PowerXL DG1 Series Option Cards User Manual Effective April 2014 New Information
PowerXL DG1 Series Option Cards Disclaimer of Warranties and Limitation of Liability The information, recommendations, descriptions, and safety notations in this document are based on Eaton’s experience and judgment and may not cover all contingencies. If further information is required, an Eaton sales office should be consulted.
PowerXL DG1 Series Option Cards Support Services Support Services The goal of Eaton is to ensure your greatest possible satisfaction with the operation of our products. We are dedicated to providing fast, friendly, and accurate assistance. That is why we offer you so many ways to get the support you need. Whether it is by phone, fax, or email, you can access Eaton’s support information 24 hours a day, seven days a week. Our wide range of services is listed below.
PowerXL DG1 Series Option Cards Table of Contents SAFETY Before Commencing the Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Definitions and Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hazardous High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Warnings and Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motor and Equipment Safety .
PowerXL DG1 Series Option Cards List of Figures Figure 1. RTC Battery Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 2. Rating Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 3. Drive Control Board Layout Showing Option Card Slots . . . . . . . . . . . . . . . . . Figure 4. Maximum Loads on +24V / EXT +24V Output . . . . . . . . . . . . . . . . . . . . . . . . Figure 5.
PowerXL DG1 Series Option Cards List of Tables Table 1. Common Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Table 2. PowerXL Series—DG1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Table 3. Wire Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Table 4. Control Wiring Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PowerXL DG1 Series Option Cards Safety Warning! Dangerous Electrical Voltage! Before Commencing the Installation ● Disconnect the power supply of the device ● Ensure that devices cannot be accidentally restarted ● 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.
PowerXL DG1 Series Option Cards Read this manual thoroughly and make sure you understand the procedures before you attempt to install, set up, operate or carry out any maintenance work on this DG1 Adjustable Frequency Drive. Definitions and Symbols WARNING WARNING The components in the drive’s power section remain energized after the supply voltage has been switched off.
PowerXL DG1 Series Option Cards Failure to follow these precautions may cause death or severe injury. WARNING This equipment has a large capacitive leakage current during operation, which can cause enclosure parts to be above ground potential. Proper grounding, as described in this manual, is required. Failure to observe this precaution could result in death or severe injury.
PowerXL DG1 Series Option Cards CAUTION CAUTION Install this drive on flame-resistant material such as a steel plate to reduce the risk of fire. CAUTION Install this drive on a perpendicular surface that is able to support the weight of the drive and is not subject to vibration, to lessen the risk of the drive falling and being damaged and / or causing personal injury.
PowerXL DG1 Series Option Cards Motor and Equipment Safety CAUTION CAUTION Do not perform any meggar or voltage withstand tests on any part of the drive or its components. Improper testing may result in damage. Make sure that the drive output terminals (U, V, W) are not connected to the utility line power as severe damage to the drive may occur.
DG1 Series Overview DG1 Series Overview This chapter describes the purpose and contents of this manual, the receiving inspection recommendations and the DG1 Series Open Drive catalog numbering system. Real Time Clock Battery Activation How to Use this Manual Simply remove the primary drive cover, locate the RTC battery directly below the keypad, and connect the white 2-wire connector to the receptacle on the control board.
DG1 Series Overview Rating Label Figure 2. Rating Label Contains SN, PN, Type, Date Contains EAN Code Contains NAED Code Date Code: 20131118 Carton Labels (U.S. and Europe) Same as rating label shown above. 2 PowerXL DG1 Series Option Cards MN040007EN—April 2014 www.eaton.
DG1 Series Overview Option Card Slots Option Board Summary The control board is located inside the control unit of the DG1 Series Drive. There are two slots, labeled A and B, on the control board. The different option boards can be added to any slots. When the DG1 Series Drive is assembled at the factory, no option boards are installed in slots A and B. If an incorrect board is plugged into either slot, the board will not work, but there is no danger to personnel or for equipment damage.
DG1 Series Overview Technical Data Table 2.
DG1 Series Overview Table 2.
DG1 Series Overview Table 2.
DG1 Series Overview Power Supply (+24 Vdc Out / +24 Vdc In) Digital Input Signal Conversion The power supply can only exist on IO1 board, which includes a 24 Vdc in and a 24 Vdc out. The active signal level depends on which potential the common input is connected to. The alternatives are +24V or Ground (0V). The 24 Vdc out is used to power up external equipment, such as encoders and auxiliary relays. Note that the total combined load on all available 24 Vdc out terminals must not exceed 250 mA.
DG1 Series Overview Installing DG1 Option Board Remove Utility line and control power from the PowerXL DG1 series drive. Install the option board in one of the slots available on the control board. To insert and remove the board, hold it in a horizontally straight position to avoid twisting the connector pins. Verify the board fits tightly in the metal clamp and plastic groove.
DG1 Series Overview EMC Directive Control Cable Grounding For the electrical equipment installed in the EMC, directive states that the equipment must not disturb the environment and must be immune to other electromagnetic disturbances in the environment. Table 4 indicates the requirements for the control wiring to meet this directive. It is recommended that the shielded cables be grounded as shown in Figure 7. Strip the cable insulation required allowing attachment to the frame with the grounding clamp.
IO1—3 x DI, 3 x DO, 1 x Thermistor, 24 Vdc/EXT Option Card IO1—3 x DI, 3 x DO, 1 x Thermistor, 24 Vdc/EXT Option Card Description Table 7. 24V Rating I/O board has 3 digital inputs, 3 digital outputs, 1 thermistor input used with 2 inputs, and 24 Vdc Input and Output. It can be placed in either Slot A or B. Terminals are keyed so they cannot be inserted incorrectly. Power Supply Specification Rated voltage 24 Vdc Power consumption from 24 Vdc_IN Voltage +24 Vdc ±10%, max.
IO1—3 x DI, 3 x DO, 1 x Thermistor, 24 Vdc/EXT Option Card Figure 8. IO1 Board Layout PowerXL DG1 Series Option Cards MN040007EN—April 2014 www.eaton.
IO1—3 x DI, 3 x DO, 1 x Thermistor, 24 Vdc/EXT Option Card Figure 9. IO1 Board Wire Layout 24VDC_IN 11 24V DC input 24VDC_Out 10 IO1 Board GND 9 DIN1 8 DIN2/TI1+ 7 DIN3/TI1- 6 CMIN 5 DO1 4 DO2 3 DO3 2 CMO 1 Note: If the thermistor inputs are selected, it removes 2 of the digital inputs to be used as the thermistor inputs. Table 8.
IO1—3 x DI, 3 x DO, 1 x Thermistor, 24 Vdc/EXT Option Card Digital Inputs The 3 digital input functions can be configured for various functions in the PowerXL DG1 drive. To configure these inputs, the standard Digital inputs menu will allow for selecting its function. DigIN: X indicates one of the onboard inputs. The option DigIN: X: IO1: Y will select one of the inputs on the IO1 card; the first X being the slot it is located in, A or B, and the second Y being the input used.
IO1—3 x DI, 3 x DO, 1 x Thermistor, 24 Vdc/EXT Option Card Digital Outputs The 3 digital output functions can be configured to various functions in the PowerXL DG1 drive. To configure these inputs, there are parameters in the option card menu for each of the outputs that will allow for selecting its function. Figure 11. Digital Output Signal Programming 14 PowerXL DG1 Series Option Cards MN040007EN—April 2014 www.eaton.
IO1—3 x DI, 3 x DO, 1 x Thermistor, 24 Vdc/EXT Option Card Thermistor Input The signal thermistor input needs to be configured before use. It will switch states at 4.7 k ohm. Table 9. Thermistor Input Configuration PTC Resistance PTC State >4.7K Open 1.8K to 10 Normal <10 Short No PTC Not Configured Figure 12. Thermistor Parameter Setting PowerXL DG1 Series Option Cards MN040007EN—April 2014 www.eaton.
IO1—3 x DI, 3 x DO, 1 x Thermistor, 24 Vdc/EXT Option Card IO1 Board Parameters Table 10. IO1 Board Parameters Monitor Menu—BX.1 Code Parameter Min. Max. Default Unit ID (Slot A / Slot B) Description R / RW BX.1.1 DI1, DI2, DI3 889 / 915 Digital Input Status R BX.1.2 DO1, DO2, DO3 888 / 914 Digital Output Status R BX.1.3 Thermistor State 887 / 913 Thermistor configure R BX.1.
IO2—1 x AI, 2 x AO Option Card IO2—1 x AI, 2 x AO Option Card Description IO board has 1 analog input that can be configured as voltage (±10V) or current (0 to 20 mA) and 2 analog outputs that can be configured as voltage (0 to 10V) or current (0 to 20 mA). DIP switches on the option card are used to configure along with parameter settings. Table 11.
IO2—1 x AI, 2 x AO Option Card Figure 13. IO2 Board Layout Figure 14. IO2 Board Wire Layout AI1+ 7 AI1- 6 AO1+ 5 AO1- 4 AO2+ 3 AO2- 2 FE/GND 1 IO2 Board Voltage Current Voltage Current Voltage Current Table 12. IO2 Board Terminals Terminal Signal Technical 1 FE Connect cable shield 2 AO2– Current: 0 (4)–20 mA, RL max. 500 ohms 3 AO2+ Voltage: 0–10V, RL >1k ohm (default setting) 4 AO1– Current: 0 (4)–20 mA, RL max.
IO2—1 x AI, 2 x AO Option Card IO2 Board Parameters Parameters are all listed in the Optional board menu for this card. Figure 15. IO2 Parameter Structure Table 13. IO2 Board Parameters Monitor Menu—BX.1 Code Parameter Min. Max. Default Unit ID (Slot A / Slot B) Description R / RW BX.1.1 AI1 Value 894 / 920 Analog Input Status R BX.1.2 AO1 Value 897 / 922 Analog Output Status R BX.1.
IO2—1 x AI, 2 x AO Option Card Parameter Menu—BX.2 Code Parameter Min. Max. Default BX.2.12 AO1 Invert 0 1 0 BX.2.13 AO1 Offset 0 9 0 BX.2.14 AO2 Mode 0 1 0 Unit % ID (Slot A / Slot B) Description R / RW 237 / 279 Analog output 1 signal inversion 0: Not Inverted 1: Inverted RW 240 / 280 Analog output minimum offset RW 898 / 924 Analog output mode 0: 0 to 20 mA 1: 0 to 10V RW BX.2.15 AO2 Function 0 269 / 281 Analog output function RW BX.2.
IO3—3 x Relay Dry Contact (2NO + 1NO/NC) Option Card IO3—3 x Relay Dry Contact (2NO + 1NO/NC) Option Card Description Table 14. IO3 Board Rating IO board has 2 form A dry contacts and 1 form C dry relay. The relay functions can be selected via parameters based off of various drive monitoring values.
IO3—3 x Relay Dry Contact (2NO + 1NO/NC) Option Card Figure 17. IO3 Board Wire Layout NO1 7 COM1 6 NO2 5 COM2 4 NO3 3 COM3 2 NC3 1 IO3 Board Table 15. IO3 Board Terminals Terminal Signal Technical 1 NC3-RO3 / common Switching capacity: 24 Vdc / 8A; 250 Vac / 8A; 125 Vdc / 0.4A Min. switching load: 5V / 10 mA 2 COM3 3 NO3-RO3 / normal close 4 COM2 5 NO2-RO2 / normal open 6 COM1 7 NO1-RO1 / normal open Switching capacity: 24 Vdc / 8A; 250 Vac / 8A; 125 Vdc / 0.4A Min.
IO3—3 x Relay Dry Contact (2NO + 1NO/NC) Option Card Table 16. IO3 Parameters Monitor Menu—BX.1 Code Parameter BX.1.1 Relay Outputs Status Min. Max. Default Unit ID (Slot A / Slot B) Description R / RW 900 / 926 Relay output status indicator R ID (Slot A / Slot B) Description R / RW 540 / 552 RO1 Function RW Parameter Menu—BX.2 Code Parameter BX.2.1 RO1 Function Select Min. Max. Default 0 Unit BX.2.2 RO2 Function Select 0 541 / 555 RO2 Function RW BX.2.
IO4—3 x PT100 RTD Thermistor Input Option Card IO4—3 x PT100 RTD Thermistor Input Option Card Description Table 18. IO4 Board Rating IO board has 3 PT100 RTD inputs for motor thermal monitoring. The inputs are designed to sense temperature from –30 °C to +200 °C, warning for PT100 sensor open or short. These sensors are used to fault the drive at a user set temperature level. Item Value Number of inputs 3 Input type PT100 Temperature range –30°C to +200°C Accuracy ≤1.5°C Table 17.
IO4—3 x PT100 RTD Thermistor Input Option Card Figure 20. IO4 Board Wire Layout IO4 Board R1+ 10 RM1 9 R1- 8 R2+ 7 RM2 6 R2- 5 R3+ 4 RM3 3 R3- 2 FE 1 PT100 PT100 Table 19. IO4 Terminal Layout Terminal Signal Technical 1 FE Connect cable shield 2 R3– PT100 Input, –30°C to +200°C, Accuracy <1.5°C 3 RM3 4 R3+ 5 R2– 6 RM2 7 R2+ 8 R1– 9 RM1 10 R1+ PT100 Input, –30°C to +200°C, Accuracy <1.5°C PT100 Input, –30°C to +200°C, Accuracy <1.
IO4—3 x PT100 RTD Thermistor Input Option Card IO4 Board Parameters Figure 21. Parameter Location Table 20. IO4 Parameters Monitor Menu—BX.1 Code Parameter BX.1.1 BX.1.2 Min. Max.
IO5—6 x DI 240 Vac input Option Card IO5—6 x DI 240 Vac input Option Card Description IO board has 6 digital inputs that are rated for 240 Vac. These inputs can be configured to various functions. Table 21.
IO5—6 x DI 240 Vac input Option Card Figure 23. IO5 Board Wire Layout IO5 Board DIN1 8 DIN2 7 DIN3 6 240Vac CMA 5 Common DIN4 4 DIN5 3 DIN6 2 240Vac CMB 1 Common Table 22.
IO5—6 x DI 240 Vac input Option Card Table 23. IO5 Parameters Monitor Menu—BX.1 Code Parameter ID (Slot A / Slot B) Description R / RW BX.1.1 AC Digital Input board 908 / 934 Input signal status R BX.1.2 AC Digital input 4–6 1696 / 1697 Input signal status R Note: X is indicating that it could be in slot A or slot B, which would change the value shown. Input functions are set in the drive application under the digital input selections.
IO5—6 x DI 240 Vac input Option Card 30 PowerXL DG1 Series Option Cards MN040007EN—April 2014 www.eaton.
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