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Installation Manual - Platt Electric Supply

1. LI i 10 63 270 0 807 9 96 253 0 122024 245 i 11 57 294 0 205 0 26 0 1 o 3 gt 1 1 e i i e 7 87 200 0 gam 3 83 972 1 23 26 26 8 590 7 53 200 le 16 91 429 5 7 87 200 0 1 62 1 o o 41 2 Y 0 59 6 1 59 40 5 0 47 12 0 im 100 0 Type 1 12 UL 3 89 98 9 1 38 35 0 3 00 89 1 38 35 0 022 5 248 im 63 0 3 01 97 iL 2 O ONE 5 6 79 172 5 71 0 63 0 62 Series VFD MNO40002EN March 2014 www eaton com 8 07 00 35 205 0 09 0 00 71 ELE 2811 5o 24 31 617 5 ad 1 0 18 4 5 8 07 _ 0 35 205 0 09 0 Minimum Dimensions A Air gap around drive B Space between two drives or drive and cabinet Free space above drive D Free space below drive For Class IP54 dimension A and 8 0 C 11 81 300 0 A B 3 15 3 15 80 0 r 80 0 L 3 94 100 0 Approximate Di
2. 9 36 237 7 208 PE 20 35 29 0 018 0 i 24 31 8 07 617 5 11 57 294 0 205 0 1 1 1 3 83 197 2 205 0l 20 35 09 0 0 135 590 7 630 0 8 15 79 Minimum Dimensions 399 2 A Air gap around drive B Space between two drives or drive and cabinet Free space above drive e D Free space below drive For Class IP54 dimension A and B 0 1 X X 1 0 59 15 0 0 43 11 0 m a 9 36 2377 1000 IP21 IP54 Metric Type 1 12 UL A B A B 948 1 39 0 3 89 98 9 1 38 35 0 390 1 38 35 0 3 00 89 2 48 3 025 3 022 5 7 630 3 050 5 AN 63 0 3 01 97 AN TI e e e 6 79 01725 03 94 100 0 51 9 2 04 51 9 72 80 248 71 0 63 0 061 Series VFD MNO040002EN March 2014 www eaton com 61 Appendix C Dimension Drawings Approximate Dimensions in Inches mm Figure 38 FR4 Dimension Drawing Flange Mount 9 36 237 7 4
3. H Chapter 6 Installation Requirements E EL E i Ke 9 fi fi Table 18 Mounting Drive Dimensions Amperes Approximate Dimensions in Inches mm Weight Size Voltage hp CT ly kW D H1 H2 H3 w2 W3 wa 0 Lb kg FR1 230Vac 0 75 3 0 55 22 35 11 789 1287 1228 1150 602 4 80 3 94 3 94 0 28 14 33 480Vac 1 5 075 37 2276 200 4 326 9 311 9 292 1 153 0 121 9 100 1 100 1 7 0 6 5 575 2 5 1 5 3 7 3 3 7 5 FR2 230Vac 5 75 3 5 5 12 5 25 963 1650 1598 1496 6 61 5 28 3 54 3 54 0 28 23 37 480Vac 75 15 55 11 12 23 244 7 419 1 405 9 380 0 167 8 1341 90 0 900 70 10 6 575 Vac GO 7 5 15 5 5 11 10 18 FR3 230Vac 10 15 75 11 31 48 10 14 2197 2146 2043 8 06 7 24 4 92 4 92 0 35 49 82 480Vac 20 30 15 22 31 46 265 1 558 0 545 0 518 9 204 6 183 9 125 0 125 0 9 0 22 6 575 Vac o 20 30 15 22 22 34 FRA 230Vac 20 30 15 22 61 88 1157 2480 3431 2327 9 36 9 13 8 07 8 07 0 35 77 60 480Vac 10 80 30 45 61 87 294 0 629 9 617 5 591 1 237 7 231 9 205 0 205 0 9 0 35 2 575 V
4. IP Modbus TCP Optional Card Control 0 Optional Card B Terminals RS 485 Terminating A Resistor UE Removable MOV Screw Removable EMC Screw w Line Ground Clamp Location Motor Ground Clamp Location Line Ground Clamp Location Grounding Grounding Strap Location Strap Location gm Line Side Control Wiring All control I O wiring must be segregated from line mains Run 240 Vac and 24 control I O in separate conduit andimotor CODING e Control I O terminals must be tightened to 4 5 in Ib 0 5 Nm Control wiring shall be shielded twisted pairs to meet EMC levels nad by IEC EN 61800 3 2004 e Wiring or ferrule size 28 12 Sol AWG 30 12 Str AWG or 0 2 2 5 mm 061 Series VFD MN040002EN March 2014 www eaton com 37 Chapter 6 Installation Requirements Safe Torque Off STO The PowerXL DG1 includes Safe Torque Off STO functionality as standard and provides solation from the control board will stop IGBT from firing Functional Safety SIL1 Certification IEC EN 61800 5 2 and DIN EN ISO 13849 Category 1 Level C Higher category levels achievable with safety relays Figure 23 Thermistor STO Wiring Diagram
5. DRIVE DIN7 Thermistor Circuit MCU Switch or relay for STO Normally Closed 1214 5 DSR Circuit e 2 1 PTC 3 Supply Pas 38 DG1 Series VFD MNO40002EN March 2014 www eaton com Connection to Power Section Figure 24 shows the general connections for the frequency inverter in the power section Three Phase Input Connection Figure 24 Connection to Power Section Terminal Designations in the Power Section e 1 L2 L3 Connection terminals for the supply voltage input input voltage e U V W Connection terminals for the three phase line to the AC motor output frequency inverter PE Connection for protective ground reference potential PES with mounted cable routing plate for shielded cables Ground Connection The ground connection is connected directly with the cable clamp plates The shielded cables between the frequency inverter and the motor should be as short as possible Connect the shielding on both ends and over a large surface area with protective ground PES Protective Earth Shielding You can connect the shielding of the motor cable directly to the cable clamp plate 360 degrees coverage with the protective ground The frequency inverter must always be connected to the ground potential via a grounding cable PE Figure 25 Grounding TAN
6. Parallel Connection of Several Motors to One Frequency Inverter Motor and Gireult Type ress dne uem ev RUPEE DEE d and Bypass Operation seduce sutor ea eaten testet Desa Baw tectis Connecting EX MOtOIS geek up 1 e REOR A UR REG EUR ORAON Nanna 10 10 10 11 11 12 14 14 15 15 15 16 16 16 17 18 19 19 20 20 22 22 PowerXL DG1 Series VFD PowerXL DG1 Series VFD MN040002EN March 2014 www eaton com iii PowerXL DG1 Series VFD Table of Contents continued CHAPTER 6 INSTALLATION REQUIREMENTS Electrical Installation Warnings and Cautions Standard Mounting Instructions DIMENSIONS 55 26 2 2 2 225 2 ete Etat a ook 11 85 31 Standard Drive MOUNTING s a ce Sad rte SERRE Power Wiring aet eem dtr eagles edes eqs Cable Selection Power and Motor Leads Line Mains and Motor Cable Installation Connection Lightening Torque Cable ROUTING sess ete etse aisd mieten te tote n ba t bd eb Wining the VED aca nce aan las t rae IR a a A a mts Rubber Grommet Installation Instructions Control BOdEdS 2 2 Len baeo teet dte Se nm NUR ROSE Sate Tor
7. DC R DIODES CHOKE DC BUS IGBT w L2 40 E sili V pm CIIM DN E L3 U PE STO STO 11111111 1 10V no 2 i gu An 28 2500 500 CPU RS 485 5 Al2 a 2500 N 24vi 19 6 GND DINT 20 7 DIN5 DIN2 21 8 DING t DIN3 22 9 DIN Hn DIN4 23 10 DIN8 OPTO CMA 24 11 CMB 25 112 GND B 2 13 24Vo gr R3NO 27 14 RINC 28 lt 15 240 222 1 RIM 29 16 GND R1NO 30 17 1 R3CM 31 18 2 R2NC 32 R2CM 33 E R2NO 34 36 DG1 Series VFD MN040002EN March 2014 www eaton com Chapter 6 Installation Requirements Control Board The main DG1 Series VFD consists of a main control board control I O connections block and two slots for extra option boards Figure 22 DG1 Series Adjustable Frequency Drive Connect DSP Part to Power Board Fan Power Wire Keypad STO Connect MCU Part to Power Board Mode Selection Battery Standard RJ45 EtherNet IP BACnet
8. Required Required Catalog Torque Wire Number Terminal Type in Ibs Range FR1 DG1 342D2xx xxxx L1 L2 L3 DC DC 5 7 14 10 AWG DG1 343D3xx xxxx 5050 W 57 14 10 AWG DG1 344D3xx xxxx 5 7 14 10 AWG DG1 345D6xx xxxx 5 7 14 10 AWG DG1 347D6xx xxxx 5 7 14 10 AWG DG1 349D0xx xxxx 5 7 14 10 AWG FR2 061 34012 L1 L2 L3 DC DC 15 6 12 6 AWG 061 34016 5550 W 156 10 6 AWG DG1 34023xx xxxx 15 6 8 6 AWG FR3 DG1 34031xx xxxx L1 L2 L3 DC DC 40 8 2 AWG DG1 34038xx xxxx 5 0 W 16 6 2 AWG DG1 34046xx xxxx 40 4 2 AWG DG1 34061xx xxxx L1 L2 L3 DC DC 95 4 1 0 AWG 061 34072 P 0 W 3 1 0 AWG DG1 34087xx xxxx 95 1 1 0 AWG 5 DG1 34105xx xxxx L1 L2 L3 DC DC 354 2 0 AWG R U V W 350 kcmil DG1 34140xx xxxx 354 3 0 AWG 350 kcmil DG1 34170xx xxxx 354 250 350 kcmil Frames Sizes FR1 FR5 All models Control terminal 4 5 28 12 Sol AWG block 30 12 Str AWG For 230V Drive Series required line and motor wire torque type and size range are listed in Table 42 Table 42 Required Line and Motor Wire Torque 230V Required Required Catalog Torque Wire Number Terminal Type in Ib Range FR1 DG1 323D7xx xxxx 11 12 13 DC 12 1 4 10 AWG DG1 324D8xx xxxx P5 P U V W 21 4 10 AWG DG1 326D6xx xxxx 21 4 10 A
9. D1 Cable 22 Step 2 Measure the outside diameter of the rubber grommet D2 and select a suitable D2 D1 lt D2 lt 01 2 mm 9 D2 Grommet Step 3 Cut the rubber grommet at the selected diameter 1502501 2 32 DG1 Series VFD MN040002EN March 2014 www eaton com Step 5 Insert the rubber grommet into the conduit plate together with the cable Step 6 Fasten the rubber grommet and cable with a self locking cable tie Self Locking CableTies o Chapter 6 Installation Requirements Figure 19 Ground Wiring Motor Ground Clamp Location Line Ground Clamp Location Grounding Strap Location Grounding Strap Location perum Line Side Motor Note Do not wire motor leads to R R This will cause damage to the drive Note Actual layout may vary slightly by frame Ground Wiring Control Wiring Run motor cables in separate conduit 7 Wire the control terminals following the details for the DO NOT RUN CONTROL WIRES in same conduit specific option boards shown on the following pages Cables sized per Appendix B Provide dedicated wire for low impedance ground between drive and motor DO NOT USE conduit as gr
10. EN NAN 061 Series VFD 040002 2014 www eaton com 43 Appendix A Technical Data and Specifications Appendix A Technical Data and Specifications Table 28 PowerXL Series 061 Attribute Description Specification Input ratings Input voltage Uin 208V to 240V 380V to 500V 525V to 600V 15 to 1096 Input frequency 50 Hz to 60 Hz variation up to 45 Hz to 66 Hz Connection to power Once per minute or less Starting delay 3 s to FR2 4 s 5 s 6 s FR5 Short circuit withstand rating 100 Output ratings Output voltage 0 to Uin Continuous output current IL ambient temperature maximum 40 C up to 60 C with derating overload 1 1 x IL 1 min 10 min IH ambient temperature maximum 50 C up to 60 C with derating overload 1 5 x IH 1 min 10 min Overload current 15096 respectively 11096 1 min 10 min Initial output current 20096 2 s 20 s Output frequency 0 400 Hz standard Frequency resolution 0 01 Hz Control characteristics Control methods Frequency control Speed control Open loop speed control Open loop torque control Switching frequency Range FR1 3 1 kHz to 12 kHz 84 5 1 kHz to 10 kHz efaults FR1 3 4 kHz IH 6 kHz IL FR4 5 3 6 kHz Automatic switching frequency dera
11. iv PowerXL DG1 Series VFD MN040002EN March 2014 www eaton com PowerXL DG1 Series VFD List of Figures Figure 1 RIC Battery Comnection mosse Sod abere DEN Mew AE ee 1 Fig re 2 Rating tabel sss coser nae attt dob orta bean dades 2 Figure Catalog Numbering System 3 Figure 4 Drive System PDS Power Drive System 9 Figure 5 AC Power Networks with Grounded Neutral Point TN TT Networks 10 Figure 6 Description of the DG1 Series 12 Figure 7 Block Diagram Elements of DG1 Frequency Inverters 13 Iig re 8 Selectiori Criteria sse khe e seu RH RN ud 14 Figure 9 Identification on the FI Circuit Breakers 16 Fig re 10 EMC Measures end betont cet dob boe t debo deles ad 18 Figure 11 Parallel tad pa AUG 20 Figure 12 Example of a Motor Ratings Plate 20 Figure 13 Star and Delta Circuit Types 1 20 Figure 14 V Hz CharacteristiC CUTVe oiu tee bt dec abt o 21 Figure 15 Bypass Motor Control Example 22 Fig re 16 Mountirig Spa6e iioc eeu nouit eatis E 24 Fig
12. Contains SN PN Type Date Contains EAN Code Contains NAED Code SAFETY US CA RoHS 2 Date Code 20131118 Carton Labels U S and Europe Same as rating label shown above 2 DG1 Series VFD 040002 2014 www eaton com Chapter 1 DG1 Series Overview Catalog Number System Figure 3 Catalog Numbering System Series Power Part Options D 61 34 408 FB 21 Basic Naming Coating of Boards D Drive C Coated Series Phase Reference Internal Brake Chopper Enclosure IP Rating G1 General purpose 3 3 INPUT 3 OUTPUT N No brake chopper 21 IP21 Type 1 B Brake chopper 54 54 12 Input Output Voltage Rating 2 230V 208 240V 15 41096 4 400V 380 500V 1596 41095 Internal EMC Filter Display Option 5 575V 525 600V 1596 10 Internal filter C LCD graphical Output Current Rating CT 208 240 380 500 525 600 307 3 73 0 55 kW 0 75 hp 202 22A 0 75 kW 1 hp 303 33A 1 5 kW 2 hp 408 4 8A 0 75 KW 1 hp 303 33A 1 1 kW 1 5 hp 405 4 5A 2 2 kW 3 hp 6D6 6 6A 1 1 kW 1 5 hp 4D3 43A 1 5 kW 2 hp 705 7 5A 3 7 kW 5 hp 7D8 7 8A 1 5 kW 2 hp 5D6 5 6A 2 2 kW 3 hp 010 10A 5 5 kW 7 5 hp 011
13. o Chapter 2 Engineering Considerations Table 11 Drive System Components Item No 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 current protective devices 4 Input contactor disconnector 5 Frequency inverter mounting installation power connection EMC measures circuit examples 6 Output contactor disconnector 7 Output reactor dV dT filter sine wave filter 8 Motor protection thermistor can be connected to drive directly 9 Cable lengths motor cables shielding EMC 10 Motor and application parallel operation of multiple motors on a VFD bypass circuit DC braking 061 Series VFD MN040002EN March 2014 www eaton com Chapter 2 Engineering Considerations Electrical Power Network Input Connection and Configuration The DG1 Series frequency inverters can be connected and operated with all control point grounded AC power networks see IEC 60364 for more information Figure 5 AC Power Networks with Grounded Neutral Point TN TT Networks TN S TN C L1 L1 L2 L2 L3 L3 N PEN PE TN C S TT L1 L1 L2 L2 L3 L3 N N PE The frequency inverter can be applied to all types of power networks above If multiple frequency inverters with single phase supplies are to be connected a s
14. e 12 e 13 e 14 Elements of DG1 Frequency Inverters Maintenance Measures and Intervals Maximum Motor Cable Length by Frame Size without dV dT Protected C2 Ratings e 15 Assignment of Frequency Inverters to Example Motor Circuit e 16 Bypass Control e dies wl ace SO POR e 17 Space Requirements for Mounting the DG1 Series VFD and Airflow e 18 Mounting Drive Dimensions e 19 Tightening Torque 2 e 20 Spacing Between Parallel Motor Cables Table 21 Maximum Motor Cable Length by Frame Size without dV dT Protected C2 Ratings Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab vi e 22 e 23 e 24 e 25 Input Power and Motor Cable Stripping and Wire Lengths VO Connection estia ae oce Sra ao otis od Aot l O SpecitiCatlODs dieitur oct ee dle ee t t be pe 1st Environment 2nd Environment EMC Levels According to 61800 3 2004 e 26 Control Wiring Requirements sss sis ccs eemper er d 6 27 Gable
15. 150 1 110 _ CT Iu 150 Size Amp Suffix Pv W Pv W Pv W Pv W Pv Pv Pv W Pv W FR1 2D2 3D3 4D3 5 7 9 D6 D6 FR2 012 016 023 390 330 360 292 FR3 031 038 046 700 494 603 472 FRA 061 072 087 1083 870 1080 875 5 105 170 1906 1479 1755 1429 FR6 205 Brake Resistor Sizing Table 38 Brake Resistor Sizing Data 230V 460V 575V Brake Chopper Minimum Brake Chopper Minimum Brake Chopper Minimum Frame Nominal Current Resistance Nominal Current Resistance Nominal Current Resistance Size at 80 C A Ohm at 80 C A Ohm at 80 C A Ohm FR1 30 0 15 3 25 0 36 4 2 53 0 8 7 52 0 17 5 FR3 70 0 6 6 70 0 13 0 FR4 200 0 2 3 400 0 2 3 5 200 0 23 400 0 23 FR6 Note FR6 and 575V available in 2015 54 DG1 Series VFD MN040002EN March 2014 www eaton com Appendix C Dimension Drawings Approximate Dimensions in Inches mm Figure 31 FR1 Dimension Drawing Appendix C Dimension Drawings
16. er bp asd 28 29 e 30 061 xi ay stage North America Cable and Fuse Sizes 208 Vac to 240 Vac Ratings International Cable and Fuse Sizes 208 Vac to 240 Vac Ratings e 31 North America Cable and Fuse Sizes 440 to 500 Vac Ratings e 32 e 33 e 34 e 35 e 36 International Cable and Fuse Sizes 380 to 440 Vac Ratings 230V Temperature and Switching Frequency Deratings VT 230V Temperature and Switching Frequency Deratings CT 460V Temperature and Switching Frequency Deratings VT 460V Temperature and Switching Frequency Deratings CT e 37 Heat LOSS Data sux cde teo DAE ad RO ri e 38 e 39 e 40 e 41 e 42 e 43 e 44 Brake Resistor Sizing Data s seem aere x d esed Fuse Ratings 400V Drive Series Fuse Ratings 230V Drive Series Required Line and Motor Wire Torque 400 Required Line and Motor Wire Torque 230V Required Line and Motor Wire Torque 400V Required Line and Motor Wire Torque 230V PowerXL DG1 Series VFD 4 2 2014 www eaton com Awoeeoenntoouw w h A NNNNNN
17. kW Rating VT lj hp VT Ij A CT ly A VT I Catalog Number FR1 0 55 0 75 0 75 1 3 7 48 DG1 323D7FB C21C 0 75 1 1 1 1 5 4 8 6 6 DG1 324D8FB C21C 1 1 1 5 1 5 2 6 6 78 DG1 326D6FB C21C 1 5 22 2 3 78 1 DG1 327D8FB C21C 22 3 3 11 12 5 DG1 32011FB C21C FR2 3 3 7 5 12 5 17 5 DG1 32012FB C21C 3 7 5 5 5 75 17 5 25 DG1 32017FB C21C 5 5 7 5 7 5 10 25 31 DG1 32025FB C21C FR3 7 5 11 10 15 31 48 DG1 32031FB C21C 11 15 15 20 48 61 DG1 32048FB C21C FRA 15 18 5 20 25 61 75 DG1 32061FN C21C 18 5 22 25 30 75 88 DG1 32075FN C21C 22 30 30 40 88 114 DG1 32088FN 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 FRE 55 75 75 100 211 261 DG1 32211FN C21C 75 90 100 125 261 312 DG1 32261FN C21C Table 3 Type 12 IP54 230V 50 Hz 230V 50 Hz 230V 60 Hz 230V 60 Hz Current Current Frame Size kW Rating kW Rating VT lj hp VT I A Catalog Number FR1 0 55 0 75 0 75 1 3 7 48 DG1 323D7FB C54C 0 75 1 1 1 1 5 4 8 6 6 DG1 324D8FB C54C 1 1 1 5 1 5 2 6 6 7 8 DG1 326D6FB C54C 1 5 2 2 2 3 78 11 DG1 327D8FB C54C 2 2 3 3 11 12 5 DG1 32011FB C54C FR2 3 3 7 5 12 5 175 DG1 32012FB C54C 37 55 5 75 175 25 DG1 32017FB C54C 55 75 75 10 25 3 DG1 32025FB C54C FR3 7 5 11 10 15 31 48 DG1 32031FB C54C 11 15 15 20 48 6 DG1 32048FB C54C FRA 15 18 5 20 25 61 75 DG1 32061FN C54C 18 5 22 25 30 75 88 DG1 32075FN C54C 22 30 30 40 88 114 DG
18. r 128 0 23 94 4 80 100 0 0 0 28 7 0 122 0 8 E qs 0 47 12 0 3 e 12 28 312 0 7 89 200 4 3 94 100 0 NG 1 Jd 0 0 28 7 0 1 A LL Exe i 0 28 7 0 3 94 100 0 3 83 97 2 Y 3570 BET Minimum Dimensions Air gap around drive 7 03 Space between two drives 178 5 drive and cabinet 1 space above drive D Free space below drive 1 54 to For Class IP54 dimension A and B 0 i d 0 53 13 5 0 41 10 5 6 02 153 0 3 94 100 0 4 A B 0 79 20 0 1 IP21 IP54 Metric Type 1 12 UL 29 0 4 29 0 1 20 30 5 4 1 38 35 0 173 44 0 2 0 25 3 0 0 89 P 22 5 D 2 24 D 1 97 50 0 299 O E 0 3 0 22 5 1 95 0 i 100 3 44 0 44 0 1 28 32 5 1 28 32 5 061 Series VFD MNO040002EN March 2014 www eaton com 55 Appendix C Dimension Drawings Approximate Dimensions in Inches mm Figure 32 FR1 Dimension Drawing Flange Mount 0 85 21 5 Na d i A 200 4 9 0 78 19 9 11 50 292 0 1 10 28 0 1 1 0 53 13 5 o L 5 31 134 9 2 60 66 0 IP21 IP54 Metric 35 0 34 4 35
19. 29 30 34 35 42 42 42 44 46 47 48 49 50 51 52 53 54 54 65 66 66 67 67 68 Safety AN Warning Dangerous Electrical Voltage Before Commencing the Installation Disconnect the power supply of the device Ensure that devices cannot be accidentally restarted Verify isolation from the supply Earth and short circuit the device Cover or enclose any adjacent live components Only suitably qualified personnel in accordance with EN 50110 1 2 VDE 0105 Part 100 may work on this device system Before installation and before touching the device ensure that you are free of electrostatic charge The functional earth FE PES must be connected to the protective earth PE or the potential equalization The system installer is responsible for implementing this connection Connecting cables and signal lines should be installed so that inductive or capacitive interference does not impair the automation functions Install automation devices and related operating elements in such a way that they are well protected against unintentional operation Suitable safety hardware and software measures should be implemented for the I O interface so that an open circuit on the signal side does not result in undefined states in the automation devices Ensure a reliable electrical isolation of the extra low voltage of the 24V supply Only use power supply units complying with IEC 60364 4 41 VDE 0100 Part 410 HD384 4 41
20. The three phase motor with the rating plate based on Figure 13 can be run in a star or delta connection The operational characteristic curve is determined by the ratio of motor voltage and motor frequency in this case 87 Hz Characteristic Curve In the delta circuit with 400V and 87 Hz the motor shown in Figure 13 was released with three times fold output 71 3 kW Because of the higher thermal loading using only the next higher motor output according to the list 1 1 KW is recommended The motor in this example therefore still has 1 47 fold higher output compared with the listed output 0 75 kW With the 87 Hz characteristic curve the motor also works in the range from 50 Hz to 87 Hz with an un attenuated field The pull out torque remains at the same level as in input operation with 50 Hz The heat class of the motor must be at least F in 87 Hz operation Chapter 5 Motor and Application V Hz Characteristic Curve Figure 14 V Hz Characteristic Curve 50 87 Table 15 shows the allocation of possible frequency inverters depending on the input voltage and the type of circuit Table 15 Assignment of Frequency Inverters to Example Motor Circuit See Figure 14 Frequency Inverters DG1 323D7FB DG1 343D3FB DG1 344D3FB Rated operational current 3 7A 3 3A 4 3A Input voltage 3 AC 230V 3 AC 400V 3 AC 400V Motor circuit Delta Star Delta V Hz characteristic curv
21. CAUTION Before connecting the drive to AC mains make sure that the EMC protection class settings of the drive are appropriately made according to instructions in this manual e f the drive is to be used in a floating distribution network remove screws at MOV and EMC See Installation in Corner Grounded Network on Page 43 and Installation in IT System on Page 43 respectively Disconnect the internal filter when installing the drive on an system an ungrounded power system or a high resistance grounded over 30 ohm power system otherwise the system will be connected to ground potential through the EMC filter capacitors This may cause danger or damage the drive Disconnect the internal filter when installing the drive on a corner grounded TN system otherwise the drive will be damaged Note When the internal EMC filter is disconnected the drive might be not EMC compatible Do not attempt to install or remove the MOV or EMC screws while power is applied to the drive s input terminals Motor and Equipment Safety CAUTION Do not perform any meggar or voltage withstand tests on any part of the drive or its components Improper testing may result in damage CAUTION Prior 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 PowerXL DG1 Series
22. 2014 www eaton com 19 Chapter 5 Motor and Application Parallel Connection of Several Motors to One Frequency Inverter Figure 11 Parallel Connection int 1 2 M3 Connecting motors in parallel reduces the load resistance at the frequency inverter output The total stator inductance is lower and the leakage capacity of the lines greater As a result the current distortion is greater than in a single motor circuit To reduce the current distortion you should use motor reactors see in Figure 11 in the output of the frequency inverter The current consumption of all motors connected in parallel must not exceed the frequency inverter s rated output current 12 Electronic motor protection cannot be used when operating the frequency inverter with several parallel connected motors You must however protect each motor with thermistors and or overload relays The use of a motor protective circuit breaker at the frequency inverter s output can lead to nuisance tripping 20 061 Series VFD MNO40002EN March 2014 www eaton com 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 nameplate Figure 12 Example of a Motor Ratings Plate 230A 400 Y V S1 0 75kW 1430 rpm
23. 58 Figure 35 Dimension Drawing 59 Figure 36 Dimension Drawing Flange Mount 60 Figure 37 FR4 Dimension Drawing 61 Figure 38 FR4 Dimension Drawing Flange Mount 62 Figure 39 FR5 Dimension Drawing 63 Figure 40 FR5 Dimension Drawing Flange Mount 64 PowerXL DG1 Series VFD MN040002EN March 2014 www eaton com PowerXL DG1 Series VFD List of Tables Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab eT COMMON ADDreviatlOris lt 2 on edu GEN ADEL ET SR 6 2 iiu um aum ass cot debe ides ptc tates 65 T2 PbA sss RR REOR ea eae ADR RR AVE es Type MIP2 ote oa a se act Selah ds ga atti eed quede d d IDE ZAP OA Lc irs tocar rt EU DA RI eC AERA NER nas e 6 Frame T uuo haere tpe bur yea Pr dete n Een gd QI aapa 2 3 a qv RASSE 6 8 ETANG es ese osa eps eas dee eet a e P d 09 Framed oves ley qe Me RECUR ee ee quur NIA PUDE ORAT Rd e 10 s seb m sedem cec ode del aot dob deh deb odo utes e d e 11 Drive System Components
24. 11A 2 2 kW 3 hp 706 7 6A 3 kW 5 hp 013 1353 7 5 kW 10 hp 012 12 54 kW 5 hp VT 900 9A 4 kW 7 5 hp VT 018 18A 11 kW 15 hp 017 17 5A 3 7 kW 5 hp 012 12A 5 5 kW 7 5 hp 022 22A 15 kW 20 hp 025 25A 5 5 kW 7 5 hp 016 16A 7 5 kW 10 hp 027 27A 18 kW 25 hp 031 31A 7 5 kW 10 hp 023 23A 11 kW 15 hp 034 34A 22 kW 30 hp 048 48A 11 kW 15 hp 031 31A 15 kW 20 hp 041 41A 30 kW 40 hp 061 61A 15 kW 20 hp 038 38A 18 kW 25 hp 052 52A 37 kW 50 hp 075 75A 18 5 kW 25 hp 046 46A 22 kW 30 hp 062 62A 45 kW 60 hp 088 88A 22 kW 30 hp 061 61A 30 kW 40 hp 080 80A 55 kW 75 hp 114 114A 30 kW 40 hp 072 72A 37 kW 50 hp 100 100A 75 kW 100 hp 143 143A 37 kW 50 hp 087 87A 45 kW 60 hp 125 125A 90 kW 125 hp 170 170A 45 kW 60 hp 105 105A 55 kW 75 hp 144 144A 110 kW 150 hp 211 211A 55 kW 75 hp 140 140A 75 kW 100 hp 208 208A 160 kW 200 hp 261 261A 75 kW 100 hp 170 170A 90 kW 125 hp 205 205A 110 kW 150 hp 261 261A 132 kW 200 hp 061 Series VFD MN040002EN March 2014 www eaton com 3 Chapter 1 DG1 Series Overview Power Ratings and Product Selection DG1 Series Drives 208 240 Volt Table 2 Type 1 IP21 230V 50 Hz 230V 50 Hz 230V 60 Hz 230V 60 Hz Current Current Frame Size kW Rating
25. DXG SPR CTRLBOARD Control board cover DXG SPR BCOVER DXG SPR BCOVER DXG SPR BCOVER Type 1 IP21 standard cover DXG SPR FR5CVR DXG SPR FR5CVR Main fan kit DXG SPR FR5FAN DXG SPR FR5FAN Control fan DXG SPR FR5CF DXG SPR FR5CF Bus capacitor DXG SPR FR5BC DXG SPR FR5BC Main power board DXG SPR 2FR5MPB DXG SPR 4FR5MPB EMI 1 board DXG SPR 2FR5E1B DXG SPR 4FR5E1B 2 board DXG SPR 2FR5E2B DXG SPR 4FR5E2B EMI 3 board DXG SPR FR5E3B DXG SPR FR5E3B IGBT module DXG SPR FR5IGBT DXG SPR FR5IGBT Rectifier module DXG SPR 2FR5RM DXG SPR 4FR5RM Brake chopper module DXG SPR 2FR5BCM DXG SPR 4FR5BCM Middle chassis cover DXG SPR FRBMCC DXG SPR FR5MCC Outer housing DXG SPR FR50H DXG SPR FR50H UL conduit plate DXG SPR FR5CPUL DXG SPR FR5CPUL IEC conduit plate DXG SPR FRS5IECCP DXG SPR FRSIECCP Notes Factory recommended spare parts G 575V available in 2015 8 DG1 Series VFD 040002 2014 www eaton com Chapter 2 Engineering Considerations Introduction This chapter describes the most important features in the energy circuit of a drive system that you should take into consideration in your project planning Figure 4 Drive System PDS z Power Drive System L1 DUM E i E FPETUTHZTUS Ei s 6 7 FEL
26. Fieldbus Communication Modbus BACnet 2 R3NO Relay 3 Normally Open At Speed Relay output 3 shows VFD is at Ref Frequency 28 RING Relay 1 Normally Closed Run Relay output 1 shows VFD is in a run state 29 R1CM Relay 1 Common 30 RINO Relay 1 Normally Open 31 R3CM Relay 3 Common At Speed Relay output 3 shows VFD is at Ref Frequency 32 R2NC Relay 2 Normally Closed Fault Relay output 2 shows VFD is in a fault state 33 R2CM Relay 2 Common 34 R2NO Relay 2 Normally Open 34 DG1 Series VFD 040002 2014 www eaton com Chapter 6 Installation Requirements Figure 20 Terminal Block Layout de 14 15 16 19 20 21 22 23 24 25 26 DO1 3 GND 5 AO2 118 1 1 2 24Vo 10V 1 412 4 AO1 17 Al2 RING 28 8210 32 R1CM 29 R2CM 33 R1NO 30 R2NO 34 GND 6 24Vi DIN5 7 DIN6 8 DIN2 DIN7 9 DIN3 DIN8 10 CMB 11 CMA R3NO 27 R3CM 31 GND 12 A 24Vo 13 B NG Table 24 I O Specifications Specification Item Analog Input 1 Selectable for either Voltage or Current reference signal 0 to 10V 0 4 to 20 mA Rj 250 ohm differential Analog Input 2 Selectable for either Voltage or Current reference signal 0101 OV 10 to 10V 0 4 to 20 mA 250 ohm differential Digital inputs 8 Positi ve or negat
27. 208 Vac to 240 Vac Ratings Appendix B Installation Guidelines Terminal Cable Size 208V Input 208V Input Current Current Fuse Mains and Frame Amp Current Current Rating Motor Cable Main Terminal Earth Terminal Size Suffix VT IL at 50 C at 40 C gG gL 2 mm Cu mm FR1 3D7 32 44 3 7 48 6 3 1 541 5 0 2 6 solid or 0 75 6 0 2 4 stranded 408 44 6 1 4 8 6 6 10 3 1 541 5 0 2 6 solid or 0 75 6 0 2 4 stranded 606 6 1 72 6 6 78 16 3 1 541 5 0 2 6 solid or 0 75 6 0 2 4 stranded 708 72 10 2 7 8 11 16 3 1 541 5 0 2 6 solid or 0 75 6 0 2 4 stranded 011 10 2 11 6 11 12 5 16 3 1 541 5 0 2 6 solid or 0 75 6 0 2 4 stranded FR2 012 10 2 16 3 12 5 17 5 20 37144 0 5 16 4 16 017 16 2 23 2 17 5 25 32 34 4 0 5 16 4 16 025 23 1 29 25 31 32 3 646 0 5 16 4 16 FR3 031 28 7 442 31 48 50 3516 16 16 35 2 5 25 048 444 56 48 61 63 3 16 16 16 35 2 5 25 FR4 061 56 4 64 6 61 75 80 3 25416 16 50 6 50 075 69 4 78 75 88 100 3 35416 16 50 6 50 088 81 4 943 88 114 125 3 50425 16 50 6 50 FR5 114 105 5 129 114 143 160 3 70435 50 185 10 120 143 132 3 157 143 170 200 3 95450 50 185 10 120 170 157 3 189 170 211 250 3 150 95 50 185 10 120 FR6 211 195 2 211 261 8 261 241 4 261 212 Notes Line and motor cable size is selected according to IEC60364 5 52 2009 Table B 52 4 for copper conductor wi
28. DXG SPR FR2CPUL DXG SPR FR2CPUL IEC conduit plate DXG SPR FR2CPIEC DXG SPR FR2CPIEC Notes Factory recommended spare parts 575V available in 2015 6 DG1 Series VFD MN040002EN March 2014 www eaton com Table 8 Frame 3 Description Standard keypad Catalog Number 230V DXG KEY LCD Chapter 1 DG1 Series Overview Catalog Number 480V DXG KEY LCD Catalog Number 575V DXG KEY LCD Main control board DXG SPR CTRLBOARD DXG SPR CTRLBOARD DXG SPR CTRLBOARD Control board cover DXG SPR BCOVER DXG SPR BCOVER DXG SPR BCOVER Type 1 IP21 standard cover DXG SPR FR3CVR DXG SPR FR3CVR Main fan kit D DXG SPR FR3FAN DXG SPR FR3FAN Control fan DXG SPR FR34CF DXG SPR FR34CF Bus capacitor DXG SPR FR3BC DXG SPR FR3BC Main power board DXG SPR 2FR3MPB DXG SPR 4FR3MPB EMI board DXG SPR 2FR3EB DXG SPR 4FR3EB Drive board DXG SPR 2FR3DB DXG SPR 4FR3DB Output board DXG SPR FR30B DXG SPR FR30B o Middle chassis cover DXG SPR FR3MCC DXG SPR FR3MCC Outer housing DXG SPR FR30H DXG SPR FR30H UL conduit plate DXG SPR FR3CPUL DXG SPR FR3CPUL IEC conduit plate DXG SPR FR3CPIEC DXG SPR FR3CPIEC Notes Factory recommended spare parts G 575V available in 2015 Table 9 Frame 4 Description Standard keypad Catalog Number 230V D
29. FR5 100 0 100 0 100 0 100 0 94 8 89 6 844 77 8 71 2 646 580 FR6 50 C FR1 75 0 750 750 750 750 750 750 70 8 667 625 583 500 FR2 80 6 80 6 80 6 80 6 80 6 806 806 774 742 710 677 613 84 9 840 840 840 840 84 840 811 772 734 695 618 FR4 87 6 875 878 87 6 83 7 79 8 758 70 9 66 0 611 56 2 FR5 82 9 829 829 829 780 732 68 3 622 56 1 500 439 FR6 60 C FR1 583 583 583 583 583 583 583 542 500 458 41 7 333 FR2 67 7 677 677 677 677 677 677 645 613 581 548 484 FR3 71 330 713 71 3 71 3 71 3 713 713 675 638 600 56 2 487 FR4 724 724 724 724 68 8 652 61 7 572 527 483 438 FR5 68 3 68 3 683 683 640 59 8 555 502 448 395 341 FR6 Note available in 2015 52 DG1 Series VFD 040002 2014 www eaton com Appendix B Installation Guidelines Table 36 460V Temperature and Switching Frequency Deratings CT Constant Torque CT High Percentage of Rated Current Overload Switching Frequency H Frame Temperature Size 1kHz 2kHz 3kHz 36kHz 4kHz 5 6kHz 7kHz 8kHz 9kHz 10kHz 12kHz 40 1 00 0 100 0 100 0 100 0 100 0 100 0 100 0 961 921 882 822 76 3 2 00 0 100 0 100 0 100 0 100 0 100 0 1000 1000 100 0 1000 93 5 8
30. 1 No 2 Phillips FR5 No 3 Phillips FR1 FR3 10 in Ib 1 1 Nm PE SNG 14 in Ib 1 6 Nm Sy c FR 229 M6 35 in Ib 4 0 Nm 15 FR1 FR3 25 et FR4 FR5 CAUTION Before connecting the AC drive to mains make sure that the EMC protection class settings of the drive are appropriately made Note After having performed the change write EMC level modified on the sticker included in the DG1 delivery see Figure 26 and note the date Unless already done attach the sticker close to the name plate of the AC drive Product Modified Sticker Figure 26 Product Modified Sticker Product modified Chapter 6 Installation Requirements Checking the Cable and Motor Insulation 1 Check the motor cable insulation as follows e Disconnect the motor cable from terminals U V and W of the DG1 Series drive and from the motor Measure the insulation resistance of the motor cable between each phase conductor as well as between each phase conductor and the protective ground conductor e The insulation resistance must be 1M ohm Check the input power cable insulation as follows Disconnect the input power cable from terminals L1 N L2 N and L3 of the DG1 Series drive and from the utility line feeder Measure the insulation resistance of the input power cable between each phase conductor as well as between each phase conductor and the
31. 10 80 26 528 _ 6 5 134 0 1 i 2 42 61 5 1 8 86 3 83 225 0 97 2 n 1 lo o P 4 23 19 589 0 8 86 14 28 225 0 362 8 2 42 61 5 i 9 roy 5 28 0 31 134 0 8 0 8 66 220 0 Type 1 12 UL 2 77 70 3 _1 26 32 0 3 00 89 6 2 2 19 55 5 60 DG1 Series VFD MNO40002EN March 2014 www eaton com Minimum Dimensions A Air gap around drive 0 35 4 92 125 0 09 0 0 71 Ref 9180 o LU o 21 46 545 0 5 0 18 T N 4 5 4 92 0 35 125 0 09 0 Space between two drives drive and cabinet Free space above drive D Free space below drive For Class IP54 dimension A and 8 0 C 7 87 200 0 A B A B 1 97 1 97 50 0 r 50 0 D 3 15 80 0 Approximate Dimensions in Inches mm Figure 37 FR4 Dimension Drawing Appendix C Dimension Drawings
32. 143 0 5 28 134 0 00 28 a camo 7 900 0 1 A eq 2 El d 15 98 406 0 9 63 244 7 3 54 90 0 7 N 1 i aM E 872 Ed 354 ze 20 28 7 0 1 0 22 5 5 90 0 14 96 9 16 50 1 380 0 419 0 9 22 Minimum Dimensions A Air gap around drive B Space between two drives or 5 drive and cabinet 1 9 Free space above drive i 11 A D Free space below drive 0 55 14 0 0 45 11 4 MN 3 54 90 0 For Class IP54 dimension A and 0 6 61 167 8 C 6 30 160 0 IP21 IP54 Metric Type 1 12 UL 30 0 1 30 32 0 44 30 0 1 30 32 0 4 2 00 5 Boe lee A B 1 18 30 0 51 9 r 48 5 r 1 91 48 5 VG i OQ i gt 1 OO 1 11 990 3 9 28 3 28 3 UT 5 80 n 147 147 2 sean on 449 39 0 44 9 C 1 54 39 0 1 54
33. 17 Space Requirements for Mounting the 061 Series VFD and Airflow Cooling Air Frame AO C D Required Size Voltage hp kW Amperes In mm In mm In mm In mm CFM m3 h 480 Vac 1 5 0 75 3 7 22 16 20 20 100 50 38 5 5Vac 2 5 18 37 33 75 2 230 Vac 4 15 3 55 125 25 1 18 1 18 6 30 2 36 55 480 75 15 55 11 12 23 30 30 160 60 94 5 5Vac 75 15 55 11 10 18 FR3 230 Vac 10 15 75 M 31 48 197 197 787 3 15 126 480 Vac 20 30 15 22 31 46 50 50 200 80 214 575 20 20 15 22 22 34 FRA 230 Vac 20 30 15 22 61 88 315 3 15 11 81 3 94 153 480 Vac 40 60 30 45 61 87 80 80 300 100 260 575Vac 40 60 30 45 41 62 285 230 40 60 30 45 114 170 3 15 3 15 11 81 787 366 480 Vac 75 125 55 90 105 170 80 80 300 200 622 575 75 125 55 90 80 125 FR69 230 75 100 55 75 211 261 480 Vac 150 200 110 150 205 261 575 Vac 150 200 110 160 144 208 Notes Minimum clearances A and B for drives with Type 12 IP54 enclosure is 0 mm in G ratings at 400V 50 Hz The above guidelines apply unless testing has been completed to validate a design outside of these recommendations G FR6 and 575 Vac available in 2015 24 DG1 Series VFD MN040002EN March 2014 www eaton com Dimensions Approximate Dimensions in mm Figure 17 Type 1 12 Open Drives
34. 6 AWG FR3 DG1 34031xx xxxx Grounding terminal 10 10 4 AWG 061 34038 10 0 4 AWG DG1 34046xx xxxx 10 8 4 AWG FR4 DG1 34061xx xxxx Grounding terminal 14 8 1 0 AWG DG1 34072xx xxxx 14 6 1 0 AWG DG1 34087xx xxxx 14 6 1 0 AWG FR5 DG1 34105xx xxxx Grounding terminal 35 6 AWG 250 kcmil DG1 34140xx xxxx 35 6 AWG 250 kcmil DG1 34170xx xxxx 35 4 AWG 250 kcmil 061 Series VFD MN040002EN March 2014 www eaton com 67 Appendix D Safety Instructions for UL and cUL For 230V Drive Series required grounding wire torque type and size range are listed as below Table 44 Required Line and Motor Wire Torque 230V Required Required Catalog Torque Wire Number Terminal Type in Ib Range FR1 DG1 323D7xx xxxx Grounding terminal 10 4 10 AWG DG1 324D8xx xxxx 0 4 10 AWG DG1 326D6xx xxxx 0 4 10 AWG 061 32708 0 4 10 AWG 061 32011 0 4 10 AWG FR2 DG1 32012xx xxxx Grounding terminal 10 2 6 AWG DG1 32017xx xxxx 0 0 6 AWG DG1 32025xx xxxx 0 0 6 AWG FR3 DG1 32031xx xxxx Grounding terminal 10 0 4 AWG DG1 32048xx xxxx 0 0 4 AWG FR4 DG1 32061xx xxxx Grounding terminal 14 8 1 0 AWG DG1 32075xx xxxx 4 6 1 0 AWG DG1 32088xx xxxx 4 6 1 0 AWG FR5 DG1 32114xx xxxx Grounding terminal 35 6 AWG 250 kcmil DG1 32143xx xxxx 35 6 AWG 250 kcmil 061 32170 35 4 AWG 250 kcmil 68
35. 7 688 649 60 0 551 502 FR6 60 C FR1 68 0 68 0 68 0 68 0 68 0 680 680 65 9 63 7 61 6 584 552 FR2 74 2 742 742 742 742 742 742 710 677 645 597 548 FR3 82 0 820 820 820 820 820 820 803 787 770 738 705 FR4 74 6 74 6 748 74 6 72 1 69 7 67 3 64 9 623 598 570 FR5 64 0 64 0 640 64 0 60 9 578 547 517 47 9 442 405 FR6 Note FR6 available in 2015 50 061 Series VFD MNO40002EN March 2014 www eaton com Appendix B Installation Guidelines Table 34 230V Temperature and Switching Frequency Deratings CT Constant Torque CT High Percentage of Rated Current Overload Ig Frame Switching Freguency Temperature Size 1kHz 2kHz 3kHz 36kHz 4kHz 5 6kHz 7kHz 8kHz 9kHz 10kHz 12kHz FR2 00 0 100 0 100 0 100 0 100 0 100 0 100 0 100 0 100 0 100 0 100 0 100 0 FR3 00 0 100 0 100 0 100 0 100 0 100 0 100 0 100 0 100 0 100 0 100 0 100 0 FR4 00 0 100 0 100 0 100 0 100 0 100 0 100 0 100 0 96 2 923 885 FR5 00 0 100 0 100 0 100 0 100 0 100 0 100 0 100096 9619 922 882 FR6 50 C FR1 00 0 100 0 100 0 100 0 100 0 977 95 5 91 8 882 845 791 73 6 FR2 00 0 100 0 100 0 100 0 100 0 100 0 100 0 98 0 96 0 940 910 88 0 FR3 0
36. Branch Circuit Short Circuit Protection Integral solid state short circuit protection does not provide branch circuit protection Branch circuit protection must be provided in accordance with the National Electrical Code and any additional local codes 400V Drive Series are suitable for use on a circuit capable of delivering not more than 100 000 rms symmetrical amperes 500 volts maximum when protected by UL and cUL CSA Recognized Class T fuse with A I C rating of 100 kA minimum Refer to the following information for recommended fuse ratings See Table 39 Table 39 Fuse Ratings 400V Drive Series Catalog Frame Size Number Fuse Rating 1 DG1 342D2xx xxxx 600V 10A DG1 343D3xx xxxx 600V 10A DG1 344D3xx xxxx 600V 10A DG1 345D6xx xxxx 600V 10A DG1 347D6xx xxxx 600V 15A DG1 349D0xx xxxx 600V 15A 2 DG1 34012xx xxxx 600V 20A DG1 34016xx xxxx 600V 30A DG1 34023xx xxxx 600V 35A 3 DG1 34031xx xxxx 600V 50A DG1 34038xx xxxx 600V 60A DG1 34046xx xxxx 600V 80A 4 DG1 34061xx xxxx 600V 100A DG1 34072xx xxxx 600V 110A DG1 34087xx xxxx 600V 125A 5 DG1 34105xx xxxx 600V 175A DG1 34140xx xxxx 600V 200A DG1 34170xx xxxx 600V 250A 061 Series VFD 040002 2014 www eaton com 65 Appendix D Safety Instructions for UL and cUL 230V Drive Series are suitable for use on a circuit capable of delivering not more than 100 000 rms symmetrical ampe
37. Choose the cross section of the PE conductor in the motor lines at least as large as the cross section of the phase lines U V W Cables and Fuses The cross sections of the cables and line protection fuses used must correspond with local standards For an installation in accordance with UL guidelines Use UL recognized Class T fuses for the branch circuit protection e Use 75 C copper wire only Use UL listed conduit fittings with the same type rating Type 1 Type 12 as the enclosure See Appendix D Safety Instructions for UL and cUL for details 16 DG1 Series VFD MN040002EN March 2014 www eaton com Use power cables with insulation according to the specified input voltages for the permanent installation A shielded cable is not required on the input side A completely 360 shielded low impedance cable is required on the motor side The length of the motor cable depends on the RFI class and must not exceed approximately 300 ft 100m without additional filtering Residual Current Device RCD RCD Residual Current Device Residual current device residual current circuit breaker FI circuit breaker Residual current circuit breakers protect persons and animals from the existence not the origination of impermissibly high contact voltages They prevent dangerous and in some cases deadly injuries caused by electrical accidents and also Serve as fire prevention A CAUTION This drive can cause a DC cu
38. DG1 Series VFD 040002 2014 www eaton com E T N Powering Business Worldwide Eaton is dedicated to ensuring that reliable efficient and safe power is available when it s needed most With unparalleled knowledge of electrical power management across industries experts at Eaton deliver customized integrated solutions to solve our customers most critical challenges Our focus is on delivering the right solution for the application But decision makers demand more than just innovative products They turn to Eaton for an unwavering commitment to personal support that makes customer success a top priority For more information visit www eaton com electrical Eaton 1000 Eaton Boulevard Cleveland OH 44122 United States Eaton com 2014 Eaton All Rights Reserved Eaton is a registered trademark Printed in USA Publication No MNO40002EN 214910 All other trademarks are property March 2014 of their respective owners
39. Mains and Motor Main Terminal Earth Terminal Size Suffix CT Iu VT IL at 50 C at 40 C gG gL Cable Cu mm mm Cu mm FR1 2D2 2 0 3 1 2 2 3 3 6 3 1 5 1 5 0 2 6 solid or 0 75 6 3D3 31 4 33 43 6 3 1 5 1 5 403 4 0 52 43 5 6 10 3 1 5 1 5 0 75 6 506 5 2 74 5 6 7 6 16 3 1 5 1 5 0 75 6 706 74 84 7 6 9 16 3 1 5 1 5 0 75 6 900 8 4 11 2 9 12 16 3 1 5 1 5 0 75 6 FR2 012 11 2 15 12 16 20 3 444 0 5 16 4 16 016 14 9 21 5 16 23 25 3 444 0 5 16 4 16 023 214 29 23 31 32 3 6 0 5 16 4 16 FR3 031 28 8 352 31 38 40 3 16 16 16 35 2 5 25 038 35 3 42 6 38 46 50 3 16 16 16 35 2 5 25 046 42 8 55 7 46 61 63 3 16 16 16 35 2 5 25 FRA 061 56 7 65 7 61 72 80 3 25 16 16 50 6 50 072 66 9 79 4 72 87 100 3 35 16 16 50 6 50 087 80 9 97 87 105 125 3 50 25 16 50 6 50 FR5 105 97 6 129 105 140 160 3 70435 50 185 10 120 140 130 1 157 140 170 200 3 95 50 50 185 10 120 170 158 0 189 170 205 250 3 120 70 50 185 10 120 FR6 205 190 6 205 261 315 3 240 120 261 261 310 350 2 3 95 50 Notes Line and motor cable size is selected according to IEC60364 5 52 2009 Table B 52 4 for copper conductor with PVC insulation with a wiring condition of ambient temperature 30 C in air and an installation method of B2 cables in conduit and cable trunking systems For other wiring conditions please refer to the standard of IEC60364 5 52 2009 for suitable cable sizes is changed earthing conductor size should also be changed according
40. by the National Electric Code Failure to follow this precaution may result in death or severe injury A WARNING This drive can cause a DC current in the protective earthing conductor Where a residual current operated protective RCD or monitoring RCM device is used for protection in case of direct or indirect contact only an RCD or RCM of Type B is allowed on the supply side of this product A WARNING Carry out wiring work only after the drive has been correctly mounted and secured PowerXL DG1 Series VFD A WARNING Before opening the drive covers Disconnect all power to the drive including external control power that may be present Wait a minimum of five minutes after all the lights on the keypad are off This allows time for the DC bus capacitors to discharge A hazard voltage may still remain in the DC bus capacitors even if the power has been turned off Confirm that the capacitors have fully discharged by measuring their voltage using a multimeter set to measure the DC voltage Failure to follow these precautions may cause death or severe injury A WARNING The opening of the branch circuit protective device may be an indication that a fault current has been interrupted To reduce the risk of fire or electric shock current carrying parts and other components of the controller should be examined and replaced if damaged If burnout of the current element of an overload relay occurs the
41. in Inches mm Motor Wiring in Inches mm Size B1 C1 D1 A2 B2 C2 D2 FR1 0 39 1 77 0 39 1 38 0 39 1 77 0 39 1 38 10 45 10 35 10 45 10 35 FR2 0 59 1 77 0 59 1 77 0 59 1 57 0 59 1 57 15 45 15 45 15 40 15 40 FR3 0 59 1 57 0 59 1 97 0 59 1 57 0 59 1 97 15 40 15 50 15 40 15 50 FRA 0 98 2 56 0 98 4 72 0 98 2 56 0 98 4 72 25 65 25 120 25 65 25 120 FR5 1 10 6 10 1 10 9 45 1 10 6 10 1 10 9 45 28 155 28 240 28 155 28 240 FRG Note FR6 available in 2015 Cable Routing Wiring the VFD If conduit is being used for wiring use separate conduits for Refer to the table on Page 30 for maximum cable lengths by line voltage mains motor cables and all interface control frame size wiring If three or more motor cables are used each conductor must To meet the UL requirements if conduit is being used for have its own overcurrent protection wiring the enclosure openings provided for conduit connections in the field shall be closed by UL listed conduit fittings with the same type rating Type 1 Type 12 as the enclosure Avoid running motor cables 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 Page 30 30 061 Series VFD MNO40002EN March 2014 www eaton com Power Wiring Notice Do not disca
42. on fusing requirements Chapter 6 Installation Requirements Connection Tightening Torque Table 19 Tightening Torque 9 Frame Power Wire Ground Wire Control Wire 9 Size In Lb Nm In Lb Nm In Lb Nm 1 230V 12 1 1 4 10 1 1 4 5 0 5 480V 575V 5 5 0 6 FR2 15 6 1 8 10 1 1 4 5 0 5 FR3 40 4 5 10 1 1 4 5 0 5 FRA 95 10 7 14 1 6 4 5 0 5 FR5 354 40 35 4 0 4 5 0 5 FR6 Available in 2015 Notes Strip the motor and power cables as shown in Figure 18 on next page 2 Both UL and IEC tools may be used G Applies to strained wire solid wire or ferrule installations Table 20 Spacing Between Parallel Motor Cables Cable Length Less than 164 ft 50m Less than 657 ft 200m Distance Between Cables 1 ft 0 3 m 3 ft 1 0 Table 21 Maximum Motor Cable Length by Frame Size without dV dT Protected C2 Ratings Frame Size Maximum Cable Length m FR1 100 FR2 150 FR3 150 FRA 200 FR5 200 Notes C1 protection requires external filtering Consult factory C3 protection is covered under C2 protection levels 061 Series VFD 040002 2014 www eaton com 29 Chapter 6 Installation Requirements Figure 18 Input Power and Motor Cable Stripping Lengths Ground Ground Power Motor Table 22 Input Power and Motor Cable Stripping and Wire Lengths Power Wiring
43. protective ground conductor e The insulation resistance must be 1M ohm Check the motor insulation as follows Disconnect the motor cable from the motor and open any bridging connections in the motor connection box Measure the insulation resistance of each motor winding The measurement voltage must equal at least the motor nominal voltage but not exceed 1000V e The insulation resistance must be 1M ohm 061 Series VFD 040002 2014 www eaton com 39 Chapter 7 EMC Installation Chapter 7 EMC Installation The responsibility to meet the local system EMC limit values and electromagnetic compatibility requirements is the responsibility of the end user or the system operator This operator must also take measures to minimize or remove emissions in the environment concerned see figure on Page 41 He must also use means to increase the interference immunity of the system devices In a drive system PDS with frequency inverters you should take measures for electromagnetic compatibility EMC while doing your planning because changes or improvements to the installation site which are required in the installation or while mounting are normally associated with additional higher costs The technology and system of a frequency inverter cause the flow of high frequency leakage current during operation All grounding measures must therefore be implemented with low impedance connections over a large surface a
44. signals for example motor cables and sensitive cables analog signal and measurement values are shielded apart from one another with EMC compatible connections The effectiveness of the cable shield depends on a good shield connection and a low shield impedance Use only shields with tinned or nickel plated copper braiding Braided steel shields are unsuitable Control and signal lines analog digital should always be grounded on one end in the immediate vicinity of the supply voltage source PES Chapter 7 EMC Installation Installation Requirements Figure 27 EMC Compliant Setup 460 480 Vac a 24Vdc 24Vdc 1181 in 115 120 Vac 115 120 Vac 230 240 230 240 2300 mm 400 Vac 400 Vac 460 480 Vac 460 480 Vac Notes Power cable L1 L2 L3 and U V W Control and signal 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 shielding in the output of the frequency inverter with a large surface area contact to the ground potential PES Large area cable shield contacts with motor Large area earth connection of all metallic parts 061 Series VFD MN040002EN March 2014 www eaton com 41 Chapter 7 EMC Installation International EMC Protection Cable Requirements
45. 0 440 6 0 22 5 56 4 80 122 0 EZ TA 2 84 72 2 0 26 65 9 0 26 6 5 i i i 1 40 i 35 5 3 83 97 2 10 63 1 13 94 270 0 980411 354 0 10 63 270 0 1 1 40 35 5 6 31 m Type 1 12 UL 1 20 30 5 1 40 35 0 1 70 44 0 2 89 A 7 200 2 20 D 57 0 97 0000000000000 Moda 44 0 1 30 32 5 1 30 32 5 DG1 Series VFD MN040002EN March 2014 www eaton com 3 94 0 28 7 0 71100 0 0 47 12 0 O i 12 64 321 0 LA fx 1 0 28 7 0 Minimum Dimensions A Air gap around drive B Space between two drives or drive and cabinet Free space above drive D Free space below drive For Class IP54 dimension A and 8 0 _ C 3 94 100 0 L D 1 97 50 0 L AJB 0 79 20 0 Appendix C Dimension Drawings Approximate Dimensions in Inches mm Figure 33 FR2 Dimension Drawing 5 63
46. 0 0 100 0 100 0 100 0 100 090 100 0 100 0 100 0 100 0 100 0 100 0 100 0 FR4 00 0 100 0 100 0 100 0 971 543 014 88 5 847 808 770 5 00 0 100 0 100 0 100 0 951 903 85 4 80 6 745 684 624 FR6 m 60 C FR1 83 6 83 6 83 6 83 6 83 6 800 787 755 727 700 659 61 896 FR2 92 0 92 0 920 920 92 0 92 0 92 0 130 090 168 0 80 090 101 3 68 0 FR3 91 7 917 91 7 91 7 91 7 90 6 896 885 875 861 847 83 3 FR4 83 9 83 9 83 9 83 9 807 775 744 71 3 674 63 6 598 5 79 4 79 4 794 794 756 718 679 641 595 540 503 FR6 Note available in 2015 061 Series VFD MN040002EN March 2014 www eaton com 51 Appendix B Installation Guidelines Table 35 460V Temperature and Switching Frequency Deratings VT Variable Torque VT Low Percentage of Rated Current Overload 1 Switching Frequency Temperature Size 1kHz 2kHz 3kHz 36kHz 4kHz 5kHz 6kHz 7kHz 8kHz 9kHz 10 2 12kHz 40 1 100 0 100 0 100 0 100 0 100 0 100 0 100 0 938 875 81 3 750 625 FR2 100 0 100 0 100 0 100 0 100 0 100 0 100 0 95 2 90 3 855 8060 710 FR3 100 0 100 0 100 0 100 0 100 0 100 0 100 0 95 5 910 865 820 730 FR4 100 0 100 0 100 0 100 0 95 7 914 871 81 8 764 711 657
47. 0 4 14 24 10 18 10 6D6 6 1 72 6 8 75 6 6 7 8 10 4 14 24 10 18 10 7D8 72 10 2 9 6 10 6 78 11 15 4 4 24 10 18 10 011 10 2 11 6 11 12 5 15 12 14 24 10 18 10 FR2 012 10 2 16 3 152 16 7 12 5 17 5 20 10 12 20 6 12 6 017 16 2 232 22 242 17 5 25 30 8 10 20 6 12 6 025 23 1 29 28 30 8 25 31 35 8 10 20 6 12 6 FR3 031 28 7 44 2 42 46 2 31 48 60 6 10 6 2 14 4 048 44 4 56 54 594 48 61 80 4 8 6 2 14 4 FR4 061 56 4 64 6 68 74 8 61 75 100 3 8 6 1 0 10 1 0 075 69 4 78 80 88 75 88 110 2 6 6 1 0 10 1 0 088 81 4 94 3 104 114 88 114 125 1 0 6 6 1 0 10 1 0 FR5 114 105 5 129 130 143 114 143 175 3 0 6 1 0 350 8 250 kcmi kcmil 143 132 3 157 154 169 143 170 200 4 0 6 1 0 350 8 250 kcmi kemil 170 157 3 189 192 211 170 211 250 300 4 1 0 350 8 250 kcmi kemil FR6 211 195 2 248 261 211 261 3 261 241 4 312 312 261 312 3 Notes Line and motor cable size is selected according to UL508C Table 40 3 for copper conductor rated 75 C Use only with copper wire rated 75 C here Size requirements for other different wire types are defined in the National Electrical Code ANSI NFPA 70 Earthing conductor size is determined by the maximum overcurrent device rating used ahead of the drive according to UL508C Table 6 4 G f power cubes or bypass are used a UL recognized Class T fuse is recommended 4 Available in 2015 46 DG1 Series VFD 040002 2014 www eaton com Table 30 International Cable and Fuse Sizes
48. 1 32088FN C54C FR5 30 37 40 50 114 143 DG1 32114FN C54C 37 45 50 60 143 170 DG1 32143FN C54C 45 55 60 75 170 211 DG1 32170FN C54C FRE 55 75 75 100 211 261 DG1 32211FN C54C 75 90 100 125 261 312 DG1 32261FN C54C Note FR6 available in 2015 DG1 Series VFD 040002 2014 www eaton com DG1 Series Drives 380 500 Volt Table 4 Type 1 IP21 Chapter 1 DG1 Series Overview 400V 50 Hz 400V 50 Hz 460V 60 Hz 460V 60 Hz Current Current Frame Size kW Rating kW Rating VT lj hp VT Ij Catalog Number 0 75 11 1 1 5 22 33 DG1 342D2FB C21C 1 1 1 5 1 5 2 3 3 4 3 DG1 343D3FB C21C 1 5 2 2 2 3 4 3 5 6 DG1 344D3FB C21C 22 3 3 5 5 5 7 6 DG1 345D6FB C21C 3 4 5 7 6 9 DG1 347D6FB C21C 4 5 5 7 5 9 12 DG1 349D0FB C21C FR2 5 5 75 75 10 12 16 DG1 34012FB C21C 7 5 11 10 15 16 23 DG1 34016FB C21C 11 15 15 20 23 31 DG1 34023FB C21C FR3 15 18 5 20 25 31 38 DG1 34031FB C21C 18 5 22 25 30 38 46 DG1 34038FB C21C 22 30 30 40 46 61 DG1 34046FB C21C FRA 30 37 40 50 61 72 DG1 34061FN C21C 37 45 50 60 72 87 DG1 34072FN C21C 45 55 60 75 87 105 DG1 34087FN C21C FR5 55 75 75 100 105 140 DG1 34105FN C21C 75 90 100 125 140 170 DG1 34140FN C21C 90 110 125 150 170 205 DG1 34170FN C21C FRE 110 132 150 200 205 261 DG1 34205FN C21C 132 160 200 250 261 310 DG1 34
49. 1 IP21 standard cover DXG SPR FRICVR DXG SPR FRICVR Main fan kit DXG SPR FR1FAN DXG SPR FR1FAN Control fan DXG SPR 2FR1CF DXG SPR 4FR1CF Main power board DXG SPR 2FR1MPB DXG SPR 4FRTMPB EMI board DXG SPR 2FR1EB DXG SPR 4FR1EB Middle chassis cover DXG SPR FRiIMCC DXG SPR FRIMCC Outer housing DXG SPR FR10H DXG SPR FR10H UL conduit plate DXG SPR FR1CPUL DXG SPR FR1CPUL IEC conduit plate DXG SPR FR1CPIEC DXG SPR FR1CPIEC Notes Factory recommended spare parts 575V available 2015 Table 7 Frame 2 Description Standard keypad Catalog Number 230V DXG KEY LCD Catalog Number 480V DXG KEY LCD Catalog Number 575V DXG KEY LCD Main control board DXG SPR CTRLBOARD DXG SPR CTRLBOARD DXG SPR CTRLBOARD Control board cover DXG SPR BCOVER DXG SPR BCOVER DXG SPR BCOVER Type 1 IP21 standard cover DXG SPR FR2CVR DXG SPR FR2CVR Main fan kit DXG SPR FR2FAN DXG SPR FR2FAN Control fan DXG SPR FR2CF DXG SPR FR2CF Bus capacitor DXG SPR 2FR2BC DXG SPR 4FR24BC Main power board DXG SPR 2FR2MPB DXG SPR 4FR2MPB EMI board DXG SPR 2FR2EB DXG SPR 4FR2EB IGBT module DXG SPR FR2IGBT DXG SPR FR2IGBT Middle chassis cover DXG SPR FR2MCC DXG SPR FR2MCC Outer housing DXG SPR FR20H DXG SPR FR20H UL conduit plate
50. 10 10 20 6 12 6 023 214 29 27 21 27 35 8 10 20 6 12 6 FR3 031 28 8 352 34 27 34 50 8 10 6 2 14 4 038 35 3 42 6 40 34 40 60 6 10 6 2 14 4 046 42 8 55 7 52 40 52 80 4 8 6 2 14 4 FR4 061 56 7 65 7 65 52 65 100 4 8 6 1 0 10 1 0 072 66 9 79 4 77 65 7 110 3 6 6 1 0 10 1 0 087 80 9 97 9 77 9 125 1 6 6 1 0 10 1 0 FR5 105 97 6 129 124 96 124 175 3 0 6 1 0 350 kemil 8 250 kcmil 140 130 1 157 156 124 156 200 3 0 6 1 0 350 kemil 8 250 kcmil 170 158 0 189 180 156 180 250 250 kemil 4 1 0 350 kemil 8 250 kcmil FR6 205 190 6 240 180 240 350 3 e e 261 302 240 302 400 3 Notes Line and motor cable size is selected according to UL508C Table 40 3 for copper conductor rated 75 C Use only with copper wire rated 75 C here Size requirements for other different wire types are defined in the National Electrical Code ANSI NFPA 70 G Earthing conductor size is determined by the maximum overcurrent device rating used ahead of the drive according to UL508C Table 6 4 G f power cubes or bypass are used a UL recognized Class T fuse is recommended 9 Available in 2015 48 DG1 Series VFD 040002 2014 www eaton com Table 32 International Cable and Fuse Sizes 380 Vac to 440 Vac Ratings Appendix B Installation Guidelines Terminal Cable Size 400V Input 400V Input Current Current Fuse Frame Amp Current Current Rating
51. 2014 www eaton com 15 Chapter 4 Safety and Switching Chapter 4 Safety and Switching Fuses and Cable Cross Sections The fuses and wire cross sections allocated for power side connections depend on the rated input current and output current of the frequency inverter without AC choke A CAUTION When selecting the cable cross section take the voltage drop under load conditions into account The consideration of other standards for example VDE 0113 or VDE 0289 is the responsibility of the user The national and regional standards for example VDE 0113 EN 60204 must be observed and the necessary approvals for example UL at the site of installation must be fulfilled When the device is operated in a UL approved system use only UL approved fuses fuse bases and cables See Appendix D Safety Instructions for UL and cUL for details CAUTION The specified minimum PE conductor cross sections in this manual must be maintained The minimum size of the protective earthing conductor must comply with the requirements of EN 61800 5 1 and or the local safety regulations Touch currents in this frequency inverter are greater than 3 5 mA AC According to product standard IEC EN 61800 5 1 an additional equipment grounding conductor of the same cross sectional area as the original protective earthing conductor must be connected or the cross section of the equipment grounding conductor must be at least 10 mm Cu
52. 261FN C21C Table 5 Type 12 IP54 400V 50 Hz 400V 50 Hz 460V 60 Hz 460V 60 Hz Current Current Frame Size kW Rating CT Ily kW Rating VT lj hp VT I Catalog Number 0 75 11 1 1 5 22 3 3 DG1 342D2FB C54C 1 1 15 1 5 2 3 3 4 3 DG1 343D3FB C54C 15 2 2 2 3 4 3 5 6 DG1 344D3FB C54C 2 2 3 3 5 5 6 76 DG1 345D6FB C54C 3 4 5 7 6 9 DG1 347D6FB C54C 4 5 5 7 5 9 12 DG1 349D0FB C54C FR2 5 5 75 75 10 12 16 DG1 34012FB C54C 75 11 10 15 16 23 DG1 34016FB C54C 11 15 15 20 23 31 DG1 34023FB C54C FR3 15 18 5 20 25 31 38 DG1 34031FB C54C 18 5 22 25 30 38 46 DG1 34038FB C54C 22 30 30 40 46 61 DG1 34046FB C54C FRA 30 37 40 50 61 72 DG1 34061FN C54C 37 45 50 60 72 87 DG1 34072FN C54C 45 55 60 75 87 105 DG1 34087FN C54C FR5 55 75 75 100 105 140 DG1 34105FN C54C 75 90 100 125 140 170 DG1 34140FN C54C 90 110 125 150 170 205 DG1 34170FN C54C FRE 110 132 150 200 205 261 DG1 34205FN C54C 132 160 200 250 261 310 DG1 34261FN C54C Note FR6 available in 2015 061 Series VFD 040002 2014 www eaton com Chapter 1 DG1 Series Overview Replacement Parts Table 6 Frame 1 Description Standard keypad Catalog Number 230V DXG KEY LCD Catalog Number 480V DXG KEY LCD Catalog Number 575V DXG KEY LCD Main control board DXG SPR CTRLBOARD DXG SPR CTRLBOARD DXG SPR CTRLBOARD Control board cover DXG SPR BCOVER DXG SPR BCOVER DXG SPR BCOVER Type
53. 39 0 39 0 061 Series VFD 040002 2014 www eaton com 57 Appendix C Dimension Drawings Approximate Dimensions in Inches mm Figure 34 FR2 Dimension Drawing Flange Mount 134 0 MSZ 7 64 194 0 DUE 107 472 120 0 17 6 57 167 0 9 271 10 00 26 0 98 25 0 1 38 35 0 06 5 E i i q e 180 0 97 2 14 96 17 74 380 0 i 450 5 7 09 9 93 180 0 252 2 1 28 n 4 NN 1 38 1 35 0 1 9 9 1 0 55 14 0 472 E 4 54 5 10 0 41 10 3 120 0 115 2 4 129 5 Type 1 12 UL 1 26 32 0 1 26 32 0 204 51 9 1 91 48 5 01 11 2004 028 3 5 79 4472 1 77 449 1 1 1 1 54 39 0 1 54 39 0 58 061 Series VFD 040002 2014 www eaton com 3 54 00 28 6800 70 0 51 i 0 Me
54. 7 0 FR3 00 0 100 0 100 0 100 0 100 0 100 0 100 0 100 0 100 0 95 7 891 82 6 FR4 00 0 100 0 100 0 100 0 100 0 100 0 100 0 948 897 845 79 3 FR5 00 0 100 0 100 0 100 0 541 882 824 75 0 67 6 60 3 52 9 FR6 50 C FR1 00 0 100 0 100 0 100 0 100 0 95 7 914 871 829 78 6 722 65 8 FR2 00 0 100 0 100 0 100 0 100 0 95 7 91 3 87 0 82 6 78 3 71 7 65 2 FR3 00 0 100 0 100 0 100 0 100 0 948 89 1 8379 78 3 72 8 647 56 5 FR4 00 0 100 0 100 0 100 0 960 920 87 9 82 9 77 9 728 678 FR5 00 0 100 0 100 0 100 0 94 1 882 824 750 67 6 603 52 9 FR6 60 C FR1 92 1 92 1 92 190 92 190 921 872 822 77 3 72 3 67 4 60 0 52 6 FR2 78 3 783 783 783 78 3 73 9 696 652 60 9 565 500 435 FR3 80 4 80 4 80 4 804 804 761 717 674 63 0 587 522 457 FR4 87 4 874 874 874 83 000 787 744 690 63 6 583 529 FR5 824 82 4 82 4 82 4 77 2 721 66 9 605 540 47 6 412 FR6 Note available in 2015 061 Series VFD MN040002EN March 2014 www eaton com 53 Appendix B Installation Guidelines Heat Loss Data Table 37 Heat Loss Data 230V 60 Hz 400V 50 Hz 460V 60 Hz 575V 60 Hz Frame 110 150 VT iL 110 150 110
55. Chapter 3 Product Overview Figure 7 Block Diagram Elements of DG1 Frequency Inverters R R DC gt 12 YYY e e e e 2 2 A Jh 7 BR 1 1 e TRES POLES 8 o M L24 de HEN NI 3 lE EN 4 PE PE 1 m t A EN AN doe diete T oe YY Y oe e e EMC Table 12 Elements of DG1 Frequency Inverters Item No 1 Description Supply L1 L2 L3 PE input supply voltage Ue at 50 60 Hz 061 32 230V class three phase input connection 3 AC 230V 240V 061 34 400V class three phase input connection 3 AC 400V 480V EMC connection of internal nternal interference suppression filter category C2 to IEC EN 61800 3 interference suppression filter to PE Rectifier bridge converts the AC voltage of the electrical network into DC voltage DC link with charging resistor capacitor and switching mode power supply unit SMPS Switching Mode Power Supply DC link voltage with three phase input connection 3 AC 1 41 x Uin Inverter The IGBT based inverter converts the DC voltage of the DC link Unc into a three phase AC voltage U2 with variable amplitude and frequency f2 Sinusoidal pulse width modulation PWM with V f control can be switche
56. Dimension Drawings 25 0 35 125 0 iil 0 71 5 018 0 21 46 545 0 EET 1 4 92 0 18 4 5 09 0 Minimum Dimensions A Air gap around drive B Space between two drives or drive and cabinet C Free space above drive D Free space below drive For Class IP54 dimension A and 0 4 92 C 7 87 125 0 200 0 _ 8 06 204 6 Type 1 12 UL 2 77 70 3 1 97 1 97 1 26 32 0 90 0 eee 1 26 32 0 43 3 00 89 X1 922 5 ono M DOQ 1283 _ D 3 15 80 0 1 92 48 8 1 2 03 51 5 www eaton com 59 Appendix C Dimension Drawings Approximate Dimensions in Inches mm Figure 36 FR3 Dimension Drawing Flange Mount 0 96 1 09 24 5 210 44 265 1 n 2 gt 20 41 518 5 E d 1 24 r 31 6 e 4 15 6 28 0 59 15 0 105 5 159 6 1 26 32 0 54 022 5 3 00 14 22 20 1 e 935 0 OO 49 0 OA 2 i 7 24 184 0 Pe 9 51 241 6 8 66 220 0 7
57. Dimensions A Air gap around drive P 00 35 09 0 Space between two drives drive and cabinet Free space above drive D Free space below drive For Class IP54 dimension A and 0 A B 3 15 80 0 D 7 87 200 0 A B 3 15 80 0 061 Series VFD MN040002EN March 2014 www eaton com 63 Appendix C Dimension Drawings Approximate Dimensions in Inches mm Figure 40 Dimension Drawing Flange Mount 11 34 288 0 e 13 41 340 7 0 77 1 08 27 5 00 79 220 0 T 13 46 342 0 12 68 gt S 11 0 8 66 220 0 go 5 09 0 ad 2 58 obi 65 5 n 2 aso 8 66 220 0 BAN 383 001 97 2 30 51 lo 7750 NANG 112 8 66 948 0 220 0 37 32 948 0 1 ro ccc CM Sea 8 66 24 09 SSS 220 0 611 8 a o lo o 1 38 35 0 ie 88 5 7 01 178 0 520 8 22 132 0 208 7 1 1 64 IP21 IP54 Met
58. Electrical components in a system machine have an interaction effect on each other Each device not only emits Low Volt id interference but is also affected by it The interference can Voltage Supply Gri be produced by galvanic capacitive and or inductive sources or by electromagnetic radiation In practice the limit between line conducted interference and radiated emitted interference is around 30 MHz Above 30 MHz cables and conductors act like antennas that radiate electromagnetic waves 1st Environment Electromagnetic compatibility EMC for frequency controlled drives variable frequency drives is implemented in accordance with product standard IEC EN 61800 3 This includes the complete power drive system PDS from the input supply to the motor including all components as well AY as cables This type of drive system can consist of several pu individual drives The generic standards of the individual components in a PDS compliant with IEC EN 61800 3 do not apply These Category C1 Category C1 C2 component manufacturers however must offer solutions that ensure standards compliant use In Europe maintaining the EMC guidelines is mandatory Low Voltage Supply Grid A declaration of conformity CE always refers to a typical power drive system PDS The responsibility to comply with the legally stipulated limit values and thus the provision of electromagnetic compatibility is u
59. Only use cables protective switches and contactors that feature the indicated permissible nominal current value CAUTION Debounced inputs may not be used in the safety circuit diagram According to product standard IEC EN 61800 5 1 an additional equipment grounding PE conductor of the same cross sectional area as the original protective earthing conductor must be connected or the cross section of the equipment grounding conductor must be at least 10 mm Cu A WARNING The components in the drive s power section remain energized after the supply voltage has been switched off After disconnecting the supply wait at least five minutes before removing the cover to allow the intermediate circuit capacitors to discharge Pay attention to hazard warnings Chapter 6 Installation Requirements Standard Mounting Instructions e Select the mounting location based on requirements listed in this chapter e Mounting surface must be a vertical flat non flammable surface e 061 Series open drives may be mounted side by side or stacked vertically as outlined in this chapter e Surface must be strong enough to support the drive and not subject to excessive motion or vibration Mark the location of the mounting holes on the mounting surface using the template provided on the cover of the cardboard shipping package e Using fasteners appropriate to your VFD and mounting surface securely attach the VFD to the mounting sur
60. PowerXL DG1 Series VFD Installation Manual Effective March 2014 New Information L au o Jm E T N i is PowerXL DG1 f AAN DANGER 5 MIN ETN Powering Business Worldwide PowerXL DG1 Series VFD Disclaimer of Warranties and Limitation of Liability The information recommendations descriptions and safety notations in this document are based on Eaton s experience and judgment and may not cover all contingencies If further information is required an Eaton sales office should be consulted Sale of the product shown in this literature is subject to the terms and conditions outlined in appropriate Eaton selling policies or other contractual agreement between Eaton and the purchaser THERE ARE NO UNDERSTANDINGS AGREEMENTS WARRANTIES EXPRESSED OR IMPLIED INCLUDING WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE OR MERCHANTABILITY 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 BECOM PART OF OR MODIFY ANY CONTRACT BETWEEN THE PARTIES In no event will Eaton be responsible to the purchaser or user in contract in tort including negligence strict liability or otherwise for any special indirect incidental or consequential damage or loss whatsoever including but not limited to damage or loss of use of equipment plant or power system cost of capital loss of power ad
61. S2 Deviations of the input voltage from the rated value must not exceed the tolerance limits given in the specifications otherwise this may cause malfunction and dangerous operation Emergency stop devices complying with IEC EN 60204 1 must be effective in all operating modes of the automation devices Unlatching the emergency stop devices must not cause a restart Devices that are designed for mounting in housings or control cabinets must only be operated and controlled after they have been installed and with the housing closed Desktop or portable units must only be operated and controlled in enclosed housings PowerXL DG1 Series VFD Measures should be taken to ensure the proper restart of programs interrupted after a voltage dip or failure This should not cause dangerous operating states even for a short time necessary emergency stop devices should be implemented Wherever faults in the automation system may cause injury or material damage external measures must be implemented to ensure a safe operating state in the event of a fault or malfunction for example by means of separate limit switches mechanical interlocks and so on Depending on their degree of protection adjustable frequency drives may contain live bright metal parts moving or rotating components or hot surfaces during and immediately after operation Removal of the required covers improper installation or incorrect operation of motor or adjustable frequ
62. The screened cables between the variable frequency drive and the motor should be as short as possible Connect the screening on both sides and across a large area 360 overlap to the protective earth PE The power screening protective earth PES connection should be in the immediate proximity of the variable frequency drive and directly on the motor terminal box Prevent the screening from becoming unbraided e g by pushing the opened plastic sheath over the end of the screening or with a rubber grommet on the end of the screening As an alternative in addition to a broad area cable clip you can also twist the shielding braid at the end and connect to protective ground with a cable clip To prevent EMC disturbance this twisted shielding connection should be made as short as possible Screened three or fourwire cable is recommended for the motor cables The green yellow line of a fourwire cable connects the protective ground connections from the motor and the variable frequency drive and therefore minimizes the equalizing current loads on the shielding braid f there are additional subassemblies in a motor feeder such as motor contactors overload relays motor reactor sinusoidal 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 connection cables should not be any lo
63. VFD 040002 2014 www eaton com Chapter 6 Installation Requirements FR3 Mounting Instructions FR4 Mounting Instructions Step 1 Lift the drive out of the carton Remove the Step 1 Lift the drive out of the carton with the cardboard packaging Remove the packaging Step 2 Attach the drive to the mounting plate with four M6x15 or 1 4 inch screws and four M6 or 1 4 inch nuts The opening dimensions on the mounting plate should follow required dimensions refer to the drive mounting template printed on the outside carton Step 2 Attach the drive to the mounting plate with four 8 15 or 3 8 inch screws and four 8 or 3 8 inch nuts The opening dimensions on the mounting plate should follow required dimensions refer to the drive mounting template printed on the outside carton Screw Four M6x15 or 1 4 inch Nut Four M6 or 1 4 inch DT 8 rcl by gt 3 Pak Ta 4 ERA Screw Four M8x15 or 3 8 inch cues Nut Four M8 or 3 8 inch 061 Series VFD MN040002EN March 2014 www eaton com 27 Chapter 6 Installation Requirements FR5 Mounting Instructions Step 1 Remove the carton from the drive Step 4 Attach the drive to the mounting plate with four 8 20 or 3 8 inch screws and four 8 or 3 8 inch ii nuts with an 8 or 3 8 inch wrench The opening dimensions on the mounting pla
64. VFD A CAUTION Do not touch any components on the circuit boards Static voltage discharge may damage the components A CAUTION Before starting the motor check that the motor is mounted properly and aligned with the driven equipment Ensure that starting the motor will not cause personal injury or damage equipment connected to the motor A CAUTION Set the maximum motor speed frequency in the drive according to the requirements of the motor and the equipment connected to it Incorrect maximum frequency settings can cause motor or equipment damage and personal injury A CAUTION Before reversing the motor rotation direction ensure that this will not cause personal injury or equipment damage CAUTION Make sure that no power correction capacitors connected to the drive output or the motor terminals to prevent drive malfunction and potential damage A CAUTION Make sure that the drive output terminals U V W are not connected to the utility line power as severe damage to the drive may occur CAUTION When the control terminals of two or more drive units are connected in parallel the auxiliary voltage for these control connections must be taken from a single source which can either be one of the units or an external supply CAUTION The drive will start up automatically after an input voltage interruption if the external run command is on A CAUTION Do not control the motor with the disconnect
65. WG DG1 327D8xx xxxx 2 1 4 10 AWG DG1 32011xx xxxx 21 2 10 AWG FR2 DG1 32012xx xxxx 11 12 13 DC DC 15 6 0 6 AWG DG1 32017xx xxxx M P U V W 56 8 6 AWG DG1 32025xx xxxx 5 6 8 6 AWG FR3 DG1 32031xx xxxx 11 12 13 DC 40 6 2 AWG DG1 32048xx xxxx 1 VW 4 2 AWG 4 DG1 32061xx xxxx 11 12 L3 DC DC 95 3 1 0 AWG DG1 32075xx xxxx 850 W g 2 1 0 AWG DG1 32088xx xxxx 95 1 0 AWG FR5 DG1 32114xx xxxx 11 12 L3 DC DC 354 3 0 AWG R U V W 350 kcmil DG1 32143xx xxxx 354 4 0 AWG 350 kcmil DG1 32170xx xxxx 354 300 350 kcmil All Frames Sizes FR1 FR5 All models Control terminal 45 28 12 Sol AWG block 30 12 Str AWG Note The line and motor wire size for DG1 32088xx xxxx can only be 1 0 AWG Appendix D Safety Instructions for UL and cUL Grounding For 400V Drive Series required grounding wire torque type and size range are listed in Table 43 Table 43 Required Line and Motor Wire Torque 400V Required Required Catalog Torque Wire Number Terminal Type in Ib Range FR1 DG1 342D2xx xxxx Grounding terminal 10 14 10 AWG DG1 343D3xx xxxx 10 14 10 AWG DG1 344D3xx xxxx 10 14 10 AWG DG1 345D6xx xxxx 10 14 10 AWG DG1 347D6xx xxxx 10 14 10 AWG DG1 349D0xx xxxx 10 14 10 AWG FR2 DG1 34012xx xxxx Grounding terminal 10 12 6 AWG DG1 34016xx xxxx 10 0 6 AWG DG1 34023xx xxxx 10 0
66. XG KEY LCD Catalog Number 480V DXG KEY LCD Catalog Number 575V DXG KEY LCD Main control board DXG SPR CTRLBOARD DXG SPR CTRLBOARD DXG SPR CTRLBOARD Control board cover DXG SPR BCOVER DXG SPR BCOVER DXG SPR BCOVER Type 1 IP21 standard cover DXG SPR FR4CVR DXG SPR FRACVR Main fan kit DXG SPR FR4FAN DXG SPR FR4FAN Control fan DXG SPR FR34CF DXG SPR FR34CF Bus capacitor DXG SPR 2FR4BC DXG SPR 4FR24BC Main power board DXG SPR 2FRAMPB DXG SPR 4FR4MPB EMI board DXG SPR 2FR4EB DXG SPR 4FR4EB Softstart board DXG SPR 2FR4SB DXG SPR 4FR4SB IGBT module DXG SPR 2FR4IGBT DXG SPR 4FR4IGBT Rectifier module DXG SPR 2FR4RM DXG SPR 4FR4RM Brake chopper module DXG SPR 2FR4BCM DXG SPR 4FR4BCM Middle chassis cover DXG SPR FR4MCC DXG SPR FRAMCC Outer housing DXG SPR FR40H DXG SPR FR40H UL conduit plate DXG SPR FR4CPUL DXG SPR FRACPUL IEC conduit plate DXG SPR FRACPIEC DXG SPR FRACPIEC Notes Factory recommended spare parts 575V available in 2015 061 Series VFD 040002 2014 www eaton com Chapter 1 DG1 Series Overview Table 10 Frame 5 Description Standard keypad Catalog Number 230V DXG KEY LCD Catalog Number 480V DXG KEY LCD Catalog Number 575V DXG KEY LCD Main control board DXG SPR CTRLBOARD DXG SPR CTRLBOARD
67. ac 9 40 60 30 45 41 62 FR5 230Vac 40 60 30 45 114 170 1341 34 98 2965 2783 1134 1110 8 66 8 66 0 35 154 32 480Vac 75 175 55 40 105 170 340 7 888 5 753 1 706 9 288 0 281 9 2200 220 0 9 0 70 0 575 75 125 55 90 80 125 FRE 230 75 100 55 75 211 261 480 150 200 110 150 205 261 575 150 200 110 160 144 208 Note FR6 and 575 Vac available in 2015 061 Series VFD MN040002EN March 2014 www eaton com 25 Chapter 6 Installation Requirements Standard Drive Mounting FR1 Mounting Instructions FR2 Mounting Instructions Step 1 Lift the drive out from the carton Remove the Step 1 Lift the drive out from the carton Remove the packaging packaging SN Step 2 Attach the drive to the mounting plate with four 5 15 or 3 16 inch screws and four or 3 16 inch nuts The opening dimensions on the mounting Step 2 Attach the drive to the mounting plate with four plate should follow required dimensions refer to M5x15 or 3 16 inch screws and four or 3 16 inch the drive mounting template printed on the outside nuts The opening dimensions on the mounting carton plate should follow required dimensions refer to the drive mounting template printed on the outside carton Screw Four 5 15 or 3 16 inch Nut Four 5 1 or 3 16 inch Screw Four 5 15 or 3 16 inch Nut Four M5 or 3 16 inch 26 DG1 Series
68. alculation of system harmonics a Harmonic Estimation Calculator Tool is available at www eaton com drives Chapter 2 Engineering Considerations Reactive Power Compensation Devices Special compensation measures on the power supply side is not required for DG1 Series drives which take on very little reactive power of the fundamental harmonics from the AC power supply network cos 0 98 In the AC power networks with non choked reactive current compensation devices current deviations can enable parallel resonance and undefinable circumstances In the project planning for the connection of frequency inverters to AC power networks with undefined circumstances please consider using AC chokes 061 Series VFD MNO040002EN March 2014 www eaton com 11 Chapter 3 Product Overview Chapter 3 Product Overview Component Identification Figure 6 Description of the DG1 Series Fan Middle Power Drive Control Heatsink chassis board board B cover Keypad A cover Bottom chassis DC choke Conduit plate EMI Terminal Output Optional board board card 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 phase AC voltage with adjustable frequency and assigned amplitude values for the variable speed control of three phase asynchronous motors 12 DG1 Series VFD MN040002EN March 2014 www eaton com
69. complete overload relay must be replaced A WARNING Operation of this equipment requires detailed installation and operation instructions provided in the Installation Operation manual intended for use with this product This information is provided on the CD ROM floppy diskette s or other storage device included in the container this device was packaged in it should be retained with this device at all times A hard copy of this information may be ordered from Eaton literature fulfillment PowerXL DG1 Series VFD MNO40002EN March 2014 www eaton com ix PowerXL DG1 Series VFD A WARNING Before servicing the drive Disconnect all power to the drive including external control power that may be present Place a DO NOT TURN ON label on the disconnect device Lock the disconnect device in the open position Failure to follow these instructions will result in death or serious injury A WARNING The drive outputs U V W must not be connected to the input voltage or the utility line power as severe damage to the device may occur and there may be a risk of fire A WARNING The heat sink and or outer enclosure may reach a high temperature Pay attention to hazard warnings AN Hot Surface Risk of Burn DO NOT TOUCH CAUTION Any electrical or mechanical modification to this drive without prior written consent of Eaton will void all warranties and may result in a safety hazard in addition and voidin
70. count for S1 operation IEC 60034 1 When operating multiple motors in parallel on one frequency inverter the motor output should not be more than three power classes apart Ensure that the motor is not overdimensioned If a motor in speed control mode is under dimensioned the motor rating must only be one rating level lower Chapter 5 Motor and Application Connecting Motors in Parallel The DG1 frequency inverters allow parallel operation of several motors using multi pump application control mode Multi pump application several motors with the same or different rated operational data The sum of all motor currents must be less than the frequency inverter s rated operational current e application parallel control of several motors The sum of the motor currents plus the motors inrush currents must be less than the frequency inverter s rated operational current Parallel operation at different motor speeds can be implemented only by changing the number of pole pairs and or changing the motor s transmission ratio A CAUTION Debounced inputs may not be used in the safety circuit diagram If you are connecting multiple motors on one frequency inverter you must design the contactors for the individual motors according to utilization category AC 3 Selecting the motor contactor is done according to the rated operational current of the motor to be connected 061 Series VFD 040002
71. d to speed control with slip compensation DG1 32 3 7A to 261A DG1 34 2 2A to 261A 100 at an ambient tempe of 200 for 2 s every 20s Motor connection U T1 V T2 W T3 with output voltage U2 0 10096 Ue and output frequency f2 0 400 Hz output current I2 ature of 122 F 50 C with an overload capacity of 150 for 60 s every 600 s and a starting current Keypad with control buttons graphic display control voltage control signal terminals micro switches and interface for the PC interface module option Three phase asynchronous motor variable speed control of three phase asynchronous motor for assigned motor shaft power values P2 DG1 32 0 55 kW to 75 kW 230V 50 Hz or 0 75 hp to 100 hp 240V 60 Hz DG1 34 0 75 kW to 150 kW 400V 50 Hz or 1 hp to 200 hp 460V 60 Hz DC link chokes to minimize current harmonics 061 Series VFD 040002 2014 www eaton com 13 Chapter 3 Product Overview Selection Criteria The frequency inverter 3 is selected according to the supply voltage of the input supply 1 and the rated current of the assigned motor 2 The circuit type A Y of the motor must be selected according to the supply voltage 1 The rated output current le of the frequency inverter must be greater than equal to the rated motor current Figure 8 Selection Criteria wo min T When selecting the drive t
72. distributors or sales offices Voice 877 ETN CARE 386 2273 8 00 a m 6 00 p m EST After Hours Emergency 800 543 7038 6 00 p m 8 00 a m EST Drives Technical Resource Center Voice 877 ETN CARE 386 2273 option 2 option 6 8 00 a m 5 00 p m Central Time U S UTC 6 email TRCDrivesQEaton com For Customers in Europe Contact Phone 49 0 228 6 02 3640 Hotline 49 0 180 5 223822 email AfterSalesEGBonn Eaton com www eaton com moeller aftersales ii PowerXL DG1 Series VFD MNO40002EN March 2014 www eaton com Table of Contents SAFETY Before Commencing the Installation Definitions and Symbols Hazardous High Voltage sexe x wwe yd ah dh a tucked ode enter he Warnings and Cautions cese etr GES A ee RRA pelea AY BAX Motor and Equipment Safety 2 2 2 CHAPTER 1 DG1 SERIES OVERVIEW How to Use this Manual i 6 ERE GREG eu Receiving and Inspection Real Time Clock Battery Activation babel na ez tnt e ret det Carton Labels U S and Europe Catalog Number System Power Ratings and Product Selection Heplacenment Palits a sta d
73. ditional expenses in the use of existing power facilities or claims against the purchaser or user by its customers resulting from the use of the information recommendations and descriptions contained herein The information contained in this manual is subject to change without notice Cover Photo Eaton PowerXL DG1 Series Drive PowerXL DG1 Series VFD MNO40002EN March 2014 www eaton com i PowerXL DG1 Series VFD Support Services Support Services The goal of Eaton is to ensure your greatest possible satisfaction with the operation of our products We are dedicated to providing fast friendly and accurate assistance That is why we offer you so many ways to get the support you need Whether it is by phone fax or email you can access Eaton s support information 24 hours a day seven days a week Our wide range of services is listed below You should contact your local distributor for product pricing availability ordering expediting and repairs Website Use the Eaton Website to find 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 Center if you need assistance with placing an order stock availability or proof of shipment expediting an existing order emergency shipments product price information returns other than warranty returns and information on local
74. e Motor current 3 5A 2 0A 3 5A Motor voltage ratings plate 230V 400V 230V Motor speed 1430 min 1430 min 2474 min Motor frequency 50 Hz 50 Hz 87 Hz Notes Star connection 400V 50 Hz G Delta connection 230V 50 Hz Delta connection 400V 87 Hz Note the permitted limit values of the motor 061 Series VFD 040002 2014 www eaton com 21 Chapter 5 Motor and Application Bypass Operation If you want to have the option of operating the motor with the frequency inverter or directly from the input supply the input branches must be interlocked mechanically A CAUTION Debounced inputs may not be used in the safety circuit diagram A changeover between the frequency inverter and the input supply must take place in a voltage free state A WARNING The frequency inverter outputs U V W must not be connected to the input voltage destruction of the device risk of fire Figure 15 Bypass Motor Control Example 111213 M1 Table 16 Bypass Motor Control Item No Description 1 Input bypass contactor 2 Output contactor 22 DG1 Series VFD 040002 2014 www eaton com A CAUTION Debounced inputs may not be used in the safety circuit diagram Switch S1 must switch only when frequency inverter T1 is at zero current Contactors and switches S1 in the frequency inverter output and
75. e 1g at 15 8 Hz to 150 Hz FR1 FR5 44 DG1 Series VFD 040002 2014 www eaton com Table 28 PowerXL Series DG1 continued Appendix A Technical Data and Specifications Attribute Description Specification Ambient conditions Shock Storage and shipping maximum 15 g 11 ms in package continued EN 60068 2 27 Overvoltage Overvoltage Category Ill Pollution degree Pollution Degree 2 Enclosure class IP21 Type 1 standard in entire kW hp range 54 12 option Note Keypad or keypad hole plug required to be mounted in drive for 1 54 12 rating Immunity Fulfills EN 61800 3 2004 first and second environment MTBF FR1 165 457 hours FR2 134 833 hours FR3 102 515 hours FR4 121 567 hours FR5 108 189 hours FR6 Available in 2015 Standards Safety UL 508C CSA C22 2 No 274 13 and EN 61800 5 1 EMC 2 EN 61800 3 2004 Category C2 The drive can be modified for IT networks and corner grounding TN system Electrostatic discharge Second environment IEC 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 Vac 2828 Vdc Approvals EN 61800 5 1 2007 CE UL and cUL see nameplate for more detailed approvals Fieldbus connections EtherNet IP Modbus TCP Modbu
76. ency drive may cause the failure of the device and may lead to serious injury or damage The applicable national accident prevention and safety regulations apply to all work carried out on live adjustable frequency drives The electrical installation must be carried out in accordance with the relevant regulations for example with regard to cable cross sections fuses PE Transport installation commissioning and maintenance work must be carried out only by qualified personnel IEC 60364 HD 384 and national occupational safety regulations Installations containing adjustable frequency drives must be provided with additional monitoring and protective devices in accordance with the applicable safety regulations Modifications to the adjustable frequency drives using the operating software are permitted All covers and doors must be kept closed during operation To reduce hazards for people or equipment the user must include in the machine design measures that restrict the consequences of a malfunction or failure of the drive increased motor speed or sudden standstill of motor These measures include Other independent devices for monitoring safety related variables speed travel end positions and so on Electrical or non electrical system wide measures electrical or mechanical interlocks e Never touch live parts or cable connections of the adjustable frequency drive after it has been disconnected from the power sup
77. eos dar ot e abate ahead A Sau e ad d CHAPTER 2 ENGINEERING CONSIDERATIONS DtroOdUuctloh S wih b dowels bike ed daw bi Electrical Power Network nput Voltage Frequeney s doge Be ee Hee n wee Me Rk Ic eoa nput Voltage Balance outta wats a eme Rp CERO RU wd KD ERR TR Total Harmonie Distortion THD sin cedat eder tme tes ed Reactive Power Compensation Devices CHAPTER 3 PRODUCT OVERVIEW Component Identification 2 Selection Criteria Lees tei cole alae ed PCT TED Bah ST Maintenance and Inspection STOLAG 655 ua ora c Service and Warranty xu die HIR AES CHAPTER 4 SAFETY AND SWITCHING Fuses and Cable Cross Sections andi FUSES aaa eh domm edet ede qute Pete ot te ptt alee Residual Current Device RCD CONTACTO i n mo caede dote redi dnd 6 etr nete teet ae s er UE DET S em DEEP CHAPTER 5 MOTOR AND APPLICATION Motor Selection ge aos ced hee WR pe tp dole Connecting Motors in Parallel
78. face using all four mounting hole locations When mounting one unit above the other the lower unit air outlet must be directed away from the inlet air used by the upper one The clearance between the upper and lower unit should equal C D See Figure 16 on next page 1 Measure the mounting space to ensure that it allows the minimum space surrounding the VFD Series drive Drive dimensions are on Appendix C 2 Make sure the mounting surface is flat and strong enough to support the drive is not flammable and is not subject to excessive motion or vibration 3 Ensure that the minimum airflow requirements for your drive are met at the mounting location 4 Mark the location of the mounting holes on the mounting surface using the template provided on the cover of the cardboard shipping package 5 Using fasteners appropriate to your drive and mounting surface securely attached the drive to the mounting surface using all four screws or bolts Mounting Dimensions Refer to Appendix C for drive dimensions 061 Series VFD 040002 2014 www eaton com 23 Chapter 6 Installation Requirements Figure 16 Mounting Space Table
79. for the direct start must be designed based on utilization category AC 3 for the rated operational current of the motor Connecting EX Motors Note the following when connecting explosion protected motors The frequency inverter must be installed outside the EX area Note the branch and country specific standards for explosion protected areas ATEX 100a Note the standards and information of the motor manufacturer regarding operation on frequency inverters for example if motor reactors or sine wave filters are specified e Temperature monitors in the motor windings thermistor thermo Click are not to be connected directly to frequency inverters but must be connected via an approved trigger apparatus for EX areas Chapter 6 Installation Requirements This chapter contains all of the information required to properly install and prepare the DG1 Series VFD for operation The contents are listed to serve as a list of tasks needed to complete the installation Included in this section are e Line mains and motor power wiring e O control wiring Electrical Installation Warnings and Cautions A WARNING Carry out wiring work only after the frequency inverter has been correctly mounted and secured A WARNING Electric shock hazard risk of injuries Carry out wiring work only if the unit is de energized A CAUTION Debounced inputs may not be used in the safety circuit diagram Fire hazard
80. g of the 19 listing A CAUTION Install this drive on flame resistant material such as a steel plate to reduce the risk of fire CAUTION Install this drive on a perpendicular surface that is able to support the weight of the drive and is not subject to vibration to lessen the risk of the drive falling and being damaged and or causing personal injury A CAUTION Prevent foreign material such as wire clippings or metal shavings from entering the drive enclosure as this may cause arcing damage and fire A CAUTION Install this drive in a well ventilated room that is not subject to temperature extremes high humidity or condensation and avoid locations 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 A CAUTION When selecting the cable cross section take the voltage drop under load conditions into account The consideration of other standards is the responsibility of the user The user is responsible for compliance with all international and national electrical standards in force concerning protective grounding of all equipment A CAUTION The specified minimum PE conductor cross sections in this manual must be maintained Touch current in this equipment exceeds 3 5 mA AC The minimum size of the protective earthing conductor shall comply with the requirements
81. he following criteria must be known Type of motor three phase asynchronous motor nput voltage rated operating voltage of the motor for example 3 AC 400 Rated motor current guide value dependent on the circuit type and the supply voltage Load torque quadratic constant e Starting torque Ambient temperature rated value 122 F bO C When connecting multiple motors in parallel to the output of a frequency inverter the motor currents are added geometrically separated by effective and idle current components When you select a frequency inverter make sure that it can supply the total resulting current If necessary for dampening and compensating the deviating current values motor reactors or sinusoidal filters must be connected between the frequency inverter and the motor The parallel connection of multiple motors in the output of the frequency inverter is only permitted with V Hz characteristic curve control 14 DG1 Series VFD MNO40002EN March 2014 www eaton com If you connect a motor to an operational frequency inverter the motor draws a multiple of its rated operational current When you select a frequency inverter make sure that the starting current plus the sum of the currents of the running motors will not exceed the rated output current of the frequency inverter Switching in the output of the frequency inverter is only permitted with V Hz characteristic curve control Proper U
82. ing device disconnecting means instead use the control panel start and stop keys and or commands via the I O board of the drive The maximum allowed number of charging cycles of the DC capacitors i e powerups by applying power is five in ten minutes PowerXL DG1 Series VFD MN040002EN March 2014 www eaton com xi PowerXL DG1 Series VFD A CAUTION Improper drive operation f the drive is not turned on for a long period the performance of its electrolytic capacitors will be reduced f it is stopped for a prolonged period 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 to the line voltage The voltage should be increased gradually using an adjustable AC source Failure to follow these instructions can result in injury and or equipment damage For more technical information contact the factory or your local Eaton sales representative xii PowerXL DG1 Series VFD MN040002EN March 2014 www eaton com Chapter 1 DG1 Series Overview This chapter describes the purpose and contents of this manual the receiving inspection recommendations and the DG1 Series Open Drive catalog numbering system How to Use this Manual The purpose of this manual is to provide you with information necessary to install set and customize parameters start up troubleshoot and mai
83. ive logic 18 to 30 Vdc one input can be used as thermistor input 24V output Auxil iary Voltage 24V 15 total max 250 mA on board include optional cards 10 VREF Output Reference Voltage 10V 3 max load 10 mA Analog Outputs 0 4 0 20 mA max 500 ohm 0101 10 mA Digital Output Open collector output 50 mA 48V for CE 50 mA 36V for UL Relay Outputs 3 Programmable relay outputs 2 x Form C Relay 1 and Relay 2 and 1 x Form A Relay 3 Relay 3 can be used as thermistor output Switching capacity 24 Vdc 6A 48 Vdc 2A 240 Vac 6A 125 Vdc 0 4A 061 Series VFD 040002 2014 www eaton com 35 Chapter 6 Installation Requirements Figure 21 Basic Internal Control Wiring Diagram
84. l 15 98 406 0 i ji 0 22 5 5 20 28 7 0 3 54 90 0 Minimum Dimensions A Air gap around drive B Space between two drives or drive and cabinet Free space above drive D Free space below drive For Class IP54 dimension A and 8 0 6 30 160 0 1 18 30 0 2 36 60 0 Approximate Dimensions in Inches mm Figure 35 FR3 Dimension Drawing 10 44 265 1 20 41 518 5 Y e o o i 0 45 11 3 4 0 59 15 0 63 3 3 035 0 48 8 IP21 IP54 Metric 39 0 200 t es Le 51 5 55 5 21 7 48 190 0 7 24 184 0 TREE Es 4 92 97 558 0 1 3 83 97 2 13 49 342 6 2 19 55 5 DG1 Series VFD 040002 2014 Appendix C
85. ltimately the responsibility of the end user or system operator This operator must also take measures to minimize or remove emission in the environment concerned see Figure 10 He must also use means to increase the interference immunity of the devices of the system 2 d Environment With their high interference immunity up to category C2 DG1 frequency inverters are ideal for use in commercial networks 1st environment Table 14 Maximum Motor Cable Length by Frame Size without dV dT Protected C2 Ratings Frame Size Maximum Cable Length m Category C3 C4 FRI 100 FR2 150 FR3 150 FR4 200 FR5 200 18 DG1 Series VFD MN040002EN March 2014 www eaton com Chapter 5 Motor and Application Motor Selection General recommendations for motor selection Use three phase powered asynchronous motors with short circuit rotors and surface cooling also called inverter motors or standard motors for the frequency controlled drive system PDS Other specifications such as external rotor motors slip ring motors reluctance motors synchronous or servo motors can also be run with a frequency inverter but normally require additional planning and discussion with the motor manufacturer Use only motors with at least heat class F 311 F 155 C maximum steady state temperature Fourpole motors are preferred synchronous speed 1500 min at 50 Hz or 1800 min at 60 Hz Take the operating conditions into ac
86. ly G f power cubes or bypass are used a Class gG gL fuse is recommended Available 2015 061 Series VFD 040002 2014 www eaton com Earthing conductor size is determined by the cross sectional area of phase conductors according to IEC EN61800 5 1 2007 Table 5 So if phase conductor size 49 Appendix B Installation Guidelines Temperature Deratings Table 33 230V Temperature and Switching Frequency Deratings VT Variable Torque Percentage of Rated Current Overload 1 Frame Switching Frequency Temperature Size 1kHz 2kHz 3kHz 36kHz 4kHz 5kHz 6kHz 7kHz 8kHz 9kHz 10 2 12kHz 40 1 100 0 100 0 100 0 100 0 100 0 100 0 100 0 968 936 904 856 80 8 FR2 100 0 100 0 100 0 100 0 100 0 100 0 100 0 973 94 6 91 9 870 83 9 FR3 100 0 100 0 100 0 100 0 100 0 100 0 100 0 100 0 100 0 100 0 100 0 100 0 FR4 100 0 100 0 100 0 100 0 97 8 95 6 93 4 91 2 874 836 798 FR5 100 0 100 0 100 0 100 0 95 5 910 865 820 784 747 71 FR6 50 C FR1 84 0 840 840 840 840 840 840 808 77 6 744 696 648 FR2 871 871 871 871 871 871 871 844 81 7 790 750 71 096 FR3 934 934 934 93 4 93 4 934 934 934 93490 934 90 2 869 FR4 87 7 87 7 87 7 87 7 85 5 83 3 81 1 78 9 760 731 702 FR5 80 6 805 80 6 80 6 767 72
87. mensions in Inches mm Figure 39 FR5 Dimension Drawing 1 08 il 00 79 920 0 Y a 6 4 1 14 29 0 30 51 775 0 34 98 888 5 1 333 n n 3 80 96 5 IP21 1P54 Metric 40 0 40 0 104 0 3 025 3 2 075 0 i OO 107 0 F HO NI 197 0 _ AN Ml 64 0 140 0 11 34 288 0 Appendix C Dimension Drawings 11 10 1 11 34 288 0 22512200 1 E FTN 3 83 Power DG1 97 2 Sen 29 65 0 e 753 0 22 57 573 3 8 66 220 0 Type 1 12 UL 1 57 1 57 00 89 40 0 40 0 0225 409 104 0 02 95 MM 075 0 4211 107 0 2 um cae NI EN 7 ANNE E 0 2 52 5 51 64 0 140 0 8 66 m 220 0 7 00 35 29 0 00 71 018 0 29 65 753 0 Minimum
88. mple phase compensation capacitors connect multiple frequency inverters in parallel make a direct connection to the input bypass Observe the technical data and connection requirements For additional information refer to the equipment nameplate or label at the frequency inverter and the documentation Any other usage constitutes improper use Maintenance and Inspection DG1 frequency inverters are maintenance free However external influences may affect the function and the lifespan of the DG1 frequency inverter We therefore recommend that the devices are checked regularly and the following maintenance measures are carried out at the specified intervals If the DG1 frequency inverter is damaged by external influences contact Eaton Technical Service Table 13 Maintenance Measures and Intervals Maintenance Measure Maintenance Interval Clean cooling vents cooling slits If required Check the fan function 6 24 months depending on the environment Filter in the switching cabinet doors see manufacturer specifications 6 24 months depending on the environment Check the tightening torques of the terminals control signal terminals power terminals Regularly Check connection terminals and all metallic surfaces for corrosion 6 24 months depending on the environment Storage If the frequency inverter is stored before use suitable ambient conditions must be ensured at
89. n from rated value of the frequency Max 496 The board tolerance band of the DG1 frequency inverter considers the rated value for European as EU ULN 230V 400V 50 Hz and American as USA 240V 480V 60 Hz standard voltages e 230V 50 Hz EU and 240V 60 Hz USA at DG1 32 e 400V 50 Hz EU and 480V 60 Hz USA at DG1 34_ For the bottom voltage value the permitted voltage drop of 496 in the consumer circuits is also taken into account therefore a total of 1496 e 230V device class DG 1 32 208V 1596 to 240V 10 177V 0 to 264V 0 400V device class DG1 34 380V 1596 to 500V 10 323V 0 to 550V 4096 The permitted frequency range is 50 60 Hz 45 Hz 0 to 66 Hz 0 Input Voltage Balance Due to the uneven loading on the conductor and with the direct connection of greater power ratings deviations from the ideal voltage form and asymmetrical voltages can be caused in three phase AC power networks These asymmetric divergences in the input voltage can lead to different loading of the diodes in input rectifiers with three phase supplied frequency inverters and as a result an advance failure of this diode In the project planning for the connection of three phase supplied frequency inverters consider only AC power networks that handle permitted asymmetric divergences in the input voltage lt 4396 If this condition is not fulfilled or symmetry at the connection loca
90. nger than about 300 mm 42 DG1 Series VFD 040002 2014 www eaton com Table 25 1st Environment 2nd Environment EMC Levels According to EN 61800 3 2004 Cable Type Category 2 Category C3 Level T Line voltage mains 1 1 1 Motor cable 30 2 2 Control cable 4 4 4 Note 360 earthing of the shield with cable glands in motor end needed for EMC Level C2 Table 26 Control Wiring Requirements Item Directive Product IEC 61800 2 Safety UL 508C IEC EN 61800 5 1 EMC at default Immunity EN IEC 61800 3 2nd environment settings Radiated emissions EN IEC 61800 3 Transient Testing included 1st environment Conducted emissions EN IEC 61800 3 Category C1 is possible with external filter connected to drive Please consult factory Category C2 with internal filter maximum of 10m motor cable length Category C3 with internal filter maximum of 50m motor cable length Table 27 Cable Categories Cable Description Category All cables are rated for the specific operating voltage 1 Intended for fixed installation 2 Symmetrical power cable equipped with a concentric protection wire 3 Symmetrical power cable with compact low impedance shield Recommended cable transfer impedance of 1 30 MHz max See figure below 4 Screened cable equipped with compact low impedance shield Figure 28 Cable Description PE Conductor and Shield PE Conduc
91. nt meet the following conditions General This drive should be operated at a maximum ambient temperature of 40 in low overload VT rating and 50 in high overload CT rating This drive should be installed in environment of Pollution Degree 2 or better Overvoltage Category To comply with standard CSA C22 2 No 274 13 requirement the following applies to cUL applications This drive should be installed in environment of Overvoltage Category III For 400V Series Transient surge suppression shall be installed on the line side of this equipment and shall be rated 500V phase to ground suitable for Overvoltage Category and shall provide protection for a rated impulse withstand voltage peak of 6 kV For 230V Series Transient surge suppression shall be installed on the line side of this equipment and shall be rated 240V phase to ground suitable for Overvoltage Category 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 overload protection that reacts when it reaches 102 596 of FLA This drive can accept and act upon a signal from a thermal sensor or switch embedded in the motor or from an external protective relay to achieve the motor over temperature protection Therefore in order to achieve the motor over temperature protection a sensor from the motor will be needed
92. ntain the Eaton DG1 Series adjustable frequency drive AFD To provide for safe installation and operation of the equipment read the safety guidelines at the beginning of this manual and follow the procedures outlined in the following chapters before connecting power to the DG1 Series AFD Keep this operating manual handy and distribute to all users technicians and maintenance personnel for reference Receiving and Inspection The DG1 Series AFD has met a stringent series of factory quality requirements before shipment It is possible that packaging or equipment damage may have occurred during shipment After receiving your DG1 Series AFD please check for the following Check to make sure that the package includes the Instruction Leaflet ILO40016EN Quick Start Guide 040006 User Manual CD CD040002EN and accessory packet The accessory packet includes Rubber grommets Control cable grounding clamps Additional grounding screw Inspect the unit to ensure it was not damaged during shipment Make sure that the part number indicated on the nameplate corresponds with the catalog number on your order If shipping damage has occurred please contact and file a claim with the carrier involved immediately If the delivery does not correspond to your order please contact your Eaton Electrical representative Note Do not destroy the packing The template printed on the protective cardboard can be used for marking
93. of EN 61800 5 1 and or the local safety regulations A CAUTION Touch currents in this frequency inverter are greater than 3 5 According to product standard IEC EN 61800 5 1 an additional equipment grounding conductor of the same cross sectional area as the original protective earthing conductor must be connected or the cross section of the equipment grounding conductor must be at least 10 mm Cu Drive requires that only copper conductor should be used A CAUTION Debounced inputs may not be used in the safety circuit diagram Residual current circuit breakers RCD are only to be installed between the AC power supply network and the drive A CAUTION Debounced inputs may not be used in the safety circuit diagram If you are connecting multiple motors on one drive you must design the contactors for the individual motors according to utilization category AC 3 Selecting the motor contactor is done according to the rated operational current of the motor to be connected x PowerXL DG1 Series VFD 040002 2014 www eaton com A CAUTION Debounced inputs may not be used in the safety circuit diagram A changeover between the drive and the input supply must take place in a voltage free state CAUTION Debounced inputs may not be used in the safety circuit diagram Fire hazard Only use cables protective switches and contactors that feature the indicated permissible nominal current value
94. ound 201 Utility Drive Motor Ground Inside Motor Conduit Box CAUTION Improper grounding could result in damage to the motor and or drive and could void warranty Note For ease of access the board terminals blocks can be unplugged for wiring 8 Wire control to the control board Note Drive default is programmed for external interlock 061 Series VFD 040002 2014 www eaton com 33 Chapter 6 Installation Requirements I O Connection e Run 240 Vac and 24 Vdc control wiring in separate conduit e Communication wire to be shielded Table 23 Connection SWI 10 10 1 1 20 20 2 sm1 2 a Al2sw2L3 _ AI2 0 20 mA AI2 0 10V AI2 10 10V SW2 On Off RS 485 matching resistor Pin Signal Name Signal Default Setting Description 1 10 Ref Output Voltage 10 Vdc Supply Source 8 4 2 Analog Input 1 0 10 V Voltage Speed Reference Programmable to 4 mA to 20 mA 3 Analog Input 1 Ground Analog Input 1 Common Ground I 4 Al2 Analog Input 2 4 mA to 20 mA Current Speed Reference Programmable to 0 10V e 5 2 Analog Input 2 Ground Analog Input 2 Common Ground 6 GND 1 0 Signal Ground 1 0 Ground for Reference and Con
95. ply Due to the charge in the capacitors these parts may still be live after disconnection Fit appropriate warning signs PowerXL DG1 Series VFD MN040002EN March 2014 www eaton com vii PowerXL DG1 Series VFD Read this manual thoroughly and make sure you understand the procedures before you attempt to install set up operate or carry out any maintenance work on this DG1 Adjustable Frequency Drive Definitions and Symbols A WARNING This symbol indicates high voltage It calls your attention to items or operations that could be dangerous to you and other persons operating this equipment Read the message and follow the instructions carefully This symbol is the Safety Alert Symbol It occurs with either of two signal words CAUTION or WARNING as described below A WARNING Indicates a potentially hazardous situation which if not avoided can result in serious injury or death A CAUTION Indicates a potentially hazardous situation which if not avoided can result in minor to moderate injury or serious damage to the product The situation described in the CAUTION may if not avoided lead to serious results Important safety measures are described in CAUTION as well as WARNING Hazardous High Voltage WARNING Motor control equipment and electronic controllers are connected to hazardous line voltages When servicing drives and electronic controllers there may be exposed components with housings or protru
96. que Off STO sein do ot eee Connection to Power Section Three Phase Inp t issues cct sene ee a cet COR Terminal Designations in the Power Section x ato een ste t dec e luo dote ta eos ned Product Modified Sticker e eee Checking the Cable and Motor Insulation CHAPTER 7 EMC INSTALLATION EMC Measures in the Control Panel Screen Tur a 1 ettet 2122 02 23 nstallation Requirements nternational EMC Protection Cable Requirements nstallation in Corner Grounded Network ristallatior IridT SVSterri ox te e eee be CU be APPENDIX A TECHNICAL DATA AND SPECIFICATIONS APPENDIX B INSTALLATION GUIDELINES Cabl and Euse Sizing Gebet Ru aa al Temperature Deratings H at Eoss Datar ee Ree seo E Reti NIHU Brak Resistor SIZING os exo Y ede A e Ee re abet APPENDIX C DIMENSION DRAWINGS APPENDIX D SAFETY INSTRUCTIONS FOR UL AND CUL QL Standards Compliance veas d SE oe Field sac
97. rd the plastic bag containing the wiring hardware 1 Remove the A cover by removing 4 screws then lifting the A cover away from the base PowerXL 061 AAN DANGER 5 MIN Wiring Hardware Contents European rubber grommet and flat rubber grommet for IP54 integrity Modification label Detachable cable clamp Attachable grounding strap Ground strap mounting screws Chapter 6 Installation Requirements Power Wiring Grounding 2 Remove power wiring protection plate Use power motor cable tables on Appendix B Add attachable grounding clamps qty 2 on each side of drive 4 Pass motor input power wires cables through base wiring plate 5 If shielded cable is used connect the shields of input power and motor cables shields to ground 6 Wire power terminals L1 L2 L3 motor terminal U V W and grounding terminals per Figure 19 Power and motor leads must be in separate conduit To meet the UL requirements if conduit is being used for wiring the enclosure openings provided for conduit connections in the field shall be closed by UL listed conduit fittings with the same type rating Type 1 Type 12 as the enclosure 061 Series VFD MN040002EN March 2014 www eaton com 31 Chapter 6 Installation Requirements Rubber Grommet Installation Instructions Step 1 Measure the outside diameter of the cable D1 used to connect to the drive
98. rea With leakage currents greater than 3 5 mA in accordance with VDE 0160 or EN 61800 5 1 either the protective conductor must have a cross section of at least 10 mm e the protective conductor must be open circuit monitored and the supply must be automatically disconnected in case of discontinuity of the protective earthing conductor or the second protective conductor must be fitted For an EMC compliant installation we recommend the following measures e Installation of the frequency inverter in a metallic electrically conducting enclosure with a good connection to earth Shielded motor cables short cable lengths Ground all conductive components and housings in a drive system using as short a line as possible with the greatest possible cross section Cu braid EMC Measures in the Control Panel For EMC compatible installation connect all metallic parts of the device and the switching cabinet together over broad surfaces and so that high frequencies will be conducted Mounting plates and cabinet doors should make good 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 40 DG1 Series VFD 040002 2014 www eaton com Install the frequency inverter as directly as possible without spacers on a metal plate mounting plate Route input and motor cables in the
99. requency inverter According to product standard IEC EN 61800 5 1 an additional equipment grounding PE conductor of the same cross sectional area as the original protective earthing conductor must be connected or the cross section of the equipment grounding conductor must be at least 10 mm Cu Residual current circuit breakers must be suitable for the protection of installations with DC current component in case of fault scenario RCD type B high leakage currents brief discharges of pulse current spikes Chapter 4 Safety and Switching Input Contactor The input contactor enables an operational switching on and off of the supply voltage for the frequency inverter and Switching off in case of a fault The input contactor is designed based on the input current ILN of the frequency inverter and the utilization category AC 1 IEC 60947 Input contactors and the assignment to DG1 frequency inverters are explained in Appendix A While planning the project make sure that inching operation is not done via the input contactor of the frequency inverter on frequency controlled drives but through a controller input of the frequency inverter The maximum permitted operating frequency of the input voltage with the DG1 frequency inverter is one time per minute normal operation 061 Series VFD 040002 2014 www eaton com 17 Chapter 4 Safety and Switching EMC Measures Figure 10 EMC Measures
100. res 240 volts maximum when protected by UL and cUL CSA Recognized Class T fuse with an A I C rating of 100 kA minimum Refer to the following information for recommended fuse ratings See Table 40 Table 40 Fuse Ratings 230 Drive Series Catalog Frame Size Number Fuse Rating 1 061 32307 600V 10A 061 32408 600V 10A DG1 326D6xx xxxx 600V 10A 061 32708 600V 15 061 32011 600V 15 2 DG1 32012xx xxxx 600V 20A 061 32017 600V 30A DG1 32025xx xxxx 600V 35A 3 061 32031 600V 60A DG1 32048xx xxxx 600V 80A 4 DG1 32061xx xxxx 600V 100A 061 32075 600V 110A DG1 32088xx xxxx 600V 125A 5 DG1 32114xx xxxx 600V 175A 061 32143 600V 200A 061 32170 600V 250A 66 DG1 Series VFD 040002 2014 www eaton com Field Wiring e The field installed conductors for this drive should be 75 C copper wire only e The enclosure openings provided for conduit connections in the field shall be closed by UL Listed conduit fittings with same type rating as the enclosure Type 1 Type 12 Line and Motor Wiring For 400V Drive Series required line and motor wire torque type and size range are listed in Table 41 Table 41 Required Line and Motor Wire Torque 400V
101. ric and Type 1 12 UL 1011 With flange kit installed the bottom wiring box should be removed 9 8 66 220 0 DG1 Series VFD 040002 2014 www eaton com 8 66 00 35 220 0 09 0 00 71 018 0 0 29 65 753 0 0 35 09 0 C 11 81 300 0 80 0 4 D 7 87 a Minimum Dimensions A Air gap around drive B Space between two drives or drive and cabinet C Free space above drive D Free space below drive For Class IP54 dimension A and 0 L A B 3 15 A B 3 15 80 0 Appendix D Safety Instructions for UL and cUL Appendix D Safety Instructions for UL and cUL CAUTION The UL and cUL compliance can be maintained only if this drive is installed according to the requirements of Appendix D Safety Instructions for UL and cUL Failure to follow these instructions may result in UL and cUL non compliance UL Standards Compliance This drive is tested in accordance with UL508C and CSA C22 2 No 274 13 and is found to comply with these requirements To ensure continued compliance when using this drive or when using it in combination with other equipme
102. rrent in the protective earthing conductor Where a residual current operated protective RCD or monitoring RCM device is used for protection in case of direct or indirect contact only an RCD or RCM of Type B is allowed on the supply side of this product Figure 9 Identification on the Fl Circuit Breakers Frequency inverters work internally with rectified AC currents If an error occurs the DC currents can block a type A RCD circuit breaker from triggering and therefore disable the protective functionality A CAUTION Debounced inputs may not be used in the safety circuit diagram AC DC sensitive RCD type B Residual current circuit breakers RCD are only to be installed between the AC power supply network and the frequency inverter Safety relevant leakage currents can occur while handling and when operating the frequency inverter if the frequency inverter is not grounded because of a fault Leakage currents to ground are mainly caused by foreign capacities with frequency inverters between the motor phases and the shielding of the motor cable and via the Y capacitors of the RFI filter The size of the leakage current is mainly dependent upon the e length of the motor cable shielding of the motor cable height of the switching frequency of the inverter e design of the RFI filter grounding measures at the site of the motor The leakage current to ground is greater than 3 5 mA with a f
103. s RTU BACnet Safety protections Overvoltage protection Yes Overvoltage trip limit 240V drives 456V 480V drives 911V Undervoltage protection Yes Undervoltage trip limit 240V drives 211V 480V drives 370V Earth fault protection Yes Input phase supervision Yes Motor phase supervision Yes Overcurrent protection Yes Unit overtemperature protection Yes Motor overload protection Yes Motor stall protection Yes Motor underload protection Yes DC bus overvoltage control Yes Short circuit protection of 24V reference voltages Surge protection Yes differential mode 2 kV common mode 4 kV Common coated boards Yes prevents corrosion 061 Series VFD 040002 2014 www eaton com 45 Appendix B Installation Guidelines Appendix B Installation Guidelines Cable and Fuse Sizing See Page 30 for cable stripping guidelines Table 29 North America Cable and Fuse Sizes 208 Vac to 240 Vac Ratings iei onnection Size 208V Input 208V Input Ni Amp Current Current Fuse Wire Size AWG AWG Frame Amp Current Current Rating Rating Rating Line and Line and Size Suffix at 230V at 208V at50 C at40 C _ Class T Motor Ground Motor Ground FR1 3D7 32 44 42 4 6 3 7 48 10 4 4 24 10 18 10 408 44 6 1 6 0 6 6 48 6 6 1
104. se The 061 frequency inverters are electrical apparatus for controlling variable speed drives with three phase motors They are designed for installation in machines or for use in combination with other components within a machine or system After installation in a machine the frequency inverters must not be taken into operation until the associated machine has been confirmed to comply with the safety requirements of Machinery Safety Directive MSD 89 392 EEC meets the requirements of EN 60204 The user of the equipment is responsible for ensuring that the machine use complies with the relevant EU Directives The CE markings on the DG1 frequency inverter confirm that when used in a typical drive configuration the apparatus complies with the European Low Voltage Directive LVD and the EMC Directives Directive 2006 95 EC and Directive 2004 108 EC In the described system configurations DG1 frequency inverters are suitable for use in public and non public networks A connection to IT networks networks without reference to earth potential is permissible only to a limited extent because the device s built in filter capacitors connect the network with the earth potential enclosure On earth free networks this can lead to dangerous situations or damage to the device isolation monitoring required To the output of the frequency inverter terminals U V W you must not connect a voltage or capacitive loads for exa
105. sions at or above line potential Extreme care should be taken to protect against shock Stand on an insulating pad and make it a habit to use only one hand when checking components Always work with another in case an emergency occurs person Disconnect power before checking controllers or performing maintenance Be sure equipment is properly earthed e Wear safety glasses whenever working on electronic controllers or rotating machinery A WARNING The components in the drive s power section remain energized after the supply voltage has been switched off After disconnecting the supply wait at least five minutes before removing the cover to allow the intermediate circuit capacitors to discharge Pay attention to hazard warnings JN DANGER 5 MIN A WARNING Electric shock hazard risk of injuries Carry out wiring work only if the unit is de energized A WARNING Do not perform any modifications on the AC drive when it is connected to mains Warnings and Cautions A WARNING Be sure to ground the unit following the instructions in this manual Ungrounded units may cause electric shock and or fire A WARNING This equipment should only be installed adjusted and serviced by qualified electrical maintenance personnel familiar with the construction and operation of this type of equipment and the hazards involved Failure to observe this precaution could result in death or severe injur
106. switch cabinet as close to the ground potential as possible This is because free moving cables act as antennas When laying HF cables for example shielded motor cables or suppressed cables for example input supply cables control circuit and signal cables in parallel a minimum clearance of 11 81 in 300 mm should be ensured in order to prevent the radiation of electromagnetic energy Separate cable routing should also be ensured when large voltage potential differences are involved Any necessary crossed cabling between the control signal and power cables should always be implemented at right angles 90 degrees Never lay control or signal cables in the same duct as power cables Analog signal cables measured reference and correction values must be shielded Earthing The ground connection PE in the cabinet should be connected from the input supply to a central earth point mounting plate All protective conductors should be routed in star formation from this earth point and all conductive components of the PDS frequency inverter motor reactor motor filter main choke are to be connected Avoid ground loops when installing multiple frequency inverters in one cabinet Make sure that all metallic devices that are to be grounded have a broad area connection with the mounting plate Screen Earth Kit Cables that are not shielded work like antennas sending receiving Make sure that any cables that may carry disruptive
107. te should follow required dimensions refer to the drive mounting template printed on the outside carton Screw Four M8x20 or 3 8 inch Nut Four M8 or 3 8 inch Step 2 Remove the four screws used to fix the drive to the pallet with an 8 or 3 8 inch wrench 28 DG1 Series VFD 040002 2014 www eaton com Power Wiring Selection Motor cable connections are made to terminals U V and W Cable Selection Power and Motor Leads Use UL approved heat resistant copper cables only 75 or higher for all units rated e Line voltage mains should be Class 1 wire only outside North America Refer to the following tables for cable sizing guidelines North America 208V to 240V Appendix B North America 380V to 500V Appendix B All other International 380V to 600V Appendix B Line Mains and Motor Cable Installation The input line and motor cables must be sized in accordance with the rated DG1 VFD input and output current If motor temperature sensing is used for overload protection the output cable size may be selected based on the motor specifications Maximum symmetrical supply current is 100 000A RMS for all size DG1 VFDs Input Fusing Fuses are rated based on 061 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
108. th PVC insulation with a wiring condition of ambient temperature 30 C in air and an installation method of B2 cables in conduit and cable trunking systems For other wiring conditions please refer to the standard of 60364 5 52 2009 for suitable cable sizes is changed earthing conductor size should also be changed accordingly If power cubes or bypass used a Class gG gL fuse is recommended Available in 2015 061 Series VFD 040002 2014 www eaton com Earthing conductor size is determined by the cross sectional area of phase conductors according to IEC EN61800 5 1 2007 Table 5 So if phase conductor size 47 Appendix B Installation Guidelines Table 31 North America Cable and Fuse Sizes 440 Vac to 500 Vac Ratings NEC Terminal Connection 400V Input 400V Input NEC Motor Current Current Fuse Wire Size AWG Size AWG Frame Amp Current Current Amp Rating Rating Line and Line and Size Suffix at 460V at 50 C at 40 C ClassT Motor Ground Motor Ground FR1 202 2 0 3 1 3 0 24 3 0 0 4 14 30 10 18 10 303 3 1 4 34 3 0 34 10 14 4 30 10 18 10 403 4 0 5 2 4 8 34 48 10 14 4 30 10 18 10 5D6 5 2 74 7 6 48 7 6 10 14 14 30 10 18 10 7D6 74 8 4 7 6 9 5 4 4 30 10 18 10 9D0 84 112 11 9 12 15 14 14 30 10 18 10 FR2 012 112 15 14 11 14 20 12 2 20 6 12 6 016 14 9 21 5 21 14 21 30
109. the mounting points of the DG1 AFD on the wall or in a cabinet Chapter 1 DG1 Series Overview Real Time Clock Battery Activation To activate the real time clock RTC functionality in the PowerXL DG1 Series AFD the RTC battery already mounted in the drive must be connected to the control board Simply remove the primary drive cover locate the RTC battery directly below the keypad and connect the white 2 wire connector to the receptacle on the control board Figure 1 RTC Battery Connection Table 1 Common Abbreviations Abbreviation Definition CT Constant torque with high overload rating 15096 VT Variable torque with low overload rating 11096 High Overload 150 Low Overload 11096 AFD Adjustable Frequency Drive VFD Variable Frequency Drive 061 Series VFD 040002 2014 www eaton com 1 Chapter 1 DG1 Series Overview Rating Label Figure 2 Rating Label Type DG1 347D6FB C21C Style No 9702 1001 00P Article No XXXXXX PowerXL DG1 VFD CTNT Input Output 3KW U V 380 440 30 0 30 4KW F Hz 50 60 2 0 400Hz 8 4 7 619 5HP U V 440 500 30 0 30 HP F Hz 50 60 Hz 0 400 Hz 18 4 7 6 7 6 Enclosure Rating TYPE 1 IP 21 User installation manual MN040002EN Serial No XXXXXXXXXX mammam Field installed conductors must be copper rated at 75 c www eaton com Madein China
110. the site of storage e Storage temperature to 158 F A0 C 70 C Relative average air humidity 9596 noncondensing EN 50178 To prevent damage to the DC link capacitors storage times longer than 12 months are not recommended Chapter 3 Product Overview Charging the Internal DC Link Capacitors After extended storage times or extended downtimes during which no power is supplied gt 12 months the capacitors in the internal DC link must be recharged in a controlled manner in order to prevent damage To do 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 Service and Warranty In the unlikely event that you have a problem with your DG1 frequency inverter please contact your local sales office When you call have the following information ready e the exact frequency inverter part no see nameplate e the date of purchase detailed description of the problem that has occurred with the frequency inverter If some of the information printed on the nameplate is not legible please state only the information that is clearly legible This information can also be found on the cover of the control terminals Information concerning the guarantee can be found in the Eaton General Terms and Conditions of Sale 061 Series VFD MN040002EN March
111. ting in case of overload oo D Frequency reference Analog input resolution 0 1 10 bit accuracy 1 Panel reference resolution 0 01 Hz Field weakening point 20 Hz to 400 Hz Acceleration time 0 1 s to 3000 s Deceleration time 0 1 s to 3000 s Braking torque DC brake 3096 x Motor Rated Torque Tn without brake chopper Dynamic braking with optional brake chopper using an external brake resistor 10096 continuous maximum rating Ambient conditions Ambient operating temperature 10 C no frost to 50 C 10 no frost to 40 C up to 60 C with derating CT up to 55 C with derating VT Storage temperature 40 C to 70 C Relative humidity 0 95 RH noncondensing non corrosive Air quality Chemical vapors Mechanical particles Tested according to IEC 60068 2 60 Test Key Flowing mixed gas corrosion test Method 1 H2S hydrogen sulfide and 502 sulfur dioxide Designed according to IEC 60721 3 3 unit in operation class 3C2 IEC 60721 3 3 unit in operation class 352 Altitude 10096 load capacity no derating up to 3280 ft 1000 mJ 196 derating for each 328 ft 100 m above 3280 ft 1000 max 9842 ft 3000 m 2000 m for corner grounded earth main systems Vibration 5 150 Hz EN 61800 5 1 EN 60668 2 6 Displacement amplitude 1 mm peak at 5 Hz to 15 8 Hz FR1 FR5 Maximum acceleration amplitud
112. tion is uncertain the use of an assigned AC choke is recommended Total Harmonic Distortion THD Non linear consumers loads in an AC supply system produce harmonic voltages that again result in harmonic currents These harmonic currents at the inductive and capacitive reactances of a mains supply system produce additional voltage drops with different values that are then overlaid on the sinusoidal mains voltage and result in distortions In supply systems this form of noise can give rise to problems in an installation if the sum of the harmonics exceeds certain limit values Non linear consumers harmonics producers include for example nduction and arc furnaces welding devices Current converters rectifiers and inverters soft starters variable frequency drives e Switched mode power supply units computers monitors lighting uninterrupted power supply UPS The THD value THD Total Harmonic Distortion is defined 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 2 02 UZ 02 U THD x 100 U fundamental component U n order harmonic component The THD value of the harmonic distortion is stated in relation to the rms value of the total signal as a percentage On a variable frequency drive the total harmonic distortion is around 12096 To assist in the c
113. tor EN A PA Shield Installation in Corner Grounded Network Corner grounding is allowed for all the drive types In these circumstances the EMC protection class must be changed to level C4 following the instructions below Installation in IT System If your supply network is an IT impedance grounded system but your AC drive is EMC protected according to class C2 you need to modify the EMC protection of the AC drive to EMC level C4 This is done by removing the built in EMC Screw with a simple procedure described below A WARNING Do not perform any modifications on the AC drive when it is connected to mains A WARNING Electric shock hazard risk of injuries Carry out wiring work only if the unit is de energized After disconnecting the supply wait at least five minutes before removing the cover to allow the intermediate circuit capacitors to discharge A WARNING Failure to follow these instructions will result in death or serious injury Frame 1 to Frame 5 Remove the main cover of the AC drive see Figure 30 and locate the screw jumper connecting the built in RFI filters to ground Remove the screw jumper to disconnect the EMC protection Once the screw is removed it can be reconnected to re engage the EMC protection Chapter 7 EMC Installation Figure 29 Locations of the EMC Screw in Frame 1 Frame 2 Frame 3 and Frame 4
114. trol lt 1 DING Digital Input 5 Preset Speed Sets frequency output to Preset Speed 1 8 DING Digital Input 6 Preset Speed B1 Sets frequency output to Preset Speed 2 L 9 DIN7 Digital Input 7 Emergency Stop TI Input forces VFD output to shut off L 10 DIN8 Digital Input 8 Force Remote TIH Input takes VFD from Local to Remote r 11 CMB 015 to 018 Common Grounded Allows source input 12 GND 1 0 Signal Ground 1 0 Ground for Reference and Control 13 24V 24 Output Control voltage output 100 mA max 14 001 Digital Output 1 Ready Shows the drive is ready to run 15 24Vo 24 Output Control voltage output 100 mA max I 16 GND 1 0 Signal Ground 1 0 Ground for Reference and Control 17 A014 Analog Output 1 Output Frequency Shows Output frequency to motor 0 60 Hz 4 mA to 20 mA 18 A024 Analog Output 2 Motor Current Shows Motor current of motor 0 FLA 4 mA to 20 mA 19 24 24 Vdc Input External control voltage input 20 DIN1 Digital Input 1 Run Forward Input starts drive in forward direction start enable 21 DIN2 Digital Input 2 Run Reverse Input starts drive in reverse direction start enable 22 DIN3 Digital Input 3 External Fault Input causes drive to fault 23 DIN4 Digital Input 4 Fault Reset Input resets active faults L_ 24 CMA DI1 to DI4 Common Grounded Allows source input 25 A 5 485 Signal A Fieldbus Communication Modbus BACnet 26 B RS 485 Signal B
115. ure 17 Typex1 12 Open DIlves xs dd BEGGS TE OR eee ae te EG 25 Figure 18 Input Power and Motor Cable Stripping Lengths 30 Figure 19 Ground Wiring aa saya aa San cnt Jan ag OR RR eg EROR do and 33 Figure 20 Terminal Block LayOut i a ce Eee ob detail d tates 35 Figure 21 Basic Internal Control Wiring Diagram 36 Figure 22 DG1 Series Adjustable Frequency Drive 37 Figure 23 Thermistor STO Wiring Diagram 38 Figure 24 Connection to Power Section 38 Figure25 Gro tndlhng west tute CEPR CIS PRG EGO EC 39 Figure 26 Product Modified Sticker 39 Figure 27 EMC Compliant Setup 460 480 41 Figure 28 Cable Description 42 Figure 29 Locations of the EMC Screw in Frame 1 Frame 2 Frame and Frame 4 43 Figure 30 Locations of the EMC Screws in Frame 5 43 Figure 31 FR1 Dimension Drawing 55 Figure 32 FR1 Dimension Drawing Flange Mount 56 Figure 33 FRZ Dimension Drawing 57 Figure 34 FR2 Dimension Drawing Flange Mount
116. y A WARNING Components within the drive are live when it is connected to power Contact with this voltage is extremely dangerous and may cause death or severe injury A WARNING Line terminals L1 L2 L3 motor terminals U V W and the DC link brake resistor terminals DC DC R RA are live when the drive is connected to power even if the motor is not running Contact with this voltage is extremely dangerous and may cause death or severe injury viii PowerXL DG1 Series VFD 4 2 2014 www eaton com A WARNING Even though the control I O terminals are isolated from line voltage the relay outputs and other l O terminals may have dangerous voltage present even when the drive is disconnected from power Contact with this voltage is extremely dangerous and may cause death or severe injury A WARNING This equipment has a large capacitive leakage current during operation which can cause enclosure parts to be above ground potential Proper grounding as described in this manual is required Failure to observe this precaution could result in death or severe injury A WARNING Before applying power to this drive make sure that the front and cable covers are closed and fastened to prevent exposure to potential electrical fault conditions Failure to observe this precaution could result in death or severe injury A WARNING An upstream disconnect protective device must be provided as required
117. ymmetrical distribution to the three external conductors shall be taken into account In addition the total current of all single phase consumers is not to cause an overload of the neutral conductor N conductor The connection and operation of frequency inverters to asymmetrically grounded TN networks phase grounded delta network Grounded Delta USA or neutral point ungrounded or high resistance grounded gt 30 ohms IT networks is only conditionally permissible In these networks above mentioned the internal interference suppression filter of frequency inverter must be disconnected unscrew the screw marked EMC see Installation in System on Page 43 Then the required filtering for EMC electromagnetic compatibility is no longer present degrade to Class T Measures for EMC are mandatory in a drive system in order to meet the legal requirements for EMC and low voltage regulations Good grounding measures are a prerequisite for the effective insert of further measures such as shielding of filters Without respective grounding measures further steps are superfluous 10 DG1 Series VFD 040002 2014 www eaton com Input Voltage and Frequency The standardized input voltages IEC 60038 VDEO17 1 for energy suppliers EVU guarantee the following conditions at the transition points e Deviation from the rated value of voltage Max 10 e Deviation in voltage phase balance Max 3 Deviatio

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