ae8-1411 - ev2 three phase series variable speed drives 208 … · 2019-07-29 · ev2 three phase...
TRANSCRIPT
© 2019 Emerson Climate Technologies, Inc.
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AE8-1411 R3 February 2019
EV2 Three Phase Series Variable Speed Drives 208-240V, 5.5 kW / 8.0 kW 380-460V, 5.5kW / 8.0 kW
TABLE OF CONTENTS
SAFETY INSTRUCTIONS ........................................... 2
Important Safety Information .................................... 2 QUALIFIED PERSONNEL ONLY ........................ 2 ELECTRICAL SHOCK HAZARD ......................... 2 FIRE HAZARD – NOT FOR USE WITH FLAMMABLE REFRIGERANTS .......................... 2
Signal Word Definition ............................................. 2
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 ......................... 3 Wiring Diagram ........................................................ 3
OPERATION & FUNCTION ........................................ 3
Hi-pot Procedure / Set-up ........................................ 3 Temperature & Humidity .......................................... 3 Pre-operation Checks .............................................. 4 Power On/Off ........................................................... 4 Communication Setting ............................................ 4 Input Voltage and Input Current ............................... 4 Speed Control .......................................................... 4 Start-up .................................................................... 4
Shutdown ................................................................. 4 Fault Clearing .......................................................... 4 Lockout Faults ......................................................... 4 Stator Heat Control .................................................. 4 Status Indication ...................................................... 5
LED for COMMS ................................................. 5 Operation Indicating LED (Green LED605 for EV20XXX-J models, LED805 for EV20-XXX-K models) ................................................................ 5 Protection Indicating LED (Yellow LED604 for EV20XXX-J models, LED 804 for EV20XXX-K models) ................................................................ 5 Hardware Fault Indicating LED (Red LED 603 for EV20XXX-J models, LED 803 for EV20XXX-K models) ................................................................ 5 LED for Drive Control (Green LED602 for EV20XXX-J- models, LED802 for EV20XXX-K- models.) ............................................................... 5
Power Interrupt ........................................................ 5 Drive Configuration .................................................. 5 High Pressure Cut Out ............................................ 5 Drive Cooling ........................................................... 6 Air Cooled Heat Exchanger ..................................... 6 Cold Plate Heat Exchanger ..................................... 6 Foldback .................................................................. 6 Troubleshooting ....................................................... 6 EMC Guidelines: ...................................................... 6 Figure 1 – U.S. Drive Model 3D Wiring Diagram .... 7 Figure 2 – U.S. Wiring diagram ............................... 7 Figure 3 - E.U. Drive Model 3D Wiring Diagram ..... 8 Figure 4 – E.U. Wiring Diagram .............................. 8 Table 1 – Communication Connector Pin Definition 9 Table 2 – Sensor Connector Pin Definition ............. 9
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SAFETY INSTRUCTIONS
This bulletin includes important safety information. OEMs integrating the Copeland Scroll™ variable speed drive into a system should ensure that their own employees follow this bulletin and provide any necessary safety information to those involved in manufacturing/installing the drive, purchasers of systems, and service personnel who may need to maintain and repair the systems.
Important Safety Information
Failure to follow these warnings could result in serious personal injury or death.
QUALIFIED PERSONNEL ONLY
• OEMs are responsible for system design, selection of appropriate components, integration of this component into the system, and testing the system. OEMs must ensure that staff involved in these activities are competent and qualified.
• Only qualified and authorized HVAC or refrigeration personnel are permitted to install, commission, troubleshoot and maintain this equipment. Electrical connections must be made by qualified electrical personnel.
• Observe all applicable standards and codes for installing, servicing, and maintaining electrical and refrigeration equipment.
ELECTRICAL SHOCK HAZARD
• Before servicing, disconnect and lock out power, and discharge all capacitors for a minimum of two minutes.
• Molded electrical plug must be used when required.
FIRE HAZARD – NOT FOR USE WITH FLAMMABLE REFRIGERANTS
• This drive is not for use in systems with flammable refrigerants. In the event of a refrigerant leak, the drive may ignite the refrigerant resulting in fire and explosion.
Signal Word Definition
The signal word explained below is used throughout the document to indicate safety messages.
WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.
WARNING
These commodities, technology or software, are subject to the U.S. Export Administration Regulations (EAR). Diversion contrary to U.S. law is prohibited. ECCN: EAR99
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INTRODUCTION
Product Description
The inverter drive has been developed specifically for variable speed compressors utilizing non-flammable refrigerants. The drive will power the compressor, control the compressor running speed, provide compressor and drive protection and communicate with the master controller. The drive requires cooling and is typically installed in a system near the compressor.
Theory of Drive Operation
The primary purpose of the drive is to convert the 50/60 Hz AC input voltage into a variable frequency, variable voltage output to power the variable speed scroll compressor. The drive conditions the AC input Voltage through a series of conditioning processes to arrive at the desired output. The drive first converts the AC input voltage into a DC bus. The DC voltage is then pulse-width modulated to replicate a sinusoidal current at the desired frequency and voltage.
Agency Recognition
UL 60730-1, IEC 60335-1, IEC 60335-2-34
Nomenclature
The model number of the drive includes the power rating and nominal voltage input to the drive. See Applications Engineering for complete explanation of all of the alpha and numeric characters in the drive model number.
INSTALLATION
Drive Handling
Handle and store the drive correctly to prevent damage.
• Never cut across the drive with anything sharp. Do not use a sharp blade to open the protection bag
• Hold the drive only by the edges of the heatsink. Do not hold by the components on the drive or drive accessories.
• Once opened do not stack the drives on each other.
• Use electrostatic discharge control wristbands and anti-static mats when touching the drive.
• Torque all screw terminals to 18-20 lb-in (2.0-3 N-m) to prevent any damaged to the inverter and filter board.
Mounting
The drive should be located as close to the compressor as possible, preferably within 5 feet, since the wiring between the drive and the compressor is unshielded.
Air-cooled drives are supported inside the HVAC system by an extended heatsink plate. The plate mounts through an opening in the cabinet sheet metal to expose the heat exchanger to the condenser fan air stream. The flange contains a gasket surface to prevent water from entering the electronics side of the control box.
The flat plate option accommodates installation to systems using the mating gas or liquid cooled cold plate heat exchanger. The cold coupling plate is designed by OEM to accommodate the system design.
There are holes in the drive mounting flange for mounting purposes. These holes will accommodate a M5 sized screw for mounting.
Drive Accessories and Dimensions
Refer to Addendum for accessories. Contact Application Engineering for all detailed dimensions with tolerances and drawings.
Wiring Diagram
Refer to Figures 7-10 for a detailed description of the drive wiring diagrams. Refer to Table 1 and Table 2 for a detailed description of the connector pins definition.
OPERATION & FUNCTION
Hi-pot Procedure / Set-up
Refer to Addendum for hi-pot procedure and setup. Please call your Application Engineer for additional details.
Temperature & Humidity
Drive operating temperature range: -25°C to 65°C Drive storage temperature range: -40°C to 85°C Humidity: Maximum relative humidity 95%
The drive is designed to meet creepage and clearance requirements for a maximum altitude of 2000 meters.
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Pre-operation Checks
Before operating, make sure that all the wires are correctly and tightly connected. Improper connections may cause fire or electric shock.
Power On/Off
The drive should use rated AC power supply: 50/60Hz, 380-460V on EV20XXM-KX-XXX models and 208-240V on EV20XXM-JX-XXX drive models. Use of incorrect power supply may damage the drive. Make sure that the correct combination of power supply, drive and accessories are used.
When powering off the drive, wait for at least 2 minutes to ensure that the drive is completely turned off.
Communication Setting
The drive is designed to be used in a master-slave configuration where the master is a system controller. Two standard Modbus protocols are available: RTU and ASCII.
Users can select RTU Mode or ASCII Mode by writing the value of related register according to the Modbus Map. For example, to choose the RTU Mode under ASCII Mode, write 0x2345 passwords to Register 200 to get Modbus Map Access first, and then write 0002H to the register 201. Power off the drive and repower on again, and then the communication mode will be changed to RTU mode.
Users can also change the slave ID, baud rate, parity and stop bit method. Detailed parameters and default values are in the Modbus Map (refer to Addendum).
Modbus uses a three-layer protocol – physical, data link, and application. Refer to Addendum for additional details.
Input Voltage and Input Current
The drives are designed for rated AC power supply: 50/60Hz, 380-460V on EV20XXM-KX-XXX models and 208-240V on EV20XXM-JX-XXX drive models. Published performance for the drive and compressor combination will have a performance tolerance specified on the compressor performance data sheet when the Drive input voltage is in the specified range as above.
Drive Max AC Input Current
EV2080J 22A RMS
EV2080K 13A RMS
EV2055J 16A RMS
EV2055K 10A RMS
Speed Control
The frequency range of EV2 is from 15Hz to 120Hz. If the frequency set by system controller is less than 15Hz but not zero, then the compressor will work at 15Hz. Similarly, if the frequency set by system controller is greater than 120Hz, then the compressor will work at 120Hz.
Start-up
Refer to Addendum for start-up procedures and requirements.
Shutdown
Refer to Addendum for shutdown procedures and requirements.
Fault Clearing
Faults will not clear unless they are commanded by system control.
To clear faults, use the following method:
1. The compressor has been shut down for at least 35 seconds.
2. The fault condition no longer exists (registers 78-85).
3. The drive has received a zero speed command (register 101 = 0).
4. The drive has been disabled (register 100 = 0).
5. Write '1' to register 103.
Faults will not clear unless all items above are true.
Lockout Faults
There are specific faults that will cause the drive to 'lockout' after 10 consecutive occurrences. These faults are noted in the Addendum.
These faults will not clear unless the power to the drive is fully cycled.
Stator Heat Control
In actual use, the system controller may decide whether to preheat or not according to the environment. When preheating is needed, the system
WARNING
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controller sends register 100 a compressor enable command and register 102 a stator heating power value. The drive transmits up to 50W DC power to warm-up the compressor.
The stator heating is ON if the followings are true:
1. There are no active errors.
2. Compressor enabled.
3. Compressor speed is set zero.
4. Stator heater power setting is from 10~50.
If the system sends a speed demand to the drive while the stator is heating; the drive should stop stator heating and start the compressor. While running, if the system sends a zero speed command, the drive should shut down the compressor automatically, and then resume the stator heating to the value saved in Stator Heater Power Memory Register (a value or zero = off).
Status Indication
There are two control chips on the drive board and all of them have their own LED for status display. COMMS MCU has three LED indicators, DSP has one LED indicator.
LED for COMMS
Operation Indicating LED (Green LED605 for EV20XXX-J models, LED805 for EV20-XXX-K models) When the drive is in normal state (no protection and fault), the drive is in a standby state and the compressor is not running; the LED will blink at 0.5Hz frequency. If the compressor is running, the LED will always be on.
Protection Indicating LED (Yellow LED604 for EV20XXX-J models, LED 804 for EV20XXX-K models) When the drive is under protection, the yellow LED will blink 'N' times. Refer to the Troubleshooting section within the Addendum for more information.
Hardware Fault Indicating LED (Red LED 603 for EV20XXX-J models, LED 803 for EV20XXX-K models) When the drive is under hardware fault, the red LED will blink 'N' times. Refer to the Troubleshooting section within the Addendum for more information.
LED for Drive Control (Green LED602 for EV20XXX-J- models, LED802 for EV20XXX-K- models.) When the drive is in normal state, whether the compressor is running or standby, the LED will blink at 1Hz frequency. When the drive is under protection or hardware fault, the LED will blink at 8Hz frequency.
N - Yellow LED = PROTECTION N - Red LED = FAULT
Power Interrupt
Power interrupts can result in a drive trip that won't harm the drive. The drive can withstand interrupts of a short duration (<=10 ms), but will trip on anything longer.
Drive Configuration
Another feature available on the drive is the option to change communication parameters, configure the drive to use different types of compressors and sensors. Modbus registers 200 - 207 and 209 -212 serve this function (refer to Modbus Map within the Addendum for details).
These options are password protected. Register 200 must have the correct password written before any parameters can be changed. All register functions and default values are located in the Modbus Map.
• Registers 201-204 are for communication parameters.
• Registers 203 and 204 are automatically configured by the drive, based on baud rate and parity information from the system controller.
• Register 205 is for compressor model type.
• Registers 206 & 207 are for sensor type configurations.
• Register 209 designates voltages for various models.
• Register 210 is controlled shutdown rate configuration.
• Register 211 and 212 are configured for speed ramp up and ramp down rate configuration.
• Register 213 is configured for ramp-up speed level at start-up.
• Reg.214 is configured for auto communication detection.
Once configured only changes to registers 201-204 will require power cycle for the changes to be implemented
Refer to Addendum for configuration process flow and communication settings process flow.
High Pressure Cut Out
CN610 on EV20XXX-J9-XXX and CN806 on EV20XXX-K9-XXX are 2-port connectors on each model. The output is a 3.3VDC signal. The high-pressure cutout switch must be normally closed. If the switch is open, the drive will not operate. The output current range for the high-pressure contact will range from 5mA – 10mA.To ensure correct functionality of
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the high-pressure switch for the system’s lifetime, typically gold-plated contacts are recommended. Refer Table-2 for detailed pinout.
This port is hardware Protected Electronic Circuit (PEC) according to IEC 60335-1 and software is Class-B.
Drive Cooling
Because of the power electronics used in the drive and the associated heat generation, drive cooling is required to keep the drive components in their design temperature range. The allowable temperature range of the drive (The ambient air surrounding the drive) is -4°F to 140°F. Drive temperature should be monitored during system development at system extreme conditions to ensure that the maximum allowable drive temperature isn’t exceeded. The highest drive temperature will typically occur during high load conditions or during high drive ambient.
The minimum recommended thermal capacity removal should be approximately 270 Watts and a maximum components temperature of 85˚C.
Drive Over Temperature Protection
The drive is self-protected against high internal temperatures. There are different modes of protection; temperature high and foldback. For temperature high refer to Troubleshooting Table within Addendum. For foldback protection refer to Addendum for more information.
Air Cooled Heat Exchanger
Drives cooled by the aluminum air cooled heat exchanger are designed to be in the air flow stream of the condenser. The air-cooled heat exchanger must be installed so that the heat exchanger fins are parallel to the cooling air flow. The airflow must be a minimum of 3 meters/sec measured at the outlet of heatsink in the direction of airflow.
Cold Plate Heat Exchanger
The cold plate design can be used when another cooling source is available – suction gas from the evaporator coil, subcooled liquid refrigerant, glycol solution from a geothermal loop, water from a cooling tower, etc. When refrigerant is used for drive cooling, the heat given up by the drive is transferred into the refrigeration system. This can be a net gain for heating applications and a net loss for cooling applications.
There must be thermal grease between flat plate cold plate.
There is no standard for the thickness requirement of thermal grease; normally, it's between 0.2mm-0.4mm.
The entire surface of the flat plate must be covered. Dow Corning 340 silicone heat sink compound or similar product is recommended. Refer to Addendum for cold plate details.
The soldering/brazing that is required to connect the cooling source to the cold plate should be performed before the cold plate is attached to the drive, to prevent overheating drive components with the torch.
Foldback
To protect the drive components and the compressor; the compressor speed will 'foldback' or slow down to help reduce risk to components. The foldback event(s) will be flagged in the drive's Modbus registers. This will allow the operating system to respond and mitigate the conditions causing foldback.
For further information refer to Addendum.
Troubleshooting
The drive may indicate fault or protection for various reasons. If fault or protection occurs, users should power down the drive, check the drive, and check the drive running condition carefully. For the description, check and handling of these faults or protections, please refer to the Troubleshooting – Fault and Protection within Addendum
EMC Guidelines:
Mount the EMI filter as close as possible to the drive.
Install the star earth (ground) connection as close as possible to the drive. A non-coating screw is recommended for installation on the service panel to maintain a good ground connection. The star connection includes:
• System Input ground
• Drive Heat-sink ground
• EMI filter ground The use of additional ferrites and numbers of turns in the input power supply cables, compressor cables, sensor cables are optional but preferred based on system application and noise level.
Any of the input power supply cables, sensor cables, compressor cables and communication cables should not cross or touch each other to avoid noise coupling.
Use of shielded cable is optional depending on system application, but if used it’s mandatory to have correct connections on both sides of the cable.
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Figure 1 – U.S. Drive Model 3D Wiring Diagram
Figure 2 – U.S. Wiring diagram
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Figure 3 - E.U. Drive Model 3D Wiring Diagram
Figure 4 – E.U. Wiring Diagram
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Table 1 – Communication Connector Pin Definition
Pin Number
Description Figure
1 RS485 (+)
2 Not Used
3 Not Used
4 RS485 (-)
5 Common
6 EMI Drain Wire
Description Part Number
6-Pin Connector Housing Molex 0039012065
or Equivalent
Connector Pins Molex 0039000038
or Equivalent
Table 2 – Sensor Connector Pin Definition
Pin Number
Description Figure
1 Sensor Pin
2 3.3VDC
3 Not Used
4 Not Used
A1 High Pressure Signal
A2 3.3VDC
(DLT Sensor) Connector (Pin -1 to 4) P/N Information
Description Part Number
4-Pin Connector Housing Molex 39-01-2045 or Equivalent
Connector Pins Molex 39-00-0428 or Equivalent
(HPS) Connector (A1/A2) P/N Information
Description Part Number
2-Pin Connector Housing JST Sales America XLP-02V or
Equivalent
Connector Pins JST Sales America SXF-41T-P0.7
or Equivalent
The contents of this publication are presented for informational purposes only and are not to be construed as warranties or guarantees, express or
implied, regarding the products or services described herein or their use or applicability. 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. Responsibility for proper selection, use and maintenance of any
Emerson product remains solely with the purchaser or end user.
The contents of this publication are presented for informational purposes only and are not to be construed as warranties or guarantees, express or
implied, regarding the products or services described herein or their use or applicability. 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. Responsibility for proper selection, use and maintenance of any
Emerson product remains solely with the purchaser or end user.
TABLE OF CONTENTS
1 Start-up and Shutdown Sequence Of The Compressor ............................................................... 2
2 Drive Foldback Information ............................................................................................................... 3
3 Modbus Map ....................................................................................................................................... 5
4 Drive Configuration Flow Charts .................................................................................................... 11
5 Troubleshooting Guide .................................................................................................................... 12
6 Hi-pot Testing .................................................................................................................................... 15
7 Accessories ....................................................................................................................................... 15
ADDENDUM to AE8-1411 02/13/2019
1 START-UP AND SHUTDOWN SEQUENCE OF THE COMPRESSOR
Table 1 - Start-up Sequence
Stage Description Target Speed (rpm) Ramp Up Rate (rpm/s) Duration (s)
I Compressor command started 1200 600 2
II Compressor continues to ramp up 1500 60 5
III Compressor remains at the platform speed
1500 (Configurable) - 10
IV Compressor reaches commanded speed
Commanded Default = 60 -
Table 2 - Shutdown Sequence
Stage Description Target Frequency (rpm)
Ramp Down Rate (rpm/s)
I Compressor Shutdown requested - -
II Compressor gets to minimum speed
900 Default = 150
III Compressor Stop - -
Figure 1 – Start-up Sequence
Speed
Time
1500-3500RPM (Reg.213) Customer configured
1200 RPM
2 S 7 S 17 S
15S
600 RPM / S
60 RPM / S
60-360RPM/S (Reg.211)
60-360RPM/S (Reg.212)
Ramp Up/Down rate is
Customer configured
Figure 2 – Shutdown Sequence
2 DRIVE FOLDBACK INFORMATION
Table 3 – Input Current Foldback
Condition Action taken by the Drive
1 Input Current >= Foldback Current Will reduce the speed at the rate of 20 rpm/s
2 Recovering Current <= Input Current < Foldback Current
Will remain in the current speed
3 Input Current < Recovering Current Speed will be recovered to commanded speed
4
If the compressor load is not recovered and continue to exceed the foldback limit in one of the conditions below:
• After compressor running speed has reached to 2100rpm and then stay at 2100rpm for >= 30sec. OR
• If the original running speed was already < 2100rpm for >= 30sec
Compressor will be tripped
Table 4 – Output Current Foldback
Condition Action taken by the Drive
1 Output Current >= Foldback Limit of operating speed range
Will reduce the speed at the rate of 20 rpm/s
2 Recovering Current <= Output Current < Foldback Limit of operating speed range
Will remain in the current speed
3 Output Current < Recovering Current Speed will be recovered to commanded speed
4 If the compressor load is not recovered and continue to exceed the foldback limit in one of the conditions below:
Compressor will be tripped
Stop
Shutdown Initiated
60-360RPM/S (Reg.210)
900RPM (Minimum Speed)
Shutdown Down rate is
Customer configured
• After compressor running speed has reached to 2100rpm and then stay at 2100rpm for >= 30sec. OR
• If the original running speed was already < 2100rpm for >= 30sec
Table 5 – Inverter Temperature Foldback
Condition Action taken by the Drive
1 Inverter Temperature >= Foldback Temperature Will reduce the speed at the rate of 20 rpm/s
2 Recovering Temperature <= Inverter Temperature < Foldback Temperature
Will remain in the current speed
3 Inverter Temperature < Recovering Temperature Speed will be recovered to commanded speed
4
If the compressor load is not recovered and continue to exceed the foldback limit in one of the conditions below:
• After compressor running speed has reached to 2100rpm and then stay at 2100rpm for >= 30sec. OR
• If the original running speed was already < 2100rpm for >= 30sec
Compressor will be tripped
3 MODBUS MAP
Modbus Register
Register Type Description Fault Shutdown
Units Bytes Data Format
0
Serial and Model Numbers
(Read)
Drive Model Number
N/A N/A 32 bytes ASCII
character
string
EV20XXM-C1-19X/89X 0XX:power Ex. 055 = 5.5kW max capacity
1
Drive Serial Number
N/A N/A 32 bytes ASCII
character
string
ADXXXXXXX Ex. AD13K0001 AD: Production Code 13:2013,production year. K: Month Code, A=Jan, B=Feb,…,L=Dec. 0001: Product Serial Number.
3
Configuration
and Status Parameter
(Read)
Configuration and Status Parameter
(Read)
Allowed maximum Speed (for speed limit
protection)
N/A Hz 2 Bytes Value: 0~120 = 0~120Hz Ex. : If value = 100, then maximum allowed running speed = 100Hz
4
Allowed minimum Speed (for speed limit
protection)
N/A Hz 2 Bytes Value: 0~120 = 0~120Hz Ex. : If value = 100, then minimum allowed running speed = 100Hz
5
Drive status
N/A
N/A
2 Bytes
Bit0: PFC Chip Reset 0 = Normal Working 1= PFC Chip Reset Bit1: DSP Chip Reset 0 = Normal Working 1= DSP Chip Reset Bit2: Drive Running Status 0 = Normal 1= Under Faults Bit3: PFC Status 0 = OFF 1 = ON Bit4: Compressor Status 0 = OFF 1 = ON Bit5: Compressor Parameters Update 0 = No Update 1 = Updating Bit6: Frequency Descending Protection 0 = Normal Working 1 = Under Protection Bit7: Protection State 0 = Normal State 1 = Under Protection Bit8: Frequency Stable Flag 0 = Stable 1 = Not Stable Bit9: Frequency Increase Flag 0 = No Increase 1= Frequency Increase Bit10: Frequency Decrease Flag 0 = No Decrease 1= Frequency Decrease Bit11: Frequency Set Outsize 0 = Set OK 1= Set Value Outsize Bit12: Compressor Starting Flag 0 = Not Starting 1= Compressor Starting
10 Comms Main Version (High Word)
N/A N/A 2 Bytes
11 Comms Main Version (Low Word)
N/A N/A 2 Bytes
14
DSP Main Version (High Word)
N/A
N/A
2 Bytes
15 DSP Main Version (Low Word) N/A N/A 2 Bytes
17
Trip Limits (Read)
Trip Limits
(Read)
AC Input Over Current N/A Amps (RMS)
2 Bytes 12.4 Ex. If Value = 512, then Conversion = 512/(2^4)
18 DC Bus Over Voltage N/A Volts (RMS)
2 Bytes 12.4 Ex. If Value = 512, then Conversion = 512/(2^4)
19 DC Bus Under Voltage N/A Volts (RMS)
2 Bytes 12.4 Ex. If Value = 512, then Conversion = 512/(2^4)
20 AC Input Over Voltage N/A Volts (RMS)
2 Bytes 12.4 Ex. If Value = 512, then Conversion = 512/(2^4)
21 AC Input Under Voltage N/A Volts (RMS)
2 Bytes 12.4 Ex. If Value = 512, then Conversion = 512/(2^4)
22 Power Module Over Temp N/A Celsius 2 Bytes 11.5 Ex. If Value = 512, then Conversion = 512/(2^5)
32 DC Bus Voltage Low N/A Volts (RMS)
2 Bytes 12.4 Ex. If Value = 512, then Conversion = 512/(2^4)
35 Power Module Temp High N/A Celsius 2 Bytes 11.5 Ex. If Value = 512, then Conversion = 512/(2^5)
38 Sensor 2 (Thermistor, DLT) High Temp Limit
N/A Celsius 2 Bytes 11.5 Ex. If Value = 512, then Conversion = 512/(2^5)
48
Drive Status/Readings
(Read)
Compressor Phase Current Fold Back Status
N/A N/A 2 Bytes 0 = No; 1 = Yes
49 Power Module Temp Fold Back Status
N/A N/A 2 Bytes 0 = No; 1 = Yes
50 AC Input Current Fold Back Status
N/A N/A 2 Bytes 0 = No; 1 = Yes
59 Power-Up Status N/A N/A 2 Bytes 0 = Not Ready 1 = Power-Up Complete
60 Compressor running speed N/A RPM 2 Bytes 15.1 Ex. If Value = 512, then Conversion = 512/(2^1)
61 Compressor Phase Current N/A Amps (RMS)
2 Bytes 7.9 Ex. If Value = 512, then Conversion = 512/(2^9)
62 Compressor Phase Current Limit N/A Amps (RMS)
2 Bytes 7.9 Ex. If Value = 512, then Conversion = 512/(2^9)
64 DC Bus Voltage N/A Volts (DC)
2 Bytes 12.4 Ex. If Value = 512, then Conversion = 512/(2^4)
65 AC Input Voltage N/A Volts (RMS)
2 Bytes 12.4 Ex. If Value = 512, then Conversion = 512/(2^4)
66 AC Input Current N/A Amps (RMS)
2 Bytes 8.8 Ex. If Value = 512, then Conversion = 512/(2^8)
67 AC Input Power N/A Watts 2 Bytes 16.0 Ex. If Value = 512, then Conversion = 512/(2^0)
68 Compressor Phase Current N/A Amps (RMS)
2 Bytes 8.8 Ex. If Value = 512, then Conversion = 512/(2^8)
70 Power Module Temp N/A Celsius 2 Bytes 11.5 Ex. If Value = 512, then Conversion = 512/(2^5)
77
Sensor 2 (Thermistor, DLT) Reading
N/A
Celsius
2 Bytes 11.5
Ex. If Value = 512, then Conversion = 512/(2^5)
78
1st Fault Occurred (Read)
Compressor Phase Over Current Immediate Shutdown
N/A Bit 0 0 = No; 1 = Yes Lockout (After 10 fault occurrences*)
AC Input Over Current Immediate Shutdown
N/A Bit 1 0 = No; 1 = Yes
DC Bus Over Voltage Immediate Shutdown
N/A Bit 2 0 = No; 1 = Yes
DC Bus Under Voltage Immediate Shutdown
N/A Bit 3 0 = No; 1 = Yes
AC Input Over Voltage Controlled Shutdown
N/A Bit 4 0 = No; 1 = Yes
AC Input Under Voltage Controlled Shutdown
N/A Bit 5 0 = No; 1 = Yes
AC Input Loss of Phase Controlled Shutdown
N/A Bit 6 0 = No; 1 = Yes
Sensor 1 (High Pressure Switch Open)
Immediate Shutdown
N/A Bit 8 0 = No; 1 = Yes
Power Module Over Temp Immediate Shutdown
N/A Bit 11 0 = No; 1 = Yes
Lost Rotor Position Immediate Shutdown
N/A Bit 13 0 = No; 1 = Yes Lockout (After 10 fault occurrences*)
79
1st Fault Occurred (Read)
DC Bus Voltage Low N/A N/A Bit 0 0 = No; 1 = Yes
Compressor Phase Over Current (Intermediate)
Immediate Shutdown
N/A Bit 1 0 = No; 1 = Yes
Compressor Phase Current Fold Back Timeout
Controlled Shutdown
N/A Bit 2 0 = No; 1 = Yes
Power Module Temp. Fold Back Timeout
Controlled Shutdown
N/A Bit 3 0 = No; 1 = Yes
AC Input Current Fold Back Timeout
Controlled Shutdown
N/A Bit 4 0 = No; 1 = Yes
Auto Config Communication Timeout
N/A N/A Bit 6 0 = No; 1 = Yes
Modbus Communication Lost Controlled Shutdown
N/A Bit 7 0 = No; 1 = Yes
Sensor 2 (Thermistor, DLT) High Temp
Immediate Shutdown
N/A Bit 8 0 = No; 1 = Yes
Power Module Temp High Controlled Shutdown
N/A Bit 11 0 = No; 1 = Yes
Comms to DSP Communication Lost
Controlled Shutdown
N/A Bit 14 0 = No; 1 = Yes
80
Multiple Faults Occurred (Read)
Compressor Phase Over Current Immediate Shutdown
N/A Bit 0 0 = No; 1 = Yes Lockout (After 10 fault occurrences*)
AC Input Over Current Immediate Shutdown
N/A Bit 1 0 = No; 1 = Yes
DC Bus Over Voltage Immediate Shutdown
N/A Bit 2 0 = No; 1 = Yes
DC Bus Under Voltage Immediate Shutdown
N/A Bit 3 0 = No; 1 = Yes
AC Input Over Voltage Controlled Shutdown
N/A Bit 4 0 = No; 1 = Yes
AC Input Under Voltage Controlled Shutdown
N/A Bit 5 0 = No; 1 = Yes
AC Input Loss of Phase Controlled Shutdown
N/A Bit 6 0 = No; 1 = Yes
Sensor 1 (High Pressure Switch Open)
Immediate Shutdown
N/A Bit 8 0 = No; 1 = Yes
Power Module Over Temp Immediate Shutdown
N/A Bit 11 0 = No; 1 = Yes
Lost Rotor Position
Immediate Shutdown
N/A
Bit 13
0 = No; 1 = Yes Lockout (After 10 fault occurrences*)
DC Bus Voltage Low
N/A
N/A
Bit 0
0 = No; 1 = Yes
81
Multiple Faults Occurred (Read)
Compressor Phase Over Current (Intermediate)
Immediate Shutdown
N/A Bit 1 0 = No; 1 = Yes
Compressor Phase Current Fold Back Timeout
Controlled Shutdown
N/A Bit 2 0 = No; 1 = Yes
Power Module Temp. Fold Back Timeout
Controlled Shutdown
N/A Bit 3 0 = No; 1 = Yes
AC Input Current Fold Back Timeout
Controlled Shutdown
N/A Bit 4 0 = No; 1 = Yes
Auto Config Communication Timeout
N/A N/A Bit 6 0 = No; 1 = Yes
Modbus Communication Lost Controlled Shutdown
N/A Bit 7 0 = No; 1 = Yes
Sensor 2 (Thermistor, DLT) High Temp
Immediate Shutdown
N/A Bit 8 0 = No; 1 = Yes
Power Module Temp High Controlled Shutdown
N/A Bit 11 0 = No; 1 = Yes
Comms to DSP Communication Lost
Controlled Shutdown
N/A Bit 14 0 = No; 1 = Yes
82
1st Fault Occurred (Read)
Compressor Phase Current Imbalance
Immediate Shutdown
N/A Bit 0 0 = No; 1 = Yes
Micro Electronic Fault or Drive EEPROM Fault
Immediate Shutdown
N/A Bit 2 0 = No; 1 = Yes Lockout (After 10 fault occurrences*)
Compressor Model Configuration Error
Controlled Shutdown
N/A Bit 6 0 = No; 1 = Yes
High Pressure Sensor Type Configuration Error
Controlled Shutdown
N/A Bit 7 0 = No; 1 = Yes
83
1st Fault Occurred (Read)
Sensor 2 (Thermistor, DLT) Low Temp or Open
Immediate Shutdown
N/A Bit 2 0 = No; 1 = Yes
Power Module Temp Low or Sensor Open fault
Immediate Shutdown
N/A Bit 5 0 = No; 1 = Yes
Fault Limit Lockout N/A N/A Bit 15 Lockout Status 0 = No; 1 = Yes
84
Multiple Faults Occurred (Read)
Compressor Phase Current Imbalance
Immediate Shutdown
N/A Bit 0 0 = No; 1 = Yes
Micro Electronic Fault or Drive EEPROM Fault
Immediate Shutdown
N/A Bit 2 0 = No; 1 = Yes Lockout (After 10 fault occurrences*)
Compressor Model Configuration Error
Controlled Shutdown
N/A Bit 6 0 = No; 1 = Yes
High Pressure Sensor Type Configuration Error
Controlled Shutdown
N/A Bit 7 0 = No; 1 = Yes
85
Multiple Faults Occurred (Read)
Sensor 2 (Thermistor, DLT) Low Temp or Open
Immediate Shutdown
N/A Bit 2 0 = No; 1 = Yes
Power Module Temp Low or Sensor Open fault
Immediate Shutdown
N/A Bit 5 0 = No; 1 = Yes
Fault Limit Lockout N/A N/A Bit 15 Lockout Status 0 = No; 1 = Yes
Modbus Register
Register Type Description Bytes Data Format Default Values
Additional Notes
100
Standard Commands (Read/Write)
Compressor Enable
2 Bytes 0 = Disable 1 = Enable 0
101 Compressor
Speed Demand
2 Bytes 16.0 Ex. If Value = 512, then Conversion = 512/(2^0) 1RPM/bit
0
102 Stator Heater
Demand
2 Bytes 16.0 0 = Disable Ex. If Value = 512, then Conversion = 512/(2^0) 1Watt/bit
0
103 Faults Clear Command
2 Bytes 1=Fault Clear, non-1= No Action
0
200
Customer Configuration
Parameter (Read/Write)
Customer Configuration
Parameter (Read/Write)
Map access Password
2 Bytes Password = 0x2345 Customer access to 201~214
N/A
201
Modbus Format
2 Bytes
1 = ASCII 2 = RTU
2
The drive has a feature to detect the baud rate and parity of the system
controller and automatically configure to those values.
Example: If controller is running at 19200bps and Even parity, 1 stop bit.
Then registers are automatically configured to Reg.203 = 19200 &
Reg.204 = 1
202 ModBUS Slave ID Address
2 Bytes 1-247 45
203
ModBUS Baud Rate
2 Bytes 1200 = 1200BPS 2400 = 2400BPS 4800 = 4800BPS 9600 = 9600 BPS 19200 = 19200 BPS 38400 = 38400 BPS
19200
204
ModBUS Parity
2 Bytes 1=Even parity, 1 stop bit; 2=Odd parity, 1 stop bit; 3=No Parity, 2 stop bits: 4=Even parity, 2 stop bits: 5=Odd parity, 2 stop bits; 6=No parity, 1 stop bit
1
205
Compressor Model Number
2 Bytes 0 = Not Configured 301 = ZPV0212E-2E9 (900 - 7200RPM) 311 = ZPV0212E-2E9 Rev1 (900 - 7200RPM) 303 = ZHV0212P-2E9 (900 - 7200RPM) 313 = ZHV0212P-2E9 Rev1 (900 - 7200RPM) 305 = ZHW0152P-2E9 (900 - 7200RPM) 410 = ZPV0282E-2E9 (900 - 7200RPM) 411 = ZPV0282E-2E9 Rev1 (900 - 7200RPM) 501 = ZPV0382E-2E9 (900 - 7200RPM) 511 = ZPV0382E-2E9 Rev1 (900 - 7200RPM) 502 = ZPV0342E-2E9 (900 - 7200RPM) 512 = ZPV0342E-2E9 Rev1 (900 - 7200RPM) 503 = ZHV0342P-2E9 (900 - 7200RPM) 513 = ZHV0342P-2E9 Rev1 (900 - 7200RPM)
0
505 = ZHW0302P-2E9 (900 - 7200RPM) 551 = ZPV038CE-2E9 (900 – 7200RPM) 581 = ZPV038CE-2E9 Rev1 (900 – 7200RPM) 555 = ZPV0412E-2E9 (900 – 7200RPM) 556 = ZPV041CE-2E9 (900 – 7200RPM)
206 Sensor 1 (HP Switch)
2 Bytes 0 = Not Configured 100 = HP Switch N/C (normally closed)
0
207 Sensor 2 (Scroll Thermistor, DLT)
2 Bytes 0 = N/A 100 = 10Kohm resistor (to simulate 25oC DLT temp) 200 = DLT 1 (Sensor)
0 When configured to “100”, the DLT limit at Reg.38 is not applicable, it is only for lab usage.
209
Customer Configuration
Parameter (Read/Write)
3 Phase Drive
Voltage Models
2 Bytes
0 = Not Configured 1 = 3phase 460V rating 2 = 3phase 380V rating
0
210
Controlled Shutdown Rate Config Option
2 Bytes
16.0 0 = Not Configured Can be configured in increments of "20" (20 to 120). Decimal value of 20 = 60rpm/sec Ex. If Value = 50, then it's 150rpm/sec
50
These values need to be re-configured only if different shutdown, ramp up &
ramp down rates are required.
211
Speed Ramp-up Rate Config
Option
2 Bytes
16.0 0 = Not Configured Can be configured in increments of "20" (20 to 120). Decimal value of 20 = 60rpm/sec Ex. If Value = 20, then it's 60rpm/sec
20
212
Speed Ramp-down Rate Config
Option
2 Bytes 16.0 0 = Not Configured Can be configured in increments of "20" (20 to 120). Decimal value of 20 = 60rpm/sec Ex. If Value = 20, then it's 60rpm/sec
20
213
Ramp-up Speed Level Config Option during
Start-up
2 Bytes 16.0 100RPM/bit 0 = Default Ramp-up profile at start-up Ex. 15 = 1500RPM Range: 1500RPM to 3500RPM in 100RPM increments
0
214
Auto-Comm Configuration
Selection
2 Bytes 0 = Auto Detection Enabled Bit1 =1 Auto Detection Disabled
0
Auto Communication Detection Enable/Disable option.
When Bit1 = 1 (Manually baud rate and parity configured at registers Reg.203 & 204)
*Note: After 10 occurrences of a particular lockout related fault within 10hours time period, the drive will go into hard
lockout and need to be power cycled to clear the fault.
4 DRIVE CONFIGURATION FLOW CHARTS
Apply Power to Drive
Write Password “0x2345” to Register 200.
Read Registers 201 to 214(203 & 204 are
autoconfigured by the drive)
Do values match spec?
Faults?Query fault status
Write values according to Modbus Map to Registers
205 to 214Operate drive
Troubleshoot according to the fault
YES
YES
NO
NO
5 TROUBLESHOOTING GUIDE
Item Fault/Protection Check and Handling Registers Bit Blink Code RED &
YELLOW LEDs**
1
Compressor Phase Over Current
1. Check the U/V/W connections on drive side 78 80 0 1 or 3
2. Check the compressor motor windings
3. Check the compressor is operating with in specified limits.
Sensor on Drive not reading properly - Replace Drive
4
2 Compressor Phase Current Fold Back
Timeout
Compressor phase current ≥ foldback protection value (for 30 seconds). Check if the compressor is operating outside the specified speed range.
79 81 2 16
3
AC Input Over Current
1. Check the line voltage is too low.
78
80
1
11
2. Check the line voltage for noise.
3. Check the compressor is operating with in specified limits. 4. If the problem still persists, then it's possibly a drive component issue. Replace the drive
14
15
AC Input Current Sampling Fault
Sensor on Drive not reading properly 5
4
DC Bus Over Voltage
1. Check the DC bus voltage if it is > 800VDC or 450V* 2. Check the compressor is operating with in specified limits.
78
80
2
7
5
DC Bus Under
Voltage
1. Check the DC bus voltage if it is < 300VDC or 170VDC* 2. Check the compressor is operating with in specified limits.
78
80
3
8
6
AC Input Over
Voltage
1. Check the line voltage if it is > 575VAC or 275VAC. 2. Check the compressor is operating with in specified limits.
78
80
4
10
7
AC Input Under
Voltage
1. Check the line voltage if it is < 295VAC or 170VAC*. 2. Check the compressor is operating with in specified limits.
78
80
5
9
8
Power Module Over Temp
Verify proper airflow over the heat-sink of the drive. Remove any obstructions. Check that the compressor is operating within specified limits. Check the mounting screws on the drive, make sure they are tight. If the problem, still persists replace the drive.
78
80
11
4
9
Lost Rotor Position
1. Check the U/V/W connections on drive side & compressor side. 2. Check the compressor motor windings 3. Check system charge levels, if too high this problem can occur.
78
80
13
2
10 Compressor Phase Current Imbalance
82 84 0 14
11
Microelectronic Fault 1. DSP self-check error, restart the drive and fault should go away. 2. If problem persists, replace the drive.
82
84
2
13
EEPROM fault 12
12
Power Module Temp Low or Sensor Open
fault
Verify proper airflow over the heat-sink of the drive. Remove any obstructions. Check that the compressor is operating within specified limits. Check the mounting screws on the drive, make sure they are tight. If the problem, still persists replace the drive.
83
85
5
2
13
DC Bus Voltage Low
Check the AC power supply and if the right voltage is supplied according to the drive model. The drive running condition is not stable. Check the compressor load and makes sure it is OK. Restart the drive again.
79
81
0
17
14
AC Input Current
Fold Back Timeout.
1. Check the line voltage if it is < 187VAC. 2. Check the compressor is operating with in specified limits. 3. If problem persists, replace the drive.
79
81
4
15
15
Modbus Communication Lost
1. Check mod-bus communication cable connections. 2. Check the communication parameters are set right. 3. Power cycle the drive. 4. If problem persists, replace the drive.
79
81
7
11
16 Sensor 2 (Thermistor, DLT) High Temp
1. Check the DLT/Scroll Thermistor connection. 2. Check the compressor is operating with in specified limits.
79 81 8 6
17
Power Module Temp High
Verify proper airflow over the heat-sink of the drive. Remove any obstructions. Check that the compressor is operating within specified limits. Check the mounting screws on the drive, make sure they are tight. If the problem, still persists replace the drive.
79
81
11
18
18
COM MCU and DSP Communication Lost
1. Check mod-bus communication cable connections. 2. Check the communication parameters are set right. 3. Power cycle the drive. 4. If problem persists, replace the drive.
79
81
14
8
19
Power Module Temp. Fold Back Timeout
Verify proper airflow over the heat-sink of the drive. Remove any obstructions. Check that the compressor is operating within specified limits. Check the mounting screws on the drive, make sure they are tight. If the problem, still persists replace the drive.
79
81
3
21
20
Sensor 1 (High Pressure Switch
Open)
Condensing Pressure beyond limit, system issue.
78
80
8
20
21
Sensor 1 (High Pressure Sensor)
Low or Open
Condensing Pressure below limit, system issue.
82
84
5
N/A
22 Compressor Model Configuration Error
Compressor model and configuration code do not match
82 84 6 22
23 High Pressure Sensor Type
Configuration Error
Pressure sensor and configuration code do not match
82 84 7 23
24 Sensor 2 (Thermistor, DLT) Low Temp or
Open
1. Check the DLT/Scroll Thermistor connection. 2. Check the resistance of the sensor to ensure values are with in specified limits.
83 85 2 3
25 AC Input Voltage Sampling Fault
Sensor on Drive not reading properly N/A N/A N/A 6
26 AC Input Loss of Phase Protection
Input Power Phase missing, check the power supply connections.
78 80 6 16
27 DC BUS Voltage Sampling Fault
Sensor on Drive not reading properly N/A N/A N/A 7
28 Fault Limit Lockout Certain faults have a trip limit, see modbus map for details
82 84 15 N/A
29 Motor Weak Magnetic Protection
Input Voltage or DC bus Voltage too low. Check compressor is operating in specified limits.
N/A N/A N/A 12
30 Auto Config Communication Fault
Timeout
Baud rate or Parity of the system controller not matching with drive. Check whether system controller is working, then Power Cycle the drive.
79 81 6 17
*Note: Two different values are for EV2080M & EV2055M models.
**Note: LED603 = RED LED604 = YELLOW for EV20XXX-J- models. LED803 = RED LED804 = YELLOW for EV20XXX-K- models.
6 HI-POT TESTING
There many different types of dielectric testers available. When selecting one to use ensure it
has the following features:
• Can test to voltages up to 3000VDC or higher.
• Can read leakage currents less than 10µA.
• Has Arc Detection available.
Recommended test settings:
• APPLIED VOLTAGE: 2500 VDC
• MAXIMUM LEAKAGE CURRENT: Contact Applications Engineer
• RAMP UP TIME: 8 Seconds
• DWELL TIME: 5 Seconds
• RAMP DOWN: 8 Seconds
Please call your Application Engineer for additional details.
7 ACCESSORIES
Accessory Assembly P/N Drive Models Compressor Models
Compressor Molded Plug Cable 10 AWG, Fork
Terminal (OEM)
529-0243-02 5.5kW, 8.0kW All 3Ton & 5Ton Compressors
Compressor Molded Plug Cable (Service)1
529-0243-03 5.5kW, 8.0kW All 3Ton & 5Ton Compressors
1 Service cable will require field mounting of proper connector type on drive end of power cable