Eaton PowerXL DG1 User manual

Installation Manual
PowerXL DG1 and SVX Enclosed Drives Instructions

DISCLAIMER OF WARRANTIES AND LIMITATION OF LIABILITY
The product discussed in this literature is subject to terms and conditions outlined in Eaton Electrical Inc. selling policies.
The sole source governing the rights and remedies of any purchaser of this equipment is the relevant Eaton Electrical Inc.
selling policy.
NO WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WARRANTIES OF FITNESS FOR APARTICULAR PURPOSE
OR MERCHANTABILITY, OR WARRANTIES ARISING FROM COURSEOF DEALING OR USAGE OF TRADE, ARE MADE
REGARDING THE INFORMATION, RECOMMENDATIONS AND DESCRIPTIONS CONTAINED HEREIN.
In no event will Eaton Electrical Inc. be responsible to the purchaser or user in contract, in tort (including negligence), strict
liability or otherwise for any special, indirect, incidental or consequential damage or loss whatsoever, including but not
limited to damage or loss of use of equipment, plant or power system, cost of capital, loss of power, additional expenses
in the use of existing power facilities, or claims against the purchaser or user by its customers resulting from the use of
the information, recommendations and descriptions contained herein. The information contained in this manual is subject to
change without notice.

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PowerXL DG1 and SVX Enclosed Drives Instructions
POWERXL DG1 AND SVX ENCLOSED DRIVES INSTRUCTIONS IL040060EN April 2020 www.eaton.com
1. SAFETY ............................................................................ 05
2. GENERAL DESIGN ................................................................... 05
3. DOCUMENTATION ................................................................... 06
4. IDENTIFICATION ..................................................................... 06
4.1 UNIT Identification LABELS ...................................................................06
4.2 CAT NUMBER NOMENCLATURE ..............................................................07
5. ELECTRICAL RATINGS ................................................................ 09
5.1 Input voltage (VIN) ..........................................................................09
5.2 Output voltage (VOUT) .......................................................................09
5.3 Output AMPS ..............................................................................09
5.4 Output frequency ...........................................................................09
5.5 Short circuit interrupting rating.................................................................09
6. ENVIRONMENTAL RATINGS ........................................................... 09
7. PRODUCT FAMILY/DESIGN TYPE ....................................................... 09
7.1 EGS and SVX standard design .................................................................09
7.2 EGF and CFX filtered design ..................................................................09
7.3 EGP and CPX clean power design ..............................................................09
8. STD OPTIONS ........................................................................10
9. ENCLOSURES ........................................................................11
9.1 Enclosure Options ..........................................................................11
9.2 Enclosure Outline Dim and Mounting Details .....................................................11
10. INSTALLATION & MOUNTING NOTES ....................................................11
11. COMPONENT LOCATIONS..............................................................11
12. WIRING .............................................................................11
12.1 Important Wiring Notes ......................................................................11
12.2 Conduit Plates .............................................................................11
12.3 Input Power Wiring..........................................................................11
12.4 Motor Wiring ..............................................................................11
12.5 Grounding.................................................................................11
12.6 Control Wiring .............................................................................11
13. WIRING TECHNICAL INFORMATION ..................................................... 12
13.1 Input Wiring ...............................................................................12
13.2 Output Wiring..............................................................................12

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PowerXL DG1 and SVX Enclosed Drives Instructions
POWERXL DG1 AND SVX ENCLOSED DRIVES INSTRUCTIONS IL040060EN April 2020 www.eaton.com
WARNING
This symbol indicates high voltage. It calls your
attention to items or operations that could be
dangerous to you and other persons operating
this equipment. Read the message and follow the
instructions carefully.
WARNING
Indicates a potentially hazardous situation which, if not
avoided, can result in serious injury or death.
CAUTION
Indicates a potentially hazardous situation which, if not
avoided, can result in minor to moderate injury, or serious
damage to the product. The situation described in the
CAUTION may, if not avoided, lead to serious results.
Important safety measures are described in CAUTION
(as well as WARNING).
IMPORTANT
This symbol is the “Safety Alert Symbol.” It occurs with
either of two signal words: CAUTION or WARNING, as
described below.
NOTE
When the internal EMC filter is disconnected, the drive
might be not EMC compatible.
• Do not attempt to install or remove the MOV or EMC
screws while power is applied to the drive’s input
terminals
WARNING
Motor control equipment and electronic controllers are
connected to hazardous line voltages. When servicing
drives and electronic controllers, there may be exposed
components with housings or protrusions at or above
line potential. Extreme care should be taken to protect
against shock.
• Stand on an insulating pad and make it a habit to use
only one hand when checking components
• Always work with another person in case an
emergency occurs
• Disconnect power before checking controllers or
performing maintenance
• Be sure equipment is properly earthed
• Wear safety glasses whenever working on electronic
controllers or rotating machinery
WARNING
The components in the drive’s power section remain
energized after the supply voltage has been switched
off. After disconnecting the supply, wait at least five
minutes before removing the cover to allow the
intermediate circuit capacitors to discharge.
Pay attention to hazard warnings!
WARNING
Do not perform any modifications on the AC drive when
it is connected to mains.
CAUTION
Any electrical or mechanical modification to this drive
without prior written consent of manufacturer will void all
warranties and may result in a safety hazard in addition and
voiding of the UL®listing.
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.

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PowerXL DG1 and SVX Enclosed Drives Instructions
POWERXL DG1 AND SVX ENCLOSED DRIVES INSTRUCTIONS IL040060EN April 2020 www.eaton.com
1. SAFETY
Read and follow all safety information shown in the
Installation Manual included in the documentation packet
provided with each unit.
WARNING
Disconnect Incoming power before servicing this control
or motor.
Operation of this equipment requires detailed installation
and operation instructions. This information is included in
the documentation packet supplied with the unit. It should
be retained with this device at all times. A hard copy of this
information may be ordered at www.Eaton.com/us/en-us.
CAUTION
“Risk of Electric Shock” Wait 10 minutes before servicing to
allow to BUS Capacitors to discharge.
WARNING
The opening of the branch-circuit protective device
may be an indication that a fault current has been
interrupted. To reduce the risk of fire or electric shock,
current-carrying parts and other components of the
controller should be examined and replaced if damaged.
For bypass designs, if a burnout of the current element
of the overload relay occurs, the complete overload
relay must be replaced.
WARNING
Hazardous Voltage
Can cause severe
injury or death.
Disconnect
incoming power
before servicing
control or motor.
1202-227A
DANGER
HIG H
VOLT A G E
ALLO W 10 MINUT E S F O R
BUSCAPA C I TORS T O
DISCHARGEB EFORE
S E R V ICING UNIT.
2. GENERAL DESIGN
There are 6 product families: EGS, EGF, EGP, SVX, CFX,
and CPX. The EGS (PowerXL DG1 drive) and SVX product
families denote the standard design offering. The EGF
(PowerXL DG1 drive) and CFX product families include
a Passive Filter which delivers 5% - 7% Total Harmonic
Distortion (THD). The EGP and CPX includes an 18-Pulse
transformer for 3% - 5% Total Harmonic Distortion.
All products are enclosed variable frequency drives (VFDs)
that convert either single-phase or three-phase AC input
power into three-phase output power for controlling motors.
Some configurations incorporate bypass circuits.
• All models are enclosed in either a wall mounted or a
floor standing metal enclosure.
• All models contain options for a short circuit protective
device, fuses, surge protection device, thermal-magnetic
circuit breaker, fusible disconnect, motor circuit protector,
an associated disconnect handle/operator, 3% input and
output reactors, and dV/dt filter.
• Eaton’s PowerXL DG1 Enclosed Drive family incorporates
the latest Eaton drive technology into pre-engineered
enclosed solutions covering the industry’s most common
applications. Using the benefits of the PowerXL DG1,
the enclosed family provides enhanced user safety with
the Safe Torque Off feature as well as industry leading
energy efficiency from Eaton’s patented Active Energy
Control algorithm.
• Eaton’s line of enclosed SVX drives combine the proven
performance from Eaton’s SVX drives with the enhanced
capabilities of enclosed control. With a comprehensive
list of pre-engineered options, Eaton’s SVX enclosed
drives eliminate the lead time normally associated
with customer specific options. For those applications
with more unique or complex requirements, Eaton
offers individually engineered solutions to meet
the customer’s needs.

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PowerXL DG1 and SVX Enclosed Drives Instructions
POWERXL DG1 AND SVX ENCLOSED DRIVES INSTRUCTIONS IL040060EN April 2020 www.eaton.com
3. DOCUMENTATION
This document provides supplemental information to the
open or component VFD manuals. Inside the enclosure or
inside the shipping carton of each unit is a documentation
packet that includes the electrical schematic, connection
diagram, installation manual and other component
publications and warranty information for the unit.
For custom drive setup and/or operation, please refer to
the following documents, available at
http://www.eaton.com/drives.
PowerXL DG1 drive:
SVX9000 General Purpose drive:
Installation Manual MN040002EN
Quick Start Guide MN040012EN
Instruction Leaflet IL040016EN
Application Manual MN040004EN
Option Cards Manual MN040007EN
Communication Manual MN0400010EN
User Manual MN04001004E, MN04001001E,
MN04003016E
Quick Start Guide MN04003009E
Application Manual MN04004001E and SVCH0203
Option Board Manual MN04003001E
Communication Manual
MN04012010E, MN04003008E,
MN04003003E, MN04012006E,
MN04012005E, MN04003006E,
MN04002005E, MN032005EN
4. IDENTIFICATION
4.1 UNIT Identification LABELS
The unit is identified by a catalog number shown on a
Rating label located inside the door
Figure 1. Rating Label
Limited information is available under the Keypad
Cat No: 4D68A008A032430
Input: 208VAC 3PH 50/60Hz 24.2A
Output: 0-208VAC 3PH 0-320Hz 46.2A
Max H.P. 273A, 100hp
Order No: G.O. Number Here
Catalog number
Rating
Figure 2. Information Label under Keypad
Alternate Rating label may be used

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PowerXL DG1 and SVX Enclosed Drives Instructions
POWERXL DG1 AND SVX ENCLOSED DRIVES INSTRUCTIONS IL040060EN April 2020 www.eaton.com
4.2 CATALOG NUMBER NOMENCLATURE
Each Catalog number consists of 18 digits, each digit or combination of digits in the catalog number indicates a rating,
feature or option. The catalog is located in PDF format on the website at www.eaton.com/drives
Notes
1Brake chopperis a factory-installedoptiononly. Braking resistors soldseparately. See DG1 drives startingon Page V6-T2-59 for selection.
2Additional enclosure options including NEMA 4, 4X, 7 and 9 are available. Please contact the factory forconguration and pricing.
3Part number conguration continued on the following page.
EGS 3D5 1 D 1
Product Family
EGS = Enclosed DG1 drives - standard
Output Ampere Rating
208 V 230 V 480 V
3D5= 3.5 A, 0.75hp
4D6= 4.6 A, 1 hp
6D6= 6.6 A, 1.5 hp
7D5= 7.5 A, 2 hp
010 = 10.6 A, 3 hp
016 = 16.7 A, 5 hp
024 = 24.2 A, 7.5 hp
030 = 30.8 A, 10 hp
046 = 46.2 A, 15 hp
059 = 59.4 A, 20 hp
074 = 74.8 A, 25 hp
088 = 88 A, 30 hp
114 = 114 A, 40 hp
143 = 143 A, 50 hp
169 = 169 A, 60 hp
211 = 211 A, 75 hp
273 = 273 A, 100 hp
3D2= 3.2 A, 0.75 hp
4D2= 4.2 A, 1 hp
6D0= 6.0 A, 1.5 hp
6D8= 6.8 A, 2 hp
9D6= 9.6 A, 3 hp
015 = 15.2, 5 hp
022 = 22 A, 7.5 hp
028 = 28 A, 10 hp
042 = 42 A, 15 hp
054 = 54 A, 20 hp
068 = 68 A, 25 hp
080 = 80 A, 30 hp
104 = 104 A, 40 hp
130 = 130 A, 50 hp
154 = 154 A, 60 hp
192 = 192 A, 75 hp
248 = 248 A, 100 hp
312 = 312 A, 125 hp
2D1= 2.1 A, 1 hp
3D0= 3.0 A, 1.5 hp
3D4= 3.4 A, 2 hp
4D8= 4.8 A, 3 hp
7D6= 7.6 A, 5 hp
011 = 11 A, 7.5 hp
014 = 14 A, 10 hp
021 = 21 A, 15 hp
027 = 27 A, 20 hp
034 = 34 A, 25 hp
040 = 40 A, 30 hp
052 = 52 A, 40 hp
065 = 65 A, 50 hp
077 = 77 A, 60 hp
096 = 96 A, 75 hp
124 = 124 A, 100 hp
156 = 156 A, 125 hp
180 = 180 A, 150 hp
240 = 240 A, 200 hp
302 = 302 A, 250 hp
Phasing, Voltage
1= Input: Three-phase, 208 V
Output: Three-phase
2= Input: Three-phase, 230 V
Output: Three-phase
4= Input: Three-phase, 480 V
Output: Three-phase
5= Input: Three-phase, 575 V
Output: Three-phase
J= Input: Single-phase, 230 V
Output: Three-phase
K= Input: Single-phase, 480 V
Output: Three-phase
Braking Application
1
A= No brake chopper, low overload
B= Brake chopper, low overload
C= No brake chopper, high overload
D= Brake chopper, high overload
Enclosure Rating
2
1= NEMA Type 1
2= NEMA Type 12
3= NEMA Type 3R
6= NEMA Type 1 Filtered and gasketed
•= Custom option
______
Options3
See Page V6-T2-76 for catalog number
option selection.

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PowerXL DG1 and SVX Enclosed Drives Instructions
POWERXL DG1 AND SVX ENCLOSED DRIVES INSTRUCTIONS IL040060EN April 2020 www.eaton.com
EGS 3D5 1 D 1 2 0 0 B 1 0 0 0 0
Power Disconnect Options
0= None
1= MCP disconnect1
2= Circuit breaker
3= Circuit breaker/isolation fusing
4= Circuit breaker/isolation fusing/3% input reactor
5= Circuit breaker/isolation fusing/SPD
6= Circuit breaker/isolation fusing/SPD/3% input reactor
7= Circuit breaker/3% input reactor
8= Circuit breaker/SPD
9= Circuit breaker/SPD/3% input reactor
A= Fused disconnect
B= Fused disconnect/SPD
C= Fused disconnect/SPD/3% input reactor
D= Fused disconnect/3% input reactor
E= Isolation fuses
F= Isolation fuses/3% input reactor
G= Isolation fuses/SPD
H= Isolation fuses/SPD/3% input reactor
• = Custom option2
Base Catalog Number Example
See PageV6-T2-75 for base catalog
number selection.
Bypass Options3
0= None
1= Manual HOA bypass
2= Manual HOAbypass/isolation fusing
3= Manual HOAbypass/isolation fusing/3% input reactor
4= Manual HOAbypass/isolation fusing/SPD
5= Manual HOA bypass/isolation fusing/SPD/3% input reactor
6= Manual HOA bypass/3% input reactor
7= Manual HOAbypass/SPD
8= Manual HOA bypass/SPD/3% input reactor
H= Manual HOA RVSS bypass
J= Manual HOARVSS bypass/isolation fusing
K= Manual HOA RVSS bypass/isolation fusing/3% input reactor
L= Manual HOA RVSS bypass/isolation fusing/SPD
M= Manual HOA RVSS bypass/isolation fusing/SPD/3% input reactor
N= Manual HOA RVSS bypass/3% input reactor
P= Manual HOARVSS bypass/SPD
R= Manual HOA RVSS bypass/SPD/3% input reactor
• = Custom option2
Output Power Options4
0= None
A= Output contactor
B= 3% Output reactor
D= dV/dt lter
E= 3% Output Reactor/output contactor
G= dV/dt/output contactor
• = Custom option2
Option Boards 2
Same options and codes as Option Boards 1
Option Boards 1
0= No option
1= 3 x DI, 3 x DO, 1 Thermistor, 24 Vdc/EXT
2= 1 x AI, 2 x AO (isolated to control board)
3= 3 x relay dry contact (2NO + 1NO/NC)
4= 3 x PT100 RTD thermistor input
5= 6 DI 240 Vac input
• = Custom option2
Communication Options
0= No option
1= PROFIBUS-DP
3= CANopen (slave)
4= DeviceNet
5= PROFIBUS-DP (D9 connector)
D= SmartWire-DT
• = Custom option2
Enclosure Options
0= None
1= Floor stand—12 inches
2= Floor stand—22 inches
A= Space heater
B= Space heater & 12-inch oor stands
C= Space heater & 22-inch oor stands
• = Custom option2
Light Options5
0=None
1=Non-bypass light kit—Power On, Run, Fault
2=Bypass light kit—On, VFD Run, Fault, Bypass Run
• = Custom option2
Control Options5
0=None
1=Speed pot
2= Start-stop pushbutton
3= Start-stop pushbutton with speed pot
A= HOA switch
B= Start-stop pushbutton with speed pot & HOA switch
C= Start-stop pushbutton with HOA switch
D= HOA switch with speed pot
• = Custom option2
Notes
1HMCP disconnect option required and only available whenbypass is selected.
2More options are available as Engineered to Order through the Bid Manager tool.
3All bypass options include third contactor for drive isolation when in bypass mode.
4Output contactor not available with bypass. Bypass comes standard with output contactor.
5Pilot devices are 22 mm standard. 30 mm options are available as engineered to order through the Bid Manager tool.

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PowerXL DG1 and SVX Enclosed Drives Instructions
POWERXL DG1 AND SVX ENCLOSED DRIVES INSTRUCTIONS IL040060EN April 2020 www.eaton.com
5. ELECTRICAL RATINGS
5.1 Input voltage (VIN)
Available Ratings are: 208V, 230V, 480V, Three Phase
50/60Hz and 230V, 480V Single Phase 50/60Hz. Note: Not
all designs are available for all voltages.
5.2 Output voltage (VOUT)
Output range from 0 to input voltage (Vin) rating.
5.3 Output AMPS
Maximum output ranges from 1.6A to 1100A based on
Model and Input voltage ratings.
5.4 Output frequency
Output frequency ranges from 0Hz to 320 Hz.
5.5 Short circuit interrupting rating
Please refer to the unit nameplate for SCCR ratings, which
are based on the components used.
Additional branch circuit protection must be provided in
accordance with the National Electrical Code, any other local
codes, or equivalent.
6. ENVIRONMENTAL RATINGS
Enclosure Ratings: Type 1, 12, 3R, and Type 1 Filtered and
Gasketed.
Max Ambient Operating Temperature: 40C. 50C may be
available for some models.
Storage Temperature: -40 to 70C.
7. PRODUCT FAMILY/DESIGN TYPE
The designs are defined in the catalog number
nomenclature.
EGS = Standard Design using Eaton DG1/DH1 VFD
EGF = Passive Filtered Design using Eaton DG1/DH1 VFD
EGP = Clean Power (18-Pulse) Design using Eaton DG1/
DH1 VFD
SVX = Standard Design using Eaton SVX/SPX VFD
CFX = Passive Filtered Design using Eaton SVX/SPX VFD
CPX = Clean Power (18-Pulse) Design using Eaton
SVX/SPX VFD
ote:N Not all designs are available for all voltages.
7.1 EGS and SVX standard design
Standard designs are defined as any design that uses either
an EATON DG1 VFD (EGS) or and EATON SVX VFD (SVX).
Standard designs can be either non-bypass, or bypass
designs.
7.2 EGF and CFX filtered design
Design that uses either an EATON DG1 VFD (EGF) or and
EATON SVX VFD (CFX) and a passive filter for 5% - 7% Total
Harmonic Distortion. Designs can be either non-bypass or
bypass designs.
7.3 EGP and CPX clean power design
Design that uses either an EATON DG1 VFD (EGP) or and
EATON SVX VFD (CPX) and an 18-Pulse transformer for
3% - 5% Total Harmonic Distortion. Designs can be either
non-bypass or bypass designs.

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PowerXL DG1 and SVX Enclosed Drives Instructions
POWERXL DG1 AND SVX ENCLOSED DRIVES INSTRUCTIONS IL040060EN April 2020 www.eaton.com
8. STD OPTIONS
Std Options are defined by the catalog number
nomenclature.
Bypass Option - Contains a reduced voltage soft starter
(RVSS) bypass or a standard across the line (ATL) bypass.
This option also provides a door mounted 3 position selector
switch used to select the VFD, OFF or BYPASS operating
mode.
SPD - This is a device designed to protect electrical devices
from voltage spikes.
VFD Fuses - This option consists of three fuses, which
are factory mounted in the enclosure. Fuses provide fault
protection of the VFD input power. Fast acting fuse Class J
or Class T will be used to protect the VFD. The fuses are not
used in the bypass mode.
Input Reactors - This device protects the drive from
potentially harmful voltage spikes and reduces harmonic
distortion.
Circuit Breaker Fused Disconnect - Provides a means of
disconnecting the product from the line and the operating
mechanism can be padlocked in the OFF.
Output Contactor - This option provides a positive
disconnection of the VFD output from the motor terminals.
Output Reactors - This option provides a 3% reactor
located on the load side of the VFD to provide harmonic
noise mitigation to reduce the transient voltage (DV/DT) at
the motor terminals.
DVDT Filter - This option located on the load side of the
VFD, provides harmonic noise mitigation to reduce the
transient voltage (DV/DT) at the motor terminals.
Floor Stand - This option converts a size AX, BX or CX
enclosure that is normally wall mounted enclosure to a floor
standing enclosure.
Heater - This option is in a Type 3R enclosure. This includes
an optional condensation protection with the use of a
space heater. The heater is powered via an internal 120VAC
source, but has the capability feature to use external power
by removing jumpers. The option contains a panel mounted
thermostat that can be adjusted by the customer.
Speed Pot - This option provides the ability to adjust the
frequency reference using a door-mounted potentiometer.
This option uses the 10 Vdc reference from the VFD to
generate a 0–10V signal at the analog voltage input signal
terminal of the VFD.
Stop/Start Push Buttons - This option provides door
mounted START and STOP pushbuttons.
HOA Switch - This option provides a three-position selector
switch that allows the user to select either a HAND or
AUTO mode of operation. HAND mode is defaulted to
keypad operation, and AUTO mode is defaulted to control
from an external terminal source. These modes of operation
can be configured via programming to allow for alternate
combinations of start and speed sources. Start and speed
sources include keypad, I/O and fieldbus.
Light Option - pilot light: VFD Run, VFD Fault, Bypass Run
& Bypass Run & VFD faulted.
Communication Options - Communication options include
PROFIBUS-DP, CANopen, DeviceNet, and PROFIBUS-DP
(D9 Connector) for all product families. In addition,
the communication option available for the PowerXL
DG1 enclosed families is the SmartWire-DT. Additional
communication options available for the SVX9000 enclosed
families are LONWORKS, MODBUS, MODBUS (D9
connector), MODBUS TCP, BACnet, Johnson Controls N2,
Ethernet/IP, and RS-232 with D9 connector.
Option Boards - The available option boards are 3 x DI, 3 x
DO, 1 Thermistor, 24Vdc / EXT (DG1 ONLY); 1 x AI, 2 x AO
- Isolated to control board (DG1 ONLY); 3 x relay dry contact
- 2NO + 1NO / NC (DG1 ONLY); 3 x PT100 RTD thermistor
input (DG1 ONLY); 6 DI 240Vac input (DG1 ONLY); 6 DI, 1
ext +24 Vdc / EXT + 24 Vdc (SVX ONLY); 1 RO (NC-NO), 1
RO (NO), 1 thermistor (SVX ONLY); 1 AI (mA isolated), 2 AO
(mA isolated), 1 ext +24 Vdc / EXT +24 Vdc (SVX ONLY); 3
RO (NO) (SVX ONLY); 1 ext +24 Vdc / EXT +24 Vdc, 3 Pt100
(SVX ONLY); 1 RO (NO), 5 DI 42–240 Vac input (SVX ONLY);
Encoder low volt +5V / 15V /24V (High Performance Drive
Only); Encoder high volt +15V / 24V (High Performance
Drive Only); Double encoder (High Performance Drive Only).
Customers may pick up to two option boards.