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Eurotherm Drives 590 DRV Digital Product Manual

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Summary of Contents for Eurotherm Drives 590 DRV Digital

  • Page 3 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. Ruptured semiconductor devices may release toxic materials. Contact Eurotherm Drives or the semiconductor manufacturer for proper disposal procedures for semiconductors or other material.
  • Page 4 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.
  • Page 13 900 HP, the supply is limited to 230/460 VAC. The 590 DRV Digital drive is available as a four-quadrant, regenerative or a two-quadrant, non-regenerative drive. Each includes full transient and overload protection and uses highly advanced electronic control of motor acceleration and deceleration of speed and torque.
  • Page 14 On-board Fuse Protection and Contactor: each drive has AC thyristor fuses and a DC contactor. Regenerative models have DC output fuse protection. • Power Isolation: the 590 DRV Digital drive's control circuitry is electrically isolated from the power circuitry, enhancing system interconnection and safety.
  • Page 15 Standardized parts helps reduce the variety of spares needed to maintain a multi-drive system. Read this section before you remove the 590 DRV Digital drive from its packing materials. Though engineered for heavy industrial use, you can damage the unit by handling it improperly.
  • Page 17 Figures 2.3, 2.4, 2.5, and 2.6 identify the parts contained in 590 DRV Digital drives rated 7.5 through 100 HP. These parts are discussed in the succeeding chapters. Figure 2.3 shows the fuses, transformer, and contactor in the power chassis.
  • Page 18 The fuse replacement label for 7.5 through 100 HP models is located on the back side of the controller mounting panel (see Figure 2.4). It is visible when the top section of the DRV (including the controller) is lowered for access to the fuses and drive terminations.
  • Page 23 Eurotherm Drives Customer Service. Installing a 590 DRV Digital drive requires a few standard hand tools. A socket wrench to fit either ¼-20 or M6 (as applicable) bolts and nuts is needed to mount the drive to the panel. Screwdrivers and a wire crimping tool are needed to make various electrical connections.
  • Page 24 Lower the bottom slots of the 590 DRV Digital drive onto the studs, making sure the studs are between the washers and the panel. Once the drive is resting on the bottom studs, lean it back onto the top two studs.
  • Page 25 Incoming AC supply and output motor connections are shown in Figure 3.2 and 3.3. If you need electrical terminals for motor and supply connections, Eurotherm Drives has UL-approved crimp Connector Kits terminal kits available in the following armature current ranges:...
  • Page 26 Connect the main AC power supply to terminals L1, L2, and L3 (see Figure 3.2) through the correctly sized branch circuit protection and an AC line reactor or dedicated drive isolation transformer. Eurotherm Drives stocks a series of reactors designed to connect to the 590 DRV Digital AC supply Isolation TX terminals.
  • Page 27 Optional DIN Rail other signal devices. To prevent exceeding the overall 590 DRV Digital drive depth limit of 11.5 inches, the depth of these components must not exceed three inches. Wire harnesses from these devices should be kept tight to the devices and routed to the left side of the drive with the drive harness.
  • Page 28 The connectors to terminal blocks A, B and C must be isolated signal voltages. Never perform high voltage resistance or dielectric strength tests without first completely disconnecting the drive from the circuit being tested. Terminal C5 (ENABLE) is connected to terminal C9 (+24V) internally through a normally-opened auxiliary contact on the DRV main contactor.
  • Page 29 The output is hardwired and not software configurable. Refer to Appendix A for the terminal's output rating and signal scaling. This connection is optional. The 590 DRV Digital drive accepts the following types of speed feedback signals: Feedback Options •...
  • Page 30 Armature voltage feedback, the default, does not require a feedback device, external isolator or any external connections. All other types of speed feedback requires external connections from the feedback device to a separately ordered controller mounted option board. The part numbers for each type of feedback option board is listed below.
  • Page 31 The drive can accept a standard, 4-channel, quadrature complimentary, wire-ended electrical encoder signal as speed feedback. Four feedback boards are available, each having a different supply voltage Encoder Option rating. Complimentary line driver encoders are recommended. Refer to Appendix A for typical encoder connection listings.
  • Page 32 A switchable calibration card ships with all 590 DRV Digital drives rated through 400 HP. Models rated 500 HP and above ship with a resistor calibration card. You can order the resistor card on lower horsepower models as an option.
  • Page 33 b. For full speed tachometer generator output larger than 200 volts, an external resistor (R ) is required in series with tachometer generator connection to terminal B2. The suggested >200V Signal values for R6 and R7 are: R6 = 120 kW R7 = 68 kW External Resistor Sizing...
  • Page 34 5. Field voltage calibration. Calibrating the drive for the motor field voltage is not required; however, resistors R12 and Field Voltage R13 are connected in series and must total 100 kW to assure best performance. Control The switchable calibration card is shipped on all models rated through 400 HP. The card, shown below in Figure 3.9, calibrates the drive for the motor armature voltage, armature current, and field current.
  • Page 35 As with armature current, the range depends on the type of drive. The overall range is from 0.1 - 19.9A with 590 DRV Digital drive models. Turn the rotary switches to the appropriate setting for your motor. Figure 3.9 is Set Field Current set for a 8.4 amp field.
  • Page 36 After installing and wiring the drive, complete the following checks. They will assure the drive and motor can be safely powered up without injuring personnel or damaging equipment. 1. Check the main power supply voltage. Supply volts right? 2. Verify that the control transformer is tapped for the main supply voltage. TX tapped right? 3.
  • Page 46 The 590 DRV Digital drive is shipped with a default configuration designed to control a shunt or permanent magnet field DC motor. You can adjust the drive's parameters or change its configuration to achieve optimum performance and perform specific control applications.
  • Page 47 Disconnect or isolate motor connections from the controller before performing a megger insulation, or high voltage tests on the motor windings. 4. Make sure all settings on the 590 DRV Digital drive calibration card are set to the correct values for Voltage & Current your motor dataplate information (see the calibration card information in Chapter 3).
  • Page 48 6. If any changes were made to the drive's parameters settings, SAVE PARAMETERS. This is an essential step in setting up your 590 DRV Digital drive and should not be overlooked. The AUTOTUNE function tunes the current loop automatically and sets the proportional gain, integral gain, and the discontinuous/continuous breakpoint for optimum drive response for a given motor.
  • Page 49 Make sure it is safe to power and turn the motor and that operation of the motor and the drive will not pose a danger to personnel or equipment. 1. Stop the drive (remove the START/RUN signal) then disconnect the main supply power. Stop Drive 2.
  • Page 50 591SP (non-regenerative) drive on a motor with an AC tachometer generator. Or, use the for AC Tachs regenerative 590 DRV Digital drive and disable the drive's reverse bridge thyristors under SETUP PARAMETERS:: CURRENT LOOP:: REGEN MODE. • Did the motor rotate in the wrong direction but at the correct speed? Reverse the field connections.

  • Page 51: Armature Voltage Feedback

    5. If the motor continues to run away after checking the feedback sign and field polarity check whether the drive actually receives it speed feedback signal. Monitor DIAGNOSTICS:: TACH VOLTS when using No feedback an analog tachometer generator. For Microtach or wire-ended encoders, check DIAGNOSTICS:: signal? ENCODER RPM.
  • Page 52 2. MICROTACH or WIRE-ENDED ELECTRICAL ENCODERS • Ensure that the CALIBRATION:: ENCODER LINES parameter equals the pulses per revolution Microtach rating of the encoder (1000 for Microtachs). You can read the feedback encoder rpm under DIAG- NOSTICS:: ENCODER RPM in the MMI or in SAM under the FEEDBACK software block. Adjust ENCODER LINES •...
  • Page 53 3. Verify that SETUP PARAMETERS:: FIELD CONTROL:: FLD CURRENT VARS:: FLD WEAK VARS:: FLD WEAK ENABLE is ENABLED: Enable FIELD WEAKENING 4. Ensure that SETUP PARAMETERS:: FIELD CONTROL:: FLD CURRENT VARS:: FLD WEAK VARS:: MIN FLD CURRENT is set correctly for the motor to reach top speed. MIN FLD CURRENT Set MIN FIELD is calculated using the formula: CURRENT...

  • Page 54: Save Parameters

    P3 to upload and download drive parameters. To safeguard the parameters you have set with the MMI, you can configure the 590 DRV Digital drive in a password- protected mode. At the initial power up, the DISPLAY PASSWORD command is automatically cleared to zero. If the controller password is set at any value other than zero, the MMI is in a restricted mode and the MMI display can be displayed but not altered.

  • Page 55: To Change Password

    All 590 DRV Digital drives are shipped with the default password 0x0000 which is displayed in the MMI. If the default password does not work, contact your supplier for the new password. Once you have entered the correct code, you may use the CHANGE PASSWORD function to set your own restricted password.
  • Page 56 The most valuable tools for finding and resolving faults are the MMI and the LED display. You can also monitor alarms and troubleshoot faults remotely through a computer interface if a RS422 serial communications option card (AH385826U001) is installed on the drive. Most drive problems are encountered during commissioning or soon after start-up.
  • Page 57 You will need the following tools for most troubleshooting procedures: • Voltmeter • Megger If available, the following tools can provide more detailed information for problem-solving: • Oscilloscope • Hand tachometer You may also need screwdrivers and/or wrenches to restore electrical connections that are incorrect or have come loose. Six light emitting diode [LED] indicators are located just to the right of the MMI display.
  • Page 58 All six LEDs are ON under normal running conditions. Figure 5.2 shows the LED states after common actions and other faults occur. An unlit LED indicates a problem that prevents controller operation and requires user attention. The table in Figure 5.3 shows what to check when an LED is off.
  • Page 59 "controller healthy" logic variable. This variable corresponds to the ALARM STATUS software block output HEALTHY (tag number 122). The default shipped drive configuration of the 590 DRV Digital drive tags the HEALTHY logic parameter to digital O/ P 2 (terminal B6).
  • Page 65 If a symbolic message appears, cycle power on the controller to clear the fault. If the message repeats, call Eurotherm Drives Customer Service. The hexadecimal code for the first alarm is saved in HEALTH STORE. HEALTH STORE resets when the drive is restarted.
  • Page 66 This example shows how HEALTH WORD, HEALTH STORE, and LAST ALARM are updated. During operation, the controller trips on P3 PORT ALARM (0x0800), the drive loses three-phase power when an SCR fuse blows (0x0200) and the motor overheats causing the thermistor to open (0x0010). HEALTH WORD is: 0x0800 + 0x0200 + 0x0010 = 0x0A10.
  • Page 67 Many signals can be monitored in the MMI display. The diagnostic parameters are "read-only" and are very useful for tracing configuration problems. The following tables contain a description of each parameter and its range. Param- eters denoted with an asterisk (*) are the controller's analog or digital I/O. The drive has been shipped with its I/O tagged to the parameter listed in the description field.
  • Page 69 This section contains troubleshooting information and a flowchart for identifying and correcting hardware problems in the 590 DRV Digital drive. NOTE. Repair of the 590 DRV is limited basic part replacement only. Troubleshooting and electronic component replacement at the board level is not recommended. Only the control and power boards, the control fuse F1 and the SCR packs are designed to be replaced.
  • Page 70 The 590 drive derives its control power from an internal power supply circuit requiring a 110 VAC supply with a frequency range of 40 to 70 Hz. This power is normally supplied off one phase of the main drive supply through a DRV mounted control transformer.
  • Page 71 If the motor field supply fails while the drive is running a motor, the drive should trip on either an OVERSPEED alarm, or a FIELD FAILED alarm.
  • Page 72 This flowchart is used for troubleshooting problems associated with the main contactor, AM, including wiring. Refer to the Schematic Diagrams in Appendix L when troubleshooting.
  • Page 73 Non-regenerative drives contain three SCR packs, A, B, and C. Each SCR pack contains two thyristors. Three additional SCR packs (D, E, and F) mount above SCR packs A, B and C for regenerative drives. The layout of the SCR packs is shown in Figure 5.17 as they appear on the drive heatsink, from left to right. Use the tables in Figure 5.18 to determine which SCR pack is bad.
  • Page 74 Several alarm messages are caused by problems with the motor. Most motor problems relate to insulation breakdown, overtemperature and armature brush and commutation problems. Check the motor armature and field with a megger to ensure that the motor winding insulation has not degraded and shorted one conductor to another or to ground. Continuity checks require an ohmmeter for determining whether motor windings or leads have opened or shorted.
  • Page 75 Terminal A8, TOTAL SPEED SETPOINT, is compiled from SETPOINTS 1 through 4. Monitor each setpoint individually in SETUP PARAMETERS::SPEED LOOP::SETPOINTS. If one is incorrect, i.e. has been left at an undesired value, simply "dial it" back to zero. When parameter RAMP HOLD is ON, the ramp output is held to its last input value. Set RAMP HOLD to OFF to allow the signal to change.
  • Page 76 If you have reviewed your installation and start up procedures and followed the troubleshooting guide but still cannot solve a persistent problem, contact Eurotherm Drives Customer Service at (704) 588-3246. Make certain you have the following information available before calling:...
  • Page 78 Because of its solid state design, the 590 DRV Digital drive has few items requiring service or maintenance. Service typically is a matter of replacing fuses, checking electrical contacts, and isolating problems in the overall system application. Service procedures must be performed by qualified personnel with an understanding of the dangers inherent in high voltage applications and the precautions necessary when servicing industrial equipment.
  • Page 79 To access the internal parts of the power section, loosen the two ¼-turn screws holding the controller top to the drive at the top of the controller case. Loosening the ¼ turn screws while the 590 DRV is mounted vertically will allow the controller section to pivot downward.
  • Page 80 5. Inspect all wiring and terminals for evidence of burning and abrasion. 6. Verify the tightness of: a. Line and load fuse connections to fuses F1, F2, F3, F4, F5, and F7 (if fitted). (TORQUE) b. The three ground stud connections. (TORQUE) c.
  • Page 81 This procedure requires a 3/16 inch flat blade screwdriver. 1. Disconnect the control wire terminals, terminal blocks A, B, and C, from the control door. 2. Loosen the two captive screws holding the door closed. They are located under the top and bottom flaps. 3.
  • Page 82 This procedure shows how to remove and reattach the power supply board. Removing the power supply board requires a #2 Phillips head screwdriver, a flat blade screwdriver, and a pair of needle nose pliers. 1. Use electrostatic discharge safety procedures to eliminate static charges from the technician, tools, and work area. 2.
  • Page 83 7. Now the board is free to be removed. Slide the board as far to the right as it will go. Tilt the left side of the board up and then lift the board out of the chassis. Make sure none of the loose wires catch on the board or components as you lift the board out of the chassis.
  • Page 84 Figure 6.10 - Gate Lead Guides Figure 6.11 - Fan and Ground Connections NOTE. Before attempting to replace an SCR, perform the SCR troubleshooting procedure in Chapter 7 to identify the defective SCR. For illustrative purposes, SCR letter F is assumed to be defective in the following procedure. Replacing SCRs requires a #2 Phillips head screwdriver, a 3/8 inch flat blade screwdriver, and a 4mm Allen wrench.
  • Page 85 6. Repeat this procedure in the reverse order when replacing SCRs. The tightening torques for installing SCRs and reassembling the buss bars are: SCR mounting screws M5 x 18 socket head 3.3 - 4.4 lb-ft (4.5 - 6.0 Nm) SCR buss bar screws M5 x 10 Phillips head 1.8 - 2.6 lb-ft (2.4 - 3.5 Nm) 3-phase buss bar screws...
  • Page 86 Control circuitry is fully isolated from main power supply. A 16-bit microprocessor performs the majority of the control functions in the 590 DRV Digital drive. External digital and analog I/O terminal communicate directly with the drive microprocessor. RS422 serial communication which provides access to all drive parameters for computer interfacing is available as an option.
  • Page 87 Steady State Error Armature voltage feedback 0.1% Analog tachometer generator feedback 0.01% Wire-ended electrical encoder approved feedback 0.01% 5701/5901 Microtach fiber optic encoder feedback 0.0% (absolute) Quadraloc Mark II digital controller. Signal Resolution 10 bits (±0.0001 accuracy) Encoder Resolution Maximum Microtach frequency 50 kHz Maximum encoder frequency 100 kHz Frequency (Hz) = Encoder Lines per Revolution ×...
  • Page 88 10 amps, 250 volts, fused @ 3A (FS2) The following list shows the DC loading of Eurotherm Drives products. Add up all the loads on the auxiliary supply to ensure that power demand is within the output specifications. If the demand exceeds the output capacity, add an auxiliary power supply to the system.
  • Page 89 Refer to the drawings at the end of Chapter 3 for DRV dimensions. Refer to the diagrams on the inside front cover for the 590 DRV Digital drive terminal blocks and connections. A drawing of the drive software block diagram is printed on the manual's inside front cover. A more detailed diagram appears in the fold out drawing at the end of Appendix D.
  • Page 90 H. The 590 DRV Digital drive also has a RS232 serial communications port, system port (P3), which is integrated into the control board and allows uploading and downloading of drive configurations to and from a remote location using a personal computer (PC).
  • Page 91 The A, B, and C terminal blocks under the lower controller access panel are the connecting points for the myriad controls and accessories that make up the 590 DRV controller system. The terminals and their purposes are summa- rized below; more detailed descriptions follow.
  • Page 92 The following sections list the specifications for the input and output terminals. Resolution 10 bits plus sign; i.e. 10mV 0.1% of full scale deflection Input Impedance 100kW with a 1 ms filter for terminal A3 and a 2 ms filter for the other terminals.
  • Page 93 A1/0 VDC (Signal) This terminal is the zero VDC reference for signals only, i.e., signals originating from terminal blocks A and B. It must not be used as a return point for currents originating from terminal block C. A2/Analog Input 1 This terminal is the speed setpoint.
  • Page 94 This terminal provides a latched +24 VDC signal for the DRIVE HEALTHY condition signal. DRIVE HEALTHY is TRUE whenever there are no software or hardware alarms present. It is reset when the RUN signal is removed from B7/Digital Output 3 This terminal provides a +24 VDC signal for the DRIVE READY message.
  • Page 95 the RAMPED SETPOINT INPUT at the rate or change determined by the acceleration, deceleration ramp time, and "S- ramp" parameters. C8/Digital Input 3 This terminal is the CURRENT DEMAND ISOLATE, which changes the drive operation from speed control to current control.
  • Page 96 The 590 DRV Digital drive is preconfigured to run in armature voltage feedback control, which requires no feedback device. Accordingly, each is shipped without a feedback option card. Order one of the four cards described below when using an analog tachometer generator, Microtach or wired-ended encoder for speed feedback.
  • Page 97 The 5701 Microtach Receiver Option is used with the 5701 Microtach encoder to provide a highly accurate speed feedback measurement. The option uses the Eurotherm Drives patented fiber optic 5701 encoder output transmission circuitry for noise immune data transfer over plastic fiber optic cable. A convenient board-mounted, plug-in terminal block and fiber optic receiver terminal are provided for field connections.
  • Page 98 This option contains ESD sensitive parts. Observe static control precautions when handling, installing, and servicing this option. 1. Use the Fiber Optic Cable Cutter (LA385204) to dress the fiber optic cable connecting to the option card. The cable must be cleanly and squarely cut to work properly. The Microtach encoder end of the fiber optic cable requires a red fiber optic plug (CI055069) for termination.
  • Page 99 The 5901 Microtach Receiver Option is used with the 5901 Microtach encoder to provide highly accurate speed feedback measurement. It provides all the features of the 5701 Microtach with the additional advantage of glass fiber optic cable. A convenient board-mounted plug-in terminal block and fiber optic receiver terminal are provided for field connections.
  • Page 100 This option contains ESD sensitive parts. Observe static control precautions when handling, installing, and servicing this option. 1. Use the connector kit JA352597 to properly terminate ST terminals to both ends of the glass fiber optic cable. Each ST terminal requires a cleave crimp, a cable anchor and crimp sleeve. 2 After attaching the cable ST terminals, connect the cable to the Microtach and receiver card.
  • Page 101 1. Connect the encoder as shown in Figure A.6. 2. Install all wiring as instructed in the Eurotherm Drives Installation Note Sheet (HG050610). Also refer to drawing HG351946, the Installation Notes which are shipped with the card. Exercise special care wiring the encoders to the option board due to the low signal levels.
  • Page 102 In cases when the encoder receiver card or the drive cannot supply enough power for the encoder, use an external power supply connected directly to the encoder. The supply should be isolated from ground; that is, neither the 0 VDC nor the +VDC should be connected to ground. When using single ended encoders: 1.
  • Page 104 The Man Machine Interface (MMI) is the primary tool for communicating with the 590 DRV Digital drive. It allows the user to custom configure the drive, tune it for optimal performance and monitor its operation and diagnostic points. The MMI consists of a two-line alphanumeric liquid crystal display (LCD) and a four-button keypad mounted on the front of the drive.
  • Page 105 RAMPS, AUX I/O, etc. The 590 DRV Digital drive is shipped with MMI settings that represent a common set of parameters for general use. These settings are listed in Appendix C. Use caution when modifying these settings to ensure the new settings are the most appropriate for your situation.
  • Page 106 If your 590 DRV Digital drive was ordered with special features or configurations or if you have entered non-default values in the MMI settings, a four-button reset will overwrite these settings. Before attempting to modify existing parameter settings, record them in this manual (Appendix E) so you can reenter them later, if necessary.
  • Page 108 The shipping configuration in the 590 DRV Digital drive allows the user to start up and run a DC motor in simple speed control. The power of the 590SP, however, is its configurability and its ability to be tuned for optimum perfor- mance or for a specific control application.
  • Page 109 DIGITAL DC DRIVE MENU LEVEL The RAMPS parameters set the shape and duration of the ramp used for starting and changing speeds. The STOP RATES menu contains a separate deceleration rate for MENU LEVEL controlled stopping of the drive. DIAGNOSTICS Note: This block is ignored by the drive unless SYSTEM:: MENU LEVEL CONFIGURE I/O:: BLOCK DIAGRAM:: RAMP O/P DEST is...
  • Page 111 The ramp will function when a ramp input is present. When DIGITAL I/P 2 is ON, RAMP HOLD stops the ramp output from changing. Even when the ramp input signal is removed, RAMP HOLD keeps the ramp output from changing. Once RAMP HOLD is OFF, the ramp resumes. This figure shows the effect of setting MIN.
  • Page 112 When AUTO RESET is ENABLED, the ramp output resets to RESET VALUE each time the drive is enabled. In this example, RESET VALUE is 0.00%. It does not reset if the drive is disabled. The ramp input is set to X% at time t .
  • Page 113 DIGITAL DC DRIVE MENU LEVEL The AUX I/O parameters allow an external computer or PLC to access or control input and output terminals using serial communications (see Appendix H). MENU LEVEL DIAGNOSTICS MENU LEVEL START, JOG, and ENABLE from digital input terminals C3, C4 and C5, respectively, SETUP PARAMETERS connect directly to the AUX I/O block.
  • Page 115 DIGITAL DC DRIVE MENU LEVEL The JOG/SLACK parameters can modify or replace the ramp input speed demand to provide jog, take up slack and crawl speed functions. Use a spare digital input to MENU LEVEL switch between modes and achieve full functionality. DIAGNOSTICS MENU LEVEL SETUP PARAMETERS...
  • Page 117 DIGITAL DC DRIVE MENU LEVEL RAISE/LOWER provides electronic motor operated potentiometer (MOP) functionality. MENU LEVEL DIAGNOSTICS Note: This block is ignored by the drive unless SYSTEM:: CONFIGURE I/O:: BLOCK DIAGRAM:: RAISE/LOWER DEST is MENU LEVEL connected to a non-zero tag. SETUP PARAMETERS SETUP PARAMETERS RAMPS...
  • Page 118 These curves illustrate the raise/lower functionality. When EXTERNAL RESET is set TRUE, the raise/lower output resets to RESET VALUE (default = 0.00%). When RAISE INPUT is TRUE, the output increases at INCREASE RATE. The output cannot exceed MAX VALUE. The reverse is true when LOWER INPUT is TRUE. The lower input reduces the output at DECREASE RATE.
  • Page 119 DIGITAL DC DRIVE MENU LEVEL The parameters and sub-menus in the FIELD CONTROL block control the drive's full wave, single phase, motor field thyristor bridge circuit. Field weakening is a standard MENU LEVEL feature on all 590 controllers. DIAGNOSTICS MENU LEVEL SETUP PARAMETERS The inputs to FIELD CONTROL come from FLD VOTAGE VARS and FLD CURRENT VARS.
  • Page 121 DIGITAL DC DRIVE MENU LEVEL These variables tune the field current loop with proportional and integral control. MENU LEVEL DIAGNOSTICS The inputs to FLD CURRENT VARS are the field current feedback from calibration and the field weakening current demand from FIELD CONTROL::FLD CURRENT MENU LEVEL SETUP PARAMETERS VARS::FLD WEAK VARS.
  • Page 123 DIGITAL DC DRIVE MENU LEVEL Field weakening allow DC motors to operate above base speed in the constant horse- power control range. For stable operation, the drive must have a speed feedback signal MENU LEVEL generated by either an analog tachometer generator, Microtach or wire-ended encoder. DIAGNOSTICS MENU LEVEL SETUP PARAMETERS...
  • Page 125 DIGITAL DC DRIVE MENU LEVEL CURRENT PROFILE scales the current limit for applications where motors have a reduced ability to commutate the armature current at low field currents. Normally this MENU LEVEL is required when using field weakening. DIAGNOSTICS MENU LEVEL SETUP PARAMETERS SPEED FEEDBACK from the speed loop is the input.
  • Page 127 DIGITAL DC DRIVE MENU LEVEL The STOP RATES parameters are used when stopping using a normal stop or a program stop. MENU LEVEL DIAGNOSTICS MENU LEVEL SETUP PARAMETERS Inputs are SPEED SETPOINT and SPEED FEEDBACK from the speed loop, RUN from terminal C3, and PROGRAM STOP from terminal B8.
  • Page 129 STOP ZERO SPEED settings below 0.25% will keep the drive enabled after reaching STOP ZERO SPEED for the CON- TACTOR DELAY time. This setup is useful in jog applications.
  • Page 130 These curves illustrate the sequence when a normal stop takes longer than the STOP LIMIT time. The drive disables and the contactor de-energizes at that time.
  • Page 131 PROGRAM STOP is a latched function. Once a PROGRAM STOP signal is received (terminal B8 goes to zero volts), the stop continues even if 24 volts is reconnected to terminal B8.
  • Page 132 The time out logic is the same for both a normal stop and a program stop. PROGRAM STOP LIMIT, however, sets the maximum duration of a program stop before the contactor de-energizes and the drive disables.
  • Page 133 DIGITAL DC DRIVE MENU LEVEL SETPOINT SUM 1 allows the summing and scaling of three analog inputs to produce SPT. SUM OUTPUT. MENU LEVEL DIAGNOSTICS Note: This block is ignored by the drive unless SYSTEM:: CONFIGURE I/O:: BLOCK DIAGRAM:: SPT SUM 1 DEST is MENU LEVEL connected to a nonzero tag.
  • Page 135 DIGITAL DC DRIVE MENU LEVEL STANDSTILL determines when the speed setpoint is zero and the motor has stopped. MENU LEVEL DIAGNOSTICS The inputs are SPEED FEEDBACK from the speed loop and SPEED SETPOINT MENU LEVEL from setpoints. The outputs are AT ZERO SPEED, AT STANDSTILL, and AT SETUP PARAMETERS ZERO SETPOINT.
  • Page 136 These curves show the drive's operation when STANDSTILL LOGIC is ENABLED. When both the speed feedback and speed setpoint signals are within the ZERO THRESHOLD, the drive is disabled.
  • Page 137 DIGITAL DC DRIVE MENU LEVEL SPEED LOOP selects the speed feedback source and tunes the speed loop PI to produce a current demand. MENU LEVEL DIAGNOSTICS MENU LEVEL The speed loop has four inputs: SETUP PARAMETERS 1. SPEED DEMAND from STOP RATES SETUP PARAMETERS RAMPS 2.
  • Page 139 DIGITAL DC DRIVE MENU LEVEL ADVANCED has two sub-menus, ADAPTION and ZERO SPD. QUENCH. ADAPTION changes the proportional and integral profiles. ZERO SPD. QUENCH MENU LEVEL disables SCR firing when the drive is stopped. DIAGNOSTICS MENU LEVEL SETUP PARAMETERS ADVANCED has one input, RAMPING from RAMPS. SETUP PARAMETERS Inputs for ADAPTION are PROP.
  • Page 141 DIGITAL DC DRIVE MENU LEVEL SETPOINTS combine four setpoints into a total speed setpoint. MENU LEVEL DIAGNOSTICS The default inputs to SETPOINTS are analog input 2, terminal A3, ratioed 5703 MENU LEVEL output, SPT. SUM O/P, RAMP OUTPUT, and I DMD ISOLATE. The output is SETUP PARAMETERS SPEED SETPOINT.
  • Page 143 DIGITAL DC DRIVE MENU LEVEL CURRENT LOOP takes the current demand, limits it through four clamps, and then uses a PI loop to control the output. MENU LEVEL DIAGNOSTICS MENU LEVEL The inputs are current demand from the speed loop or terminal A3, current limit SETUP PARAMETERS clamps from CURRENT PROFILE and the inverse time overload, and current feedback from CALIBRATION.
  • Page 145 DIGITAL DC DRIVE MENU LEVEL INHIBIT ALARMS allows you to disable certain alarms and leave drive operation uninterrupted if the related fault occurs. MENU LEVEL DIAGNOSTICS MENU LEVEL SETUP PARAMETERS Do not inhibit any alarms if a danger to personnel or equipment may SETUP PARAMETERS result.
  • Page 147 DIGITAL DC DRIVE MENU LEVEL The CALIBRATION block scales the signals from the calibration card and speed feedback board. MENU LEVEL DIAGNOSTICS MENU LEVEL Each input signal from the calibration board and the speed feedback board can be SETUP PARAMETERS digitally scaled to provide greater precision.
  • Page 150 To customize performance and get optimum use out of the 590 DRV Digital drive, you may need to configure, or reroute software connections to and from the drive's inputs and outputs and to and from the drive's software blocks. You can configure the drive and change software block parameter values either through the MMI or with a personal computer (PC) running the software package ConfigEd Lite (see the ConfigEd Lite Software Manual RG352747).
  • Page 151 There are only two types of parameters : logic or value. Logic parameters are boolean— or either ON (1) or OFF (0). The MMI displays logic signals in a variety ways, each associated with the ON and OFF state like ENABLED/ DISABLED, TRUE/FALSE, POSITIVE/NEGATIVE, or EVEN/ODD.
  • Page 152 590SP DC DRIVE MENU LEVEL The 590 series controller has five analog inputs. Analog input 2 can be scaled but its destination is fixed. All the other inputs are fully configurable. MENU LEVEL DIAGNOSTICS MENU LEVEL SYSTEM SYSTEM SOFTWARE SYSTEM CONFIGURE I/O CONFIGURE I/O CONFIGURE ENABLE...
  • Page 154 Inputs can be connected to any writable parameter. The read/write status of each parameter is listed in the right- hand column in Appendices G, H, and I. RO is read only and RW is read/write. In this example, an operator wishes to control the acceleration time of the drive speed ramp over a 0 to 30 second range with an external potentiometer.
  • Page 155 1. Set CONFIGURE I/O::CONFIGURE ENABLE to ENABLE. 2. Set ANIN 3 (A4)::DESTINATION TAG to 0. This step disconnects input 3 from RAMP INPUT. 3. Set BLOCK DIAGRAM::SPT SUM O/P DEST to 5 4. Set DIGIN 1 (C6)::DESTINATION TAG to 8 5.
  • Page 156 590SP DC DRIVE MENU LEVEL The 590 series controller has two configurable analog outputs. MENU LEVEL DIAGNOSTICS MENU LEVEL SYSTEM SYSTEM SOFTWARE SYSTEM CONFIGURE I/O CONFIGURE I/O CONFIGURE ENABLE CONFIGURE I/O ANALOG INPUTS CONFIGURE I/O ANALOG OUTPUTS ANALOG OUTPUTS ANOUT 1 (A7) ANALOG OUTPUTS ANOUT 2 (A8)
  • Page 158 The source of an analog output signal can be read from any parameter. It is important to remember that other param- eters do not "send" signals to the output terminal. An output terminal "retrieves" the signal from the parameter described by its SOURCE TAG parameter. The % TO GET 10 VDC value is based on the range of the source.
  • Page 159 1. Set CONFIGURE I/O::CONFIGURE ENABLE to ENABLE. 2. Find the tag number for current demand in the parameter list in Appendix I. (It is 66.) 3. Set ANALOG OUTPUTS::ANOUT 2 (A8):: SOURCE TAG to 66. 4. Set ANALOG OUTPUTS::ANOUT 2 (A8):: % TO GET 10V to 200%. 5.
  • Page 160 590SP DC DRIVE MENU LEVEL The 590 series controller has three configurable digital inputs. MENU LEVEL DIAGNOSTICS MENU LEVEL SYSTEM SYSTEM SOFTWARE SYSTEM CONFIGURE I/O CONFIGURE I/O CONFIGURE ENABLE CONFIGURE I/O ANALOG INPUTS CONFIGURE I/O ANALOG OUTPUTS CONFIGURE I/O DIGITAL INPUTS DIGITAL INPUTS DIGIN 1 (C6) DIGITAL INPUTS...
  • Page 162 They can also send two fixed values to a VALUE parameter as determined by the state of the input terminal. The default connections in the 590 DRV Digital drive allow the digital inputs to switch LOGIC parameters. These are the connections from terminal C6 to tag 90 (BIPOLAR CLAMPS), C7 to tag 118 (RAMP HOLD), and C8 to tag 119 (I DMD.
  • Page 163 1. Set CONFIGURE I/O::CONFIGURE ENABLE to ENABLE. 2. Find the tag number for LINK 1's source tag in the parameter list in Appendix H. (It is 364.) 3. Set DIGIN 1 (C6)::DESTINATION TAG to 364. 4. Find the tag number for AUX I/O::ANOUT 2 in the parameter list in Appendix H. (It is 129.) 5.
  • Page 164 590SP DC DRIVE MENU LEVEL The 590 series controller has three digital outputs. Each output is configurable. MENU LEVEL DIAGNOSTICS MENU LEVEL SYSTEM SYSTEM SOFTWARE SYSTEM CONFIGURE I/O CONFIGURE I/O CONFIGURE ENABLE CONFIGURE I/O ANALOG INPUTS CONFIGURE I/O ANALOG OUTPUTS CONFIGURE I/O DIGITAL INPUTS CONFIGURE I/O...
  • Page 166 Digital outputs can read all parameters (the same as the analog outputs). When used with a VALUE parameter, MODULUS removes the sign from the value (so -100 becomes 100). The THRESHOLD (>) parameter determines when the output is HIGH or LOW. The input signal must exceed the parameter for the output to go HIGH. IN- VERTED, when TRUE, inverts the result of the output from the threshold test.
  • Page 167 590SP DC DRIVE MENU LEVEL The 5703 peer-to-peer communication option transfers parameters from drive to drive through the serial port, P3. See Appendix E for additional information on the option. MENU LEVEL DIAGNOSTICS MENU LEVEL SYSTEM SYSTEM SOFTWARE SYSTEM CONFIGURE I/O CONFIGURE I/O CONFIGURE ENABLE CONFIGURE I/O...
  • Page 168 590SP DC DRIVE MENU LEVEL The parameters in Block Diagram connect the outputs of Raise/Lower, Ramps, Setpoint Sum 1, and the Special Blocks functions to destinations as required. These MENU LEVEL functions are only executed when the destinations are connected to a nonzero tag. If a DIAGNOSTICS function is not required, set its destination to tag 0.
  • Page 170 590SP DC DRIVE MENU LEVEL The drive has ten INTERNAL LINKS. They have two common uses; connecting an internal input to an internal output and connecting an input terminal to multiple MENU LEVEL destinations. DIAGNOSTICS None of the links are connected in the default configuration. MENU LEVEL SYSTEM SYSTEM...

  • Page 172: Appendix I. (They Are 2 And 3.)

    This example is similar to the first example in the Analog Inputs section of this chapter. As before, the ends of the external pot are connected to the drive's 0 to +10 VDC supply (terminals A1 and B3), the wiper of the pot is connected to terminal A2 and the calibration parameter of the Analog Input 1 is set to 5.00% to scale the input signal to 30 seconds, maximum.
  • Page 175 The following listing of version 3.2 MMI parameters contains the default MMI values. Use it to keep track of any modifications you may make during installation and commissioning. Any parameters changed by the factory before shipping are listed in the column SETTING 1. NOTE.
  • Page 176 PARAMETER NAME DEFAULT SETTING 1 SETTING 2 SETTING 3 258 MIN VALUE -100.00% 259 MAX VALUE 100.00% 307 EXTERNAL RESET FALSE SETUP PARAMETERS::SPECIAL BLOCKS Setup Parameters::Special Blocks::Diameter Calc. 424 LINE SPEED 0.00% 437 REEL SPEED 0.00% 425 MIN DIAMETER 10.00% 426 MIN SPEED 5.00% 462 RESET VALUE...
  • Page 177 PARAMETER NAME DEFAULT SETTING 1 SETTING 2 SETTING 3 Setup Parameters::Special Blocks::PID (continued) 413 RATIO 2 418 DIVIDER 1 414 DIVIDER 2 408 ENABLE ENABLED 409 INT. DEFEAT 403 FILTER T.C. 0.100 SECS 473 MODE 474 MIN PROFILE GAIN 20.00% 475 PROFILED GAIN SETUP PARAMETERS::FIELD CONTROL 170 FIELD ENABLE...
  • Page 178 PARAMETER NAME DEFAULT SETTING 1 SETTING 2 SETTING 3 SETUP PARAMETERS::CALIBRATION 20 ARMATURE V CAL. 21 IR COMPENSATION 0.00% 22 ENCODER RPM 1000 RPM 24 ENCODER LINES 1000 23 ANALOG TACH CAL 10 ZERO SPD. OFFSET 0.00% 25 ARMATURE I (A9) BIPOLAR 180 SPDFBK ALM LEVEL 50.00%...

  • Page 179: Alarm Status

    PARAMETER NAME DEFAULT SETTING 1 SETTING 2 SETTING 3 Setup Parameters::Speed Loop::Advanced::Adaption (continued) 271 PROP. GAIN 272 INT. TIME CONST. 0.500 SECS Setup Parameters::Speed Loop::Advanced::Zero Spd. Quench 284 ZERO SPD. LEVEL 0.50% 285 ZERO IAD LEVEL 1.50% Setup Parameters::Speed Loop::Setpoints 289 SETPOINT 1 0.00% 289 SETPOINT 1...
  • Page 180 PARAMETER NAME DEFAULT SETTING 1 SETTING 2 SETTING 3 SERIAL LINKS SERIAL LINKS::MAIN PORT (P1) 146 SRL LINK ENABLE ENABLED 138 GROUP ID (GID) 139 UNIT ID (UID) 148 ASCII / BINARY ASCII 150 BAUD RATE 9600 152 ESP SUP. (ASCII) DISABLED 144 CHANGEBAND (BIN) 0.00%...
  • Page 181 PARAMETER NAME DEFAULT SETTING 1 SETTING 2 SETTING 3 SERIAL LINKS::PNO CONFIG (continued) 316 PNO 116 317 PNO 117 318 PNO 118 319 PNO 119 320 PNO 120 321 PNO 121 322 PNO 122 323 PNO 123 324 PNO 124 325 PNO 125 326 PNO 126 327 PNO 127...

  • Page 182: Parameter Name

    PARAMETER NAME DEFAULT SETTING 1 SETTING 2 SETTING 3 System::Configure I/O::Analog Outputs::ANOUT 1 (A7) 245 % TO GET 10V 100.00% 362 MODULUS FALSE 464 OFFSET 0.00% 251 SOURCE TAG System::Configure I/O::Analog Outputs::ANOUT 2 (A8) 248 % TO GET 10V 100.00% 363 MODULUS FALSE 465 OFFSET...
  • Page 183 PARAMETER NAME DEFAULT SETTING 1 SETTING 2 SETTING 3 260 RAISE/LOWER DEST 293 RAMP O/P DEST 294 SPT SUM 1 DEST 400 PID O/P DEST 431 DIAMETER 442 TAPER 450 SETPOINT SUM 2 435 POS. I CLAMP 436 NEG. I CLAMP System::Configure I/O::Internal Links System::Configure I/O::Internal Links::LINK 1 364 SOURCE TAG...
  • Page 184 PARAMETER NAME DEFAULT SETTING 1 SETTING 2 SETTING 3 SYSTEM::miniLINK (continued) 342 VALUE 4 0.00% 343 VALUE 5 0.00% 344 VALUE 6 0.00% 345 VALUE 7 0.00% 379 VALUE 8 0.00% 380 VALUE 9 0.00% 381 VALUE 10 0.00% 382 VALUE 11 0.00% 383 VALUE 12 0.00%...
  • Page 185 480 VAC, 590 LINK DRV. When ordering spare parts or requesting technical assistance from Eurotherm Drives, please provide the unit's catalog number and revision number. Both numbers are printed on the 590 DRV serial number label. Figure G.1 shows the locations of both numbers on the label.
  • Page 186 The power module spares lists identify each model DRV by catalog number less the letter for the controller door. Each table lists all parts, their corresponding Eurotherm Drives part numbers and the quantity of each part used for that model DRV. The DRV Revison column lists the model revision in which the parts were used.
  • Page 203 The SYSTEM PORT(P3) is a non-isolated RS232 serial communications port integrated on the 590 DRV Digital drive control board. The port is used off-line 590SP DC DRIVE (while the drive is stopped) for transferring and saving drive configuration files using...

  • Page 204: System Port (P3)

    NOTE. Set the drive's P3 BAUD RATE to match the computer's communication port transmission rate. The P3 Communications port has +24 VDC on two pins. Use the correct cable (Eurotherm Drives part number CM351909) to avoid damaging the host computer. This cable is described on page E-3.
  • Page 205 6. Start the MMI text download from the 590 Digital drive by selecting “DUMP MMI—> P3”. NOTE. Enabling the transmitting port in a serial communications setup intiates data transfer. Therefore, enable the receiving port— the host computer, in this case— before beginning communication at the transmitting port, or the drive's P3 port.
  • Page 206 A UDP Upload transfers a parameter file from the host computer to the 590 Digital drive. This information is written directly to EEPROM, so all the drive’s current settings will be overwritten. 1. Connect the 590 Digital drive P3 port using the appropriate lead to the host computer. 2.
  • Page 207 The 5703 also supports master/slave ratioed speed locking, although the unit is not intended to supplant Quadraloc— which integrates external speed/phase and position locked loops— in applications requiring absolute speed or position control. The 5703 is housed in a DIN rail mountable box and is provided with a “ribbon” cable to connect into the controller’s RS232 port.
  • Page 209 The supervisory communications optional interface makes supervising and monitoring 590 Digital drives simple. It provides an isolated RS422 serial data port that can be installed on each drive. These serial links can be bussed together to allow an intelligent device to monitor or update the parameters of a network of drives. Refer to the documentation shipped with the option for detailed technical and wiring information.
  • Page 210 DIGITAL DC DRIVE MENU LEVEL The MAIN PORT (P1) requires an optional communications board (catalog number 654D-RS422). It provides an isolated RS422 communications port required for MENU LEVEL interfacing to PLCs, supervisory computers, etc. DIAGNOSTICS MENU LEVEL SYSTEM MENU LEVEL SERIAL LINKS SERIAL LINKS MAIN PORT (P1)
  • Page 211 The AUX PORT (P2) provides a non-isolated RS422 serial port to the 590 Digital DIGITAL DC DRIVE MENU LEVEL drive. This port is designed for use with other Eurotherm Drives products only. The isolated communications option for the P1 port should be used for all foreign communi- MENU LEVEL cation requirements.
  • Page 212 DIGITAL DC DRIVE MENU LEVEL Provides user configurable serial link parameters. To configure these PNOs, SYS- TEM:: CONFIGURE I/O:: CONFIGURE ENABLE must be set to ENABLED. When MENU LEVEL the parameter is enabled, the serial communication link is disabled. Communications DIAGNOSTICS restarts once CONFIGURE ENABLE is set back to DISABLED.
  • Page 214 The communications protocol used by Eurotherm group instruments, including Eurotherm Drives, comes under the heading of Binary Synchronous Communications Data Link Control (BSCDLC). The communication mode conforms to the following American National Standard definition: ANSI standard x3.28 Revision 1976 Establishment and Termination Control Procedures Subcategory 2.5 Two-way Alternate, Non switched Multipoint with Centralized Operation and Fast Select.
  • Page 215 Control characters are ASCII binary codes which define actions rather than information. Below lists the six ASCII codes used. The 590 Digital drive or associated Eurotherm instrument has an address, the first digit being the “group” number (GID) in the range 0 to 7, the second a “unit” number (UID) in the range 0 to F. This yields 128 different addresses from 00 to FF.
  • Page 216 The 590 Digital drive uses an ASCII free-format mode of operation for data transfer to make it easy to implement with languages such as BASIC, PASCAL, FORTRAN, and assembler languages. As a result, users can create simple supervisory systems to run on an IBM PC. Numerical data is transferred by transmitting a string of characters.
  • Page 217 The computer initially has master status, with the 590 Digital drive in slave status. It begins by transmitting a mes- sage, known as the “establish connection” message, which is represented by the following format: (EOT) (GID) (GID) (UID) (UID) (CI) (C2) (ENQ) These symbols are defined as follows:...
  • Page 218 After the message has been sent, the computer adopts slave status and expects to receive a reply from the 590 Digital drive. In so doing, the 590 Digital drive assumes master status and, if the 590 Digital drive has successfully received the message in full, it responds in the following form: (STX) (C1) (C2) (D1) (D2) (D3)..(DN) (ETX) (BCC) which constitutes a message defined as:...
  • Page 219 Under certain circumstances, the computer may not receive a response from the 590 Digital drive. This could be due to any of the following reasons: i. Group/Unit address identifiers are not recognized. ii. An error (for example parity) is found in one or more of the characters up to and including (ENQ). iii.
  • Page 220 Only when all these tasks have been successfully completed does the 590 Digital drive send the (ACK) re- sponse to the computer. This signifies that the message was correctly received and implemented. If any of the checks fail, the 590 Digital drive immediately sends a negative acknowledgment. Note: When data is out-of-range, the drive returns (NAK) and discards the data.
  • Page 221 The computer uses the termination procedure when it wishes to stop selecting one 590 Digital drive and establish connection with another. This is achieved by sending the ‘establish connection’ sequence. The computer retains master status and transmits an (EOT) character to reset all instruments on the data link to be responsive to the next GID-UID address parameter.
  • Page 222 (INO) Instrument number. It contains the address of the slave drive and is equivalent to combining the GID and UID characters of the ASCII mode. (PNO) Parameter number. It is equivalent to combining the C1 and C2 characters of the ASCII mode and is sent as a hexadecimal number rather than two ASCII characters.
  • Page 223 In addition to the above, there are two types of continuation messages (sent by the supervisor). These are: Only valid if sent following a multiparameter poll. Only valid if sent following any type of poll. It requests a repetition of the previous reply. Data values are presented in three consecutive characters, D1, D2 and D3.
  • Page 224 1. There are more PNO numbers available. 2. Serial port P1 (isolated RS422/-485) supports even (default) or odd parity. 3. The new serial link PNO numbers include some dedicated parameters, similar to those already present in previous versions of software, and also 16 configurable parameters. The 16 configurable parameters have PNO’s 112 to 127 (ASCII mnemonics 70 to 7F).
  • Page 229 † = These fields depend on the destination TAG number...
  • Page 230 In normal inquiry polling mode, block 1 is polled. 1 HP022047C. Eurotherm International Bisynch Communications Handbook. 2 (additions) 570 Product Manual. Part nos. HA056929 (main body), HA058040 Each of the Eurotherm Group instruments which support ASCII protocol contains a minimum set of parameters. These are known as the Prime Set and allow access to the following: In addition to the Prime Set, each drive or instrument supports an application set of parameters to allow fast access to commonly required variables such as process variables, setpoints, and PI gains.
  • Page 232 It is possible to make serial communications operate without following all the recommendations in this section; however, the recommendations will promote greater reliability. If possible, avoid using host computers which take their transmitter to a high impedance state (tri-state) when idling. If it is unavoidable, then it is essential to use properly screened cable, such as suggested below.
  • Page 233 Use cable which has two twisted pairs, with each pair individually screened, as shown below. The characteristic impedance should be between 100 and 150W...
  • Page 259 This appendix contains wiring diagrams and schematic diagrams of several 590 DRV Digital DC Drives. The wiring diagrams show the wiring connections between the SCR chassis and the power supply boards. These drawings also show the assembly of the SCR bussing. The schematic diagrams show the internal wiring connections of the drive.
  • Page 279 Early model 590 drives rated 164 A through 675 A use a three-board power supply design. When supplying the field externally on a three-board power supply drive rated 164 A through 270 A, move the field supply jumpers on the power supply board as shown in Figure L.20. Move the RED wire from internal terminal FI to internal terminal FE-R and the YELLOW wire from FI to FE-Y.
  • Page 280 Refer to NOTE 5 and NOTE 6 in the drawings for external stack drives (500 through 1000 HP) in Figures L.11, L.13, L.15 and L.17. Connect the external AC field supply to terminal connections FL1 and FL2. The field supply circuitry is fused internally at 30 A within the 590 DRV controller whether the supply is provided internally or externally.
  • Page 281 MMI. Additional information and diagrams are placed after the block diagram. Tag numbers are associated with each function block parameter and are used to configure the 590 DRV Digital drive. Each function block diagram lists the tag number, MMI parameter name, description, signal range and default value.
  • Page 282 DIGITAL DC DRIVE MENU LEVEL DIAMETER CALC. is used to calculate roll diameters in winder applications. It cal- culates diameter by dividing the LINE SPEED by REEL SPEED. The resulting diam- MENU LEVEL DIAGNOSTICS eter is a percentage of the maximum full roll diameter. A lead section, adjacent line section, or surface driven speed sensing device is required to supply the line speed sig- nal.
  • Page 284 DIGITAL DC DRIVE MENU LEVEL TAPER CALC. uses two inputs, tension setpoint and taper setpoint, to create the ten- sion demand. The operator usually controls these setpoints. MENU LEVEL DIAGNOSTICS NOTE. This block is ignored by the drive unless SYSTEM:: CONFIGURE I/ O:: BLOCK DIAGRAM:: TAPER is connected to a non-zero tag.
  • Page 285 DIGITAL DC DRIVE MENU LEVEL This block performs two functions. First, it switches the drive from speed mode to ten- sion mode using the TENSION ENABLE switch. Second, it switches the current lim- MENU LEVEL DIAGNOSTICS its as required for over or under winding. When TENSION ENABLE is ENABLED, one current clamp (chosen by OVER WIND) uses the TENSION DEMAND signal and the other uses the default value.
  • Page 286 DIGITAL DC DRIVE MENU LEVEL SETPOINT SUM 2 allows two scalable inputs and one unscalable input to be com- bined. These are used for friction compensations in CPW and basic summing for SPW. MENU LEVEL DIAGNOSTICS Inputs 0 and 1 can be scaled individually using their respective ratio and divider pa- rameters.
  • Page 288 DIGITAL DC DRIVE MENU LEVEL The PID block executes a Proportional + Integral + Derivative control algorithm with an added filter to attenuate high-frequency noise. P, PD, PI, or PID can be selected as MENU LEVEL DIAGNOSTICS required. The algorithm modifies the error between the setpoint and the feedback with the proportional, integral, and derivative terms.
  • Page 290 Derivative gain instantaneously boosts the PID output signal. Increasing DERIVATIVE TC decreases the damping which causes overshoot and oscillations in most cases resulting in an unacceptable system reponse. NOTE. For most applications, derivative gain is never used and is usually left at its default value of 0.000 seconds.
  • Page 291 Each section contains a simplified block diagram showing the configuration's connections. The user must make those connections before the control options will function. These configurations are available from Eurotherm Drives on disk as an ASCII file for uploading to the drive.
  • Page 292 DIAMETER CALC., TAPER CALC., TORQUE CALC., and SETPOINT SUM 2. NOTE. This configuration does not support field weakening. A configuration containing field range compensation is available. Call Eurotherm Drives Customer Support at (703) 471-4565 for detailed instructions using this option.
  • Page 293 TAPER CALC. uses signals from terminals A5, TENSION SETPOINT, and A6, TAPER SETPOINT, to produce the tension demand. SETPOINT SUM 2 multiplies the tension demand by diameter to produce the torque demand. The torque demand is then combined with compensations for fric- tional losses to produce the final torque used to control the motor.
  • Page 295 These parameters are located in the SYSTEM::CONFIGURE I/O menu. RAMP O/P DEST = 309 SETPOINT SUM 1::INPUT 0 DIAMETER = 447 SETPOINT SUM 2::RATIO 0 TAPER = 444 SETPOINT SUM 2::INPUT 0 SETPOINT SUM 2 = 432 TORQUE CALC.::TORQUE DEMAND POS.
  • Page 296 DESTINATION TAG to 462. A 0 to +10 volt signal now provides the preset where +10 volts is the full or maximum roll diameter. That signal can be generated by an operator potentiometer, a Eurotherm Drives 5570 Ranger ultrasonic transducer (catalog number 311-LB), or other diameter input device.
  • Page 297 The following procedures describe the steps for starting up CPW winders. These steps customize the drive for the calibration phase. 1. Check that all parameters are set to the default values described in the installation section. Check Parameters 2. Set MIN DIAMETER to the core as a percentage of full roll. If there is more than one core size, Set Min Diameter it should be set to the smallest, for example, if the smallest core is 3.5 inches and the maximum full roll is 42 inches then MIN DIAMETER is:...
  • Page 298 6. Set JOG/SLACK::TAKE UP 1 to 100 percent and increase the tension setpoint signal. The Continued spindle should run up to full speed. Take Up 1 = 100% 7. Reduce the tension setpoint signal to 0.00% and monitor DIAGNOSTICS:: CURRENT DE- Mon.
  • Page 299 A speed programmed winder, SPW, provides closed-loop center winder control. It programs the motor speed using either loadcell or dancer feedback for tension control. This configuration provides standard features used in center winder applications including: diameter calculation with memory and preset, tension and taper, PID for loadcell tension or dancer position control, and over/under winding. It can control unwinds or rewinds for single-spindle and turret winders.
  • Page 300 In dancer position applications, the controller attempts to keep the dancer stationary by varying the winder speed. TAPER CALC. uses signals from terminals A5, TENSION SETPOINT, and A6, TAPER SETPOINT, to produce the dancer loading. Dancer loading affects web tension by setting the force the dancer exerts on the web. The PID setpoint, PID:: INPUT 1, is a fixed value set in the MMI representing the desired position of the dancer.
  • Page 301 TINATION TAG to 462. A 0 to +10 volt signal now provides the preset where +10 volts is the full or maximum roll diameter. That signal can be generated by an operator potentiometer, a Eurotherm Drives 5575 Ranger ultrasonic transducer (catalog number 5575-LB), or other diameter input device.
  • Page 303 The loadcell tension feedback or dancer position signal is connected to terminal A3, TENSION FEEDBACK. Full ten- sion should be scaled to be +9 volts to allow 10 percent over range. When a dancer is used, the drive requires a mini- mum range of three volts.
  • Page 304 The following procedures describe the steps for starting up SPW winders. These steps customize the drive for the calibration phase. 1. Check that all parameters are set to the default values described in the installation section. Check settings 2. Set the MIN DIAMETER to the core as a percentage of full roll. If there is more than one core Set Min Diameter size, it should be set to the smallest, for example if the smallest core is 3.5 inches and the maxi- mum full roll is 42 inches then the MIN DIAMETER is:...
  • Page 305 6. Check the tension loop performance by making step changes to the tension demand and moni- Continued toring the tension feedback. Increasing the proportional gain gives faster response but at some Check tension loop point the winder will become unstable. If this occurs, reduce the gain until it regains stability. The proportional gain is controlled by a profiler using PROP.
  • Page 306 A typical process line contains a number of sections using one or more control modes. This configuration provides the standard features required by a line drive section to perform Draw, Ratio, Loadcell, Dancer position, or Torque con- trol. It also includes Reverse, Anti-reverse, Agitate, Slack take-up/pay-out, Jog, Ramp, and Raise/Lower. Pull rolls, coaters, ovens, treaters, laminators, presses, and more can be controlled with the 590 drive.
  • Page 307 SC provides the drive with control features required for a line drive section. SC uses drive terminals for all inputs and outputs, both analog and digital. These terminals may need to be re-configured depending on the functions required for the particular application. A typical web process line will have a master or lead drive that sets the speed of the line and other slave drives which follow in a variety of ways.
  • Page 308 Draw controls speed but does not directly control tension. Tension control uses an outer control loop to adjust the section speed. The loadcell provides the feedback signal for the control loop. Speed is adjusted to keep the feedback signal from the loadcell at a fixed value, the tension setpoint.
  • Page 309 The Raise/Lower function uses digital inputs to increase and decrease Draw, Ratio, or Tension. This permits gauge controls or other automatic systems with logic outputs to connect directly with the drive. These parameters are located in the SYSTEM::CONFIGURE I/O menu. RAMP O/P DEST = 309 SETPOINT SUM 1:: INPUT 0...
  • Page 311 10 to 90 percent, the setpoint would be 50 percent. The tension feedback signal from a loadcell must be scaled using a loadcell amplifier, such as the Eurotherm Drives 5530/1 or 5530/2, before connecting into terminal A6, TENSION FEEDBACK, on the 590 drive. At full tension, the output should be adjusted to read +9 volts to allow 10 percent overrange.
  • Page 312 The following procedures describe a methodology for starting and tuning a tension control line drive section. The first steps assure the drive section parts are calibrated correctly. The PID setup steps tune the section for best performance. 1. Set all the PID parameters to the default values (see Appendix H). Check PID settings 2.
  • Page 313 For dancer applications, the feedback signal should be connected to be more positive when the web is tight and less positive when the web is slack. In this arrangement, dancer feedback will increase the speed when the web is slack. The trim range value depends on the nature of the web.
  • Page 314 Using draw with non-extensible materials requires very small speed differences between line drive sections which, in turn, requires very precise speed control. Analog inputs and outputs may not provide adequate precision or stability. The digital 590 drive's speed accuracy can be greatly improved by direct, serial connection between drives using the 5703 Peer-to-Peer interface (catalog number 655-RS232).
  • Page 315 Ratio mode sets the section speed to the line speed multiplied by the ratio input. To select ratio mode, set SETPOINT SUM 1:: RATIO 0 to 0.00 percent. Terminal A4, LINE SPEED REFERENCE, supplies the line speed signal. Termi- nal A2, DRAW/RATIO, receives the ratio setpoint. It is multiplied by the line speed to produce the speed demand. The maximum range of terminal A2 is -300 to +300 percent.
  • Page 316 The motor rotation can be reversed by terminal C8, REVERSE. This SC configuration only works when in torque, draw, or ratio mode. To provide a section reverse ability for tension feedback modes, change the configuration to route the line speed reference and trim signals through SETPOINT SUM 1 parameters INPUT 0 and INPUT 1. If it is necessary to ensure that a section does not reverse, even if reversing would be required to maintain tension or dancer position, then use the Anti-reverse function.
  • Page 317 INPUT, tag 262. The output of the Raise/Lower function is connected to SETPOINT SUM 1:: RATIO 1, tag 6, or SETPOINT SUM 2:: INPUT 0, tag 444. The analog input that is replaced, either A2, DRAW/RATIO or A5, TEN- SION SETPOINT, must have its destination tag set to zero. When using loadcell tension control, the PID trim loop O/P SCALER (TRIM) needs to be higher for extensible web than for non-extensible web.