Cutler Hammer, Div of Eaton Corp DC1 Operation Manual
Manual
12/13 MN04020003Z-EN
PowerXL
™
DC1
Variable Frequency Drive
All proprietary names and product designations are brand names or trademarks
registered to the relevant title holders.
Break-Down Service
Please call your local representative:
http://eaton.com/moeller/aftersales
or
Hotline After Sales Service:
+49 (0) 180 5 223822 (de, en)
AfterSalesEGBonn@eaton.com
For customers in US/Canada contact:
EatonCare Customer Support Center
Call the EatonCare Support Center if you need assistance with placing an order,
stock availability or proof of shipment, expediting an existing order, emergency
ship-ments, product price information, returns other than warranty returns, and
informa-tion on local distributors or sales offices.
Voice: 877-ETN-CARE (386-2273) (8:00 a.m. – 6:00 p.m. EST)
After-Hours Emergency: 800-543-7038 (6:00 p.m. – 8:00 a.m. EST)
Drives Technical Resource Center
Voice: 877-ETN-CARE (386-2273) option 2, option 6
(8:00 a.m. – 5:00 p.m. Central Time U.S. [UTC-6])
email: TRCDrives@Eaton.com
www.eaton.com/drives
Original operating manual
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 operating manual.
1. edition 2012, publication date 10/12
2. edition 2013, publication date 12/13
© 2012 by Eaton Industries GmbH, 53105 Bonn
Authors: Sven Stahlmann, Jörg Randermann, Philipp Hergarten
Redaction: René Wiegand
All rights reserved, also for the translation.
No part of this manual may be reproduced, stored in a retrieval system, or
transmitted in any form or by any means, electronic, mechanical, photocopying,
micro-filming, recording or otherwise, without the prior written permission of
Eaton Industries GmbH, Bonn.
Subject to alteration.
Danger!
Dangerous electrical voltage!
Before commencing the installation
• Disconnect the power supply of the device.
• Ensure that devices cannot be accidentally retriggered.
• Verify isolation from the supply.
• Ground and short-circuit.
• Cover or enclose neighbouring units that are live.
• Follow the engineering instructions (IL) of the device
concerned.
• Only suitably qualified personnel in accordance with
EN 50110-1/-2 (VDE 0105 Part 100) may work on this device/
system.
• Before installation and before touching the device ensure
that you are free of electrostatic charge.
• The functional earth (FE) must be connected to the
protective earth (PE) or to the potential equalizing.
The system installer is responsible for implementing this
connection.
• Connecting cables and signal lines should be installed so
that inductive or capacitive interference do 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 connection so that a cable or
wire breakage on the signal side does not result in
undefined states in the automation device.
• Ensure a reliable electrical isolation of the low voltage for
the 24 V supply. Only use power supply units complying
with IEC 60364-4-41 or HD 384.4.41 S2 (VDE 0100 part 410).
• Deviations of the mains voltage from the nominal value
must not exceed the tolerance limits given in the technical
data, 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 switching off devices
must not cause restart.
• Built-in devices for enclosures or cabinets must only be
run and operated in an installed state, desk-top devices or
portable devices only when the housing is closed.
• Measures should be taken to ensure the proper restart of
programs interrupted after a voltage dip or failure. This
Eaton Industries GmbH
should not cause dangerous operating states even for a
Safety instructions
short time. If necessary, emergency switching off devices
should be implemented.
• Wherever faults in the automation system may cause
damage to persons or property, 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.).
• During operation, and depending on their degree of
protection, variable frequency drives may have live,
uninsulated, moving, and/or rotating parts, as well as hot
surfaces.
• The impermissible removal of the required cover,
improper installation or incorrect operation of the motor or
variable frequency drive can cause the failure of the
device and serious injury and/or material damage.
• Comply with all applicable national accident prevention
regulations (e.g. BGV A3) when working with energized
variable frequency drives.
• The electrical installation must be carried out in
accordance with the relevant regulations (e.g. with regard
to cable cross sections, fuses, PE).
• All transport, installation, commissioning and maintenance work must only be carried out by trained personnel
(observe IEC 60364, HD 384 or DIN VDE 0100 and national
accident prevention regulations).
• If applicable, systems in which variable frequency drives
are installed must be equipped with additional monitoring
and protective devices in accordance with the applicable
safety regulations, e.g., the German Equipment and
Product Safety Act, accident prevention regulations, etc.
Making changes to the variable frequency drives by using
the operating software is allowed.
• Keep all covers and doors closed during operation.
• When designing the machine, the user must incorporate
mechanisms and measures that limit the consequences of
a drive controller malfunction or failure (an increase in
motor speed or the motor's sudden stop) so as to prevent
hazards to people and property, e.g.:
– Additional stand-alone devices for monitoring parame-
ters that are relevant to safety (speed, travel, end
positions, etc.)
– Electrical and non-electrical safety devices (interlocks
or mechanical locks) for mechanisms that protect the
entire system
– Due to the possibility of there being capacitors that are
still holding a charge, do not touch live device parts or
terminals immediately after disconnecting the variable
frequency drives from the supply voltage. Heed the
corresponding labels on the variable frequency drives
I
II
Table of contents
0 About this manual ..................................................................... 7
0.1 List of revisions ............................................................................ 7
0.2 Target group................................................................................. 7
0.3 Writing conventions ..................................................................... 7
0.3.1 Hazard warnings of material damages ......................................... 7
0.3.2 Hazard warnings of personal injury .............................................. 8
0.3.3 Tips............................................................................................... 8
0.4 Abbreviations ............................................................................... 9
0.5 Mains supply voltages.................................................................. 10
0.6 Units of measurement ................................................................. 10
1 DC1 device series ....................................................................... 11
1.1 Introduction .................................................................................. 11
1.2 System overview ......................................................................... 12
1.3 Checking the Delivery .................................................................. 13
1.4 Rated operational data ................................................................. 15
1.4.1 Rated operational data on the nameplate .................................... 15
1.4.2 Key to part numbers..................................................................... 16
1.5 Designations for the elements in variable frequency drives
with an IP20 degree of protection................................................ 18
1.6 Designations for the elements in variable frequency drives
with an IP66 degree of protection................................................ 19
1.7 Features ....................................................................................... 20
1.8 Selection criteria........................................................................... 22
1.9 Proper use.................................................................................... 23
1.10 Maintenance and inspection ........................................................ 24
1.11 Storage......................................................................................... 24
1.12 Charging the internal DC link capacitors ...................................... 25
1.13 Service and warranty.................................................................... 25
2 Engineering................................................................................. 27
2.1 Introduction .................................................................................. 27
2.2 Electrical power network ............................................................. 28
2.2.1 Mains connection and configuration ............................................ 28
2.2.2 Mains voltage and frequency ....................................................... 29
2.2.3 Voltage balance ............................................................................ 29
2.2.4 Total Harmonic Distortion (THD) .................................................. 30
2.2.5 Idle power compensation devices ............................................... 30
2.2.6 Mains chokes ............................................................................... 31
2.2.7 Sine filter ...................................................................................... 32
DC1 variable frequency drive 12/13 MN04020003Z-EN www.eaton.com 1
2.3 Safety and switching.................................................................... 33
2.3.1 Fuses and cable cross-sections ................................................... 33
2.3.2 Residual current circuit-breaker (RCD)......................................... 34
2.3.3 Mains contactors ......................................................................... 35
2.4 EMC compliance.......................................................................... 35
2.5 Motor ........................................................................................... 37
2.5.1 Motor Selection ........................................................................... 37
2.5.2 Parallel connection of motors ...................................................... 37
2.5.3 Circuit types with three-phase motors......................................... 38
2.5.4 87-Hz Characteristic curve ........................................................... 39
2.5.5 Connecting EX motors................................................................. 40
3 Installation.................................................................................. 41
3.1 Introduction.................................................................................. 41
3.2 Mounting ..................................................................................... 41
3.2.1 Mounting position........................................................................ 42
3.2.2 Free space ................................................................................... 42
3.2.3 Fixing ........................................................................................... 44
3.2.4 Installing cable glands (IP66)........................................................ 48
3.3 EMC installation........................................................................... 51
3.3.1 EMC measures in the control panel............................................. 51
3.3.2 EMC screw .................................................................................. 55
3.3.3 Screen earth kit............................................................................ 56
3.4 Earthing........................................................................................ 56
3.4.1 Protective earth............................................................................ 57
3.4.2 Motor earthing ............................................................................. 57
3.4.3 Earth-fault protection ................................................................... 57
3.4.4 VAR screw ................................................................................... 57
3.5 Electrical Installation .................................................................... 58
3.5.1 Connection to power section....................................................... 59
3.5.2 Connection on control section ..................................................... 66
3.5.3 Block diagrams............................................................................. 75
3.5.4 Insulation test .............................................................................. 82
4 Operation.................................................................................... 83
4.1 Checklist for commissioning........................................................ 83
4.2 Operational hazard warnings........................................................ 84
4.3 Commissioning with control signal terminals (default settings) .. 85
4.4 Commissioning with local controls (IP66).................................... 88
4.5 Commissioning with keypad........................................................ 90
4.6 Commissioning with field bus / SmartWire-DT............................ 92
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5 Parameters.................................................................................. 93
5.1 Operating unit .............................................................................. 93
5.1.1 Shortcuts...................................................................................... 94
5.1.2 Display unit................................................................................... 94
5.1.3 Menu Navigation .......................................................................... 94
5.2 Setting parameters....................................................................... 95
5.2.1 Operating unit .............................................................................. 95
5.2.2 drivesConnect .............................................................................. 95
5.2.3 Field bus/SmartWire DT ............................................................... 95
5.3 List of parameters ........................................................................ 96
5.3.1 Parameter Lock ............................................................................ 97
5.3.2 Default settings............................................................................ 97
5.4 I/0 control ..................................................................................... 98
5.5 Digital and analog inputs .............................................................. 99
5.6 Operational data indicator ............................................................ 103
6 Drives control ............................................................................. 105
6.1 Control level ................................................................................. 105
6.2 Second acceleration and deceleration time ................................. 106
6.2.1 Stop function with two different deceleration times ................... 107
6.3 Motor ........................................................................................... 108
6.3.1 Circuit types for motor stator windings........................................ 108
6.3.2 87-Hz Characteristic curve ........................................................... 109
6.3.3 U/f characteristic curve ................................................................ 111
6.3.4 Speed behavior without slip compensation ................................. 112
6.3.5 Speed behavior with slip compensation ...................................... 113
6.4 Braking ......................................................................................... 115
6.4.1 DC-braking.................................................................................... 115
6.4.2 Regenerative braking ................................................................... 116
6.4.3 Mechanical brake (actuation)........................................................ 117
7 Applications................................................................................ 121
7.1 Analog inputs changeover............................................................ 121
7.1.1 Scaled value range (AI1)............................................................... 122
7.2 External fault (EXT)....................................................................... 123
7.3 Connecting a thermistor............................................................... 123
7.4 Fixed frequency setpoint values .................................................. 124
7.4.1 Fixed frequency............................................................................ 124
7.4.2 Frequency jump ........................................................................... 125
7.5 Motor potentiometer.................................................................... 127
7.6 Motor current monitoring............................................................. 130
7.7 Autostart function ........................................................................ 132
7.8 Setpoint input via keypad ............................................................. 133
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8 Modbus RTU............................................................................... 135
8.1 General ........................................................................................ 135
8.1.1 Communications.......................................................................... 135
8.1.2 COM Port..................................................................................... 136
8.1.3 Enable .......................................................................................... 136
8.1.4 Modbus data format .................................................................... 136
8.2 Modbus parameters..................................................................... 137
8.3 Operating mode Modbus RTU..................................................... 139
8.3.1 Structure of the master request .................................................. 140
8.3.2 Structure of the slave response................................................... 141
8.3.3 Modbus: Register mapping.......................................................... 142
8.3.4 Explanation of function code........................................................ 147
9 CANopen..................................................................................... 149
9.1 Data Types................................................................................... 149
9.2 System overview ......................................................................... 150
9.2.1 COM Port..................................................................................... 151
9.2.2 Enable .......................................................................................... 152
9.2.3 Bus termination resistor............................................................... 152
9.2.4 Baud rate ..................................................................................... 152
9.2.5 Set CANopen user address.......................................................... 153
9.2.6 Parameters that need to be configured ....................................... 153
9.2.7 Transmission Type....................................................................... 155
9.3 Object list..................................................................................... 156
9.3.1 EDS file ........................................................................................ 156
9.3.2 Communication-specific objects .................................................. 157
9.3.3 Server SDO Parameter ................................................................ 158
9.3.4 Manufacturer-specific objects...................................................... 160
10 Error Messages .......................................................................... 163
10.1 Introduction.................................................................................. 163
10.2 Error Messages............................................................................ 163
10.2.1 Acknowledge error message (Reset)........................................... 163
10.2.2 Fault log ....................................................................................... 163
10.3 Error list........................................................................................ 165
4 DC1 variable frequency drive 12/13 MN04020003Z-EN www.eaton.com
11 Annex .......................................................................................... 167
11.1 Features ....................................................................................... 168
11.2 General rated operational data ..................................................... 170
11.3 Technical data .............................................................................. 173
11.3.1 DC1-1D......................................................................................... 173
11.3.2 DC1-12 ......................................................................................... 175
11.3.3 DC1-32 ......................................................................................... 177
11.3.4 DC1-34 ......................................................................................... 179
11.3.5 DC1-34 ......................................................................................... 181
11.4 Dimensions and frame size.......................................................... 183
11.5 Variable frequency drives for single-phase AC motors ................ 185
11.6 DX-SPL-RJ45-2SL1PL .................................................................. 187
11.7 External keypad............................................................................ 188
11.7.1 DX-KEY-… .................................................................................... 188
11.7.2 DX-KEY-LED ................................................................................. 190
11.7.3 DX-KEY-OLED .............................................................................. 191
11.8 DX-NET-SWD3 ............................................................................. 193
11.9 PC-Interface cards........................................................................ 194
11.9.1 DX-COM-STICK ............................................................................ 194
11.9.2 DX-COM-PCKIT ............................................................................ 195
11.9.3 DX-CBL-PC1M5............................................................................ 196
11.9.4 drivesConnect .............................................................................. 197
11.10 Expansion modules ...................................................................... 197
11.10.1 DXC-EXT-IO110, DXC-EXT-IO230 ................................................ 197
11.10.2 DXC-EXT-2RO .............................................................................. 200
11.10.3 DXC-EXT-2RO1AO ....................................................................... 202
11.11 Cables and fuses.......................................................................... 204
11.12 Mains contactors.......................................................................... 207
11.13 EMC cable brackets ..................................................................... 209
11.14 Radio interference suppression filter ........................................... 210
11.15 Braking resistances ...................................................................... 212
11.15.1 DX-BR3-100.................................................................................. 212
11.16 Mains chokes ............................................................................... 215
11.17 Motor chokes ............................................................................... 217
11.18 Sine filter ...................................................................................... 219
11.19 List of parameters ........................................................................ 221
Alphabetical index ..................................................................... 229
DC1 variable frequency drive 12/13 MN04020003Z-EN www.eaton.com 5
6 DC1 variable frequency drive 12/13 MN04020003Z-EN www.eaton.com
0 About this manual
0.1 List of revisions
0 About this manual
0.1 List of revisions
This manual contains specific information designed to enable you to select a
DC1 variable frequency drive, connect it, and use its parameters to configure
it as required for your specific needs.
frequency drive sizes. Any differences between and special characteristics of
the various rating levels and sizes will be noted accordingly.
The following significant amendments have been introduced since previous
issues:
The manual applies to all DC1 variable
Publication
date
12/13 Completely revised
10/12 Initial issue
Page Subject New Modification Deleted
0.2 Target group
The content of MN04020003Z-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.
0.3 Writing conventions
Symbols with the following meaning are used in this manual:
Indicates instructions to be followed.
0.3.1 Hazard warnings of material damages
NOTICE
Warns about the possibility of material damage.
✓✓
DC1 variable frequency drive 12/13 MN04020003Z-EN www.eaton.com 7
0 About this manual
0.3 Writing conventions
0.3.2 Hazard warnings of personal injury
CAUTION
0.3.3 Tips
￫
￫
Warns of the possibility of hazardous situations that may
possibly cause slight injury.
WARNING
Warns of the possibility of hazardous situations that could result
in serious injury or even death.
DANGER
Warns of hazardous situations that result in serious injury or
death.
Indicates useful tips.
In order to make it easier to understand some of the figures
included in this manual, the variable frequency drive housing, as
well as other safety-relevant parts, has been left out. However,
it is important to note that the variable frequency drive must
always be operated with its housing in its proper place, as well
as with all required safety-relevant parts.
￫
￫
8 DC1 variable frequency drive 12/13 MN04020003Z-EN www.eaton.com
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:
www.eaton.eu/powerxl
0.4 Abbreviations
The following abbreviations are used in this manual:
dec Decimal (base-10 numeral system)
EMC Electromagnetic compatibility
FE Functional earth
FS Frame Size
FWD Forward run (clockwise rotating field)
GND Ground (0-V-potential)
hex Hexadecimal (base-16 numeral system)
ID
IGBT Insulated gate bipolar transistor
LED Light Emitting Diode (LED)
LSB
MSB
OLED Organic Light Emitting Diode
PC Personal Computer
PDS Power Drive System (magnet system)
PE Protective earth
PES EMC connection to PE for screened lines
PNU Parameter number
REV Reverse run (anticlockwise rotation field active)
ro
rw Read/Write (read/write access)
SCCR
UL
DS Default settings
Identifier (unique ID)
Least significant bit
Most significant bit
Read Only (read access only)
Short Circuit Current Rating
Underwriters Laboratories
0 About this manual
0.4 Abbreviations
DC1 variable frequency drive 12/13 MN04020003Z-EN www.eaton.com 9
0 About this manual
0.5 Mains supply voltages
0.5 Mains supply voltages
The rated operating voltages stated in the following table are based on the
standard values for networks with a grounded star point.
In ring networks (as found in Europe) the rated operating voltage at the
transfer point of the power supply companies is the same as the value in the
consumer networks (e.g. 230 V, 400 V).
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 DC1 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 %
- 10%) while, in the 400-V cate-
LN
(60 Hz).
The permissible power supply for the DC1 series is listed in the Technical
Specifications section in the annex.
0.6 Units of measurement
Designation
Length 1 in (’’) 25.4 mm 0.0394 inch
Power
Torque
Temperature 1°F (TF) -17.222 °C (TC) TF=TC×9/5+32 Fahrenheit
Speed
Weight 1lb 0.4536 kg 2.205 pound
Flow rate 1 cfm 1.698 m3/min 0.5889 cubic feed per minute
The rated mains voltage operational data is always based on mains frequencies of 50/60 Hz within a range of 48 to 62 Hz.
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
US-American value SI value Conversion value US-American
Designation
1HP=1.014PS 0.7457 kW 1.341 horsepower
1 lbf in 0.113 Nm 8.851 pound-force inches
1rpm 1min
-1
1 Revolutions per minute
10 DC1 variable frequency drive 12/13 MN04020003Z-EN www.eaton.com
1 DC1 device series
1.1 Introduction
1 DC1 device series
1.1 Introduction
Due to their ease of use and high reliability, DC1 PowerXL™ variable
frequency drives are ideal for general applications involving three-phase
motors. In addition, an integrated radio interference suppression filter and a
flexible interface ensure that the inverters meet a number of important
needs in the machine building industry when it comes to the optimization of
production and manufacturing processes.
For installations in control panels, devices with a performance range
of 0.37 (for 230 V) to 11 kW (for 400 V) are available in a compact and
sturdy design featuring three available sizes (FS1, FS2, FS3) and a degree
of protection of IP20.
For distributed local installations, there are three sizes covering a performance range of 0.37 (for 230 V) to 7.5 kW (for 400 V) and featuring a degree
of protection of IP66. These models come in two versions: with and without
local controls. These local controls include a setpoint potentiometer, a
selector switch for switching operating directions, and a lockable main
switch on the mains side.
The computer-based drivesConnect parameter configuration program
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.
L1/L
L2/N
L3
0
REV
FWD
OFF
PWR
ON
1
2
3
4
5
6
7
8
9
10
11
U
V
W
IP20 degree of protection IP66 degree of protection, without
local controls
Figure 1: Designs, enclosure versions
IP66 degree of protection, with local
controls
DC1 variable frequency drive 12/13 MN04020003Z-EN www.eaton.com 11
1 DC1 device series
R
e
a
d
y
I
O
A
L1/L
L2/N
L3
U
V
W
1
2
3
4
5
6
7
8
9
10
1
1
⑤
④
⑥
①
②
③
⑦
1.2 System over view
1.2 System overview
Figure 2: System overview (example)
a DC1-… variable frequency drives
b DX-LN… mains choke, DX-LM3-… motor choke, DX-SIN3-… sine filter
c Integrable DX-BR… braking resistance (only for IP20, FS2 and FS3)
d DXC-EXT-… expansion module
e DX-NET-SWD3 SmartWire-DT interface (only in IP20)
f DX-COM-STICK communication module and accessories (e. g. DX-CBL-… connection cable)
g DE-KEY-… keypad (external)
12 DC1 variable frequency drive 12/13 MN04020003Z-EN www.eaton.com
1.3 Checking the Delivery
L1/L
L2/N
L3
U
V
W
1
2
3
4
5
6
7
8
9
10
11
1 DC1 device series
1.3 Checking the Delivery
￫
to make sure that you received the correct variable frequency
drive.
Before opening the package, please check the nameplate on it
Figure 3: Nameplate location
The DC1 series variable frequency drives are carefully packaged and
prepared for delivery. The devices should be shipped only in their original
packaging with suitable transportation materials. 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 adequate tools and inspect the contents immediately after receipt in order to ensure that they are complete and undamaged.
DC1 variable frequency drive 12/13 MN04020003Z-EN www.eaton.com 13
1 DC1 device series
L1/L
L2/N
L3
U
V
W
1
2
3
4
5
6
7
8
9
10
11
1.3 Checking the Delivery
The packaging must contain the following parts:
• DC1 series variable frequency drive,
• an instructional leaflet
• IL04020009Z for devices with an IP20 degree of protection
• IL04020013Z for devices with an IP66 degree of protection
• A data carrier (CD-ROM) containing documentation for the variable
frequency drives
IL
Figure 4: Equipment supplied
CD
14 DC1 variable frequency drive 12/13 MN04020003Z-EN www.eaton.com
1.4 Rated operational data
a
Voltage categories
DC1 variable frequency drives are subdivided into the following mains
voltage categories:
• 115 V: DC1-1D…
• 230 V: DC1-12…, DC1-32…
• 400 V: DC1-34…
1.4.1 Rated operational data on the nameplate
The device-specific rated operational data for the DC1 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
DC1-344D1FB-A20N Part no.:
Input
Output
Power
S/N
1 DC1 device series
1.4 Rated operational data
DC1 = DC1 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 RFI filter
B = integrated Brake Chopper
A = LED display (7-segment text display)
20 = IP20 degree of protection
N = basic device
Rated operational data of mains connection
Three-phase AC voltage (U
380 - 480 V voltage, 50/60 Hz frequency, input phase current (4.3 A).
Load side (motor) rated operational data:
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 asynchronous motor (1500 min
Serial number
variable frequency drive is an electrical apparatus.
Read the manual (in this case MN04020003Z-EN) before making any electrical
connections and commissioning.
3~ AC),
e
), output phase current (4.1 A), output frequency
e
-1
at 50 Hz/1800 rpm at 60 Hz)
IP20/Open type
25072012 Manufacturing date: 25.07.2012
DC1 variable frequency drive 12/13 MN04020003Z-EN www.eaton.com 15
Degree of protection of the housing: IP 20, UL (cUL) Open Type
1 DC1 device series
1.4 Rated operational data
1.4.2 Key to part numbers
The catalog no. or part no. for the DC1 series of variable frequency drives is
made up of four sections.
Series – Power section – Model – Version
The following figure shows it in greater detail:
D C 1 - 1 2 4 D 1 F N - A 2 0 N Explanation
Type
N = basic device
Degree of protection
20 = IP20 / NEMA 0
66 = IP66 / NEMA 4X
6S = IP66 with switch / NEMA 4X, switched
Display unit (display)
A = LED 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
1 = 115 V (110 - 115 V ±10 %)
2 = 230 V (200 - 240 V ±10 %)
4 = 400 V (380 - 480 V ±10 %)
D = 115 V input / 230 V output (voltage doubler)
Connection in power section
1 = Single-phase mains connection / three-phase motor connection
3 = Three-phase mains connection / three-phase motor connection
S = Single-phase mains connection / single-phase motor connection
Device series
DC1 = variable frequency drive, compact, Series 1
(D = Drives, C = Compact, 1 = Series)
Figure 5: Key to part numbers
1) Please refer to manual MN04020004Z-EN
16 DC1 variable frequency drive 12/13 MN04020003Z-EN www.eaton.com
Catalog number examples
Inscription Meaning
1 DC1 device series
1.4 Rated operational data
DC1-124D1FN-A20N DC1 = DC1 series variable frequency drive
DC1-327DOFB-A66N
DC1-34024NB-A20N
DC1-342D2FN-A6SN
1) In the case of variable frequency drives without an integrated EMC filter, external measures (e.g., external radio
interference suppression filters) must be used for operation in accordance with IEC/EN 61800-3 in order to
comply with the relevant limits concerning electromagnetic compatibility (EMC).
1 = Single-phase mains connection / three-phase motor connection
2 = 230 V mains voltage category (200 - 240 V ±10%)
4D1 = 4.1 A rated operational current (output current)
F = Integrated radio interference suppression filter (RFI, EMC measure)
N = No integrated braking chopper
A = LED display (7-segment) on operating unit
20 = Degree of protection IP20 / NEMA 0
N = basic device
DC1 = DC1 series variable frequency drive
3 = Three-phase mains connection / three-phase motor connection
2 = 230 V mains voltage category (200 - 240 V ±10%)
7D0 = 7 A rated operational current (output current)
F = Integrated radio interference suppression filter (RFI, EMC measure)
B = Integrated Brake Chopper. An external braking resistance (optional) is required for
this function.
A = LED display (7-segment) on operating unit
66 = degree of protection IP66
N = basic device
DC1 = DC1 series variable frequency drive
3 = Three-phase mains connection / three-phase motor connection
4 = 400 V mains voltage category (380 - 480 V ±10%)
024 = 24 A rated operational current (output current)
N = No integrated radio interference suppression filter (RFI)
B = Integrated Brake Chopper. An external braking resistance (optional) is required for
this function.
A = LED display (7-segment) on operating unit
20 = Degree of protection IP20 / NEMA 0
N = basic device
DC1 = DC1 series variable frequency drive
3 = Three-phase mains connection / three-phase motor connection
4 = 400 V mains voltage category (380 - 480 V ±10%)
2D2 = 2.2 A rated operational current (output current)
F = Integrated radio interference suppression filter (RFI, EMC measure)
N = No integrated braking chopper
A = LED display (7-segment) on operating unit
6S = Degree of protection IP66 / NEMA 4X with switches (mains switch, enable/phase
sequence, potentiometer) for local control
N = basic device
/
NEMA 4X
1)
￫
DC1 variable frequency drive 12/13 MN04020003Z-EN www.eaton.com 17
ence suppression filter is required for DC1-…Nx-… models.
In accordance with IEC/EN 61800-3, an external radio interfer-
1 DC1 device series
L1/L
L2/N
L3
U
V
W
1
2
3
4
5
6
7
8
9
10
11
⑧
⑦
⑥
⑤
①
②
③
④
1.5 Designations for the elements in variable frequency drives with an IP20 degree of protection
1.5 Designations for the elements in variable frequency drives with an IP20 degree of protection
The following drawing serves as an example showing the designations used
for the elements in DC1 variable frequency drives with a size of FS1 and an
IP20 degree of protection.
Figure 6: Designations (IP20)
a Fixing holes (screw fastening)
b Connection terminals in power section (mains side)
c Cutout for mounting on mounting rail
d Connection terminals in power section (motor feeder)
e Control signal terminals (plug-in)
f Communication interface (RJ45)
g Operating unit with 5 control buttons and LED display
h Info card
18 DC1 variable frequency drive 12/13 MN04020003Z-EN www.eaton.com
1 DC1 device series
L2
N
L3
U
V
W
L1
N
1 2
3
4 5 6 7 8 9 10
1 2
3 4 5 6 7 8 9 1
0
11
①
⑨
⑧
⑦
②
③
④
⑤
⑥
1.6 Designations for the elements in variable frequency drives with an IP66 degree of protection
1.6 Designations for the elements in variable frequency drives with an IP66 degree of protection
The following drawing serves as an example showing the designations used
for the elements in DC1 variable frequency drives with a size of FS1 and an
IP66 degree of protection.
Figure 7: Designations (IP66)
a Local controls with connection (in DC1-…-A6SN only)
Setpoint potentiometer
Selector switch for switching operating directions
Mains transfer switch (lockable)
b Operating unit with 5 control buttons and LED display
c Control signal terminal strip (plug-in)
d Connection terminals in power section (motor feeder) and cableway for EMC cable gland
e Nameplate
f Fixing holes (screw fastening)
g Heat sink
h Connection terminals in power section (mains side) and cableway for cable gland
i Communication interface (RJ45)
The info card and three additional knockouts for cable glands are found under
the lower terminal cover.
DC1 variable frequency drive 12/13 MN04020003Z-EN www.eaton.com 19
1 DC1 device series
+
-
+
-
+
-
M
3 ~
U
L3
L2/N
L1/L
W
V
U
②①③④⑤⑥⑦
⑩
⑪
⑧⑨
DC+DC- BR
EMC VAR
CPU
1 … 11
PES
1.7 Features
1.7 Features
DC1 series variable frequency drives convert the voltage and frequency of an
existing AC supply system into a DC voltage.
This DC voltage is then used to generate a single-phase or three-phase AC
voltage with an adjustable frequency and assigned amplitude values for the
variable speed control of AC motors and three-phase asynchronous motors.
Figure 8: Block diagram; components in a DC1 variable frequency drive
a L1/L, L2/N, L3, PE supply, mains supply voltage U
DC1-1D…: single-phase mains connection (1 AC 115 V), with voltage doubler,
motor feeder (3 AC 230 V)
DC1-12…: single-phase mains connection (1 AC/2 AC 230 V/240 V), motor feeder (3 AC 230 V)
DC1-32…: three-phase mains connection (3 AC 230 V/240 V), motor feeder (3 AC 230 V)
DC1-34…: three-phase mains connection (3 AC 400 V/480 V), motor feeder (3 AC 400 V)
b Internal radio interference suppression filter (not in DC1-1D…), 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 and DC link
(DC- and DC+ connection only in FS2 and FS3 sizes with IP20 degree of protection)
f Braking chopper for external braking resistance (DC+ and BR connection only in FS2 and FS3 sizes)
g Inverter. The IGBT based inverter converts the DC voltage
of the DC link (U
) into a three-phase AC voltage (U2) with variable amplitude and frequency (f2).
DC
LN=Ue
at 50/60 Hz:
20 DC1 variable frequency drive 12/13 MN04020003Z-EN www.eaton.com
1 DC1 device series
1.7 Features
h Motor connection with output voltage U2 (0 to 100% Ue) and output frequency f2 (0 to 500 Hz)
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
DC1-1D…: 2.3 - 5.8 A
DC1-12…: 2.3 - 15 A
DC1-32…: 2.3 - 18 A
DC1-34…: 2.2 - 24 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
Continuously variable speed control for motors with the rated motor shaft outputs (P
DC1-1D…: 0.37 - 1.1 kW (230 V, 50 Hz) or 0.5 - 1.5 HP (230 V, 60 Hz)
DC1-12…: 0.37 - 4 kW (230 V, 50 Hz) or 0.5 - 5 HP (230 V, 60 Hz)
DC1-32…: 0.37 - 4 kW (230 V, 50 Hz) or 0.5 - 5 HP (230 V, 60 Hz)
DC1-34…: 0.75 - 11 kW (400 V, 50 Hz) or 1 - 15 HP (460 V, 60 Hz)
j Control section with operating unit and control buttons, seven-segment display, control voltage,
plug-in control signal terminals
k RJ45 interface for the computer and fieldbus connection (OP bus, Modbus RTU, CANopen)
, output current):
e
):
2
DC1 variable frequency drive 12/13 MN04020003Z-EN www.eaton.com 21
1 DC1 device series
1.8 Selection criteria
1.8 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
supply voltage.
The rated output current I
of the variable frequency drive must be greater
e
than or equal to the rated motor current.
cos ϕ 0.79
-1
P-08
50 Hz
P-09
L1/L
L2/N
L3
1
2
3
4
5
6
7
8
9
1
0
11
U
V
W
Figure 9: Selection criteria
P-07
230/400 V 3.2/1.9 A
0,75 KW
1410 mi n
P-10
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).
• Ambient conditions (control cabinet installation for IP20 degree of
protection and direct local installation for IP66 degree of protection)
￫
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 sine filters must be installed between the variable
frequency drive and the motor.
22 DC1 variable frequency drive 12/13 MN04020003Z-EN www.eaton.com
When connecting multiple motors in parallel to the output of a
added geometri-
1.9 Proper use
1 DC1 device series
1.9 Proper use
The DC1 variable frequency drives are not domestic appliances. They are
designed only for industrial use as system components.
The DC1 variable frequency drives are electrical devices for controlling variable speed drives with three-phase motors. They are designed for installation
in machines or for use in combination with other components within a
machine or system
If installed in a machine, the variable frequency drives must not be placed
into operation until it is confirmed that the relevant machine complies with
the safety requirements set forth in the 2006/22/EC Machinery Directive
(meets the requirements set forth in 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 DC1 variable frequency drives confirm that the devices
meet the requirements set forth in the European Union's Low Voltage and
EMC Directives (Directives 2006/95/EC and 2006/42/EC) when used in their
typical drive configuration.
In the described system configurations, DC1 variable frequency drives are
suitable for use in public and non-public networks.
A connection of a DC1 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 rating plate 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 DC1 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).
DC1 variable frequency drive 12/13 MN04020003Z-EN www.eaton.com 23
1 DC1 device series
1.10 Maintenance and inspection
1.10 Maintenance and inspection
DC1 series variable frequency drives will be maintenance-free as long as the
general rated operational data ( Section 1.5, „Designations for the
elements in variable frequency drives with an IP20 degree of protection“,
page 18) is adhered to and the specific technical data (see annex) for the
corresponding ratings is taken into account. Please note, however, that
external influences may affect the operation and lifespan of a DC1 variable
frequency drive.
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 DC1 variable frequency drives
Maintenance measures Maintenance interval
Clean cooling vents (cooling slits)
Check to make sure that the fan and the
7-segment display are working properly
(press all five buttons simultaneously,
starting with the Stop button)
Check the filter in the control panel doors
(see the manufacturer's 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 12 months
please enquire
6 - 24 months (depending on the environment)
6 - 24 months (depending on the environment)
On a regular basis, at periodic intervals
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
(￫ Section 1.12, „Charging the internal DC link capacitors“)
There are no plans for replacing or repairing individual components of DC1
variable frequency drives!
If the DC1 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.
1.11 Storage
If the DC1 variable frequency drive is stored before use, suitable ambient
conditions must be ensured at the site of storage:
• Storage temperature: -40 - +60 °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 1.12, „Charging the internal DC link capacitors“).
24 DC1 variable frequency drive 12/13 MN04020003Z-EN www.eaton.com
1.12 Charging the internal DC link capacitors
After extended storage times or extended downtimes during which no
power is supplied (> 12 months), the capacitors in the internal DC link must
be recharged in a controlled manner in order to prevent damage. To do this,
the DC1 variable frequency drive must be supplied with power, with a
controlled DC power supply unit, via two mains connection terminals
(e.g. L1 and L2).
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).
DC
1 DC1 device series
1.12 Charging the internal DC link capacitors
1.13 Service and warranty
• DC1-12…, DC1-32…: about 324 V DC at U
• DC1-34…: about 560 V DC at U
￫
In the unlikely event that you have a problem with your DC1 variable
frequency drive, please contact your local sales office.
When you call, have the following data ready:
• The
• 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.
Due to the internal voltage doubler circuit, the capacitors in
DC1-1D… variable frequency drives cannot be reformed using
the connection terminals!
Please contact your local sales office.
exact variable frequency drive part number (see nameplate),
= 400 V AC
e
= 230 V AC
e
24-hour hotline: +49 (0)1805 223 822
E-Mail:
DC1 variable frequency drive 12/13 MN04020003Z-EN www.eaton.com 25
AfterSalesEGBonn@eaton.com
1 DC1 device series
1.13 Service and warranty
26 DC1 variable frequency drive 12/13 MN04020003Z-EN www.eaton.com
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