Applying Sensorless Vector Control (SLVC)

Sensorless Vector Control (SLVC) operation relies on continuous recalculation of

the rotor position, and if, for any reason, the motor position information is lost
(“Loss of Orientation”) the response of the drive is unpredictable. Loss of
orientation can be caused be an incorrectly commissioned motor, loss of motor
temperature information following power failure, or similar disturbances.

Sensorless Vector Control requires careful commissioning and setting up. This
should only be carried out by commissioning engineers who have experience of
operating MM440 / G120 drives in SLVC.

Important Note:

SLVC should not be used:

1. where the motor inverter power ratio is less or more than 1:4
2. where the maximum frequency is greater than 200Hz
3. on multi – motor applications
4. If a contactor is placed between the inverter and the motor; respectively
the contactor must never be opened whilst the inverter is running.
5. for hoisting applications

When the frequency inverter loses its orientation, then the motor can no longer
be stopped with OFF1 or OFF3. This is the reason that when commissioning the
drive, either OFF2-function or the pulse inhibit must also be connected-up (see
also ID: 7497349 How can the MM440 be shut down in the event of loss of
Vector action?).

Recommended means of commissioning

For correct operation under SLVC control it is extremely important that the motor
data is correctly entered and that the motor identification is carried out. The order
this is carried out is also important as the quick commissioning procedure
provides the initial motor model, and the motor identification measurements
refine this.

The procedure for doing this is as follows:

1. Quick Commissioning and setting initial motor model

P0003 = 2 (allows user access level 2)

P0010 = 1 (Quick Commissioning)

P0300 and the following: Motor data according to motor nameplate

P0700, P1000, P1080/P1082, P1120/P1121 control selection, setpoint selection,

Fmin/Fmax, ramp times etc.

P1300 = 20 Sensorless Vector Control

P1910 = 1 (A0541 will appear at this point > see also: 2.Motor Identification
using)

P3900 = 1
“busy” will appear on the BOP for approximately 1 minute, or longer an very large
inverters, while the motor parameters are being calculated. After this A0541 will
now be flashing on the BOP.
This completes the quick commissioning and the initial motor model is now
complete.

2. Motor Identification using P1910

Two automated series of measurements must now be carried out.

Note: The measurements should be carried out on a cold motor. It is also

necessary to ensure that the motor ambient temperature is correctly entered in
P0625. Factory setting = 20°C. A potentially necessary change must be done
after the quick commissioning has been completed (P3900) but before the motor
identification measurements are carried out.

P1910 = 1. Give a RUN command: This initiates the motor identification

measurements.

A0541 will continue to flash; a number of measurements are made by pumping

current into the motor for short bursts making an audible hum. This is followed by
“busy” on the BOP while the internal motor parameters are calculated.

If you get a fault message F0041 (Failure, motor data identification), this means
that the measured value does not match the expected value from the initial motor
model. In this case, check the wiring (particularly star / delta connection) and also
the parameter values entered. If all of these are ok, then you should try to run the
drive, unloaded, in V/f control (set P1300 = 0), with a setpoint of ca. 80% of motor
rated frequency. Look at the value for output current (r0027) and enter this as the
motor magnetisation current in P0320 (as % value of motor rated current, P0305)
and recalculate the motor parameters (set P0304 = 1).

The identification of saturation curve, P1910 = 3, can improve the performance:

This should be done after 1910 = 1.
Once P1910 is set to 3, A0541 will appear anew. Now give RUN command. The
behaviour will be similar to the description above.

At this point, the inverter can be run under SLVC. However an optimisation
procedure is recommended to get best regulation.

3. Speed control optimization using P1960

When speed controller optimisation is enabled (P1960 = 1) the warning A0542

will become active. When the drive is next started it will do the optimisation tests.
The drive will accelerate the motor to 20 % of P0310 (rated motor frequency)
using the ramp up time P1120 and then under torque control go to 50 % of
P0310 (rated motor frequency). The drive will then ramp back down to 20 %
using the ramp down time P1121.
This procedure is repeated several times and then average time taken.
When the test is complete P1960 will be cleared to zero.

Note:
The speed loop optimisation may not be suitable for some applications due to the
nature of the test i.e. accelerating under torque control from 20 % to 50 %.

4. manual speed control optimization

a. Motor Model

SLVC requires a good motor model. A good measure of this is r1787 (Output of
Xm adaptation). This should be below +/- 15%. If this not the case you may need
to improve the model.

The motor model can be improved by measuring the magnetisation current.

Refer to the document ID: 22078991 “Application Description: Measuring the
Magnetising Current” for the correct procedure, or use the procedure described
previously. If the procedure cannot be followed (e.g. because the motor cannot
be decoupled form load) then you should try values of magnetisation current (set
P0320 followed by P0340 = 1 to recalculate the motor model) until you find that
r1787 is in an acceptable range.

Note: once you have established the correct magnetisation current for a motor,
this will be more or less valid for all motors of that type, so it should not be
necessary to carry out these measurements for each motor, but rather set P320
appropriately.
b. Performance

The motor identification will set initial values for the sensorless vector control
which will allow the motor to be run up to 50 Hz. In order to get good vector
performance, it is necessary to optimise the vector control loop according to the
mechanics of the motor / load system.

The following parameters can be adjusted by the user to improve performance.

For best results you should use an oscilloscope to measure the effect of any
adjustments:

P0003 = 3
P0342: motor / load inertia ratio in combination with P1496 (scaling acceleration
pre-control)
P1470: SVC P gain
P1472: SVC I term
P1520/P1521: Torque limits
P1610: SVC open loop boost
P1750: enable observer model

Refer to function diagrams 7000, 7200, 7500, 7800 and 7900 in the Parameter
List of the MICROMASTER 440 or SINAMICS G120.

P0342 - The total/motor inertia ratio - should be appropriately set where this is
known or can be estimated as described. This is used in conjunction with P1496
to generate an extra torque to overcome load inertia. For best results set P1496
= 100% and try values of P0342 = 1, 3, 6 etc. You should see that the
performance becomes better with increasing values until the value is set too high
and causes instability. This is normally only useful for system where a pulse of
torque is required to start an inertial load moving, but not subsequently required.

P: P1470 - Gain speed controller (SLVC) and I: P1472 - Integral time n-ctrl.
(SLVC) – these are initially set to allow a large range of applications. The optimal
settings are dependent on the mechanical system. Good results can be achieved
by increasing the P-term and decreasing the I-term while observing the system
behaviour. Ideally this should be done by looking at the unfiltered output
frequency (r0066) on a scope via the analogue output (P0771[0] = 66). It is also
useful to monitor the output current, either current, either with a clamp as shown
or using a second analogue output (P0771[1] = 27).

Here are examples of how changing the values of P1470 and P1472 affect a
resonance while ramping up. In each case trace (A) is the motor current using a
clamp and trace (B) is the unfiltered output frequency (r0066)
 
P1470 = 12; P1472 = 80 ms

P1470 = 6; P1472 = 25 ms

P1511 - additional torque setpoint.

This is particularly useful for applications where instantaneous torque is required
(e.g. lifting drive). This can be connected to a value as follows: P1511 = 2890
and set P2890 = xx% (e.g. 40%).

P1520 - Upper torque limit and P1521 - Lower torque limit

Reducing these can reduce instability, while increasing can give better dynamic
performance.

P1610 - SVC boost for open loop operation.

Sets continuous torque boost in lower speed range of SLVC (sensorless vector
control). Value is entered in [%] relative to rated motor torque r0333.
The default is 50% and this can be increased to increase low speed torque.

P1750 - Control word of motor model

This parameter controls the operation of the sensorless vector control (SLVC) at
very low frequencies.
Setting P1750.0 = 0 allows the observer model to be used from standstill
provided that the frequency setpoint is greater than 5 Hz. Setting P1750.1 = 0
allows the observer model to be used when passing through 0 Hz. In general
using the observer model provides best performance and avoids the transition
between open loop and Sensorless Vector Control at 5 Hz.

P1755 - switchover frequency for vector control.

This is the base frequency or cut in point for the vector model. The 5 Hz default
setting operates V/f mode both sides of zero. E.g. at default the control mode
between -5 Hz to +5 Hz will return to V/f mode (P1300 to 1). This value can be
reduced below its 5 Hz default setting on large motors to allow full vector control
below the 5 Hz default. However this should not be reduced below 2x motor
rated slip frequency. The reason for this setting is that it is difficult to maintain
accurate motor modelling with small motor currents.

Note that optimised performance will depend on what you are trying to achieve
(e.g. this might be different depending on whether you require very good speed
holding or high torque at low speeds). You should always test and measure
against this.

Please don't forget to permanently save the data with Ram to Rom (P971 = 1).

Before leaving site, you should always test your settings across a range of loads
and also in worst case conditions.
Try shock loading, coupling and decoupling load, or if this not possible run the
motor up to a given speed, set the ramp times P1120/P1121 to 0, and give a
frequency setpoint step change of a few Hz (add fixed frequency using DIN).

The optimised values you have achieved should be useable on any machine of
identical mechanical and electrical construction. However we always recommend
carrying out the motor identification measurements (1910 = 1 & 3). After this the
values for P1470 etc. can be entered without the need for a full optimisation.