Emerson COPELAND EVA3 Bulletin

Single phase series variable speed drives

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AE8-1435

TABLE OF CONTENTS

SAFETY INSTRUCTIONS ..................................... 2

Important Safety Information ............................... 2

QUALIFIED PERSONNEL ONLY ..................... 2

ELECTRICAL SHOCK HAZARD...................... 2

FIRE HAZARD – USE WITH FLAMMABLE

REFRIGERANTS .......................................... 2

Signal Word Definition ...................................... 3

INTRODUCTION .................................................. 3

Product Description ........................................... 3

Theory of Drive Operation .................................. 3

Agency Recognition........................................... 3

Nomenclature ................................................... 3

INSTALLATION ................................................... 3

Drive Handling .................................................. 3

Handle and store the drive correctly to prevent

damage. .......................................................... 3

Mounting.......................................................... 3

Drive Accessories and Dimensions ...................... 4

Wiring Diagram ................................................. 4

OPERATION & FUNCTION ................................... 4

Hi-pot Procedure / Set-up ................................... 4

Temperature, Humidity and Altitude ..................... 4

Pre-operation Checks ........................................ 4

Power On/Off ................................................... 4

Communication Setting ...................................... 4

Physical Layer .................................................. 4

Data Link Layer ................................................ 4

Emerson Classification:

Internal

EVA3 Single Phase Series Variable Speed Drives

208-240VAC, 4.2kW & 7.1kW

Application Layer .............................................. 4

Input Voltage and Input Current........................... 6

Compressor & Fan Motor Speed Control .............. 6

Start-up ........................................................... 6

Shutdown ........................................................ 7

Fault Clearing................................................... 7

Lockout Faults .................................................. 7

Stator Heat Control ........................................... 7

Status Indication ............................................... 7

Power Interrupt ................................................. 7

Drive Configuration ........................................... 7

High Pressure Cut Out....................................... 7

Drive Cooling ................................................... 8

Drive Over Temperature Protection ..................... 8

Air Cooled Heat Exchanger ................................ 8

Foldback ......................................................... 8

Troubleshooting................................................ 8

EMC Guidelines:............................................... 8

Table 1 – J7 (RS485) Communication Connector Pin

Definition ....................................................... 11

Table 2 – Sensor Connector Pin Def inition .......... 12

Table 3 – J8 Fan Motor Connector Pin Def inition . 12

Compressor Start-up and Shutdown Profile ........14

Drive Foldback Information ................................16

Modbus Map......................................................21

Drive Configuration Flowcharts ..........................47

Troubleshooting Guide ......................................53

Hi-pot Testing....................................................63

Accessories ......................................................64

March 2023

Table of Contents

Summary of Contents for Emerson COPELAND EVA3

Page 1 Drive Configuration Flowcharts ......47 Pre-operation Checks ........4 Power On/Off ........... 4 Troubleshooting Guide ........53 Communication Setting ........4 Hi-pot Testing............63 Physical Layer ..........4 Data Link Layer ..........4 Accessories ............64 © 2023 Emerson Climate Technologies, Inc. Emerson Classification: Internal...
Page 2 While systems using f lammable refrigerant are designed to mitigate the risk of ignition if the refrigerant is released, fire and explosion can still occur. Personnel must be specifically trained on safe procedures for working with flammable refrigerants. See Climate.Emerson.com/flammable for inf ormation on flammable refrigerant safety and training.
Page 3 These holes will accommodate an M5 sized screw for mounting. These commodities, technology or software, are subject to the U.S. Export Administration Regulations (EAR). Emerson Classification: Internal Diversion contrary to U.S. law is prohibited. ECCN: EAR99 © 2023 Emerson Climate Technologies, Inc.
Page 4 The drive is designed to be used in a master-slave conf iguration where the drive acts as the slave device. The drive can operate on a bus containing multiple slave devices. Emerson Classification: Internal © 2023 Emerson Climate Technologies, Inc.
Page 5 2 Bytes Request 0x007B Function code 1 Byte 0x06 Byte Count 1 Byte 2 x *N 0x0000 to *N x 2 0x0000 to Register Address 2 Bytes Register Values 0xFFFF Bytes 0xFFFF Emerson Classification: Internal © 2023 Emerson Climate Technologies, Inc.
Page 7 The high-pressure cutout port is hardware Protected DC power to the compressor. In cool environments the Electronic Circuit (PEC) according to IEC 60335-1 and system may wish to preheat the compressor prior to sof tware is Class-B. Emerson Classification: Internal © 2023 Emerson Climate Technologies, Inc.
Page 8 For the description, check and handling of these faults or protections, please ref er to the Troubleshooting – Fault and Protection within Addendum Emerson Classification: Internal © 2023 Emerson Climate Technologies, Inc.
Page 9 The use of additional f errites and numbers of turns in the input power supply cables, compressor cables, sensor cables, aluminum shielding enclosure are optional but preferred based on system application and noise level. Emerson Classification: Internal © 2023 Emerson Climate Technologies, Inc.
Page 10 AE8-1435 Figure 1 – 4.2kW Drive Wiring Diagram Emerson Classification: Internal © 2023 Emerson Climate Technologies, Inc.
Page 11 Figure 2 – 7.1kW Drive Wiring Diagram Table 1 – J7 (RS485) Communication Connector Pin Definition Description Figure Number Not Connected Description Part Number 4-Pin Connector Header JST P/N B04B-PASK-1 or Equivalent Emerson Classification: Internal © 2023 Emerson Climate Technologies, Inc.
Page 12 Emerson Climate Technologies, Inc. and/or its affiliates (collectively "Emerson"), as applicable, reserve the right to modify the design or specifications of such products at any time without notice. Emerson does not assume responsibility for the selection, use or maintenance of any product.
Page 13: Table Of Contents
TABLE OF CONTENTS Compressor Start-up and Shutdown Profile............... 14 Drive Foldback Information ....................16 Modbus Map ........................21 Drive Configuration Flowcharts ..................47 Troubleshooting Guide..................... 53 Hi-pot Testing ........................63 Accessories ........................64 Emerson Classification: Internal © 2023 Emerson Climate Technologies, Inc.
Page 14: Compressor Start-Up And Shutdown Profile
Stage Description (rpm) (rpm/s) Drive receives compressor speed demand of 0 (controlled shutdown request). Default: 200 Compressor reaches minimum speed. (Configurable) Compressor has stopped. This speed may vary based on compressor selected. Emerson Classification: Internal © 2023 Emerson Climate Technologies, Inc.
Page 15 AE8-1435 Figure 1 – Compressor Startup Profile Emerson Classification: Internal © 2023 Emerson Climate Technologies, Inc.
Page 16: Drive Foldback Information
The condensing fan is limited by power, i.e. when a 1/3Hp fan is selected, the drive will allow speeds up to the maximum speed (register 1003) or 1/3Hp, whichever is reached first. Emerson Classification: Internal © 2023 Emerson Climate Technologies, Inc.
Page 17 During this mode if the envelope time out [reg. 55] reaches 0, the “Envelope Limit Timeout” fault will occur [reg. 79&81, bit 2]. Emerson Classification: Internal © 2023 Emerson Climate Technologies, Inc.
Page 18 Table 4. Figure 3 shows an example of what the speed vs torque curve may look like, this curve will vary based on the compressor model selected. Figure 3 – Basic Envelope Example Speed vs Torque Curve Emerson Classification: Internal © 2023 Emerson Climate Technologies, Inc.
Page 19 Table 5 shows the actions the drive will take based on different conditions for the act ive envelope protection with minimum speed control. Emerson Classification: Internal © 2023 Emerson Climate Technologies, Inc.
Page 20 Speed < Min Speed (Current Zone) the minimum speed of the current zone. Report the “Envelope Limit Timeout” fault and Envelope Timeout = 0 set the compressor speed to 0. Emerson Classification: Internal © 2023 Emerson Climate Technologies, Inc.
Page 21: Modbus Map
The number of bytes returned is based on the number of ASCII characters being transmitted. The maximu m length is Notes 1) When requesting to read register 0 or 1, only a single register can be read. Attempting to read registers 0 & 1 sequentially, will return an exception code. Emerson Classification: Internal © 2023 Emerson Climate Technologies, Inc.
Page 22 Set whenever the compressor is Status running or stator heating. 0: Stable | 1: Unstable Compressor Set whenever the compressor speed Frequency Stable demand vs running speed difference is 100rpm or greater. Emerson Classification: Internal © 2023 Emerson Climate Technologies, Inc.
Page 23 Compressor motor software version currently running on the drive. Compressor Motor Software Version [Low Word] Boot Software Version [High Word] Boot software installed on the drive. Boot Software Version [Low Word] Emerson Classification: Internal © 2023 Emerson Climate Technologies, Inc.
Page 24 The under-voltage trip limit for the 12.4 Voltage Trip Limit AC input. Compressor Power The compressor power module trip Module Over 11.5 limit that will trigger an immediate °C Temperature Trip shutdown. Limit Emerson Classification: Internal © 2023 Emerson Climate Technologies, Inc.
Page 25 These values are what the drive uses as limits, e.g. if the input current is at the “AC Input Current Limit”, then the drive will not provide additional power to run the compressor or fan. Notes 1) Registers 16 through 41 are using a signed fixed-point notation. Emerson Classification: Internal © 2023 Emerson Climate Technologies, Inc.
Page 26 Envelope Foldback Set whenever the drive is folding Status back due to the envelope limitation. 0: Ok | 1: Corrupted Autosaved Data Set whenever the automatically Status saved data is corrupted. Emerson Classification: Internal © 2023 Emerson Climate Technologies, Inc.
Page 27 This indicates when the drive has completed the power up process. Compressor Running The actual running speed of the 15.1 Speed compressor. Compressor Torque The compressor’s torque demand. Demand Compressor Torque The envelope torque limit. Limit Emerson Classification: Internal © 2023 Emerson Climate Technologies, Inc.
Page 28 (DLT) sensor. The drive can still safely run without being calibrated, efficiency may be affected. Notes Registers 52 through 55, and registers 60 through 77 are using a signed fixed-point notation. Emerson Classification: Internal © 2023 Emerson Climate Technologies, Inc.
Page 29 Compressor Loss of Phase Loss of Compressor Motor Control Compressor Power Module Over Temperature PFC Over Temperature Compressor Startup Fault Pre-Charge Relay Open DC Bus Voltage Low Controlled Envelope Limit Timeout Temp foldback timeout Emerson Classification: Internal © 2023 Emerson Climate Technologies, Inc.
Page 30 Compressor Phase Over Current AC Input Over Current DC Bus Over Voltage DC Bus Under Voltage AC Input Over Voltage Immediate AC Input Under Voltage PFC Desaturation High Pressure Switch Compressor Loss of Phase Emerson Classification: Internal © 2023 Emerson Climate Technologies, Inc.
Page 31 Pre-Charge Relay Open DC Bus Voltage Low Envelope Limit Timeout Temp foldback timeout Modbus Communications Lost Controlled Discharge Line Temperature High Board Temperature High Compressor Power Module Temperature High PFC Temperature High Emerson Classification: Internal © 2023 Emerson Climate Technologies, Inc.
Page 32 High Pressure Sensor Configuration Immediate Compressor U-Phase Over Current Compressor V-Phase Over Current Compressor W-Phase Over Current Compressor Module Over Current Discharge Line Temperature Low Controlled Board Temperature Low Compressor Power Module Temperature Low Emerson Classification: Internal © 2023 Emerson Climate Technologies, Inc.
Page 33 Compressor Phase Current Imbalance Micro Electronic Fault Drive Configuration Immediate Compressor Model Configuration High Pressure Sensor Configuration Compressor U-Phase Over Current Compressor V-Phase Over Current Compressor W-Phase Over Current Compressor Module Over Current Emerson Classification: Internal © 2023 Emerson Climate Technologies, Inc.
Page 34 External Sensor Lost Stator Heat Overcurrent Fault Limit Lockout Lockout fault. Only detected when compressor is running. In order to clear the fault limit lockout, the drive must be fully power cycled. Emerson Classification: Internal © 2023 Emerson Climate Technologies, Inc.
Page 35 Condensing The condensing temperature used 11.5 °F Temperature in the active envelope control. The drive must be enabled to run either the fan and/or the compressor Emerson Classification: Internal © 2023 Emerson Climate Technologies, Inc.
Page 36 Used to select the compressor the drive is paired with. 4.2kW 311: ZPV0212E-2E9 313: ZHV0212P-2E9 Compressor 305: ZHW0152P-2E9 16.0 Selection 3, 6 7.1kW 411 = ZPV0282E-2E9 512 = ZPV0342E-2E9 513 = ZHV0342P-2E9 511 = ZPV0382E-2E9 Emerson Classification: Internal © 2023 Emerson Climate Technologies, Inc.
Page 37 Range: 30 – 600 Ramp Rate Default: 200 Sets the rate at which the drive will decrease the compressor speed. Compressor Negative 16.0 RPM/s Range: 30 – 600 Ramp Rate Default: 200 Emerson Classification: Internal © 2023 Emerson Climate Technologies, Inc.
Page 38 3 = Active Envelope Protection with Minimum Speed Control Default: 1 Sets the amount of time the compressor runs at the “Compressor Dwell Speed”. Compressor Dwell 16.0 Time Range: 10 – 300 Default: 10 Emerson Classification: Internal © 2023 Emerson Climate Technologies, Inc.
Page 39 5 seconds, 2 successive messages will need to be sent down for the drive to re-calculate the baud rate and respond. 3) Register 221 uses the special function code (0x64), see the example below, changing the access level 1 password from (0x2345) to (0x1998). Emerson Classification: Internal © 2023 Emerson Climate Technologies, Inc.
Page 40 Fan Status Set whenever the fan is running. 1005 0: Stable | 1: Unstable Set whenever the fan speed Fan Frequency Stable demand vs running speed difference is 10rpm or greater. Emerson Classification: Internal © 2023 Emerson Climate Technologies, Inc.
Page 41 1022 11.5 °C will trigger an immediate shutdown. Trip Limit Fan Power Module The fan power module trip limit that Temperature High 1035 11.5 °C will trigger a controlled shutdown. Limit Emerson Classification: Internal © 2023 Emerson Climate Technologies, Inc.
Page 42 1051 0: Ok | 1: Limited Fan Output Power Set whenever the drive is providing Limit the fan output power limit and cannot deliver more output power. Emerson Classification: Internal © 2023 Emerson Climate Technologies, Inc.
Page 43 Shutdown Units Bytes Fault Occurred Fan Phase Over Current Fan Phase Current Imbalance 1078 Immediate Fan U-Phase Over Current Fan V-Phase Over Current Fan W-Phase Over Current Fan Module Over Current Emerson Classification: Internal © 2023 Emerson Climate Technologies, Inc.
Page 44 Fan Loss of Phase Loss of Fan Motor Control Fan Power Module Over Temperature Fan Startup Fault Fan Power Module Temperature Low / Sensor Fault 1079 Controlled Fan Power Module Temperature High Emerson Classification: Internal © 2023 Emerson Climate Technologies, Inc.
Page 45 Fan Module Over Current Fan Loss of Phase Loss of Fan Motor Control Fan Power Module Over Temperature Fan Startup Fault 1081 Controlled Fan Power Module Temperature Low / Sensor Fault Emerson Classification: Internal © 2023 Emerson Climate Technologies, Inc.
Page 46 Only detected when the fan is running. Fan Demand [Write Only] Register Format Name Description Units Bytes This tells the drive what speed to 1101 16.0 Fan Speed Demand run the fan at. Emerson Classification: Internal © 2023 Emerson Climate Technologies, Inc.
Page 47: Drive Configuration Flowcharts
Table 6. When reading register 200, the current access level is returned. Once a drive has been successfully configured it is ready to run, see Figure 6 for an example of how to control the drive. Emerson Classification: Internal © 2023 Emerson Climate Technologies, Inc.
Page 48 Ramp Rate speed demand. See Figure 1. This configures how fast the Compressor Negative compressor responds to a decreased Ramp Rate speed demand. See Figure 1. Emerson Classification: Internal © 2023 Emerson Climate Technologies, Inc.
Page 49 1/3 Hp Regal Beloit 1/3 Hp Broad Ocean [C54041] [5SAA39DSP1003] [ZW702B000010] ZPV0212E-2E9 ZHV0212P-2E9 42C_A_K2BB3_NB13 42C_A_K2BB3_RA13 42C_A_K2BB3_BA13 ZHW0152P-2E9 Fan Motor Compressor 1/3 Hp Regal Beloit No Fan Motor [5SAA39DSP1007] ZPV0212E-2E9 ZHV0212P-2E9 42C_A_K2BB3_RB13 42C_A_K2BB3 ZHW0152P-2E9 Emerson Classification: Internal © 2023 Emerson Climate Technologies, Inc.
Page 50 ZPV0412E-2E9 ZPV041CE-2E9 Fan Motor Compressor 1/2 Hp Regal Beloit 1/3 Hp Broad Ocean 1/2 Hp Broad Ocean [5SBA39FSP1004] [ZW702B000010] [ZW702B500013] ZPV0282E-2E9 ZPV0342E-2E9 ZHV0342P-2E9 ZPV0382E-2E9 71C_A_K2BB5_RA12 71C_A_K2BB5_BA13 71C_A_K2BB5_BA12 ZPV038CE-2E9 ZHW0302P-2E9 ZPV0412E-2E9 ZPV041CE-2E9 Emerson Classification: Internal © 2023 Emerson Climate Technologies, Inc.
Page 51 AE8-1435 Fan Motor Compressor 1/3 Hp Regal Beloit 1/2 Hp Regal Beloit No Fan Motor [5SAA39DSP1007] [5SBA39KSP1008] ZPV0282E-2E9 ZPV0342E-2E9 ZHV0342P-2E9 ZPV0382E-2E9 71C_A_K2BB5_RB13 71C_A_K2BB5_RB12 71C_A_K2BB5 ZPV038CE-2E9 ZHW0302P-2E9 ZPV0412E-2E9 ZPV041CE-2E9 Emerson Classification: Internal © 2023 Emerson Climate Technologies, Inc.
Page 52 Once the operate drive state has been entered, the envelope protection method will not change unless the drive has power cycled or it has been changed. During this state the fault status will need to b e periodically monitored to know if a fault has occurred. Emerson Classification: Internal © 2023 Emerson Climate Technologies, Inc.
Page 53: Troubleshooting Guide
187VAC. PFC Desaturation 1.Verify that the DC bus voltage is greater than 220VDC. 2.Verify adequate airflow is supplied across the heatsink of the drive. 3.If problem persists, replace the drive. Emerson Classification: Internal © 2023 Emerson Climate Technologies, Inc.
Page 54 4.If problem persists, replace the drive. Compressor 1.Check the U, V, & W, Startup Fault connections on the drive & compressor side. 2.Check the compressor motor windings. Emerson Classification: Internal © 2023 Emerson Climate Technologies, Inc.
Page 55 4.If problem persists, replace the drive. Modbus 1.Check the Modbus Communications communications cable. Lost 2.Verify cable shielding / noise immunity. 3.Verify the communications settings are correct. 4.Power cycle drive. 5.If problem persists, replace drive. Emerson Classification: Internal © 2023 Emerson Climate Technologies, Inc.
Page 56 2.Verify adequate airflow is supplied across the heatsink of the drive. 3.Check all the mounting screws on the drive, verify they are all properly tightened. 4.If problem persists, replace the drive. Emerson Classification: Internal © 2023 Emerson Climate Technologies, Inc.
Page 57 2.If problem persists, replace the drive. Compressor U- 1.Check the compressor U, V, and Phase Over W connections. Current 2.Check the compressor motor windings. 3.Check that the compressor is operating within the specified limits. Emerson Classification: Internal © 2023 Emerson Climate Technologies, Inc.
Page 58 3.Verify the sensor is mounted in the proper location. Board 1.Verify ambient temperature is Temperature Low above the minimum operating temperature of drive. Emerson Classification: Internal © 2023 Emerson Climate Technologies, Inc.
Page 59 2.Check the compressors U, V, and W connections. 3.Check the compressor motor windings. 1.Power cycle the drive. Fault Limit Lockout 2.Troubleshoot the faults that caused the fault limit lockout. Emerson Classification: Internal © 2023 Emerson Climate Technologies, Inc.
Page 60 2. Check the fan U, V, and W connections. Fan Module 3. Check the fan motor windings. Over Current 4. Check that the fan is operating within the specified power limits. Emerson Classification: Internal © 2023 Emerson Climate Technologies, Inc.
Page 61 1079 Fan Power 1. Verify ambient temperature is above the minimum Module operating temperature of drive. Temperature 2. Power cycle drive. Low / Sensor 3. If problem persists, replace drive Fault Emerson Classification: Internal © 2023 Emerson Climate Technologies, Inc.
Page 62 2. Verify adequate airflow is supplied across the Module heatsink of the drive. Temperature 3. Check all the mounting screws on the drive, verify High they are all properly tightened. 4. If problem persists, replace the drive. Emerson Classification: Internal © 2023 Emerson Climate Technologies, Inc.
Page 63: Hi-Pot Testing
Contact Application Engineer for more details on connections and wiring setup. • Execute Test. • Note and record the maximum leakage current during the dwell period. • Once test is complete, safely disconnect the component and store it properly. Emerson Classification: Internal © 2023 Emerson Climate Technologies, Inc.
Page 64: Accessories
Start-up Cable Kit All Compressors (for developmental work) 998-0860-00 7.1kW Service cable will require field mounting of proper connector type on drive end of power cable. Optional, only required if using fan control. Emerson Classification: Internal © 2023 Emerson Climate Technologies, Inc.

Emerson COPELAND EVA3 Bulletin

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Summary of Contents for Emerson COPELAND EVA3