Manual PowerXL™ DC1 Variable Frequency Drives Installation Manual 04/16 MN04020003Z-EN
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Danger! Dangerous electrical voltage! Before commencing the installation • Disconnect the power supply of the device. • Ensure that devices cannot be accidentally retriggered. • Verify isolation from the supply. • Ground and short-circuit. • Cover or enclose neighbouring units that are live. • Follow the engineering instructions (IL) of the device concerned. • Only suitably qualified personnel in accordance with EN 50110-1/-2 (VDE 0105 Part 100) may work on this device/ system.
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Table of contents 0 About this manual ..................................................................... 5 0.1 Target group................................................................................. 5 0.2 0.2.1 0.2.2 0.2.3 0.2.4 List of revisions ............................................................................ Writing conventions ..................................................................... Hazard warnings of material damages .........................................
2 2.3 Cable cross-sections .................................................................... 39 2.4 2.4.1 2.4.2 2.4.3 2.4.4 Safety and switching.................................................................... Disconnecting device................................................................... Fuses ........................................................................................... Residual current circuit-breaker (RCD) ......................................... Mains contactors ........
3.7 3.7.1 3.7.2 3.7.3 3.7.4 3.7.5 3.7.6 3.7.7 3.7.8 3.7.9 3.7.10 Block diagrams............................................................................. 96 DC1-1D… ..................................................................................... 97 DC1-12…...................................................................................... 98 DC1-32…, DC1-34… (in FS1, FS2, FS3)....................................... 99 DC1-32…, DC1-34… (in FS4) .....................................................
6.4 Cable cross-sections .................................................................... 143 6.5 Fuses ........................................................................................... 145 6.6 Mains contactors ......................................................................... 148 6.7 Mains chokes............................................................................... 151 6.8 Radio interference suppression filter ........................................... 153 6.
0 About this manual 0.1 Target group 0 About this manual This manual (MN04020003Z-DE) contains specific information designed to enable you to select and connect a DC1 variable frequency drive. It covers all DC1 frame sizes. Any differences between and special characteristics of the various models will be noted accordingly. Accessories that can be used to modify the DC1 variable frequency drive according to your specific needs will be listed where applicable.
0 About this manual 0.2 List of revisions 0.2.1 Writing conventions Symbols with the following meaning are used in this manual: ▶ Indicates instructions to be followed. 0.2.2 Hazard warnings of material damages NOTICE Warns about the possibility of material damage. 0.2.3 Hazard warnings of personal injury CAUTION WARNING DANGER ￫ Indicates useful tips.
0 About this manual 0.3 Documents with additional information 0.3 Documents with additional information ￫ More information on the devices described here can be found on the Internet under: www.eaton.eu/powerxl as well as in EATON Download Center: http://www.eaton.de/EN/EatonDE/ProdukteundLoesungen/Electrical/ Kundensupport/DownloadCenter/index.htm In the Quick Search box, enter the document name (“MN04020003”, for example). 0.
0 About this manual 0.5 Mains supply voltages 0.5 Mains supply voltages The rated operating voltages stated in the following table are based on the standard values for networks with a grounded star point. In ring networks (as found in Europe) the rated operating voltage at the transfer point of the power supply companies is the same as the value in the consumer networks (e.g. 230 V, 400 V).
1 DC1 device series 1.1 Introduction 1 DC1 device series 1.1 Introduction Due to their ease of use and high reliability, DC1 PowerXL™ variable frequency drives are ideal for general applications involving three-phase motors. In addition, an integrated radio interference suppression filter and a flexible interface ensure that the inverters meet a number of important needs in the machine building industry when it comes to the optimization of production and manufacturing processes.
1 DC1 device series 1.2 System overview 1.
1 DC1 device series 1.3 Checking the Delivery 1.3 Checking the Delivery ￫ Before opening the package, please check the nameplate on it to make sure that you received the correct variable frequency drive. The DC1 series variable frequency drives are carefully packaged and prepared for delivery. The devices should be shipped only in their original packaging with suitable transportation materials.
1 DC1 device series 1.4 Rated operational data 1.4 Rated operational data 1.4.1 Rated operational data on the nameplate The device-specific rated operational data of the DC1 variable frequency drive is listed on the nameplate of the device.
1 DC1 device series 1.4 Rated operational data Nameplate inscription The inscription of the nameplate has the following meaning (example): Inscription Meaning DC1-344D1FB-A20N Part no.: DC1 = DC1 series variable frequency drive 3 = Three-phase mains connection / three-phase motor connection 4 = 400 V mains voltage category 4D1 = 4.
1 DC1 device series 1.4 Rated operational data 1.4.2 Key to part numbers The catalog no. or part no. for the DC1 series of variable frequency drives is made up of four sections.
1 DC1 device series 1.4 Rated operational data Catalog number examples Inscription Meaning DC1-124D1FN-A20N DC1 = DC1 series variable frequency drive 1 = Single-phase mains connection / three-phase motor connection 2 = 230 V mains voltage category (200 - 240 V ±10 %) 4D1 = 4.
1 DC1 device series 1.4 Rated operational data 1.4.3 Features 1.4.3.1 DC1-1D…device series Mains voltage: 1 AC 110 - 115 V (±10 %), 50/60 Hz Output voltage: 3 AC 230 V, 50/60 Hz Assigned Instance Motor Power Display (operating unit) Local controls Radio interference suppression filter Degree of protection Size Brake chopper An internal voltage doubler will increase the mains supply voltage to 230 V (output voltage).
1 DC1 device series 1.4 Rated operational data 1.4.3.2 DC1-12…device series Mains voltage: 1 AC 220 - 240 V (±10 %), 50/60 Hz Display (operating unit) Local controls Radio interference suppression filter Degree of protection Size Brake chopper Output voltage: 3 AC 220 - 240 V, 50/60 Hz Ie P 1) (230 V, 50 Hz) P 2) (220 - 240 V, 60 Hz) A kW HP DC1-122D3NN-A20N 2.3 0.37 1/2 LED – – IP20 FS1 – DC1-122D3FN-A20N 2.3 0.37 1/2 LED – ✓ IP20 FS1 – DC1-122D3NN-A66N 2.3 3) 0.
Display (operating unit) Local controls Radio interference suppression filter Degree of protection Size Brake chopper 1 DC1 device series 1.4 Rated operational data Ie P 1) (230 V, 50 Hz) P 2) (220 - 240 V, 60 Hz) A kW HP DC1-12011NB-A6SN 10.53) 2.2 3 LED ✓ – IP66 FS2 ✓ DC1-12011FB-A6SN 10.53) 2.
1 DC1 device series 1.4 Rated operational data 1.4.3.3 DC1-32… device series Mains voltage: 3 AC 220 - 240 V (±10 %), 50/60 Hz Display (operating unit) Local controls Radio interference suppression filter Degree of protection Size Brake chopper Output voltage: 3 AC 220 - 240 V, 50/60 Hz Ie P 1) (230 V, 50 Hz) P 2) (220 - 240 V, 60 Hz) A kW HP DC1-322D3NN-A20N 2.3 0.37 1/2 LED – – IP20 FS1 – DC1-322D3NN-A66N 2.33) 0.37 1/2 LED – – IP66 FS1 – DC1-322D3NN-A6SN 2.33) 0.
Display (operating unit) Local controls Radio interference suppression filter Degree of protection Size Brake chopper 1 DC1 device series 1.4 Rated operational data Ie P 1) (230 V, 50 Hz) P 2) (220 - 240 V, 60 Hz) A kW HP DC1-32024NB-A20N 24 5.5 7-1/2 LED – – IP20 FS3 ✓ DC1-32024FB-A20N 24 5.5 7-1/2 LED – ✓ IP20 FS3 ✓ DC1-32030NB-A20N 30 7.5 10 LED – – IP20 FS4 ✓ DC1-32030FB-A20N 30 7.
1 DC1 device series 1.4 Rated operational data 1.4.3.4 DC1-34… device series Mains voltage: 3 AC 380 - 480 V (±10 %), 50/60 Hz Display (operating unit) Local controls Radio interference suppression filter Degree of protection Size Brake chopper Output voltage: 3 AC 380 - 480 V, 50/60 Hz Ie P 1) (400 V, 50 Hz) P 2) (440 - 480 V, 60 Hz) A kW HP DC1-342D2NN-A20N 2.2 0.75 1 LED – – IP20 FS1 – DC1-342D2FN-A20N 2.2 0.75 1 LED – ✓ IP20 FS1 – DC1-342D2NN-A66N 2.2 3) 0.
Display (operating unit) Local controls Radio interference suppression filter Degree of protection Size Brake chopper 1 DC1 device series 1.4 Rated operational data Ie P 1) (400 V, 50 Hz) P 2) (440 - 480 V, 60 Hz) A kW HP DC1-349D5NB-A66N 9.5 3) 4 5 LED – – IP66 FS2 ✓ DC1-349D5FB-A66N 9.5 3) 4 5 LED – ✓ IP66 FS2 ✓ DC1-349D5NB-A6SN 9.5 3) 4 5 LED ✓ – IP66 FS2 ✓ DC1-349D5FB-A6SN 9.5 3) 4 5 LED ✓ ✓ IP66 FS2 ✓ DC1-34014NB-A20N 14 4) 5.
1 DC1 device series 1.5 Description 1.5 Description 1.5.1 IP20 degree of protection (FS1 to FS4) The following drawing serves as an example showing the designations used for the elements in DC1 variable frequency drives with an IP20 degree of protection and a size of FS1.
1 DC1 device series 1.5 Description 1.5.2 IP66 degree of protection (FS1 to FS3) The following drawing serves as an example showing the designations used for the elements in DC1 variable frequency drives with an IP66 degree of protection and a size of FS1.
1 DC1 device series 1.6 Voltage categories 1.6 Voltage categories DC1 variable frequency drives are divided into three voltage categories: 115 V: 110 - 115 V ±10 % ￫ DC1-1D 200 V: 200 - 240 V ±10 % ￫ DC1-12…, DC1-32… 400 V: 380 - 480 V ±10 % ￫ DC1-34… • • • a For more information on how to run single-phase AC motors using the DC1 variable frequency drive, please refer to Application Note AP040037EN, “DC1 Variable Frequency Drives – Operating Single Phase Motors”. ftp://ftp.moeller.
1 DC1 device series 1.6 Voltage categories • L1 L2 L3 PE DC1-32… • Three-phase power supply, rated operating voltage 230 V • ULN = 3~, 200 - 240 V ±10 %, 50/60 Hz • Ie = 2.3 - 46 A • Motor: 0.
1 DC1 device series 1.7 Selection criteria 1.7 Selection criteria Select the variable frequency drive according to the supply voltage ULN of the supply system and the rated operational current of the assigned motor. The circuit type (Δ / ) of the motor must be selected according to the supply voltage. The variable frequency drive’s rated output current Ie must be greater than or equal to the rated motor current. P-08 P-07 1 2 3 4 L1/L L2/N L3 5 6 7 U 8 9 10 11 V W 230/400 V 3.2/1.
1 DC1 device series 1.7 Selection criteria ￫ When connecting multiple motors in parallel to the output of a variable frequency drive, the motor currents are added geometrically – separated by effective and reactive current components. When you select a variable frequency drive, make sure that it can supply the total resulting current.
1 DC1 device series 1.8 Output reduction (derating) 1.
1 DC1 device series 1.8 Output reduction (derating) Examples showing how to apply derating factors 2.2 kW motor (400 V, 5 A), installation altitude of 2,000 m above sea level, ambient temperature of 45 °C, wall-mounted in mechanical room, required switching frequency of 16 kHz. a) Selected variable frequency drive: DC1-349D5FB-A6SN, rated operational current of 9.5 A, switching frequency of 8 kHz (default setting).
1 DC1 device series 1.9 Proper use 1.9 Proper use The DC1 variable frequency drives are electrical devices 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. The DC1 variable frequency drives are not domestic appliances. They are designed only for industrial use as system components.
1 DC1 device series 1.10 Maintenance and inspection 1.10 Maintenance and inspection DC1 series variable frequency drives will be maintenance-free as long as the general rated operational data (see annex) is adhered to and the specific technical data (see annex) for the corresponding ratings is taken into account. Please note, however, that external influences may affect the operation and lifespan of a DC1 variable frequency drive.
1 DC1 device series 1.12 Charging the internal DC link capacitors 1.12 Charging the internal DC link capacitors After extended storage times or extended downtimes during which no power is supplied (> 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 DC1 variable frequency drive must be supplied with power, with a controlled DC power supply unit, via two mains connection terminals (e.g. L1 and L2).
1 DC1 device series 1.13 Service and warranty 34 DC1 Variable Frequency Drive 04/16 MN04020003Z-EN www.eaton.
2 Engineering 2.1 Introduction 2 Engineering 2.1 Introduction This chapter describes the most important features in the energy circuit of a magnet system (PDS = Power Drive System), which you should take into consideration in your project planning. It contains instructions that must be followed when determining which device to use with which rated motor output, as well as when selecting protection devices and switchgear, selecting cables, cable entries, and operating the DC1 variable frequency drive.
2 Engineering 2.
2 Engineering 2.2 Electrical power network 2.2 Electrical power network 2.2.1 Mains terminal and configuration DC1 variable frequency drives can be connected to and run on all neutral point-grounded AC supply systems (TN-S, TN-C, TT grounding systems; please refer to IEC 60364) without any limitations.
2 Engineering 2.2 Electrical power network 2.2.
2 Engineering 2.3 Cable cross-sections 2.2.4 Total Harmonic Distortion (THD) 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. ￫ In order to reduce the THD value (up to 30 %), it is recommended to use a DX-LN… mains choke (￫ Section 2.5, “Mains chokes“, page 42). 2.2.
2 Engineering 2.4 Safety and switching A symmetrical, fully screened (360°), low-impedance motor cable must be used. The length of the motor cable depends on the RFI class and the environment. For US installations, UL-listed cables (AWG) should be used exclusively. These cables must have a temperature rating of 70 °C (158 °F), and will often require installation inside a metal conduit (please consult the applicable local standards).
2 Engineering 2.4 Safety and switching 2.4.3 Residual current circuit-breaker (RCD) When using variable frequency drives (DC1-3…) that work with a threephase power supply (L1, L2, L3), make sure to use type B AC/DC sensitive residual current devices exclusively. When using variable frequency drives that work with a single-phase power supply (L, N) (DC1-12… and DC1-1D…), you may use type A and type B residual current devices (RCD).
2 Engineering 2.5 Mains chokes 2.5 Mains chokes Mains chokes reduce the total harmonic distortion, the mains feedback and improve the power factor. The apparent current on the mains side is then reduced by around 30 %. Towards the variable frequency drive, the main chokes dampen the interference from the supply network. This increases the electric strength of the variable frequency drive and lengthens the lifespan (diodes of the mains power rectifier, internal DC link capacitors).
2 Engineering 2.6 Radio interference suppression filter 2.6 Radio interference suppression filter DC1-12xxxF…, DC1-32xxxF…, and DC1-34xxxF… variable frequency drives feature an internal radio interference suppression filter. When combined with a motor cable that is screened and earthed 360° on both ends, they make it possible to comply with the stringent EMC limits for conducted interference corresponding to category C1 in the 1st environment (IEC/EN 61800-3).
2 Engineering 2.7 Braking resistances 2.7 Braking resistances In certain operating states, the motor may run as a generator in certain applications (regenerative braking operation).
2 Engineering 2.7 Braking resistances In the case of units with a frame size of FS2 or FS3, brake resistor DX-BR3-100 (PD = 200 W) can be inserted underneath the heat sink. In addition, parameter P-34 must be set to a value of 1 in order to protect against thermal overloads (braking chopper activated with electronic overload protection).
2 Engineering 2.7 Braking resistances Selecting brake resistors Brake resistors are selected based on continuous power dissipation PDB and maximum peak pulse power PPeak. The brake resistor must be adequate for both powers. The maximum pulse power is defined by the braking torque – kinetic energy Wkin during braking – that is fed back by the motor during braking.
2 Engineering 2.8 Motor chokes 2.8 Motor chokes It is recommended to use a motor choke if using long cable lengths and/or connecting several motors in parallel. The motor reactor is in the output of the variable frequency drive. Its rated operational current must always be greater than/equal to the rated operational current of variable frequency drive. For DC1 variable frequency drives, it is recommended to use a motor choke for motor cable lengths of 100 meters or more.
2 Engineering 2.9 Sine filter 2.9 Sine filter Sine filters can be used to remove high-frequency components from a variable frequency drive’s output voltage, reducing conducted and emitted interference as a result.
2 Engineering 2.10 Switching to the output side 2.10 Switching to the output side Typical applications for switching at the DC1 variable frequency drive’s output include: • • • • Cases in which a bypass circuit is implemented. Cases in which it must be possible to switch on various motors as necessary. Cases in which several motors are connected in parallel and need to be switched individually. Cases in which the motor must be de-energized quickly in the event of an emergency stop (safety shutdown).
2 Engineering 2.10 Switching to the output side 2.10.2 switch-disconnectors Switch-disconnectors are used as repair and maintenance switches in industrial, trade, and building service management applications. At the output of variable frequency drives, they are primarily used to locally switch off motors (pumps, fans) that pose a risk of unintended starting during maintenance or repairs.
2 Engineering 2.10 Switching to the output side 2.10.3 Bypass circuit WARNING Never connect the DC1 variable frequency drive’s output terminals U, V, and W to the power feed system (L1, L2, L3)! Connecting the mains voltage to the output terminals can result in the variable frequency drive being irreparably damaged.
2 Engineering 2.10 Switching to the output side 2.10.4 Connecting Motors in Parallel ￫ If multiple motors are connected in parallel, the total of their motor currents must be lower than the DC1 variable frequency drive’s rated operational current. Connecting motors in parallel will reduce the load resistance at the variable frequency drive’s output.
2 Engineering 2.10 Switching to the output side ① a Motor choke (DX-LM3…) or sine filter (DX-SIN3…) Q11, Q12, Q13, …: Motor protection (utilization category AC-3) Q11 Q12 Q13 F1 F2 F3 U1 V1 W1 M1 M 3 ˜ U1 V1 W1 M2 M 3 ˜ U1 V1 W1 M3 F1, F2, F3, …: Overload relay (bimetallic relay or PKE) M 3 ˜ Figure 19: Example: Parallel connection of several motors to one variable frequency drive DC1 Variable Frequency Drive 04/16 MN04020003Z-EN www.eaton.
2 Engineering 2.11 Three-phase motor 2.11 Three-phase motor 2.11.1 Motor Selection ￫ Check whether the DC1 variable frequency drive you selected and the AC motor you will be using are compatible with each other as per the corresponding voltage (mains and motor voltage) and rated operational current.
2 Engineering 2.11 Three-phase motor 2.11.2 Circuit types with three-phase motors A three-phase motor’s stator winding can be connected in a star connection or delta circuit as per the mains voltage (ULN = output voltage U2) and the rated operational data on the motor’s nameplate (rating plate). 230/400 V 3.2/1.9 A cosϕ 0.
2 Engineering 2.11 Three-phase motor 2.11.3 Single-phase AC motors It is strictly prohibited to use the DC1 variable frequency drives described in this manual to run single-phase AC motors (induction motors), single-phase asynchronous motors (capacitor motors), shaded-pole motors, etc. There are other DC1 variable frequency drive models designed for use with these motors: DC1-S1… and DC1-S2… with IP20 and IP66 degrees of protection.
3 Installation 3.1 Introduction 3 Installation 3.1 Introduction This chapter provides a description of the installation and the electrical connections for the variable frequency drive DC 1 series. ￫ While installing and/or assembling the variable frequency drive, cover all ventilation slots in order to ensure that no foreign bodies can enter the device. ￫ Perform all installation work with the specified tools and without the use of excessive force.
3 Installation 3.3 Mounting 3.3 Mounting The engineering instructions in this section are meant to show how to install the device in a suitable enclosure for devices with degree of protection IP20 in compliance with standard EN 60529 and/or any other applicable local regulations. • • • • The enclosures must be made of a material with high thermal conductivity.
3 Installation 3.3 Mounting 3.3.1 Mounting position DC1 series variable frequency drives are designed to be mounted vertically. The maximum permissible inclination is 30°. ≦ 30º ≦ 30º ≦ 30º ≦ 30º Figure 23: Mounting position 3.3.2 Cooling measures To ensure that there is sufficient air circulation, appropriate thermal clearances must be maintained, with these clearances depending on the size of the specific variable frequency drive.
3 Installation 3.3 Mounting When variable frequency drives with internal fans are installed vertically over each other, an air baffle must be placed between the devices. Failure to do so may expose the device on top to a thermal overload caused by the guided air flow (device fan). V EMC c c VAR V Figure 25: Deflector due to increased circulation caused by device fan ￫ Devices with high magnetic fields (e. g. reactors or transformers) should not be installed close to the variable frequency drive.
3 Installation 3.3 Mounting The values specified in ￫ Table 3 are recommended values for an ambient temperature of up to +50 °C with an IP20 degree of protection or +40 °C with an IP66 degree of protection, an installation altitude of up to 1,000 m, and a switching frequency of up to 8 kHz. ￫ Typical heat loss makes up about 3 % of the operational load conditions. ① Size with IP20 degree of protection Minimum clearance ① FS1, …, FS4 ≧ 15 mm (≧ 0.
3 Installation 3.3 Mounting 3.3.3 Fixing All DC1 variable frequency drive frame sizes can be mounted with screws. Moreover, frame sizes FS1 to FS3 with an IP20 degree of protection can be mounted on a mounting rail as well. ￫ Dimension and weight specifications for the DC1 variable frequency drive can be found in the ￫ Section 6.3, “Dimensions“, page 140.
3 Installation 3.3 Mounting 3.3.3.2 Fixing on a mounting rail As an alternative to screw fixing, DC1 variable frequency drives with sizes FS1, FS2 and FS3 and a degree of protection of IP20 can also be mounted on a mounting rail as per IEC/EN 60715. 1.38” If you use EMC mounting adapters (DX-EMC-MNT-…), use a tall mounting rail (15 mm) preferably. 35 ￫ 1 0.04” 0.29” 0.59” 7.
3 Installation 3.3 Mounting Dismantling from mounting rails ▶ To remove the device, push down the spring-loaded clip. A cutout marked on the lower edge of the device is provided for this purpose. A flat-bladed screwdriver (blade width 5 mm) is recommended for pushing down the clip. f 5 mm (f 0.197“) EMC VAR 1 3 2 Figure 30: Dismantling from mounting rails 64 DC1 Variable Frequency Drive 04/16 MN04020003Z-EN www.eaton.
3 Installation 3.4 IP66 / NEMA4X degree of protection 3.
3 Installation 3.5 EMC installation 3.5 EMC installation The responsibility to comply with the legally stipulated limit values and thus the provision of electromagnetic compatibility is the responsibility of the end user or system operator. This operator must also take measures to minimize or remove emission in the environment concerned. He must also utilize means to increase the interference immunity of the devices of the system.
3 Installation 3.5 EMC installation ￫ Route mains and motor cables in the control cabinet as close to the ground potential as possible. This is because free moving cables act as antennas. ￫ If routed in parallel, cables carrying high frequencies (e.g., screened motor cables) and clean cables (e.g., mains supply cable, control and signal cables) should be installed at a distance of at least 100 mm from each other in order to avoid electromagnetic interference.
3 Installation 3.5 EMC installation 3.5.2 Earthing The protective earth (PE) in the control panel should be connected from the mains supply to a central earth point (mounting plate, system earth). The PE conductor’s cross-sectional area must be at least as large as that of the incoming mains supply cable. If there are leakage currents greater than 3.5 mA, the PE conductor must have a minimum cross-sectional area of 10 mm2.
3 Installation 3.5 EMC installation 3.5.2.3 Earth-fault protection A fault current to earth can be produced by variable frequency drives due to their system characteristics. DC1 series variable frequency drives have been designed in such a way that the smallest possible fault current will be produced in compliance with standards applicable worldwide.
3 Installation 3.5 EMC installation 3.5.3.1 EMC screw NOTICE The screw labeled EMC must not be manipulated as long as the variable frequency drive is connected to the mains or there is a DC link voltage. ￫ The EMC screw galvanically connects the EMC filter’s mainsside capacitors to the earthing (PE). The screw must be screwed in all the way to the stop (factory setting) in order for the variable frequency drive to comply with EMC standards.
3 Installation 3.5 EMC installation performed and the test must then be repeated. The system must then fail the test, indicating that the overvoltage protection components have been reconnected. NOTICE The screw labeled VAR (￫ Figure 36, page 69) must not be manipulated as long as the variable frequency drive is connected to the mains or there is a DC link voltage. 3.5.4 Screen earth kit Cables that are not screened work like antennas (sending, receiving).
3 Installation 3.5 EMC installation 3.5.5 EMC cable brackets Frame-size-specific DX-EMC-MNT-… cable brackets can be used to easily route and secure cables in the connection area of a DC1 variable frequency drive with a frame size of FS1 to FS3 and an IP20 degree of protection. These cable brackets are mounted on the variable frequency drive’s mains connection side (DX-EMC-MNT-…N) and motor side (DX-EMC-MNT-…M) using the corresponding mounting holes, and are then connected to the drive’s earthing.
3 Installation 3.5 EMC installation ￫ For more information and technical data on DX-EMC-MNT-… EMC cable brackets, please refer to instruction leaflet IL040010ZU. ￫ DX-EMC-MNT-… EMC cable brackets are sold as individual units. There are different brackets for each DC1 variable frequency drive size (FS1 to FS3). The gland plates and their fixing screws are included in the equipment supplied with the cable brackets. Connection example DX-EMC-MNT ... N FS1, FS2: = 4 x M4 FS3: = 4 x M5 1.
3 Installation 3.5 EMC installation 3.5.6 General installation diagram ~ AC ① PE ② ⑥ B A B DC- L1/L L2/N L3 A 1 2 3 4 5 6 7 ③ 8 9 10 11 12 13 COM 14 15 16 17 18 DC+ BR U V PES W ⑤ B A PES ④ PES ≧ 100 mm (≧ 3.
3 Installation 3.6 Electrical Installation 3.6 Electrical Installation CAUTION DANGER Carry out wiring work only after the variable frequency drive has been correctly mounted and secured. Electric shock hazard - risk of injuries! Carry out wiring work only if the unit is de-energized. NOTICE Fire hazard! Only use cables, circuit-breakers, and contactors that feature the indicated permissible nominal current value.
3 Installation 3.6 Electrical Installation 3.6.1 Connection to power section The connection to the power section is normally made via the connection terminals: L1/L, L2/N, L3, PE for the mains-side supply voltage. The phase sequence does not matter.
3 Installation 3.6 Electrical Installation 3.6.1.
3 Installation 3.6 Electrical Installation Size Terminals Description FS4 PE L1 L2 L3 EMC L1 L2 L3 Connection with three-phase supply voltage: • DC1-32… (230 V) • DC1-34… (400 V, 480 V) Motor connection for three-phase motors: • DC1-32… (230 V) • DC1-34… (400 V, 480 V) DC+ BR DC- U V W PES Remark: DC+ , DC-: DC link connection if using an external DC power supply or DC link coupling. The terminals’ plastic cover can be removed if necessary.
3 Installation 3.6 Electrical Installation 3.6.1.2 Terminals in power section for units with IP66 degree of protection On units with an IP66 degree of protection, the connection area is located behind the lower enclosure cover. To open the cover, release the two latches by turning them counterclockwise (90 degrees) so that they are in a vertical position [1]. Once the latches are released, you can lift the cover off [2].
3 Installation 3.
3 Installation 3.6 Electrical Installation 3.6.1.3 Stripping lengths and tightening torques PE PE PE PE A1 Mains 1~ A1 A1 A1 Mains 3~ Motor DC-Link, Brake Resistor Figure 43: Stripping lengths in the power section Mains = Electrical power network (supply voltage) Motor = Motor connection DC-Link = DC link coupling Brake Resistor = Braking resistance (brake chopper) Table 8: Terminal capacities and tightening torques Frame size FS1 FS2 FS3 FS4 A1 mm in 8 10 10 10 - 11 0.3 0.39 0.39 0.39 - 0.
3 Installation 3.6 Electrical Installation 3.6.1.4 Connecting the motor cable The screened cables between the variable frequency drive and the motor should be as short as possible. Figure 44: Connection on motor side ▶ ▶ Connect the screening, on both sides and across a large area (360° overlap), to the protective earth (PE) .The power screening’s protective earth (PES) connection should be in the immediate proximity of the variable frequency drive.and directly on the motor terminal box.
3 Installation 3.6 Electrical Installation The following figure shows the construction of a four-wire, screened motor line (recommended specifications).
3 Installation 3.6 Electrical Installation 3.6.1.5 Cable glands IP66 In the case of units with an IP66 degree of protection, a total of six cable glands can be installed. The lower section will come with two knockouts for cable glands that have already been removed and that are intended for the connections in the power section (Mains ①, Motor ②). Meanwhile, the center knockout in the lower section, which will not yet have been removed, is intended for an external brake resistor.
3 Installation 3.6 Electrical Installation ￫ Make sure that the cable glands have at least an IP66 degree of protection. Table 9: Cable glands that can be used (figures 47, 48) Range Control section Size Hole size PG-gland Metric gland FS1 2 x 22 mm 2 x PG 13.5 1 x PG 16 2 x M20 1 x M25 FS2 Control ③ FS3 Power section FS1 3 x 22 mm 3 x PG 13.5 3 x M20 FS2 Mains ① Motor ② FS3 1 x 22 mm 2 x 25 mm 1 x PG 13.5 2 x PG 16 1 x M20 2 x M25 The EMC cable gland must be earthed properly – e.
3 Installation 3.6 Electrical Installation 3.6.
3 Installation 3.6 Electrical Installation 3.6.2.1 Terminal capacities and stripping lengths The terminal capacities and stripping lengths are listed in the following table. Table 10: Control signal terminal sizes and designs M3 mm2 mm2 AWG mm in N/m ft-lbs mm 0.2 - 2.5 0.2 - 1.5 24 - 12 5 0.2 0.5 0.42 0.4 x 2.5 3.6.2.
3 Installation 3.6 Electrical Installation ￫ The control terminals’ functions and electrical parameters can be changed with • Parameter, • Expansion modules DXC-EXT-… (￫ Section 7.1.2, “DXC-EXT-2RO output expansion“, page 166 and ￫ Section 7.1.3, “DXC-EXT-2RO1AO output expansion“, page 168). 3.6.2.3 Connection example DI2 +10 V AI1 0V 1 2 3 5 6 7 1 15 mm (0.59”) DI1 ≦ 20 m (≦ 65.62 ft) +24 V PES 2 3 2 Cu 2.
3 Installation 3.6 Electrical Installation Alternatively, in addition to the broad area gland plate, you can twist the screen braid at the end and connect to the protective earth with a cable lug. To prevent EMC disturbance, this twisted shielding connection should be made as short as possible Prevent the screen from becoming unbraided at the other end of the control cable, e.g. by using a rubber grommet.
3 Installation 3.6 Electrical Installation 3.6.2.4 Digital Input Signals Control terminals 2, 3, 4, and 6 all have the same function and mode of operation as digital inputs (DI1 to DI4). A logic level of +24 V (positive logic) is used: • • 8 - 30 V = High (logic “1”) 0 - 4 V = Low (logic “0”) The internal control voltage from control signal terminal 1 (+24 V, maximum 100 mA) or an external voltage source (+24 V) can be used for this. The permissible residual ripple must be less than ±5 % ΔUa / Ua.
3 Installation 3.6 Electrical Installation 3.6.2.5 Digital Output (Transistor) When using the device’s default configuration, control signal terminal 8 will be configured as an analog output (AO). It can be set to work as a digital output instead (DO) with parameter P-25. Transistor output DO can deliver a digital signal via control signal terminal 8 with the device’s internal control voltage (+24 V). The maximum permissible load current is 20 mA.
3 Installation 3.6 Electrical Installation 3.6.2.7 Analog output signal OV AO < 20 mA There is an analog voltage signal (0 - 10 V) available at control signal terminal 8. This output can handle a maximum load of 20 mA. Parameter P-25 is used to configure whether this output signal will be provided at the terminal. 8 f-Out 0...+10 V 9 + - ￫ Figure 56: Analog output (AO) (connecting example) Control terminals 7 and 9 are the common 0 V reference potential for all analog and digital input signals.
3 Installation 3.6 Electrical Installation Figure 57: Connection examples with suppressor circuit 3.6.2.9 RJ 45 interface The RJ45 port located in the front (IP20) or under the connection terminal cover (IP66) can be used to directly connect the device to communication modules and fieldbus connections. The internal RS-485 connection transmits Modbus RTU and CANopen data.
3 Installation 3.6 Electrical Installation 3.6.2.10 Control signal terminals IP66 In the case of DC1 variable frequency drives with an IP66 degree of protection, the plug-in control signal terminals are located under the terminal cover. In version DC1-…A6SN, the local controls will already be connected.
3 Installation 3.6 Electrical Installation 3.6.3 Thermistor connection Motor thermistors and motor thermal switches (Thermoclick) can be connected to control signal terminal 4 (DI3 = digital input 3) in order to provide protection against thermal motor overloads. In this case, parameter P-15 must be used to select the EXTFLT (external fault) setting for DI3, and parameter P-47 must be set to a value of 6 (Ptc-th). 1 2 3 4 5 6 7 8 9 10 11 PES T1 T2 U V W PE M3∼ ϑ PTC type ≧ 2.5 kΩ trip level ≦ 1.
3 Installation 3.7 Block diagrams 3.7 Block diagrams The following block diagrams show all the connection terminals on a DC1 variable frequency drive and their functions when in their default settings. 96 DC1 Variable Frequency Drive 04/16 MN04020003Z-EN www.eaton.
3 Installation 3.7 Block diagrams 3.7.1 DC1-1D… Mains voltage ULN: 1-phase, 110 (-10 %) - 115 (+10 %) V, 50/60 Hz Motor Voltage U2: 3-phase, U2 = 2 x ULN (voltage doubling), 0 - 50/60 Hz (max. 500 Hz) 9 10 11 6 A, 250 V AC 5 A, 30 V DC 8 0V AI1 (DI4) 7 RUN 0...+10 V, < 20 mA f-Out + 6 AO (DO) 5 0V +10 V 4 +10 V Out < 10 mA REF 0...
3 Installation 3.7 Block diagrams 3.7.2 DC1-12… Mains voltage ULN: single-phase, 200 (-10 %) - 240 (+10 %) V, 50/60 Hz Motor voltage U2: 3-phase, U2 = ULN, 0 - 50/60 Hz (max. 500 Hz) FS2, FS3 RUN 0...+10 V, < 20 mA f-Out + 9 0V 8 AO (DO) 7 0V 6 AI1 (DI4) REF 0...
3 Installation 3.7 Block diagrams 3.7.3 DC1-32…, DC1-34… (in FS1, FS2, FS3) Mains voltage ULN: DC1-32…: 3-phase, 200 (-10 %) - 240 (+10 %) V, 50/60 Hz DC1-34…: 3-phase, 380 (-10 %) - 480 (+10 %) V, 50/60 Hz Motor voltage U2: 3-phase, U2 = ULN, 0 - 50/60 Hz (max. 500 Hz) Size: FS1, FS2 and FS3 with IP20 degree of protection FS2, FS3 9 0V 8 RUN 0...+10 V, < 20 mA f-Out + AI1 (DI4) 7 AO (DO) 6 0V +10 V 5 +10 V Out < 10 mA REF 0...
3 Installation 3.7 Block diagrams 3.7.4 DC1-32…, DC1-34… (in FS4) Mains voltage ULN: DC1-32…: 3-phase, 200 (-10 %) - 240 (+10 %) V, 50/60 Hz DC1-34…: 3-phase, 380 (-10 %) - 480 (+10 %) V, 50/60 Hz Motor voltage U2: 3-phase, U2 = ULN, 0 - 50/60 Hz (max. 500 Hz) Size: FS4 with IP20 degree of protection ① DC- 9 10 11 6 A, 250 V AC 5 A, 30 V DC 8 0V AI1 (DI4) 7 RUN 0...+10 V, < 20 mA f-Out + 6 AO (DO) 5 0V +10 V 4 +10 V Out < 10 mA REF 0...
3 Installation 3.7 Block diagrams 3.7.5 DC1-1D…Nx-A6SN Mains voltage ULN: 1-phase, 110 (-10 %) - 115 (+10 %) V, 50/60 Hz Motor Voltage U2: 3-phase, U2 = 2 x ULN (voltage doubling), 0 - 50/60 Hz (max. 500 Hz) Size: FS1 and FS2 with IP66 degree of protection ② 1 AC 110 - 115 V 50/60 Hz L1/L L2/N ① REV OFF FWD ④ f-Soll 0...
3 Installation 3.7 Block diagrams ① Reference value potentiometer (0 - fmax) ② Operating direction selector switch (FWD = Clockwise rotating field, REV = Counterclockwise rotating field) ③ Mains switch (PWR = Power) ④ External brake resistors can be connected to devices with a frame size of FS2 or bigger. ￫ DC1-1D variable frequency drives do not have an internal radio interference suppression filter.
3 Installation 3.7 Block diagrams 3.7.6 DC1-1D…Nx-A66N Mains voltage ULN: 1-phase, 110 (-10 %) - 115 (+10 %) V, 50/60 Hz Motor Voltage U2: 3-phase, U2 = 2 x ULN (voltage doubling), 0 - 50/60 Hz (max. 500 Hz) Size: FS1 and FS2 with IP66 degree of protection DC1-32... 3 AC 200 - 240 V 50/60 Hz DC1-34...
3 Installation 3.7 Block diagrams 3.7.7 DC1-12…-A6SN Mains voltage ULN: single-phase, 200 (-10 %) - 240 (+10 %) V, 50/60 Hz Motor voltage U2: 3-phase, U2 = ULN, 0 - 50/60 Hz (max. 500 Hz) Size: FS1, FS2 and FS3 with IP66 degree of protection ② 1 AC 200 - 240 V 50/60 Hz L1/L L2/N ① REV OFF FWD f-Soll 0...
3 Installation 3.7 Block diagrams 3.7.8 DC1-12…-A66N Mains voltage ULN: single-phase, 200 (-10 %) - 240 (+10 %) V, 50/60 Hz Motor voltage U2: 3-phase, U2 = ULN, 0 - 50/60 Hz (max.
3 Installation 3.7 Block diagrams 3.7.9 DC1-32…-A6SN, DC1-34…-A6SN Mains voltage ULN: DC1-32…: 3-phase, 200 (-10 %) - 240 (+10 %) V, 50/60 Hz DC1-34…: 3-phase, 380 (-10 %) - 480 (+10 %) V, 50/60 Hz Motor voltage U2: 3-phase, U2 = ULN, 0 - 50/60 Hz (max. 500 Hz) Size: FS1, FS2 and FS3 with IP66 degree of protection DC1-32... 3 AC 200 - 240 V 50/60 Hz ② DC1-34... 3 AC 380 - 480 V 50/60 Hz L1/L L2/N L3 ① REV OFF FWD f-Soll 0...
3 Installation 3.7 Block diagrams 3.7.10 DC1-32…-A66N, DC1-34…-A66N Mains voltage ULN: DC1-32…: 3-phase, 200 (-10 %) - 240 (+10 %) V, 50/60 Hz DC1-34…: 3-phase, 380 (-10 %) - 480 (+10 %) V, 50/60 Hz Motor voltage U2: 3-phase, U2 = ULN, 0 - 50/60 Hz (max. 500 Hz) Size: FS4 with IP20 degree of protection DC1-32... 3 AC 200 - 240 V 50/60 Hz DC1-34...
3 Installation 3.8 Insulation testing 3.8 Insulation testing The variable frequency drive of the DC1 series are tested, delivered and require no additional testing. CAUTION CAUTION On the control signal and the connection terminals of the variable frequency drive, no leakage resistance tests are to be performed with an insulation tester.
3 Installation 3.9 Protection against electric shock 3.
3 Installation 3.9 Protection against electric shock 110 DC1 Variable Frequency Drive 04/16 MN04020003Z-EN www.eaton.
4 Operation 4.1 Checklist for commissioning 4 Operation 4.1 Checklist for commissioning Before placing the frequency converter into operation, use the checklist below to make sure that all the following requirements are met: No. Activity Notes 1 Mounting and wiring have been carried out in accordance with the corresponding instruction leaflet (￫ IL04020009Z, IL04020013Z, IL04020024ZU).
4 Operation 4.2 Operational hazard warnings 4.2 Operational hazard warnings Please observe the following notes. DANGER DANGER DANGER DANGER Commissioning is only to be completed by qualified technicians. Hazardous voltage! The safety instructions on pages I and II must be followed. The components in the variable frequency drive’s power section are energized if the supply voltage (mains voltage) is connected. For instance: L1/L, L2/N, L3, DC+, DC-, BR, U/T1, V/T2, W/T3 power terminals.
4 Operation 4.2 Operational hazard warnings NOTICE Any contactors and switching devices on the line side are not to be opened during motor operation. Inching operation using the mains contactor is not permitted. Contactors and switchgear (repair and maintenance switches) on the motor side must not be opened while the motor is in operation. Inching operation of the motor with contactors and switching devices in the output of the variable frequency drive is not permissible.
4 Operation 4.3 Commissioning with control terminals (default settings) 4.3 Commissioning with control terminals (default settings) DC1 variable frequency drives come pre-configured for their rated mains voltage and motor output. Once the corresponding motor and mains voltage are connected, these drives allow for direct operation via their control signal terminals.
4 Operation 4.3 Commissioning with control terminals (default settings) ▶ You can now set the output frequency (0 - 50 Hz) and, as a result, the speed of the connected three-phase motor (0 - nMotor), by using the potentiometer via terminal 6 (0 - +10 V proportional voltage signal). The change in output frequency here is delayed based on the specified acceleration and deceleration ramps. When using the device’s default settings, these times will be set to 5 seconds.
4 Operation 4.4 Commissioning with local controls 4.4 Commissioning with local controls DC1-…-A6SN variable frequency drives with local controls are configured and wired at the factory. They can be started directly using the local controls when the rated motor output for the mains voltage is connected (see the connecting example below). ￫ Make sure that the switches ② und ③ are open before switching on the mains voltage.
4 Operation 4.
4 Operation 4.5 Handling the keypad 4.5 Handling the keypad The keypad can be used to configure the DC1 variable frequency drive’s parameters and monitor its operation. ￫ Manual MN04020004Z, “DC1 Variable Frequency Drives – Parameter Manual”, goes over how to configure the individual parameters. 4.5.1 Operating unit elements The following figure shows the elements of the DC1 variable frequency drive integrated operating unit.
4 Operation 4.5 Handling the keypad Table 14: Keypad buttons Button Attribute ID Explanation OK • Navigating in parameter mode • Opens and closes the parameter interface (press the button and hold it down for more than two seconds) • Saves parameter changes • Changes the value being displayed: A, rpm, etc.
4 Operation 4.5 Handling the keypad 4.5.2 Adjust parameters Table 15: Modify parameters Commands Description Press the OK button and hold it down for two seconds in order to access the parameter interface. → The display will show the parameter that was last used. Use the ▲ and ▼ buttons to select a parameter. Press the OK button. The value of the selected parameter can be changed. Use the ▲ and ▼ buttons to change the parameter’s value. Press the OK button to confirm the parameter value change.
4 Operation 4.5 Handling the keypad 4.5.4 Extended parameter set Table 17: Enabling and disabling access to the extended parameter set Description Commands Enabling access to the extended parameter set Press the OK button and hold it down for two seconds in order to access the parameter interface The display will show the parameter that was last used. Use the ▲ and ▼ buttons to select parameter P-14 Press the OK button.
4 Operation 4.6 Help leaflets 4.6 Help leaflets DC1 variable frequency drives come with two help cards that show the most important control connections and parameters. This makes it possible to quickly and easily commission the drives with their default settings when using the rated motor output (“out-of-the-box operation”).
4 Operation 4.
4 Operation 4.6 Help leaflets When the DC1 variable frequency drive is used with its default settings, parameter P-08 will show the drive’s rated operational current. The motor protection function can be adjusted to match the motor being used by changing this value to the rated motor current. If the motor current exceeds the value set in P-08, the dots on the display (I x t) will flash to indicate that there is an overload.
5 Error messages 5.1 Introduction 5 Error messages 5.1 Introduction DC1 series variable frequency drives come with several built-in monitoring functions. When a deviation from the correct operating status is detected, an error message will be displayed; in the inverter’s default settings, the relay contact will open (control signal terminals 10 and 11). 5.2 Fault History The most recent four error messages will be stored in the order in which they occurred (with the most recent one in the first place).
5 Error messages 5.2 Fault History The example below shows how to access the fault log. View Description Operating state Stop Press the OK button and hold it down for about two seconds. The most recently accessed parameter will be shown (example: P-00) The last digit on the display will flash. Use the ▲ (Up) or ▼ (Down) arrow buttons to select parameter P-13 and confirm your selection by pressing the OK pushbutton. Last error message. Example: P-def (Parameter default = Default settings loaded).
5 Error messages 5.3 Fault list 5.3 Fault list The following table shows the failure codes, the possible causes and indicates corrective measures. Table 20: Error messages list Message Error no. [dec] Possible causes and fixes STOP – Ready to start. There is no drive enable signal present. There are no error messages present. OI-b 01 Excessively high braking current • Check the brake resistor and its wiring for short-circuits and ground faults.
5 Error messages 5.3 Fault list Message Error no. [dec] Possible causes and fixes O.Volt 06 Overvoltage in DC link The DC link voltage value can be viewed using parameter P0-20. P0-36 contains a fault register with the last values before the unit was switched off (scan time: 256 ms). • Check to make sure that the supply voltage falls within the range for which the variable frequency drive is sized.
6 Technical Data 6.1 General rating data 6 Technical Data 6.
6 Technical Data 6.1 General rating data Technical data Symbol Unit Value 110 - 115 V, 200 - 240 V U kV ±1, phase to phase/neutral conductor ±2, phase/neutral conductor to earth 380 - 480 V U kV ±2, phase to phase ±4, phase to earth 110 - 115 V, 200 - 240 V U kV 1.5 380 - 480 V U kV 2.
6 Technical Data 6.1 General rating data Technical data Symbol Unit Inrush current Value < ILN Motor feeder Output voltage DC1-1D… U2 V 3~ 0 - 2 x Ue (voltage doubler) DC1-12…, DC1-32…, DC1-34… U2 V 3~ 0 - Ue at 230 V, 50 Hz P kW 0.37 - 4 at 400 V, 50 Hz P kW 0.75 - 22 f2 Hz 0 - 50/60 (max. 500 Hz) Hz 0.1 Assigned motor output Output Frequency Range, parameterizable resolution Rated operation current Ie A IP20: 2.3 - 46 IP66: 2.
6 Technical Data 6.
6 Technical Data 6.2 Specific rated operational data 6.2 Specific rated operational data The following tables list the specific rated operational data for the individual DC1 series based on the corresponding rated operational current. Examples DC1- 1D 2D3 … Rated operational current (2D3 ≙ 2.
6 Technical Data 6.2 Specific rated operational data 6.2.1 DC1-1D…device series Variable frequency drives with voltage doubler ULN = 2 x U2: 115 V → 230 V Size Symbol Unit 2D3 4D3 5D8 Rated operational current Ie A 2.3 4.3 5.8 Overload current for 60 s every 600 s il A 3.45 6.45 8.7 4.03 7.53 10.15 Starting current for 2 s every 20 s Apparent power at rated operation1) 230 V S kVA 0.92 1.71 2.31 at 230 V, 50 Hz P kW 0.37 0.75 1.1 at 220 - 240 V, 60 Hz P HP 0.5 t1 1.
6 Technical Data 6.2 Specific rated operational data 6.2.2 DC1-12…device series Size Symbol Unit 2D3 4D3 7D0NN 7D0FN 7D0NB 7D0FB 011 015 Rated operational current Ie A 2.3 4.3 7 7 10.5 15 Overload current for 60 s every 600 s il A 3.45 6.45 10.5 10.5 15.75 22.5 A 4.03 7.53 12.25 12.25 18.38 26.25 Starting current for 2 s every 20 s Apparent power at rated operation 230 V S kVA 0.92 1.71 2.79 2.79 4.18 5.98 Apparent power at rated operation 240 V S kVA 0.96 1.
6 Technical Data 6.2 Specific rated operational data 6.2.3 DC1-32… device series Size Symbol Unit 2D3 4D3 7D0NN 7D0NB 7D0FB Rated operational current Ie A 2.3 4.3 7 7 Overload current for 60 s every 600 s il A 3.45 6.45 10.5 10.5 A 4.03 7.53 12.25 12.25 Starting current for 2 s every 20 s Apparent power at rated operation 230 V S kVA 0.92 1.71 2.79 2.79 Apparent power at rated operation 240 V S kVA 0.96 1.79 2.91 2.91 at 230 V, 50 Hz P kW 0.37 0.75 1.5 1.
6 Technical Data 6.2 Specific rated operational data DC1-32… device series Continue Size Symbol unit 011 018 024 030 046 Rated operational current Ie A 10.5 18 24 30 46 Overload current for 60 s every 600 s il A 15.75 27 36 45 69 A 18.38 31.5 42 52.5 80.5 Starting current for 2 s every 20 s Apparent power at rated operation 230 V S kVA 4.18 7.17 9.55 11.94 18.30 Apparent power at rated operation 240 V S kVA 4.36 7.48 9.96 12.46 19.10 at 230 V, 50 Hz P kW 2.
6 Technical Data 6.2 Specific rated operational data 6.2.4 DC1-34…device series Size Symbol unit 2D2 4D1NN 4D1FN 4D1NB 4D1FB 5D8 9D5 Rated operational current Ie A 2.2 4.1 4.1 5.8 9.5 Overload current for 60 s every 600 s il A 3.3 6.15 6.15 8.7 14.25 A 3.85 7.18 7.18 10.15 16.63 Starting current for 2 s every 20 s Apparent power at rated operation 400 V S kVA 1.52 2.84 2.84 4.02 6.58 Apparent power at rated operation 480 V S kVA 1.83 3.41 3.41 4.82 7.
6 Technical Data 6.2 Specific rated operational data DC1-34…device series Continue Size Symbol Unit 014 018 024 030 039 046 Rated operational current Ie A 14 18 24 30 39 46 Overload current for 60 s every 600 s il A 21 27 36 45 58.5 69 A 24.5 31.5 42 52.5 68.25 80.5 Starting current for 2 s every 20 s Apparent power at rated operation 400 V S kVA 9.67 12.47 16.63 20.76 26.99 31.83 Apparent power at rated operation 480 V S kVA 11.64 14.96 19.95 24.91 32.
6 Technical Data 6.3 Dimensions 6.3 Dimensions b2 6.3.1 Frame sizes FS1 to FS3 in IP20 ⌀ ⌀1 b1 b ⌀2 EMC VAR 1 2 3 4 5 6 7 8 9 10 11 a1 a c1 c Figure 76: Dimensions for DC1 with IP20 degree of protection (NEMA 0) Table 21: Dimensions, weights, and sizes for IP20 Frame size a a1 b b1 b2 c c1 ⌀1 ⌀2 m mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) kg (lbs) FS1 81 (3.19) 50 (1.97) 184 (7.24) 170 (6.69) 7 (0.28) 124 (4.88) 4 (0.16) 6 (0.
6 Technical Data 6.3 Dimensions 10.5 mm (0.41") 6.3.2 Frame size FS4 in IP20 EMC L1 L2 ⌀ 8 mm (⌀ 0.31") L3 ⌀ 14.5 mm (⌀ 0.57") 1 EMC DC+ BR DC- U 2 V 3 4 5 6 7 8 9 10 11 400 mm (15.75") 418.5 mm (16.48") 8.4 kg (18.52 lbs) W 125 mm (4.92") 173 mm (6.81") 4 mm (0.16") 211 mm (8.31") Figure 77: Dimensions and weight for DC1 with frame size of FS4 and IP20 (NEMA 0) degree of protection DC1 Variable Frequency Drive 04/16 MN04020003Z-EN www.eaton.
6 Technical Data 6.3 Dimensions 6.3.3 Frame sizes FS1 to FS3 in IP66 ⌀1 REV PWR 0 ⌀2 FWD OFF b1 b1 b ON b2 b1 a1 a1 c1 a1 a c Figure 78: Dimensions for DC1 with IP66 degree of protection (NEMA 4X) Table 22: Dimensions, weights, and sizes for IP66 Frame size a a1 b b1 b2 c c1 ⌀1 ⌀2 m mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) kg (lbs) FS1 161 (6.34) 148.5 (5.85) 232 (9.13) 189 (7.44) 25 (0.98) 184 (7.24) 3.5 (0.14) 4 (0.15) 8 (0.
6 Technical Data 6.4 Cable cross-sections 6.4 Cable cross-sections The “Maximum terminal capacity” specification indicates the maximum possible sizes that can be connected to the power terminals. The crosssectional areas and gauges that should be used for the power supply and motor connections are recommendations for the corresponding frame sizes and ratings and are provided as examples. ￫ Use the general installation instructions and local conditions as a basis when selecting terminal capacities.
6 Technical Data 6.4 Cable cross-sections Device Type DC1-32046… Frame size FS4 Maximum terminal capacity Input current ILN Cross-sectional area/ gauge that should be used for the power supply (L1/L, L2/N, L3, PE) Output current (rated operational current) Ie Cross-sectional area/ gauge that should be used for the motor connection (U, V, W, PE) mm2 AWG/ kcmil 1) A mm2 AWG/ kcmil 1) A mm2 AWG/ kcmil 1) 16 5 50.
6 Technical Data 6.5 Fuses 6.5 Fuses The Eaton circuit-breakers and fuses listed below are examples and can be used without additional measures. If you use other circuit-breakers and/or fuses, make sure to take their protection characteristic and operational voltage into account. When using other circuit-breakers, it may be necessary to also use fuses depending on the circuit-breaker’s model, design, and settings.
6 Technical Data 6.5 Fuses Table 25: Specified fuses Device Type Input current Fuse or miniature circuit-breaker ILN IEC (Type B or gG) UL (Class CC or J) A A A Eaton type Eaton type Mains voltage 115 V Supply voltage (50/60 Hz) ULN 110 (-10 %) - 115 (+10 %) V Ue 115 V AC, single-phase / U2 230 V AC, three-phase (internal voltage doubler) ① ①, 2 phase ④ ⑤ DC1-1D2D3… 7.8 10 FAZ-B10/1N FAZ-B10/2 10D27 10 LPJ-10SP DC1-1D4D3… 15.
6 Technical Data 6.5 Fuses Device Type Input current Fuse or miniature circuit-breaker ILN IEC (Type B or gG) UL (Class CC or J) A A A Eaton type Eaton type Mains voltage 400 V Supply voltage (50/60 Hz) ULN 380 (-10 %) - 480 (+10 %) V Ue 400 V AC, three-phase / U2 400 V AC, three-phase ① ② ③ ④ DC1-342D2… 3.5 6 FAZ-B6/3 PKM0-6.3 6D27 6 LPJ-6SP DC1-344D1NN… 5.6 10 FAZ-B10/3 PKM0-10 10D27 10 LPJ-10SP DC1-344D1FN… 5.
6 Technical Data 6.6 Mains contactors 6.6 Mains contactors ￫ The mains contactors listed here are based on the variable frequency drive’s rated input-side mains current ILN without an external mains choke. The contactor should be selected based on thermal current Ith = Ie (AC-1) at the specified ambient air temperature. NOTICE The inching operation is not permissible via the mains contactor (Pause time ≧ 30 s between switching off and on).
6 Technical Data 6.6 Mains contactors Table 26: Mains contactors Device Type Input current Mains contactor (thermal current AC-1) ILN Type (max. 50 oC and IEC) A Type (max. 40 oC and UL) A A Mains voltage 115 V Supply voltage (50/60 Hz) ULN 110 (-10 %) - 115 (+10 %) V Ue 115 V AC, single-phase / U2 230 V AC, three-phase (internal voltage doubler) DC1-1D2D3… 7.8 DILEM-…+P1DILEM 50 DILEM-…+P1DILEM 50 DC1-1D4D3… 15.8 DILEM-…+P1DILEM 50 DILEM-…+P1DILEM 50 DC1-1D5D8… 21.
6 Technical Data 6.6 Mains contactors Device Type Input current Mains contactor (thermal current AC-1) ILN Type (max. 50 oC and IEC) A Type (max. 40 oC and UL) A A Mains voltage 400 V Supply voltage (50/60 Hz) ULN 380 (-10 %) - 480 (+10 %) V Ue 400 V AC, three-phase / U2 400 V AC, three-phase 150 DC1-342D2… 3.5 DILEM-… 20 DILEM-… 20 DC1-344D1NN… 5.6 DILEM-… 20 DILEM-… 20 DC1-344D1FN… 5.6 DILEM-… 20 DILEM-… 20 DC1-344D1NB… 5.6 DILEM-… 20 DILEM-… 20 DC1-344D1FB… 5.
6 Technical Data 6.7 Mains chokes 6.7 Mains chokes For more information and technical data on DX-LN… mains chokes, please refer to instruction leaflet IL00906003Z. a DX-LN1… Figure 80: DEX-LN1… mains chokes (single-phase) Table 27: Assigned mains chokes (single-phase) Device Type Input current Mains choke, single-phase (ULN max. 260 V +10 %, 50/60 Hz ±10 %) Type (max. 50 oC) Type (max.
6 Technical Data 6.7 Mains chokes DX-LN3… Figure 81: Mains chokes DEX-LN3… (three-phase) Table 28: Assigned mains chokes (three-phase) Device Type Input current Mains choke, three-phase (ULN max. 500 V +10 %, 50/60 Hz ±10 %) Type (max. 50 oC) Type (max. 40 oC) ILN Ie Ie A A A Mains voltage 230 V Supply voltage (50/60 Hz) ULN 200 (-10 %) - 240 (+10 %) V Ue 230 V AC, three-phase / U2 230 V AC, three-phase DC1-322D3… 3.4 DX-LN3-004 3.7 DX-LN3-004 3.9 DC1-324D3… 5.6 DX-LN3-006 5.
6 Technical Data 6.8 Radio interference suppression filter 6.8 Radio interference suppression filter L0AD LINE Figure 82: DX-EMC…-FS… (base-mounted filters with prefabricated connection cables) and DX-EMC… (side-mounting filters) external radio interference suppression filters DX-EMC… external radio interference suppression filters should always be installed in the immediate proximity of the corresponding variable frequency drive.
6 Technical Data 6.8 Radio interference suppression filter Table 29: Assigned radio interference suppression filter (single-phase) Device Type Size Input current Radio interference suppression filter, single-phase Max. mains voltage ULN: 250 V +0%, 50/60 Hz ±10% Max. ambient temperature: 50 oC Part no.
6 Technical Data 6.8 Radio interference suppression filter Table 30: Assigned radio interference suppression filter (three-phase) Device Type Frame size Input current Radio interference suppression filter, three-phase Max. mains voltage ULN: 520 V +0%, 50/60 Hz ±10% Max.
6 Technical Data 6.8 Radio interference suppression filter Device Type Frame size Input current Radio interference suppression filter, three-phase Max. mains voltage ULN: 520 V +0%, 50/60 Hz ±10% Max.
6 Technical Data 6.9 Braking resistances 1 2 T1 T2 6.9 Braking resistances Figure 83: Examples of DX-BR… brake resistor designs NOTICE The specified minimum resistance RBmin must not be fallen below. CAUTION Brake resistors get extremely hot during operation! The following tables provide examples of DX-BR… brake resistors rated for individual DC1 variable frequency drives.
6 Technical Data 6.9 Braking resistances ￫ All brake resistors feature a temperature switch for protection against thermal overload. This dry contact (N/C) can be directly integrated into the DC1 variable frequency drive’s control section and work as an external fault message (control terminal 10, DI5, parameter P9-08 = 5). 1 T1 RB ϑ 2 T2 Exception: The DX-BR3-100 resistor does not feature a protective switch.
159 RBrec Ω RBmin Ω Resistance value kW Pmax FS2 100 100 1.1 DC1 Variable Frequency Drive FS3 FS2 FS2 22 50 100 25 50 100 4 2.2 1.5 04/16 MN04020003Z-EN www.eaton.com DC1-32046FB-A20N DC1-32046NB-A20N DC1-32030FB-A20N DC1-32030NB-A20N DC1-32024FB-A20N DC1-32024NB-A20N DC1-32018FB-A20N DC1-32018NB-A20N DC1-32011FB-A20N DC1-32011NB-A20N DC1-327D0FB-A20N DC1-327D0NB-A20N FS4 FS4 FS3 FS3 FS2 FS2 10 15 20 24 50 100 10 15 20 25 50 100 11 7.5 5.5 4 2.
160 Size RBrec Ω RBmin Ω Resistance value kW Pmax DC1 Variable Frequency Drive 04/16 MN04020003Z-EN www.eaton.com FS4 FS4 FS4 FS3 FS3 FS3 FS2 FS2 FS2 22 22 30 50 80 100 120 200 210 22 22 30 50 80 100 120 200 250 22 18.5 15 11 7.5 5.5 4 2.2 1.
6 Technical Data 6.10 Motor chokes 6.10 Motor chokes Figure 84: Motor choke DX-LM3… Table 32: Motor chokes that should be used Device Type Rated operational current Motor choke (three-phase) that should be used Max. ULN: 750 VAC +0%; max. f2: 400 Hz Maximum fPWM switching frequency: 12 kHz (rms) 1) Maximum ambient temperature: 70 oC Type (max. 50 oC) Type (max. 40 oC) Ie Ie Ie A A A DC1-1D2D3… 2.3 DX-LM3-005 4.8 DX-LM3-005 5 DC1-1D4D3… 4.3 DX-LM3-005 4.8 DX-LM3-005 5 DC1-1D5D8… 5.
6 Technical Data 6.10 Motor chokes Device Type Rated operational current Motor choke (three-phase) that should be used Max. ULN: 750 VAC +0%; max. f2: 400 Hz Maximum fPWM switching frequency: 12 kHz (rms) 1) Maximum ambient temperature: 70 oC Type (max. 50 oC) Type (max. 40 oC) Ie Ie Ie A A A DC1-342D2… 2.2 DX-LM3-005 4.8 DX-LM3-005 5 DC1-344D1… 4.1 DX-LM3-005 4.8 DX-LM3-005 5 DC1-345D8… 5.8 DX-LM3-008 7.6 DX-LM3-008 8 DC1-349D5… 9.5 DX-LM3-011 10.
7 Accessories 7.1 Device-specific accessories 7 Accessories Device-specific DXC… accessories, as well as the general accessories from the PowerXL (DX…) system, are available for DC1 variable frequency drives. 7.1 Device-specific accessories DCX… device-specific accessories are connected directly to the plug-in control signal terminals on DC1 variable frequency drives, making it easy to expand the drives’ functionality.
7 Accessories 7.1 Device-specific accessories 7.1.1 DXC-EXT-IO… coupling module Coupling modules DXC-EXT-IO110 and DXC-EXT-IO230 can be used to integrate the digital inputs on DC1 variable frequency drives directly into circuits with 110 V AC / 230 V AC. In the actual coupling mode, the inputs (connection terminals 1 to 4 and 12 and 13) are galvanically isolated from the variable frequency drive‘s digital inputs (DI1 to DI4).
7 Accessories 7.
7 Accessories 7.1 Device-specific accessories 7.1.2 DXC-EXT-2RO output expansion 1 2 3 4 5 6 7 8 9 10 11 Figure 88: DXC-EXT-2RO Expansion module DXC-EXT-2RO can be used to convert digital output DO1 (control signal terminals 8 and 9) on DC1 variable frequency drives to a dry contact relay output K2 (N/O). When this option is used, the variable frequency drive will have two dry relay contacts available and will be able to switch voltages of up to 250 V AC and 220 V DC.
7 Accessories 7.1 Device-specific accessories P-25 4 5 6 7 8 9 10 0V 3 6 AI 0 ... +10 V 2 5 +10 V < 20 mA 4 DI3 3 DI2 1 2 DI1 1 +24 V < 100 mA DC1 P-18 = 1 RUN 11 7 8 9 K2 f-Soll 10 250 V AC 220 V DC ≦1A 11 K1 4.7 kΩ Figure 89: Block diagram DXC-EXT-2RO Parameter Definition The K1 relay output’s function can be configured using parameter P-18 (default setting = 1: RUN).
7 Accessories 7.1 Device-specific accessories 7.1.3 DXC-EXT-2RO1AO output expansion 1 2 3 4 5 6 7 8 9 10 11 Figure 90: DXC-EXT-2RO1AO Expansion module DXC-EXT-2RO1AO was developed with HVAC applications in mind. It can switch the “Drive running” and “Shutdown due to fault” messages with two separate relays (K1, K2).
7 Accessories 7.1 Device-specific accessories DANGER Dangerous voltage! Expansion module DXC-EXT-2RO1AO must not be placed into operation until all mounting and installation work has been completed. Any other use will be considered to be an inappropriate use. P-18 = 1 READY DC1 1 2 3 4 5 6 7 8 9 10 11 4 5 6 FWD f-Soll 7 AO1 0 ... +10 V/ 20 mA 0V DI3 3 0V DI2 2 AI1 0 ... +10 V DI1 1 +10 V < 20 mA +24 V, <100 mA K1 8 9 K2 12 10 13 11 250 V AC/220 V DC, 1 A f-Out + 4.
7 Accessories 7.1 Device-specific accessories 7.1.4 DXC-EXT-LOCSIM simulator 1 2 3 4 5 6 7 8 9 10 11 Figure 92: DXC-EXT-LOCSIM DXC-EXT-LOCSIM is a simple commissioning and test simulator for DC1 variable frequency drives. Three microswitches and a PCB mount potentiometer make it possible to easily put the variable frequency drive into operation “out of the box” based on the corresponding help cards when using the drive’s default settings ￫ Section “4.6 Help leaflets”, page 122.
7 Accessories 7.2 General accessories (List) 7.
7 Accessories 7.2 General accessories (List) 172 DC1 Variable Frequency Drive 04/16 MN04020003Z-EN www.eaton.
Alphabetical index A Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 AC motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 AC supply systems . . . . . . . . . . . . . . . . . . . . . . . . 37 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163 After-Sales Service . . . . . . . . . . . . . . . . . . . . . . . . 33 Air circulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Alarm messages . . . . . . . . . . . . . . . . .
G Gland plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 GND (ground) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Ground contact currents . . . . . . . . . . . . . . . . . . . . 75 Mounting position . . . . . . . . . . . . . . . . . . . . . . 57, 59 H Harmonics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Hazard warnings of material damages . . . . . . . . . . . . . . . . . . . . 6 of personal injury . . . . . . . . . . . . . . . . . . . . . . .
Supply voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Switch-disconnector . . . . . . . . . . . . . . . . . . . . . . . 50 Switching Frequency . . . . . . . . . . . . . . . . . . . . . 153 System overview . . . . . . . . . . . . . . . . . . . . . . . . . . 10 T Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 Terminal capacity . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
