Eaton VFD Drives PowerXL DG1 general purpose series

Eaton frequency inverter PowerXL DG1 series - sturdy on the outside, efficient on the inside.

The latest addition to the PowerXL family is the DG1 series of general purpose drives, which are characterized by their sturdy design and ease of use. Specially designed for use in pumps, fans and belt conveyors, and in machine building applications more generally, the DG1 drives complete Eaton’s product offering in this area. As a result, our customers can always count on us to provide the right product, for both simple and complex applications for serial production in machine building and beyond.

Superior technology.
The drive technology used in pumps, fans, conveyor belts or compressors is of crucial importance, both for the machine building sector and for the material handling and building services industries. In this regard, ease of use and energy efficiency are important considerations. That is why we have developed the PowerXL DG1 drives specifically for this type of application, while also equipping them with a sturdy design, high availability and versatile functionality.
Sturdy design.
The drives offer enhanced heat resistance and are able to deliver full performance at ambient temperatures of up to 50 °C (IP21 and IP54). Moreover, their 100 kA short-circuit-proof output is best in class on the market, while the especially durable fans and the flexibly adjustable fan controller contribute to increased reliability. The sturdy design of the drives is also evident in their degree of protection: The DG1 models with an output range of up to 160 kW are available with IP20 degree of protection, alongside IP21 and IP54. The devices with a performance range between 200 kW and 630 kW are available with IP00 degree of protection, and are therefore suitable for installation in control cabinets, for example.
A technology that makes your work easier.
Thanks to the self-explanatory type codes, auto-tune functions and the convenient parameter configuration (with only 18 basic parameters), commissioning the PowerXL drives is quick and easy, which keeps the costs associated with planning, installation and technical support to a minimum. The drives can be programmed via the keypad and the multi-language LCD display, or via a PC. In addition, the operating panel can also be used to quickly copy the parameter configurations to other devices.

Push-through mounting Effectively prevents heat loss inside the control panel.
The push-through mounting frame makes it possible to place the power section behind the mounting plate. Mounting frames are available for all frame sizes and degrees of protection. In addition, the push-through technology (IP54) makes it possible to conduct the heat loss away from the drives by means of a separate cooling air duct, or out of the control cabinet, as required. This not only saves space, but also eliminates the costs associated with any separate cooling equipment.
Sturdy in hostile environments: IP54 degree of protection, enhanced PCB protection.
The DG1 drives offer enhanced PCB protection, enabling them to withstand high humidity as well as corrosive ambient air. And thanks to their high degree of protection (IP54) they can be used even in places where no control panels are available.

Parameter configuration made simple.
The drive parameters can be quickly and easily configured using the integrated LCD display. In fact, only 18 basic parameters have to be configured, including the motor’s rated specifications, such as the voltage, current, and frequency, as well as the basic application settings, and the drive is ready to go. In addition, the language of the user interface can also be adjusted, thereby eliminating the need for time-consuming searches in the manual. Once the parameters have been set, the application is up and running right away.

Eaton drive PowerXL DG1 series – a multi-purpose drive for demanding applications.

The DG1 drives are the perfect match for demanding, speed- and torquedependent applications. They stand out for their high performance range (up to 630 kW), compact dimensions and high level of functionality. To help you adapt the drives to your application, they have been equipped with a dual rating: 150 percent overload for machine applications, and 110 percent for pumps and fans. If an application only requires an overload of 110 percent, a DG1 originally sized for an overcurrent of 150 percent can also be used to drive a motor with the next higher rating.
Prepared for all eventualities.
Users can choose between four standard applications with tailor-made configurations. This makes it possible to optimally configure the drive in line with the requirements at hand; parameters and functions that are not required can simply be hidden.
Ready straight out of the box.
The initial commissioning process will start automatically the moment the drive is switched on for the first time. During this process, you will be asked for basic information about the application, such as the ramp times, motor specifications, the application type, the menu language, and the local time. The queried data are the same as for any other PowerXL variable frequency drive.
Extensive features.
The DG1 series is suitable for virtually any application; it supports the Modbus RTU, Modbus TCP, EtherNet/IP and BACnet MS/TP protocols as standard and features an integrated EMC filter (C2 for public mains), a braking transistor, and a high output range up to 630 kW. The following standard applications are already pre-programmed:
- standard 
- multi-pump
- multi-PID
- multi-purpose.
The drives can be operated either with sensorless vector control (SVC) or with V/f control. Depending on the drive type being used, both operating modes will support rated overload operation at 150 percent or 110 percent.

Real-time clock, timer and calendar functions.
The DG1 drives feature an integrated real-time clock. This clock is backed by a battery and will add an accurate timestamp to any fault message. It can also perform time-controlled actions via additional timer and calendar functions without the need for a higher-level controller or manual intervention by a technician.
Powerful performance even at extreme overloads.
The overload range is one of the unique strengths of the DG1 drives. With sensorless vector control (SLV), the torque can be briefly increased to up to 200 percent, which makes the DG1 the ideal choice for applications with extreme overload requirements.
Ready to connect thanks to the EMC filter.
All DG1 drives feature an integrated category C2 EMC filter for public mains connection, in accordance with IEC/EN 61800-3. This eliminates the need for external components with additional wiring, thereby saving additional space inside the control panel.
No derating up to 50 °C.
All DG1 drives with IP21 or IP54 degree of protection can be operated at ambient temperatures of up to 50 °C without derating (i.e. they can run at their full rated current). If the temperature is not expected to exceed this level, machine and system manufacturers can thus achieve significant cost savings: there is no need for additional ventilation systems, and the option of side-by-side mounting makes it possible to take full advantage of the space inside the control panel. This in turn facilitates further savings by reducing the overall size of the control panel.

Eaton vfd PowerXL DG1 series power management.

Energy saving functionality.
The energy management feature minimizes energy losses by using a patented method for dynamic V/f curve adjustment to optimize efficiency. Compared to other out-of-the-box solutions, this makes it possible to realize cost savings of between 2 percent and 10 percent.

Energy cost calculator.
The integrated energy cost calculator provides a direct comparison to conventional contactor control systems. Once the local utility company‘s energy prices are entered into the system, the calculator will immediately display the amount of money that has been saved by using the DG1 on a daily, weekly, monthly and annual basis. As a result, you will be able to keep your operating costs (OPEX) under control at all times.

Fans and pumps.

Multi-pump drives.
Various modes are available for controlling and regulating multi-pump systems in water/wastewater applications. The DG1 drives use the integrated PID controllers to set up fill level or pressure controls, thereby eliminating the need for any external controllers. In this context, the DG1 drives can control one or more master drives or backup drives, as necessary, while the real-time clock makes it possible to use an alternating pump control scheme for all pumps. This versatility not only reduces the equipment costs, but also maximizes system availability and efficiency.
Cold weather mode.
The DG1 drives are also suitable for use in extreme environmental conditions. In addition to their heat resistance up to 50 °C, they also come with a dedicated cold weather mode that allows them to operate at temperatures as low as -30 °C without any external heating systems. In short, the DG1 drives are the perfect choice for outdoor applications at extremely low temperatures.
Scheduled cleaning function.
The integrated cleaning function has been specially developed for use in pump applications. It automatically removes dirt and any other particles from inside the pump, to prevent these from obstructing the pump’s normal operation. The cleaning function can also be activated automatically at certain intervals via the integrated real-time clock, thereby reducing manual maintenance and increasing system availability.
Fire mode.
For fire protection purposes in buildings or in sensitive environments such as tunnels, the DG1 drives can be operated in the so-called fire mode. When this mode is enabled, the internal protective functions that would normally cause the device to shut down will be disabled to ensure the continued operation of fire pumps and smoke ventilation systems. In addition, the fire mode comes with comprehensive configuration options, including fixed setpoints, switchable setpoint inputs, and fail-safe activation.
Manual/automatic operation.
Operators can switch between manual and automatic modes by means of co ntrol commands or with the keypad, thus enabling them to intervene in the control system at any time.

Eaton frequency inverter PowerXL DG1 series motor and system protection.

Flying start.
The integrated motor pick-up control function enables the drive to “catch” a spinning motor that was activated by a load before the drive itself was up and running. This so-called flying start catches the motor at its current speed and then guides it to the setpoint, thereby also reducing downtime.
Skipping of frequencies.
In order to avoid mechanical resonance during operation, it is possible to define up to three frequency bands in which continuous operation is not permitted. This protects the mechanics and also keeps maintenance to a minimum.
Motor identification run.
Modern sensorless vector control requires a greater amount of information than that generally provided on the rating plate. This is why DG1 drives have been equipped with an identification run function that makes it possible to gather the missing information from the rating plate, conveniently and without damaging the system.
Electronic motor overload protection.
The motor protection function thermally monitor the motors in order to protect it against overloads. By changing only one parameter, this protection can be extended from CLASS 5 to higher trip classes such as CLASS 40. As a result, no external motor protection relays are necessary. In addition, it is also possible to limit the motor current and to initiate further actions including a shutdown, if necessary should any pre-defined thresholds be exceeded.
Stall protection.
In the event of overload, the motor will stall, resulting in a dramatic drop in speed that may cause a complete standstill. The DG1 drives are designed to detect when an overload is imminent, and will initiate automatic countermeasures in order to keep the motor and the application at large safely under control.
Password protection.
If one of the more than 700 adjustable parameters was changed by accident, it can be tedious to identify the culprit without the aid of a PC. To prevent this, the drive parameters can be protected against accidental and unauthorized access by means of a password. More specifically, operators will still be able to see the settings, but they will not be able to change them without the password, thereby maximizing the operational reliability of the drives.

Brake chopper.
Should it become necessary to decelerate a higher inertia, or if the load supplies too much regenerative energy, the drive speed can be adjusted and returned to the setpoint by means of a braking chopper and an external braking resistor. The guidelines for certain applications require the motor to be stopped for specific, usually very brief periods, in which case a braking chopper is the ideal solution. Frame sizes 1 to 3 come with a braking chopper as standard, while it is optionally available for the larger frame sizes.
Flux brake.
One alternative to brake choppers is the use of a flux brake. This brakes the motor electrically by means of its own magnetic field, so that the braking force will also be conducted through the motor.