Feature packed variable frequency drives for simple and advanced motor applications.
The Eaton PowerXL DM1 series of variable frequency drives (VFD) — a.k.a. inverter drives — pack a lot of functionality into a small footprint and are available in single-phase and three-phase variants, with power ratings of up to 22kW. In addition to which the DM1 Pro version comes with safe torque off, an LCD keypad and extensive communication protocols as standard.
In this article we will briefly explore the range of options available, before taking a closer look at the features, commissioning, and support for simple and advanced motor applications.
Options
Catalogue number system from the PowerXL DM1 Installation Manual.
The DM1 catalogue number system provides an insight into the range of options which are available. This including not only different supply types, voltage and power ratings, but also optional integrated EMC filtering, communications and LCD panel. However, note that not every combination may be available and all current models feature an internal brake chopper. For further details, please see the PowerXL DM1 documentation.
Note that two power ratings are provided for each model and these are for constant torque (CT) / high overload and variable torque (VT) / low overload. In the case of the three-phase model which we will be looking at here, the ratings are 2.2kW CT and 3kW VT.
As one might expect the physical size increases with power rating and the PowerXL DM1 series are packaged in four different frame sizes, denoted FR1 through FR4.
Next, we’ll be taking a closer look at model DM1-345D6EB-S20S-EM (283-0971) and features which are common to all PowerXL DM1 Pro versions with EMC filtering.
Features
A label on the side of the VFD provides details of the power rating, input and output. The ingress protection (IP20) is also noted here and the document reference for the installation manual.
The drive can be secured to a mounting plate via either two M5-20 screws or DIN rail.
Main Connections
On the underside, there are three terminals for the supply voltage and three for connecting the load, plus two in the centre for connecting a brake resistor. With ventilation beneath these terminals.
Included in the box are a pair of ferrite cores in support of EMC Class 2 and Class 3 installations, which require the cores to be fitted to the input and output cabling.
Just above the supply and load terminals are grounding positions which are accessed by removing the top plastic cover.
Installation in corner-ground network and IT systems is also possible and requires the drive to be configured for EMC Class 4 by removing the EMC/MOV screws.
Warning: please see the installation manual for comprehensive installation and safety information!
Control Connections
Above the grounding positions, there are connectors for Ethernet and a remote keypad or PC. DM1 Pro models include out-of-the-box support for TCP/IP networking, may be configured to use DHCP or a static IP address, and support SNTP for accurate network time synchronisation.
Modbus TCP, EtherNet/IP (industrial protocol) and BACnet IP protocols are all supported, along with a web user interface. For added security a trusted IP filter may be enabled and the addresses of authorised systems added to a white list.
Where the VFD is installed inside an cabinet or some difficult to reach location and local access would prove beneficial, a remote LCD keypad (122-4338) may be connected.
The same RJ45 port can also be used with a USB to RJ45/RS-485 cable (192-8828) for configuring and monitoring the VFD via PC software.
Just to the right of the Ethernet and keypad connectors are two rows of terminals numbered 1-14, which provide connections for:
- RS-485 (Modbus RTU or BACnet MS/TP)
- Digital inputs
- Analogue input
- Analogue output
- +10v and +24v power
The four digital inputs are programmable, for use with positive or negative logic and 18 to 30Vdc.
The analogue input can be configured for 0-10Vdc or 4-20mA current loop and has a 10-bit resolution. Similarly, the analogue output can be set to 0-10Vdc or 4-20mA.
Above these terminals is a row of five screwless terminals that are connected to one form C and one N/O form A relay, which are rated at up to 3.0A at 240Vac for resistive loads and 0.5A inductive.
A handy legend is provided on the inside of the plastic cover.
STO Function
A yellow block of three terminals is positioned directly above the keypad connector and these are for two safety torque off (STO) inputs plus a common connection.
Safety architecture functional block diagram.
The terminals are bridged by default, but the bridge can be removed to allow connection to an emergency stop switch. Then when either or both of the STO1 and STO2 switches are opened the motor will shut down.
Commissioning
Configuration may be carried out via the keypad and a start-up wizard is provided to help you quickly get up and running, setting key parameters such as the minimum and maximum frequency and motor nominal current.
Main keypad navigation menu.
The comprehensive documentation also lists the many available configuration parameters and their menu locations.
However, a much more convenient method of configuration is provided courtesy of Eaton PowerXpert inControl, which can be installed on a PC and connected to the PowerXL DM1 via:
- RS-485 (Modbus RTU mode)
- USB (192-8828)
- Ethernet (Modbus TCP)
- Bluetooth
The software provides a wealth of features and may be used in offline mode with the ability to compare parameter files, perform parameter distribution and import/export parameter files. And also in online mode whereby changes can be made in real-time and with the ability to monitor device parameters, trend data and fault conditions, and control the device.
Applications
Multi-pump control curve.
The flexible PowerXL DM1 series is suited to diverse array of motor control applications and Eaton provide a manual which details the following applications:
- Standard
- Fan control
- Pump control
- Multi-purpose
The fan application builds on features in standard and provides those specific for HVAC applications and fan-related protective features. Such as damper control, fire mode, smoke purge and broken belt protection.
The pump control application also builds on standard and provides features specific for pumping applications and pump related protective features. Functions include pump derag mode, valve control, backspin control, minimum run time and broken pipe detection, amongst others.
Finally, the multi-purpose application is designed for a large set of applications and with the ability to have advanced motor control systems. It takes the same functions provided in the standard, fan, and multi-pump applications and adds in some additional control techniques. Functions include motor potentiometer reference control, external rake control and motor identification.
Multi-purpose application default I/O connection.
Detailed parameter lists, control curves and I/O connections etc. are provided with the applications.
Security
Security can be paramount for many SCADA and Industrial IoT (IIoT) applications and the PowerXL DM1 Communication Manual provides a section on security hardening, which includes measure such as ensuring that default credentials are not used in production, parameters are locked and physical access is restricted as appropriate. In addition to which a white paper, Cybersecurity considerations for electrical distribution systems, is available and firmware updates may be downloaded via the PowerXL DM1 product page.
Final Words
The flexible Eaton PowerXL DM1 series of VFDs and in particular the Pro versions pack a lot of features into a convenient package, with the ability to integrate with control and monitoring systems via a selection of communications protocols. Extensive documentation is available which covers not only installation, but providing detailed configuration for communications options and applications. Supported also by a start-up wizard for rapid configuration and feature-rich PC software for advanced configuration ease and diagnostics.
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