Next generation VFD series boasts many advanced features and is suited to the most demanding and mission critical applications.
Eaton PowerXL DX1 are a series of high performance variable frequency drive (VFD), with a speed accuracy of ≤0.01% of rated speed and wide speed range (1000:1), available in power ratings from 0.75 up to 132 kW (constant torque). Support is provided for voltage/frequency, sensorless and closed-loop vector control, and driving permanent magnet and synchronous reluctance motors.
The PowerXL DX1 series include out-of-the-box support for a wealth of communications protocols which can be used to underpin the delivery of Industry 4.0 applications. The drives feature an onboard IEC/EN 61131-3 PLC, directly integrate numerous safety and security features, can be commissioned via a web browser and have their firmware updated remotely, and are available with a full colour touchscreen for streamlined setup, maintenance and troubleshooting.
The drives feature onboard support for digital and analogue inputs and outputs, along with relays and Modbus RTU/TCP. In addition to which, DX1 capabilities can be extended via an option card which adds fibre communications for multiple drive master-follower configurations, along with cards which add Profinet and Ethernet IP ports, additional analogue/digital IO, and relays.
Next we’ll take a look at the available catalogue options, before exploring the PowerXL DX1 series features, expansion options and typical applications. For comprehensive documentation, please see the Eaton PowerXL DX1 Series VFD Application Manual.
Base Options
The catalogue number system shows the range of options which are available, such as input/output voltage, power and output current rating, filtering and brake chopper, display type and IP rating. Note that EMEA and rest of world models have an additional “E” suffix.
The Application Manual also includes tables grouped by voltage range and IP rating, which make it easy to select the precise model based on these, plus the power rating and display type.
In this article we’ll be taking a closer look at catalogue number DX1-343D3FB-T21CE, a 480V IP21 part with touchscreen and a power rating of 2kW. However, except the power range all features we will covered here are common to all drives in the PowerXL DX1 series.
Features
A label affixed to the body provides details of the power input and output ratings. Here we can see that this drive is for use with a 380-500V 3-phase supply and has an IP21 rating.
The drive is secured in place via four screws or bolts.
In addition to featuring a touchscreen, a particularly neat feature is that this can be remotely mounted and simply connected via Ethernet cabling. The same port can also be used for configuration and firmware update via a USB to RJ45 adapter.
Loosening four screws in the plastic cover enables this to be removed in order to provide access to connectors and to fit option cards.
A steel plate at the bottom of the drive has eight pre-cut holes for cable glands.
Main Connections
The power supply and motor terminals are located beneath a metal plate secured by a further two screws. All DX1 models are fitted with both an internal EMC filter and DC choke.
EMC filtering can also be removed for corner-grounded and IT system installation. Please see the Installation Manual for detailed information on EMC and other installation related matters.
Control Connections
There is an RJ45 Ethernet port and next to this a second RJ45 port for PC serial connection. DX1 drives can be configured to use DHCP or a static IP address, and support SNTP for accurate time synchronisation. The web interface is secured using TLS and AES-128 encryption.
Support is provided for not only Modbus TCP, Ethernet/IP and ProfiNet, but also the MQTT protocol which is rapidly becoming a standard for Internet of Things (IoT) integration and used in many industrial applications. This is available via both its standard TCP port and using MQTT over WebSockets, which can aid use via firewalls and provides yet further possibilities, such as creating dynamic, feature rich browser-based applications which display operational data.
A bank of pluggable coloured terminals along the left side provide access to RS-485 for use with Modbus RTU, analogue and digital IO, relays, and safe torque off (STO) inputs. Each function group has it’s own colour (safety, analogue, digital, relay…)
The Installation Manual provides a selection of typical wiring diagrams and above we can see one for closed loop control, with connections for the mains supply, motor power, motor encoder and emergency stop, for example.
PLC
DX1 drives feature an integrated IEC EN61131 standard compliant PLC which can be programmed in a variety of ways, including functional block diagrams, ladder diagrams and Structured Text. Typical uses include converting between different units, conditional logic for e.g. limit switch monitoring and multi-drive applications, and motor brake control, to name but a few.
Safety
Onboard support is provided for safe torque off (SIL 3, PLe, Cat.4).
With the addition of the Functional Safety (FS) and closed-loop control (S-ABZ) option cards, DX1 drives also gain support for the following IEC-compliant safety functions:
- SS1. Safe Stop.
- SS2. Safe Stop 2.
- SOS. Safe Operational Stop.
- SLA. Safe Limited Acceleration.
- SAR. Safe Acceleration Range.
- SLS. Safe Limited Speed.
- SSR. Safe Speed Range.
- SDI. Safe Direction.
- SBC. Safe Brake Control.
- SSM. Safe Speed Monitor.
Thereby removing the need for an external safety relay or PLC and motor contactors, with the increased space requirements, cabling and complexity that these bring.
Security
Cybersecurity is in increasingly hot topic and particularly in the area of SCADA and Industrial IoT (IIoT). Fortunately, DX1 drives benefit from security to standard IEC/EN 62443-4-2 Level 1.
DX1 series drives implement numerous security features, such as three different user access levels:
- Observer. Can only view monitor parameters.
- Operator. Can perform limited parameter configuration. Access to motor control and run the machine.
- Installer. Can perform parameter configuration, new user creation/deletion, password reset.
Providing a powerful feature for machine builders and installers, which helps to prevent against end user misconfiguration of critical parameters and facilitates good security practices.
Other security features include user inactivity timeout, a motor running lock which prevents motor parameters being changed while in run mode, TLS network security, the ability to disable individual network protocols and set up IP address white lists, and extensive logging which includes four different types of audit log, with the possibility of exporting logs for offline analysis.
The Application Manual includes security hardening guidelines which extend over 11 pages. In addition to which a white paper, Cybersecurity considerations for electrical distribution systems, is available for download and firmware may be updated via multiple mechanisms.
Option Cards
Above can be seen the four option card slots labelled A-D.
At the time of writing the following option cards are available:
- IO1. 3 x DI, 3 x DO, 1 x Thermistor, 24 Vdc/EXT
- IO2. 1 x AI, 2 x AO
- IO3. 3 x Relay dry contact (2NO + 1NO/NC)
- IO4. 3 x PT100 RTD thermistor input
- IO5. 6 x DI 120Vac / 240 Vac input
- ABZ Encoder Card
- SABZ Safety Encoder Card
- Functional Safety Card
- Dual-Port Ethernet/IP Card
- Dual-Port ProfiNet Card
- Fiber Optic Card
Providing a great deal of IO flexibility, directly integrating support for advanced functional safety features, expanding fieldbus connectivity, and enabling sophisticated multi-drive solutions.
With two or more drives in a master-follower configuration these are daisy chained with fibre optic cabling, providing a robust solution with up to 50m between each drive pair.
For further details see the Option Cards User Manual and Fiber Optic Option Card User Manual.
Commissioning and Monitoring
DX1 drives may be configured via local or remote mounted keypad or touchscreen which is connected to the drive RJ45 keypad port. A startup wizard is provided to facilitate initial configuration with a base set of parameters. For further details see the Quick Start Guide.
Configuration may also be carried out via a PC and USB to RJ45 adapter connected to the keypad port, and via Ethernet and RS-485 serial port connection also.
The user-friendly Power Xpert inControl software provides comprehensive configuration support.
inControl additionally provides a number of other powerful features, such as configurable graphing, viewing active and historical faults, and event analysis.
The SD card slot located beneath the display may be used for capturing data logging from the onboard oscilloscope, along with CSV fault logs, and loading firmware updates.
Final Words
The Eaton PowerXL DX1 VFD series is suited to a wide range of demanding industrial applications which require precise speed and torque control, with a high degree of functional safety and prevention against cyber attacks. This includes pumps, fans, rolling mills, printing machines, stamping presses, extruders, winders, cranes, hoists and elevators, and much more.
DX1 VFDs feature support for advanced multi-drive, custom logic and IEC standard functional safety solutions, without the need for external PLCs and safety relays; thereby reducing the time, cost and effort of installation, particularly in IP54 environments.
A full colour touchscreen and web server facilitate streamlined configuration, maintenance and troubleshooting. While fieldbus and IoT protocol support enable the creation of Industry 4.0 solutions. With security to IEC/EN 62443-4-2 Level 1 and features to prevent against both cyber attacks and end user misconfiguration.
— Andrew Back
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