Energy Saving Mode MM440 G120 DOCU v2 1 en PDF

http://support.automation.siemens.
com/WW/view/en/22078436
Application description 01/2014
Energy-saving mode with
MICROMASTER 440 and
SINAMICS G120
STARTER script to implement the energy saving mode by means of the
free function blocks (FFB)
Warranty and liability

Energy-saving mode with MICROMASTER 440 and SINAMICS G120
Item-ID: 22078436, Version V2.1, 01/2014 2

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Warranty and liability

Note
The Application Examples are not binding and do not claim to be complete
regarding the circuits shown, equipping and any eventuality. The Application
Examples do not represent customer-specific solutions. They are only intended
to provide support for typical applications. You are responsible for ensuring that
the described products are used correctly. These application examples do not
relieve you of the responsibility to use safe practices in application, installation,
operation and maintenance. When using these Application Examples, you
recognize that we cannot be made liable for any damage/claims beyond the
liability clause described. We reserve the right to make changes to these
Application Examples at any time without prior notice.
If there are any deviations between the recommendations provided in these
application examples and other Siemens publications e.g. Catalogs the
contents of the other documents have priority.
We do not accept any liability for the information contained in this document.
Any claims against us based on whatever legal reason resulting from the use of
the examples, information, programs, engineering and performance data etc.,
described in this Application Example shall be excluded. Such an exclusion shall
not apply in the case of mandatory liability, e.g. under the German Product Liability
Act (Produkthaftungsgesetz), in case of intent, gross negligence, or injury of life,
body or health, guarantee for the quality of a product, fraudulent concealment of a
deficiency or breach of a condition which goes to the root of the contract
(wesentliche Vertragspflichten). The damages for a breach of a substantial
contractual obligation are, however, limited to the foreseeable damage, typical for
the type of contract, except in the event of intent or gross negligence or injury to
life, body or health. The above provisions do not imply a change of the burden of
proof to your detriment.

Any form of duplication or distribution of these Application Examples or excerpts
hereof is prohibited without the expressed consent of Siemens Industry Sector.

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informa-
tion
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Table of contents

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Table of contents
Warranty and liability ................................................................................................... 2
Preposition ................................................................................................................... 4
Validity .......................................................................................................................... 4
Application description ............................................................................................... 4
1 Task ..................................................................................................................... 5
2 Function description ......................................................................................... 5
3 Circuit and sequence diagram ......................................................................... 6
4 Parameterization of the drive inverter ............................................................. 8
4.1 Enabling the PID controller permanently.............................................. 8
4.2 Enabling the PID controller as a function of the frequency ................ 10
5 Executing scripts in STARTER ...................................................................... 11
6 Related literature ............................................................................................. 12
7 Contact.............................................................................................................. 12
8 History............................................................................................................... 12

Preposition

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Preposition
Aim of the application
This application was generated in order to show users the possibility of the
realisation of the energy saving mode on the drive inverters MICROMASTER 440
and SINAMICS G120.
Scope
The following core issues are discussed in this application:
Description of the method
Parameterization of the drive inverter
Executing scripts in STARTER
Exclusion
This application does not include any description of the following
STARTER commissioning tool
Basic commissioning of the frequency inverter
Commissioning higher-level controls
It is assumed that readers have basic knowledge about these subjects.

Validity
Due to differences in the parameter structure this application only applies to...
MICROMASTER 4
SINAMICS CU240x with FW < V4.0.
Examples for the energy-saving mode implementation for the SINAMICS G120
Control Units CU240B-2 and CU240E-2 with firmware V4.4 you will find in the
following application descriptions:
SINAMICS G120: Pressure controlled vacuum pumps
http://support.automation.siemens.com/WW/view/en/77491905
SINAMICS G120: Pressure controlled compressor

Application description
This application shows how the energy saving mode can be executed on the drive
inverters MICROMASTER 440 and SINAMICS G120.

1 Task

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1 Task
MICROMASTER 430 is a drive inverter which has been specifically designed for
pump and fan drive applications. When compared to standard drive units, special
functions have been implemented, for example, the energy-saving mode. The
following document will show how for applications, where the MICROMASTER 430
is not suitable as a result of the supply voltage and power rating, the energy-saving
mode functionality can be implemented using the free blocks of MICROMASTER
440.

2 Function description
A pump, driven by a variable frequency drive fills a water reservoir and establishes
a pressure in the system. As long as water is being drawn from the system, the
drive inverter is operational. The integrated PID controller ensures that either the
water level or the pressure remains constant.

Figure 2-1 Block diagram of a closed-loop pressure controlled drive

If water is no longer being drawn from the system, the drive inverter is ramped-
down to the minimum frequency as a result of the PID controller and remains there
until the level / pressure continues to decrease because water is being drawn. The
drive frequency then increases again. During the time that the drive is at the
minimum frequency, it is possible to power it down and then power it up again as a
function of the level / pressure. However, during this time, power must be
connected to the drive as otherwise the PID controller would not operate.

f
pressure equalizing
reservoir
f(t)
pressure
sensor
motor
motor
control
load
PID
P2273
(
PID
)
PID
setpoint
PID
limit
PID
RFG
PID
feedback
Limit RFG AFM
Min. frequency
0.00 ... 650.00 [Hz]
P1080.D (0.00)
3 Circuit and sequence diagram

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The following blocks are necessary to realize this circuit:
Word comparator CMP1 and CMP2
Memory flip-flop RS-FF1
Timer1
AND1 logic element

Figure 3-1 Interconnecting the free blocks

The system deviation of the PID controller is compared with a positive and a
negative limit value using the two comparators. The two limit values are entered as
a % at connectors P2889 and P2890. If the setpoint/actual value difference is
greater than P2889, the output of CMP1 is high and the RS-FF 1 is set. Further, if
an on command is present at AND1, the drive inverter is powered-up via control
word 1 (P0840). The setpoint for the drive is obtained from the addition of the up
ramp (P1120) to the minimum frequency and the setpoint from the PID controller -
which is also enabled via a ramp-up function (P2293). The drive then corrects the
setpoint / actual value difference. If, as a result of the closed-loop control, the
setpoint / actual value difference is less than the value P2889, the set input of the
RS-FF1 is withdrawn. The drive goes to the minimum speed which should be set
so that water is pumped at precisely this speed. If the actual value continues to
increase, the setpoint / actual value deviation becomes negative. When the
negative limit (P2890) is exceeded, RS-FF1 is reset. Timer 1 implements an
adjustable power-off delay. When this expires, the drive inverter is powered-down
P2800 P2801[0]
&
P2810
Index0
Index1
r2811
r2852
r722.0
Digital input 0/1
T 0
ON delay
0 T
OFF delay
T T
ON/OFF delay
Pulse Generator
0
1
2
3
P2851(1)
Mode
P2850
(5.0s) P2800 P2802[0]
T
P2849
Index 0
P2885
r2886
x1
x2
Index0
Index1
Out = x1 x2
CMP
P2800 P2802[12]
P2889
r2273
PID error
Start level
converter
P2887
r2888
x1
x2
Index0
Index1
Out = x1 x2
CMP
P2800 P2802[13]
r2273
P2890
PID error
Stop level
converter
SET
(Q=1)
RESET
(Q=0)
Q
Q
P2840
Index0
Index1
POWER ON
1
r2841
r2842
P2800 P2801[14]
P0840
Index0
Converter
ON/OFF1

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again. The drive inverter is only powered-up again if the system deviation
increases above the limit value parameterized using P2889.

Figure 3-2 Sequence diagram, energy-saving mode

DI0/1
r2886
r2888
r2841
r2852
P0840.0
t
t
f
min
Binary input 0/1
output comparator 1 -
set RS-flipflop
comparator 2 -
reset RS-flipflop
output Timer 1
release delay
output AND 1
converter ON / OFF
output RS-FF 1
%
r2272: CO: PID scaled feedback
CO: Filtered PID
setp. after RFG
%
t
t
0
0
r2273: CO: PID error
r0024 CO: Act. filtered
output frequency
PID active PID active Energy saving mode active
P2889
P2890
4 Parameterization of the drive inverter
4.1 Enabling the PID controller permanently

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Minimum frequency: The minimum frequency P1080 must be set so that the drive
is able to establish additional pressure in the pressure reservoir in order to initiate
the shutdown via the limit value monitor.
Limiting the PID controller: The PID controller is always operational if power is
connected to the drive. The limit of the output is set to zero. In order that the drive
doesn't suddenly accelerate to the value of the PID controller output when it is
powered-up, the PID controller output limit is withdrawn using a ramp-function
generator (P2293) as soon as the PID controller is enabled.

Enabling the PID controller: The PID controller is enabled via the function f
act
>
P2155. P2155 should, for example, be 0.05 Hz below the value of P1080.

Table 4-1 Parameterization of the drive inverter
Parameter
No.
Designation Parameter
value
Note / comments
P0003 Access level 3 3: Expert
P0701[0] Digital input 0/1 (DI0/DI1)

99 99: Enable BICO parameterization
P0840[0] BI: ON/OFF1 r2811.0 Enable ON/OFF1 = Output of the
AND1
P1070[0] CI: Main setpoint 0 no main setpoint
P1080[0] Min. frequency 30.00 Min. frequency = 30 Hz
P1120[0] Ramp-up time 2.00 Ramp-up time = 2.00 s
P1120[0] Ramp-down time 2.00 Ramp-down time = 2.00 s
P2200[0] BI: Enable PID controller 1 1: PID controller permanently
activated
P2251 PID mode 1 1: PID as trim
P2253[0] CI: PID setpoint r0755.0 CI: PID setpoint = analog input 0/1
P2257 Ramp-up time for PID setpoint 10.00 Ramp-up time for PID setpoint =
10.00 s
P2258 Ramp-down time for PID
setpoint
10.00 Ramp-down time for PID setpoint =
10.00 s
P2264[0] CI: PID feedback r0755.1 PID feedback = analog input 1/2
P2293 Ramp-up /-down time of PID
limit
2.00 Ramp-up /-down time of PID limit =
2.00 s
P2800 Enable FFBs 1 1: Enable
P2801[0] Activate FFBs 1 Activate AND1 (Level 1)
P2801[14] Activate FFBs 1 Activate RS-FF1 (Level 1)
P2802[0] Activate FFBs 1 Activate Timer1 (Level 1)
P2802[12] Activate FFBs 1 Activate CMP1 (Level 1)
P2802[13] Activate FFBs 1 Activate CMP2 (Level 1)
P2810[0] BI: AND 1 r0722.0 1
st
input of the AND1 = DI0/1
P2810[1] BI: AND 1 r2852.0 2
nd
input of the AND1 = Output of
the Timer 1

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Parameter
No.
Designation Parameter
value
Note / comments
P2840[0] BI: RS-FF 1 r2886.0 Set input of the RS-FF1 = Output of
the CMP1
P2840[1] BI: RS-FF 1 r2888.0 Reset input of the RS-FF1 = Output
of the CMP2
P2849 BI: Timer 1 r2841.0 Input signal of the Timer 1 = Q-
output of the RS-FF1
P2850 Delay time of timer 1 5.0 Delay time of timer 1 = 5.0 s
P2851 Mode timer 1 1 1: OFF delay (seconds)
P2885[0] CI: CMP 1 r2273.0 1
st
input of the CMP1 = PID error
P2885[1] CI: CMP 1 P2889 2
nd
input of the CMP1 = Fixed
setpoint 1 in [%]
P2887[0] CI: CMP 2 P2890 1
st
input of the CMP2 = Fixed
setpoint 2 in [%]
P2887[1] CI: CMP 2 r2273.0 2
nd
input of the CMP2 = PID error
P2889 CO: Fixed setpoint 1 in [%] 5.00 Fixed setpoint 1 = 5.00 %
P2890 CO: Fixed setpoint 2 in [%] -5.00 Fixed setpoint 2 = -5.00 %

4.2 Enabling the PID controller as a function of the frequency

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4.2 Enabling the PID controller as a function of the
frequency
Enabling the PID controller: If it is to be avoided that the PID controller is already
operational before the drive has reached the minimum frequency, then the PID
controller enable (P2200) can be switched as a function of the output frequency f
act

> P2155 (refer to fig. 4-1). In this case, threshold f_1 (P2155) is set to 0.05 Hz
below the minimum frequency (P1080).

Figure 4-1 Enabling the PID controller as a function of the frequency

The following parameters must in addition be set up in the drive inverter:

Table 4-2 Enabling the PID controller as a function of the frequency
Parameter
No.
Designation Parameter value Note / comments
P2150[0] Hysteresis frequency f_hys 2.00 f_hys = 2.00 Hz
P2155[0] Threshold frequency f_1 29.95 f_1 = 29.95 Hz
P2156[0] Delay time of threshold freq f_1 0 Delay time of f_1 = 0 ms
P2200[0] BI: Enable PID controller r0053.4 Enable PID controller = f_act >
P2155 (f_1)

Tconst. freq. filt
0 ... 1000 [ms]
P2153.D (5)
Threshold freq f_1
0.00 ... 650.00 [Hz]
P2155.D (29.95)
Hyst. freq. f_hys
0.00 ... 10.00 [Hz]
P2150.D (2.00)
Delay time of f_1
0 ... 10000 [ms]
P2156.D (10)
CO/BO: St. Wd 2
r0053
r0053
|f_act| > P2155 (f_1)
T 0
0
1
{
.4
f_act P2200
Index 0
BI: Enable
PID controller
5 Executing scripts in STARTER

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5 Executing scripts in STARTER
For fast parameter changes, you can use the attached script files.
Note:
Before you execute a script on the drive, please set your drive inverter to the
factory settings (P0010 = 30, P0970 = 1) and carry-out a quick commissioning
(P0010 = 1) of the drive.

The procedure in detail:
1. Save the attached script file in a folder on your computer hard drive.

2. Set-up a script folder for the drive in your STARTER project by clicking with the
righthand mouse key on the drive; then click on Expert (lefthand mouse key)
and on Insert script folder.
A new folder appears SCRIPTS at the lower end of the tree.

3. Import the script from your folder into STARTER as described below:
Using the righthand mouse key click on the tab "SCRIPTS";
Click on "ASCII import..." and open the required script file;
Assign a name to the opened file and acknowledge with OK.

4. Go Online with the drive.

5. Execute the script by clicking with the righthand mouse key on the script and
clicking Accept and execute;
or open the script by double clicking on it and then pressing the button
Accept and execute.

Also refer to the application Entry ID: 22078810 "STARTER: Generating
application macros" (Chapter 1.5 Save Expert List and User-defined Lists as
Script, section Series commissioning of a number of drives using scripts).
6 Related literature

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6 Related literature
Table 6-1
Topic Title / Link
\1\ Siemens Industry
Online Support
http://support.automation.siemens.com
\2\ Download page of
this entry

\3\
Manuals
SINAMICS G120
http://support.automation.siemens.com/WW/view/en/22339653/133300
\4\ MICROMASTER 4
http://support.automation.siemens.com/WW/view/en/10804923/133300
\5\
Applications
STARTER: Generating application macros
SINAMICS G120: Pressure controlled vacuum pumps
SINAMICS G120: Pressure controlled compressor

7 Contact
Siemens AG
Industry Sector
I DT MC PMA APC
Frauenauracher Strasse 80
91056 Erlangen
Germany
mailto: tech.team.motioncontrol@siemens.com

8 History
Table 8-1
Version Date Modifications
V1.0 06/2003 First edition
V2.0 11/2008 Second edition
V2.1 01/2014 Link added to examples with CU240B/E-2, FW V4.4

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