Cutler Hammer, Div of Eaton Corp DA1 Operation Manual

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Manual

10/12 MN04020005Z-EN

PowerXL

™

DA1 Variable Frequency Drives

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All brand and product names are trademarks or registered trademarks of the owner concerned.

Emergency On Call Service

Please call your local representative:

http://www.eaton.com/moeller/aftersales

or Hotline of the After Sales Service: +49 (0) 180 5 223822 (de, en)

AfterSalesEGBonn@eaton.com

Original Operating Instructions

The German-language edition of this document is the original operating manual.

Translation of the original operating manual

All editions of this document other than those in German language are translations of the original German manual.

published 2012, edition date 10/12

Production: René Wiegand Translation: globaldocs GmbH

No part of this manual may be reproduced in any form (printed, photocopy, microfilm or any other process) or processed, duplicated or distributed by means of electronic systems without written permission of Eaton Industries GmbH, Bonn.

Subject to alteration without notice.

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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 restarted.

• Verify isolation from the supply.

• Earth and short circuit the device.

• Cover or enclose any adjacent live components.

• Follow the engineering instructions (AWA/IL) for the device concerned.

• 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 equalisation. 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 24 V supply. Only use power supply units complying with IEC 60364-4-41 (VDE 0100 Part 410) or HD384.4.41 S2.

• Deviations of the mains 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.

Eaton Industries GmbH

Safety instructions

• 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. If 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 etc.).

• Depending on their degree of protection, frequency inverters 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 frequency inverter 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 on live frequency inverters.

• The electrical installation must be carried out in accordance with the relevant regulations (e. g. 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 frequency inverters must be provided with additional monitoring and protective devices in accordance with the applicable safety regulations. Modifications to the frequency inverters using the operating software are permitted.

• All covers and doors must be kept closed during operation.

• To reduce the 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 etc.).

– Electrical or non-electrical system-wide measures

(electrical or mechanical interlocks).

– Never touch live parts or cable connections of the

frequency inverter after it has been disconnected from the power supply. Due to the charge in the capacitors, these parts may still be live after disconnection. Fit appropriate warning signs.

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Page 5

0 About this Manual ..................................................................... 5

0.1 Target group................................................................................. 5

0.2 Writing conventions ..................................................................... 5

0.3 Abbreviations ............................................................................... 6

0.4 Mains supply voltages.................................................................. 7

0.5 Units............................................................................................. 7

1 DA1 device series ....................................................................... 9

1.1 Introduction .................................................................................. 9

1.2 System overview ......................................................................... 10

1.3 Checking the Delivery .................................................................. 11

1.4 Rated data .................................................................................... 13

1.4.1 Rating data on the nameplate ...................................................... 13

1.4.2 Key to part numbers..................................................................... 14

1.4.3 General rated operational data ..................................................... 16

1.4.4 Features ....................................................................................... 19

1.5 DA1 layout.................................................................................... 21

1.6 Features ....................................................................................... 22

1.7 Selection criteria........................................................................... 24

1.8 Proper use.................................................................................... 25

1.9 Maintenance and inspection ........................................................ 26

1.10 Storage......................................................................................... 26

1.11 Charging the internal DC link capacitors ...................................... 27

1.12 Service and warranty.................................................................... 27

2 Engineering................................................................................. 29

2.1 Introduction .................................................................................. 29

2.2 Electrical power network ............................................................. 30

2.2.1 Mains connection and configuration ............................................ 30

2.2.2 Mains voltage and frequency ....................................................... 31

2.2.3 Voltage balance ............................................................................ 31

2.2.4 Total Harmonic Distortion (THD) .................................................. 32

2.2.5 Idle power compensation devices ............................................... 33

2.2.6 Mains chokes ............................................................................... 33

2.3 Safety and switching.................................................................... 34

2.3.1 Fuses and cable cross-sections ................................................... 34

2.3.2 Residual current device................................................................ 35

2.3.3 Mains contactors.......................................................................... 36

2.4 EMC compliance .......................................................................... 36

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2.5 Motor and Application.................................................................. 38

2.5.1 Motor selection............................................................................ 38

2.5.2 Parallel connection of motors ...................................................... 38

2.5.3 Circuit types with three-phase motors......................................... 40

2.5.4 87-Hz Characteristic curve ........................................................... 40

2.5.5 Bypass operation ......................................................................... 42

2.5.6 Connecting EX motors................................................................. 43

2.5.7 Sinusoidal filter............................................................................. 43

3 Installation.................................................................................. 45

3.1 Introduction.................................................................................. 45

3.2 Mounting ..................................................................................... 45

3.2.1 Mounting position........................................................................ 46

3.2.2 Cooling measures ........................................................................ 46

3.2.3 Control panel installation.............................................................. 49

3.2.4 Fixing ........................................................................................... 50

3.3 EMC installation........................................................................... 53

3.3.1 EMC measures in the control panel............................................. 53

3.3.2 Earthing........................................................................................ 54

3.3.3 EMC screw .................................................................................. 55

3.3.4 VAR screw ................................................................................... 56

3.3.5 Screen earth kit............................................................................ 56

3.4 Electrical Installation .................................................................... 58

3.4.1 Power section connections.......................................................... 59

3.4.2 Connection on control section ..................................................... 64

3.4.3 Block diagrams............................................................................. 72

3.4.4 Insulation test .............................................................................. 74

4 Operation.................................................................................... 75

4.1 Checklist for commissioning........................................................ 75

4.2 Hazard warnings for operation ..................................................... 76

4.3 Commissioning with control signal terminals (default settings) .. 77

5 Error messages .......................................................................... 81

5.1 Introduction.................................................................................. 81

5.1.1 Error messages............................................................................ 81

5.1.2 Acknowledge fault (Reset)........................................................... 81

5.1.3 Error list........................................................................................ 83

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6 Parameters.................................................................................. 87

6.1 Operating unit .............................................................................. 129

6.1.1 Display unit................................................................................... 130

6.1.2 Menu Navigation .......................................................................... 130

6.1.3 Setting parameters....................................................................... 130

6.1.4 Parameter selection ..................................................................... 131

6.2 Digital and analog inputs .............................................................. 132

6.2.1 Digital Input (DI) ........................................................................... 135

6.2.2 Analog Input (AI)........................................................................... 136

6.2.3 Digital / analog outputs................................................................. 144

6.2.4 Drives control ............................................................................... 148

6.2.5 Second acceleration and deceleration time ................................. 149

6.2.6 Frequency jump ........................................................................... 150

6.2.7 Start Function............................................................................... 151

6.2.8 Motor ........................................................................................... 153

6.2.9 Fixed frequency setpoint values .................................................. 155

6.2.10 V/f characteristic curve................................................................. 157

6.2.11 Braking ......................................................................................... 162

6.3 Operational data indicator ............................................................ 168

6.4 Setpoint input (REF) ..................................................................... 169

7 Serial interface (Modbus RTU).................................................. 171

7.1 General......................................................................................... 171

7.1.1 Communication ............................................................................ 171

7.1.2 Serial interface ............................................................................. 172

7.2 Modbus parameters..................................................................... 173

7.3 Operating mode Modbus RTU ..................................................... 174

7.3.1 Structure of the master request................................................... 175

7.3.2 Structure of the slave response ................................................... 176

7.3.3 Modbus: Register mapping.......................................................... 177

7.3.4 Explanation of function code........................................................ 185

8 CANopen..................................................................................... 187

8.1 Data Types ................................................................................... 187

8.2 System overview ......................................................................... 188

8.2.1 Bus termination resistors ............................................................. 190

8.2.2 Baud rate...................................................................................... 190

8.2.3 Set CANopen station address ...................................................... 190

8.2.4 Parameters that need to be configured ....................................... 190

8.3 Object list ..................................................................................... 191

8.3.1 EDS file ........................................................................................ 191

8.3.2 Communication-specific objects .................................................. 192

8.3.3 Server SDO Parameter................................................................. 193

8.3.4 Manufacturer-specific objects...................................................... 195

8.3.5 Control word (Index 2000

) ....................................................... 198

hex

8.4 Error messages ............................................................................ 200

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9 Appendix..................................................................................... 203

9.1 Special technical data................................................................... 203

9.1.1 DA1-12 device series................................................................... 204

9.1.2 DA1-32 device series................................................................... 205

9.1.3 DA1-32 device series................................................................... 206

9.1.4 DA1-34 device series................................................................... 207

9.2 Dimensions and frame size.......................................................... 209

9.3 PC interface card.......................................................................... 211

9.3.1 DX-COM-STICK............................................................................ 211

9.3.2 drivesConnect.............................................................................. 214

9.3.3 Cables and fuses.......................................................................... 215

9.4 Mains contactors ......................................................................... 219

Alphabetical index ..................................................................... 221

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0 About this Manual

0.1 Target group

0 About this Manual

0.1 Target group

This manual contains special information required for the correct selection and connection of a DA1 variable frequency drive and its configuration to your specific requirements using the parameters. All information applies to the specified hardware and software versions. The manual describes all sizes of the DA1 device series. The differences and special characteristics of each rating level and size are listed accordingly.

The content of MN04020005Z-EN manual is written for engineers and electricians. A specialist knowledge of electrical engineering and fundamental technical principles is needed for commissioning.

We assume that you have a good knowledge of engineering fundamentals and that you are familiar with handling electrical systems and machines, as well as with reading technical drawings.

0.2 Writing conventions

Symbols used in this manual have the following meanings:

 Indicates instructions to be followed.

Indicates useful tips.

￫

NOTICE

Warns about the possibility of material damage.

CAUTION



Warns of the possibility of hazardous situations that may possibly cause slight injury.

DANGER

Warns of hazardous situations that result in serious injury or death.

For greater clarity, the name of the current chapter and the name of the current section are shown in the page header.

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0 About this Manual

0.3 Abbreviations

￫

The following abbreviations are used in this manual.

EMC Electromagnetic compatibility

FE Functional earth

FS Frame Size

FWD Forward run (clockwise rotating field)

GND Ground (0-V-potential)

IGBT Insulated gate bipolar transistor

LCD Liquid Crystal Display

PDS Power Drive System (magnet system)

PES EMC connection to PE for screened lines

PNU Parameter number

REV

In order to make it easier to understand some of the images included in this manual, the housing of the variable frequency drive, as well as other safety-relevant parts, have been left out. However, it is important to note that the variable frequency drive must always be operated with its housing placed properly, as well as with all required safety-relevant parts.

All the specifications in this manual refer to the hardware and software versions documented in it.

More information on the devices described here can be found on the Internet under:

http://www.eaton.com/moeller

Protective earth 

Reverse run (anticlockwise rotation field active)

Underwriters Laboratories

Default settings

 Support

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0.4 Mains supply voltages

0 About this Manual

0.4 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).

In star networks (as found in North America), the rated operating voltage at the transfer point of the utility companies is higher than in the consumer network. Example: 120 V  115 V, 240 V  230 V, 480 V  460 V.

The DA1 variable frequency drive’s wide tolerance range takes into account a permissible voltage drop of 10 % (i.e. U gory, it takes into account the

North American mains voltage of 480 V + 10 %

(60 Hz).

The permissible power supplies for the DA1 series are listed in the Technical Data section in the appendix.

The rated mains voltage operational data is always based on mains frequencies of 50/60 Hz within a range of 48 to 62 Hz.

- 10 %) while, in the 400-V cate-

0.5 Units

Every physical dimension included in this manual uses international metric system units, otherwise known as SI (Système International d’Unités) units. For the purpose of the equipment's UL certification, some of these dimensions are accompanied by their equivalents in imperial units.

Table 1: Unit conversion examples

designation

Length 1 in (’’) inch 25.4 mm 0.0394

Power

Torque

Temperature 1°F (TF) Fahrenheit -17.222 °C (TC) TF=TC×9/5+32

Speed

Weight 1lb pound 0.4536 kg 2.205

US-American value

1HP=1.014PS horsepower 0.7457 kW 1.341

1lbfin pound-force inches 0.113 Nm 8.851

1rpm Revolutions per minute 1min

US-American designation

SI value Conversion value

-1

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0 About this Manual

0.5 Units

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1 DA1 device series

1.1 Introduction

1 DA1 device series

1.1 Introduction

DA1 series variable frequency drives are suited to applications involving the frequency control of motors within an output range of 0.75 kW (at 230 V) to 160 kW (at 400 V).

DA1 series devices feature a compact and rugged design and are available in seven sizes (FS2, ... , FS8), as well as with protection types IP20, IP40, IP55 and IP66. For protection type IP66, there is also a model with a mains switch and controls for local control available.

Due to their ease of use and handling, the innovative technology behind them, and a high level of reliability, DA1 variable frequency drives are particularly suitable for use in general applications. 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.

The computer-supported parameter configuration software ensures data integrity and reduces the time required for commissioning and maintenance.

In addition, the comprehensive accessories available increase the inverters’ flexibility in all areas of application.

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1 DA1 device series

1.2 System overview

⑥

①

⏚

DC-

L1/L

L2/N

②

⑤

1 2 3 4 5 6 7 8 9 10 11 12 13

COM

14 15 16 17 18

⏚

DC+

PROFIBUS DP-V1

④

③

Figure 1: DA1 variable frequency drives system overview

a DA1-… variable frequency drives b DX-LN-… main chokes, DX-LM3-… motor reactors, DX-SIN3-… sinusoidal filters c DX-BR… braking resistance d Fieldbus connection and expansion group e DX-COM-STICK communication module and accessories (e. g. DX-CBL-… connection cable) f DE-KEY-… keypad (external)

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1.3 Checking the Delivery

1 DA1 device series

1.3 Checking the Delivery

￫

make sure that you received the correct variable frequency drive.

⏚

DC-

L1/L

L2/N

1 2 3 4 5 6 7 8 9 10 11 12 13

COM

14 15 16 17 18

⏚

DC+

Figure 2: Location of nameplate on DA1 variable frequency drive

Before opening the package, please check the label on it to

The DA1 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. Please take note of the labels and instructions on the packaging, as well as of those meant for the unpacked device.

Open the packaging with suitable tools and inspect the contents immediately after delivery to ensure that they are complete and undamaged.

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1 DA1 device series

1.3 Checking the Delivery

The packaging must contain the following parts:

• DA1 series variable frequency drive,

• an instructional leaflet

• IL04020010Z for devices with FS2 and FS3 size with IP20 protection

type,

• IL04020011Z for devices with FS4 to FS7 sizes with IP55 protection

type,

• IL04020012Z for panel-version variable frequency drives of size FS8

• A data carrier (CD-ROM) containing documentation for DA1 series vari-

able frequency drives.

⏚

DC-

L1/L

L2/N

1 2 3 4 5 6 7 8 9 10 11 12 13

COM

14 15 16 17 18

⏚

DC+

Figure 3: Equipment supplied with DA1 variable frequency drive

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1.4 Rated data

Voltage categories

DA1 variable frequency drives are divided into following voltage categories:

• 230 V: DA1-12…, DA1-32…

• 400 V: DA1-34…

1.4.1 Rating data on the nameplate

The device-specific rated operational data for the DA1 variable frequency drive is listed on the nameplate on the right side of the device.

The inscription of the nameplate has the following meaning (example):

Inscription Meaning

DA1-344D1FB-A20N Part no.:

Input

Output

Power

S/N Serial number

1 DA1 device series

1.4 Rated data

DA1 = DA1 series variable frequency drive 3 = Three-phase mains connection / three-phase motor connection 4 = 400 V mains voltage category 4D1 = 4.1 A rated operational current (4-decimal-1, output current) F = Integrated radio interference suppression filter B = Integrated brake chopper A = LED display (7-segment text display) 20 = IP20 protection type N = Standard basic device

Power connection rating: Three-phase AC voltage (U 380 - 480 V voltage, 50/60 Hz frequency, input phase current (4.3 A).

Load side (motor) rating: Three-phase AC voltage (0 - U (0 - 500 Hz)

Assigned motor output:

1.5 kW at 400 V/2 HP at 460 V for a four-pole, internally cooled or surface-cooled three-phase motor (1500 rpm at 50 Hz/1800 rpm at 60 Hz)

Variable frequency drive is an electrical apparatus. Read the manual (in this case MN04020005Z-EN) before making any electrical connections and commissioning.

3~ AC),

), output phase current (4.1 A), output frequency

IP20/Open type

25072012 Manufacturing date: 07-25-2012

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Protection type of the housing: IP20, UL (cUL) Open type

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1 DA1 device series

1.4 Rated data

1.4.2 Key to part numbers

The catalog no. or part no. for the DA1 series of variable frequency drives is made up of four sections.

Series – Power section – Model – Version

The following figure shows it in greater detail:

D A 1 - 1 2 4 D 1 F N - A 2 0 N Explanation

Type

N = Standard basic device C = With coated printed circuit boards

Protection type

20 = IP20 / NEMA 0 40 = IP40 / NEMA 1 55 = IP55 / NEMA 3 66 = IP66 / NEMA 4X 6S = IP66 with switch / NEMA 4X, switched

Display unit (display)

A = LED display B = OLED display

Brake Chopper

N = No internal brake chopper B = Brake chopper

EMC (radio interference suppression filter)

N = No internal RFI filter F = Internal RFI filter

Rated operational current (examples) 2D2 = 2.2 A 4D1 = 4.1 A 024 = 24 A

Mains voltage category 2 = 230 V (200 - 240 V ±10 %) 4 = 400 V (380 - 480 V ±10 %)

Connection in power section

1 = Single-phase mains connection / three-phase motor connection 3 = Three-phase mains connection / three-phase motor connection

Device series

DA1 = Variable frequency drive, advanced, Series 1 (D = Drives, A = Advanced, 1 = Series)

Figure 4: Key to part numbers of the DA1 variable frequency drives

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Catalog number examples

Inscription Meaning

1 DA1 device series

1.4 Rated data

DA1-124D3NN-A20C DA1 = DA1 series variable frequency drive

DA1-122D3FN-A20N

DA1-327D0FB-A20N

DA1-34014FB-B66N

DA1-34018FB-A20C

1 = Single-phase power supply 2 = Mains voltage category: 230 V (200 V - 240 V ±10 %) 4D3 = Rated operational current: 4.3 A N = No internal radio interference suppression filter N = No internal brake chopper A = LED display 20 = IP20 protection type C = Coated printed circuit boards

DA1 = DA1 series variable frequency drive 1 = Single-phase power supply 2 = Mains voltage category: 230 V (200 V - 240 V ±10 %) 2D3 = Rated operational current: 2.3 A N = Internal radio interference suppression filter N = No internal brake chopper A = LED display 20 = IP20 protection type N = Not coated printed circuit boards

DA1 = DA1 series variable frequency drive 3 = Three-phase mains supply voltage 2 = Mains voltage category: 230 V (200 V - 240 V ±10 %) 7D0 = Rated operational current: 7.0 A N = Internal radio interference suppression filter B = internal brake chopper A = LED display 20 = IP20 protection type N = Not coated printed circuit boards

DA1 = DA1 series variable frequency drive 3 = Three-phase mains supply voltage 4 = Mains voltage category: 400 V (380 V - 480 V ±10 %) 014 = Rated operational current: 14 A N = Internal radio interference suppression filter B = internal brake chopper B = OLED display 66 = IP66 protection type N = Not coated printed circuit boards

DA1= DA1 series variable frequency drive 3 = Three-phase mains supply voltage 4 = Mains voltage category: 400 V (380 V - 480 V ±10 %) 018 = Rated operational current: 18 A N = Internal radio interference suppression filter B = internal brake chopper A = LED display 20 = IP20 protection type C = Coated printed circuit boards

￫

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suppression

filter is required for operation as per IEC/EN 61800-3.

For DA1-xxxxxNx-xxxx devices, an external radio interference

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1 DA1 device series

1.4 Rated data

1.4.3 General rated operational data

Technical Data Formula

General

Standards EMC: EN 61800-3:2004+A1-2012

Certifications and manufacturer’s declarations on conformity CE, UL, cUL, c-Tick

Production quality RoHS, ISO 9001

Climatic proofing ρ

Ambient air temperature

Operation

IP20 (NEMA 0) ϑ °C -10 - +50 (frost-free and condensation-free)

IP55 (NEMA 3) ϑ °C -10 - +45

IP66 (NEMA 4X) ϑ °C -10 - +40 (frost-free and condensation-free)

Storage ϑ °C -10 - +60

Electrostatic discharge (ESD, EN 61000-4-2:2009 V kV ±4, contact discharge

Fast transient burst (EFT/B, EN 61000-4-4: 2004) V kV ±1, at 5 kHz, control signal terminals

Overvoltage (surge, EN 61000-4-5: 2006)

200 - 240 V V kV ±1, Phase to phase/neutral conductor

380 - 480 V V kV ±2, Phase to phase

Dielectric strength (flash, EN 61800-5-1: 2007)

200 - 240 V V kV 1.5

380 - 480 V V kV 2.5

Radio interference class (EMC)

Category and maximum screened motor cable length

C1 l m 5

C2 l m 25

C3 l m 50

Mounting position Vertical, max. ±30°

Altitude H m 0 - 1000 above sea level,

Degree of protection IP20 (NEMA 0)

Busbar tag shroud BGV A3 (VBG4, finger- and back-of-hand proof)

sign

Unit Value

Radio interference: EN 55011: 2010 Safety: EN 61800-5: 2007 Protection type: EN 60529: 1992

Note: FS8 units are not UL or cUL certified as of this writing

% < 95 %, average relative humidity (RH),

non-condensing (EN 50178)

±8, air discharge

±2, at 5 kHz, motor connection terminals, single-phase mains connection terminals ±4, at 5 kHz, three-phase mains connection terminals

±2, Phase/neutral conductor to earth

±4, Phase to earth

> 1000 with 1 % load current reduction every 100 m, max. 2000 with UL approval, max. 4000 (without UL)

IP40 (NEMA 1) IP55 (NEMA 3) IP66 (NEMA 4X)

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1 DA1 device series

1.4 Rated data

Technical Data Formula

sign

General

Main circuit / power section

Power supply system

Rated operational voltage

DA1-12… U

DA1-32… U

DA1-34… U

Mains frequency f Hz 50/60 (48 - 62)

Power factor cos ϕ >96

Phase Imbalance % max. 3

Maximum short-circuit current (supply voltage) I

Mains switch-on frequency Maximum of one time every 30 seconds

Mains network configuration (AC power supply network)

Motor feeder

Output voltage

DA1-12…, DA1-32…, DA1-34… U

Output Frequency

Range, parameterizable f

Resolution Hz 0.1

Overload current

for 60 s % 150

for 3 s % 200

Pulse frequency

FS2, …, FS7 f

PWM

Operating mode V/Hz control, slip compensation, vector control

DC braking

Time before start t s 0 - 25, in the event of a stop

Motor pick-up control function (for catching spinning motors)

Brake chopper

Braking current during continuous operation % 100 (Ie)

Maximum braking current % 150 for 60 s

Unit Value

V 1~ 230 (200 V -10 % - 240 V +10 %)

V 3~ 230 (200 V -10 % - 240 V +10 %)

V 3~ 400 (380 V -10 % - 480 V +10 %)

kA 5

TN and TT earthing systems with directly earthed neutral point. IT earthing systems with PCM insulation monitoring relays only. Operation on phase-earthed networks is only permissible up to a maximum phase-earth voltage of 300 VAC.

V 3~ 0 - U

Hz 0 - 50/60 (max. 500)

kHz max. 32

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1 DA1 device series

1.4 Rated data

Technical Data Formula

Unit Value

sign

General

Control section

Control Voltage

Output voltage (control signal terminal 1) U

Load rating (control terminal 1) I

Reference voltage (control terminal 5) U

Load rating (control terminal 5) I

V DC 24

mA 100

V DC 10

mA 10

Digital input (DI)

Count 3 - 5

Logic (level) Increase

Response time t ms <4

Input voltage range High (1) U

Input voltage range Low (0) U

V DC 8 - 30

V DC 0 - 4

Analog Input (AI)

Count 0 - 2

Resolution 12-bit

Accuracy % < 1 to the final value

Response time t ms <4

Input voltage range U

Input current range I

V DC -10 - +10, (Ri ~ 72 kΩ)

mA 0/4 - 20 (RB ~ 500 Ω)

Digital output (DO) / relay output (K)

Count 2 (analog/digital) / 2 relay

Output voltage U

Output current I

out

V DC 0 - 10, 24

mA 0/4 - 20

Relays N/O contact, 6 A (250 V AC) / 5 A (30 V DC)

Changeover contacts, 6 A (250 V AC) / 5 A (30 V DC)

Interface (RJ45) OP bus, Modbus RTU, CANopen

Control level Control signal terminal/operating unit/interface

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Page 23

1.4.4 Features

1 DA1 device series

1.4 Rated data

Part no.

Rated opera-

tional current

[A] [kW] [A]

Mains supply voltage: 1 AC 230 V Motor connection voltage: 3 AC 230 V, 50/60 Hz

DA1-124D3…

DA1-127D0… 7 1.5 6.3 2 6.8 F N IP20, IP66 FS2

DA1-12011… 11 2.2 8.7 3 9.6 F N, B IP20, IP66 FS2

Mains supply voltage: 3 AC 230 V, 50/60 Hz Motor connection voltage: 3 AC 230 V, 50/60 Hz

DA1-324D3…

DA1-327D0… 7 1.5 6.3 2 6.8 F B IP20, IP66 FS2

DA1-32011… 10.5 2.2 8.7 3 9.6 F B IP20, IP66 FS2

DA1-32012…

DA1-32024… 24 5.5 19.6 7.5 22 F B IP20, IP66 FS3

DA1-32024… 24 5.5 19.6 7.5 22 F B IP55 FS4

DA1-32039… 39 7.5 26.4 10 28 F B IP55 FS4

DA1-32046… 46 11 38 15 42 F B IP55 FS4

DA1-32061… 61 15 51 20 54 F B IP55 FS5

DA1-32072… 72 18.5 63 25 68 F B IP55 FS5

DA1-32090…

DA1-32110…

DA1-32150…

DA1-32180…

DA1-32202… 202 55 173 75 192 F B IP55 FS7

DA1-32248… 248 75 233 100 248 F B IP55 FS7

1) The rated motor currents apply to normal internally and surface-cooled three-phase asynchronous motor (1500 rpm at 50 Hz, 1800 rpm

2) Take motor data into account (6 A = normalized rated value as per UL 580 C) Operation may be limited to a reduced motor load.

4.3 0.75 3.2 1 4.2 F N IP20, IP66 FS2

4.3 0.75 3.2 1 4.2 F B IP20, IP66 FS2

18 4 14.8 5 15.2 F B IP20, IP66 FS3

90 22 71 30 80 F B IP55 FS6

110 30 96 40 104 F B IP55 FS6

150 37 117 50 130 F B IP55 FS6

180 45 141 60 154 F B IP55 FS6

Assigned motor power

P (230 V, 50 Hz)

at 60 Hz).

Radio inter-

ference

suppression

Brake

chopper

(integrated)

Protection

type

P (220 - 240 V, 60 Hz)

[HP] [A]

N = No F = Yes

N = No B = Yes

IP FS

Size

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Page 24

1 DA1 device series

1.4 Rated data

Part no.

Rated opera-

tional current

[A] [kW] [A]

Assigned motor power

P (400 V, 50 Hz)

P (440 - 480 V, 60 Hz)

[HP] [A]

Radio inter-

ference

suppression

Brake

chopper

(integrated)

Degree of

protection

N = No F = Yes

N = No B = Yes

IP FS

Mains supply voltage: 3 AC 400 V, 50 Hz / 480 V, 60 Hz Motor connection voltage: 3 AC 400 V, 50 Hz / 440 - 480 V, 60 Hz

DA1-342D2…

2.2 0.75 1.9 1 2.1 F B IP20, IP66 FS2

DA1-344D1… 4.1 1.5 3.6 2 3.4 F B IP20, IP66 FS2

DA1-345D8… 5.8 2.2 5 3 4.8 F B IP20, IP66 FS2

DA1-349D5…

DA1-34014…

9.5 4 8.5 5 7.6 F B IP20, IP66 FS2

14 5.5 11.3 7.5 11 F B IP20, IP66 FS3

DA1-34018… 18 7.5 15.2 10 14 F B IP20, IP66 FS3

DA1-34024… 24 11 21.7 15 21 F B IP20, IP66 FS3

DA1-34024…

24 11 21.7 15 21 F B IP55 FS4

DA1-34030… 30 15 29.3 20 27 F B IP55 FS4

DA1-34039… 39 18.5 36 25 34 F B IP55 FS4

DA1-34046… 46 22 41 30 40 F B IP55 FS4

DA1-34061… 61 30 55 40 52 F B IP55 FS5

DA1-34072… 72 37 68 50 65 F B IP55 FS5

DA1-34090… 90 45 81 60 77 F B IP55 FS6

DA1-34110… 110 55 99 75 96 F B IP55 FS6

DA1-34150… 150 75 134 100 124 F B IP55 FS6

DA1-34180…

DA1-34202…

180 90 161 125 156 F N, B IP55 FS6

202 110 196 150 180 F N, B IP55 FS7

DA1-34240… 240 132 231 200 240 F N, B IP55 FS7

DA1-34302…

302 160 279 250 302 F N, B IP55 FS7

DA1-34370… 370 200 349 300 361 F N, B IP40 FS8

DA1-34450…

1) The rated motor currents apply to normal internally and surface-cooled three-phase asynchronous motor (1500 rpm at 50 Hz, 1800 rpm

450 250 437 350 414 F N, B IP40 FS8

at 60 Hz).

Size

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Page 25

1.5 DA1 layout

⑩

⑨

⑦

①

②

③

⑥

④

⑤

⑧

⏚

L1/L

L2/N

DC-

⏚

DC+

1 2 3 4 5 6 7 8 9 10 11 12 13

14 15 16 17 18

COM

1 DA1 device series

1.5 DA1 layout

The following drawing shows examples of named elements of the DA1 variable frequency drives in different frame sizes.

Figure 5: Designation on the DA1 variable frequency drive

a Fixing holes (screw fastening) b Connection terminals in power section (mains side) c Cutout for mounting on mounting rail (only for FS2 and FS3) d Control terminals (plug-in) e Relay terminals (plug-in) f Connection terminals in power section (motor feeder) g Slot for field bus card or expansion module h Communication interface (RJ45) i Operating unit with 5 control signal terminals and LED display j Info card

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Page 26

1 DA1 device series

1.6 Features

DA1 series variable frequency drives convert the voltage and frequency of an existing AC supply system 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.

L1/L

L2/N



②①③④⑤⑥⑦

EMC VAR

⑩

DC+DC- BR

⑧⑨

3 ~



⑫

⑪

Figure 6: Block diagram; components in a DA1 variable frequency drive

a L1/L, L2/N, L3, PE supply, mains supply voltage U

DA1-12…: single-phase mains connection (1 AC/2 AC 230 V/240 V), motor feeder (3 AC 230 V) DA1-32…: single-phase mains connection (3 AC 230 V/240 V), motor feeder (3 AC 230 V) DA1-34…: single-phase mains connection (3 AC 400 V/480 V), motor feeder (3 AC 400 V)

b Internal radio interference suppression filter, EMC connection to PE c Internal voltage filter, VAR connection to PE d Rectifier bridge: it converts the AC voltage of the electrical supply to a DC voltage. e Internal DC link with charging resistor, capacitor and switched-mode power supply unit

(SMPS = Switching-Mode Power Supply).

f Brake chopper for external braking resistor (DC+ and BR connection) g Inverter. The IGBT based inverter converts the DC voltage

of the DC link (U

h Motor connection with output voltage U

The connection in the motor feeder is implemented with a screened cable that is earthed on both sides across a large area (PES). Rated operational current (I DA1-12…: 4.3 - 10.5 A DA1-32…: 4.3 - 248 A DA1-34…: 2.2 - 450 A 100 % at an ambient temperature of +50 °C with an overload capability of 150 % for 60 s and a starting current of 175 % for 2 s.

i Three-phase asynchronous motor,

variable speed control of three-phase asynchronous motor for assigned motor shaft power values

DA1-12…: 0.75 - 2.2 kW (230 V, 50 Hz) oder 1 - 3 HP (230 V, 60 Hz) DA1-32…: 0.75 - 75 kW (230 V, 50 Hz) oder 1 - 100 HP (230 V, 60 Hz) DA1-34…: 0.75 - 160 kW (400 V, 50 Hz) oder 1 - 255 HP (460 V, 60 Hz)

) into a three-phase AC voltage (U2) with variable amplitude and frequency (f2).

CPU STO

1 … 11, 14 … 18 12 13

at 50/60 Hz:

LN=Ue

(0 to 100 % Ue) and output frequency f2 (0 to 500 Hz)

, output current):

PES

22 DA1 Variable Frequency Drives 10/12 MN04020005Z-EN www.eaton.com

Page 27

1 DA1 device series

1.6 Features

j Control section with operating unit and control buttons, 7-digital display assembly, control voltage,

plug-in control signal terminals, plug-in relay terminal

k RJ45 interface for the PC and fieldbus connection (Modbus RTU, CANopen) l Safe Torque-Off

Safe removal of torque as per SIL 2 (EN 61508) / PL d (EN ISO 13849-1)

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Page 28

1 DA1 device series

⏚

L1/L

L2/N

DC-

⏚

DC+

1 2 3 4 5 6 7 8 9 10 11 12 13

14 15 16 17 18

COM

P1-07

P1-08

P1-10

P1-09

P4-05

1410 min

-1

230/400 V 3.2/1.9 A

50 Hz

0,75 KW

cos ϕ 0.79

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 ( / ) of the motor must be selected according to the rated operational current.

The rated output current I

of the variable frequency drive must be greater

than or equal to the rated motor current.

Figure 7: Selection criteria – Rating plate data

When selecting the drive, the following criteria must be known:

• Type of motor

• Mains voltage = rated operating voltage of the motor (e. g. 3~ 400 V),

• Rated motor current (recommended value, dependent on the circuit type

and the power supply)

• Load torque (quadratic, constant),

• Starting torque,

• Ambient air temperature (rated value e. g. +40 °C).

￫

variable frequency drive, the motor currents are cally

– separated by effective and idle current components.

When you select a variable frequency drive, 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 installed between the variable

When connecting multiple motors in parallel to the output of a

frequency drive and the motor.

24 DA1 Variable Frequency Drives 10/12 MN04020005Z-EN www.eaton.com

added geometri-

Page 29

1.8 Proper use

1 DA1 device series

1.8 Proper use

The DA1 variable frequency drives are not domestic appliances. They are designed only for industrial use as system components.

The DA1 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.

After installation in a machine, the variable frequency drives 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 DA1 variable frequency drive confirm that, when used in a pean Low Voltage Directive (LVD) and the EMC Directives (Directive 73/23/ EEC, as amended by 93/68/EEC and Directive 89/336/EEC, as amended by 93/68/EEC).

typical drive configuration, the apparatus complies with the Euro-

In the described system configurations, DA1 variable frequency drives are suitable for use in public and non-public networks.

A connection of a DA1 variable frequency drive to IT networks (networks without reference to earth potential) is permissible only to a limited extent, since 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).

￫

Observe the technical data and connection requirements. For additional information, refer to the equipment nameplate or label of the variable frequency drive and the documentation. Any other usage constitutes improper use.

To the output (terminals U, V, W) of the DA1 variable frequency drive you must not:

• connect a voltage or capacitive loads (e.g. phase compensa-

tion capacitors),

• connect multiple variable frequency drives in parallel,

• make a direct connection to the input (bypass).

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Page 30

1 DA1 device series

1.9 Maintenance and inspection

DA1 series variable frequency drives will be maintenance-free as long as the general rated operational data ( Section 1.4.3, “General rated operational data“, page16) is adhered to and the specific technical data (see appendix) for the corresponding ratings is taken into account. Please note, however, that external influences may affect the operation and lifespan of a DA1 variable frequency drive.

We therefore recommend that the devices are checked regularly and the following maintenance measures are carried out at the specified intervals.

Table 2: Recommended maintenance for DA1 variable frequency drives

Maintenance measures Maintenance interval

Clean cooling vents (cooling slits) Please enquire

Check the fan function 6 - 24 months (depending on the environment)

Filter in the switching cabinet doors (see manufacturer specifications)

Check all earth connections to make sure they are intact

Check the tightening torques of the terminals (control signal terminals, power terminals)

Check connection terminals and all metallic surfaces for corrosion

Motor cables and shield connection (EMC)

Charge capacitors

6 - 24 months (depending on the environment)

On a regular basis, at periodic intervals

6 - 24 months; when stored, no more than 12 months later (depending on the environment)

According to manufacturer specifications, no later than 5 years

12 months (￫ Section 1.11, “Charging the internal DC link capacitors“)

1.10 Storage

There are no plans for replacing or repairing individual components of DA1 variable frequency drives.

If the DA1 variable frequency drive is damaged by external influences, repair is not possible.

Dispose of the device according to the applicable environmental laws and provisions for the disposal of electrical or electronic devices.

If the DA1 variable frequency drive is stored before use, suitable ambient conditions must be ensured at the site of storage:

• Storage temperature: -40 - +70 °C,

• Relative average air humidity: < 95 %, non condensing (EN 50178),

• To prevent damage to the RASP DC link capacitors, storage times longer

than 12 months are not recommended ( Section 1.11, “Charging the internal DC link capacitors“).

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Page 31

1.11 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 DA1 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).

In order to prevent the capacitors from having excessively high leakage currents, the inrush current should be limited to approximately 300 to 800 mA (depending on the relevant rating). The variable frequency drive must not be enabled during this time (i.e. no start signal). After this, the DC voltage must be set to the magnitudes for the corresponding DC link voltage (U

 1.41 x Ue) and applied for one hour at least (regeneration time).

1 DA1 device series

1.11 Charging the internal DC link capacitors

1.12 Service and warranty

• DA1-12…, DA1-32…: about 324 V DC at U

• DA1-34…: about 560 V DC at U

= 400 V AC.

= 230 V AC.

In the unlikely event that you have a problem with your DA1 variable frequency drive, please contact your local sales office.

When you call, have the following data ready:

• The

exact variable frequency drive part number (see nameplate),

• the date of purchase,

• a detailed description of the problem which has occurred with the

variable frequency drive.

If some of the information printed on the rating plate is not legible, please state only the data which are clearly legible.

Information concerning the guarantee can be found in the Terms and Conditions Eaton Industries GmbH.

24-hour hotline: +49 (0)1805 223 822

E-Mail:

AfterSalesEGBonn@eaton.com

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Page 32

1 DA1 device series

1.12 Service and warranty

28 DA1 Variable Frequency Drives 10/12 MN04020005Z-EN www.eaton.com

Page 33

2 Engineering

③

②

①

L1 L2 L3 PE

⑤

④

⑦

⑩

⑨

⑧

⑥

RCD

L1/L

L2/N

L3 PE

DC+

PES

I > I > I >

⑪

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.

Figure 8: Example of a magnet system with a three-phase feeder unit

for a three-phase motor

a Network configuration, mains voltage, mains frequency, interaction with p.f. correction systems b Fuses and cable cross-sections, cable protection c Protection of persons and domestic animals with residual current protective devices d Mains contactor e Main choke, radio interference filter, line filter f Variable frequency drive: mounting; installation; power connection; EMC compliance;

circuit examples

g Motor reactor, dV/dt filter, sinusoidal filter h Motor protection; Thermistor overload relay for machine protection i Cable lengths, motor cables, shielding (EMC) j Motor and application, parallel operation of multiple motors on a variable frequency drive

(only for V/f), bypass circuit; DC braking

k Braking resistance; dynamic braking

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Page 34

2 Engineering

PEN

EMC

L2/N

L1/L

VAR

PH1

20 mm (0.79")



EMC

VAR

2.2 Electrical power network

2.2.1 Mains connection and configuration

The variable frequency drives of the DA1 series can be connected and operated with all control-point grounded AC supply systems (see IEC 60364 for more information in this regard).

Figure 9: AC power networks with earthed center point (TN-/TT networks)

￫

to the three main poles, if multiple variable frequency drives with single-phase incoming unit are to be connected.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 variable frequency drives to asymmetrically grounded TN networks (phase-grounded Delta network “Grounded Delta“, USA) or non-grounded or high-resistance grounded (over 30 ) IT networks is only conditionally permissible.

Operation on non-earthed networks (IT) requires the use of suit-

While planning the project, consider a symmetrical distribution

￫

able insulation monitors (e.g. pulse-code measurement method).

In networks with an earthed main pole, the maximum phase-

￫

earth voltage must not exceed 300 VAC.

If DA1 series variable frequency drives are connected to an asymmetrically earthed network or to an IT network (non-earthed, insulated), the internal radio interference suppression filter must be disconnected (by unscrewing the screw marked EMC).

30 DA1 Variable Frequency Drives 10/12 MN04020005Z-EN www.eaton.com

Figure 10: EMC screw location

Page 35

2 Engineering

2.2 Electrical power network

The required filter winding for electromagnetic compatibility (EMC) no longer exists in this case.

￫

2.2.2 Mains voltage and frequency

The standardized rated operating voltages (IEC 60038, VDE 017-1) of power utilities guarantee the following conditions at the connection point:

• Deviation from the rated value of voltage:

maximum ±10 %

• Deviation in voltage phase balance:

maximum ±3 %

• Deviation from rated value of the frequency:

maximum ±4 %

The broad rated value for European as (EU: ULN = 230 V/400 V, 50 Hz) and American as (USA: U

Measures for electromagnetic compatibility are mandatory in a magnet system, to meet the legal standards for EMC- and lowvoltage regulations.

Good earthing measures are a prerequisite for the effective insert of further measures such as screen earth kit or filters here. Without respective grounding measures, further steps are superfluous.

tolerance band of the DA1 variable frequency drive considers the

= 240 V/480 V, 60 Hz) standard voltages:

2.2.3 Voltage balance

• 230 V, 50 Hz (EU) and 240 V, 60 Hz (USA) at DA1-12…, DA1-32…

200 V - 10 % - 240 V + 10 % (190 V - 0 % - 264 V + 0 %)

• 400 V, 50 Hz (EU) and 480 V, 60 Hz (USA) at DA1-34…

380 V - 10 % - 480 V + 10 % (370 V - 0 % - 528 V + 0 %)

The permissible frequency range for all voltage categories is 50/60 Hz (48Hz-0%-62Hz+0%).

Because of 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 mains voltage can lead to different loading of the diodes in mains rectifiers with three-phase supplied variable frequency drives and as a result, to an advance failure of this diode.

￫

If this condition is not fulfilled, or symmetry at the connection location is not known, the use of an assigned main choke is recommended.

In the project planning for the connection of three-phase supplied variable frequency drives (DA1-3…), consider only AC supply systems that handle permitted asymmetric divergences in the mains voltage  +3 %.

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Page 36

2 Engineering

THD

n2xx=

---------------------- -=



n=2



2.2 Electrical power network

2.2.4 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 which 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:

• Induction and arc furnaces, welding devices,

• Current converters, rectifiers and inverters, soft starters, variable fre-

quency drives,

• 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. For example, the THD for a current is:

Where I

is the rms value of the fundamental frequency current and n is the

order of a harmonic with its own frequency, which is an integer multiple of the fundamental frequency (Fourier analysis). Example:

5th harmonic of a mains frequency of 50 Hz : 5 x 50 Hz = 250 Hz.

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 120 %. A mains choke (such as 4 % u the supply side of a variable frequency drive enables the

THD value with a

) on

single-phase supply (B2 diode rectifier bridge) to be reduced to around 80 % and with a three-phase supply (B6 diode rectifier bridge) to around 50 %. The supply quality is thus improved and the mains supply distortion is reduced. The power factor is also improved.

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Page 37

2.2.5 Idle power compensation devices

Compensation on the power supply side is not required for the variable frequency drives of the DA1 series. From the AC power supply network they only take on very little reactive power of the fundamental harmonics (cos  ~ 0.98).

2 Engineering

2.2 Electrical power network

2.2.6 Mains chokes

￫

Main chokes (also known as commutating chokes) increase the choke of the mains supply cable. This extends the current flow period and dampens mains deviations.

These 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 rectifier, internal DC link capacitors).

￫

In the AC supply systems with non-choked reactive current compensation devices, current deviations can enable parallel resonance and undefinable circumstances.

In the project planning for the connection of variable frequency drives to AC supply systems with undefined circumstances, consider using main chokes.

For the operation of the DA1 variable frequency drive, the application of main chokes is not necessary. We do recommend however that an upstream mains choke is used since the network quality is not known in most cases.

While planning the project, consider assigned to a single variable frequency drive for decoupling.

When using an adapting transformer (assigned to a single variable frequency drive), a main choke is not necessary.

Main chokes are designed based on the mains-side input cur-

(ILN) of the variable frequency drive.

rent

DA1 Variable Frequency Drives 10/12 MN04020005Z-EN www.eaton.com 33

that a main choke is only

Page 38

2 Engineering

2.3 Safety and switching

2.3.1 Fuses and cable cross-sections

The fuses and wire cross-sections allocated for power-side connections depend on the rated mains current I out main choke).

The recommended fuses and their assignment to the variable frequency drives are listed in Page 218 the appendix.

of the variable frequency drive (with-

NOTICE

When selecting the cable cross-section, take the voltage drop under load conditions into account.

The consideration of other standards (e.g. 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. The permissible cables must have a heat resistance of 75 °C.

The connection terminals marked with  and the metallic enclosure (IP66) must be connected to the earth-current circuit.

The leakage currents to earth (as per EN 50178) are greater than 3.5 mA. They are listed for the individual ratings in the appendix, under the specific technical data on Page 203.

￫

As per the requirements in standard EN 50178, a protective earth (PE) must be connected. The cable cross-section must be at least 10 mm cables.

NOTICE

The specified minimum PE conductor cross-sections (EN 50178, VDE 0160) must be maintained.

or consist of two separately connected earthing

A completely (360°) screened low impedance cable on the motor side is required. The length of the motor cable depends on the RFI class and the environment.

￫

34 DA1 Variable Frequency Drives 10/12 MN04020005Z-EN www.eaton.com

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).

Page 39

2.3.2 Residual current device

Residual current devices (RCD) are also known as residual current device (GFCI) or residual current circuit breaker (RCCB).

Residual current devices protect people and farm animals from the presence (not the production!) of impermissibly high touch voltages. gerous to prevent fires.

2 Engineering

2.3 Safety and switching

They prevent dan-

(including fatal) injuries caused by electrical accidents and also serve

￫

Residual current devices must be suitable for:

• the

• high leakage currents (300 mA),

• Briefly diverting surge currents

CAUTION



Marking on the residual current device

AC/DC sensitive (RCD, part no. B)

￫

Only AC/DC sensitive residual current devices (RCD, type B) may be used with variable frequency drives (EN 50178, IEC 755).

Variable frequency drives work internally with rectified AC currents. If an error occurs, the DC currents can block an RCD safety device of type A from triggering and therefore disable the protective functionality.

protection of installations with DC current component in

case of fault scenario (RCD, type B),

NOTICE

Residual current devices (RCD) are only to be installed between the AC power supply network and the variable frequency drive.

￫

Leakage currents to earth are mainly caused by foreign capacities with variable frequency drives: between the motor phases and the shielding of the motor cable and via the star capacitor of the radio interference suppression filter.

DA1 Variable Frequency Drives 10/12 MN04020005Z-EN www.eaton.com 35

Safety-relevant leakage currents can occur while handling and when operating the variable frequency drive, if the variable frequency drive is not earthed.

Page 40

2 Engineering

2.4 EMC compliance

2.3.3 Mains contactors

The size of the leakage currents is mainly dependent upon the:

• length of the motor cable,

• shielding of the motor cable,

• height of the pulse frequency (switching frequency of the inverter),

• Design of the radio interference suppression filter

• grounding measures at the site of the motor.

The mains contactor enables an operational switching on and off of the supply voltage for the variable frequency drive and switching off in case of a fault.

2.4 EMC compliance

The mains contactor is designed based on the mains-side input current I the variable frequency drive for utilization category AC-1 (IEC 60947) and the ambient air temperature at the location of use. Mains contactors and their assignment to the variable frequency drives belonging to the DC1 series are listed in the appendix (Table 27, page 220).

￫

Electrical components in a system (machine) have a reciprocal effect on each other. Each device not only emits interference but is also affected by it. This occurs as a result of galvanic, capacitive and/or inductive coupling or through electromagnetic radiation. In practice, the limit between line-conducted interference and emitted interference is around 30 MHz. At values above 30 MHz the lines and cables act like antennas and radiate the electromagnetic waves.

While planning the project, make sure that inching operation is not done via the mains contactor of the variable frequency drive on frequency-controlled drives, but through a controller input of the variable frequency drive.

The maximum permissible mains voltage switch-on frequency for the (normal operation).

DA1 variable frequency drive is once every 30 seconds

Electromagnetic compatibility (EMC) for frequency controlled drives (variable speed drives) is implemented in accordance with product standard IEC/EN 61800-3. This includes the complete power magnet system (PDS = Power Drive System), from the mains supply to the motor, including all components, as well as cables ( Figure 8, page 29). This type of drive system can also consist of several individual drives.

The generic standards of the individual components in a magnet system compliant with IEC/EN 61800-3 do not apply. These component manufacturers, however, must offer solutions that ensure standards-compliant use.

In Europe, maintaining the EMC Directive is mandatory.

36 DA1 Variable Frequency Drives 10/12 MN04020005Z-EN www.eaton.com

Page 41

2 Engineering

1. Environment

Public medium-voltage system

PCC

Category C1

Category C2

Category C1 / C2 Category C1 / C2

Category C3 / C4

1.or 2. environment 2. Environment

Public low-voltage system

Private mains

Industrial mains

2.4 EMC compliance

A declaration of conformity (CE) refers always to a “typical“ power magnet system (PDS). The responsibility to comply with the legally stipulated limit values and thus the provision of electromagnetic compatibility is ultimately the responsibility of the end user or system operator. Measures must be taken to remove or minimize emission in the associated environment ( Figure 11). He must also utilize means to increase the interference immunity of the devices of the system.

With their high interference immunity up to category C3, DA1 variable frequency

The DA1…-F… version (with integrated RFI filter) makes it possible to comply with the stringent limit values for conducted emission for category C1 in the 1st environment. This requires a correct EMC installation ( Page 53) and the observance of the permissible motor cable lengths and the maximum switching frequency (f

In the case of variable frequency drives without an internal radio interference suppression filter, longer motor cable lengths and lower leakage currents can sometimes be achieved for the individual categories by using a dedicated external radio interference suppression filter.

drives are ideal for use in harsh industrial networks (2nd environment).

) of the inverter.

PWM

The required EMC measures should be taken into account in the engineering phase. Improvements and modifications during mounting and installation or even at the installation site involve additional and even considerably higher costs.

Figure 11: EMC environment and categories

DA1 Variable Frequency Drives 10/12 MN04020005Z-EN www.eaton.com 37

Page 42

2 Engineering

2.5 Motor and Application

2.5.1 Motor selection

General recommendations for motor selection:

• For a frequency-controlled magnet system (PDS), use three-phase AC

motors with squirrel-cage rotors and surface cooling, also known as three-phase asynchronous motors or standard motors. Other types of motors, such as external rotor motors, wound-rotor motors, reluctance motors, permanent-magnet motors, synchronous motors, and servomotors can also be operated with a variable frequency drive, but normally require additional engineering in consultation with the motor's manufacturer.

• Only use motors that have insulation class F (maximum steady state

temperature of 155 °C) at least.

-1

• Choose 4 pole motors preferably (synchronous speed: 1500 min

50 Hz and 1800 min

• Take

• When operating multiple motors in parallel on one variable frequency

• Ensure that the motor is not overdimensioned. If it is underdimensioned

the operating conditions into account for S1 operation (IEC 60034-1).

drive, the motor output should not be more than three power classes apart.

in the “speed control“ (slip compensation) operating mode, the motor output may only be one single assigned output level lower.

-1

at 60 Hz).

2.5.2 Parallel connection of motors

The DA1 variable frequency drives allow parallel operation of several motors in “V/f control mode“:

• With multiple motors with the same or different rated operational data:

The total of the motor currents must be less than the rated operational current of the variable frequency drive.

• Connecting and disconnecting individual motors: The total of the motor

currents in operation, plus the motor’s inrush current, must be less than the rated operational current of the variable frequency drive.

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.

Connecting motors in parallel reduces the load resistance at the variable frequency drive 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.

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Page 43

2 Engineering

2.5 Motor and Application

To reduce the current distortion, you should use motor reactors (see  in Figure12) in the output of the variable frequency drive.

①

Q11

U1 V1 W1 U1 V1 W1 U1 V1 W1

Figure 12: Parallel connection of several motors to one variable frequency drive

Q12

Q13

NOTICE

If multiple motors are connected in parallel to a single variable frequency drive, make sure to dimension the individual motors’ contactors for utilization category AC-3. The

motor contactor must be selected according to the rated operational current of the motor that will be connected.

The current consumption of all motors connected in parallel

￫

must not exceed the variable frequency drive’s rated output cur-

rent I

When operating multiple motors in parallel, you cannot use the

￫

variable frequency drive’s electronic motor protection. You will have to protect each motor individually with thermistors and/or a current transformer-operated overload relay.

￫

variable frequency drives can result in motors being disconnected in an undefined manner and is only possible in select applications.

DA1 Variable Frequency Drives 10/12 MN04020005Z-EN www.eaton.com 39

The use of motor-protective circuit-breakers at the output of

Page 44

2 Engineering

1410 mi n

230/400 V 3.2/1.9 A

50 Hz

-1

0,75 KW

cos ϕ 0.79

U1 V1 W1

W2 U2 V2

U1 V1 W1

W2 U2 V2

2.5 Motor and Application

2.5.3 Circuit types with three-phase motors

The three-phase motor’s stator winding can be connected in a star or delta circuit as per the rated operational data on the rating plate.

Figure 13: Example of a motor

rating plate

Figure 14: Configuration types:

2.5.4 87-Hz Characteristic curve

The three-phase motor with the rating plate in Figure13 can be operated with either a start or delta circuit. The operational characteristic curve is determined by the ratio of motor voltage to motor frequency in this case.

The 87 Hz characteristic curve is used to operate the three-phase standard motor with the rating plate in Figure13 with a delta circuit on a 400 V network at 87 Hz. To enable this, the variable frequency drive must deliver the higher current for delta circuits (3.2 A) and the motor frequency (V/Hz key point) must be set to 87 Hz on the variable frequency drive.

This results in the following advantages:

• The motor’s speed adjustment range is increased by a factor of 3 (from

50 Hz to 87 Hz)

• The motor’s efficiency is improved, since the motor speed increases

while the (absolute) slip remains the same and therefore is smaller, percentage-wise, relative to the new (higher) speed.

• Greater power can be taken from the motor (P ~ M x n), making it possi-

ble in some cases to use a motor one size smaller (and therefore more affordable) for the application (e.g. travel motor in crane drives)

• The machine speed of existing machines can be increased without

having to change the motor and/or transmission. In other words, operation does not take place within the field-weakening range.

Star-connected circuit (left), delta circuit (right)

40 DA1 Variable Frequency Drives 10/12 MN04020005Z-EN www.eaton.com

￫

Due to the higher thermal load, it is recommended to only use the next higher listed motor output and to only use motors with an insulation class of F at the very least.

Page 45

2 Engineering

8750

400

U2 [V]

f [Hz]

max

230

2.5 Motor and Application

￫

rpm must be taken into account. Consult the manufac-

5,000 turer’s specifications.

If using 2 pole motors (p = 1), the high speed of approximately

Figure 15: V/Hz characteristic curve

for the rating plate of the motor from  Figure 13

a Star connection: 400 V, 50 Hz b Delta circuit: 230 V, 50 Hz c Delta connection: 400 V, 87 Hz

The following Tabelle 3 shows the allocation of possible variable frequency drives depending on the mains voltage and the type of circuit.

Table 3: Assignments between variable frequency drives and V/Hz characteristic curve

( Figure 15)

Physical parameters DA1-124D3… DA1-324D3… DA1-342D2… DA1-344D1…

Rated operational current 4.3 A 4.3 A 2.2 A 4.1 A

Mains voltage 1AC230V 3AC 230V 3AC400V 3AC400V

V/f-characteristic curve ② ② ① ③

Motor circuit

Motor current

Motor voltage 3AC 0-230V 3AC 0-230V 3AC 0-400V 3AC 0-400V

Motor speed 1430 min

Motor frequency 50 Hz 50 Hz 50 Hz 87 Hz

1) Note the permitted limit values of the motor!

Delta circuit (230 V) Delta circuit (230 V) Star-connected circuit

3.5 A 3.5 A 2.0 A 3.5 A

-1

1430 min

-1

(400 V)

1430 min

-1

Delta circuit (230 V)

2474 min

-1 1)

DA1 Variable Frequency Drives 10/12 MN04020005Z-EN www.eaton.com 41

Page 46

2 Engineering

2.5 Motor and Application

2.5.5 Bypass operation

When it is necessary to be able to power the motor directly with mains voltage independently from the variable frequency drive (bypass operation), the branches must be mechanically interlocked.

NOTICE

The system may only switch (S1) between the variable frequency drive (T1) and mains voltage (see Figure16) while in a de-energized state.

CAUTION



Q11

L1 L2 L3

UVW

The variable frequency drive’s outputs (U, V, W) must not be connected to the mains voltage (destruction risk, fire hazard).

I>I>I

Figure 16: Bypass motor control (example)

￫

42 DA1 Variable Frequency Drives 10/12 MN04020005Z-EN www.eaton.com

When running the motor directly with mains voltage, protective measures (circuit-breaker with thermal overload protection  or overload relay ) against overload must be in place.

Contactors and switches (S1) in the variable frequency drive output and for the direct start must be designed based on utilization category AC-3 for the rated operational current of the motor.

Page 47

2.5.6 Connecting EX motors

①

②

5 1015202530354045

The following aspects must be taken into account when connecting explosion-proof motors:

• The variable frequency drive must be installed outside the EX area.

• All applicable industry-specific and country-specific regulations for haz-

• The specifications and instructions provided by the motor’s manufac-

• Temperature monitors in the motor windings (thermistor, Thermo-Click)

2.5.7 Sinusoidal filter

Sinusoidal filters are connected in the output of a variable frequency drive.

2 Engineering

2.5 Motor and Application

ardous locations (ATEX 100a) must be complied with.

turer with regard to operation with a variable frequency drive – e.g., whether motor reactors (dV/dt limiting) or sinusoidal filters are required – must be taken into account.

must not be connected directly to the variable frequency drive, but instead must be connected through a relay approved for the hazardous location (e.g. EMT6).

1U1

1V1

1W1



1W2

1V2

1U2

3 ~

Figure 17: Circuit Diagram of a sinusoidal filter

U ∼

The sinusoidal filter removes high-frequency components above the set resonance frequency from the variable frequency drive output voltage (U This reduces the conducted and radiated emission.

a Without sinusoidal filter b With sinusoidal filter

f: Rotating field frequency n: Order of harmonics

Figure 18: High frequency components of the output voltage

DA1 Variable Frequency Drives 10/12 MN04020005Z-EN www.eaton.com 43

Page 48

2 Engineering

U∼

2.5 Motor and Application

The output voltage of the sinusoidal filter (U~) achieves a sinusoidal shape with a slight superimposed ripple voltage.

The THD factor of the sinusoidal voltage is normally 5 to

Figure 19: Output voltage to motor

: Variable frequency drive output voltage

U~: Simulated sinusoidal voltage

10 %.

Advantages of sinusoidal filters:

• Long motor cable lengths with reduced conducted and radiated inter-

ference

• Reduced motor losses and noise

• Longer motor lifespan

Disadvantages of sinusoidal filters:

• Voltage drop of up to 9 % caused by system

(approx. 36 V if U

= 400 V)

• higher heat dissipation,

• A fixed pulse frequency is required

• Require more space inside the control panel

NOTICE

Sinusoidal filters must only be used with permanently set pulse frequencies.

44 DA1 Variable Frequency Drives 10/12 MN04020005Z-EN www.eaton.com

Page 49

3 Installation

3.1 Introduction

3 Installation

3.1 Introduction

This chapter explains how to install and electrically connect DA1 series variable frequency drives.

3.2 Mounting

￫

The instructional leaflets in this section are meant to show how to install the device in a suitable enclosure for devices with protection type 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 conductiv-

ity.

• If a control panel with ventilation openings is used, the openings must

be located above and below the variable frequency drive in order to allow for proper air circulation. The air should come in from below the variable frequency drive and leave above it.

• If the environment outside the control panel contains dirt particles (e.g.,

dust), a suitable particulate filter must be placed on the ventilation openings and forced ventilation must be used. The filters must be maintained and cleaned if necessary.

• An appropriate enclosed control panel (without ventilation openings)

must be used in environments containing large percentages or amounts of humidity, salt, or chemicals.

While mounting 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.

DA1 Variable Frequency Drives 10/12 MN04020005Z-EN www.eaton.com 45

Page 50

3 Installation

≦ 30º

3.2 Mount i ng

3.2.1 Mounting position

DA1 series variable frequency drives are designed to be mounted vertically. The maximum permissible inclination is 30°.

3.2.2 Cooling measures

Figure 20: Mounting position

In order to guarantee sufficient air circulation, enough thermal clearance must be ensured according to the frame size (rating) of the variable frequency drive.

12345678910111213

COM

DC+ BR U V W

L2/N L3DC- L1/L

12345678910111213

COM

14 15 16 17 18

DC+ BR U V W

Figure 21: Space for air-cooling

46 DA1 Variable Frequency Drives 10/12 MN04020005Z-EN www.eaton.com

Page 51

3 Installation

3.2 Mount i ng

Table 4: Minimum clearance and required cooling air

Size a b c d Air through-put

[mm] [in] [mm] [in] [mm] [in] [mm] [in] [m3/h] [ft3/min]

FS2 50 1.97 46 1.81 75 2.95 75 2.95 18.7 11

FS3 50 1.97 52 2.05 100 3.94 100 3.94 44.2 26

FS4 10 0.39 71 2.8 200 7.87 200 7.87 – –

FS5 10 0.39 70 2.76 200 7.87 200 7.87 – –

FS6 10 0.39 140 5.52 200 7.87 200 7.87 – –

FS7 10 0.39 140 5.52 200 7.87 200 7.87 – –

The values in 4 are recommended values for an ambient air temperature of up to +50 °C, an installation altitude of up to 1000 m, and a pulse frequency of up to 8 kHz.

￫

≧ 15 mm (≧ 0.59”)

Figure 22: Minimum required clearance

conditions.

in front of the variable frequency drive

Please note that the mounting makes it possible to open and

Typical heat loss makes up about 3 % of the operational load

￫

close the control signal terminal covers without any problems.

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).

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Page 52

3 Installation

3.2 Mount i ng

Figure 23: Air baffle due to increased circulation with device fan

￫

Devices with high magnetic fields (e.g. reactors or transformers) should not be installed close to the variable frequency drive.

48 DA1 Variable Frequency Drives 10/12 MN04020005Z-EN www.eaton.com

Page 53

3.2.3 Control panel installation

⏚

L1/L

L2/N

DC-

⏚

DC+

1 2 3 4 5 6 7 8 9 10 11 12 13

4 15 16 17 18

COM

3 Installation

3.2 Mount i ng

Figure 24: Control panel dimensioning

Calculation of control panel surface:

[m2]

ΔT x K

A = Control panel surface [m

= Total heat dissipation [W] of all fitted devices

] calculated according to IEC 890)

T = Temperature difference [K], (default value = 5.5 K)

K = Heat transfer coefficient [W/(m2xK)]

(standard value = 5.5 for steel control panels)

DA1 Variable Frequency Drives 10/12 MN04020005Z-EN www.eaton.com 49

Page 54

3 Installation

3.2 Mount i ng

3.2.4 Fixing

Variable frequency drives with frame sizes of FS2 and FS3 can be fastened with screws or on a mounting rail. Sizes FS4 to FS8 can only be fastened using screws.

3.2.4.1 Fixing with screws

￫

Install the variable frequency drive only on a nonflammable mounting base (e.g., on a metal plate).

Dimension and weight specifications for the DA1 variable frequency drive can be found in the appendix ( Page 209).

The number and layout of required mounting dimensions a1 and b1, the tightening torque for the screws, etc. are listed in  Section 9.2, “Dimensions and frame size“.

Use screws with a washer and split washer with the permissible tightening torque in order to protect the enclosure and safely and reliably mount the device.

EMC

VAR

Figure 25: Mounting dimensions

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Page 55

3 Installation

7.5 15

3.2 Mount i ng

Figure 26: Mounting preparation

 First fit the screws at the specified positions, mount the variable fre-

quency drive and then fully tighten all screws.

￫

3.2.4.2 Fixing on mounting rails

As an alternative to screw mounting, DA1 variable frequency drives of sizes FS2 and FS3 can also be mounted on a mounting rail as per IEC/EN 60715.

Figure 27: Mounting rail conforming with IEC/EN 60715

 To do this, place the variable frequency drive on the mounting rail from

above [1] and press it down until it snaps into place [2].

The permitted maximum tightening torque for the fixing screws is 1.3 Nm.

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Page 56

3 Installation

EMC

VAR

f 5 mm (f 0.197“)

3.2 Mount i ng

EMC

VAR

EMC

VAR

Figure 28: Fixing to the mounting rail

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.

Figure 29: Dismantling from mounting rails

52 DA1 Variable Frequency Drives 10/12 MN04020005Z-EN www.eaton.com

Page 57

3.3 EMC installation

3 Installation

3.3 E MC in st allat i on

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 ( Figure 11, page 37). He must also utilize means to increase the interference immunity of the devices of the system.

In a magnet system (PDS) with variable frequency drives, you should take measures for electromagnetic compatibility (EMC) while doing your engineering, since changes or improvements to the installation site, which are required in the installation or while mounting, are normally associated with additional higher costs as well.

The technology and system of a variable frequency drive 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 area.

With leakage currents greater than 3.5 mA, in accordance with VDE 0160 or EN 60335, either

• the cross-sectional area of the protective conductor must be  10 mm

• The protective conductor must be open-circuit monitored, or

• the second protective conductor must be fitted.

For an EMC-compliant installation, we recommend the following measures:

• Installation of the variable frequency drive in a metallically conductive

housing with a good connection to ground,

• screened motor cables (short cables).

￫

Ground all conductive components and housings in a magnet system using as short ble cross-section (Cu-drain wire).

3.3.1 EMC measures in the control panel

For the 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 control panel doors should make good contact and be connected with short HF-drain wires. Avoid using painted surfaces (Anodized, chromized). An overview of all EMC measures is provided in Figure31 on Page 53.

￫

Install the variable frequency drive as directly as possible (without spacers) on a metal plate (mounting plate).

line as possible with the greatest possi-

￫

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Route mains and motor cables in the switch cabinet as close to the ground potential as possible. This is because free moving cables act as antennas.

Page 58

3 Installation

3.3 E MC in st allat i on

3.3.2 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.

Every variable frequency drive must be individually connected to the power supply system's protective earth directly at the location of installation (system earthing). This protective earth must not pass through any other devices.

When laying HF cables (e.g. shielded motor cables) or suppressed cables (e.g. mains supply cables, control circuit and signal cables) in parallel, a minimum clearance of 300 mm should be ensured in order to prevent the radiation of electromagnetic energy. You should also use separate cable entries if there is a great difference in voltage potentials. 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 screened.

3.3.2.1 Protective earth

All protective conductors should be routed in a star topology starting from the central earth point, and all of the drive system's conductive components (variable frequency drive, motor reactor, motor filter, main choke) should be connected.

The earth-fault loop impedance must comply with all locally applicable industrial safety regulations. In order to meet UL requirements, UL-listed ring cable lugs must be used for all earth wiring connections.

￫

This refers to the legally required protective earth for a variable frequency drive. An earthing terminal on the variable frequency drive, or the system earth, must be connected to a neighboring steel element in the building (beam, ceiling joist), an earth electrode in the ground, or a mains earth bus. The earth points must meet the requirements set forth by the applicable national and local industrial safety regulations and/or regulations for electrical systems.

Avoid ground loops when installing multiple variable frequency drives in one control panel. Make sure that all metallic devices that

are to be grounded have a broad area connection with the

mounting plate.

54 DA1 Variable Frequency Drives 10/12 MN04020005Z-EN www.eaton.com

Page 59

3.3.2.2 Motor earthing

EMC

L2/N

L1/L

VAR

PH1

20 mm (0.79")



EMC

VAR

The motor earth must be connected to one of the earthing terminals on the variable frequency drive and to a neighboring steel element in the building (beam, ceiling joist), an earth electrode in the ground, or a mains earth bus.

3.3.2.3 Earth-fault protection

A fault current to earth can be produced by variable frequency drives due to their system characteristics. DA1 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. This fault current must be monitored by a residual current device (RCD, type B).

3.3.3 EMC screw

3 Installation

3.3 E MC in st allat i on

Figure 30: EMC and VAR screws in a DA1

variable frequency drive with protection type IP20

NOTICE

The screw labeled EMC must not be manipulated as long as the variable frequency drive is connected to the mains.

The EMC screw galvanically connects the EMC filter’s capaci-

￫

tors to earth. The screw must be screwed in all the way to the stop (factory setting) in order for the variable frequency drive to comply with the EMC standard.

Due to their system characteristics, variable frequency drives with an internal EMC filter will produce a larger fault current to earth than devices without a filter. For applications in which this larger leakage current may cause malfunction messages or disconnections (residual current device), the EMC filter’s internal protective earth can be disconnected (remove the EMC screw to do this). Local EMC regulations must be taken into account when doing so. If necessary, a specific low-leakage-current EMC filter must be connected upstream.

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Page 60

3 Installation

3.3 E MC in st allat i on

3.3.4 VAR screw

In connections to isolated power sources (IT networks), the EMC screw should be removed. The earth fault monitors required for IT networks must be suitable for operation with power electronic devices (IEC 61557-8).

DA1 series variable frequency drives are equipped with an overvoltage filter for the input supply voltage that is designed to protect the devices from noise pulses in the mains voltage. Pulse spikes are typically caused by lightning strikes or by switching operations in other high-power devices on the same supply.

If high potential tests are performed on a system, these overvoltage protection components may cause the system to fail the test. In order to make it possible to perform this type of hipot tests, the overvoltage protection components can be disconnected by removing the VAR screw. The screw must be screwed back in after the high potential tests are performed and the test must then be repeated. The system must then fail the test, indicating that the overvoltage protection components have been reconnected.

3.3.5 Screen earth kit

NOTICE

The screw labeled VAR ( Figure 30, page 55) must not be manipulated as long as the variable frequency drive is connected to the mains.

Cables that are not screened work like antennas (sending, receiving).

￫

The effectiveness of the cable shield depends on a good shield connection and a low shield resistance.

￫

For a proper EMC connection, cables emitting interference (e.g. motor cables) and susceptible cables (analog signal and measurement values) must be screened and laid separately from each other.

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).

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Page 61

3 Installation

⏚

L1/L

L2/N

DC-

⏚

DC+

1 2 3 4 5 6 7 8 9 10 11 12 13

14 15 16 17 18

COM

24 V DC

②

①

②

①

≧ 300 mm

(≧ 11.81“)

115/120 V AC 230/240 V AC 400 V AC 460/480 V AC

24 V DC

115/120 V AC 230/240 V AC 400 V AC 460/480 V AC

PES

15 mm

(0.59“)

PES



3.3 E MC in st allat i on

Figure 31: EMC-compliant surface mounting

a Power cable: mains voltage, motor connection, braking resistance b Control and signal lines, fieldbus connections

Large-area connection of all metallic control panel components. Mounting surfaces of variable frequency drive and cable screen must be free from paint. Cable screen of cables at variable frequency drive’s output with earth potential (PES) across large surface

area Large-area cable screen contacts with motor. Large-area earth connection of all metallic parts.

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Page 62

3 Installation

3.4 Electrical Installation

CAUTION



Carry out the wiring work only after the variable frequency drive has been correctly mounted and secured.

DANGER

Electric shock hazard - risk of injuries! Carry out wiring work only if the unit is de-energized.

NOTICE

Fire hazard! Only use cables, protective switches, and contactors that feature the indicated permissible nominal current value.

NOTICE

In DA1 variable frequency drives, earth leakage currents are greater than 3.5 mA (AC). According to product standard IEC/EN 61800-5-1, an additional equipment grounding conductor must be connected, or the cross-section of the equipment grounding

conductor must be at least 10 mm



￫

DANGER

The components in the variable frequency drive’s power section remain energized up to five (5) minutes after the supply voltage has been switched off (intermediate circuit capacitor discharging time).

Pay attention to hazard warnings!

Complete the following steps with the specified tools and without using force.

58 DA1 Variable Frequency Drives 10/12 MN04020005Z-EN www.eaton.com

Page 63

3.4.1 Power section connections

The connection to the power section is normally made via the connection terminals:

• L1/L, L2/N, L3, PE for

The phase sequence does not matter.

• DC+, DC-, PE for DC voltage supplies

• U, V, W, PE for the input wiring to the motor

• BR, DC+ for an external braking resistance

⏚

3 Installation

3.4 Electrical Installation

the mains-side supply voltage.

L1/L

L2/N

⏚

Figure 32: Connection in power section (schematic)

The number and the arrangement of the connection terminals used depend on the variable frequency drive’s size and model.

NOTICE

The variable frequency drive must always be connected with ground potential via a grounding conductor (PE).

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3 Installation

3.4 Electrical Installation

3.4.1.1 connection cables

Mains Motor DC link, Brake Resistor

Figure 33: connection cables

Table 5: Stripping lengths in the power section

Size A1

FS2 8 (0.3) FS3 FS4 FS5 FS6 FS7

mm (in)

8 (0.3) – – – –

Mains = Electrical supply system, Motor = Motor connection, DC-Link = Internal DC link, Brake Resistor = Braking resistance

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Page 65

3.4.1.2 Terminals in power section

DC- L1/L L2/N L3

⏚

DC- L1/L L2/N L3

L1 L2PEL3

Table 6: Terminations

Frame size

Terminations Description

3 Installation

3.4 Electrical Installation

FS2 FS3 FS4 FS5 FS6 FS7

PES

￫

Connection with single-phase supply voltage:

• DA1-12… (230 V)

Connection with three-phase supply voltage:

• DA1-32… (230 V)

• DA1-34… (400 V, 480 V)

⏚

DC+ BR U V W

Motor connection for three-phase motors:

• DA1-12… (230 V)

• DA1-32… (230 V)

• DA1-34… (400 V, 460 V)

optional: External braking resistance (R

In sizes FS2 and FS3, the DC+, DC-, and BR terminals are covered with plastic covers at the factory. They can be uncovered if necessary.

)

3.4.1.3 connection cables

In all single-phase supply variable frequency drives terminal L3 is covered with a plastic cover. Do not uncover this terminal!

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° over-

lap), 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.

 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

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3 Installation

3.4 Electrical Installation

and connect to protective ground with a cable clip. To prevent EMC disturbance, this twisted shielding connection should be made as short as possible ( Figure 35).

15 mm

(0.59’’)

PES

Figure 34: Screened connection cable

Figure 35: Connection with twisted cable screen

Recommended value for twisted cable shielding: b  1/5 a

Screened, four-wire cable is recommended for the motor cables. The greenyellow line of this 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.

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3 Installation

PH2

1 Nm

(8.85 lb-in)

3.4 Electrical Installation

The following figure shows the construction of a four-wire, screened motor line (recommended specifications).

Figure 36: Four-core screened motor supply cable

a Cu shield braid b PVC outer casing c Drain wire (copper strands) d PVC core insulation, 3 x black, 1 x green–yellow e Textile and PVC fillers

If 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 longer than about 300 mm.

3.4.1.4 Configuration and terminal capacities

The connection terminals’ layout depends on the size of the power section.

The cross-sections to be used in the connections and the tightening torques for screws are listed in the following.

Table 7: Cross-sectional areas and tightening torques

Size mm

FS2 … FS7

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AWG MM in N/m MM

0.2 - 2.5 24 - 12 8 0.31 0.5 0.6 x 3.5

Page 68

3 Installation

1 2 3 4 5 6 7 8 9 10 11

12 13

14 15 16

17 18

15 mm

(0.59’’)

PES

3.4 Electrical Installation

3.4.2 Connection on control section

The 13-terminal and 5-terminal strips have a plug-in design and are mounted in the front.

Figure 37: Location of plug-in control signal terminals

The control cables should be screened and twisted. The screening is applied on one side in the proximity of the variable frequency drive (PES).

￫

Prevent the screening from becoming unbraided, i.e. by pushing the separated plastic covering over the end of the shielding or with a rubber grommet on the end of the screening.

Figure 38: Preventing the screening from becoming unbraided

Alternatively, in addition to the broad area cable clip, you can also twist the shielding braid at the end and connect to the protective ground with a cable lug. To prevent EMC disturbance, this twisted shielding connection should be made as short as possible ( Figure 35, page 62).

64 DA1 Variable Frequency Drives 10/12 MN04020005Z-EN www.eaton.com

Prevent the screen from becoming unbraided at the other end of the control cable, e.g. by using a rubber grommet. The shield braid must not make any connection with the protective ground here because this would cause problems with an interference loop.

Page 69

Figure 39: Example for an insulated end of the control cable

5 6

1 2

+10 V AI1

0 V

+24 V DI1

DI2

PES

4K7

FWD REV

ZB4-102-KS1

15 mm

(0.59”)

Cu 2.5 mm

≦ 20 m

(≦ 65.62 ft)

3.4.2.1 Arrangement and designation of the control signal terminals

ESD measures

Discharge yourself on a grounded surface before touching the control signal terminals and the circuit board to prevent damage through electrostatic discharge.

3 Installation

3.4 Electrical Installation

The following figure shows the layout and designations for the DA1 variable frequency drive's control signal terminals.

1234567891011

+24

DI1

DI2

DI3

+10 V

AI11

0 V

AO1

Figure 40: Arrangement and factory designations for the control signal terminals

0 V

DI4

AO1

STO+

STO-

K11

15 16 17

K14

K12

K23

K24

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3 Installation

3.4 Electrical Installation

3.4.2.2 Functions of control signal terminals

The functions that are set in the ex-factory and the electrical connection data of control signal terminals are listed in the following table.

Table 8: Factory-set functions of the control terminals

Terminal

Signal Description Default settings

1+24V Control voltage for DI1 - DI5,

output (+24 V)

2DI1

Digital input 1 8 - +30 V (High, Ri>6kΩ) Start enable FWD

3DI2 Digital Input 2 8 - +30 V (High, Ri>6kΩ) Start enable REV

Maximum load 100 mA, Reference potential 0 V

–

4DI3 Digital Input 3 8 - +30 V (High, Ri>6kΩ) Fixed frequency FF1/FF2

5+10V Reference voltage,

Output (+10 V)

6AI1

DI4

Analog input 1 Digital Input 5

Maximum load 10 mA Reference potential 0 V

• Analog: 0 - +10 V (Ri>72kΩ) 0/4 - 20 mA (R

=500Ω)

–

Frequency reference value

Can be switched with parameter P2-30

• digital: 8 - 30 V (high)

70V Reference potential 0 V = connection terminal 9 –

8 AO1

DO1

Analog output 1 Digital output 1

• Analog: 0 - +10 V, maximum 20 mA Can be switched with parameter P2-11

Output frequency

• digital: 0 - +24 V

90V Reference potential 0 V = connection terminal 7 –

10 DI4

AI2

Digital Input 4 Analog input 2

• Analog: 0 - +10 V (Ri>72kΩ) 0/4 - 20 mA (R

=500Ω)

Fixed frequency FF2

Can be switched with parameter P2-30

• digital: 8 - 30 V (high)

11 AO2

DO2

Analog output 2 Digital output 2

• Analog: 0 - +10 V, maximum 20 mA Can be switched with parameter P2-13

Output current

• digital: 0 - +24 V

12 STO+ Safe Torque Off + Enable = +24 V –

13 STO-

14 K11 Relay 1, changeover contact Maximum switching load:

Safe Torque Off - Enable = 0 V –

active = FAULT

250 V AC/6 A or 30 V DC/5 A

15 K14 Relay 1, changeover contact (N/O) Maximum switching load:

active = FAULT

250 V AC/6 A or 30 V DC/5 A

16 K12 Relay 1, changeover contact (N/C) Maximum switching load:

active = FAULT

250 V AC/6 A or 30 V DC/5 A

17 K23 Relay 2, N/O contact Maximum switching load:

active = FAULT

250 V AC/6 A or 30 V DC/5 A

18 K24 Relay 2, N/O contact Maximum switching load:

active = FAULT

250 V AC/6 A or 30 V DC/5 A

1) programmable function

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Page 71

3 Installation

DI1

FWD

+24 V

DI3

FF1/FF2

DI2

REV

DI4

(AI2)

FF2

+24 V Out

< 100 mA

AI1

(DI5)

CPU

AO1

(DO1)

f-Out

0...+10 V/20 mA

f-Soll

0...+10 V/20 mA 11

AO2

(DO2)

A-Out

0...+10 V/20 mA

3.4 Electrical Installation

The DA1 variable frequency drive has four control inputs (control signal terminals 2, 3, 4, 6 and 10). Three of these are permanently set as digital control inputs; while the others can be set to work as digital or analog control inputs.

The variable frequency drive comes with the following default setting:

• Control signal terminal 2 as digital input 1 (DI1),

• Control signal terminal 3 as digital input 2 (DI2),

• Control signal terminal 4 as digital input 3 (DI3),

• Control signal terminal 6 as analog input 1 (AI1).

• Control signal terminal 10 as digital input 4 (DI4),

Control signal terminals 8 and 11 can be used as digital or analog outputs. They are set up as analog outputs (AO) in the default configuration that comes with the variable frequency drive when it is delivered.

Figure 41: Control signal terminals (digital / analog)

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3 Installation

3.4 Electrical Installation

3.4.2.3 Analog input signals

Depending on how parameters P1-12 and P1-13 are set, control signal terminals 6 (AI1) and 10 (AI2) can be connected to analog signals.

• 0 - +10 V

• 0 - 10 V with scaling and operating direction change

• 0 - 20 mA

• 4 - 20 mA or 20 - 4 mA with open-circuit monitoring (< 3 mA)

3.4.2.4 Analog output signal

An analog signal is available at control signal terminals 8 and 11. These outputs can handle a maximum load of 20 mA. The output signal is configured using parameters P2-11 (AO1) and P2-13 (AO2) ( Table 10, Page 87).

Parameters P2-12 (AO1) and P2-14 (AO2) are used to configure the formats for the analog inputs:

Parameter value

1 10 - 0 V

2 0 - 20 mA

5 20 - 4 mA

￫

The assignments between the values and functions are described in  Section 6.2.2, “Analog Input (AI)“, page136.

Control signal terminals 7 and 9 are the common 0 V reference potential for all analog and digital input signals.

Configuration

0 - 10 V

20 - 0 mA

4 - 20 mA

< 20 mA

f-Out

0...+10 V

Figure 42: Analog output (AO) (connecting example)

Control signal terminals 7 and 9 are the common 0 V reference

￫

68 DA1 Variable Frequency Drives 10/12 MN04020005Z-EN www.eaton.com

potential for all analog and digital output signals.

Page 73

3.4.2.5 Digital Input Signals

Control signal terminals 2, 3, 4, 6 and 10 all have the same function and mode of operation as digital inputs (DI1 to DI5).

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 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 % U

The parameter configuration and the way functions are assigned are described in  Section 6.2.1, “Digital Input (DI)“, page135.

3 Installation

3.4 Electrical Installation

a/Ua

￫

Control signal terminals 7 and 9 are the common 0 V reference potential for all analog and digital input signals.

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3 Installation

3.4 Electrical Installation

3.4.2.6 Digital output (Transistor)

Control signal terminals 8 and 11 are set up as analog outputs (AO) in the default configuration that comes with the variable frequency drive when it is delivered. Parameters P2-11 and P2-13 ( Table 10, Page 87) can be used to set them up as digital outputs (DO) instead.

Transistor outputs DO1 and DO2 can deliver a digital signal via control signal terminals 8 and 11 using the device’s internal control voltage (+24 V). The maximum permissible load current is 20 mA.

+ 24 V

< 20 mADOOV

8 9

Figure 43: Connection example (interposing relay with free-wheeling diode:

￫

3.4.2.7 Digital Output (Relay)

Control signal terminals 14, 15 (N/O), and 16 (N/C) are connected to the DA1 variable frequency drive’s internal relay 1 in a potential-free manner.

Control signal terminals 17 and 18 are connected to internal relay 2 (N/O) in a potential-free manner.

The relay function can be configured using parameters P2-15 and P2-18 ( Table 10, Page 87).

The electrical connection specifications for control signal terminals are:

• 250 V AC, max. 6 A

• 30 V DC, max. 5 A

ETS4-VS3; article no. 083094)

Control signal terminals 7 and 9 are the common 0 V reference potential for all analog and digital output signals.

We recommend connecting any connected loads as follows:

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Page 75

250 V ∼ : ≦ 6A

Error

RUN

16 17 1814 15

AC DC

Varistor

(+)

(

)

Diode

RC ﬁlter

30 V ⎓ : ≦ 5A

Figure 44: Connection examples with suppressor circuit

3 Installation

3.4 Electrical Installation

3.4.2.8 RJ 45 interface

The RJ45 port located on the bottom part of the DA1 variable frequency drive makes it possible to connect directly to communication modules and fieldbus connections.

The internal RS485 connection handles transmissions for the OP bus, Modbus RTU, and CANopen field bus systems.

⏚

DC-

L1/L

L2/N

PIN 8

(PIN2)

PIN 7

(PIN 1)

Figure 45: RJ45 port on DA1 variable frequency drive

RS485

RJ45

1 2 3 4 5 6 7 8 9 10 11 12 13

COM

⏚

14 15 16 17 18

DC+

￫

nation resistor. Use DX-CBL-TERM if necessary.

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DA1 variable frequency drives do not have an internal bus termi-

Page 76

3 Installation

⏚

DC+

DC-

3 AC 230 V

WVU

3 ~



STO-

+24 V Out

< 100 mA

24 V

DI1

FWD

REV

FF1/FF2

FF2

DI2

DI310DI4

AI2

STO+

L1/L

EMC

+10 V Out

< 10 mA

AI1

DI5

0 V

L2/N

VAR

CPUSTO

10 V

0 V

f-Soll

1 AC 230 V 50/60 Hz

PES

①

15 16

Error

RUN

17 18 8

9 11

6 A, 250 V AC

5 A, 30 V DC

6 A, 250 V AC

5 A, 30 V DC

A-Out

0 V 0 V

f-Out

+24 V DO

PIN 8

(PIN2)

PIN 7

(PIN 1)

RS485

3.4 Electrical Installation

3.4.3 Block diagrams

3.4.3.1 DA1-12…

The following block diagrams show all the connection terminals on a DA1 variable frequency drive and their functions when in their default settings.

Figure 46: DA1-12… block diagram

Variable frequency drive with phase motor connection

72 DA1 Variable Frequency Drives 10/12 MN04020005Z-EN www.eaton.com

 External braking resistors can be connected to devices of size FS2 to

FS8

single-phase supply system voltage and three-

Page 77

3.4.3.2 DA1-32…, DA1-34…

⏚

DC+

DC-

WVU

3 ~



STO-

+24 V Out

< 100 mA

24 V

DI1

FWD

REV

FF1/FF2

FF2

DI2

DI310DI4

AI2

STO+

EMC

+10 V Out

< 10 mA

AI1

DI5

0 V

PIN 8

(PIN 2)

PIN 7

(PIN 1)

VAR

RS485

CPU

STO

10 V

0 V

f-Soll

PES

①

15 16

Error

RUN

17 18 8

9 11

6 A, 250 V AC

5 A, 30 V DC

6 A, 250 V AC

5 A, 30 V DC

A-Out

0 V 0 V

f-Out

L1/L

L2/N

3 AC 230 V 3 AC 400/480 V 50/60 Hz

+24 V DO

3 Installation

3.4 Electrical Installation

Figure 47: DA1-32…, DA1-34… block diagram

Variable frequency drive motor connection

 External braking resistors can be connected to devices of size FS2 to

FS8

DA1 Variable Frequency Drives 10/12 MN04020005Z-EN www.eaton.com 73

with three-phase mains supply voltage and three-phase

Page 78

3 Installation

3.4 Electrical Installation

3.4.4 Insulation test

The variable frequency drive of the DA1 series are tested, delivered and require no additional testing.

CAUTION



If insulation testing is required in the power circuit of the PDS, you must consider the following measures.

3.4.4.1 Testing the motor cable insulation

 Disconnect the motor cable from the connection terminals U, V and W of

the variable frequency drive and from the motor (U, V, W). Measure the insulation resistance of the motor cable between the individual phase conductors and between the phase conductor and the protective conductor.

The insulation resistance must be greater than 1 M.

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.

CAUTION

Wait at least 5 minutes after switching the supply voltage off before you disconnect one of the connection terminals (L1/L, L2/N, L3, DC-, DC+, BR) of the variable frequency drive.

3.4.4.2 Testing the mains cable insulation

 Disconnect the power cable from the mains supply network and from

the connection terminals 1/L, L2/N and L3 of the variable frequency drive. Measure the insulation resistance of the mains cable between the individual phase conductors and between each phase conductor and the protective conductor.

The insulation resistance must be greater than 1 M.

3.4.4.3 Testing the motor insulation

 Disconnect the motor cable from the motor (U, V, W) and open the

bridge circuits (star or delta) in the motor terminal box. Measure the insulation resistance of the individual motor windings. The measurement voltage must at least match the rated operating voltage of the motor but is not to exceed 1000 V.

The insulation resistance must be greater than 1 M.

￫

Consider the notes from the motor manufacturer in testing the insulation resistance.

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Page 79

4 Operation

4.1 Checklist for commissioning

Before placing the variable frequency drive into operation, use the checklist below to make sure that all the following requirements are met:

No. Activity Notes

4 Operation

4.1 Checklist for commissioning

Mounting and wiring have been carried out in accordance with the corresponding instructional leaﬂet ( IL04020015Z, IL04020011Z, IL04020012Z, IL04020010Z).

All wiring and line section leftovers, as well as all the tools used, have been removed from the variable frequency drive’s proximity.

All terminals in the power section and in the control section were tightened with the specified torque.

The lines connected to the output terminals (U, V, W, DC+, DC-, BR) of the variable frequency drive are not short-circuited and are not connected to ground (PE).

The variable frequency drive has been earthed properly (PE).

All electrical terminals in the power section (L1/L, L2/N, L3, U, V, W, DC+, DC-, BR, PE) were implemented properly and were designed in line with the corresponding requirements.

Each single phase of the supply voltage (L or L1, L2, L3) is protected with a fuse.

The variable frequency drive and the motor are adapted to the mains voltage. ( Section 1.4.1, “Rating data on the nameplate“, page13, connection type (star, delta) of the motor tested).

The quality and volume of cooling air are in line with the environmental conditions required for the variable frequency drive and the motor.

All connected control cables comply with the corresponding stop conditions (e.g., switch in OFF position and setpoint value= zero).

The parameters that were preset at the factory have been checked with the list of parameters ( Table 10, page 87).

The effective direction of a coupled machine will allow the motor to start.

All emergency switching off functions and safety functions are in an appropriate condition.

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4 Operation

4.2 Hazard warnings for operation

Please observe the following notes.

DANGER



Commissioning is only to be completed by qualified technicians.

DANGER

Hazardous voltage!

The safety instructions on pages I and II must be followed.

DANGER

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. The control signal terminals are isolated from the line power potential. There can be a dangerous voltage on the relay terminals (10, 11) even if the variable frequency drive is not being supplied with mains voltage (e.g., integration of relay contacts in control systems with voltage > 48 V AC / 60 V DC).



DANGER

Pay attention to hazard warnings!

DANGER

Following a shutdown (fault, mains voltage off), the motor can start automatically (when the supply voltage is switched back on) if the automatic restart function has been enabled ( parameters P2-36).

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Page 81

4 Operation

4.3 Commissioning with control signal terminals (default settings)

NOTICE

Any contactors and switchgear on the power side are not to be opened during motor operation. Inching operation using the power switch 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 switchgear in the output of the variable frequency drive is not permitted.

NOTICE

Make sure that there is no danger in starting the motor. Disconnect the driven machine if there is a danger in an incorrect operating state.

￫

If motors are to be operated with frequencies higher than the standard 50 or 60 Hz, then these operating ranges must be approved by the motor manufacturer. The motors could be damaged otherwise.

4.3 Commissioning with control signal terminals (default settings)

DA1 variable frequency drives are set in the factory and can be started directly via the control signal terminals by connecting the motor outputs allocated for the mains voltage (see connection example below).

￫

Following are a series of simplified connecting examples that use the default settings.

You can skip this section if you want to set up the parameters directly for optimal operation of the variable frequency drive based on the motor data (rating plate) and the application.

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Page 82

4 Operation

WVU

3 ~



675

1 23

+24 V

FWD

0...+10 V

0 V

+10 V

L1/L

L2/N

L3L1

REV

f-Soll

STO+

STO-

4.3 Commissioning with control signal terminals (default settings)

Connecting example for three-phase motor

Connecting example for three-phase motor Terminal designation

L1/L Single-phase power supply

L2/N

L3 –

 Ground connection

1 Control voltage +24 V (output, maximum 100 mA)

2 FWD, Start release clockwise rotating field

3 REV, Start release left rotating field

U Connection for three-phase ac motor



5 Setpoint value voltage +10 V (Output, maximum 10 mA)

6 Frequency reference value f-Set (Input 0 – +10 V)

7 Reference potential (0 V)

12 Safe Torque Off +

13 Safe Torque Off -

connection (DA1-12…)

(three-phase motor)

Three-phase power supply connection (DA1-32…, DA1-34…)

 Connect the variable frequency drive according to the connecting exam-

ple above for the simple commissioning with the specified default settings (see connecting example above).

The potentiometer should have a fixed resistance (connection to control signal terminals 5 and 7) of at least 1 k, up to a maximum of 10 k. A standard fixed resistance of 4.7 k is recommended.

Make sure that the enable contacts (FWD/REV) are open and the STO is connected correctly before switching on the mains voltage.

If the connections for the setpoint value potentiometer cannot

￫

be clearly allocated with terminals 5, 6 and 7, you should set the potentiometer to about 50 % before giving the start release (FWD/REV) for the first time.

When the specified supply voltage is applied at the mains connection terminals (L1/L, L2/N, L3), the switched-mode power supply unit (SMPS) in the internal DC link will be used to generate the control voltage and light up the

78 DA1 Variable Frequency Drives 10/12 MN04020005Z-EN www.eaton.com

7-segment LED display (STOP).

At this point, the variable frequency drive will be ready for operation (correct operating status) and in Stop mode.

Page 83

4 Operation

4.3 Commissioning with control signal terminals (default settings)

The start release is done by actuating one of the digital inputs with +24 V:

• Terminal 2: FWD = Clockwise rotating field (Forward Run)

• Terminal 3: REV = Counterclockwise rotating field (Reverse Run)

The FWD and REV control commands are interlocked (exclusive OR) and require a rising voltage edge.

The frequency is shown with a minus sign with a start release with a left rotating field (REV).

 You can now set the output frequency (0 - 50 Hz) and, as a result, the

speed of the connected three-phase motor (0 - n potentiometer via terminal 6 (0 - +10 V proportional voltage signal). The change in output frequency here is delayed based on the specified accel-

eration and deceleration ramps.

the default settings, these times are

set to 5 seconds and to 10 seconds from a frame size FS4.

The acceleration and deceleration ramps specify the time change for the output frequency: from 0 to f

(WE = 50 Hz) or from f

max

) by using the

Motor

back to 0.

max

Figure48 shows a good example of the process, if the release signal (FWD/ REV) is switched on and the maximum setpoint voltage (+10 V) is applied. The speed of the motor follows the output frequency depending on the load and moment of inertia (slip), from zero to n

max

If the release signal (FWD, REV) is switched off during operation, the inverter is blocked immediately (STOP). The motor comes to an uncontrolled stop (see  in Figure48). The acceleration time is set in parameter P1-03.

FWD REV

+24 V

RUN STOP

= 50 Hz

P1-07

~ n

max

①

P1-03

Figure 48: Start-Stop command with maximum setpoint value voltage

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4 Operation

4.3 Commissioning with control signal terminals (default settings)

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5 Error messages

5.1 Introduction

DA1 series variable frequency drives come with several internal monitoring functions. When a deviation from the correct operating state is detected, an error message will be displayed; in the inverter’s default settings, the relay contact will open (control signal terminals 14 and 15).

5.1.1 Error messages

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). Error messages can be read from parameter P0-13 and the P0-... monitor values.

5.1.2 Acknowledge fault (Reset)

To acknowledge and reset the current error message, you can either switch off the supply voltage or press the STOP pushbutton.

5 Error messages

5.1 Introduction

5.1.2.1 Fault log

The fault log (P0-13) stores the most recent four error messages in the order in which they occurred. The most recent error message will always be shown as the first value when P0-13 is accessed. To see the remaining error messages one after the other, press the  (Up) button. Their order will be indicated by means of flashing dots in the 7-segment digital display assembly.

￫

To get more information regarding the fault, go to the “Monitor“ menu (P0-…). The values in the fault log (P0-13) will not be deleted if the variable frequency drive is reset to its default settings!

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5 Error messages

5.1 Introduction

The example below shows how to access the fault log.

Indicator Explanation

Operating state Stop

Press OK button

The parameter that was last accessed will be shown. The last digit on the display will flash.

Use the ▲ (Up) or ▼ (Down) arrow key to select parameter P1-14 and confirm your selection by pressing the OK pushbutton. The last digit on the display will flash.

Use the ▲ (Up) or ▼ (Down) arrow key to set a parameter value of 101 or 201 and confirm your selection by pressing the OK pushbutton.

Use the ▲ (Up) or ▼ (Down) arrow keys to select parameter P0-13 and confirm your selection by pressing the OK pushbutton. The last digit on the display will flash.

Last error message. Example: P-def (Parameter default = Default settings loaded).

Use the arrow button ▲ (Up) to go to the next error message.

Second most recent error message: Example: V-Volt (undervoltage message). The dot on the right will flash.

The third most recent error message will be shown after pressing the ▲ arrow key (Up).

Example: E-trip (external error message) The two dots on the right will flash.

The oldest error message will be shown after you press the ▲ arrow key (Up) once more.

Example: V-Volt (undervoltage message) The three dots on the right will flash.

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5 Error messages

5.1 Introduction

5.1.3 Error list

The following table lists the failure codes, the possible causes and indicates corrective measures.

Table 9: Error messages list

Indicator

no-Flt 00 no error – –

0I-b 01 Overcurrent braking resis-

OL-br

0- I 03 Overcurrent motor • Overcurrent at output

I .t-trP

SAFE-I

Ovolts 06 Overvoltage DC link Overvoltage at DC link Power supply problem

V-volts

O-t 08 Overtemperature Heat sink overtemperature Check the variable frequency drive's ambient air

V-t 09 Excessively low tempera-

Fault Code Designation Possible cause Notes

Brake chopper overcurrent Overcurrent in braking resistor circuit

tance

02 Braking resistor thermal

overload

04 Thermal motor overload The DA1 variable frequency drive

05 Safe Torque Off fault Power supply at STO input inter-

07 DC link undervoltage DC link undervoltage Normally occurs if the power is switched off.

ture (frost)

Braking resistance overload Increase the deceleration time (P1-04), reduce the

• Motor overload

• Overtemperature at heat sink

was switched off after more than 100 % of the value set in P1-08 was delivered for a period of time.

rupted

Heat sink undertemperature The variable frequency drive will be switched off if

Check the wiring to the braking resistance. Check the brake resistor value (P6-19). Make sure that the minimum resistance values are being adhered to.

load's moment of inertia, or connect additional braking resistors in parallel. Make sure that the minimum resistance values are being adhered to.

Motor with constant speed: Determine the overload or fault. Motor starts: The load stalled or has seized, or the brake is not open. Check whether there is a star/delta motor wiring error. Motor accelerates/decelerates: The excessively short acceleration/deceleration time is requiring too much power. If P1-03 or P1-04 cannot be increased, a more powerful variable frequency drive is required. Cable fault between variable frequency drive and motor.

Check whether the decimal places are flashing (variable frequency drive overloaded) and either raise the acceleration ramp (P1-03) or reduce the motor load. Make sure that the cable length matches the variable frequency drive specifications. Check the load mechanically in order to make sure that it is free, that nothing is getting jammed or locked, and there are no other mechanical faults.

Increase the deceleration ramp time P-04.

If it occurs during running, check the power supply voltage.

temperature. Check whether additional clearance or cooling is required.

the ambient temperature < -10 °C. Raise the temperature over -10 °C in order to start the variable frequency drive.

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5 Error messages

5.1 Introduction

Indicator Fault Code Designation Possible cause Notes

P-dEF 10 Parameter default The parameter's default setting

E-triP 11 External fault External shutdown (on digital

SC-ObS

FLt-dc

P-LoSS

h0-I

th-Flt 16 Thermistor fault Defective thermistor on heat sink Please contact your closest Eaton representative.

dAtA-F 17 Data error Internal memory error Parameter not stored; default settings loaded back.

4-20F

dAtA-E

V- dEF

F-Ptc 21 Motor thermistor fault Defective thermistor in motor Reduce the load on the motor.

FAn-F

O-hEAt

O- tor9

V- tor9

OVt- F

SAFE- 2 29 Safe Torque Off fault Power supply at STO input inter-

12 Communication fault Communication loss error Check the communications connection between

13 Large residual ripple in DC

link

14 Mains connection phase

fault

15 Instantaneous motor over-

current

18 Live zero error Analog input current outside range Make sure that the input current falls within the

19 Data error Internal memory error Parameter not stored; default settings loaded back.

20 User parameter default

22 Internal fan fault Internal fan fault Check the internal fan and replace if necessary.

23 Excessively high ambient

temperature

24 Torque exceeded Torque has exceeded the limit

25 Torque fallen below Excessively low torque Only visible if hoisting mode (P2-18 = 8) is enabled.

26 Output fault Fault at variable frequency drive

has been loaded.

input 3)

Excessively large residual ripple in DC link

Shutdown caused by input phase loss

Excessively high ambient temperature

value

output

rupted

Press the STOP pushbutton. The DA1 variable frequency drive is ready for an application-specific configuration.

External safety shutdown on digital input 3. The normally-closed contact opened for some reason. If a motor thermistor is connected, check whether the motor is too hot.

the variable frequency drive and external devices. Make sure that each individual variable frequency drive on the network has a unique address.

Check to make sure that all three phases are present and have a voltage tolerance of less than 3%. Reduce the motor load

A variable frequency drive intended for use with a three-phase power supply has lost one of its input phases.

If the problem occurs again, please contact your closest Eaton representative.

range defined by P-16.

If the problem occurs again, please contact your closest Eaton representative.

Make sure that the internal fan is working. Reduce the pulse frequency (P2-24). Reduce the load on the motor. Make sure that hot air is not flowing into the variable frequency drive from surrounding devices.

Reduce the load on the motor. Increase the acceleration time (P2-03).

Check the brake settings in the variable frequency drive.

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Indicator Fault Code Designation Possible cause Notes

5 Error messages

5.1 Introduction

Enc- 01 30 Encoder feedback error

Enc- 02

Enc- 03 32 Incorrect PPRs configured

Enc- 04 33 Channel A fault Channel A is faulty.

Enc- 05 34 Channel B fault Channel B is faulty.

Enc- 06 35 Channel A and B fault Channels A and b are faulty.

AtF- 01 40 Auto-tune error Winding resistance error The winding resistance varies between the indi-

AtF- 02 41 Winding resistance error The winding resistance is too high.

AtF- 03

AtF- 04

AtF- 05

Out- Ph

Sc- t01

Sc- t02

Sc- t03 52 Plug-in module (field bus)

Sc- t04

31 Speed error The difference between the measured speed and

42 Motor inductance error The motor inductance is too low.

43 Motor inductance error The motor inductance is too high.

44 Motor data error The measured motor data does not match.

49 Motor connection phase

50 Modbus communications

51 Communication fault

53 I/O plug-in module commu-

(visible only if the DXAEXT-ENCOD encoder module is plugged in and fastened)

fault

error

CANopen

communications error

nications error

Communication fault Communications and data errors

the calculated speed in the variable frequency drive is too large.

vidual windings. Check the motor's wiring.

Check the motor’s wiring. Use the motor output to check whether the motor and the variable frequency drive are compatible.

Check the motor’s wiring.

Check the motor’s wiring. Use the motor output to check whether the motor and the variable frequency drive are compatible.

Motor phase fault An output phase is not connected to the motor.

Check the motor’s wiring. Use the motor output to check whether the motor and the variable frequency drive are compatible.

Increase P5-06 to an appropriate value. Check whether the PLC is still running. Check the cable connections.

A CANopen frame was not received within the time set in P5-06.

Internal loss of communications between variable frequency drive and optional module

Increase P5-06 to an appropriate value. Check whether the PLC is still running. Check the cable connections.

Check to make sure that the module is plugged in correctly.

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5 Error messages

5.1 Introduction

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6 Parameters

￫

parameter P1-14 must be set to 201 for access to all parameters.

Table 10: Description list for DA1 parameters

PNU ID Access right Value Description DS

RUN ro/rw

Parameter group P1 – quick-start

P1-01 129 ✓ rw Maximum frequency / maximum speed 50.0

P1-10 = 0 → P1-02 - 5 x P1-09 → Hz P1-10 > 0 → P1-02 - 5 x P1-09 x 60 s → rpm The maximum output frequency / motor speed limit in Hz or rpm. If P-10 > 0, the value entered / displayed will be shown in rpm.

P1-02 102 ✓ rw Minimum frequency / minimum speed 0

P1-10 = 0 → 0-P1-01→ Hz P1-10 > 0 → 0 - P1-01 → rpm The minimum output frequency / minimum speed limit in Hz or rpm. If P-10 > 0, the value entered / displayed will be shown in rpm.

P1-03 103 ✓ rw Acceleration time (acc1) 5 (10 from

FS4)

0.1 - 600 s

When first switching on or after activating the default settings

P1-04 104 ✓ rw Deceleration time (dec1) 5 (10 from

0.1 - 600 s

P1-05 ✓ rw Stop Function 1

0 Ramp, deceleration =

Regenerative braking. Deceleration time with the value set under P1-04 (dec1). If the energy that is fed back by the motor during the dynamic braking is too high, the deceleration time has to be extended. In devices with an internal braking transistor, the excess energy can be dissipated with an external braking resistance (optional)

1 Free coasting =

After the start enable (FWD/REV) is switched off or the STOP pushbutton is pressed (P1-12 and P1-13), the motor will coast uncontrolled.

2 Ramp, quick stop = regenerative braking.

Deceleration time 2 with the value set under P2-25 (dec2). If the energy that is fed back by the motor during the dynamic braking is too high, the deceleration time has to be extended. In devices with an internal braking transistor, the excess energy can be dissipated with an external braking resistor (optional).

FS4)

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6 Parameters

PNU ID Access right Value Description DS

RUN ro/rw

3 Free coasting, with activated braking chopper =

After the start enable (FWD/REV) is switched off or the STOP pushbutton is pressed (P1-12 and P1-13), the motor will coast uncontrolled. If the energy that is fed back by the motor during the dynamic braking is too high, the deceleration time has to be extended. In devices with an internal braking transistor, the excess energy can be dissipated with an external braking resistor (optional).

P1-06 106 ✓ rw Energy optimization 0

0 Deactivated

1 Activated

If it is selected, the energy optimization function will attempt to reduce the total energy consumed by the variable frequency drive and the motor during operation at constant speeds and with light loads. The output voltage applied at the motor will be reduced. The energy optimization function is intended for applications in which the variable frequency drive is run for specific periods at a constant speed and with a light load, independently of whether the torque is constant or varies.

P1-07 107 – rw Nominal voltage of the motor 230

Setting range: 0. 20 - 250 / 500 V (￫ Motor ratings plate) Pay attention to the supply voltage and the type of circuit in the stator winding!

Note:

This parameter value has a direct influence on the V/f characteristic curve (e.g. operation with 87 Hz characteristic curve). This must be especially taken into account in the case of values (P1-07) that deviate from the variable frequency drive’s rated operational data (U

= 100 %). This may cause the over-exci-

tation of the motor and thus lead to an increased thermal load.

P1-08

108 – rw Rated motor current 4.8

Setting range: 0.2 x Ie - Ie [A] (￫ Motor rating plate) I

= Variable frequency drive’s rated operational current

P1-09 109 – rw Nominal frequency of the motor 50.0

Setting range: 25 - 500 Hz (￫ Motor rating plate)

Note:

This parameter value is also automatically applied as the cutoff frequency for the V/Hz characteristic curve.

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6 Parameters

PNU ID Access right Value Description DS

RUN ro/rw

P1-10 110 ✓ rw Nominal speed of the motor 0

0 - 30000 rpm (￫ motor rating plate)

Note:

This parameter can be optionally set to the motor’s rated speed (revolutions per minute, rating plate). If it is set to the factory default setting of 0, all speed-related parameters will be shown in Hz; slip compensation for the motor will be disabled. Entering the value on the motor's rating plate will enable the slip compensation function, and the variable frequency drive's display will show the motor speed in the estimated rpm. All speed-related parameters (such as the minimum and maximum frequencies and the fixed frequencies) will also be shown in rpm.

P1-11 111 – rw Output voltage at zero frequency 3.0

0.00 - 20.0 %

Voltage amplification is used in order to increase the motor voltage applied at low output frequencies so as to improve the torque at low speeds, as well as the starting torque.

P1-12

Note:

A high start voltage enables a high torque at the start.

Notice:

A high torque at low speed causes a high thermal load on the motor. If temperatures are too high, the motor should be equipped with an external fan.

140 – rw Control level 0

0 Control signal terminals (I/O)

The variable frequency drive will respond directly to signals applied to the control signal terminals.

1 Keypad (KEYPAD FWD)

The variable frequency drive can only be controlled in the forward direction if an external or remote control keypad is used.

2 Keypad (KEYPAD FWD/REV)

The variable frequency drive can be controlled in both the forward and reverse directions by using an external or remote control keypad. Pressing the START pushbutton will toggle between the forward and reverse directions.

3 PID controller

The output frequency will be controlled by the internal PID controller.

4 Field bus

Control via Modbus RTU (RS485) interface or optional fieldbus connection (e.g., PROFIBUS DP).

5 Slave mode

The variable frequency drive will run in slave mode; in this mode, the output frequency will depend on the master variable frequency drive and can only be changed there. The variable frequency drives are connected to each other using the variable frequency drive's RJ45 interface.

6 Field bus (CANopen) via RJ45 interface

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6 Parameters

PNU

P1-13 113 – ro Digital input (analog input) function

P1-14 114 ✓ rw Parameter range access code 0

Extended parameter range Level 2 (access: P1-14 = 101 or P1-14 = 201) Parameter group P2 - functions

P2-01

P2-02

P2-03

ID Access right Value Description DS

RUN ro/rw

(Depends on P2-40 or P6-30 Extended parameter access code)

Set the value to 101 (default setting) to enable access to the extended parameter menu. Modify via P2-40. To enable access to all parameters, set the value to 201. Change using P6-30.

201 ✓ rw Fixed frequency FF1 / speed 1 5.0

P1-10 = 0 → -P1-02 - P1-01 → Hz P1-10 > 0 → -P1-02 - P1-01 x 60 s → rpm (1/min)

0.00 Hz (P1-02) up to the maximum frequency value (P1-01). Activation via digital inputs depending on parameters P1-12 and P1-13 according to the "Input value DA1" table.

202 ✓ rw Fixed frequency FF2 / speed 2 10.0

P1-10 = 0 → -P1-02 - P1-01 → Hz P1-10 > 0 → -P1-02 - P1-01 x 60 s → rpm (1/min)

0.00 Hz (P1-02) up to the maximum frequency value (P1-01). Activation via digital inputs depending on parameters P1-12 and P1-13.

203 ✓ rw Fixed frequency FF3 / speed 3 25.0

P1-10 = 0 → -P1-02 - P1-01 → Hz P1-10 > 0 → -P1-02 - P1-01 x 60 s → rpm (1/min)

0.00 Hz (P1-02) up to the maximum frequency value (P1-01). Activation via digital inputs depending on parameters P1-12 and P1-13.

P2-04

P2-05

P2-06 206 ✓ rw Fixed frequency FF6 / speed 6 0.0

204 ✓ rw Fixed frequency FF4 / speed 4 50.0

P1-10 = 0 → -P1-02 - P1-01 → Hz P1-10 > 0 → -P1-02 - P1-01 x 60 s → rpm (1/min)

0.00 Hz (P1-02) up to the maximum frequency value (P1-01). Activation via digital inputs depending on parameters P1-12 and P1-13.

201 ✓ rw Fixed frequency FF5 / speed 5 0.0

P1-10 = 0 → -P1-02 - P1-01 → Hz P1-10 > 0 → -P1-02 - P1-01 x 60 s → rpm (1/min)

0.00 Hz (P1-02) up to the maximum frequency value (P1-01). Activation via digital inputs depending on parameters P1-12 and P1-13.

P1-10 = 0 → -P1-02 - P1-01 → Hz P1-10 > 0 → -P1-02 - P1-01 x 60 s → rpm (1/min)

0.00 Hz (P1-02) up to the maximum frequency value (P1-01). Activation via digital inputs depending on parameters P1-12 and P1-13.

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6 Parameters

PNU

ID Access right Value Description DS

RUN ro/rw

P2-07 207 ✓ rw Fixed frequency FF7 / speed 7 0.0

P1-10 = 0 → -P1-02 - P1-01 → Hz P1-10 > 0 → -P1-02 - P1-01 x 60 s → rpm (1/min)

0.00 Hz (P1-02) up to the maximum frequency value (P1-01). Activation via digital inputs depending on parameters P1-12 and P1-13.

P2-08 208 ✓ rw Fixed frequency FF8 / speed 8 0.0

P1-10 = 0 → -P1-02 - P1-01 → Hz P1-10 > 0 → -P1-02 - P1-01 x 60 s → rpm (1/min)

0.00 Hz (P1-02) up to the maximum frequency value (P1-01). Activation via digital inputs depending on parameters P1-12 and P1-13.

P2-09 209 ✓ rw Frequency skip 1, bandwidth (hysteresis range) 0

0.00 - P1-01 (f

max

)

P2-10 210 ✓ rw Frequency skip 1, center 0

P1-02 (f

) - P1-01 (f

min

max

)

The skip frequency function is used to prevent the variable frequency drive from being run at a specific output frequency, e.g. at a frequency that will cause mechanical resonance in a specific machine. Parameter P2-10 is used to define the center of the skip frequency band and is used together with parameter P2-09. The output frequency will run through the specified band at the speeds set in P1-03 or P1-04 without holding an output frequency that falls within the defined band. If the frequency reference value applied to the variable frequency drive falls within the band, the output frequency will remain at the upper or lower limit of the band.

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6 Parameters

PNU ID Access right Value Description DS

RUN ro/rw

P2-11 211 ✓ rw AO1 signal 8

Digital output → +24 V DC

0 RUN, enable (FWD, REV)

1 READY, ready for operation

2 Output frequency = frequency reference value

3 Output frequency > zero speed

4 Output frequency closing threshold > P2-16

Switch off threshold < P2-17

5 Output current closing threshold > P2-16

6 Output torque closing threshold > P2-16

7 AI2 signal level closing threshold > P2-16

8 Output frequency f-Out → 0 - 100 % f

9 Output current → 0 - 200 % Ie (P1-08)

10 Torque MN → 0 - 200 % (calculated value)

11 Output power PN → 0 - 150 % (Ie)

P2-12 212 ✓ rw AO1, signal range A0-10

A0-10 0 - 10 V

A10-0 10 - 0 V

A0-20 0 - 20 mA

A20-0 20 - 0 mA

A4-20 4 - 20 mA

A20-4 20 - 4 mA

Switch off threshold < P2-17

Analog output → P2-12

max

(P1-01)

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6 Parameters

PNU ID Access right Value Description DS

RUN ro/rw

P2-13 213 ✓ rw AO1 signal 9

Digital output → +24 V DC

0 RUN, enable (FWD, REV)

1 READY, ready for operation

2 Output frequency = frequency reference value

3 Output frequency > zero speed

4 Output frequency closing threshold > P2-19

Switch off threshold < P2-20

5 Output current closing threshold > P2-19

6 Output torque closing threshold > P2-19

7 AI2 signal level closing threshold > P2-19

8 Output frequency f-Out → 0 - 100 % f

9 Output current → 0 - 200 % Ie (P1-08)

10 Torque MN → 0 - 200 % (calculated value)

11 Output power PN → 0 - 150 % (Ie)

P2-14 214 ✓ rw AO1, signal range A0-10

A0-10 0 - 10 V

A10-0 10 - 0 V

A0-20 0 - 20 mA

A20-0 20 - 0 mA

A4-20 4 - 20 mA

A20-4 20 - 4 mA

Switch off threshold < P2-20

Analog output → 0 - 10 V DC

max

(P1-01)

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6 Parameters

PNU ID Access right Value Description DS

RUN ro/rw

P2-15 215 ✓ rw K1 signal (Relay Output 1) 1

Used to select the function assigned to the relay output. The relay has three output terminals (changeover contacts): Logic 1 indicates that the relay is active: This is why terminals 14 and 15 are connected to each other.

0 RUN, enable (FWD, REV)

1 READY, ready for operation

2 Output frequency = frequency reference value

3 Output frequency > 0 Hz

4 Output Frequency

Closing threshold > P2-16 Switch off threshold < P2-17

5 Output current

Closing threshold > P2-16 Switch off threshold < P2-17

6 Output torque (calculated value)

7 Analog Input (AI2)

P2-16 216 ✓ rw AO1 / K1 upper limit 100.0

P2-17 217 ✓ rw AO1 / K1 lower limit 0.0

Closing threshold > P2-16 Switch off threshold < P2-17

The adjustable upper limit value that is being used in connection with settings 4 to 7 of P2-11 and P2-15

0.0 - 200.0 %

The adjustable lower limit value that is being used in connection with settings 4 to 7 of P2-11 and P2-15

0.0 - 200.0 %

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6 Parameters

PNU ID Access right Value Description DS

RUN ro/rw

P2-18 218 ✓ rw K2 signal (Relay Output 1) 0

Used to select the function assigned to the relay output. The relay has two output terminals: Logic 1 indicates that the relay is active: This is why terminals 17 and 18 are connected to each other.

0 RUN, enable (FWD, REV)

1 READY, variable frequency drive ready for operation

2 Output frequency = frequency reference value

3 Output frequency > 0 Hz

4 Output Frequency

Closing threshold > P2-16 Switch off threshold < P2-17

5 Output current

Closing threshold > P2-16 Switch off threshold < P2-17

6 Output torque (calculated value)

7 Analog input (AI) 2

8 PLC for external (hub) brake.

P2-19

P2-20 220 ✓ rw AO2/K2 lower limit 0.0

P2-21

P2-22 222 ✓ rw scaled display value 0

219 ✓ rw AO2/K2 upper limit 100.0

221 ✓ rw Scaling factor for value 0.00

0 Output Frequency

1 Output current

2 Analog input 2

3 P0-80 value

Closing threshold > P2-16 Switch off threshold < P2-17

This setting also enables the special operating mode for hoisting gear. Please contact your sales office for details.

The adjustable upper limit value that is being used in connection with settings 4 to 7 of P2-13 and P2-18

0.0 - 200.0 %

The adjustable lower limit value that is being used in connection with settings 4 to 7 of P2-13 and P2-18

0.0 - 200.0 %

The variable selected with P2-22 is scaled with the factor selected in P2-21.

-30.00 - 30.00

Used to select the variable that should be scaled with the factor specified in P2-21.

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6 Parameters

PNU

P2-23 223 ✓ rw Holding time for speed of 0 0.2

P2-24 224 ✓ – Clock frequency FS2: 16 kHz

P2-25

P2-26 226 ✓ rw Flying restart circuit 0

P2-27 227 ✓ rw Delay time in Standby mode 0.0

ID Access right Value Description DS

RUN ro/rw

Used to define the time that the variable frequency drive will continue to output 0 Hz (after reaching 0 Hz) before stopping.

0.0 - 60.0 s

FS3, FS4, FS5: 8 kHz FS6, FS7: 4kHz

4 - 32 kHz

RMS switching frequency of power stage. A higher frequency will reduce motor noise and improve the output current's waveform, while causing increased heat loss in the variable frequency drive.

225 ✓ rw Quick stop deceleration ramp time/deceleration time (dec 2) 0.0

Ramp time for quick deceleration ramp

Note:

In the event of a power failure, it is selected automatically or via a digital input (DI) if P2-38 = 2. If the parameter is set to 0.0, the motor will coast until it stops.

0.0 - 240.0 s

If this parameter is enabled, the variable frequency drive will attempt, upon starting, to determine whether the motor is already turning and to reduce its current speed in a controlled manner. A brief deceleration will occur if motors that are not already turning are started.

0 Deactivated

1 Enabled

Activates the Standby mode

0.0 Standby mode deactivated

> 0 - 250 s The drive will switch to standby mode (the output will be deac-

tivated) if the minimum speed (P1-02) is maintained for the time specified in this parameter. Operation will resume automatically as soon as the setpoint frequency increases to a frequency higher than P1-02.

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Cutler Hammer, Div of Eaton Corp DA1 Operation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Safety instructions

Table of contents

0 About this Manual

0.1 Target group

0.2 Writing conventions

0.3 Abbreviations

0.4 Mains supply voltages

0.5 Units

1 DA1 device series

1.1 Introduction

1.2 System overview

1.3 Checking the Delivery

1.4 Rated data

1.4.1 Rating data on the nameplate

1.4.2 Key to part numbers

1.4.3 General rated operational data

1.4.4 Features

1.5 DA1 layout

1.6 Features

1.7 Selection criteria

1.8 Proper use

1.9 Maintenance and inspection

1.10 Storage

1.11 Charging the internal DC link capacitors

1.12 Service and warranty

2 Engineering

2.1 Introduction

2.2 Electrical power network

2.2.1 Mains connection and configuration

2.2.2 Mains voltage and frequency

2.2.3 Voltage balance

2.2.4 Total Harmonic Distortion (THD)

2.2.5 Idle power compensation devices

2.2.6 Mains chokes

2.3 Safety and switching

2.3.1 Fuses and cable cross-sections

2.3.2 Residual current device

2.4 EMC compliance

2.3.3 Mains contactors

2.5 Motor and Application

2.5.1 Motor selection

2.5.2 Parallel connection of motors

2.5.3 Circuit types with three-phase motors

2.5.4 87-Hz Characteristic curve

2.5.5 Bypass operation

2.5.6 Connecting EX motors

2.5.7 Sinusoidal filter

3 Installation

3.1 Introduction

3.2 Mounting

3.2.1 Mounting position

3.2.2 Cooling measures

3.2.3 Control panel installation

3.2.4 Fixing

3.3 EMC installation

3.3.1 EMC measures in the control panel

3.3.2 Earthing

3.3.3 EMC screw

3.3.4 VAR screw

3.3.5 Screen earth kit

3.4 Electrical Installation

3.4.1 Power section connections

3.4.2 Connection on control section

3.4.3 Block diagrams

3.4.4 Insulation test

4 Operation

4.1 Checklist for commissioning

4.2 Hazard warnings for operation

4.3 Commissioning with control signal terminals (default settings)

5 Error messages

5.1 Introduction

5.1.1 Error messages

5.1.2 Acknowledge fault (Reset)

5.1.3 Error list

6 Parameters