YASKAWA Varispeed f7 User manual

Enhanced PID for

Air Compressors

F7 Drive Software

Technical Manual

Software Number: VSF11020X, Drive Models: CIMR-F7UXXXXXX-096

Document Number: TM.F7SW.096, Date: 08/01/05, Rev: 05-08

Date: 08/01/05, Rev: 05-08 Page 2 of 17 TM.F7SW.096

This document is intended to provide proper installation and use of the Yaskawa drive with custom software. This

document is a supplement to the standard drive technical manual. It describes the effects on the drive parameters

and functions with the software installed. Read and understand this document and the standard drive technical

manuals before attempting to install, adjust, operate, inspect or maintain the drive. Observe all cautions and

warnings in this document and the standard drive technical manuals. Custom software is written to add

functionality to a standard AC drive to enhance or enable use in a specific application. The software is loaded to

the flash ROM area of the control board, and replaces the standard drive software. Custom software can add new

functions, modify standard functions, or even inhibit standard functions. It can be used to modify display text or

parameter names. Custom software is usually loaded to the drive before delivery. The control board and drive

nameplate are assigned unique part numbers and the software is registered, archived, and retrievable.

When seeking support for a drive with custom software, it is imperative to provide the unique part number shown

on the drive nameplate. The software has been flashed to the control board memory and the operation of

parameters, functions, and monitors are different than the standard drive software, as described herein.

1.0 Overview

The drive’s standard PID algorithm and display has been modified to provide optimum control of non-

reciprocating rotary screw air compressors. The PID features are designed to expand the functionality and

correct some deficiencies of the drive’s standard PID algorithm. The enhanced PID function utilizes the

parameters of the standard software PID function (B5 group) as well as many new P group parameters.

Date: 08/01/05, Rev: 05-08 Page 3 of 17 TM.F7SW.096

1.1 Simplified Block Diagram of Enhanced PID: 2 Input (B5-01 = 1 or 2)

1.2 Simplified Block Diagram of Enhanced PID: 3 Input (B5-01 = 3 or 4)

(PID setpoint is independent of frequency reference)

1.3 Simplified Block Diagram of Enhanced PID: 2 Input (B5-01 = 3 or 4)

(PID setpoint is same as the frequency reference)

Date: 08/01/05, Rev: 05-08 Page 4 of 17 TM.F7SW.096

2.0 Changes from Standard Product

2.1 Enhanced PID versus Standard Software

Feature Enhanced

PID

Standard

Software

Full Range PID (2-input) √√

PID + Frequency Reference Capable (3-input) √√

PID x Frequency Reference Capable (3-input) √

PID Setpoint Offset Parameter √

PID + Trim is Accomplished Algebraically, Regardless of Commanded

Direction √

Frequency Reference as PID Setpoint √√

Parameter B5-19 “PID Setpoint” can be changed during running √

Independent Digital PID Setpoint √√

Independent Digital PID Setpoint (changeable during run) √

Multiple PID Setpoint Sources (digital preset, analog, pulse input, Modbus

RTU, option card) √√

Setpoint Ramp (when PID setpoint is from frequency reference) √√

Setpoint Ramp (all PID setpoints, regardless of source) √

Multiple PID Feedback Sources (analog, pulse input) √√

Feedback Detection (high, low, on-delay, off-delay, digital output, alarm,

fault, during run, always detected) √

PID Monitors with User Units (scaled using parameter O1-03) √

Detailed PID Monitors (proportional, integral, derivative) √

Integral Hold Digital Input √√

Positive Integral Hold Digital Input (integrator can only decrease) √

Negative Integral Hold Digital Input (integrator can only increase) √

Integral term is lower-limited to PID minimum output √

Integral term is held during sleep and the sleep minimum off time √

PID Output Limit √√

Independent + / - PID Output Limits (B5-06 PID limit now functions only as a

PID upper limit) √

PID Output Gain can be proportional to the frequency reference √

PID Output Gain (0.01 Resolution, instead of 0.1) √

Independent “Sleep Delay” and “Wake-up Delay” parameters √

Increased range for sleep mode timers (0.0 ~ 600.0 sec) √

Minimum sleep time parameter √

Parameters O1-01 and O1-02 have been removed. Parameters P2-09 and

P2-10 have taken their place √

Parameter O1-03 controls the units & scaling for U1-01, D1-XX, and U1-90

thru U1-96 √

Parameter P2-10 controls the units & scaling for U1-02, U1-05, U1-20, and

U1-46 √

Parameter P2-09 controls the displayed keypad custom units for D1-XX,

U1-01, U1-02, U1-05, U1-20, U1-46, and U1-90 thru U1-96 √

Keypad monitors are now displayed in a different order: U1-01 -> U1-90 ->

U1-02 -> U1-03 -> ….. U1-96 -> U1-01 √

PID Setpoint (U1-01), PID Feedback (U1-90), and Output Frequency (U1-

02) are displayed at power-up and return to drive mode √

Multi-function digital output for controlling the “Blowdown” valve. When the

“Blowdown” valve is energized, the air compressor can make air. Controlled

by PID feedback level, drive run status, and delay timers.

√

3. Limitations

None.

Date: 08/01/05, Rev: 05-08 Page 5 of 17 TM.F7SW.096

4. Related Parameters and Functions

4.1 Parameters

Parameter Number

Modbus Address

Parameter

Name

Digital

Operator

Display

Description

Range

Default

Change During Run

Access Level For All

Control Modes *1

B1-01 180H

Frequency

Reference

Selection

Reference

Source

Selects the frequency reference source.

0: Operator

1: Control Terminal Strip

2: Modbus RTU (Terminals R+, R-, S+, S-)

3: Option Card

4: Pulse Input (Terminal RP)

0 ~ 4 1 No Q

B5-16 1B4H

PID Sleep

Delay Time

PID Sleep

Time

Sets the sleep function delay time in terms

of seconds. The “wake-up” time delay is

controlled by P2-06.

0.0 ~

600.0

sec

0.0 No A

P1-01 600H

Feedback

Detection

Mode

Selection

Fb Det Mode

Sel

This parameter selects the characteristics of

the PID feedback detection function.

0: Output/AlwaysDet

Feedback high & low multi-function

digital outputs are enabled (if

programmed); detection is always active.

1: Output/DuringRUN

Feedback high & low multi-function

digital outputs are enabled (if

programmed); detection is active only

during run.

2: Alarm/AlwaysDet

Feedback range alarms (FRH, FRL) and

feedback high & low multi-function digital

outputs are enabled (if programmed);

detection is always active

3: Alarm/DuringRUN

Feedback range alarms (FRH, FRL) and

feedback high & low multi-function digital

outputs are enabled (if programmed);

detection is active only during run

4: Fault/AlwaysDet

Feedback range faults (FRH, FRL) and

feedback high & low multi-function digital

outputs are enabled (if programmed);

detection is always active. Drive coasts

to a stop and activates the fault contacts.

5: Fault/DuringRUN

Feedback range faults (FRH, FRL) and

feedback high & low digital outputs are

enabled (if programmed); detection is

active only during run. Drive coasts to a

stop and activates the fault contacts.

0 ~ 5 0 No A

*1: Access Level (A1-01): Q = “Quick Start”, A = “Advanced”, F = “Factory”.

Date: 08/01/05, Rev: 05-08 Page 6 of 17 TM.F7SW.096

4.1 Parameters (continued)

Parameter

Number

Modbus Address

Parameter Name

Digital Operator

Display

Description

Range

Default

Change During

Run

Access Level For All

Control Modes *1

P1-02 601H

Feedback Detection

Level (High)

Fb Det Lvl High

This parameter sets the detection level

for PID feedback (high) detection

function.

-100.0

+100.0

100.0 No A

P1-03 602H

Feedback On-

Delay Time (High)

Fb High On-Delay

This parameter sets the on-delay time for

the PID feedback detection (high)

function.

0.0

100.0

sec

0.0 No A

P1-04 603H

Feedback Off-Delay

Time (High)

Fb HighOff-Delay

This parameter sets the off-delay time for

the PID feedback (high) detection

function.

0.0 ~

100.0

sec

0.0 No A

P1-05 604H

Feedback Detection

Level (Low)

Fb Det Lvl Low

This parameter sets the detection level

for PID feedback (low) detection function.

-100.0

+100.0

0.0 No A

P1-06 605H

Feedback On-Delay

Time (Low)

Fb Low On-Delay

This parameter sets the on-delay time for

the PID feedback detection (low)

function.

0.0

100.0

sec

0.0 No A

P1-07 606H

Feedback Off-Delay

Time (Low)

Fb Low Off-Delay

This parameter sets the off-delay time for

the PID feedback (low) detection

function.

0.0

100.0

sec

0.0 No A

P1-08 607H

Feedback Detection

Hysteresis

FbDet Hysteresis

This parameter sets the hysteresis level

for the PID feedback detection function

(high & low).

0.0

10.0

10.0 No A

P2-01 60AH

PID Lower Limit

This parameter sets the PID lower limit

as a percentage of the maximum output

frequency (E1-04). Works in conjunction

with the PID Limit (B5-06), which sets the

upper limit.

Note: If P2-01 is set greater than B5-06,

an OPE12 error will be displayed.

-100.0

100.0

-100.0 Yes A

*1: Access Level (A1-01): Q = “Quick Start”, A = “Advanced”, F = “Factory”.

Date: 08/01/05, Rev: 05-08 Page 7 of 17 TM.F7SW.096

4.1 Parameters (continued)

Parameter

Number

Modbus Address

Parameter Name

Digital Operator

Display

Description

Range

Default

Change During

Run

Access Level For All

Control Modes *1

P2-02 60BH

PID Output Gain 2

Output Gain 2

This parameter sets the gain at the

output of the PID. Functions the same

as PID Output Gain (B5-10), but with

finer resolution (0.01 versus 0.1). The

total output gain is determined by B5-

10 x P2-02.

0.00

25.00

1.00 No A

P2-03 60CH

PID Setpoint Offset

Setpoint Offset

This parameter sums with the PID

setpoint (analog input, pulse input,

network communication, or parameter)

to provide an offset.

-100.0

+100.0

0.0 No A

P2-04 60DH

PID Trim Mode

Selection

PID Trm Mode Sel

This parameter selects how the PID

output will trim the frequency reference.

Active only when b5-01 = 3 or 4.

0: Constant

The PID output trim is independent

of the frequency reference.

1: Freq Ref Prop

The PID output trim is proportional

to the frequency reference.

0 ~ 1 0 No A

P2-05 60EH

Frequency

Reference

Proportional Trim

Lower Limit

FrefProp Low Lim

This parameter sets the lower limit of

the PID output trim of the frequency

reference when P2-01 = 1 (trim is

proportional to the frequency

reference). Active only when b5-01 = 3

or 4 and P2-04 = 1.

0.00

100.00

10.00 Yes A

P2-06

60FH

Wake-Up Delay

Timer

Wake Up Delay

This parameter determines the time

delay after the frequency reference

exceeds the sleep level, that the drive

will resume running.

0.0

600.0

sec

1.0 No A

P2-07

610H

Minimum Off-Time

during sleep

operation

Min Off Time

This parameter determines the

minimum amount of time the drive will

be off during sleep mode to allow the

pressure in the sump to dissipate.

0.0

6000.0

sec

30.0 No A

P2-08

611H

Blowdown Valve

Delay Time

Blowdown Delay

This parameter determines (after the

drive is started or re-started after a

sleep cycle) how long the drive has to

run for before closing the multi-function

digital output “blowdown valve”.

0.0

120.0

sec

3.0 No A

*1: Access Level (A1-01): Q = “Quick Start”, A = “Advanced”, F = “Factory”.

Date: 08/01/05, Rev: 05-08 Page 8 of 17 TM.F7SW.096

4.1 Parameters (continued)

Parameter

Number

Modbus Address

Parameter Name

Digital Operator

Display

Description

Range

Default

Change During

Run

Access Level For All

Control Modes *1

P2-09 612H

Custom Units

Display Selection

Custom Units

This parameter determines what

custom units are displayed for U1-01,

D1-XX, and U1-90 thru U1-96.

0: No units displayed

1: PSI

2: kPa

3: oF

Note: Only applicable when O1-03 ≥40

(custom units).

0 ~ 3 1 No A

P2-10 612H

Output Monitor

Units

Output Mon Units

Selects the units & scaling for the

following keypad monitors: U1-02, U1-

05, U1-20, and U1-46. Works in the

same fashion as parameter O1-03.

0: Hz

1: %

2 ~ 38: RPM (Set motor poles)

40 ~ 39999: Custom

0 ~

39999 0 No A

*1: Access Level (A1-01): Q = “Quick Start”, A = “Advanced”, F = “Factory”.

Date: 08/01/05, Rev: 05-08 Page 9 of 17 TM.F7SW.096

4.2 Monitors (U1-XX)

Control Mode *1

Monitor Number

Modbus Address

Monitor Name

Digital

Operator

Display

Description

Scaling for Multi-

function Analog

Outputs

Terminals

FM and AM

(H4-01, H4-04)

Unit

V/f

V/f w/ PG

Open Loop

Vector

Flux Vector

U1-01 040H

Frequency

Reference

Frequency

Ref

Displays the

frequency

reference.

100%:

Maximum Output

Frequency

(E1-04)

0.01

Q Q Q Q

U1-02 041H

Output

Frequency

Output Freq

Displays the output

frequency.

100%:

Maximum Output

Frequency

(E1-04)

0.01

Q Q Q Q

U1-05 044H

Motor Speed

Displays the

encoder feedback

speed or estimated

motor speed.

100%:

Maximum Output

Frequency

(E1-04)

0.01

- Q Q Q

U1-20 053H

Soft Starter

Output

SFS Output

Displays the

frequency

reference after the

Accel, Decel, and

S-curve ramps.

100%:

Maximum Output

Frequency

(E1-04)

0.01

Q Q Q Q

U1-46 06DH

Feed-Forward

Speed

FF Estimate

SPD

Displays the

estimated feed-

forward speed

(Flux Vector only).

100%:

Maximum Output

Frequency

(E1-04)

0.01

- - - F

U1-90 720H

PID Feedback

Displays the PID

feedback as a

percentage of the

maximum output

frequency.

100%:

Maximum Output

Frequency

(E1-04)

0.1%

*2 Q Q Q Q

U1-91 721H

PID Input

Displays the PID

input value as a

percentage of the

maximum output

frequency.

100%:

Maximum Output

Frequency

(E1-04)

0.1%

*2 Q Q Q Q

U1-92 722H

PID Output

Displays the PID

output value as a

percentage of the

maximum output

frequency.

100%:

Maximum Output

Frequency

(E1-04)

0.1%

*2 Q Q Q Q

U1-93 723H

PID

Proportional

Output

PID P Output

Displays the PID

proportional value

as a percentage of

the maximum

frequency.

100%:

Maximum Output

Frequency

(E1-04)

0.1%

*2 Q Q Q Q

*1: Access Level (A1-01): Q = “Quick Start”, A = “Advanced”, F = “Factory”.

*2: Unit and scaling based on O1-03 (Display Scaling) setting. When O1-03 ≥40 (custom units), the displayed

units on the keypad are determined by parameter P2-09.

*3: Unit and scaling based on P2-10 (Output Monitor Units) setting. Parameter P2-10 operates exactly the same

way as O1-03. When P2-10 ≥40 (custom units), the displayed units on the keypad are determined by

parameter P2-09.

Date: 08/01/05, Rev: 05-08 Page 10 of 17 TM.F7SW.096

4.2 Monitors (U1-XX) (continued)

Control Mode *1

Monitor Number

Modbus Address

Monitor Name

Digital

Operator

Display

Description

Scaling for Multi-

function Analog

Outputs

Terminals

FM and AM

(H4-01, H4-04)

Unit

V/f

V/f w/ PG

Open Loop

Vector

Flux Vector

U1-94 724H

PID Integral

Output

PID I Output

Displays the PID

integral value as a

percentage of

maximum output

frequency.

100%:

Maximum Output

Frequency

(E1-04)

0.1%

*2 Q Q Q Q

U1-95 725H

PID Derivative

Output

PID D Output

Displays the PID

derivative value as

a percentage of the

maximum output

frequency.

100%:

Maximum Output

Frequency

(E1-04)

0.1%

*2 Q Q Q Q

U1-96 726H

PID Setpoint

Displays the PID

setpoint as a

percentage of the

maximum output

frequency.

100%:

Maximum Output

Frequency

(E1-04)

0.1%

*2 Q Q Q Q

*1: Access Level (A1-01): Q = “Quick Start”, A = “Advanced”, F = “Factory”.

*2: Unit and scaling based on O1-03 (Display Scaling) setting. When O1-03 ≥40 (custom units), the displayed

units on the keypad are determined by parameter P2-09.

*3: Unit and scaling based on P2-10 (Output Monitor Units) setting. Parameter P2-10 operates exactly the same

way as O1-03. When P2-10 ≥40 (custom units), the displayed units on the keypad are determined by

parameter P2-09.

4.3 Multi-function Digital Input Settings (H1-0X)

Setting Display Description Available For All

Control Modes

80 Positive Integral

Hold Closed: Integral is permitted to decrease, but not increase. √

81 Negative

Integral Hold Closed: Integral is permitted to increase, but not decrease. √

√: Available.

4.4 Multi-function Digital Output Settings (H2-0X)

Setting Display Description Available For All

Control Modes

40 Feedback High

Closed: PID feedback has exceeded P1-02 level for the time

set in P1-03. √

41 Feedback Low

Closed: PID feedback has fallen below the P1-05 level for the

time set in P1-06. √

42 Blowdown

Valve

Closed: Drive has received a run command, the P2-08 delay

timer has expired, and the PID feedback high detection

function is not on (level set in P1-02). Opens immediately

after the run command is removed or the PID feedback high

detection function is satisfied.

√

√: Available.

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