Closed-loop control
Requirements You have completed exercise 5, chapter 3 (basic commissioning)

Task Change the value of the minimum speed.

In many HVAC applications, it is necessary to define a minimum speed which is
equivalent to an output frequency of 10 Hz. To be able to enter the correct
speed now, you need to calculate it from the motor's rated speed. To do this, we
use the following formula:

nmin = ( fmin / fSync ) * nSync

in this example (fmin=10 Hz, fSync=50 Hz, nSync=1500 rpm, since 4-pole):

nmin = ( fmin / fSync ) * nSync

= (10 Hz / 50 Hz) * 1500 rpm = 1/5 * 1500 rpm
nmin = 300 rpm

Note: If the rated data of your training device are different to the above, please
calculate nmin accordingly.
Alternatively, fmin=10 Hz can be taken from the table below:
2-pole: nmin = 600 rpm
4-pole: nmin = 300 rpm
6-pole: nmin = 200 rpm
8-pole: nmin = 150 rpm

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Training Document 5 - 27 Setpoint channel and Closed-loop control
Task Dependent on the application and mechanics, damage may result if the unit
speed is too high . Then on one hand, the setpoint can be limited or the limit can
be set in the drive.
Set a limit at a maximum of 1000 rpm!

1. Set the upper speed limit to 1000 rpm

>> G120_ > > Setpoint channel > Frequency/speed limitation
> Maximum limitation
2. Test the limit.

3. The analog input now has an invalid setting range. Change the scaling so
that the entire setting range is used:
>> G120_ > Inputs/outputs > Analog inputs
Here, please consider the parameterized minimum and maximum values in
relation to the reference speed (1500 rpm, p2000)
4. Test the new setting range.

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Training Document 5 - 28 Setpoint channel and Closed-loop control
Task Dependent on the application and mechanics, resonances may occur in the unit
at a particular speed and cause damage.
Activate a suppression speed!

1. Set a suppression speed of 600 rpm with a bandwidth of ± 100 rpm:

>> G120_ > Setpoint channel > Speed limitation
> Skip frequency bands
2. Switch on the drive and change the setpoint slowly from the minimum to the
maximum speed.
What do you observe?
From which setpoint is the suppression range passed through quickly?

PPPPPPPPPPPPPPPPPPPPPPPPPPPPPP

PPPPPPPPPPPPPPPPPPPPPPPPPPPPPP

PPPPPPPPPPPPPPPPPPPPPPPPPPPPPP

3. Load the original project (exercise 5, chapter 3, basic commissioning) back

into the drive to reset all the changes.

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Training Document 5 - 29 Setpoint channel and Closed-loop control
SITRAIN Page Course DR-G12-PM
Training Document 5 - 30 Setpoint channel and Closed-loop control