Eurotherm 590A SERIES User manual

HA387179 Issue 10
EUROTHERM
DRIVES
590A SERIES THREE PHASE CONVERTORS
PRODUCT MANUAL
A WARNING GIVES THE READER INFORMATION WHICH IF
DISREGARDED COULD CAUSE INJURY OR DEATH
All rights strictly reserved. No part of this document may be stored in a retrieval system, or transmitted in any form or by any means to persons not
employed by a Eurotherm group company without written permission from Eurotherm Drives Ltd.
Although every effort has been taken to ensure the accuracy of this document it may be necessary, without notice, to make amendments or correct
omissions. Eurotherm Drives cannot accept responsibility for damage, injury, or expenses resulting therefrom.
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WARRANTY
Eurotherm Drives warrants the goods against defects in design, materials and workmanship for the period of 12
months from the date of delivery on the terms detailed in Eurotherm Drives Standard Conditions of Sale
IA058393C.
Eurotherm Drives reserves the right to change the content and product specification without notice.
COPYRIGHT in this document is reserved to Eurotherm Drives Ltd.
INTENDED USERS
This manual is to be made available to all persons who are required to configure, install or service the equipment
described herein or any other associated operation.
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WARNINGS AND INSTRUCTIONS
THESE WARNINGS AND INSTRUCTIONS ARE INCLUDED TO ENABLE THE USER TO OBTAIN THE
MAXIMUM EFFECTIVITY AND TO ALERT THE USER TO SAFETY ISSUES
NEVER WORK ON THE CONTROLLER, MOTOR, OR AUXILIARY EQUIPMENT WITHOUT
FIRST ISOLATING ALL SUPPLIES TO THE SYSTEM.
This is a product of the restricted sales distribution class according to iec 61800-3. In a domestic environment
this product may cause radio interference in which case the user may be required to take adequate measures.
This product is designated as ‘professional Equipment’ as defined in EN61000-3-2. Permission of the supply
authority shall be obtained before connection to the low voltage supply.
APPLICATION AREA: Industrial (non consumer) motor speed control utilising dc shunt machines.
PRODUCT MANUAL: The product manual is to provide a description of how the product works and is not intended
to describe how the apparatus works into which it may be installed.
This product manual is to be made available to all persons who are required to: design an application install and service
or any other associated operation with this product.
APPLICATION ADVICE: Applications advice and training is available from Eurotherm Drives Ltd.
INSTALLATION: Ensure that mechanically secure fixings are used as recommended.
ENSURE THAT THE ENCLOSURE INTO WHICH THIS PRODUCT IS MOUNTED IS SUITABLE FOR
THAT ENVIRONMENT (NOTE: THIS PRODUCT MAY BE IP00 OR IP20 AND HENCE REQUIRES
FURTHER PROTECTION TO AVOID PERSONAL INJURY).
Ensure that cooling and air flow around the product are as recommended.
Ensure that cables and wire terminations are as recommended and clamped to required torque.
Ensure that the installation and commissioning of this product are carried out by a component person.
Ensure that the product rating is not exceeded.
APPLICATION RISK: The integration of this product into other apparatus or system is not the responsibility
of Eurotherm Drives Ltd as to its applicability, effectivity or safety of operation or of other apparatus or systems.
Where appropriate the user should consider some aspects of the following risk assessment.
RISK ASSESSMENT: Under fault conditions or conditions not intended.
1. The motor speed may be incorrect. }In these situations the users own risk
2. The motor speed may be excessive }assessment should provide either
3. The direction of rotation may be incorrect. }sufficient guarding to prevent risk of
injury or additional redundant monitoring
and safety systems.
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4. The motor may be energised unless the installation specifically prevents unexpected or unsequenced energisation of
the motor.
5. Due to the use of electricity in this product, only competent persons may install or service this product and avoiding
the danger of death by electrocution or burning by using established safe working practices.
In these situations the users own risk assessment should provide for example lockable isolators to provide safe working
conditions.
NOTE: During power loss the product will not operate as specified.
MAINTENANCE: Maintenance and repair should only be performed by competent persons using only the
recommended spares (or return to factory for repair). Use of incorrect parts may create a hazard and risk of injury.
WHEN REPLACING A PRODUCT IT IS ESSENTIAL THAT ALL USER DEFINED PARAMETERS
THAT DEFINE THE PRODUCTS OPERATION ARE CORRECTLY INSTALLED BEFORE RETURNING
TO USE. FAILURE TO DO SO MAY CREATE A HAZARD AND RISK OF INJURY.
PACKAGING: The packaging is combustible and if disposed of in this manner incorrectly may lead to the generation
of toxic fumes which are lethal.
WEIGHT: Consideration should be given to the weight of the product when handling.
REPAIRS: Repair reports can only be given if sufficient and accurate defect reporting is made by the user.
Remember, the product without the required precautions can represent an electrical hazard and risk of injury, and that
rotating machinery is a mechanical hazard and risk of injury.
PROTECTIVE INSULATION:
1. All exposed metal insulation is protected by basic insulation and bonding to earth i.e. Class 1.
NOTE: Earth bonding is the responsibility of the installer.
2. All signal terminals (terminals 1-39) are SELV, i.e., protected by double insulation (Class 2). The purpose of this
protection is to allow safe connection to other low voltage equipment and is not designed to allow these terminals to be
connected to any unisolated potential.
Ensure all wiring rated for highest system voltage.
NOTE: Thermal sensors contained within the motor are to be double insulated.
ENCLOSURE:
To maintain compliance with the European Low Voltage Directive Standards VDE 0160
(1994)/EN50178(1998) the unit should be mounted inside a suitable control cubicle requiring a tool for
opening.
RCDS: Compatible with Type B RCDs only.
CONTROLLER WARRANTY: For further details on Eurotherm Drives Controller Warranty and Repair refer to the
Standard Conditions of Sale IA058393C.
EUROTHERM DRIVES RESERVE THE RIGHT TO CHANGE OR ALTER THE SPECIFICATION OF THIS
PRODUCT WITHOUT NOTICE
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TABLE OF CONTENTS
SECTION Page No.
1. INTRODUCTION 1-1
1.1 545/590A Upgrade 1-1
1.2 545 to 590A Conversion Chart 1-2
1.3 590A Introduction 1-4
2. TECHNICAL SPECIFICATIONS 2-1
2.1 Specification
2.1.1 Control 2-1
2.1.2 Power 2-2
2.2 Output Ratings 2-3
2.2.1 Armature Rating 2-3
2.2.2 Field Rating 2-4
2.3 Mechanical Details 2-4
3. PRODUCT CODE 3-1
4. INSTALLATION & WIRING
INSTRUCTIONS 4-1
4.1 Installation 4-1
4.2 Ventilation & Cooling 4-1
4.3 Basic Wiring Instructions 4-1
4.4 Notes on Wiring 4-5
4.5 Additional Installation
Requirements for UL508 4-6
Outline & Wiring Diagrams 4-7
4.6 EMC Installation Guidelines 4-19
5. TERMINAL DESCRIPTIONS 5-1
5.1 Control Board 5-1
5.2 Power Board 5-5
6. BLOCK DIAGRAM DESCRIPTION 6-1
6.1 Power Configuration 6-1
6.2 The Control Operation 6-1
6.3 Start and Stop Sequencing 6-4
BLOCK DIAGRAMS
7. BASIC SETTING UP & OPERATING
INSTRUCTIONS 7-1
7.1 Preset Adjustment Description 7-1
7.2 Option Switches 7-2
7.3 Calibration 7-4
7.3.1 Speed Calibration 7-4
7.3.2 Armature Current
Calibration 7-4
7.3.3 Field Voltage Calibration 7-5
7.4 Before Attempting to Connect
Power 7-5
7.5 Preparation 7-5
7.6 Checking the Drive & Setting Up 7-6
7.7 Running Performance
Adjustments 7-7
SECTION Page No.
8. DIAGNOSTIC TEST FACILITIES 8-1
8.1 Description of Diagnostic Test
Unit 8-1
8.2 Diagnostic Test Procedure 8-1
8.3 Connection/Disconnection of
Diagnostic Test Unit 8-1
8.4 Drive Condition Indicators
Description 8-1
8.5 Drive Condition Indicators Status
Recognition 8-3
8.5.1 Stop Condition 8-3
8.5.2 Start Condition 8-4
8.5.3 Diagnostic Test Unit -
Voltage Measurements 8-7
9. 590 "ALL-IN-ONE" POWER BOARD 9-1
Power Circuit Configuration
35/70/110/150/180(4Q)
Power Board Layout for 2Q
Power Board Layout for 4Q
590 Power Board (AH385621) 9-6
10 THE EUROPEAN DIRECTIVES
AND THE ‘CE’ MARK. 10-1
10.1 Eurotherm EMC ‘CE’ Mark
Validity Chart 10-2
Certificates 10-6
11 . SPARES KITS AND SPARE PART
IDENTIFICATION LIST 11-1
12. SERVICE INFORMATION 12-1
12.1 Maintenance 12-1
12.2 Customer Assistance Facilities 12-1
Disposal & Packaging 12-2
Power Circuit Configuration 150A (4Q)
Power Circuit Configuration 150A (2Q)
Power Circuit Configuration 270A (4Q)
Power Circuit Configuration 270A (2Q)
Power Circuit Configuration 450A (4Q)
Power Circuit Configuration 450A (2Q)
Power Circuit Configuration 720A (4Q)
Power Circuit Configuration 720A (2Q)
Layout Ext Stack (4Q)
Layout Ext Stack (2Q)
Circuit Diagram External Stack Controller
Schematic HB057453C
Modification List
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1 - 1
1. INTRODUCTION
1.1 545/590A UPGRADE
The 545 Series product has been applied successfully in a wide variety of applications by machine builders and
OEM's.
This short note is designed to make a quick comparison between the two products and to show just how
convenient the application of 590A will be.
TERMINALS: Control terminals now numbered 1 - 39. Starting at terminal 4 there is direct exchange between
545 and 590A.
A1 - 4
A12 - 15
B1 - 16 NO POSITIONAL CHANGE OF FUNCTION
B12 - 27
C1 - 28
C12 - 39
Terminals 1 to 3 are new for the 590A, refer to section 5-1. Power terminals refer to section 5-2.
DIAGNOSTICS: No change of functionality. Existing 5570 diagnostic unit can still be used.
NOTE: Logical diagnostics e.g. 5 now +15V is enable
0V is disable.
This eases the interpretation of logical diagnostics.
CONDITION INDICATORS (LEDS): Removal of LED4 (trigger fault).
PRESETS: New plug-in preset board with 11 presets. P1 - P10 have identical function as before. P11 allows
adjustment of field supply voltage.
OPTION SWITCHES: Extra options now available on S8 and S9. Direct exchange is:
S1 - S8/1
S2 - S8/2 NO CHANGE IN FUNCTIONALITY
S3 - S8/3
S4 - S8/4
CALIBRATION: Armature current, field voltage of speed feedback are now achieved by switch able
parameters. This allows a very quick and simple commissioning period.
BLOCK DIAGRAM: No change to the functionality, the products are interchangeable.
MECHANICAL PACKAGE: Now uses the common chassis of the 590 product range. Included is;
Auxiliary supply voltage 110/240v without tap change.
Stack supply voltage 220/500v as standard.
Field supply rating 10A and 20A.
ENCLOSURE PROTECTION: IP00 and IP20 versions available.
INTERNATIONAL STANDARDS: UL508
EMC STANDARDS: Refer to Section 10
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1 - 2
1.2 545 TO 590A CONVERSION CHART
Control Terminals A
Function 545 590A
LV Signal Common A1 4
Armature Current Compensation A2 5
Setpoint Ramp Reset A3 6
Setpoint Ramp Input A4 7
Setpoint Ramp Output A5 8
Input No 1 A6 9
Input No 2 A7 10
Inverted Sub-Total A8 11
Input No 3 A9 12
Total Setpoint A10 13
+10V Reference A11 14
-10V Reference A12 15
Control Terminals B
LV Signal Common B1 16
DC Tachogenerator Input B2 3 (17) *
Current Demand Isolate B3 18
Current Demand Output B4 19
Auxiliary Current Input B5 20
Select Auxiliary Input B6 21
Auxiliary Current Limit (+) B7 22
Main Current Limit B8 23
+10V Reference B9 24
Auxiliary Current Limit (-) B10 25
Buffered Tacho B11 26
Buffered Current B12 27
Note:-
1) 545 Terminal B1 has been replaced on the 590A by Terminal 3 for DC Tachogenerators. Terminal 17 can be
used if wire lengths are short.
2) When using an AC Tachogenerator use terminals 2 & 3 on the 590A.
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1 - 3
Control Terminals C
LV Power Common C1 28
Thermistor Input C2 29
Auxiliary Enable C3 30
Start Supply C4 31
Enable C5 32
Stop C6 33
Start C7 34
Ready C8 35
Zero Speed Relay Drive C9 36
Drive Operational Relay Drive C10 37
+24V C11 38
External Fault Reset C12 39
Power Terminals
AC Field Supply D1 D1
No Connection D2
No Connection D3
AC Field Supply D4 D2
DC Field +ve D5 D4
No Connection D6
No Connection D7
DC Field -ve D8 D3
Aux Supply Live (L) D9 D8
Aux Supply Neutral (N) D10 D7
Contactor Supply Neutral(N) D11 D6
Contactor Supply Live (L) D12 D5
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1 - 4
1.3 590A INTRODUCTION
The 590A series of motor speed controllers are designed as components which are fitted into a standard
enclosure with associated control equipment. The controllers accept standard three phase supply voltages in the
range 220 to 500 Volt AC. and provide controlled DC. output voltage and current for the armature and variable
voltage for the field, and are suitable for powering DC. shunt field and permanent magnet motors.
Control of the 590 series is implemented by means of analog and digital control loops which provides many
advanced features.
The motor armature controllers include both regenerative and non-regenerative models.
Non-regenerative controllers consist of one fully-controlled thyristor bridge with full transient and overload
protection, together with its associated electronic control circuitry, and provide accurate speed and/or torque
control in one selected direction of rotation.
Regenerative controllers consist of two fully-controlled thyristor bridges together with a sophisticated electronic
control of acceleration and deceleration, speed and torque in both directions of rotation.
All models of armature controller provide an adjustable field supply as standard. The regulator consists of a
full-wave half controlled single phase thyristor bridge with transient and overload protection. The regulator
provides a fixed voltage which is adjustable by either potentiometer or option selection switches.
The control circuit is totally isolated from the power circuit, thus simplifying the interconnection of controllers
within a system and improving operator safety. The control circuitry adjusts automatically to accept supply
frequencies in the range 50-60 Hz and possesses high immunity to supply borne interference. The armature
controllers are phase rotation insensitive.
All units are designed for simple and economical panel mounting using keyhole tags. If it is necessary to remove
the controller from the panel, disconnection and reconnection is simplified by plug-in control connectors.
Standardisation of parts wherever possible throughout the range reduces the variety of spare parts required to
maintain a multi-drive system. For example, the same basic control and trigger PCB's are used in all types of
three phase armature controller regardless of horsepower or bridge configuration.
This manual covers the following models from the 590A series.
Three phase, regenerative, four quadrant armature controllers.
590A - for currents up to 720 Amps.
598A - external stack option for currents exceeding 721 Amps.
Three phase non-regenerative, two quadrant armature controllers.
591A - for currents up to 720 Amps.
599A - external stack option for currents exceeding 721 Amps.
Commissioning and the location of faults (both within the controller and external to it), are greatly assisted by
built in Condition Indicators which show the status of the various system alarms. Further assistance is available
by use of the optional Diagnostic Test unit type 5570 which provides access to 27 alarms, inputs and principal
circuit nodes throughout the Controller. This unit, which is available as a portable hand-held instrument has
output sockets for the connection of an oscilloscope, chart recorder or other instruments.
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2 - 1
2. TECHNICAL SPECIFICATIONS
2.1 SPECIFICATION
2.1.1 Control
Enclosure Rating: IP00, to be built into a suitable cubicle.
Control Circuits: Fully isolated from power circuit. (SELV)
Output Control: Fully controlled 3-phase Thyristor Bridge.
Microprocessor implemented phase control over extended firing range.
Intended for use on 50Hz or 60Hz supplies with a frequency compliance
range of 45 to 65Hz. Phase control circuits are phase rotation insensitive.
Control Action: Advanced PI with fully adaptive current loops for optimum dynamic
performance.
Speed Control: By analog tach as standard. (AC or DC)
Speed Range: 100 to 1 typical with tach feedback. (DC)
Steady State Accuracy: 0.1% Analog Tach Feedback. (DC)
Note:
Long term analog accuracy is subject to tach temperature stability
Adjustments: All adjustments are in software can be altered by on-board pushbuttons or
via serial communications. An LCD display provides monitoring of
adjustment parameters and levels in addition to diagnostic facilities.
Protection: Interline device networks.
High energy MOV's.
Overcurrent (sub cycle over current trip with reset).
Overcurrent (inverse time).
Field failure.
Tach failure.
Motor over temperature.
Thyristor Stack over temperature (force ventilated units).
Zero speed detection.
Standstill logic.
Diagnostics: Principal circuit mode and function access.
Digital LCD monitoring.
LED circuit state indication.
LED dynamic trend display.
External monitoring/recording/CRT facilities.
Operating Temperature
Range:
0°C
+55°C
Derate linearly above 35°C for force cooled units.
Derate linearly above 45°C for naturally cooled units.
Storage: -25°C
+55°C
Protect from direct sunlight.
Ensure dry, corrosive free environment.
Transport Temperature: -25°C
+70°C
Humidity: 85% Relative humidity maximum.
Relative humidity is temperature dependent.
If the ambient temperature falls the relative humidity will rise and may
ultimately cause condensation. This should be avoided.
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2 - 2
Climatic Conditions: Class 3k3, as defined by EN50178 (1998).
Atmosphere: Non-flammable, non-condensing.
Pollution Degree:
Installation/Overvoltage
Category :
Electrical Safety Standards:
2
3
UL508, VDE0160 (1994), EN50178 (1998)
EMC Standards: See Section 10.
2.1.2 Power
Configuration: 590A, 598A* Two Anti-parallel three phase Thyristor bridges.
591A, 599A* One three phase fully controlled Thyristor bridge.
* External stack options
Mains Supply: 3-Phase, 50/60 Hz, earth referenced (TN) and non-earth referenced (IT)
Operating Supply
Tolerance:
+ 10%
Voltage ranges: 220 to 500Vac - Standard product
110 to 220Vac - Special option
220 to 660Vac - External stack module (598/599)
Supply Current: (0.9 x Idc) Amps AC rms.
Fan Supply Voltage:
(Force Vent Units)
110-120V } +/-10% Single Phase 50/60Hz
220-240V } +/-10% Single Phase 50/60Hz
Rating: 110VA when fitted
Contactor Supply: As control voltage
110-120V } +/-10% Single Phase 50/60Hz
220-240V } +/-10% Single Phase 50/60Hz
Rating: As contactor specification
Control Supply: 110-240V } +/-10% Single Phase 50/60Hz
Rating: 30VA
Note: No selection required for control supply voltage
Reference Supplies: (For speed and current
setpoints)
+10V +/- 0.01 at 5mA Max.
-10V +/- 0.01 at 5mA Max.
DC Supply: +24V Nominal Internally Regulated.
Maximum output capability 6W or 250mA.
Auxiliary loading should be totalled before specification to check DC supply
loading if excessive fit a separate power supply.
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2 - 3
2.2 OUTPUT RATINGS
2.2.1 ARMATURE RATING
590/1 598/9
Output Current Ratings
(Armature)135A 70A 110A 150A 180A 270A 360A 450A 720A 950A 1100A 1388A 1600A 1800A 2300A 2800A
Nominal Power Rating @
460V DC Assuming 95%
Motor Efficiency
15KW
(20HP)
30KW
(40HP)
45KW
(60HP)
60KW
(80HP)
75KW
(100HP)
110KW
(150HP)
150KW
(200HP)
190KW
(250HP)
300KW
(400HP)
395KW
(530HP)
455KW
(610HP)
575KW
(770HP)
660KW
(880HP)
745KW
(1000HP)
950KW
(1275HP)
1150KW
(1550HP)
Maximum Rating
Ambient 245°C 45°C 35°C 35°C 35°C 35°C 35°C 35°C 35°C 35°C 35°C 35°C 35°C 35°C 35°C 35°C
Cooling:
Forced(F)/Natural(N) Fan:
Integral(I)/Separate(S)
N
-
N
-
F
I
F
I
F
I
F
I
F
I
F
S 3
F
S
F
S
F
S
F
S
F
S
F
S
F
S
F
S
Overload Capacity
Available (Armature
Current) 4
YYYYYYYYNYY YYYYY
Field Current Rating 10A 10A 10A 10A 10A 10A 20A 20A 20A 30A 30A 30A 30A 30A 30A 30A
Maximum Supply Voltage 500V 500V 500V 500V 500V 500V 500V 500V 500V 660V 660V 660V 660V 660V 550V5 550V8
Maximum Field Supply
Voltage 500V 500V 500V 500V 500V 500V 500V 500V 500V 500V 500V 500V 500V 500V 500V 500V
Power Loss 105W 210W 330W 450W 540W 710W 1080W 1350W 2160W 2850W 3300W 4164W 4800W 5400W 6900W 8400W
Installation Drawing HG: 055805 055805 055806 055806 386968 055807 057208 057209 0574496 057829705782970578297
0578297 057829705782970578297
1Altitude derating, nominal sea level to 500 metres, derate above 500 metres at 1% per 200 metres up to maximum of 5,000 metres.
2Derate linearly at 1% per degree centigrade for temperature exceeding the maximum rating ambient. Maximum operating ambient is 55°C.
3A lower current version limited to 360Amps is available with an integral fan (HG057208).
4The standard overload capacity available is 200% for 10 seconds, 150% for 30 seconds. The 720 Amp Chassis has no overload capacity at maximum current, whereas at output currents less
than 650 Amps overload capacity is as normal.
5External Stack assemblies at 660V are not available above 2000 Amps without reference to Eurotherm Drives Internal Sales Department.
6For Installation Drawings for 720A Stock Assembly see: HG049669 Standard Mounting / HG054248 Bracket Mounting.
7Installation Drawings for External Stack Thyristor assemblies available on application to Eurotherm Drives Engineering Department.
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2 - 4
2.2.2 FIELD RATING
Output current ratings:
590A/0350-590A/2700 } i.e. from 35A build to 270A build 10A
591A/0350-590A/2700 }
590A/4500 - 590A/7200 } i.e. from 450A build to 720A build 20A
591A/4500 - 591A/7200 }
598A } i.e. external stack builds 30A
599A }
2.3 MECHANICAL DETAILS
GENERAL
1. All controllers should be mounted vertically in the cubicle to allow good air flow across the cooling fin.
Naturally cooled units should be given special consideration to permit cool air entry into and hot air exit
below and above the controller.
2. If the enclosure is totally enclosed the metal surface dissipates 50 watt sq.metre for a 10°C temperature rise.
590A AND 591A CONVERTORS
RATING UP TO 180A:75KW (100HP)
Mounting Centres: Vertical - 400mm (15.75")
Horizontal - 200mm (7.87")
Rating up to 70A
30KW (40HP)
Rating up to 150A
60KW (80HP)
Rating up to 180A
75KW (100HP)
Overall Width: 250mm (9.8") 250mm (9.8") 250mm (9.8")
Overall Height: 415mm (16.5") 440mm (17.3") 500mm (19.7")
Overall Depth: 170mm (6.7") 170mm (6.7") 170mm (6.7")
Weight: 10Kg-14Kg
(22lbs-30lbs)
15Kg
(33.2lbs)
17Kg
(37.5lbs)
Nominal Blower
Throughput:
100m3/Hour 300m3/Hour
Minimum Airflow
Clearance:
100mm (4") above
100mm (4") below
100mm (4") above
100mm (4") below
100mm (4") above
100mm (4") below
Control Terminations: Plug-on connectors with retaining catches.
Power Terminations: Bus-bars with 8mm screws and captive nuts.
Earth termination 6mm screw and captive nut.
Access: Hinge-up cover for control circuit terminals and Diagnostics socket.
Hinge-out Control Printed Board with its own independent cover.
RATING UP TO 270A:110KW (150HP)
Mounting Centres: Vertical - 400mm (15.75")
Horizontal - 200mm (7.87")
Overall Width: 250mm (9.8")
Overall Height: 500mm (19.7")
Overall Depth: 210mm (8.3")
Weight: 20Kg (44lbs)
Minimum Airflow
Clearance:
150mm (6") above and 100mm (4") below
Nominal Blower
Throughput:
350m3/Hour
Control Terminations: Plug-on connectors with retaining catches.
Power Terminations: L1/L2/L3 Bus-bars with 8mm bolts and Belville washers.
A+/A- Bus-bars with 8mm nuts, bolts and Belville washers.
Earth termination 6mm screw and captive nut.
Access: Hinge-up cover for control circuit terminals and Diagnostics socket.
Hinge-out Control Printed Board with its own independent cover.
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2 - 5
RATING UP TO 450A:190KW (250HP)
Mounting Centres: Vertical - 600mm (23.6")
Horizontal - 200mm (7.87")
Overall Width: 250mm (8.75mm") (322mm (12.7") over dc terminals)
Overall Height: 705mm (27.75") Integral Fan
675mm (26.6") Roof Fan
Overall Depth: 252mm (9.9")
Weight: 30Kg (66lbs)
Minimum Airflow
Clearance:
100mm (4") below
150mm (6") above
100mm (4") below duct for roof fan
} Integral Fan
}
} Roof Fan
Nominal Blower
Throughput:
490m3/Hour Integral Fan
Control Terminations: Plug-on connectors with retaining catches.
Power Terminations: L1/L2/L3 Bus-bars with 12mm bolts and Belville washers.
A+/A- Bus-bars with 10mm nuts, bolts and Belville washers.
Earth termination 10mm stud and Belville washer.
Access: Hinge-up cover for control circuit terminals and Diagnostic Socket.
Hinge-out Control Printed Board with its own independent cover.
RATING UP TO 720A:300KW (400HP)
Mounting Centres: (see drawing)
Overall Width: 319mm (12.6") (362mm over dc terminals)
Overall Height: 920mm (36.2") (Module only not including fan equipment and ducting).
Overall Depth: 194mm (7.6") to mounting plane.
140mm (5.5") behind mounting plane.
Weight: 65Kg (143lbs)
Minimum Airflow
Clearance:
See installation drawings HG049669F and HG045248F.
Nominal Blower
Throughput:
1000m3/Hour @ 80 mbar for rated output.
Control Terminations: Plug-on connectors with retaining catches.
Power Terminations: L1/L2/L3 Bus-bars with 14 mm bolts and Belville washers.
A+/A- Bus-bars with 10mm nuts bolts and Belville washers.
Earth termination 8mm bolts and Belville washers in 2 alternate positions.
Access: Hinge-up cover for control circuit terminals and Diagnostic Socket.
Hinge-out Control Printed Board with its own independent cover.
TERMINALS - Tightening Torque
The following table should be referred to when making connections to the controller.
Power Board Terminal Blocks 4 lb-in (0.45Nm)
Control Board Terminal Blocks 5 - 7 lb-in (0.56 - 0.79Nm)
Product Current Rating (A) Terminations Maximum Tightening Torque
0 - 180A L1, L2, L3, A+, A-
GROUND
M8 12.2lb.ft.* 16.5Nm*
M6 5.0lb.ft 6.8Nm
181A - 270A L1, L2, L3, A+, A-
GROUND
M8 12.2lb.ft. 16.5Nm
M6 5.0lb.ft. 6.8Nm
271A - 450A L1, L2, L3
A+, A-
GROUND
M12 42.2lb.ft. 57.2Nm
M10 24.2lb.ft. 32.8Nm
M10 24.2lb.ft. 32.8Nm
451A - 720A L1, L2, L3
A+, A-
GROUND
M14 67.1lb.ft. 91.0Nm
M10 24.2lb.ft. 32.8Nm
M8 12.2lb.ft. 16.5Nm
Note:* M8 CHEESEHEAD SCREW, TIGHTENING TORQUE 8.1lb.ft. 11Nm
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3 - 1
3. PRODUCT CODE
590A AND 591A THREE PHASE CONVERTERS
All members of the three phase product range can be fully specified using a digit numerical order code.
Block No No of Digits Function
1 4 Basic Product
2 4 Output Current
3 1 Supply Voltage (Power)
4 1 Supply Voltage (Auxiliary)
5 2 Special Builds
The 5 blocks are defined as follows:
Block 1: 4 Digits identifying the basic product.
590A: 3 phase, 4 Quadrant (regenerative) convertor 35A to 720A.
591A: 3 phase, 2 Quadrant (non-regenerative) convertor 35A to 720A.
598A: 3 phase, 4 Quadrant (regenerative) external stack controller.
599A: 3 phase, 2 Quadrant (non-regenerative) external stack controller.
Block 2: 4 digits identifying the DC output current rating.
590A/591A: The digits in this block represent a number between 000.0 and 999.9. To form the code from
the numbers, the decimal point is suppressed and leading zeros are added where necessary.
Examples: 234.5 Amps Code 2345
Conversely: Code 1234 123.4 Amps
598A/599A: 5 digits identifying the DC output current rating.
The digits in this block represent a number between 0000.0 and 2800.0. To form a code from
the numbers, the decimal point is suppressed and leading zeros are added where necessary
Examples: 1250 Amps Code 12500
Conversely: Code 11250 1125 Amps
Block 3: 1 Digit identifying the nominal 3 Phase AC power, supply Voltage.
0 110V
1 115V
2 208V
3 220V
4 240V
5 380V
6 415V
7 440V
8 460V
9 480V
A 500V
B 550V 598A/599A External Stacks only
C 600V 598A/599A External Stacks only
D 660V 598A/599A External Stacks only
Block 4: 1 Digit identifying the auxiliary AC control supply Voltage.
0 110V
1 115V
2
3 220V
4 240V
Block 5: 2
0
01 to 99
Digits identifying special option
No special options
Documented special options
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4 - 1
4. BASIC INSTALLATION AND WIRING INSTRUCTIONS
4.1 INSTALLATION
The 590A series motor speed controllers are designed as components which are to be fitted with other control
equipment in a suitable enclosure. The control units are all designed to mount directly onto a flat surface. They
should be fastened by means of bolts or screws through the fixing points at each corner. These points are in the
form of keyholes and slots to simplify fastening or removal.
Please see the relevant installation drawings in this manual for overall dimensions and positions of fixing holes
and to identify size of holes and fixings.
Note: The fixing centres of 590A series controllers are designed to allow use of 100mm grid fixing.
4.2 VENTILATION AND COOLING
In normal operation the drive unit needs to dissipate heat and must, therefore, be mounted to permit the free flow
of cool air vertically through the circuit board area, over the fuses and across the heat sink area at the back.
The normal maximum ambient operating temperatures are:-
Naturally ventilated unit: 45°C (113°F)
Fan-force cooled units: 35°C (95°F)
For operation above these limits derating of the controller may be necessary, refer to the electrical specification
within this manual or the engineering department of Eurotherm Drives.
Care should be taken to ensure that the mounting surface is also cool and that any heat generated by the adjacent
equipment is not transmitted to the drive unit.
As a general rule allow about (150mm) 6" of clear space above and below the drive for free air flow.
4.3 BASIC WIRING INSTRUCTIONS
The following set of instructions is a description of the wiring requirements of a 590A series controller
configured in the General Purpose mode for operation as a basic speed controller. The complexity of connection
when configured in any other mode for specific drive applications, precludes the inclusion of diagrams showing
all wiring options. Special options are usually part of a customer specific system and connection diagrams of
these controllers from part of the information provided for the system.
Information showing the connections required to provide a basic speed control system when using a 590 series
controller are given in wiring diagram HJ 387211.
1. Power cables must have a minimum rating of 1.1 x full load current. (1.25 x FLC when required to
comply with UL requirements).
2. Control wiring must have a minimum cross-sectioned area of 0.75mm2 (square millimetre).
3. All incoming main ac power supply connections must be protected with High Speed semiconductor
fuses. The rating of these fuses being as shown below:-
EUROPEAN STYLE FUSES
PRODUCT CODE BS88 TYPE FUSE DIN TYPE FUSE THYRISTOR A2T
BLOCK 2 FUSE
RATING
PART
NUMBER
FUSE
RATING
PART
NUMBER
@ 125°
°°
°C JUNCTION
TEMPERATURE
0010 to 0350 35A CH110353 40A CH570044 800 A2T
0351 to 0700 75A CH120753 80A CH570084 8,000 A2T
0701 to 1100 110A CH120114 160A CH580164 8,000 A2T
1101 to 1800 150A CH120154 200A CH580025 15,000 A2T
1801 to 2700 300A CH130035 550A CH590554 125,000 A2T
2701 to 4500 ------- -------------- 700A CH590075 320,000 A2T
4501 to 7200 ------- -------------- 800A CH590085 500,000 A2T
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4 - 2
4. Motor overload protection is provided in the controller by means of the thermal device in the motor
winding. This protection cannot be evaluated by UL hence it is the responsibility of the installer and/or
the local inspector to determine whether the overload protection is in compliance with the National
Electric Code or Local Code requirements
5. A substantial ground or earth connection (Protective Earth) should be made to the earth terminal of the
590A drive, the protective earth connection being indicated by the IEC grounding symbol (as defined in
IEC 417 symbol 5019) . On the 720/800A chassis two M8 terminals are provided BOTH MUST
BE connected to protective earth/ground.
6. The motor protective earth/ground connection should be run in parallel with the motor supply
conductors ideally inside the same conduit/screen/armour and be connected near to the drive to a
separate independent protective earth/ground star point. DO NOT RUN THE MOTOR PROTECTIVE
EARTH/GROUND VIA THE 590 CONTROLLER EARTH/GROUND TERMINAL. CONNECT
DIRECTLY TO ENCLOSURE EARTH/GROUND.
7. A 3 phase contactor should be connected in the main ac power supply connections with a rating suitable
for the controller concerned. The contactor does not switch current and is primarily for isolation and
sequencing of the power bridge. The main contactor must be energised directly from the controller by
connecting the coil to terminals D5 (Line) and D6 (Neutral). No additional series contacts or switches
are permitted since they will interfere with the sequencing of the controller and cause unreliability and
possible failure.
Notes:
1 If the 3-phase contactor has a coil with an inrush greater than 3 Amps a slave relay must be
used do drive the contactor
2. The contactor and slave relay (if required) must have coil voltages compatible with the
controller auxiliary supply voltage.
3. A dc contactor can be used but the sequencing must be adjusted to accommodate its use, an
auxiliary normally open volt-free contact of the contactor must be connected in series with the
"enable" input C5 to disable the drive unit after the contactor is closed.
8 A 3 phase ac line reactor should be fitted in series with the incoming main 3 phase ac power supply.
(Eurotherm Drives stock a series of reactors suitable for this duty, mechanically designed to connect
directly to the controller ac supply terminals). The reactor should be connected between the controller
and the ac contactor for optimum protection and safety. Refer to HG386828C for selection of AC LINE
REACTOR.
9. EMC filters should only be fitted on the mains side of the contactor.
10. The auxiliary or control supply (single phase 50/60Hz) should be connected to terminals D8 (Line) and
D7 (Neutral) with suitable external fuse protection. The steady state current absorbed by the controller
is nominal, the external fuse is determined chiefly by considering the contactor holding VA and the
controller cooling fans.
Notes:
1. Auxiliary supply range 110V-240V. No tapping required when switch mode power supply is
used.
2. The auxiliary supply must be connected directly to the incoming supply, no series switches or
contacts are permitted without consultation with Eurotherm Drives Engineering Department.
11. Connect the motor field (-) to terminal D3 and field (+) to terminal D4. If the motor has no field
connections, a permanent magnet motor, or if the field is derived externally, it will be necessary to
override the field fail detector by ensuring that switch S9/5 is on.
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4 - 3
W
H
G
B
C
C
C1 A
D
EL
F
CHOKE RATING DIMENSIONS (mm) Mtg Hole Terminal
TYPE (DC) A B C C1 D E F G H L W
CO055192 35A 50H 50 27.5 130 140 7.5 50 70 155 260 7M8
CO055193 70A 50H 50 27.5 130 140 7.5 72.5 92.5 155 302.5 7M8
CO055253 110A 50H 108 85 60 35 160 170 10 76 101 190 341 9M6I/P&M8O/P
CO055255 180A 50H 108 85 60 35 160 170 10 101 127 190 366 9M6I/P&M8O/P
CO057960 270A 50H 110 110 80 60 255 200 40 170 200 280 380 13 M8
CO0579611360A 50H 125 145 80 60 255 200 40 170 200 280 380 13 M10
CO057962 550A 25H 200 157 110 73 306 250 58 189 220 366 398 13 13
CO057963 720A 25H 200 157 110 73 306 250 58 189 220 366 398 13 13
CO3878861360A 50H 135 145 80 60 255 200 40 170 200 280 380 13 11/13
CO463036235A 485
H
108 85 60 35 160 170 10 76 101 190 341 9M8
CO463037270A 242
H
108 85 60 35 160 170 10 90 116 190 355 9M8
CO4630382110A 154
H
108 85 60 35 160 170 10 102 128 190 367 9M8
CO4630392180A 113
H
108 85 57 37 255 200 40 170 200 280 380 13 M6 I/P & M8 O/P
Schematic representation only, providing basic installation detail. If in doubt refer to drawing.
Notes: 1. CO057961 suitable for use with 545 series and CO387866 suitable for use with 590 series.
2. Specically for use with EMC filters.
EUROTHERM DRIVES
ISS
7
DATE
21.04.97
DRWN:
FEP
CHKD TITLE:
Outline Drawing for 3-phase Line Chokes
for DC Controllers
DRAWING NO:
HG386828C
SHT 1
OF
1 SHTS
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4 - 4
12. If an external field supply is required to the controller for application reasons this supply should be
connected to terminals D1 and D2. The magnitude of this voltage is determined by the desired field
voltage. (For more information on this subject see terminal block descriptions). The supply must be
protected externally with suitable fuses. The supply must always be derived from the Red and
Yellow phases of the main power supply with Red phase connected to terminal D1 and Yellow
phase to terminal D2.
Note: It is important that the connection of the external field supply is consistent when using an
externally supplied field regulator. To ensure correct operation Red phase and Yellow phase are
required to be those phases connected to terminals L1 and L2 respectively of the main power
connections.
It is relatively simple to change the controller from an internal to an external field type.
The red wire of the field wire loom sitting on the RED phase internal terminal (F1) must be moved to
the FE-R terminal adjacent to D1 and the yellow wire of the YELLOW phase internal terminal (F1)
must be moved to the FE-Y terminal adjacent to D2.
13. The main ac power is connected to bus bar terminals L1, L2 and L3, there is no specific phase
connection to these three terminals as the controller is phase rotation independent. The connections
must be made via the correct high speed semiconductor fuses, the main contactor and the ac line
reactor.
14. The motor armature should be connected to bus bar terminals A+ and A-. If a dc contactor is used the
poles should be interposed between the controller terminals and the motor terminals.
Note: When the controller is operating in a regenerative mode for extended periods acting as a load
generator for another machine it is advisable to fit additional protection in the armature circuit. A dc
fuse or a high speed circuit breaker will provide this protection, if in doubt consult the Eurotherm
Drives Engineering Department.
15. For normal operation the speed demand signal is connected to the "Setpoint Ramp Input" terminal 7.
This input is scaled so that:-
+10V input = maximum forward speed demand (+100%)
-10V input = maximum reverse speed demand (-100%)
The speed demand signal can be generated by connecting the two ends of an external 10K
potentiometer to the +10V reference terminal 14 and -10V reference terminal 15, the wiper of the
potentiometer being connected to the "setpoint ramp input" as the speed reference.
For non-reversing applications and 2 quadrant controller (591,etc) the speed demand only needs to
operate between 0V and +10V, the anti-clockwise end of the potentiometer should then be connected to
signal ground terminal 4. Three other terminals are provided as speed setpoint inputs: terminal 9
Setpoint No1, .terminal 10,Setpoint No.2 both giving direct speed demand by-passing the setpoint ramp
generator, terminal 12, Setpoint No. 3, provides a direct inverting speed demand which bypasses the
setpoint generator.
16. The controller has the capability of operating with two forms of feedback:-
i) Analog DC tach
ii) Analog AC tach
USE OF AC TACH IS RESTRICTED TO 2 QUADRANT 591A ONLY.
If an analog DC tach is required this should be connected with its negative terminal connected to
terminal 4 and its positive terminal connected to terminal 3. It is important that this signal cable is a
screened twisted pair cable throughout its entire length. The screen should be grounded or earthed only
at one end, any other grounding arrangement may cause problems.
If an AC tach is used it should be connected to terminals 1 and 2. It is important that this signal cable is
a screened twisted repair throughout its entire length. The screen should be grounded or earthed only at
one end, any other grounding arrangements may cause problems.
Note: Selection of AC tach or DC tach is made via option switch S 1, located on the control board.
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4 - 5
17. The Main Current Limit is adjustable by means of potentiometer P7 (under the front cover of the
controller). For normal operation the Main Current Limit terminal 23 should be connected to the +10V
Reference terminal 24. This gives adjustment on P7 of 0 to 200% full load current. If external control
of Main Current Limit is required, this is achieved by applying a variable voltage to terminal 23 so that
0 to 10 Volts gives 0 to 200% F.L.C. (when potentiometer P7 turned fully clockwise).
18. If the motor is fitted with over-temperature sensing devices such as thermostats, microtherms or PTC
thermistors these should be connected between terminals 28 and 29. If more than one temperature
sensing device is fitted they should be connected in series, if none are fitted terminals 28 and 29 must
be linked to allow the drive to run. Thermistors must have a working resistance of 200 Ohms or less
rising 2000 Ohms at over-temperature.
19. The Enable and Auxiliary Enable terminals 32 and 30 must be connected to 31 in order that the drive
may run. However, external normally closed interlock contacts may be connected in series with 30.
Interruption of the supply to terminal 30 will disable the drive and the Ready and Drive Operational
outputs.
Note: The Thermistor/microtherm and Field failure alarms normally disable the drive only while a fault
exists; if the fault clears, because the motor cools down for example, the motor will restart
automatically. However, these alarms can be made to latch the drive in the disabled stated indefinitely
by connecting 30 to 37 instead of 31 (any external interlock contacts connected in the 30 to 37 link will
also be latched in this manner). In this mode a Thermistor/microtherm, Field failure or external
interlock alarm condition can only be cleared, and the motor restarted, by removal of the start i.e. stop
and the reapplication of start
To provide the latching of the health condition without requiring the use of external wiring, switch
S8/5 can be used
20. Stop/Start control is normally provided either from two momentary contacts or from a single holding
contact.
i) Momentary contacts:-
Connect normally closed STOP contact between terminals 31 and 33.
Connect normally open START contact between terminals 33 and 34.
Note: Additional STOP push-buttons should have normally closed contacts and should be wired in
series with main STOP push-buttons between terminals 31 and 33.
ii) Single holding contact:-
Connect between terminals 31 and 34.
Open contact to STOP.
Close contact to START.
4.4 NOTES ON WIRING
1. Indicator lamps, annuniciators, etc, for "Drive On" condition should be switched by an auxiliary
contactor of the main contactor, not by the controller auxiliary relay.
2. All connections made to terminal blocks must be isolated signal voltages.
3. To avoid damaging the drive NEVER carry out high voltage resistance or dielectric strength tests
without first completely disconnecting the drive from the circuit being tested.
4. If in doubt about the connection of the dc motor to the controller check with Eurotherm Drives
Engineering Department.
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