Eurotherm 590+ Series User manual

EUROTHERM
DRIVES
590+ Series
DC Digital Converter
Product Manual
HA466461U002 Issue 1
Copyright Eurotherm Drives Limited 2001
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.
Compatible with Version 5.x Software

Cont.2
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.

Cont.3
Requirements
IMPORTANT: Please read this information BEFORE installing the equipment.
Intended Users
This manual is to be made available to all persons who are required to install, configure or
service equipment described herein, or any other associated operation.
The information given is intended to highlight safety issues, and to enable the user to obtain
maximum benefit from the equipment.
Complete the following table for future reference detailing how the unit is to be installed and
used.
INSTALLATION DETAILS
Serial Number
(see product label)
Where installed
(for your own
information)
Unit used as a:
(refer to Certification
for the Converter)
❏Component ❏Relevant Apparatus
Unit fitted: ❏Wall-mounted ;Enclosure
Application Area
The equipment described is intended for industrial (non consumer) motor speed control utilising
dc shunt machines.
Personnel
Installation, operation and maintenance of the equipment should be carried out by qualified
personnel. A qualified person is someone who is technically competent and familiar with all
safety information and established safety practices; with the installation process, operation and
maintenance of this equipment; and with all the hazards involved.
!
Safety Information

Cont.4
Hazards
WARNING!
This equipment can endanger life through rotating machinery and high voltages.
Failure to observe the following will constitute an ELECTRICAL SHOCK HAZARD.
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.
•The equipment must be permanently earthed due to the high earth leakage current.
•The drive motor must be connected to an appropriate safety earth.
•Before working on the equipment, ensure isolation of the mains supply from terminals L1,
L2 and L3.
•Never perform high voltage resistance checks on the wiring without first disconnecting the
drive from the circuit being tested.
•When replacing a drive in an application and before returning to use, it is essential that all
user defined parameters for the product’s operation are correctly installed.
•This equipment contains electrostatic discharge (ESD) sensitive parts. Observe static
control precautions when handling, installing and servicing this product.
IMPORTANT: Metal parts may reach a temperature of 90 degrees centigrade in operation.
Application Risk
The specifications, processes and circuitry described herein are for guidance only and may need
to be adapted to the user’s specific application.
Eurotherm Drives does not guarantee the suitability of the equipment described in this Manual
for individual applications.
Risk Assessment
Under fault conditions, power loss or other operating conditions not intended, the equipment
may not operate as specified. In particular:
•The motor speed may not be controlled
•The direction of rotation of the motor may not be controlled
•The motor may be energised
Guards
The user must provide guarding and /or additional safety systems to prevent risk of injury and
electric shock.
Protective Insulation
•All control and signal terminals are SELV, i.e. protected by double insulation. Ensure all
wiring is rated for the highest system voltage.
Note:
Thermal sensors contained within the motor must be double insulated.
•All exposed metalwork in the Converter is protected by basic insulation and bonding to a
safety earth.
RCDs
These are not recommended for use with this product but ,where their use is mandatory, only
Type B RCDs should be used.
!
Safety Information

Contents
Contents Page
Cont.5
Chapter 1 GETTING STARTED
Equipment Inspection and Storage...............................................................1-2
Packaging and Lifting Details.......................................................................1-2
About this Manual.........................................................................................1-2
Initial Steps ............................................................................................................... 1-2
How the Manual is Organised ................................................................................... 1-3
Chapter 2 AN OVERVIEW OF THE CONVERTER
How it Works .................................................................................................2-1
Control Features............................................................................................2-2
Understanding the Product Code..................................................................2-3
Model Number (Europe)............................................................................................ 2-3
Catalog Number (North America).............................................................................. 2-4
•Door Assembly Product Code ................................................................. 2-5
Product Identification....................................................................................2-5
Component Identification..............................................................................2-6
•590+ Controller (Frames 1 & 2)............................................................. 2-6
•590+ Door Assembly (Frames 3, 4, 5 & H)............................................ 2-7
•590+ Controller (Frame 3)..................................................................... 2-8
•590+ Controller (Frames 4 & 5)............................................................. 2-9
•590+ Product (Frame H) ...................................................................... 2-10
Chapter 3 INSTALLING THE CONVERTER
Mechanical Installation.................................................................................3-1
Unpacking the Converter .......................................................................................... 3-1
•Lifting the Converter ............................................................................... 3-1
Changing DC Output Terminals (Frame H) ................................................................ 3-2
Removing the Cover (Frame H)................................................................................. 3-2
Product Dimensions .................................................................................................. 3-3
Mounting the Converter............................................................................................. 3-4
•Recommended Tools .............................................................................. 3-4
•Ventilation and Cooling Requirements..................................................... 3-4
AC Line Choke ......................................................................................................... 3-4
Installing the Fan (Frame H) ...................................................................................... 3-5
Installing the External Vent Kit (Frames 4 & 5) ............................................................ 3-5
Electrical Installation.....................................................................................3-6
Minimum Connection Requirements (Frames 1, 2, 3, 4 & 5) ....................................... 3-8
•Important Connections ........................................................................... 3-8
•Protective Earth Connections (PE) - (Frames 1, 2, 3, 4 & 5) ...................... 3-9
•Power Wiring Connections (Frames 1, 2, 3, 4 & 5) ................................ 3-10
•Control Wiring Connections (Frames 1, 2, 3, 4 & 5) .............................. 3-13
Minimum Connection Requirements (Frame H) ........................................................ 3-17
•Protective Earth Connections (PE) - (Frame H) ........................................ 3-18
•Power Wiring Connections (Frame H).................................................... 3-19
•Control Wiring Connections (Frame H) ................................................. 3-21

Contents
Contents Page
Cont.6
Motor Field Connections ......................................................................................... 3-22
•Internal/External Supply (Frames 2, 3, 4 & 5) ........................................ 3-22
DC Contactor - External VA Sensing ........................................................................ 3-25
•Power Board - PCB Reference 385851 (Frame 3) .................................. 3-25
•Power Board – PCB Reference 466701 (Frames 4 & 5) .......................... 3-25
•External Connections (Frame H)............................................................ 3-26
Optional Equipment ....................................................................................3-27
•Fitting the Remote 6901 Operator Station ............................................. 3-27
•Speed Feedback and Technology Options............................................. 3-28
•External AC Supply EMC Filter Installation ............................................. 3-29
•Earth Fault Monitoring Systems ............................................................. 3-30
Installation Drawings..................................................................................3-31
Converter Installation Drawings ............................................................................... 3-31
Filter Installation Drawings ...................................................................................... 3-42
Line Choke Installation Drawings............................................................................. 3-48
Chapter 4 OPERATING THE CONVERTER
Pre-Operation Checks...................................................................................4-1
Control Philosophy ........................................................................................4-2
Start/Stop and Speed Control .......................................................................4-2
•Selecting Local or Remote Control........................................................... 4-3
Reading the Status LEDs ............................................................................................ 4-3
Setting-up the Converter...............................................................................4-4
Preliminaries............................................................................................................. 4-4
•Analog Tacho Calibration Option Board ................................................. 4-4
•Microtach/Encoder Feedback Option Board ............................................ 4-5
Calibration ............................................................................................................... 4-5
Selecting Speed Feedback ......................................................................................... 4-7
Initial Start-up Routine .................................................................................4-8
Performance Adjustment ......................................................................................... 4-14
•Current Loop - The Autotune Feature .................................................... 4-14
•Speed Loop.......................................................................................... 4-14
Starting and Stopping Methods ..................................................................4-15
Stopping Methods ................................................................................................... 4-15
•Normal Stop (C3)................................................................................. 4-16
•Program Stop (B8)................................................................................ 4-18
•Coast Stop (B9) .................................................................................... 4-19
•Standstill .............................................................................................. 4-19
•The Trip Condition ............................................................................... 4-19
Normal Starting Method.......................................................................................... 4-20
Advanced Starting Methods ..................................................................................... 4-20
•Starting Several Converters Simultaneously ........................................... 4-20
•Jog ...................................................................................................... 4-20
•Crawl................................................................................................... 4-20

Contents
Contents Page
Cont.7
Chapter 5 THE OPERATOR STATION
Connecting the Operator Station ..................................................................5-1
Controlling the Operator Station ..................................................................5-1
Control Key Definitions.............................................................................................. 5-2
•Keys for Programming the Converter ...................................................... 5-2
•Keys for Operating the Converter Locally ................................................ 5-2
Indications ................................................................................................................ 5-3
•Operator Station LEDs ............................................................................ 5-3
•Operator Station Alarm Messages .......................................................... 5-3
The Menu System ..........................................................................................5-4
The Local Menu ........................................................................................................ 5-5
•The L/R Key............................................................................................ 5-5
•The PROG Key ....................................................................................... 5-5
Navigating the Menu System ..................................................................................... 5-6
Changing a Parameter Value .................................................................................... 5-6
The Menu System Map .............................................................................................. 5-7
Menu Shortcuts and Special Key Combinations .......................................................... 5-8
•Quick Tag Information ........................................................................... 5-8
•Changing the Stack Size (3-button reset) ................................................. 5-8
•Resetting to Factory Defaults (2-button reset) ........................................... 5-9
Special Menu Features ................................................................................5-10
Selecting a Menu Viewing Level ............................................................................... 5-10
Selecting the Display Language ............................................................................... 5-10
Password Protection ................................................................................................ 5-11
•To Activate Password Protection ............................................................ 5-11
•To Deactivate Password Protection ........................................................ 5-12
How to Save, Restore and Copy your Settings ............................................5-13
Saving Your Application .......................................................................................... 5-13
Restoring Saved Settings .......................................................................................... 5-13
Copying an Application........................................................................................... 5-13
Chapter 6 PROGRAMMING YOUR APPLICATION
Programming with Block Diagrams..............................................................6-1
Modifying a Block Diagram ....................................................................................... 6-1
•Configuration and Parameterisation Modes ............................................ 6-1
•Making and Breaking Links in Configuration Mode ................................. 6-1
•Programming Rules ................................................................................ 6-2
•Saving Your Modifications ...................................................................... 6-2
Understanding the Function Block Description............................................................ 6-2
•MMI Menu Maps .................................................................................... 6-3
Function Block Descriptions...........................................................................6-4
•ANALOG INPUTS................................................................................... 6-5
•ANALOG OUTPUTS ............................................................................... 6-7
•AUX I/O................................................................................................. 6-8
•BLOCK DIAGRAM (MMI only) ............................................................... 6-13

Contents
Contents Page
Cont.8
•CALIBRATION ...................................................................................... 6-14
•CONFIGURE DRIVE (MMI only)............................................................. 6-17
•CURRENT LOOP .................................................................................. 6-18
•CURRENT PROFILE............................................................................... 6-21
•DIAGNOSTICS..................................................................................... 6-22
•DIAMETER CALC. ................................................................................. 6-27
•DIGITAL INPUTS .................................................................................. 6-29
•DIGITAL OUTPUTS............................................................................... 6-31
•FIELD CONTROL.................................................................................. 6-32
•ALARMS ............................................................................................... 6-35
•JOG/SLACK......................................................................................... 6-38
•LINK 11 & LINK 12............................................................................... 6-40
•MENUS................................................................................................ 6-42
•miniLINK.............................................................................................. 6-43
•OP STATION........................................................................................ 6-44
•PASSWORD (MMI only) ........................................................................ 6-46
•PID ...................................................................................................... 6-47
•RAISE/LOWER ...................................................................................... 6-50
•RAMPS ................................................................................................. 6-52
•SETPOINT SUM 1................................................................................. 6-56
•SETPOINT SUM 2................................................................................. 6-57
•SPEED LOOP ....................................................................................... 6-59
•ADVANCED ......................................................................................... 6-63
•STANDSTILL ......................................................................................... 6-64
•STOP RATES......................................................................................... 6-65
•SYSTEM PORT P3 ................................................................................. 6-67
•5703 SUPPORT.................................................................................... 6-68
•TAPER CALC. ....................................................................................... 6-69
•TEC OPTION ....................................................................................... 6-70
•TENS+COMP CALC............................................................................. 6-71
•TORQUE CALC.................................................................................... 6-73
•USER FILTER......................................................................................... 6-74
Chapter 7 TRIPS AND FAULT FINDING
Trips ..............................................................................................................7-1
What Happens when a Trip Occurs ........................................................................... 7-1
•Converter Indications.............................................................................. 7-1
•Operator Station Indications ................................................................... 7-1
Resetting a Trip Condition ......................................................................................... 7-1
Fault Finding .................................................................................................7-2
Alarm Messages ....................................................................................................... 7-2
•LAST ALARM .......................................................................................... 7-2
•HEALTH WORD...................................................................................... 7-2
•HEALTH STORE ...................................................................................... 7-2

Contents
Contents Page
Cont.9
Hexadecimal Representation of Trips ......................................................................... 7-3
Power Board LED Trip Information (Frame 4, 5 & H) .................................................. 7-4
Using the MMI to Manage Trips................................................................................. 7-5
•Trip Messages ........................................................................................ 7-5
•Symbolic Alarm Messages ...................................................................... 7-8
•Self Test Alarms...................................................................................... 7-8
•Setting Trip Conditions ........................................................................... 7-8
•Viewing Trip Conditions.......................................................................... 7-9
•Inhibiting Alarms .................................................................................... 7-9
Test Points................................................................................................................. 7-9
Chapter 8 ROUTINE MAINTENANCE AND REPAIR
Maintenance .................................................................................................8-1
•Service Procedures ................................................................................. 8-1
•Preventive Maintenance .......................................................................... 8-1
Repair............................................................................................................8-1
Saving Your Application Data .................................................................................... 8-1
Returning the Unit to Eurotherm Drives....................................................................... 8-2
Disposal ................................................................................................................... 8-2
Technical Support Checks.......................................................................................... 8-3
Fuse Replacement (Frame H) ..................................................................................... 8-4
•590+ 4Q Product (Regenerative) ............................................................ 8-4
•591+ 2Q Product (Non-Regenerative) .................................................... 8-5
Phase Assembly Replacement (Frame H) .................................................................... 8-6
Replacing the Fan (Frames 4 & 5).............................................................................. 8-8
Chapter 9 CONTROL LOOPS
Principle of Operation...................................................................................9-1
Current Loop ............................................................................................................ 9-1
•Manual Tuning....................................................................................... 9-2
Speed Loop .............................................................................................................. 9-4
Field Control............................................................................................................. 9-4
•Set-up Notes .......................................................................................... 9-4
•Current Control...................................................................................... 9-5
•Voltage Control...................................................................................... 9-5
•Field Weakening .................................................................................... 9-5
•Standby Field ......................................................................................... 9-5
Chapter 10 PARAMETER SPECIFICATION TABLE
Specification Table: Tag Number Order .....................................................10-2
Parameter Table: MMI Menu Order ........................................................10-18

Contents
Contents Page
Cont.10
Chapter 11 TECHNICAL SPECIFICATIONS
Environmental Details ............................................................................................. 11-1
EMC Compliance.................................................................................................... 11-1
Electrical Ratings - Power Circuit .............................................................................. 11-2
Power Supply Details............................................................................................... 11-3
Auxiliary Power Supply Details ................................................................................. 11-3
AC Line Choke (Frames 1, 2, 3, 4 & 5).................................................................... 11-4
AC Line Choke (Frame H) ....................................................................................... 11-5
External AC Supply (RFI) Filters ................................................................................ 11-5
Power Semiconductor Protection Fuses (Frames 1, 2, 3, 4 & 5) ................................. 11-6
Power Semiconductor Protection Fuses (Frame H)..................................................... 11-6
Power Supply Fuses................................................................................................. 11-7
Field Fuses.............................................................................................................. 11-7
Earthing/Safety Details ............................................................................................ 11-7
Terminal Definitions (Digital/Analog Inputs & Outputs) ............................................. 11-8
Terminal Information - Power Board (Frames 1, 2, 4 & 5)......................................... 11-9
Terminal Information – Control Board ................................................................... 11-12
Terminal Information (Frame H) ............................................................................ 11-16
Terminal Information – Option Boards................................................................... 11-17
Wiring Requirements for EMC Compliance ............................................................ 11-17
Wire Sizes and Termination Tightening Torques (Frames 1, 2, 3, 4 & 5).................. 11-18
Termination Tightening Torque (Frame H).............................................................. 11-19
Cooling Fans ........................................................................................................ 11-19
Spares List ............................................................................................................ 11-20
Chapter 12 CERTIFICATION FOR THE CONVERTER
Requirements for EMC Compliance .............................................................12-1
Minimising Radiated Emissions ................................................................................ 12-1
Earthing Requirements ............................................................................................ 12-1
•Protective Earth (PE) Connections .......................................................... 12-1
•Control/Signal EMC Earth Connections................................................. 12-2
Cabling Requirements ............................................................................................. 12-2
•Planning Cable Runs ............................................................................ 12-2
•Increasing Motor Cable Length ............................................................. 12-2
EMC Installation Options......................................................................................... 12-3
•Screening & Earthing (cubicle mounted, Class A) ................................... 12-3
•Star Point Earthing................................................................................ 12-4
•Sensitive Equipment.............................................................................. 12-5
Requirements for UL Compliance................................................................12-6
•Motor Overload Protection.................................................................... 12-6
•Branch Circuit/Short Circuit Protection Requirements ............................. 12-6
•Short Circuit Ratings ............................................................................. 12-6
•Field Wiring Temperature Rating........................................................... 12-7
•Operating Ambient Temperature .......................................................... 12-7
•Field Wiring Terminal Markings ............................................................ 12-7