Toshiba ASD 9 Series User manual

PID CONTROL MANUAL
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PID Control
Manual
Document Number: 58695-000
Date: March, 2008
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Introduction
Congratulations on your purchase of the Toshiba 9-Series ASD. The 9-series ASD has been designed to
provide excellent speed and torque control in an open-loop feedback configuration.
The 9-series ASD performance can be further enhanced by using either process-based or speed-based PID
control. PID is a closed-loop technique that minimizes error by reacting to three feedback values:
• One value that is proportional to the error.
• One value that is proportional to the cumulative error.
• One value that is proportional to the rate of change of the error.
Important Notice
The instructions contained in this manual are not intended to cover all details or variations in equipment
types. Nor may it provide for every possible contingency concerning the installation, operation, or
maintenance of this equipment. Should additional information be required contact your Toshiba
representative.
The contents of this manual shall not become a part of or modify any prior or existing agreement,
commitment, or relationship. The sales contract contains the entire obligation of Toshiba International
Corporation. The warranty contained in the contract between the parties is the sole warranty of Toshiba
International Corporation and any statements contained herein do not create new warranties or modify the
existing warranty.
Any electrical or mechanical modifications to this equipment without prior written consent of
Toshiba International Corporation will void all warranties and may void other safety certifications.
Unauthorized modifications may also result in a safety hazard or equipment damage.
Misuse of this equipment could result in injury and equipment damage. In no event will Toshiba
Corporation be responsible or liable for direct, indirect, special, or consequential damage or injury
that may result from the misuse of this equipment.
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Contacting Toshiba’s Customer
Support Center
Toshiba’s Customer Support Center can be contacted to obtain help in resolving any Adjustable Speed
Drive system problem that you may experience or to provide application information.
The center is open from 8 a.m. to 5 p.m. (CST), Monday through Friday. The Support Center’s toll free
number is US [phone]/Fax [phone] — Canada [phone].
You may also contact Toshiba by writing to:
Toshiba International Corporation
13131 West Little York Road
Houston, Texas 77041-9990
Attn: ASD Product Manager.
For further information on Toshiba’s products and services, please visit our website.
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About This Manual
This manual was written by the Toshiba Technical Publications Group. This group is tasked with
providing technical documentation for the 9-Series family of ASDs. Every effort has been made to
provide accurate and concise information to you, our customer.
At Toshiba we’re continuously searching for better ways to meet the constantly changing needs of
our customers. E-mail your comments, questions, or concerns about this publication.
Manual’s Purpose and Scope
This manual details the PID feedback control related parameters, functions, and their default values.
Both process and speed PID feedback control can be customized by adjusting these ASD parameter
settings.
This manual is to be used in conjunction with the operations manual specified for your 9-Series ASD.
To maximize the functionality of the ASD while operating in the PID control mode a working
familiarity with this manual will be required. This manual has been prepared for theASD installer, user,
and maintenance personnel. This manual may also be used as a reference manual or for training. With
this in mind,use this manual to develop asystem familiarity before attempting to operate the ASD using
the PID Control Function parameters
Because of our commitmentto continuous improvement,Toshiba International Corporation reserves the
right, without prior notice, to update information, make product changes, or to discontinue any product
or service identified in this publication.
Toshiba International Corporation (TIC) shall not be liable for direct, indirect, special, or
consequential damages resulting from the use of the information contained within this manual.
TOSHIBA is a registered trademark of Toshiba Corporation. All other product or trade references
appearing in this manual are registered trademarks of their respective owners.
This manual is copyrighted. No part of this manual may be photocopied or reproduced in any form
without the prior written consent of Toshiba International Corporation.
© Copyright 2008 Toshiba International Corporation.
All rights reserved.
Printed in the U.S.A.
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Table of Contents
PID Control Manual i
System Control Using PID................................................................................................1
Process/Speed PID Control...............................................................................................2
Select the PID Mode ....................................................................................................2
Specify the Process Reference Value...........................................................................2
Specify the Feedback Response...................................................................................4
Set the Limit Parameters ..............................................................................................6
Set the PID Gain Parameters........................................................................................6
Simple Position PID Control ............................................................................................6
Additional PID Related Commands ................................................................................7
Switch to Open Loop Operation...................................................................................7
Reset the Integral and Differential Gain for PID Control............................................7
Display the Process and Feedback Values...................................................................7
Scaling the Analog Input Signal...................................................................................8
PID Control Parameter Summary.................................................................................10
Parameter Descriptions ..............................................................................................12
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ii PID Control Manual
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PID Control Manual 1
System Control Using PID
PID is an operating mode that maintains a constant system output by comparing the monitored system
output (feedback) to a setpoint and compensating for the difference between the two. System
adjustments are increased or decreased as a function of the received feedback. This self-correcting
action eliminates the requirement for constant operator intervention.
The automatic adjustment may be either process-variable-, speed-, or position dependent.
The PID Control Switch parameter enables the PID function by allowing the user to select the PID
operating mode. Selecting PID Off disables the PID function.
1. PID Off — Disables the PID feedback.
2. Process PID — Monitors the control variable (e.g., temperature, pressure, etc.) as the measurement
that is to be compared to the setpoint in determining the ASD output adjustment. See Figure 1.
3. Speed PID — Monitors the ASD output speed (e.g., Motor RPM, encoder, etc.) as the measurement
that is to be compared to the speed setpoint in determining the ASD output adjustment.
See Figure 2.
4. Simple Position PID — Monitors the load position (e.g., crane, sprayer, etc.) as the measurement
that is to be compared to the setpoint in determining the ASD output adjustment. See Figure 3.
Figures 1 – 3 show the relationship of the parameters required for Process PID, Speed PID, and Easy
Position PID.
Figure 1. Diagram for F359 = Process PID.
Figure 2. Diagram for F359 = Speed PID.
Process
Reference
Value
Process Upper Limit
F367 PID Control Jump Frequency
Processing Increase/
Decrease Rate
Acceleration Time 1 - F00
9
Deceleration Time 1 - F01
0
F368
Process Lower Limit
PID Deviation
Upper Limit
F364
F365
PID Deviation
Lower Limit
PID Output
Upper Limit
F370
F371
PID Output
Lower Limit
Upper Limit
Frequency
F012
F013
Lower Limit
Frequency
Feedback Signal
Process Upper Limit
F367 PID Control Jump Frequency
Processing
Process
Increase/
Decrease Rate
Process
Increase Rate - F372
Decrease Rate - F373
F368
Process Lower Limit
PID Deviation
Upper Limit
F364
F365
PID Deviation
Lower Limit
PID Output
Upper Limit
F370
F371
PID Output
Lower Limit
Upper Limit
Frequency
F012
F013
Lower Limit
Frequency
Feedback Signal
Delay
Filter
F361
S
peed
R
eference
V
alue
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2PID Control Manual
Figure 3. Diagram for F359 = Position PID.
Process/Speed PID Control
Select the PID Mode
Select the PID mode at parameter F359 and the PID feedback source at parameter F360.
Position PID is addressed specifically in Simple Position PID Control on pg. 6.
Specify the Process Reference Value
Select the feedback input at F004 and F207. Adjust the process reference value (set point) to deliver the
desired process variable output. The commanded frequency and actual output frequency may not
always be the same because it is only the value of the process variable that is the basis of the feedback
response.
Example: Set the Process Reference Value With an External Signal.
An example of a process reference value set with an external signal is shown on the next page. Figure 4.
The desired process output is 15 psi.
A process reference value of 5 V will produce a process output of 15 psi. This process reference value
of 5 V corresponds to a frequency command of 40 Hz.
The process feedback is input at the V/I terminals. The ASD parameters F201 – F204 are set so a
feedback value of 12 mA from the pressure transducer corresponds to a frequency command of 40 Hz.
Input the frequency set points and associated process values. Set the maximum frequency to 80 Hz.
Parameter settings:
F004 = RR Input F360 = V/I Input F011 = 80.0 Hz F012 = 80.0 Hz
F201 = 20% F202 = 0 Hz F203 = 100% F204 = 80 Hz
F210 = 0% F211 = 0 V F212 = 100% F213 = 10 V
PID Control
Position Completion
Range
F381
F381
Position
Completion Range
Feedback Signal
Position
Reference
Value
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PID Control Manual 3
Figure 4. Process reference set with external signal.
Note: On the 9-Series ASD, set SW301 to either Current or Voltage as the feedback signal
type. SW301 is located on the Terminal Board of the 9-Series ASD. See the ASD
Operation Manual.
Figure 5. Feedback and Process reference signal frequency conversion.
Note: To simplify this example the Upper Limit Frequency (F012) was set to the Maximum
Frequency (F011). For real applications it is good practice to set the Upper Limit
Frequency lower than the Maximum Frequency.
Feedback Value (4 – 20 mA) Process Value (0 – 10 V) Operation Frequency Command
Value (0 – 80 Hz)
4 0 0
82.5 20
12 5.0 40
16 7.5 60
20 10 80
Sensor Range:
IICC
V/I
CC
RR
U
V
W
R
S
TM
sensor
Pressure
Pump
P
3-Phase Input
Process feedback
DC: 4 – 20 mA
Process reference value
DC: 5 V (0 – 10 V) Desired process
value: 15 psi
10 - 20 psi
20 psi
10 psi
15 psi
10 psi
20 psi
Process feedbackProcess feedback Process reference value Process reference value
(converted into frequency) (converted into frequency
)
80 Hz 80 Hz
40 Hz
0 Hz0 Hz
4 mA 20 mA 4 mA 20 mA 0 V 10 V 0 V 10 V5 V
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4PID Control Manual
Specify the Feedback Response
For V/I frequency control establish the response slope of the ASD by entering two parameter pairs.
Each parameter pair consists of an input point setting (F202 and F204) and a corresponding frequency
(F201 and F203) at that setting.
If using either RR or RX for frequency control, set their respective response slope parameters, F210 –
F213 or F216 – F219, as above.
For a 4 - 20 mA current loop feedback signal, 4 mA is 20% of 20 mA. Set parameter F201 to 20% at
4 mA and F202 to 0 Hz, F203 to 100% at 20 mA and F204 to 80 Hz.
Figure 6. V/I input points for 4-20 mA feedback signal.
Reverse the Feedback Response
A negative response slope can be established by either of two methods:
• Switch the values of the V/I Input Point Frequencies F202 and F204.
• Switch the ASD response from normal to inverted.
Example: Reverse the Response Slope Using V/I Input Point Settings.
A system using a 4 – 20 mA feedback signal requires an inverted feedback response slope. Parameters
F201 – F204 would have their values set as shown below.
Figure 7. Inverting the feedback response slope.
F202
F203
F201
4 mA 20 mA
0 Hz
80 Hz
20% 100%
F204
80 Hz
F202
0 Hz 4 mA
F201
20%
20 mA
F203
100%
F204
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PID Control Manual 5
Example: Invert the Response Slope Using an External Switch.
Use the S3 terminal as a PID normal/inverse slope characteristic switching signal input terminal.
This figure illustrates the PID feedback value (maximum frequency: 80 Hz) to the V/I terminal using
the S3 terminal to switch between the positive and negative response slope. When the switch to S3 is
open, the feedback slope is normal, and when the switch to S3 is closed, the slope is inverted.
Figure 8. Feedback response slope polarity switching with S3.
Figure 9. External switch on S3.
Table 1. Parameter settings for slope polarity switching output.
Parameter
Number Parameter Name Selectable Functions Range Setting
F117 Input Terminal 7 (S3) 0 – 131 54 - PID Positive/Negative Slope Switching
Parameter
Number Parameter Name Setting
F117 Input Terminal Function - S3 54
F201 V/I Input Point 1 Setting 20
F202 V/I Input Point 1 Frequency 0
F203 V/I Input Point 2 Setting 100
F204 V/I Input Point 2 Frequency 80
100%
20%
4 mA 20 mA
80 Hz
0 Hz
Open between S3 and CC
Closed between S3 and CC
(Set SW 301 to Current)
DC: 0 – 10 V
External analog set point
Feedback signal
DC: 4 – 20 mA
IICC
V/I
CC
S3
External discrete input to S3
V/I Feedback
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6PID Control Manual
Set the Limit Parameters
Set the high-low limit parameters. Some parameters are mode specific, as indicated in the following
table.
Table 1. Limit parameters applicability.
Set the PID Gain Parameters
Set and adjust the F362 – Proportional (P), F363 – Integral (I), and F366 – Differential (D) gain
parameters as necessary to optimize the system response. See page 14.
Simple Position PID Control
Simple Position PID control is used to keep a stopped load motionless. Simple Position PID control
would be used to keep a stopped elevator from shifting position as the elevator load changed.
Simple Position PID control mode requires the ASD be in PG Vector Feedback mode (F015 = 7 or 8)
and parameters F240, F241, and F243 set to 0.0 Hz.
Simple Position PID control is performed when a position control signal is received. The discrete input
terminal assignment for Simple Position PID control is 72. The motor position at the time the command
is received is recorded and used as the position reference point.
The parameters required for Simple Position PID Control setup are listed in the following table.
Table 2. Required Simple Position PID Control parameters.
Limit Parameters Process PID Speed PID
F364, F365 – PID Deviation Upper and Lower Limit YES YES
F368, F367 – Process Upper and Lower Limit YES YES
F370, F371 – PID Output Upper and Lower Limit YES YES
F012, F013 – Upper and Lower Limit Frequency YES YES
F011 – Maximum Frequency YES YES
F009, F010 – Acceleration and Deceleration Time YES NO
F372, F373 – Process Increasing and Decreasing Rate NO YES
F361 – Delay Filter NO YES
Parameters Function Setting
F015 V/f Control Mode Selection 7: PG Vector Feedback Control or
8: PG Vector Feedback Control
F240 Start Frequency 0.00
F241 Operating Frequency 0.00
F243 End Frequency 0.00
F359 PID Control Switching 3: Position PID Control
F360 PID Control Feedback Selection 6: PG Feedback Option
F362 Proportional Gain 0.01 – 100.00
F363 Integral Gain 0.01 – 100.00
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PID Control Manual 7
Additional PID Related Commands
Switch to Open Loop Operation
Switching between PID control and open loop operation can be done with a discrete input. Use the PID
Control OFF selection, Input Terminal functions 36 or 37, to switch from PID operation (automatic
operation) to open loop operation (manual operation).
When switching between PID and open loop operation set the manual setpoint equal to the PID setpoint
during the transition in control modes.
Reset the Integral and Differential Gain for
PID Control
The PID Differentiation/Integration Clear function is used to reset the PID control integral gain and
differential gain to the factory default values. Use discrete input terminal function 52.
Display the Process and Feedback Values
Parameters Display Unit Multiplication Factor (F702) and Display UnitSelection (F703) can be used to
modify the ASD display to give a direct reading of the process output.
If F703 is set to 1, the displayed value becomes
[Frequency displayed] × [number specified at F702] = [Value displayed]
Example: Display motor speed for a four-pole motor.
Change the display mode from the default display setting of 60 Hz to display 1800 (rpm) for a 4-pole
motor.
Set F703 to 1 – PID Process Data.
Set F702 = 30.
60 x 30 = 1800
The ASD now displays the calculated motor speed of 1800 instead of the real-time output frequency of
60.
F375 Number of PG Input Pulses 12 – 9999
F376 Number of PG Input Poles 2
F381 Simple Positioning Completion Range 100
F111-F118 (any one) Simple Positioning 72
Parameters Function Setting
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8PID Control Manual
Scaling the Analog Input Signal
Any two set points may be used to establish a response slope for the ASD. It is not necessary that the
two set points be at 0% and 100% of the feedback signal range.
Weak feedback signals can compensated for by adjusting the set points. For instance, if the feedback
signal for the voltage input terminal below were only 3 – 7 V, the same slope would be created by
entering the parameter pair settings F201-F202 and F203-F204 shown in Figure 10.
Figure 10. Example of voltage scaling to compensate for feedback amplitude.
F204
F202
F203F201
7 V
3 V
56 Hz
24 Hz
70%
30%
0 V
0% 10 V
100%
0 Hz
80 Hz
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PID Control Manual 9
Figure 11. Examples of feedback slopes.
F204
F202
Example: V/I used as a Voltage Input Terminal
F203
F201
10 V
0 V
80 Hz
0 Hz
100%0%
F213
F211
Example: RR Terminal Settings
F212
F210
10 V
0 V
80 Hz
0 Hz
100%0%
F204
F202
Example: V/I used as a Current Input Terminal
F203
F201
20 mA
4 mA
80 Hz
0 Hz
100%20%
F219
F217
Example: RX Terminal Settings
F218
F216
10 V
-10 V
80 Hz
0 Hz
100%-100%
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10 PID Control Manual
PID Control Parameter Summary
The PID-related ASD parameters are summarized in the table below.
Table 3. PID control parameters.
Parameter
Number Parameter Name Adjustment Range Default Setting
F004 Frequency Mode 1
1: V/I
2: RR
3: RX
4: Not Used
5: EOI Keypad
6: RS485
7: Communications Option Board
8: RX2 (AI1)
9: Option V/I
10: UP/DOWN Frequency (terminal board)
11: Pulse Input (option)
12: Pulse Input (motor CPU)
13: Binary/BCD Input (option)
2: RR
F009 Acceleration Time 1 0.1 – 6000 sec. Typeform
Specific
F010 Deceleration Time 1 0.1 – 6000 sec. Typeform
Specific
F011 Maximum Frequency 30.0 – 299.0 Hz 80.0
F012 Upper Limit Frequency 0.0 – F011 Hz 60.0
F013 Lower Limit Frequency 0.00 – F012 Hz 0.00
F015 V/f Pattern
0: Constant Torque
1: Voltage Decrease slope
2: Automatic Torque Boost
3: Sensorless Vector Control (Speed)
4: Sensorless Vector Control (Speed/Torque)
5: V/I 5-Point slope
6: PM Drive
7: PG Vector Feedback Control (Speed)
8: PG Vector Feedback Control (Speed/
Torque)
8: PG Vector
Feedback Control
F201 V/I Input Point 1 Setting 0 – 100% 0
F202 V/I Input Point 1 Frequency 0.00 – F011 Hz 0.00
F203 V/I Input Point 2 Setting 0 – 100% 100
F204 V/I Input Point 2 Frequency 0.00 – F011 Hz 60.00
F207 Frequency Mode 2 Same as F004 1
F210 RR Input Point 1 Setting 0 – 100% 0
F211 RR Input Point 1 Frequency 0.00 – F011 Hz 0.00
F212 RR Input Point 2 Setting 0 – 100% 100
F213 RR Input Point 2 Frequency 0.00 – F011 Hz 60.00
F216 RX Input Point 1 Setting ±100% 0
F217 RX Input Point 1 Frequency 0.00 – F011 Hz 0.00
F218 RX Input Point 2 Setting ±100% 100
F219 RX Input Point 2 Frequency 0.00 – F011 Hz 60.00
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PID Control Manual 11
F240 Starting Frequency 0.00 – F011 Hz 0.10
F241 Run Frequency 0.00 – F011 Hz 0.00
F242 Run Frequency Hysteresis 0.00 – 30.00 Hz 0.00
F243 End Frequency 0.00 – 30.00 Hz 0.00
F270 Jump Frequency 1 0.00 – F011 Hz 0.00
F271 Jump Frequency 1 Bandwidth 0.00 – 30.00 Hz 0.00
F272 Jump Frequency 2 0.00 – F011 Hz 0.00
F273 Jump Frequency 2 Bandwidth 0.00 – 30.00 Hz 0.00
F274 Jump Frequency 3 0.00 – F011 Hz 0.00
F275 Jump Frequency 3 Bandwidth 0.00 – 30.00 Hz 0.00
F359 PID Control Switching
0: PID Off
1: Process PID Control (Uses parameter limits
F367, F368)
2: Speed PID Control (Uses parameter limits
F370, F371)
3: Position PID Control
0: PID Off
F360 PID Feedback Signal
0: PID Control Disabled
1: V/I
2: RR
3: RX
4: RX2 (AI1)
5: Option V/I
6: PG Feedback Option
0
F361 PID Feedback Delay Filter 0.0 – 25.0 0.1
F362 PID Feedback Proportional (P) Gain 0.01 – 100.00 0.10
F363 PID Feedback Integral (I) Gain 0.01 – 100.00 0.10
F364 PID Deviation Upper Limit F013 – F012 Hz 60.00
F365 PID Deviation Lower Limit F013 – F012 Hz 60.00
F366 PID Feedback Differential (D) Gain 0.00 – 2.55 0.00
F367 Process Upper Limit F013 – F012 Hz 60.00
F368 Process Lower Limit F013 – F012 Hz 0.00
F369 PID Control Waiting Time 0 – 2400 sec. 0
F370 PID Output Upper Limit F013 – F012 Hz 60.00
F371 PID Output Lower Limit F013 – F012 Hz 4.00
F372 Process Increasing Rate (Speed PID
Control) 0.1 – 600.0 sec. 10.0
F373 Process Decreasing Rate (Speed PID
Control) 0.1 – 600.0 sec. 10.0
F375 Number of PG Input Pulses 12 – 9999 ASD-dependent
F376 Number of PG Input Phases 1: Single Phase
2: Two Phase ASD-dependent
F381 Positioning Completion Range 1 – 4000 100
F466 Speed PID Switching Frequency 0.00 – F011 Hz 0.00
Parameter
Number Parameter Name Adjustment Range Default Setting
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12 PID Control Manual
Parameter Descriptions
F004 — Frequency Mode 1 specifies the input source for the frequency command.
F009 — Acceleration Time sets the time in seconds for the output of the ASD to go from 0 Hz to
Maximum Frequency.
Note: Acceleration times shorter than the load will allow may cause nuisance tripping and
mechanical stress to the loads.
F010 — Deceleration Time sets the time in seconds for the output of the ASD to go from Maximum
Frequency to 0 Hz.
F011 — Maximum Frequency sets the absolute maximum frequency that the ASD will output.
Acceleration/deceleration times are calculated based on this value.
F012 — Upper Limit Frequency sets the highest frequency that the ASD will accept as a frequency
command. The ASD may output frequencies higher than Upper Limit Frequency (but no higher than
Maximum Frequency) when operating in PID Control, Torque Control, or Vector Control mode.
F013 — Lower Limit Frequency sets the lowest frequency that the ASD will accept as a frequency
command. Under certain conditions the ASD may output frequencies lower than the Lower Limit
Frequency.
• Accelerating from a stop.
• Decelerating to a stop.
• System is in PID Control, Torque Control, or Vector Control modes.
F660 Adding Input Selection Override
0: Disabled
1: V/I
2: RR
3: RX
4: Not Used
5: EOI Keypad
6: RS485
7: Communications Option Board
8: RX2 (AI1)
9: Option V/I
10: UP/DOWN Frequency (terminal board)
11: Pulse Input (option)
12: Pulse Input (motor CPU)
13: Binary/BCD Input (option)
0: Disabled
F661 Multiplying Input Selection
0: Disabled
1: V/I
2: RR
3: RX
4: F729 Setting
5: RX2 (AI1)
0: Disabled
F702 Display Unit Multiplication Factor 0.00 (Off) – 200.00 0.00
F703 Display Unit Selection 0: All Frequencies
1: PID Process Data 0: All Frequencies
F729 Panel Override Multiplication Gain ±100.00% 0.00
Parameter
Number Parameter Name Adjustment Range Default Setting
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