Eurotherm Drives 590 DRV Digital User manual

© Copyright Eurotherm Drives, Inc. 1995
All rights strictly reserved. No part of this document may be stored in a retrieval system or transmitted in any form.
Although every effort has been taken to ensure the accuracy of this manual, it may be necessary, without notice, to make amendments or correct omissions in this document. Eurotherm Drives, Inc.
cannot accept responsibility for damage, injury, or expenses resulting therefrom.
Procedures detailed in this manual are designed to be performed by personnel with sufficient training and/or experience. Only sufficiently qualified personnel familiar with the construction and
operation of industrial drive equipment and the dangers of working with high-voltage electrical systems should attempt installation, adjustment, operation, or service of this equipment. Failure to
follow these guidelines could result in damage to the equipment and severe injury or loss of life to personnel. If you are unsure of your qualifications or do not understand certain procedures in this
manual, contact Eurotherm Drives Customer Service for assistance. Before attempting any procedures in this manual, including installation, verify that the model numbers on the product and in this
manual match. If any discrepancy is found, contact Customer Service immediately.
Procedures in this manual may contain Warnings, Cautions, and Notes. A Warning gives the reader information which, if disregarded, could cause injury or death. A Caution provides the reader with
advice which, if disregarded, could cause damage to the equipment. A Note furnishes additional information for added emphasis or clarity.
Printed in the United States of America HA352494 Issue 3
590 DRV Digital
DC Drive
Product Manual
Version 3 Software

Safety Warnings
Safety
Procedures in this manual may contain Warnings, Cautions, and Notes. A Warning gives the reader information
which, if disregarded, could cause injury or death. A Caution provides the reader with advice which, if disregarded,
could cause damage to the equipment. A Note furnishes additional information for added emphasis or clarity.
The customer is responsible for assessing his or her ability to carry out the procedures in this manual. Make sure you
understand a procedure and the precautions necessary to carry it out safely before beginning. If you are unsure of
your ability to perform a function, or have questions about the procedures listed in this manual, contact Eurotherm
Drives Customer Service at [phone].
WARNING!
Only qualified personnel who thoroughly understand the operation of this equipment and any associated
machinery should install, start-up, or attempt maintenance of this equipment.
WARNING!
This equipment uses hazardous voltages during operation. Never work on it or any other control
equipment or motors without first removing all power supplies.
Caution
This equipment contains ESD (Electrostatic Discharge) sensitive parts. Observe static control
precautions when handling, installing, and servicing this device.
Caution
This equipment was tested before it left our factory. However, before installation and start up, inspect
all equipment for transit damage, loose parts, packing materials, etc.
Caution
Ruptured semiconductor devices may release toxic materials. Contact Eurotherm Drives or the
semiconductor manufacturer for proper disposal procedures for semiconductors or other material.
NOTE. The installation of this equipment must comply with all applicable national and local electrical codes.
590 DRV Digital DC Drive Product Manual iii

Terms & Conditions
EUROTHERM DRIVES INCORPORATED - TERMS AND CONDITIONS (ABRIDGED)
The following text will in no way alter or void the contents of the Eurotherm Drives, Inc. - Terms and Conditions of
Sale. It is only intended to clarify the responsibilities of each party.
Delivery, Title and Risk
. . . DELIVERY TO COMMON CARRIER OR POSTAL AUTHORITIES AT RESTON, VIRGINIA SHALL CONSTITUTE DELIVERY
AND PASSING OF TITLE TO THE CUSTOMER, WHO SHALL THEREAFTER BE RESPONSIBLE FOR DELAYS, LOSS OR
DAMAGE IN TRANSIT.
Warranty and Liability
A. Warranty of equipment found within 12 months after delivery thereof to be defective by reason of faulty materials, workmanship, or
design.
(i) The Customer will:
(a) notify Eurotherm Drives, Inc. within four weeks of the defect becoming apparent
(b) return the equipment forthwith, freight paid, to the premises of Eurotherm Drives, Inc. or
(c) at the option of Eurotherm Drives, Inc. make the equipment available at the Customer’s premises for attention by Eurotherm
Drives, Inc. personnel. Where the equipment is repaired on the Customer’s premises, the Customer accepts liability for the
payment of travel and subsistence expenses of Eurotherm Drives, Inc. personnel.
(ii) Eurotherm Drives, Inc. will:
(a) repair or (at its option) replace any equipment manufactured by Eurotherm Drives, Inc.
(b) for goods not manufactured by Eurotherm Drives, Inc., convey to the Customer only the benefits it may recover under any
guarantee the manufacturer gives to Eurotherm Drives, Inc.
B. Eurotherm Drives, Inc. accepts no liability under this clause:
(i) for damage sustained in transit, (liability for which is dealt with in paragraph 8 hereof);
(ii) for defects caused
(a) by not following the instructions supplied with the equipment during installation, operation or maintenance or
(b) by wear and tear, accident or misuse, improper operation or neglect or
(c) by fitting any equipment which does not comply with Eurotherm Drives, Inc. recommendations or
(d) otherwise as a result of failure of the Customer to comply in full with any manual or handbook containing the technical
specifications and operating instructions supplied by Eurotherm Drives, Inc. with the equipment;
(iii) where equipment has been used for an application other than that specified at the time the Order was acknowledged or not in
accordance with Eurotherm Drives, Inc. instructions;
(iv) where the Customer has failed to observe the terms of payment for the equipment and all other obligations imposed by these terms
and conditions.
C. Where equipment has been ordered, obtained or manufactured to the Customer’s own design or specification, Eurotherm Drives, Inc. can
accept no liability for any failure or defect in such equipment except insofar as such failure or defect arises directly as a result of the
failure of Eurotherm Drives, Inc. to follow the design or specification provided.
Eurotherm Drives, Inc. gives no warranty as to the fitness for any particular purpose of goods supplied to the Customer’s design or
specification.
The Customer shall indemnify Eurotherm Drives, Inc. in respect of all liability, loss or damage suffered by Eurotherm Drives, Inc. as a
result of Eurotherm Drives, Inc. following designs or specifications provided by the Customer including any such liability suffered as a
result of a claim by a third party for infringement of intellectual property rights.
D. Except as specifically set out herein, Eurotherm Drives, Inc. shall be under no liability in respect of the quality, conditions or description
of equipment or for any loss or damage howsoever caused to the Customer or to any other person and any term, condition or representa-
tion to the contrary whether express or implied by statute, common law or otherwise is hereby expressly excluded.
E. NO IMPLIED STATUTORY WARRANTY OR MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE SHALL
APPLY.
590 DRV Digital DC Drive Product Manual iv

Contents (Continued)
Cont. 1590 DRV Digital DC Drive Product Manual
590 DRV DIGITAL DC DRIVE
PRODUCT MANUAL
Safety
Eurotherm Drives Incorporated - Terms and Conditions (abridged)
Chapter 1 INTRODUCTION
Scope.................................................................................................................................................................................................................................... 1 - 1
Overview of the 590 DRV Digital Drive.................................................................................................................................................... 1 - 1
Standard Features ....................................................................................................................................................................................................... 1 - 1
Main Features......................................................................................................................................................................................................... 1 - 1
Other Features....................................................................................................................................................................................................... 1 - 2
Unpacking & Special Handling .......................................................................................................................................................................... 1 - 3
Chapter 2 IDENTIFICATION
Component Identification ................................................................................................................................................................................... 2 - 1
Labeling ............................................................................................................................................................................................................................. 2 - 1
Nameplate Label ............................................................................................................................................................................................... 2 - 1
Fuse Replacement Label................................................................................................................................................................................ 2 - 2
Terminal Tightening Torque Label......................................................................................................................................................... 2 - 2
Connector Kit Label ......................................................................................................................................................................................... 2 - 2
Labeling on High Horsepower Models ..................................................................................................................................................... 2 - 2
Chapter 3 INSTALLATION AND WIRING
Recommended Tools ................................................................................................................................................................................................ 3 - 1
Ventilation and Cooling Requirements .......................................................................................................................................................3 - 1
Mounting Instructions...............................................................................................................................................................................................3 - 2
Wiring Procedures .................................................................................................................................................................................................... 3 - 2
Mounting 7.5 through 100 HP Units....................................................................................................................................................... 3 - 2
Power Wiring........................................................................................................................................................................................................ 3 - 3
Control Wiring ..................................................................................................................................................................................................... 3 - 5
Speed Feedback ................................................................................................................................................................................................. 3 - 7
Hardware Settings ....................................................................................................................................................................................................3 - 9
Drive Calibration................................................................................................................................................................................................ 3 - 9
Control Transformer ........................................................................................................................................................................................3 - 13
Final Inspections ..........................................................................................................................................................................................................3 - 14
Chapter 4 START UP AND ADJUSTMENT
Recommended Tools ............................................................................................................................................................................................... 4 - 1
Check Motor ................................................................................................................................................................................................................. 4 - 1
Initial Drive Start ........................................................................................................................................................................................................ 4 - 2
Check Supply ................................................................................................................................................................................................................ 4 - 2
Adjust Current Loop (AUTOTUNE) ............................................................................................................................................................... 4 - 3
Armature Current Waveform Check ................................................................................................................................................ 4 - 4
Motor Rotation Check ........................................................................................................................................................................................... 4 - 5
Speed Feedback Calibration ........................................................................................................................................................................... 4 - 6

Contents (Continued)
590 DRV DIGITAL DC DRIVE
PRODUCT MANUAL
Cont. 2 590 DRV Digital DC Drive Product Manual
Chapter 4 START UP AND ADJUSTMENT (Continued)
Setup for Field Weakening ................................................................................................................................................................................ 4 - 7
Adjust Speed Loop ................................................................................................................................................................................................... 4 - 8
Other Parameters ...................................................................................................................................................................................................... 4 - 9
Recording Parameters ............................................................................................................................................................................................ 4 - 9
Password Protection ............................................................................................................................................................................................... 4 - 9
Entering a Password........................................................................................................................................................................................ 4 - 9
Changing a Password .................................................................................................................................................................................... 4 - 10
4-Button Reset ...................................................................................................................................................................................................... 4 - 10
Chapter 5 TROUBLESHOOTING
Initial Troubleshooting Procedure ................................................................................................................................................................. 5 - 1
Recommended Tools....................................................................................................................................................................................... 5 - 2
Status LED Troubleshooting ............................................................................................................................................................................... 5 - 2
LED Functions ........................................................................................................................................................................................................ 5 - 2
Health, Alarm Messages and the Trip Reset .......................................................................................................................................... 5 - 4
Symbolic Error Messages ................................................................................................................................................................................... 5 - 10
Alarm Process .............................................................................................................................................................................................................. 5 - 10
Alarm Status .......................................................................................................................................................................................................... 5 - 10
Drive Diagnostics ...................................................................................................................................................................................................... 5 - 12
Hardware Troubleshooting ............................................................................................................................................................................... 5 - 13
Control Power Missing ................................................................................................................................................................................. 5 - 14
Field Fail Procedure.......................................................................................................................................................................................... 5 - 15
Contractor Failed Procedure .................................................................................................................................................................... 5 - 16
SCR Troubleshooting...................................................................................................................................................................................... 5 - 17
Motor Checks ...................................................................................................................................................................................................... 5 - 18
Configuration Errors and General Troubleshooting ....................................................................................................................... 5 - 18
Common Performance Problems............................................................................................................................................................ 5 - 18
Parameter Toggles Between Two Conditions .................................................................................................................... 5 - 18
No SPEED DEMAND ............................................................................................................................................................................... 5 - 18
SPEED SETPOINT has an Unwanted Offset .......................................................................................................................... 5 - 19
Signal Does Not Get Through the RAMP ................................................................................................................................ 5 - 19
Test Points ....................................................................................................................................................................................................................... 5 - 19
Contacting Customer Service .......................................................................................................................................................................... 5 -20
Chapter 6 SERVICE AND MAINTENANCE
Service Procedures .................................................................................................................................................................................................. 6 - 1
Preventive Maintenance....................................................................................................................................................................................... 6 - 2
Removing Lower Cover ........................................................................................................................................................................................ 6 - 3
Changing the Controller Door ......................................................................................................................................................................... 6 - 4
Replacing the Controller ...................................................................................................................................................................................... 6 - 4
Removing the Power Supply Board.............................................................................................................................................................. 6 - 5
Replacing SCRs ........................................................................................................................................................................................................... 6 - 7

Contents (Continued)
Cont. 3590 DRV Digital DC Drive Product Manual
590 DRV DIGITAL DC DRIVE
PRODUCT MANUAL
Appendix A TECHNICAL DESCRIPTION
Control Circuits .............................................................................................................................................................................................. App. A - 1
Power Circuits................................................................................................................................................................................................. App. A - 1
Overview of Features ............................................................................................................................................................................... App. A - 1
Specifications ................................................................................................................................................................................................. App. A - 2
Storage and Operating Environment .................................................................................................................................... App. A - 2
Electrical Ratings (590 Single-board power supply: AH385851U002/U003) .................................. App. A - 3
Electrical Ratings (Three-board power supply: AH385128U004/U104) ................................................ App. A - 3
DC Supply Loading ............................................................................................................................................................................. App. A - 3
590 Controller Output Ratings .................................................................................................................................................. App. A - 4
Power Loss ................................................................................................................................................................................................ App. A - 4
Mechanical Ratings ............................................................................................................................................................................ App. A - 4
Hardware Block Diagram....................................................................................................................................................................... App. A - 4
590 Software Block Diagram ............................................................................................................................................................ App. A - 4
RS422 Communications .......................................................................................................................................................................... App. A - 5
RS232 Communications........................................................................................................................................................................... App. A - 5
Terminal Listing ............................................................................................................................................................................................... App. A - 6
Terminal Specifications ........................................................................................................................................................................... App. A - 7
Analog Input and Output Terminals ........................................................................................................................................ App. A - 7
Digital Input Terminals ...................................................................................................................................................................... App. A - 7
Digital Output Terminals ................................................................................................................................................................. App. A - 7
Terminal Descriptions................................................................................................................................................................................ App. A - 8
Feedback Option Cards.......................................................................................................................................................................... App. A - 11
Switchable Tachometer Feedback card (AH385870U001) ............................................................................... App. A - 11
5701 (Plastic Fiber Optic) Microtach Receiver Card (AH058654U001) .................................................. App. A - 12
5701 Installation Information ...................................................................................................................................................... App. A - 13
5901 (Glass Fiber Optic) Microtach Receiver Card (AH386025U001) .................................................... App. A - 14
Wire-ended Encoder Receiver Card (AH387775Uxxx) ....................................................................................... App. A - 16
Appendix B USING THE MAN MACHINE INTERFACE
Definition & Scope ....................................................................................................................................................................................... App. B - 1
Using the MMI .................................................................................................................................................................................................. App. B - 1
Access and Adjustment .................................................................................................................................................................... App. B - 1
Operation ................................................................................................................................................................................................... App. B - 1
Software Overview .................................................................................................................................................................................... App. B - 1
MMI Menu Structure ............................................................................................................................................................................ App. B - 2
Default Settings ...................................................................................................................................................................................... App. B - 2
Appendix C SETUP PARAMETERS
RAMPS .................................................................................................................................................................................................................. App. C - 2
AUX I/O .............................................................................................................................................................................................................. App. C - 6
JOG/SLACK ................................................................................................................................................................................................... App. C - 8
RAISE/LOWER ............................................................................................................................................................................................... App. C - 10

Contents (Continued)
590 DRV DIGITAL DC DRIVE
PRODUCT MANUAL
Cont. 4 590 DRV Digital DC Drive Product Manual
Appendix C SETUP PARAMETERS (Continued)
FIELD CONTROL ............................................................................................................................................................................................ App. C - 12
CURRENT PROFILE ........................................................................................................................................................................................ App. C - 18
STOP RATES ..................................................................................................................................................................................................... App. C -20
SETPOINT SUM 1........................................................................................................................................................................................... App. C -26
STANDSTILL...................................................................................................................................................................................................... App. C -28
SPEED LOOP ..................................................................................................................................................................................................... App. C -30
SPEED LOOP::ADVANCED.................................................................................................................................................................... App. C -32
SPEED LOOP::SETPOINTS ..................................................................................................................................................................... App. C -34
CURRENT LOOP ............................................................................................................................................................................................ App. C -36
INHIBIT ALARMS ........................................................................................................................................................................................... App. C -38
CALIBRATION ................................................................................................................................................................................................ App. C -40
Appendix D I/O CONFIGURATION - SYSTEM MENU
INTRODUCTION .......................................................................................................................................................................................... App. D - 1
MMI Access to CONFIGURE I/O............................................................................................................................................ App. D - 1
Parameter types .................................................................................................................................................................................... App. D - 1
Configuration procedure ............................................................................................................................................................... App. D - 2
ANALOG INPUTS ........................................................................................................................................................................................ App. D - 3
Analog Inputs - Examples ............................................................................................................................................................... App. D - 5
ANALOG OUTPUTS .................................................................................................................................................................................. App. D - 7
Analog Outputs - Examples .......................................................................................................................................................... App. D - 9
DIGITAL INPUTS ............................................................................................................................................................................................ App. D - 11
Digital Inputs - Examples ................................................................................................................................................................. App. D - 13
DIGITAL OUTPUTS ...................................................................................................................................................................................... App. D - 15
Digital Outputs - Examples ........................................................................................................................................................... App. D - 17
CONFIGURE 5703...................................................................................................................................................................................... App. D - 18
BLOCK DIAGRAM ....................................................................................................................................................................................... App. D - 19
INTERNAL LINKS ........................................................................................................................................................................................... App. D - 21
Internal Links - Example .................................................................................................................................................................... App. D -23
Appendix E MMI PARAMETER LIST
Appendix F SPARE PARTS LISTS
Decoding the Catalog Number ............................................................................................................................................................App. F - 1
Ordering Spare Parts ..................................................................................................................................................................................App. F - 1
Reading the Spare Parts Lists .................................................................................................................................................................App. F - 2
Controller Door Parts Lists .......................................................................................................................................................................App. F - 3
Speed Feedback Receiver Options List .........................................................................................................................................App. F - 3
Power Module Parts Lists ..........................................................................................................................................................................App. F - 4

Contents (Continued)
Cont. 5590 DRV Digital DC Drive Product Manual
590 DRV DIGITAL DC DRIVE
PRODUCT MANUAL
Appendix G RS232 SYSTEM PORT (P3)
SERIAL LINKS::SYSTEM PORT (P3)::P3 SETUP ......................................................................................................................... App. G - 1
Parameters ....................................................................................................................................................................................... App. G - 1
5703 SUPPORT ............................................................................................................................................................................ App. G - 1
BISYNCH SUPPORT................................................................................................................................................................... App. G - 1
UDP (Upload-Download Protocol) Support ............................................................................................................................. App. G - 2
UDP Menu Parameter Settings ................................................................................................................................................... App. G - 2
Communication Port Setup ........................................................................................................................................................... App. G - 2
Download MMI (DUMP MMI -> P3) ....................................................................................................................................... App. G - 2
UDP Download (UDP XFER -> P3) ............................................................................................................................................. App. G - 3
UDP Upload (UDP XFER <- P3) ..................................................................................................................................................... App. G - 4
Serial Link Port P3 Lead ................................................................................................................................................................... App. G - 4
5703 (Peer-to-Peer Communications Option) Support .................................................................................................. App. G - 4
Hardware Description..................................................................................................................................................................... App. G - 5
Appendix H RS422 COMMUNICATIONS (PORTS P1 & P2)
SERIAL LINKS::MAIN PORT (P1)........................................................................................................................................................... App. H - 2
SERIAL LINKS::AUX PORT (P2) ............................................................................................................................................................. App. H - 3
SERIAL LINKS::PNO CONFIG .............................................................................................................................................................. App. H - 4
Communications Standard .................................................................................................................................................................... App. H - 6
ASCII (American Standard Code for Information Interchange)................................................................................. App. H - 6
Binary Communications ........................................................................................................................................................................... App. H - 13
New Serial Link Features ........................................................................................................................................................................ App. H - 16
Serial Link Mnemonics & Parameter Number Allocation................................................................................................ App. H -22
Appendix I PARAMETER LIST BY TAG NUMBER
Appendix J PARAMETER LIST BY MENU
Appendix K PARAMETER LIST BY PARAMETER NAME
Appendix L MISCELLANEOUS DRAWINGS
External Field Wiring for Three-Board Power Supplies .................................................................................................... App. L - 21
External Stack Field Wiring .................................................................................................................................................................... App. L -22
Appendix M SPECIAL BLOCKS AND APPLICATION NOTES
Introduction ...................................................................................................................................................................................................... App. M - 1
DIAMETER CALC. ......................................................................................................................................................................................... App. M - 2
TAPER CALC. ................................................................................................................................................................................................... App. M - 4
TORQUE CALC. ............................................................................................................................................................................................ App. M - 5
SETPOINT SUM 2 ........................................................................................................................................................................................ App. M - 6
PID ........................................................................................................................................................................................................................... App. M - 8
Application Notes ...................................................................................................................................................................................... App. M - 11
590 Terminal Designations ......................................................................................................................................................... App. M - 11

Contents (Continued)
590 DRV DIGITAL DC DRIVE
PRODUCT MANUAL
Cont. 6 590 DRV Digital DC Drive Product Manual
Appendix M SPECIAL BLOCKS AND APPLICATION NOTES (Continued)
Open-Loop Winder (CPW) .................................................................................................................................................................. App. M - 12
Description ............................................................................................................................................................................................... App. M - 12
Turret Winder Applications................................................................................................................................................ App. M - 13
Installation ................................................................................................................................................................................................ App. M - 15
Block Diagram Parameters .................................................................................................................................................. App. M - 15
Internal Links .................................................................................................................................................................................... App. M - 15
Terminal I/O................................................................................................................................................................................... App. M - 15
Other Parameters ....................................................................................................................................................................... App. M - 15
Input Signal Descriptions ............................................................................................................................................................... App. M - 15
Diameter Preset ............................................................................................................................................................................ App. M - 15
Line Speed Reference............................................................................................................................................................... App. M - 16
Tension Setpoint .......................................................................................................................................................................... App. M - 16
Taper Setpoint .............................................................................................................................................................................. App. M - 16
Tension Enable .............................................................................................................................................................................. App. M - 16
Overwind/Underwind ........................................................................................................................................................... App. M - 16
Preset Enable .................................................................................................................................................................................. App. M - 16
Current Limit .................................................................................................................................................................................... App. M - 16
Startup Procedure ............................................................................................................................................................................... App. M - 17
Speed Mode ................................................................................................................................................................................... App. M - 17
Tension Mode ................................................................................................................................................................................ App. M - 17
Unwind ................................................................................................................................................................................................ App. M - 18
Rewind................................................................................................................................................................................................. App. M - 18
Closed-Loop Speed Programmed Winder (SPW) .............................................................................................................. App. M - 19
Description ............................................................................................................................................................................................... App. M - 19
Loadcell Applications ............................................................................................................................................................. App. M - 19
Dancer Position Applications ............................................................................................................................................ App. M -20
Turret Winder Applications................................................................................................................................................ App. M -20
Installation ................................................................................................................................................................................................ App. M - 21
Block Diagram Parameters .................................................................................................................................................. App. M - 21
Internal Links .................................................................................................................................................................................... App. M - 21
Terminal I/O................................................................................................................................................................................... App. M - 21
Other Parameters ....................................................................................................................................................................... App. M - 21
Input Signal Descriptions ............................................................................................................................................................... App. M - 21
Diameter Preset ............................................................................................................................................................................ App. M - 21
Tension Feedback ....................................................................................................................................................................... App. M -23
Line Speed Reference............................................................................................................................................................... App. M -23
Tension Setpoint .......................................................................................................................................................................... App. M -23
Taper Setpoint .............................................................................................................................................................................. App. M -23
Overwind/Underwind ........................................................................................................................................................... App. M -23
Preset Enable .................................................................................................................................................................................. App. M -23
Tension Enable .............................................................................................................................................................................. App. M -23
Jog.......................................................................................................................................................................................................... App. M -23
Tension Mode ................................................................................................................................................................................ App. M -24

Contents (Continued)
Cont. 7590 DRV Digital DC Drive Product Manual
590 DRV DIGITAL DC DRIVE
PRODUCT MANUAL
Appendix M SPECIAL BLOCKS AND APPLICATION NOTES (Continued)
Startup Procedure ............................................................................................................................................................................... App. M -24
Speed Mode ................................................................................................................................................................................... App. M -24
Winders with Dancer Feedback ...................................................................................................................................... App. M -25
Unwinds .............................................................................................................................................................................................. App. M -25
Section Control (SC) .................................................................................................................................................................................. App. M -26
Control Modes ...................................................................................................................................................................................... App. M -27
Draw ..................................................................................................................................................................................................... App. M -27
Ratio ...................................................................................................................................................................................................... App. M -27
Torque ................................................................................................................................................................................................. App. M -27
Tension ................................................................................................................................................................................................ App. M -28
Dancer Position ............................................................................................................................................................................ App. M -28
Additional Features ........................................................................................................................................................................... App. M -28
Reverse ............................................................................................................................................................................................... App. M -28
Anti-reverse .................................................................................................................................................................................... App. M -28
Agitate ................................................................................................................................................................................................ App. M -28
Slack Take-up/pay-out.......................................................................................................................................................... App. M -28
Jog.......................................................................................................................................................................................................... App. M -28
Ramp ..................................................................................................................................................................................................... App. M -28
Raise/Lower (Motor Operated Potentiometer Function) ............................................................................. App. M -29
Installation ................................................................................................................................................................................................ App. M -29
Block Diagram Parameters .................................................................................................................................................. App. M -29
Internal Links .................................................................................................................................................................................... App. M -29
Terminal I/O................................................................................................................................................................................... App. M -29
Other Parameters ....................................................................................................................................................................... App. M -29
Input Signal Descriptions ............................................................................................................................................................... App. M - 31
Draw/Ratio..................................................................................................................................................................................... App. M - 31
Line Reference ............................................................................................................................................................................... App. M - 31
Tension Setpoint .......................................................................................................................................................................... App. M - 31
Tension Feedback ....................................................................................................................................................................... App. M - 31
Reverse ............................................................................................................................................................................................... App. M - 31
PID Enable ......................................................................................................................................................................................... App. M - 31
Startup Procedures for Tension or Dancer Position Control .............................................................................. App. M -32
Initial Section Setup .................................................................................................................................................................. App. M -32
PID Adjustment .............................................................................................................................................................................. App. M -32
Other Settings........................................................................................................................................................................................ App. M -32
Trim Range........................................................................................................................................................................................ App. M -32
Tension ................................................................................................................................................................................................ App. M -33

Contents (Continued)
590 DRV DIGITAL DC DRIVE
PRODUCT MANUAL
Cont. 8 590 DRV Digital DC Drive Product Manual
Appendix M SPECIAL BLOCKS AND APPLICATION NOTES (Continued)
Other Features....................................................................................................................................................................................... App. M -33
Draw ..................................................................................................................................................................................................... App. M -33
Cascade Draw .............................................................................................................................................................................. App. M -33
Digital Draw ................................................................................................................................................................................... App. M -34
Ratio ...................................................................................................................................................................................................... App. M -35
Torque ................................................................................................................................................................................................. App. M -35
Reverse ............................................................................................................................................................................................... App. M -36
Anti-reverse .................................................................................................................................................................................... App. M -36
Agitate ................................................................................................................................................................................................ App. M -36
Ramp ..................................................................................................................................................................................................... App. M -36
Jog .......................................................................................................................................................................................................... App. M -36
Slack Take-up/pay-out.......................................................................................................................................................... App. M -36
Raise/Lower ................................................................................................................................................................................... App. M -36
Extensible/Non-extensible Webs ................................................................................................................................ App. M -37
Simple Winder Equations ...................................................................................................................................................................... App. M -37

1 - 1
1
Chapter 1 Introduction
590 DRV Digital DC Drive Product Manual
Chapter 1 INTRODUCTION
SCOPE
This manual covers the 590 DRV Digital series of regenerative and non-regenerative
DC motor controllers.
OVERVIEW OF THE 590 DRV DIGITAL DRIVE
The 590 DRV Digital drive is a DC motor controller package containing a 590 Digital
DC drive, DC contactor, AC supply fusing to protect the DC drive's thyristors and a
control power transformer. For models rated 7.5 through 100 HP (500 VDC armature
applications), all parts are mounted in a rugged, black anodized aluminum chassis. The
components for all higher horsepower models mount on a panel. 500 through 900 HP
models include a separate, external thyristor stack.
The 590 DRV Digital drive controls the DC output voltage and current for DC shunt
field and permanent magnet motors. Models rated through 100 HP accept standard,
three-phase, 208/230/380/415/460 volts AC, 50/60 Hz supplies; for models rated 125
through 900 HP, the supply is limited to 230/460 VAC.
The 590 DRV Digital drive is available as a four-quadrant, regenerative or a two-quadrant, non-regenerative drive. Each
includes full transient and overload protection and uses highly advanced electronic control of motor acceleration and
deceleration of speed and torque. Regenerative drives include two fully controlled thyristor bridges for forward and reverse
control of speed and torque. Non-regenerative units have one thyristor bridge for operation in only one direction of rotation.
The Man Machine Interface [MMI] display simplifies start up and troubleshooting by automatically displaying the
first fault. It is a powerful diagnostic tool with access to all alarms and most parameters within the drive. Light
emitting diode [LED] indicators on the front panel display the drive's operating status.
You can configure the drive software either through the MMI or with ConfigEd Lite, a configuration program compat-
ible with most IBM compatible personal computers (PCs) running Windows™.
NOTE. 590 DRV Digital DC drives rated through 300 HP are Underwriter Laboratory (UL®) approved
for use in the United States and Canada.
STANDARD FEATURES
Main Features
Microprocessor Control: a 16 bit microprocessor controls the drive and offers:
• Real-time fiber optic communications
• Complex control algorithms not possible with simple analog devices
• Control circuitry built around standard software blocks.
Digital Accuracy: All setpoints and variables are accessible either through analog inputs or digitally over a serial
computer communications link. Speed and current loops are processed digitally giving greater control accuracy
and repeatability than analog drives.
Feedback Options: the drive supports four types of speed feedback:
• Armature voltage feedback (standard), which requires no feedback device, connections or isolator
• Analog AC or DC tachometer generators
• Wire-ended electrical encoders
• Plastic (5701) or glass (5901) fiber optic Microtach encoders
Figure 1.1 - 590 DRV Digital
DC Drive

1 - 2
Chapter 1 Introduction
1
590 DRV Digital DC Drive Product Manual
Field Regulator: a full-wave, half-controlled, single-phase thyristor bridge with transient and overload protection
powers the motor field. The regulator provides either a fixed voltage or fixed current source, depending on the
selected mode of operation. The field current mode can also provide field weakening for systems requiring
extended speed range or constant horsepower control.
On-board Fuse Protection and Contactor: each drive has AC thyristor fuses and a DC contactor. Regenerative
models have DC output fuse protection.
Other Features
•Power Isolation: the 590 DRV Digital drive's control circuitry is electrically isolated from the power circuitry,
enhancing system interconnection and safety.
•Phase Rotation Insensitivity: the supply power can be connected in any phase order to the drive's main input
supply.
Caution
While the 590 DRV Digital drive is not sensitive to phase rotation, the auxiliary 120 VAC between
drives is. Do not tie the neutral wires from different 120 VAC sources together if the phases are rotated
from drive to drive.
•Frequency Auto Ranging: the control circuitry automatically adjusts to accept supply frequencies from 40-
70Hz and possesses high noise immunity from supply born interference.
•Man-Machine Interface (MMI): a two-line alphanumeric liquid crystal display (LCD) automatically displays
the first fault the drive registers. A four button keypad greatly enhances troubleshooting, tuning and commis-
sioning. Drive inputs and outputs and drive parameters are accessible through the LCD and the keypad and
through the software package SAM.
Figure 1.2 - 590 DRV Digital DC Drive Block Diagram

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Chapter 1 Introduction
590 DRV Digital DC Drive Product Manual
•Drive Status Indicators: six LED’s indicate the drive’s alarm and run status.
•Simple Calibration: switch selectable calibration of armature voltage, armature current and field current. Fine
tuning is performed through drive software.
•Current Loop Autotune: a built in AUTOTUNE routine automatically tunes drive current loop.
The drives are designed for simple, economical panel mounting. Disconnecting and reconnecting the controller, if
necessary, is simplified by plug-in connectors. Standardized parts helps reduce the variety of spares needed to
maintain a multi-drive system.
UNPACKING & SPECIAL HANDLING
Read this section before you remove the 590 DRV Digital drive from its packing materials. Though engineered for
heavy industrial use, you can damage the unit by handling it improperly.
Remove the foam cover and fold back the antistatic plastic
wrap from around the drive. Carefully remove any other
packing material from around the drive and place it out of the
way. Save the box and foam inserts for use should you ever
need to return the drive. Improper packaging can lead to transit
damage.
WARNING!
The 590 DRV Digital drive weighs more than 50 lbs.
Be certain you can safely lift and move this weight
before attempting to remove it from its container.
Using proper lifting techniques, remove the drive from its
packing case. Do not attempt to lift or move the drive by its
terminal connections as they are not designed for that purpose.
Lift the drive instead by the solid metal frame on which it is
constructed (see Figure 1.3). Lay the drive on a flat surface
with the access panel covers up and make sure that you do not
damage any protruding terminal connections.
Figure 1.3 - Top Hand-hold Location

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Chapter 1 Introduction
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590 DRV Digital DC Drive Product Manual

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Chapter 2 Identification
590 DRV Digital DC Drive Product Manual
Chapter 2 IDENTIFICATION
This chapter contains photographs of the 590 DRV Digital drive and the 590 controller showing the locations of
labels, fuses and other components.
COMPONENT IDENTIFICATION
Figures 2.3, 2.4, 2.5, and 2.6 identify the parts contained in 590 DRV Digital drives rated 7.5 through 100 HP. These
parts are discussed in the succeeding chapters. Figure 2.3 shows the fuses, transformer, and contactor in the power
chassis. Figure 2.4 shows the location of the labels on the back side of the controller mounting bracket. Figure 2.5
identifies the components on the controller's power supply board. Figure 2.6 shows a controller with a 3-part power
supply board. This configuration is used in all 330 amps (200 HP at 500 VDC) and larger DRVs. Figure 2.7 shows
the inside of the 590 controller after the power supply board is removed.
LABELING
Labels are affixed to each 590 DRV Digital drive. These labels lists electrical requirements, fuse replacement
information, terminal tightening torque ratings, safety warnings and the unit's model and serial numbers.
Nameplate Label
For 7.5 through 100 HP models, the nameplate label is on the left side of the power chassis (see Figure 2.1) as you
face a mounted drive. A duplicate label is also inside the unit on the back side of the controller mounting plate. Both
list the drive’s model and catalog number, revision number, serial number, corresponding manual number and electri-
cal rating information. Make sure you have all the nameplate label information available when contacting Eurotherm
Drives for service assistance.
Figure 2.1 - 590 DRV Digital DC Drive Front and Side Views (30 HP Unit Shown)
Caution Label
¼-turn Screw
Top Flap
Lower Cover
Controller Door
Bottom Flap
Nameplate
Label
Optional Din Rail
¼-turn Screw
Power
Chassis

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Chapter 2 Identification
590 DRV Digital DC Drive Product Manual
Figure 2.2 - 590 DRV Digital DC Drive with Cover Panels Open (30 HP Model Shown)
LED Display
Control Door Part Number
Terminal Information
Communications Card Position
(Optional, not installed)
Calibration Card, Resistor
Testpoints
Speed Feedback Card Position
(Optional, not installed)
Contrast Potentiometer
MMI Display
Terminal Blocks - A, B, and C
MMI Keypad
Terminal Blocks, D
Fuse Replacement Label
The fuse replacement label for 7.5 through 100 HP models is located on the back side of the controller mounting panel
(see Figure 2.4). It is visible when the top section of the DRV (including the controller) is lowered for access to the
fuses and drive terminations. To access this area, loosen the two ¼-turn screws at the top of the drive section, just
above the controller. Gently lower the top section until it comes to rest. If working on a bench, insert a spare bolt in
each of the hinge slots at the base of the top section to provide protection against the drive closing unexpectedly.
Refer to this label when replacing fuses and make sure the replacement fuses meet the label requirements.
NOTE. Figure 2.4 shows a 7.5 to 30 HP DRV chassis mounted to a back panel and opened to display
the labels. The unit is oriented so that the operator is looking down at the labels. Wiring has been
removed for clarity.
Terminal Tightening Torque Label
The terminal tightening torque label (see Figure 2.4) for 7.5 through 100 HP models is located below the fuse replace-
ment label. Refer to it when making electrical connections to avoid overtighten the terminals.
Connector Kit Label
The connector kit label (see Figure 2.4) is located next to the terminal tightening torque label. It lists the catalog
numbers of connector kits used for connecting power wires to the drive. It also lists the appropriate cable rating for
each size power terminal.
LABELING ON HIGH HORSEPOWER MODELS
The nameplate label, fuse replacement schedule and terminal torque label for higher horsepower models (models rated
150 HP and above) are located on the DRV mounting panel.

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Chapter 2 Identification
590 DRV Digital DC Drive Product Manual
Motor Connection Terminals
Figure 2.3 - Power Chassis (30 through 100 HP Units)
Figure 2.4 - Label Location On Controller Mounting Plate (30 through 100 HP Units)
Controller Mounting Bracket
F2
F3
SCR Fuses
F1
F4
F5
Control Transformer
Nameplate Label
UL/CUL Certification Label
Fuse Replacement Label
Warning and Caution Labels
Connector Kit Label
Main Contactor, AM
Armature Fuse, F7 (Regenerative
units only)
Transformer Secondary Fuse, F6
Supply
Connections
Terminal Tightening
Torque Label
Transformer Fuses

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Chapter 2 Identification
590 DRV Digital DC Drive Product Manual
FS3 FS4
PLN Connector
PLK Connector
PLL Connector
External Armature
Sense Connections
Field Pulse
Transformers
Coding Fuses
FS2, FS3, FS4
Gate Leads
Pulse Transformers
Gate Leads
Controller
Transformer
Controller
Power LED
Control Fuse
FS1
Snubbers
FS2
Contactor Pilot Relay
Figure 2.5 - Power Supply Board - AH385851U002 - Regen
PLM Connector
PLJ Connector
AH385851U003 - Non-regen (not shown)
External Field
Supply Connections