Eaton PowerXL DG1-323D7FB-C21C, Installation Manual

Page 1: ...PowerXL DG1 Series VFD Installation Manual Effective March 2014 New Information...

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Page 3: ...HANTABILITY OTHER THAN THOSE SPECIFICALLY SET OUT IN ANY EXISTING CONTRACT BETWEEN THE PARTIES ANY SUCH CONTRACT STATES THE ENTIRE OBLIGATION OF EATON THE CONTENTS OF THIS DOCUMENT SHALL NOT BECOME PA...

Page 4: ...product information You can also find information on local distributors or Eaton s sales offices Website Address www eaton com drives EatonCare Customer Support Center Call the EatonCare Support Cente...

Page 5: ...GINEERING CONSIDERATIONS Introduction 9 Electrical Power Network 10 Input Voltage and Frequency 10 Input Voltage Balance 10 Total Harmonic Distortion THD 11 Reactive Power Compensation Devices 11 CHAP...

Page 6: ...nection to Power Section 38 Three Phase Input Connection 38 Terminal Designations in the Power Section 38 Ground Connection 39 Product Modified Sticker 39 Checking the Cable and Motor Insulation 39 CH...

Page 7: ...5 Figure 18 Input Power and Motor Cable Stripping Lengths 30 Figure 19 Ground Wiring 33 Figure 20 Terminal Block Layout 35 Figure 21 Basic Internal Control Wiring Diagram 36 Figure 22 DG1 Series Adjus...

Page 8: ...gths 30 Table 23 I O Connection 34 Table 24 I O Specifications 35 Table 25 1st Environment 2nd Environment EMC Levels According to EN 61800 3 2004 42 Table 26 Control Wiring Requirements 42 Table 27 C...

Page 9: ...ograms interrupted after a voltage dip or failure This should not cause dangerous operating states even for a short time If necessary emergency stop devices should be implemented Wherever faults in th...

Page 10: ...hecking components Always work with another person in case an emergency occurs Disconnect power before checking controllers or performing maintenance Be sure equipment is properly earthed Wear safety...

Page 11: ...is allowed on the supply side of this product WARNING Carry out wiring work only after the drive has been correctly mounted and secured WARNING Before opening the drive covers Disconnect all power to...

Page 12: ...ons that are directly exposed to sunlight or have high concentrations of dust corrosive gas explosive gas inflammable gas grinding fluid mist etc Improper installation may result in a fire hazard CAUT...

Page 13: ...rior to any tests or measurements of the motor or the motor cable disconnect the motor cable at the drive output terminals U V W to avoid damaging the drive during motor or cable testing CAUTION Do no...

Page 14: ...od turn the drive on at least every six months for at least 5 hours to restore the performance of the capacitors and then check its operation It is recommended that the drive is not connected directly...

Page 15: ...040016EN Quick Start Guide MN040006EN User Manual CD CD040002EN and accessory packet The accessory packet includes Rubber grommets Control cable grounding clamps Additional grounding screw Inspect the...

Page 16: ...2 DG1 Series VFD MN040002EN March 2014 www eaton com Rating Label Figure 2 Rating Label Carton Labels U S and Europe Same as rating label shown above Contains SN PN Type Date Contains EAN Code Date Co...

Page 17: ...0 hp 2D2 2 2A 0 75 kW 1 hp 3D3 3 3A 1 1 kW 1 5 hp 4D3 4 3A 1 5 kW 2 hp 5D6 5 6A 2 2 kW 3 hp 7D6 7 6A 3 kW 5 hp 9D0 9A 4 kW 7 5 hp VT 012 12A 5 5 kW 7 5 hp 016 16A 7 5 kW 10 hp 023 23A 11 kW 15 hp 031...

Page 18: ...2088FN C21C FR5 30 37 40 50 114 143 DG1 32114FN C21C 37 45 50 60 143 170 DG1 32143FN C21C 45 55 60 75 170 211 DG1 32170FN C21C FR6 1 55 75 75 100 211 261 DG1 32211FN C21C 75 90 100 125 261 312 DG1 322...

Page 19: ...105 140 DG1 34105FN C21C 75 90 100 125 140 170 DG1 34140FN C21C 90 110 125 150 170 205 DG1 34170FN C21C FR6 1 110 132 150 200 205 261 DG1 34205FN C21C 132 160 200 250 261 310 DG1 34261FN C21C Frame Si...

Page 20: ...over DXG SPR FR1MCC DXG SPR FR1MCC 2 Outer housing DXG SPR FR1OH DXG SPR FR1OH 2 UL conduit plate DXG SPR FR1CPUL DXG SPR FR1CPUL 2 IEC conduit plate DXG SPR FR1CPIEC DXG SPR FR1CPIEC 2 Catalog Number...

Page 21: ...XG SPR FR3MCC 2 Outer housing DXG SPR FR3OH DXG SPR FR3OH 2 UL conduit plate DXG SPR FR3CPUL DXG SPR FR3CPUL 2 IEC conduit plate DXG SPR FR3CPIEC DXG SPR FR3CPIEC 2 Catalog Number Catalog Number Catal...

Page 22: ...FR5CVR 2 Main fan kit 1 DXG SPR FR5FAN DXG SPR FR5FAN 2 Control fan DXG SPR FR5CF DXG SPR FR5CF 2 Bus capacitor DXG SPR FR5BC DXG SPR FR5BC 2 Main power board DXG SPR 2FR5MPB DXG SPR 4FR5MPB 2 EMI 1 b...

Page 23: ...o Description 1 Power grid configuration input voltage input frequency interactions with PF correction systems 2 Breakers fuses cable cross sections 3 Protection of persons and animals with residual c...

Page 24: ...s further steps are superfluous Input Voltage and Frequency The standardized input voltages IEC 60038 VDE017 1 for energy suppliers EVU guarantee the following conditions at the transition points Devi...

Page 25: ...ned in standard IEC EN 61800 3 as the ratio of the rms value of all harmonic components to the rms value of the fundamental frequency It is given in percent of the total value The THD value of the har...

Page 26: ...gure 6 Description of the DG1 Series Features The DG1 frequency inverter converts the voltage and frequency of an existing AC network into a DC voltage This DC voltage is used to generate a three phas...

Page 27: ...IGBT based inverter converts the DC voltage of the DC link UDC into a three phase AC voltage U2 with variable amplitude and frequency f2 Sinusoidal pulse width modulation PWM with V f control can be...

Page 28: ...frequency inverter Switching in the output of the frequency inverter is only permitted with V Hz characteristic curve control Proper Use The DG1 frequency inverters are electrical apparatus for contr...

Page 29: ...this the DG1 variable frequency drive must be supplied with power with a controlled DC power supply unit via two mains DC bus connection terminals Please consult the factory for detailed instructions...

Page 30: ...espond with local standards For an installation in accordance with UL guidelines Use UL recognized Class T fuses for the branch circuit protection Use 75 C copper wire only Use UL listed conduit fitti...

Page 31: ...original protective earthing conductor must be connected or the cross section of the equipment grounding conductor must be at least 10 mm2 Cu Residual current circuit breakers must be suitable for th...

Page 32: ...ndividual components in a PDS compliant with IEC EN 61800 3 do not apply These component manufacturers however must offer solutions that ensure standards compliant use In Europe maintaining the EMC gu...

Page 33: ...asses apart Ensure that the motor is not over dimensioned If a motor in speed control mode is under dimensioned the motor rating must only be one rating level lower Connecting Motors in Parallel The D...

Page 34: ...r s output can lead to nuisance tripping Motor and Circuit Type The motor s stator winding can be connected in a star or delta configuration in accordance with the rated operational data on the namepl...

Page 35: ...Circuit See Figure 14 Notes 1 Star connection 400V 50 Hz 2 Delta connection 230V 50 Hz 3 Delta connection 400V 87 Hz 4 Note the permitted limit values of the motor Frequency Inverters DG1 323D7FB DG1...

Page 36: ...ly when frequency inverter T1 is at zero current Contactors and switches S1 in the frequency inverter output and for the direct start must be designed based on utilization category AC 3 for the rated...

Page 37: ...o discharge Pay attention to hazard warnings Standard Mounting Instructions Select the mounting location based on requirements listed in this chapter Mounting surface must be a vertical flat non flamm...

Page 38: ...30 Vac 0 75 3 0 55 2 2 3 7 11 0 79 20 0 79 20 3 94 100 1 97 50 22 38 480 Vac 1 5 0 75 3 7 2 2 7 6 575 Vac 3 2 5 1 5 3 7 3 3 7 5 FR2 230 Vac 4 7 5 3 5 5 12 5 25 1 18 30 1 18 30 6 30 160 2 36 60 55 94 4...

Page 39: ...28 134 1 3 54 90 0 3 54 90 0 0 28 7 0 23 37 10 6 480 Vac 7 5 15 5 5 11 12 23 575 Vac 1 7 5 15 5 5 11 10 18 FR3 230 Vac 10 15 7 5 11 31 48 10 44 265 1 21 97 558 0 21 46 545 0 20 43 518 9 8 06 204 6 7...

Page 40: ...should follow required dimensions refer to the drive mounting template printed on the outside carton FR2 Mounting Instructions Step 1 Lift the drive out from the carton Remove the packaging Step 2 At...

Page 41: ...ired dimensions refer to the drive mounting template printed on the outside carton FR4 Mounting Instructions Step 1 Lift the drive out of the carton with the cardboard Remove the packaging Step 2 Atta...

Page 42: ...e pallet with an M8 or 3 8 inch wrench Step 3 Use a hook to lift the drive Step 4 Attach the drive to the mounting plate with four M8x20 or 3 8 inch screws and four M8 or 3 8 inch nuts with an M8 or 3...

Page 43: ...1 rated input and output current Use Class T UL and cUL CSA or type gG gL IEC 60269 1 Refer to Appendix B for proper fuse size selection Consult with Eaton Electrical for further information on fusing...

Page 44: ...ables alongside or parallel to any other wiring If it is necessary to run motor cables with other wiring then maintain spacing between motor cables and other wiring in accordance with the table on Pag...

Page 45: ...power wiring protection plate Use power motor cable tables on Appendix B 3 Add attachable grounding clamps qty 2 one on each side of drive 4 Pass motor input power wires cables through base wiring pl...

Page 46: ...Step 2 Measure the outside diameter of the rubber grommet D2 and select a suitable D2 D1 D2 D1 2 mm Step 3 Cut the rubber grommet at the selected diameter Step 4 Run the cable through the rubber gromm...

Page 47: ...ables sized per Appendix B Provide dedicated wire for low impedance ground between drive and motor DO NOT USE conduit as ground CAUTION Improper grounding could result in damage to the motor and or dr...

Page 48: ...ready to run 15 24Vo 24 Vdc Output Control voltage output 100 mA max 16 GND I O Signal Ground I O Ground for Reference and Control 17 AO1 Analog Output 1 Output Frequency Shows Output frequency to mo...

Page 49: ...Ri 250 ohm differential Digital inputs 8 Positive or negative logic 18 to 30 Vdc one input can be used as thermistor input 24V output Auxiliary Voltage 24V 15 total max 250 mA on board include option...

Page 50: ...Chapter 6 Installation Requirements 36 DG1 Series VFD MN040002EN March 2014 www eaton com Figure 21 Basic Internal Control Wiring Diagram...

Page 51: ...EC EN 61800 3 2004 Run 240 Vac and 24 Vdc control I O in separate conduit Control I O terminals must be tightened to 4 5 in lb 0 5 Nm Wiring or ferrule size 28 12 Sol AWG 30 12 Str AWG or 0 2 2 5 mm2...

Page 52: ...le with safety relays Figure 23 Thermistor STO Wiring Diagram Connection to Power Section Figure 24 shows the general connections for the frequency inverter in the power section Three Phase Input Conn...

Page 53: ...fied Sticker Checking the Cable and Motor Insulation 1 Check the motor cable insulation as follows Disconnect the motor cable from terminals U V and W of the DG1 Series drive and from the motor Measur...

Page 54: ...od contact and be connected with short HF braided cables Avoid using painted surfaces anodized chromized An overview of all EMC measures is provided in the figure on Page 41 Install the frequency inve...

Page 55: ...l lines 1 to 36 fieldbus connection Large area connection of all metallic control panel components Mounting surfaces of frequency inverter and cable shielding must be free from paint Connect the cable...

Page 56: ...oidal filters or terminals the shielding of the motor cable can be interrupted close to these subassemblies and connected to the mounting plate PES with a large area connection Free or non screened co...

Page 57: ...rm any modifications on the AC drive when it is connected to mains WARNING Electric shock hazard risk of injuries Carry out wiring work only if the unit is de energized After disconnecting the supply...

Page 58: ...6 kHz Automatic switching frequency derating in case of overload Frequency reference Analog input resolution 0 1 10 bit accuracy 1 Panel reference resolution 0 01 Hz Field weakening point 20 Hz to 400...

Page 59: ...61000 4 2 4 kV CD or 8 kV AD Criterion B Fast transient burst Second environment IEC 61000 4 4 2 kV 5 kHz Criterion B Dielectrical strength Primary to secondary 3600 Vac 5100 Vdc Primary to earth 2000...

Page 60: ...208V Current CT IH at 50 C Current VT IL at 40 C Fuse Rating Class T NEC Wire Size AWG Terminal Connection Size AWG Line and Motor Ground Line and Motor Ground FR1 3D7 3 2 4 4 4 2 4 6 3 7 4 8 10 14 1...

Page 61: ...208V Input Current VT IL Current CT IH at 50 C Current VT IL at 40 C Fuse Rating gG gL Mains and Motor Cable Cu mm2 Terminal Cable Size Main Terminal Cu mm2 Earth Terminal Cu mm2 FR1 3D7 3 2 4 4 3 7...

Page 62: ...Class T NEC Wire Size AWG Terminal Connection Size AWG Line and Motor Ground Line and Motor Ground FR1 2D2 2 0 3 1 3 0 2 1 3 0 10 14 14 30 10 18 10 3D3 3 1 4 3 4 3 0 3 4 10 14 14 30 10 18 10 4D3 4 0 5...

Page 63: ...nput Current CT IH 400V Input Current VT IL Current CT IH at 50 C Current VT IL at 40 C Fuse Rating gG gL Mains and Motor Cable Cu mm2 Terminal Cable Size Main Terminal Cu mm2 Earth Terminal Cu mm2 FR...

Page 64: ...0 100 0 100 0 97 8 95 6 93 4 91 2 87 4 83 6 79 8 FR5 100 0 100 0 100 0 100 0 95 5 91 0 86 5 82 0 78 4 74 7 71 1 FR6 1 1 1 1 1 1 1 1 1 1 1 50 C FR1 84 0 84 0 84 0 84 0 84 0 84 0 84 0 80 8 77 6 74 4 69...

Page 65: ...00 0 100 0 96 2 92 3 88 5 FR5 100 0 100 0 100 0 100 0 100 0 100 0 100 0 100 0 96 1 92 2 88 2 FR6 1 1 1 1 1 1 1 1 1 1 1 50 C FR1 100 0 100 0 100 0 100 0 100 0 97 7 95 5 91 8 88 2 84 5 79 1 73 6 FR2 100...

Page 66: ...0 95 7 91 4 87 1 81 8 76 4 71 1 65 7 FR5 100 0 100 0 100 0 100 0 94 8 89 6 84 4 77 8 71 2 64 6 58 0 FR6 1 1 1 1 1 1 1 1 1 1 1 50 C FR1 75 0 75 0 75 0 75 0 75 0 75 0 75 0 70 8 66 7 62 5 58 3 50 0 FR2 8...

Page 67: ...0 0 100 0 94 8 89 7 84 5 79 3 FR5 100 0 100 0 100 0 100 0 94 1 88 2 82 4 75 0 67 6 60 3 52 9 FR6 1 1 1 1 1 1 1 1 1 1 1 50 C FR1 100 0 100 0 100 0 100 0 100 0 95 7 91 4 87 1 82 9 78 6 72 2 65 8 FR2 100...

Page 68: ...IL 110 Pv W CT IH 150 Pv W FR1 2D2 3D3 4D3 5D6 7D6 9D0 180 98 136 88 FR2 012 016 023 390 330 360 292 FR3 031 038 046 700 494 603 472 FR4 061 072 087 1083 870 1080 875 FR5 105 140 170 1906 1479 1755 14...

Page 69: ...around drive B Space between two drives or drive and cabinet C Free space above drive D Free space below drive Minimum Dimensions For Class IP54 dimension A and B 0 0 41 10 5 6 02 153 0 1 38 35 0 1 2...

Page 70: ...above drive D Free space below drive Minimum Dimensions For Class IP54 dimension A and B 0 4 80 122 0 0 28 7 0 0 28 7 0 3 94 100 0 0 47 12 0 12 64 321 0 0 26 6 5 7 01 178 0 0 26 6 5 6 31 160 4 3 94 10...

Page 71: ...o drives or drive and cabinet C Free space above drive D Free space below drive Minimum Dimensions For Class IP54 dimension A and B 0 C 6 30 160 0 1 77 44 9 1 11 28 3 5 80 147 2 A B 1 18 30 0 1 54 39...

Page 72: ...STOP BACK RESET LOCAL REMOTE OK START MS NS A Air gap around drive B Space between two drives or drive and cabinet C Free space above drive D Free space below drive Minimum Dimensions For Class IP54...

Page 73: ...ace between two drives or drive and cabinet C Free space above drive D Free space below drive Minimum Dimensions For Class IP54 dimension A and B 0 C 7 87 200 0 D 3 15 80 0 A B 1 97 50 0 13 49 342 6 3...

Page 74: ...space above drive D Free space below drive Minimum Dimensions For Class IP54 dimension A and B 0 C 7 87 200 0 D 3 15 80 0 A B 1 97 50 0 9 51 241 6 8 66 220 0 5 28 134 0 1 09 27 8 10 44 265 1 0 96 24...

Page 75: ...een two drives or drive and cabinet C Free space above drive D Free space below drive Minimum Dimensions For Class IP54 dimension A and B 0 C 11 81 300 0 D 3 94 100 0 A B 3 15 80 0 A B 3 15 80 0 0 43...

Page 76: ...ree space above drive D Free space below drive Minimum Dimensions For Class IP54 dimension A and B 0 C 11 81 300 0 D 3 94 100 0 A B 3 15 80 0 A B 3 15 80 0 8 07 205 0 0 35 9 0 0 71 18 0 0 18 4 5 24 31...

Page 77: ...een two drives or drive and cabinet C Free space above drive D Free space below drive Minimum Dimensions For Class IP54 dimension A and B 0 C 11 81 300 0 D 7 87 200 0 A B 3 15 80 0 1 14 29 0 A B 3 15...

Page 78: ...ves or drive and cabinet C Free space above drive D Free space below drive Minimum Dimensions For Class IP54 dimension A and B 0 C 11 81 300 0 D 7 87 200 0 A B 3 15 80 0 A B 3 15 80 0 30 51 775 0 0 79...

Page 79: ...able for Overvoltage Category III and shall provide protection for a rated impulse withstand voltage peak of 4 kV Motor Overload and Over Temperature Protection This drive provides solid state motor o...

Page 80: ...xxxx 600V 15A DG1 32011xx xxxx 600V 15A 2 DG1 32012xx xxxx 600V 20A DG1 32017xx xxxx 600V 30A DG1 32025xx xxxx 600V 35A 3 DG1 32031xx xxxx 600V 60A DG1 32048xx xxxx 600V 80A 4 DG1 32061xx xxxx 600V 1...

Page 81: ...G DG1 32048xx xxxx 40 4 2 AWG FR4 DG1 32061xx xxxx L1 L2 L3 DC DC R R U V W 95 3 1 0 AWG DG1 32075xx xxxx 95 2 1 0 AWG DG1 32088xx xxxx 95 1 0 AWG 1 FR5 DG1 32114xx xxxx L1 L2 L3 DC DC R R U V W 354 3...

Page 82: ...0 AWG DG1 324D8xx xxxx 10 14 10 AWG DG1 326D6xx xxxx 10 14 10 AWG DG1 327D8xx xxxx 10 14 10 AWG DG1 32011xx xxxx 10 14 10 AWG FR2 DG1 32012xx xxxx Grounding terminal 10 12 6 AWG DG1 32017xx xxxx 10 10...

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