08 Motor Theory - Control

DriveAutomation
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Motor Theory
and
Control Loops
03_Motor_Theory_Control page 1 © Siemens Industry 2013 - subject to modification
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Table of Contents
Content Page
Motor Economics ....................................................................................................................... 4
Basic Motor Components............................................................................................................ 5
Induction Motor / Synchronous Motor......................................................................................... 6
Motor Nameplate........................................................................................................................ 7
Three-Phase Voltage System / Frequency................................................................................. 8
Rotating Magnetic Field.............................................................................................................. 9
Creating Torque.......................................................................................................................... 10
Frequency and Synchronous Speed / Number of Poles.............................................................. 11
Comparison: Transformer Induction Motor.......................................................................... 12
Load and Slip.............................................................................................................................. 13
Substitute Circuit Diagram of the Induction Motor....................................................................... 14
Motor Parameters....................................................................................................................... 15
“Substitute Circuit Data”.............................................................................................................. 16
Identification / Calculation of “Substitute Circuit Data”................................................................. 20
V/Hz-Characteristic and Magnetizing Current............................................................................. 21
No-Load Current / Full Load Current / Full Load Speed.............................................................. 23
Vector Control............................................................................................................................. 24
continued next page

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Table of Contents, continued
Content Page
Available Types of Control (ID2050)............................................................................................ 25
Open Loop Test Mode (ID2050 = OLTM).................................................................................... 26
Feedback Signals foer Close Loop Vector Control...................................................................... 27
Volts by Hertz Control (ID2050 = V/Hz)....................................................................................... 28
Open Loop Vector Control (ID2050 = OLVC).............................................................................. 29
Closed Loop Vector Control (ID2050 = CLVC)............................................................................ 30
Control Schemes (“Output Process Diagram“ / 459 717)............................................................ 31
Current Controller Gains............................................................................................................. 32
Speed Controller Settings........................................................................................................... 33
Flux Controller Settings.............................................................................................................. 34
Torque Limits.............................................................................................................................. 35
Speed Rollback .......................................................................................................................... 36
Droop / Torque Control .............................................................................................................. 37
Thermal Overload Limits............................................................................................................. 38
Setting the Overload Limit and the Torque Limit......................................................................... 39
“Quick-Setting” of the Speed Controller....................................................................................... 40
Step Response of the Speed Controller...................................................................................... 41
Manual Optimization of the Speed Controller.............................................................................. 42
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Motor Economics
About 60% of the electricity generated

is consumed by motors
(in the US this equates to 1000 billion
kilowatt hours, worth $50 billion US).
6.6 kV 92% of all power consumed by motors
7.4 MW goes to induction motors.
A typical induction motor will consume
10 to 20 times its capital cost in energy
per year.
Any technology, like VFDs, that helps
conserve energy is economically
important.
0.9 % motor price

0.1 % installation, maintenance
99 % energy cost
Example: motor rating 100 kW

(for motors of higher power
ratings the percentage of
energy cost is even larger)

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Basic Motor Components
cover; beneath systems for air cooling,

water cooling or water-air heat exchanger
end rings
laminations
the
the stator
stator remains
remains stationary;
stationary;
electrical
electrical power
power is
is fed
fed to
to itit the
the rotor
rotor turns
turns and
and transmits
transmits
rotor mechanical
mechanical energy
energy to
to the
the load
load
stator
laminations
shaft
terminal
box rotor bars
Stator frame Rotor

Stator Rotor
bearings
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Induction Motor / Synchronous Motor
Induction
Induction motors
motors require
require AC
AC input
input to
to the
the stator
stator only
only (1)
(1)
1
VFD
VFD
magnetizing current
torque generating current
1
DC or AC
Synchronous
Synchronous motors motors require
require
-- AC
AC input
input to
to the
the stator
stator (1)
(1) and
and
-- DC
DC input
input to
to the
the rotor
rotor (2)
(2)
either
either DC
DC directly
directly via
via slip-rings
slip-rings or
or 2
AC
AC via
via induction
induction with
with conversion
conversion
to
to DC
DC byby diodes
diodes fixed
fixed on
on the
the rotor
rotor
(as
(as shown
shown in in the
the example)
example)

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Motor Nameplate
- Nameplates of motors refer to basic motor data only.

- Siemens motors might show the information as per
NEMA ( HP) or IEC (cos ϕ).
- The motor can be stamped for 50Hz or for 60Hz; data for
speed and torque additionally depend on the “number of
poles” (not specifically listed).
- Medium voltage motors have the star-point typically wired
internally no choice of delta- or star-connection.
SIEMENS IEC 3 Motor

KW 3260 RPM 1485 Volts 4160
1 ft lbf = 1.356 Nm AMPS 660 FRAME 504-4HV
1 hp = 0.746 kW DUTY CONT HZ 50 COS_PHI 0.89
M [Nm] = 9550 * P [kW] / n [1/min] S.F. 1.15 INSULCLASS MAXAMBIENT
T [ft lbf] = 5533 * P [hp] / n [1/min] TORQUE 20 965 Nm
SIEMENS NEMA 3 Motor SIEMENS IEC 3 Motor

HP 4420 RPM 1780 Volts 4160 KW 3250 RPM 893 Volts 4160
AMPS 520 FRAME 2212-S AMPS 550 FRAME 566-8HV
DUTY CONT HZ 60 TEMPRISE 60 C DUTY CONT HZ 60 COS_PHI 0.85
S.F. 1.15 INSULCLASS MAXAMBIENT S.F. 1.15 INSULCLASS MAXAMBIENT
TORQUE 13 740 FOOT-POUNDS TORQUE 34 756 Nm
NEMA National Electrical Manufacturers Association IEC International Electrotechnical Commission
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Three-Phase Voltage System / Frequency
3600
0
120
L1
L2L1 L1L3
L2 L3
L3L2
A three-phase voltage system consists of three sinusoidal voltages.

The time required to complete one periodic oscillation is defined as period and covers 360 degrees.
The voltages of a three-phase system are shifted by 120 degrees each.
If the sequence of voltages counts L1, L2, L3 the system is called “clockwise”; L1, L3, L2 “counterclockwise”.
Voltages in a three-phase system can be referenced to the star-point or read as phase-to-phase values;
for a symmetrical system the phase-to-phase voltage will always read: phase-to-starpoint x square root (3).
To simplify evaluations the sinusoidal voltages are generally substituted by vectors (value length).
The number of complete periodic oscillations within a one-second time period is defined as frequency
(standard: 60 Hz , e.g. in US / 50 Hz, e.g. in Europe).

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Rotating Magnetic Field
The three stator windings (phases A, B, C) are spread symmetrically in the stator
A1 C2 to uniformly fill all slots; they can be simplified into a single loop (e.g. A1 – A2).
Polarity and magnitude of the phase currents change within one period with the
frequency of the motor voltage and generate a uniformly rotating magnetic field.
B2 B1 iS
C
C1 A2
A B
A1 C2 A1 C2 A1 C2
S S
B2 S N B1 B2 B1 B2 B1
N N
C1 A2 C1 A2 C1 A2
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Creating Torque
Torque
Torque is is aa turning
turning force
force applied
applied to
to aa shaft.
shaft. IfIf the
the applied
applied torque
torque (via
(via motor
motor current)
current) is
is larger
larger than
than the
the counter-torque
counter-torque
(of
(of the
the load)
load) the
the shaft
shaft rotates.
rotates. Torque
Torque is is equal
equal to to the
the applied
applied force
force multiplied
multiplied by
by the
the radius
radius through
through which
which the
the force
force acts.
acts.
Torque is measured in “Newton meters” (Nm); The rotating magnetic field of the stator induces voltage in the rods
(according to SI, Système International d’unités) of the squirrel cage rotor creating a current flow which generates the
1 ft lbf (foot pounds) = 1.356 Nm. magnetic field of the rotor.
e.g.: one Nm of torque is the turning These two magnetic fields interact and create force F (like two
effort created by one Newton of force (F) permanent magnets, one fixed [stator], one free to rotate [rotor]).
acting on a radius (r) of one meter. This force acts on the radius of the rotor cage and creates torque.
N N
F
S N
F
S
r substitute of the magnetic

fields of stator and rotor
by permanent magnets
S N
magnetic field
of the stator
F B
S magnetic field I
of the rotor
Left-Hand- or FBI-Rule

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Frequency and Synchronous Speed / Number of Poles
2-pole
2-pole motor
motor (p=1)
(p=1) 4-pole
4-pole motor
motor (p=2)
(p=2)
A2 C1
A1 C2 A1 C2
B1 B2
C2 A1
B2 S N B1 B2 S N B1
A1 C2 A1 C2
B2 B1 B2 B1
C1 A2 C1 A2
C1 A2 C1 A2
at a frequency of e.g. 60 Hz the magnetic stator field rotates 60 times per second 60 cycles/s
within 1 minute this results in 3600 cycles (60 cycles/s) x (60 s/min)
for a 2-pole motor 1 cycle (rotation of the magnetic stator field) covers 3600
( 1 revolution of the rotor) which results in 3600 rev/min (60 cycles/s) x (60 s/min) x 1 rev/cycle
for a 4-pole motor 1 cycle covers 1800 ( 0.5 revolutions of the motor)
which results in 1800 rev/min 3600 rev/min x 0.5 = 1800 rev/min
60 x stator frequency [Hz] no. of pole pairs 1 2 3 4

The synchronous synchronous speed [rpm] =
number of pole pairs (p. phase)
speed can be no. of poles 2 4 6 8
calculated for any speed at 60 Hz 3600 1800 1200 900
stator frequency: 2 x 60 x stator frequency [Hz]
synchronous speed [rpm] = speed at 50 Hz 3000 1500 1000 750
number of poles (p. phase)
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Comparison: Transformer Induction Motor
Many requirements and features of the induction motor can be more easily understood if the induction motor is looked at
in terms of its corresponding “substitute circuit diagram”.
(The drive’s firmware actually uses algorithms based on the generally true “substitute circuit diagram” and on the specific
data of the motor used in the application motor data!).
A squirrel cage induction motor can be looked at in a way similar to a

transformer with its secondary windings short circuited. In comparison to the
vS, fS vR = 0
transformer some essential differences have to be considered:
a transformer has three windings
the rods of the induction motor represent “many windings”
the frequency on the secondary of a transformer is identical to the primary
the frequency of the rotor depends on its speed
the leakage flux ΦσP and ΦσS of a transformer is very the leakage flux ΦσS, ΦσR and ΦσM of an induction
small (closed iron core) motor is considerable (air gap between stator and rotor)
to get the main magnetic flux ΦM in the iron core only to get the main magnetic flux ΦM considerable
a small magnetizing current is required (…3%) magnetizing current is required (MV: 20 ... 30%)
Φ σM
ΦM ΦM
ΦσP ΦσS ΦσS ΦσR
transformer single phase view motor

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Load and Slip
By separating main flux and leakage flux on both ends and by introducing the ohmic resistance of the
windings the single phase view of the transformer or of the induction motor is represented as follows:
RS Lσ S Lσ R RR
ΦM
iS iR
ΦσS + ΦσM‘ ΦσR + ΦσM‘
vS
eR
LMS LMR
on the transformer the frequency to induce voltage on the secondary is the same as on the primary
voltage on the secondary is induced in same value at any time
on the induction motor the frequency to induce voltage on the rotor (eR) depends on the difference of
stator frequency versus rotor frequency ( rotor speed, nR)
the voltage on the rotor (eR) is a maximum at zero speed; at synchronous speed the voltage is zero
∆f = fS – fR fR = (nR x p) / (2 x 60) nR = 0 fR = 0 ∆f = fS
nR = nsyn fR = fS ∆f = 0
To counter the torque of the load, rotor current iR is required:

if load = “zero” then iR = 0 which needs eR = 0 given for ∆f = 0 at nR = nsyn
load = “rated” iR > 0 eR > 0 ∆f = fslip nR = nrated
The term slip (fslip) introduced above is the difference between the speed of the rotating magnetic
field ( stator frequency, fS) and the rotor speed ( in terms of rotor frequency, fR).
Slip is usually expressed as a percentage of the synchronous speed: s = (fS – fR) / fsyn
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Substitute Circuit Diagram of the Induction Motor
The “Substitute Circuit Diagram” introduces a reactance for an inductivity; the picture below shows the resulting circuit
for the diagram of the previous page.
The value of a reactance depends on the frequency (X = j ω L = j 2 π f L). The stator frequency can vary but is set by
the VFD; the rotor frequency is determined by the slip (load) exclusively. Since a change of load (change of slip, s)
results in a change of rotor current (iR) it is customary to indicate this relation by assigning a “slip-dependent value” to
the rotor resistance RR: active rotor resistance = RR / s.
RS XσS XσR RR / s
iS iR
effective values
depend on load
vS XMS XMR
As last step all elements of the rotor circuit are transformed and linked to the stator circuit (shown e.g. by X X’).
The galvanic separation disappears; currents and voltages can be linked by formulas and shown in vector diagrams.
RS XσS X‘σR R‘R / s
iS µ = iS - i‘R
iµ i‘R
vS
emf XM

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Motor Parameters
iS RC XC RS XσS iS i‘R X‘σR R‘R / s
µ = iS - i‘R
iµ
voutput vS
emf XM
VFD cable motor
VFD
VFD data
data nameplate
nameplate data
data (have
(have to
to be
be set
set !)!) substitute
substitute circuit
circuit data
data (helpful
(helpful ifif available)
available)
(must
(must never
never be
be changed
changed !)!)
Operation- and installation-data Resistances, reactances (per phase)
ID2010 rated input voltage rated values (p.u) referenced on ZN at rated slip
ID2020 rated input current - power P: 2800 kW stator resistance R1 : 207.06 mΩ
ID2030 rated output voltage - voltage U: 6800 V stator leakage reactance L1 : 12.31 mH
ID2040 rated output current - frequency f: 50 Hz rotor resistance R2 : 118.07 mΩ
- current I: 270 A rotor leakage reactance L2 : 3.52 mH
- speed n: 1487 1/min main field reactance LH : 244.53 mH
ID1010 power ID1080 stator resistance RS

cable ID1040 voltage specify ID1070 stator leakage reactance XσS
cable data
data magnetizing
(to
(to be
be set
set ifif significant)
significant) ID1020 frequency ID1060 no load current iSd (Iµ)
current
ID1090 moment of inertia JR
ID2940 resistance RC ID1050 current influence
ID2941 reactance XC ID1030 speed calculated slip
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“Substitute Circuit Data”
If the motor manufacturer provides substitute circuit data of the motor, they can be given
a) in “per-unit” values (in % of the motor base impedance)
b) in physical units (in Ohms)
In either case, the respective parameters cannot be programmed with the values as given but have to be “converted” first.
a) if the data are provided in “per-unit” values they are already referred to the motor base impedance. To enter these
values into the parameters they merely have to be multiplied by 100:
e.g. stator resistance = 0.0042 % ID 1080 = 0.0042 % * 100 = 0.42 %
b) if the data are provided in physical units they have to be referred to the motor base impedance (Z) first, then
multiplied by100 and only then entered as parameter values.
Parameter “leakage inductance, ID 1070” is to be programmed to the values of “stator leakage inductance”
and “rotor leakage inductance” added (refer to formulas below).
e.g. a motor rated 6.6 kV / 620 A / 1791 rpm / 60 Hz:
Stator resistance R1 0.029 Ω ID 1080 = 0.47 %
Rotor resistance R2 0.0260 Ω
Stator leakage inductance X1 0.792 Ω
Rotor leakage inductance X2 0.726 Ω ID 1070 = 24.7 %
No-load current IM 172 A ID 1060 = 27.7 %
Full load speed n 1791 rpm
Base impedance Z = vmotor / [ imotor * sqrt (3) ]

Stator resistance ID 1080 = 100 * ( R1 / Z )
Leakage inductance ID 1070 = 100 * ( X1 + X2 ) / Z
No-load current ID 1060 = 100 * IM / imotor

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Stator Resistor (IM + SM)

The stator resistance value (ID 1080) represents the
per-phase series resistance of the stator winding.
Typical values: 0.2 – 2.0 %; DEF = 0.1 %
For sensitive applications (full torque required for

frequencies 0 to 2 Hz) this parameter has to be set
accurately. manufacturer’s data:
hot value)
R1 = 0.5 % (
ID 1080 should be programmed to the “cold value”,
which is typically 70 % of the “hot value” which is
commonly given as manufacturer’s data.
Adapting the resistor setting appropriately avoids the

noticeable gradient of the flux overshoot. ID 1080 = 0.5 % ID 1080 = 0.35 % (70 % of 0.5 %)
Leakage Inductance (IM)

The leakage inductance value (ID 1070) represents the total leakage inductance of the motor windings (stator + rotor).
Typical values: 15 – 25 %; DEF = 16 %
This parameter affects the transient performance of the flux controller in case of steps of load or steps of speed command
in operating modes V/HZ, OLVC and CLVC.
Steady state behavior or control accuracy are not affected.
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No-Load Current (IM + SM)

Induction motor: the no-load current (ID 1060) represents the magnetizing current
Synchronous motor: the no-load current (ID 1060) represents the field current in no-load condition
Typical values: 15 – 30 %; DEF = 25 %
Like the leakage inductance, this parameter affects the transient performance of the flux controller in case of steps of load
or steps of speed command in operating modes V/HZ, OLVC and CLVC.
If the drive is operated with virtually no load (possibly coupled but run at small speed) for either application (IM, SM), the
no-load current can be set such as to get a motor voltage as per the V/Hz characteristic of the motor.
(Example: if the motor data read 6.6 kV at 60 Hz and the drive is run at 6 Hz, the no-load current has to be set for the motor
voltage to read 660 V.)
Inertia (IM)
The inertia value (ID 1090) represents the total inertia of the system (rotor + coupled masses).
The “moment of inertia” is a feed-back entry resulting from “Auto-Tuning Stage II”.
The setting has no effect on control performance.

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Saliency Constant (SM)

The saliency constant value (ID 1091) represents the ratio of the overall q-axis inductance to the d-axis mutual inductance.
Data for “leakage inductance, Ls”, “d-axis mutual inductance, Lmd” and “q-axis mutual inductance, Lmq” have to be provided
by the motor manufacturer ( data sheet).
The saliency constant calculates as follows: ID 1091 = ( Lmq + Ls ) / Lmd
Typical values: 1.0 – 1.4 %; DEF = 1.4 %
Like the leakage inductance, this parameter affects the transient performance of the flux controller in case of steps of load
or steps of speed command in operating modes SMC and CSMC.
Auto Tuning (IM + SM)

Stage I estimates the stator resistance, the leakage inductance and adjusts the tuning of the current control loop
available for control modes OLVC, CLVC (either mode without or with output filter), SMC, CSMC
Stage II estimates the no-load current, the inertia and tunes the flux loop
available for control modes OLVC, CLVC (either mode only without output filter)
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Identification / Calculation of “Substitute Circuit Data”
Other than the “operation data of the motor” which are always available on the nameplate and can be set in the assigned
parameters (ID1010 to ID1050), further values specifying the substitute circuit diagram like “stator resistance, ID1080”,
“stator leakage reactance, ID1070” and “no load current, ID1060” are not part of the nameplate and may not even be
available at site for the motor at all.
For many (basic) applications the default values of these parameters as listed in the parameter list can be kept.
In case of demanding applications, however, these values may have to be adapted. Lacking the motor manufacturer’s data
a parameter-prompted “Autotuning Routine” or a “Manual Calculation” using formulas which mathematically represent the
“substitute circuit diagram” will provide approximate values.
ID1060 “no load current”

idS = iS 1 – cosϕ as % of iS ID1060
iqS = iS2 – idS2 value required for the next step
ID1070 “stator leakage reactance”

XσS = sinϕ – ( idS / iqS ) * cosϕ * 100 ID1070
i>0/n=0
XM = ( iS / idS ) – XσS value required for the next step
sN = (nN – nsyn) / nsyn value required for the next step

(load < 30% !)
ID1080 “stator resistance”
i > 0 / n = 30%
RS = s * XM ( idS / iqS ) * 10 ID1080
KW 3260 RPM 1485 Volts 4160 A calculation based on the values of the motor on the left
AMPS 660 FRAME 504-4HV shows that “calculated” and “default-values” mach well:
DUTY CONT HZ 50 COS_PHI 0.89 ID1060 = 33.2 / 25, ID1070 = 14.26 / 16, ID1080 = 0.1 / 0.1

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V/Hz-Characteristic and Magnetizing Current
For many applications of the induction motor the magnitude of the magnetic main field is preferred to be constant for any
speed within the range of operation up to rated speed. A constant magnetic main field is given if the magnetizing current
is kept constant.
iS RS XσS iS i‘R X‘σR R‘R / s
On the basis of the “substitute circuit diagram” the relation of

µ = iS - i‘R
iµ voltage to frequency required to get a constant magnetizing
vS current can easily be found.
emf XM
iS RS XσS iS
first step:
µ = iS
iµ equation relating voltages in the stator for the
with s = 0
vS “idealized no-load operation” (iµ = iS)
RR =
emf XM
vS = RS * iS + jXσS * iS + jXM * iS (X = 2π * f * L)
iS XσS iS second step:

simplifying the equation by “disregarding RS as insignificant”
with s = 0 and rearranging the equation
µ = iS
iµ RR =
vS
vS = j * 2π * f (LσS + LM) * iS
emf XM and RS = 0
iS = iµ = vS / f * 2π * j (LσS + LM)
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V/Hz-Characteristic and Magnetizing Current
vS motor
For the simplification just introduced voltage
ID1040
iS = iµ = vS / f * 2π * j (LσS + LM)
the V/Hz-characteristic is represented by a linear curve
from f = 0, uS = 0 up to rated frequency and voltage. motor
If an “extended speed range” (beyond rated frequency) frequency
ID1020 fS
is required, the motor voltage will be kept constant.
With this simplification, however, the magnetizing current

at 0 Hz would be zero as well (no voltage no current).
vS
For a realistic V/Hz-characteristic, stator resistance RS has
to be introduced again: rated voltage
- at small frequencies RS dominates versus XσS and XM

a “boost voltage” vS0 is required to get iµ
- with increasing frequency the influence of RS decreases
in significance vS0
the “true characteristic” approaches the “linear vS0 reads about 0.2 - 0.5% for large motors fS
characteristic” of the “simplified condition”
rated frequency
iS RS XσS iS
iµ
rated magnetizing current
µ = iS
iµ with s = 0
vS RR = fS
emf XM
rated frequency

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No-Load Current / Full Load Current / Full Load Speed
iS RS XσS iS i‘R X‘σR R‘R / s vS

rated voltage
µ = iS - i‘R
iµ
vS vS0
emf XM fS
rated frequency
i‘R
The load characteristic (torque, rotor current I’R) of pumps
and fans starts with “zero load” at “zero speed” and
increases with the square of the speed. load current for
e.g. pump, fan
The stator current iS reads as added values of iµ and i’R
(vector addition !). fS
The setting of parameters ID1060 and ID1050 is required iµ
for any kind of load. For pumps and fans the change of rated magnetizing current
current over speed can be shown by a simplified relation. fS
rated frequency
iqS iS
full load
100 % current
ID1050
full load
speed simplified
ID1030
no-load
0 current
ID1060 50-60% of fS,rated
0 slip 100 % fS
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Vector Control
In the previous slides the relation of stator voltage to stator frequency with its
iS jXσS consequence for the magnetizing current have been discussed. The only type of
control based entirely on this V/Hz-characteristic is available as “OLTM”.
With exception of “running the drive without motor” (to test the “power cells” or the
“voltage and current measurement”) this control mode will rarely be used.
iS RS
All other types of control use the principle of “Vector Control” which incorporates the
use of one current controller each to control the Magnetizing Current and the Torque
Generating Current individually.
The respective setpoints originate from the flux controller (magnetization) and from
vS emf the speed controller (torque).
The actual values are calculated on the basis of the measured complex stator current
using the substitute circuit diagram and the assigned values (refer to page 15).
ϕS
iS RS XσS iS i‘R X‘σR R‘R / s Instead of currents iµ
and i’R of the substitute
circuit diagram currents
µ = iS - i‘R
iµ idS and iqS are used
iS i‘R iqS
vS
(the minor difference is
emf XM inessential to the overall
result).
iµ
idS

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Available Types of Control (ID 2050)
Test mode For test runs
• Operation via voltage/frequency characteristic (only for cell-test and CT-test) OLTM
OLTM = Open Loop Test Mode
For applications with high speed / torque

Vector control accuracy for a wide range of speed
• Frequency control without evaluation of the slip (for multiple motor applications) V / Hz
• Speed control without encoder / induction motor OLVC
Single drives with moderate requirements; typically pumps, fans
• Speed control with encoder / induction motor CLVC
Single drives with high requirements on speed properties
(accuracy, stability, dynamics)
• Speed control without encoder / synchronous motor SMC
• Speed control with encoder / synchronous motor CSMC
V / Hz = V / Hz characteristic
OLVC = Open Loop Vector Control CLVC = Closed Loop Vector Control
SMC = Synchronous Motor Control CSMC = Closed loop Synchronous Motor Control
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Open Loop Test Mode (ID2050 = OLTM)
speed frequency demand

reference
V/F
voltage demand
coordinate
transformation
iB, iC
P
vA, vB, vC
K
Control mode ”OLTM” generates the voltage setpoint according to an internally set voltage/frequency characteristic;
the characteristic is matched to the programmed motor data.
Actual values of voltage and current evaluation are available for measurement, but are not evaluated.

To
To run
run the
the drive
drive without
without motor
motor (testing
(testing the
the cells,
cells, the
the voltage
voltage measurement
measurement and
and the
the current
current measurement).
measurement).

DriveAutomation
Technologies
andDivision
Drives
Feedback Signals for Closed Loop Vector Control
V / Hz OLVC CLVC
VFD Controls VFD Controls VFD Controls
vA,B,C*
VFD
amplitude,
frequency
vA,B,C
flux flux flux
ID1040 ID1040 ID1040
ID1020 ID1020 ID1020
torque torque iB,C

torque
slip slip
ID1050 ID1050 ID1050
ID1060 ID1060 ID1060
ID1030 ID1030 ID1030
speed
speed speed E
ID1040 motor voltage ID1020 motor Frequency
ID1030 full load speed ID1050 full load current ID1060 no-load current
DriveAutomation
Technologies
andDivision
Drives
Volts by Hertz Control (ID2050 = V/Hz)
speed torque current

controller controller
iqSRef
speed
reference
iqSAct
slip P
flux comp. field current
controller controller K
flux
reference coordinate
ID 3150 idSRef transformation
idSAct iB, iC
slip P
speed
vA, vB, vC
K
actual flux
stator frequency
Increasing the load reduces the rotor speed (rotor speed “lags” the stator speed).
Regardless
Regardless of
of the
the load
load the
the actual
actual stator
stator speed
speed always
always matches
matches the
the speed
speed demand.
demand.

100%
100% “speed
“speed reference”
reference” == “full
“full load
load speed”
speed” at
at “full
“full load
load current”
current” (“synchronous
(“synchronous speed”
speed” at
at “zero
“zero load”)
load”)

For
For multi
multi motor
motor drives
drives with
with several
several (identical)
(identical) motors
motors operated
operated on
on one
one inverter.
inverter.

The
The actual
actual speed
speed ofof the
the motors
motors of
of the
the group
group will
will differ
differ from
from each
each other
other ifif the
the load
load acting
acting on
on them
them is
is not
not identical.
identical.

DriveAutomation
Technologies
andDivision
Drives
Open Loop Vector Control (ID2050 = OLVC)

iqSRef
speed
reference
iqSAct
slip P
flux
idSAct iB, iC
slip P
speed
vA, vB, vC
motor K
actual flux
speed
stator frequency
Increasing the load increases the stator speed (stator speed “leads” the rotor speed).
Regardless
Regardless of
of the
the load
load the
the actual
actual motor
motor speed
speed always
always matches
matches the
the speed
speed demand.
demand.

100%
100% “speed
reference” == “synchronous
“synchronous speed”
speed”

For
For single
single drive
drive induction
induction motors
motors of
of large
large power
power ratings
ratings with
with good
good dynamic
dynamic requirements.
requirements.

IfIf all
all motor
motor data
data are
are programmed
programmed correctly,
correctly, satisfying
satisfying closed
closed loop
loop operation
operation is
is given
given for
for any
any speed.
speed.
DriveAutomation
Technologies
andDivision
Drives
Closed Loop Vector Control (ID2050 = CLVC)

iqSRef
speed
reference
iqSAct
slip P
flux
idSAct iB, iC
slip P
speed
vA, vB, vC
motor K
actual flux
speed
motor speed
E M
Increasing the load increases the stator speed (stator speed “leads” the rotor speed).
Regardless
Regardless of
of the
the load
load the
the actual
actual motor
motor speed
speed always
always matches
matches the
the speed
speed demand.
demand. Actual speed detection by analog tacho

100%
100% “speed
reference” == “synchronous
“synchronous speed”
speed” generator or incremental encoder.

For
For single
single drive
drive induction
induction motors
motors of
of large
large power
power ratings
ratings with
with high
high requirements
requirements on
on accuracy
accuracy and
and dynamics.
dynamics.

AA command
command value
value of
of aa constant
constant or
or variable
variable torque
torque is
is followed
followed dynamically
dynamically and
and highly
highly accurately
accurately at
at any
any speed.
speed.

DriveAutomation
Technologies
andDivision
Drives
Control Schemes (“Output Process Diagram“ / 459 717)
IdS.set
IqS.set
Φset
speed reference
DriveAutomation
Technologies
andDivision
Drives
Current Controller Gains
Current Controller Gains (ID 3260, ID 3270)

Both current controllers (“magnetizing current, ids” and “torque current, iqs”) are tuned by the same set of parameters.
The current controllers evaluate the balance between setpoint and actual value and define voltage commands as output.
If the controller gains (proportional gain, ID 3260 kP, integral gain, ID 3270 1 / TN) are too low, the fundamental of the
output current will feature a non-sinusoidal waveform.
If the controller gains are too high, high frequency ringing will appear on the current waveform.
For general applications the default values will provide acceptable operation:
DEF: ID 3260 = 0.5 / ID 3270 = 25.
Reduced gain settings (40 – 75 % of the default values) are recommended for following applications:
- long cables with output filters (ElectricSubmersiblePump applications)
- synchronous transfer applications when the drive safe voltage capability is only a few percent above the line voltage
- Gen 4 drives operating under low line conditions (output voltage in “over-modulation” is close to line voltage)

DriveAutomation
Technologies
andDivision
Drives
Speed Controller Settings
Speed Controller Settings (ID 3210, ID 3220, ID 3230, ID 3240)

The speed controller evaluates the balance between setpoint and actual value and defines the torque current setpoint iqS.
If the controller gains (proportional gain, ID 3210 kP, integral gain, ID 3220 1 / TN) are too low, the speed response
is sluggish.
If the controller gains are too high, low frequency oscillations can occur in the motor speed.
For general applications the default values will provide acceptable operation:
DEF: ID 3210 = 0.02 / ID 3220 = 0.046 / ID 3230 = 0.6 / ID 3240 = 0.0488.
Reduced settings (20 – 50 % of the default values) for proportional gain (ID 3210) and integral gain (ID 3220) are
recommended for following applications:
- long cables with output filters (ElectricSubmersiblePump applications)
- extremely large fans
The gain setting “Kf” (ID 3230) defines the type of speed loop: - Kf = 1.0 regular PI speed loop
- Kf = 0.5 double speed loop
The low pass filter time constant (ID 3240) might have to be reduced to improve the dynamics of the speed controller
(the smaller low pass filter time constant provides a higher bandwidth).
DriveAutomation
Technologies
andDivision
Drives
Flux Controller Settings
Flux Controller Settings (ID 3110, ID 3120, ID 3130, ID 3150, ID 3160)

The flux controller evaluates the balance between setpoint and actual value and defines the magnetizing current setpoint idS.
The flux setpoint (ID 3150) defines the motor voltage (along with the setting of rated motor voltage, rated motor frequency).
With few exceptions the default values will provide acceptable operation:
DEF: ID 3110 = 1.72 / ID 3120 = 1.0 / ID 3130 = 0.0667 / ID 3150 = 1.0 / ID 3160 = 0.5.
Reduced settings for proportional gain (ID 3110) and integral gain (ID 3120) are recommended under following conditions:
- if oscillations of the magnetizing current setpoint ids are observed
- if a synchronous motor is operated.
If the motor flux of a synchronous motor becomes unstable at higher speed, the value of the Saliency Constant (ID 1091)
should be reduced.
The flux ramp rate (ID 3260) should be increased
- to … 2.0 for large induction motors (3 MW ….)
- to … 3.0 for synchronous motors.

DriveAutomation
Technologies
andDivision
Drives
Torque Limits
ID3150
for the optimization

of the speed controller
Speed
Reference
[SREF]
DriveAutomation
Technologies
andDivision
Drives
Speed Rollback
Speed
Speed Rollback:
Rollback:
on
on reaching the
reaching the torque
torque limit
limit the
the speed
speed reference
reference is
is reduced
reduced
If the load characteristic requires less torque at lower

speed (pumps, fans), the drive will operate at reduced
speed but exactly on torque limit.
torque
torque as required
by load at speed n
torque limit
load current for

e.g. pump, fan n
speed
reduced speed to
run at torque limit

DriveAutomation
Technologies
andDivision
Drives
Droop / Torque Control
Droop:
Droop:
the
the speed
speed reference
reference is
is reduced
reduced in
in proportion
proportion
to
to the
the torque
torque generating
generating current
current component
component
speed ID3245 If two motors run by individual VFDs operate on a common shaft (directly, via
gearbox or on a six-phase motor) they should share the common load in equal
parts (speed controlling both drives individually, torque is not shared equally).
Introducing a (roughly identical) “droop factor” in both VFDs will in about equal the
torque
load on the two drives (at the price of a speed error proportional to the load).
100% The accuracy of “load sharing” mainly depends on the “quality” of the motor model.
Torque
Torque Control:
Control:
the
the torque
torque demand
demand can
can be
be set
set by
by various
various sources
sources
To operate in “Torque Control”, variable

TorqueMode_O has to be set “true” via SOP
(operating modes OLVC, CLVC, V/Hz).
DriveAutomation
Technologies
andDivision
Drives
Thermal Overload Limits
The
The thermal
thermal load
load of
of the
the motor
motor is
is derived
derived from
from the
the calculated
calculated motor
motor temperature.
temperature. For
For the
the calculation
calculation of
of the
the motor
motor
temperature
temperature the
the value
value of
of current,
current, the
the time
time of
of current
current flow
flow and
and the
the thermally
thermally relevant
relevant mass
mass of of the
the motor
motor are
are considered.
considered.
Three types of thermal overload protection can be selected (ID1130, Overload
Three types of thermal overload protection can be selected (ID1130, Overload Select): Select):
Overload
Overload protection
protection type
type Overload
Overload protection
protection type
type Overload
Overload protection
protection type
type
“inverse
“inverse time
time with
with speed
speed derating“
derating“ “straight
“straight inverse
inverse time“
time“ “constant“
“constant“
based
based on
on motor
motor temperature
temperature based
based on
on motor
motor temperature
temperature based
based on
on fixed
fixed current
current
i temperature i temperature i ID1140 (%)

100% 200% overload
ID1139
125% overload
100% pending
10 17 25 50 100% speed 60 300 t/s t/s

ID1150
overload
Trip with fault, if operation is identified Trip with fault, if operation is identified timeout
above the marked characteristic. above the marked characteristic.
The vertical position of the points can
be set at will via ID1152 – ID1157.
trip
To use the above functions it is mandatory to correctly set ID1159, Maximum Load Inertia with fault
(“max. load inertia” to line-start the motor without overheating defines “thermal motor mass”).

DriveAutomation
Technologies
andDivision
Drives
Setting the Overload Limit and the Torque Limit
all settings are defined

as percentage of the
rated motor current
(full load current)
current If the “overload trip” is set to a value larger

120% “overload trip“ than the “torque limit” ( default settings)
the drive will never reach the overload limit
100% “constant“
(unless the speed rollback fails to limit the
80%
“inverse time with torque; possible with constant load drives).
speed derating“
If the “overload trip” is set to a value smaller
30% load characteristic than the “torque limit” the drive will trip rather
than operate on torque limit.
speed
DriveAutomation
Technologies
andDivision
Drives
“Quick-Setting” of the Speed Controller
Input (setpoint) PI controller Output (actual value)

Actual
Setpoint value oscillation
System
KP... prop. gain ID3210

t KI... integral gain ID3220 t
Set the integral gain * to VERY rough approach

zero ( P-controller).
Feed a constant input Reduce the gain to
signal (small percentage Increase the half the value.
of the maximum speed) gain until the Now increase the Reduce the integral gain
to reach an operating speed starts to integral gain until to half the value.
point beyond the limits oscillate. the speed starts to
of friction. oscillate again.
* On the Perfect Harmony Drive the
definition of “integral gain” is used
instead of “integral time”. These
definitions are inverse to each other:
large “int. time” small “int. gain”.

DriveAutomation
Technologies
andDivision
Drives
Step Response of the Speed Controller
actual speed
speed reference
actual torque
step of reference (low dynamic) step of reference (medium dynamic)
step of load
step of load (low dynamic) step of load (medium dynamic)
DriveAutomation
Technologies
andDivision
Drives
Manual Optimization of the Speed Controller
Overshoot
speed
Tolerance band
Trise t torque
Trecovery
Output (actual value) KP... prop. gain ID3210

too Increase the gain kP and KI... integral gain ID3220
slow repeat measurement
Output (actual value)
t
1 Set integral gain * KI to Output (actual value)
zero ( P-controller) 1 kP is optimal
2 Input a step of reference kP TN 2 Now increase KI
3 The manipulated value to allow only one only one undershoot;
must not go into the limit undershoot in consequence an
t overshoot of 20–50 %
* On the Perfect Harmony Drive Output (actual value)
Tan t
the definition of “integral gain” too
is used instead of “integral Decrease the gain kP
time”. These definitions are dynamic
and repeat measurement
inverse to each other: large
“int. time” small “int. gain”. t

08 Motor Theory - Control

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08 Motor Theory - Control

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DriveAutomation

03_Motor_Theory_Control page 1 © Siemens Industry 2013 - subject to modification

continued next page

03_Motor_Theory_Control page 2 © Siemens Industry 2013 - subject to modification

Table of Contents, continued

03_Motor_Theory_Control page 3 © Siemens Industry 2013 - subject to modification

About 60% of the electricity generated

0.9 % motor price

Example: motor rating 100 kW

03_Motor_Theory_Control page 4 © Siemens Industry 2013 - subject to modification

Basic Motor Components

cover; beneath systems for air cooling,

Stator frame Rotor

03_Motor_Theory_Control page 5 © Siemens Industry 2013 - subject to modification

Induction Motor / Synchronous Motor

03_Motor_Theory_Control page 6 © Siemens Industry 2013 - subject to modification

- Nameplates of motors refer to basic motor data only.

SIEMENS IEC 3 Motor

SIEMENS NEMA 3 Motor SIEMENS IEC 3 Motor

NEMA National Electrical Manufacturers Association IEC International Electrotechnical Commission

03_Motor_Theory_Control page 7 © Siemens Industry 2013 - subject to modification

Three-Phase Voltage System / Frequency

A three-phase voltage system consists of three sinusoidal voltages.

03_Motor_Theory_Control page 8 © Siemens Industry 2013 - subject to modification

Rotating Magnetic Field

03_Motor_Theory_Control page 9 © Siemens Industry 2013 - subject to modification

r substitute of the magnetic

03_Motor_Theory_Control page 10 © Siemens Industry 2013 - subject to modification

Frequency and Synchronous Speed / Number of Poles

60 x stator frequency [Hz] no. of pole pairs 1 2 3 4

03_Motor_Theory_Control page 11 © Siemens Industry 2013 - subject to modification

Comparison: Transformer Induction Motor

A squirrel cage induction motor can be looked at in a way similar to a

ΦσP ΦσS ΦσS ΦσR

transformer single phase view motor

03_Motor_Theory_Control page 12 © Siemens Industry 2013 - subject to modification

Load and Slip

To counter the torque of the load, rotor current iR is required:

03_Motor_Theory_Control page 13 © Siemens Industry 2013 - subject to modification

Substitute Circuit Diagram of the Induction Motor

RS XσS X‘σR R‘R / s

03_Motor_Theory_Control page 14 © Siemens Industry 2013 - subject to modification

iS RC XC RS XσS iS i‘R X‘σR R‘R / s

VFD cable motor

ID1010 power ID1080 stator resistance RS

03_Motor_Theory_Control page 15 © Siemens Industry 2013 - subject to modification

“Substitute Circuit Data”

Base impedance Z = vmotor / [ imotor * sqrt (3) ]

03_Motor_Theory_Control page 16 © Siemens Industry 2013 - subject to modification

“Substitute Circuit Data”

Stator Resistor (IM + SM)

For sensitive applications (full torque required for

Adapting the resistor setting appropriately avoids the

Leakage Inductance (IM)

03_Motor_Theory_Control page 17 © Siemens Industry 2013 - subject to modification

“Substitute Circuit Data”

No-Load Current (IM + SM)

03_Motor_Theory_Control page 18 © Siemens Industry 2013 - subject to modification

“Substitute Circuit Data”

Saliency Constant (SM)

Auto Tuning (IM + SM)

03_Motor_Theory_Control page 19 © Siemens Industry 2013 - subject to modification

Identification / Calculation of “Substitute Circuit Data”