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Emerson EV3 Series Application Manuallines

Emerson EV3 Series Application Manuallines

Inverter drive for zpv* variable speed compressors


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Table of Contents
Application Guidelines
EV3 Inverter Drive for
ZPV* Variable Speed Compressors
EV3015B & EV3185B


Table of Contents

Summary of Contents for Emerson EV3 Series

  • Page 1 Application Guidelines EV3 Inverter Drive for ZPV* Variable Speed Compressors EV3015B & EV3185B...
  • Page 2: Table Of Contents

    About these guidelines ....................1 Safety instructions ....................1 1.1 Icon explanation ........................1 1.2 Safety statements .........................1 1.3 General instructions ......................2 1.4 Use with A2L refrigerants......................2 Product description ..................... 4 2.1 General information about the EV3 drive ................4 2.2 Drive highlights ........................4 2.3 Models...........................4 2.4 Advanced technical information ....................4 2.5 Conformity to directives and standards ................5...
  • Page 3 4.7 Compressor shutdown ....................... 15 Optional analog board ..................16 5.1 Terminal and LED description ................... 16 5.2 Control and configuration ....................17 5.2.1 Selection of drive compressor code ............... 17 5.2.2 Clearing faults ......................18 5.2.3 Control signals ......................18 5.2.4 Stator heating control .....................
  • Page 4: About These Guidelines

    About these guidelines The purpose of these guidelines is to provide guidance in the application of Emerson drives in users’ systems. They are intended to answer the questions raised while designing, assembling and operating a system with these products. Besides the support they provide, the instructions listed herein are also critical for the proper and safe functioning of the compressors.
  • Page 5: General Instructions

    General instructions Safety risks (read carefully!) After disconnecting power, wait 10 minutes before removing the drive enclosure. Before operating and maintenance work always check that all voltages at the terminals are zero or at levels which are harmless. Always make sure the compressor has stopped completely before removing the drive enclosure.
  • Page 6 ▪ Ensure that the airstream over the heatsink does not influence the environment of the drive (keep pollution degree 2). ▪ No condensation under normal operation. ▪ Ensure that the cool plate for flat plate versions does not create condensation inside the drive. ▪...
  • Page 7: Product Description

    Product description General information about the EV3 drive The EV3 inverter drive has been developed specifically for Copeland Scroll™ compressor models ZPV066 and ZPV096. These are variable speed compressors with permanent magnet synchronous motors. The drive will power the compressor, control the compressor running speed, provide compressor and drive protection and communicate with the master controller.
  • Page 8: Conformity To Directives And Standards

    Conformity to directives and standards The EV3 drive has been designed and developed especially for the European commercial market based on applicable European Directives. The design is qualified by main safety standards EN 60335-1 (Safety for household and similar electrical appliances, Part 1: General requirements), EN 60335-2-34 (Part 2-34: Particular requirements for motor-compressor) and EN 60730-1 (Automatic electrical controls for household and similar use).
  • Page 9: Installation

    Installation Handling ▪ Correct handling and storage of the drive is essential in preventing mechanical damage. ▪ The box and the protection bag inside the box have to be opened with care. Do not use any sharp object to open the protection bag or cut across the drive. ▪...
  • Page 10: Mounting

    Mounting The drive should be located as close to the compressor as possible, preferably within 1 meter of the compressor. To avoid electromagnetic interference please ensure that the motor cables do not cross or attach to any other connecting cables. There should be at least a natural air stream inside the cabinet and around the drive to keep the temperature below 65°C.
  • Page 11: Grid Supply And Compressor Wiring

    3.4.2 Grid supply and compressor wiring Figure 4 shows the general wiring to the power grid and to the compressor. This wiring diagram does not show any system-related components like fuse breaker, RCD and the additional ferrites for EMC. Paragraph 3.4.6 "Control terminal"...
  • Page 12: Compressor Connection

    ▪ Accuracy: ± 1% ▪ Powered by: Internal 5 VDC (terminal 2) ▪ Temp. range: -40 to +155°C ▪ Reference: Emerson ECN-G series The sensor should be mounted on the discharge line approx. 120 mm away from the compressor outlet. AGL_Sol_EV3_E_Rev_01...
  • Page 13: Sto Input

    ▪ Powered by: Internal 24 VDC (terminal 4) ▪ Current flow: Typically ~10mA ▪ Reference: Emerson PS4 series Caution: Connect the safety limiter directly to terminals 6 and 7 without any relay etc. in between. Otherwise the safety will probably not be guaranteed any longer.
  • Page 14: Start-Up & Operation

    Furthermore, it provides an advanced register description. For the latest version of the Modbus map, please contact the Application Engineering department at Emerson. Drive configuration The drives were specially designed for the ZPV066 and ZPV096 compressors. The compressor code will be set by default, so it will not have to be introduced by the user.
  • Page 15: Envelope Control

    The power demand must be written in register [102]. The value represents the percentage of power (0%-100%). The maximum power that can be commanded on the stator is readable via register [52]. The relation between the power and the value introduced in register [102] is the following: ▪...
  • Page 16: Active Envelope Protection

    1: High-Speed Envelope Protection ▪ Overload Protection enabled. ▪ Normal Operation: the minimum speed is the minimum speed of the envelope. Value taken from the EEPROM and updated frequently based on the operating point. The user must take care to run the compressor within the envelope at all times.
  • Page 17: Clearing Faults

    Grey zone: ▪ Speed range: 2600-6000 rpm ▪ Allowed running time based on the evaporating temperature: o if less than -15C: 15 minutes o if higher than -15C: 30 minutes If the speed demand is less than 2600 rpm or higher than 6000 rpm, the speed is increased or decreased automatically to respect the speed range.
  • Page 18: Compressor Shutdown

    Figure 7: Start-up sequence Compressor shutdown The user has the possibility to perform an immediate shutdown or a controlled shutdown. By setting the compressor Enable register [100] to Disabled, while the speed demand is greater than 0, the drive will perform an immediate stop. Otherwise if the user sends a Disable command as well as 0 speed demand (insert 0 in Compressor Speed Demand register [101]), the drive will issue a controlled stop.
  • Page 19: Optional Analog Board

    Optional analog board The analog board is foreseen for users who do not have the possibility to control the EV3 drive via ® an RS485 communication and the Modbus protocol. To control the EV3 drive the analog board needs a digital enable signal and an analog signal to set the speed or heating demand. The drive compressor package must be selected by a 6-Digit DIP-switch.
  • Page 20: Control And Configuration

    Code Description and comments Programming port: ▪ Used for software updates via Renesas Emulators together with a special PCB board from Emerson Status LED (green): ▪ Flashing fast: Fault state ▪ Flashing slow: Standby ▪ Constantly on: Compressor running / heating...
  • Page 21: Clearing Faults

    Figure 10: Analog control board code selection NOTE: The binary code represents the binary transformation of the package code starting from right to left (from 6 to 1). 5.2.2 Clearing faults Faults are cleared automatically as long as the cause of the fault is no longer existing. In case of a drive fault the analog board will automatically send the clear fault command to the drive.
  • Page 22: Shutdown Conditions

    Based on the compressor envelope and the speed range selection (see paragraph 5.2.7 "Compressor speed range selection") it can happen that low speed demands will be ignored. 5.2.6 Shutdown conditions The drive will stop in heating as well as in running mode if one of below conditions occurs: ▪...
  • Page 23: Protections And Alerts

    Protections and alerts When the drive is in normal operation, the power LED will always be turned on and the fault LED will be off. In case the drive is in fault or protection mode, the fault LED will flash at 2 Hz for a specific number of times.
  • Page 24: Power Module Speed-Drop Protection

    Reasons for moving to the Speed-Drop Protection mode: ▪ Overtemperature of the power module ▪ Overtemperature in the discharge line ▪ Operating in field weakening range ▪ Output overcurrent ▪ Input overcurrent ▪ Drive ambient temperature foldback The controller can avoid moving to the Speed-Drop Protection mode by using registers [37], [40], [41], [42], [43], [44], [45] and [110] for control purposes.
  • Page 25: Speed Drop Protection Limits, Led And Analog Board Codes

    Speed drop protection limits, LED and analog board codes In case of failure, the alarm code is visible at the signal LED. The number of blinks is equal to the alarm code. Protective #OneEmerson No Alert and fault message Static, dynamic and recovery limits Register bit action Compressor...
  • Page 26 Protective #OneEmerson No Alert and fault message Static, dynamic and recovery limits Register bit action If the fan stops working this fault will be Compressor Cooling fan fault 85.15 triggered. trip Drive module HW over Compressor/ Dependent on the system 84.11 current PFC trip...
  • Page 27: Maintenance & Repair

    The fan is connected with a lock-type connector to the main board of the drive. Press the plastic clip of the connector and disconnect the fan. Connect the new fan and reassemble the unit. The replacement fan model is supplied by Emerson under ident number 8421949. AGL_Sol_EV3_E_Rev_01...
  • Page 28: Frequently Asked Questions

    Table 20 provides answers to frequently asked questions. Please check here first in case of problems with the installation and assembly. In case further assistance is needed please contact the Application Engineering department at Emerson. Question / Drive behaviour Corrective action Check the Fault LED from the top of the drive.
  • Page 29: Appendix 1: Drive Dimensions And Mounting Instructions (Ev3185B / Ev3150B)

    Appendix 1: Drive dimensions and mounting instructions (EV3185B / EV3150B) AGL_Sol_EV3_E_Rev_01...
  • Page 30: Appendix 2: Choke Dimensions

    Appendix 2: Choke dimensions Figure 14: DC choke 40A, 2mH for EV3150B Figure 15: DC choke 50A, 2mH for EV3185B AGL_Sol_EV3_E_Rev_01...
  • Page 31: Appendix 3: Analog Control Board Description And Dimensions

    Appendix 3: Analog control board description and dimensions Figure 16 AGL_Sol_EV3_E_Rev_01...
  • Page 32: Appendix 4: Envelopes

    Appendix 4: Envelopes Figure 17: ZPV066* compressor envelope with R410A (20°F SH, 15°F SC, 95°F ambient) Figure 18: ZPV096* compressor envelope with R410A (20°F SH, 15°F SC, 95°F ambient) AGL_Sol_EV3_E_Rev_01...
  • Page 33: Appendix 5: Advanced User Interface

    3. Emerson does not assume responsibility for the selection, use or maintenance of any product. Responsibility for proper selection, use and maintenance of any Emerson product remains solely with the purchaser or end user.
  • Page 34 The Emerson logo is a trademark and service mark of Emerson Electric Co. Emerson Climate Technologies Inc. is a subsidiary of Emerson Electric Co. Copeland is a registered trademark and Copeland Scroll is a trademark of Emerson Climate Technologies Inc.. All other trademarks are property of their respective owners.

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