Eurotherm drives 590 drv digital User manual

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 (704) 588-3246.

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

(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

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

Loadcell Applications ............................................................................................................................................................. App. M - 19

Dancer Position Applications ............................................................................................................................................ App. M -20

Turret Winder Applications................................................................................................................................................ App. M -20

Block Diagram Parameters .................................................................................................................................................. App. M - 21

Other Parameters ....................................................................................................................................................................... App. M - 21

Input Signal Descriptions ............................................................................................................................................................... App. M - 21

Tension Feedback ....................................................................................................................................................................... App. M -23

Line Speed Reference............................................................................................................................................................... App. M -23

Tension Setpoint .......................................................................................................................................................................... App. M -23

Overwind/Underwind ........................................................................................................................................................... App. M -23

Jog.......................................................................................................................................................................................................... App. M -23