Advanced PID controller features

Single Feedback and Setpoint ................ page 2

Transmitter connections to the drive ........ page 3
One Feedback and One Setpoint with
Feedback Conversion .............................. page 3
Two Feedback signals with One Setpoint page 4
T ......... page 6
Transmitter connections to the VL
VLT
wo Setpoints . page 7
T wo Feedback signals and T
Two
T ........... page 8
Transmitter connection to the VL
VLT
Serial communication .............................. page 8

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Contents

Introduction ............................................. page 2

Advanced PID controller features

Introduction:
A PID (Proportional Integral Derivative) controller is
usually used to control variable speed drives (VSD) in
HVAC systems. This controller can be part of the
Building Management System, part of an OEM
device such as an Air Handling Unit or Pump
Controller, or part of the frequency converter (VSD).
The PID controller monitors the system by
examining signals, called Feedback signals, that are
transmitted from sensors placed in the system and
comparing them with their expected value or
Setpoint. The PID controller then adjusts the speed
of the variable speed drive until the Feedback signal
equals the Setpoint.
While many VSDs contain a PI or PID controller,
they are often too complicated to set up and do not
have the capability needed for HVAC applications.
As a result, an external PID controller may be
needed. This increases the cost and complexity of
the installation. The PID controller in the VLT 6000
has been specifically designed for HVAC applications
to provide full functionality and simple programming.
The terminology used in connection to the PID
controller is well known within the HVAC industry.
Feedback and setpoint settings can directly be done
in the most common units such as Pa, PSI, m/h,
CFM, C, F etc.
Two Zone control, for example, is an important
feature for HVAC applications which is not required
for most industrial applications. In HVAC systems, it
is frequently necessary to monitor two feedback
signals. The VLT 6000 is capable of handling the
traditional single feedback with a single setpoint as
well as two feedbacks with a single setpoint, and
two feedbacks with two setpoints.
Single Feedback and Setpoint
In simple HVAC applications, such as controlling a
supply fan in a constant air volume (CAV) Air
Handling Unit or a Cooling Tower fan, a single
feedback signal may be sufficient for proper system
control. Normal or inverse operation should be
available as selections, and the ability to modify the
setpoint for seasonal changes or night time
operation are important.

Fan

Filter

Diffuser

Pressure
Transmitter

Fig.1: Constant pressure control with one feedback

Since the system does not contain VAV boxes or
has dampers that modulate, the sensor type and
location is not critical to achieve the proper energy
savings. A simple velocity sensor or pressure sensor
can be used. In this example, a pressure sensor is
placed downstream of the air filter. The setpoint is
the pressure that corresponds to the required flow.
As the resistance of the filter varies, the pressure
downstream of the filter also varies. The drive
increases or decreases the speed of the fan to
maintain a constant pressure and therefore the
desired air flow.
Other typical applications for 1 Feedback / 1
setpoint:

Supply fans for Variable Air Volume (VAV)

systems (constant static) pressure control

Water supply pumps and pressure booster

systems (constant pressure)

Cooling Tower fans (constant cooling water

temperature)

Condenser water pumps (constant cooling

water temperature or pressure)

Condenser fans (constant pressure in the

refrigeration process)

The diagram below shows how to control a simple

supply fan in a CAV system. The drive is used to
automatically eliminate the extra energy
consumption caused by oversizing and to
compensate for the changing system as the air filter
becomes clogged (blocked) over time.

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Advanced PID controller features

Transmitter connections to the drive:
Terminal 12 and 13 of the VLT 6000 provide access
to a 24 VDC, 200 mA power supply. This can be
used to power remote transmitters, so an external
power supply is generally not needed. The diagrams
below show how to wire two- and three-wire
transmitters.

The function is activated by simply setting parameter

416 to Square Root. The proportionality constant is
entered by setting in parameter 413 and 414 the
minimum and maximum value of the converted
feedback signal. Parameter 415 is used to set the
unit for this feedback signal.

Te
rm
16

ina

17

04

lS

18

05

19

12

24 VDC

13

trip

20

27

39

29

42

32

45

Common

33

50

61

53

54

Common

68

55

69

60

Analog Input

Fig. 2: 2-wire transmitter with current signal such

as 4...20 mA DC

Te
rm
16

Signal Out

ina

17

04

Power In

18

05

24 VDC

lS

19

12

20

13

trip

27

39

29

42

Common

32

45

33

50

53

61

54

Common

68

55

69

60

Analog Input
Common

Fig. 3: 3-wire transmitter with voltage signal, such

as 0...10 Volt

One Feedback and One Setpoint with

Feedback Conversion
Some HVAC applications require a precisely
controlled constant flow, such as ventilation systems
in hospitals with highly efficient Heppa filters or
cleanroom environments in industrial production
areas.
To control the flow, flow meters may be installed in
the air duct. Often these transmitters are nothing
more than pressure transmitters that contain an
electronic circuit that calculates the flow from the
pressure measurement.

Fig. 4: Feedback conversion diagram

Programming example:
Assume that a 420 mA pressure transmitter is
used and is properly installed downstream of the
filter (shown in picture 1):

Set parameter 314 to Feedback, parameter 315

(AI scale low) to 4 mA and parameter 316 (AI
scale high) to 20 mA.

Run the fan at 100% speed (nominal speed) and

used the VLTs built-in meter to measure the
current signal at the analog input terminal 60 (
AI60).

Take a flow measurement at the same location

as the pressure transmitter.

Set parameter 415, Reference and Feedback

Unit, to the flow unit used

Use the following equation to calculate the value

of parameter 414 (Maximum Feedback)
Two feedback functions can not be utilized in
connection with the feedback conversion
(linearization).

Parameter 414 = flow at 100% speed x

20 mA
Al 60 at 100%

This calculation is based on the centrifugal pump

and fan laws. These laws state that, if other
parameters in the system are constant, flow is
proportional to static pressure squared. Therefore,
flow can be determined by taking the square root of
pressure and applying a proportionality constant.

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Advanced PID controller features

Two Feedback signals with One Setpoint
Many HVAC systems require two feedback signals
for proper control. Because traditional PID
controllers in drives cannot handle this situation,
external controllers are frequently purchased. This
adds unnecessary cost to the installation.
Depending on the application, different
mathematical operations will be applied to these
feedback signals. These two signals may be:

Added to one another. This is usually used as an

offset to the feedback signal, in place of modifying
the Setpoint.

Averaged, as is the case with CO or CO2 sensors in

parking garages or temperature sensors in large
rooms with CAV heating or cooling systems.
Subtracted from each other. For example the return
fan in a VAV system being controlled to maintain a
constant difference between the supply and return
airflow (like shown in fig. 5).
I applications where a differential pressure sensor is
impractical, the signals from two pressure sensors
can be subtracted (like shown in fig. 6)

Compared to one another, with control based on

the minimum or maximum signal. In systems that
have two loads of equal size in different locations, it
is difficult to decide where to place the sensor. In
these cases, using two sensors can ensure that
both loads are satisfied. In some systems, the
minimum signal should be used for control for
example when monitoring differential pressure
across two heating or cooling loads. In other cases
the maximum signal should be used. An example for
this is when monitoring temperature while cooling
two separate critical zones such as a conference
room and the presidents office.
The diagram below shows the above mentioned to
control the return fan in a VAV system.

Supply Fan

Return Fan

Flow
Transmitter

Flow
Transmitter

Fig.5: A return fan being controlled to maintain a constant difference between supply and return airflow.

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Advanced PID controller features

The application shown in fig.5:
As the VAV boxes in the system modulate the flow
of supply air varies. If the return fan is not also
controlled, a negative pressure will be generated in
the building if more air is removed from the zone
than is supplied to it, or the zone will become over
pressurized if too little air is removed. Because the
supply and return fan system curves and fan curves
differ, controlling both fans from the same drive or
the same control signal often results in pressure
regulation problems. To avoid these problems,
velocity sensors can be placed in the supply and
return ductwork and a fixed differential flow can be
maintained. The return fans speed is controlled
properly as the VAV boxes modulate.

Instead of hydraulic pipes and an expensive

differential pressure transmitter, two simple absolute
pressure transmitters of equal type can be installed,
saving installation costs and providing great flexibility
in locating the sensors. The two transmitter
locations do not have to be close to each other,
since the electrical signal can be sent over longer
distances.

Another simple example for using the 2 feedback

function to create a differential pressure transmitter
by using two absolute pressure transmitters:

Fig.6: Subtracting the two pressure transmitters to measure differential pressure

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Advanced PID controller features

Transmitter connections to the VLT:
When two feedback signals are used with the VLT
6000, both signals must be voltage signals. Both
transmitters also must have the same range. When
the PID controller of the VLT 6000 is set up to
subtract the two signals, it is essential to note that
the feedback signal at terminal 54 is always
subtracted for the signal at terminal 53. Therefore
the larger signal must be wired to terminal 53. If the
feedback signals are added, averaged or simply
compared in size, the order of connection does not
matter.

16

Transmitter 2

24 VDC

Ter
m
17

04

ina

18

05

19

12

20

13

27

39

29

42

Common

lS

32

45

trip

33

50

61

53

54

68

55

69

60

Analog
Input
Common

Transmitter 1

Signal Out

Transmitter 1

16

Power In

17

ina

18

Common
24 VDC

Transmitter 2

500 Ohm

Ter
m

04

05

19

12

20

13

27

39

29

42

lS

32

45

Common

33

50

53

trip

61
54

68

55

Fig. 8: Two 420 mA transmitters wired to the VLT

6000, powered by its own power supply and acting
as feedback signals.

69

60

Signal Out
Common

Power In

Common
Analog Input

Fig. 7: Wiring of two 3-wire voltage signal

transmitters

When two feedback signals are used, the VLT 6000

requires that they both be connected to its analog
voltage inputs, terminal 53 and 54. Transmitters that
produce a current signal (such as 420 mA), can
easily be used by simply adding two resistors. These
resistors are connected in parallel with the analog
voltage input (between terminal 53 and 54 and
terminal 55) and provide a low resistance path for
the control current signal. The voltage drop across
the resistor is the anlaog voltage input for the VLT
6000.
The value of the resistor is easy to calculate. If the
transmitter is capable of producing 10V at 20 mA,
the value of the resistor to use is:
R=

10 Volt
20 mA

= 500

The input scaling of the VLT 6000 analog inputs in

this case would have to be 210 Volt.

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Advanced PID controller features

Two Feedback signals and Two Setpoints
Just as with two feedback signals with one setpoint,
the need for two feedback signals with two
setpoints is frequently encountered. Whenever two
critical zones exist that do not have the same
setpoint value, two feedback, two setpoint control is
required. Many pumping systems require the
monitoring and control of two loads that differ in size
and pressure drop. For these cases, 2 Zone control
is selected, Feedback 1 is associated with Setpoint
1 and Feedback 2 is associated with Setpoint 2.
The two independent groupings are continuously
monitored to satisfy both zones requirements. If 2
Zone Minimum is programmed, the drive will
regulate the system so the feedbacks are equal to

or greater than their associated setpoints. If 2 zone

maximum is programmed, the Feedbacks will be
equal to or less than their associated Setpoints. This
is used when controlling different temperatures in a
cooling situation.
The diagram below shows how to control two
different loads in a secondary pumping system. As
the temperature varies in each room, the drive will
adjust the speed the secondary chilled water pump.
Other typical applications for 2 Feedback /2 Setpoint
control include:

VAV systems with two major duct systems

supplying VAV boxes

CAV systems with two different setpoint

requirements for 2 building zones

Fig. 9: Two zone control in a secondary chilled water system

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Advanced PID controller features

Transmitter connection to the VLT:
The transmitters are connected to the VLT in the
same way as shown above with 1 setpoint and 2
feedbacks. The feedback connected to terminal 53
is assigned to setpoint 1 and the one connected to
terminal 54 to setpoint 2. Both transmitter must
have the same output signal and range.
Programming example for 2 feedback/2 setpoint
control:
Transmitter ratings:
Supply:
15-30 VDC
Output:
010 V
Range:
010 Pa

The VLT 6000 is programmed to match its input to

follow the specification of the transmitter:
Parameter

Parameter

Parameter

number

description

value

100

CONFIG. MODE

CLOSED LOOP

415

Ref./FDBK UNIT

Pa

413

MIN. FEEDBACK

414

MAX. FEEDBACK

100

308

AI [V] 53 FUNCT.

FEEDBACK

309

AI 53 SCALE LOW

310

AI 53 SCALE HIGH 100 *

311

AI [54] 54 FUNCT.

FEEDBACK

312

AI 54 SCALE LOW

313

AI 54 SCALE HIGH 100 *

314

AI [mA] 60 FUNCT. NO OPERATION

In this example, load 1 requires a pressure of at

least 30 Pa and load 2 at least 60 Pa.
Parameter

Parameter

Parameter

number

description

value

417

2 FEEDBACK CALC.

2 ZONE MIN

418

SETPOINT 1

30

419

SETPOINT 2

60

Serial communication:
In large HVAC systems, variable speed drives are
often connected to the Building Management
System (BMS) via serial communication utilizing
proprietary protocols such as Johnson Controlss
Metasys N2 and Siemens FLN or open protocols
such as LonWorks.
The BMS typically is the overall control system,
monitoring and controlling each individual
component of the system. Nevertheless the actual
control of single applications often can be
decentralized. The VLT 6000HVAC is fully capable of
operating as a stand alone closed loop application
utilizing the built-in PID controller. In this case, the
PID controller would be set up as described in this
note, while the drive receives the start/stop signal
and the one or two feedback signals directly
through the serial communication bus (par. 537
Busfeedback 1 and par. 538 Busfeedback 2).

* For maximum control accuracy, it is suggested to

used the VLT 6000s meter display (to be read in at
the Local Control Panel, LCP) to measure the actual
voltage at the terminals of the feedback signals.
SCALE HIGH is set to the values accordingly.
The reference range is generally set to equal the
range of the transmitter. In this way, the setpoint
(reference) can be set to any value that the
transmitter can produce. If required, the reference
range can be set to a range that is narrower than
the transmitters range, but it can not be set to a
wider range.
Parameter
number

Parameter
description

204

MIN. REFERENCE 0

205

MAX. REFERENCE 100

Parameter
value

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