AE8-1422 - EV2 Single Phase Series Variable Speed Drives ......2 AE8-1422 Safety Instructions Copeland Scroll™ variable speed drives are manufactured according to the latest U.S

© 2017 Emerson Climate Technologies, Inc.

1

TABLE OF CONTENTS Safety

Safety Instructions .................................................. 2 Safety Icon Explanation .......................................... 2 Instructions Pertaining to Risk of Electrical Shock, Fire, or Injury to Persons ............ 3 Safety Statements .................................................. 4 Introduction

Product Description ................................................ 5 Theory of Drive Operation ...................................... 5 Agency Recognition ................................................ 5 Nomenclature ......................................................... 5 Installation Drive Handling ........................................................ 5 Mounting ................................................................. 5 Drive Dimensions.................................................... 5 Wiring Diagram ....................................................... 5 Operation & Function ............................................... 6 Hi-pot Procedure / Set-up ....................................... 6 Temperature & Humidity ......................................... 6 Pre-operation Checks ............................................. 6 Power On/Off ......................................................... 6 Communication Setting ......................................... 6 Input Voltage and Input Current ............................. 6 Power Factor Correction ......................................... 6 Speed Control ......................................................... 6 Start-up ................................................................... 6 Shutdown ................................................................ 6

Fault Clearing ......................................................... 6 Lockout Faults ........................................................ 6 Stator Heat Control ................................................ 7 Status Indication ..................................................... 7 LED ..................................................................... 7 Operation Indicating LED (Green LED1) ............ 7 Protection Indicating LED (Yellow LED2) ........... 7 Hardware Fault Indicating LED (Red LED3) ....... 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 Cold Plate Heat Exchanger .................................... 8 Foldback ................................................................. 8 Troubleshooting ..................................................... 8 EMC Guidelines ..................................................... 8 Figures Wiring Diagram ...................................................... 9 Drive Input and Output Connections .................... 10 Tables Communication Connector Pin Definition ............ 11 Sensor Connector Pin Definition .......................... 11 Addendum

AE8-1422 October 2017

EV2 Single Phase Series Variable Speed Drives 208-240 V, 3.3 kW

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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AE8-1422

Safety Instructions

Copeland Scroll™ variable speed drives are manufactured according to the latest U.S. and European Safety Standards. Particular emphasis has been placed on the user's safety. Safety icons are explained below and safety instructions applicable to the products in this bulletin are grouped on Page 3. These instructions should be retained throughout the lifetime of the compressor. You are strongly advised to follow these safety instructions.

Safety Icon Explanation

DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury. WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. CAUTION, used with the safety alert symbol, indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

NOTICE is used to address practices not related to personal injury.

CAUTION, without the safety alert symbol, is used to address practices not related to personal injury. FLAMMABLE

DANGER

WARNING

CAUTION

NOTICE

CAUTION


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AE8-1422

Instructions Pertaining to Risk of Electrical Shock, Fire, or Injury to Persons

WARNING ELECTRICAL SHOCK HAZARD

• Disconnect and lock out power before servicing.

• Discharge all capacitors for a minimum of two minutes before servicing.

• Use compressor with grounded system only.

• Molded electrical plug must be used when required.

• Refer to original equipment wiring diagrams.

• Electrical connections must be made by qualified electrical personnel.

• Failure to follow these warnings could result in serious personal injury.

WARNING

PRESSURIZED SYSTEM HAZARD

• System contains refrigerant and oil under pressure.

• Remove refrigerant from both the high and low compressor side before removing compressor.

• Never install a system and leave it unattended when it has no charge, a holding charge, or with the service valves closed without electrically locking out the system.

• Use only approved refrigerants and refrigeration oils.

• Personal safety equipment must be used.

• Failure to follow these warnings could result in serious personal injury.

WARNING

FIRE HARD • Open flames and smoking are strictly forbidden. • Continuously check if the ambient atmosphere is nonexplosive. • During service make sure that:

o The area is well ventilated. o The materials and equipment used are suitable for use under

explosive conditions. o Only non-sparking tools are used. o Anti-static gloves and clothes are used. o A build-up of electrostatic charges is avoided.

• In the case of explosive atmosphere: o Immediately stop the compressor and de-energize the power

supply of the compressor and any other electrical component/ equipment such as crankcase heater.

o No unshielded flame is allowed. • Before opening the refrigeration, system or working on it with an unshielded

flame: o Continuously check if the ambient atmosphere is non-explosive

and ensure proper ventilation of the room before creating any naked flame. No naked flame is allowed in an explosive atmosphere.

• When atmosphere reaches a dangerous concentration of flammable gas: o Avoid any ignition source and ventilate the room further.

• Closed all valves tightly if any parts of the refrigeration systems are charged with flammable refrigerants.


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WARNING

BURN HAZARD

• Do not touch the compressor until it has cooled down.

• Ensure that materials and wiring do not touch high temperature areas of the compressor.

• Use caution when brazing system components.


• Failure to follow these warnings could result in serious personal injury or property damage.

R290 MIXTURE IN POTENTIALLY EXPLOSIVE ATMOSPHERE

• R290 mixed with air can create an explosive atmosphere.

• Immediately stop the compressor and ventilate the room if an explosive atmosphere is detected.

• No open flame is allowed.

CAUTION COMPRESSOR HANDLING

• Use the appropriate lifting devices to move compressors.


• Failure to follow these warnings could result in personal injury or property damage.

Safety Statements

• Refrigerant compressors must be employed only for their intended use.

• Only qualified and authorized HVAC or refrigeration personnel are permitted to install commission and maintain this equipment.

• Electrical connections must be made by qualified electrical personnel.

• All valid standards and codes for installing, servicing, and maintaining electrical and refrigeration equipment must be observed.


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INTRODUCTION

Product Description

The inverter drive has been developed specifically for the variable speed compressor. 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 voltage. 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 a complete explanation of all of the alpha and numeric characters in the drive model number.

INSTALLATION

Drive Handling

• Correct handling and storage of the drive is essential in preventing mechanical damage.

• Box and the protection bag inside the box need to be carefully opened. Do not use any sharp material to open the protection bag, which may damage the drive.

• Never cut across the drive with any sharp materials.

• Do not hold the components on the drive or drive accessories; this can damage them.

• Once opened do not stack the drives on each other.

• When handling the drive, the only correct way is to hold it by the edges of the heatsink or plastic tray, as applicable.

• Do not drop any mechanical tools on the drive or drive accessories.

• It is always recommended to use ESD control wrist bands while touching any part of the drive.

• It is important that all screws terminals are torqued to the range of 18-20 lb-in (2.0-3 N-m) to prevent any damaged to the inverter and filter board.

Caution must be used when lifting and installing the drive. Failure to use caution may result in bodily injury.

The drive is designed to meet creepage and clearance requirements for a maximum altitude of 2000 meters.

Personnel handling the drives in a manufacturing plant environment should guard against static electricity by using the appropriate equipment – anti-static wrist straps and mats.

Mounting

The drive should be located as close to the compressor as possible. Preferably within 5 feet of the compressor 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 heatsink 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 an M5 sized screw for mounting.

Drive Accessories and Dimensions

Refer to Addendum for accessories. Contact Application Engineering for detailed dimensions with tolerance and drawings.

Wiring Diagram

Refer to Figure 1 and 2 for a detailed description of the drive wiring diagrams and connections. Refer to Table 1 and Table 2 for a detailed description of the connector pin definition.


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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%

Pre-operation Checks

Check the drive carefully before operating. Make sure that all the wires are correctly and tightly connected. Improper operation may cause fire or injury to persons.

Power On/Off

The drive should use rated AC power supply: 50/60Hz,208~240V. Use of incorrect power supply may damage the drive. A User should make sure that the correct combination of a power supply, drive, and accessories are used.

When powering off the drive, make sure to 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. Contact Application Engineering for information.

Input Voltage and Input Current

The drives are designed for an input power supply of 208 to 240 volts 50/60 Hz. Published performance of 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 range of 208 to 240 volts.

Drive Max AC Input Current

EV2033M 15 ARMS

Power Factor Correction

The drive has active power factor correction. The drive is capable of correcting the AC input current to maximize system efficiency.

Speed Control

The speed range of EV2 is from 900 RPM to 7200 RPM. If the speed set by system controller is less than 900 RPM but not zero, then the compressor will work at 900 RPM. Similarly, if the speed set by system controller is greater than 7200 RPM, then the compressor will operate at 7200 RPM.

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.


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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 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 following 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 will stop stator heating and start the compressor. While running, if the system sends a zero-speed command, the drive will 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

The DSP microcontroller on the drive board has an LED status display, which shows the following status:

LED for COMMS

Operation Indicating LED (Green LED 1)

When the drive is in a normal state (no protection and fault), the drive is in a standby state, and the compressor is not running, the LED will always be ON. If the compressor is running, the LED will blink at 1Hz.

Protection Indicating LED (Yellow LED 2)

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 3)

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.

Power LED (Green LED 4)

Solid ON when switching power supply on the drive works normally.

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 - 208 and 210 -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.

• Register 205 is for compressor model type.

• Registers 206 & 207 are for sensor type configurations.

• Register 208 designates US or EU Power Factor Correction thresholds.

• 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.

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

CN7 is a 2-port connector. 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 the high-pressure switch for the system’s lifetime, typically gold-plated contacts are recommended. Refer Table-2 for detailed pinout.


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AE8-1422

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 -13°F to 150°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 the 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 a similar product is recommended.

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 events(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 service panel to maintain a good ground connection. The star connection includes: – System Input ground – Drive Heat-sink ground – EMI filter ground (if applicable)

• The usage 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.

Usage 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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No. Terminal Marking Terminal Description Location

1 L1/L2/GRN Power supply CN11/CN12/CN13

2 H1/H2 PFC choke CN19/CN20

3 U/V/W Compressor CN1/CN2/CN3

4 RS485 Communication CN15

5 HPS High pressure cut-out CN7

6 DLT DLT/Scroll Temperature Sensor CN10

Figure 1 – Wiring Diagram


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Figure 2 – Drive Input and Output Connections

Drive Power Input

DLT Temp

High Pressure

To PFC Choke

RS485 Communication Port

Drive Output to Compressor


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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


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


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.

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 .................................................................................................... 10

5 Troubleshooting Guide .................................................................................................................... 11

6 Hi-pot Testing .................................................................................................................................... 14

7 Accessories ....................................................................................................................................... 14

ADDENDUM to AE8-1422 10/31/2017

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 start

request

1500 (configurable) 180 9

II Compressor remains at the

platform speed

1500 - 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

9S 19 S

10S

180RPM/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 120 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 Envelope minimum foldback speed and then stay at Envelope minimum foldback speed for >= 30sec. OR

• If the original running speed was already < Envelope minimum foldback speed for >= 30sec

Compressor will be tripped

Stop

Shutdown Initiated

60-360RPM/S (Reg.210)

900RPM (Minimum Speed)

Shutdown Down rate is

Customer configured

Table 4 – Output Current or Torque Foldback


1 Output Current or Torque >= Foldback Limit of operating speed range

Will reduce the speed at the rate of 60 rpm/s

2 Recovering Current or Torque <= Output Current or Torque < Foldback Limit of operating speed range


3 Output Current or Torque < Recovering Limit Speed will be recovered to commanded speed

4





Table 5 – Inverter Temperature Foldback


1 Inverter Temperature >= Foldback Temperature Will reduce the speed at the rate of 180 rpm/s

2 Recovering Temperature <= Inverter Temperature < Foldback Temperature


3 Inverter Temperature < Recovering Temperature Speed will be recovered to commanded speed

4





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)

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

12

SW Version (Read)

DSP Boot Version (High Word)

N/A N/A 2 Bytes

16.8.8 Ex. 4.20.0: 4=Production ver; 20= Internal Major ver; 0= Internal Minor ver

13 DSP Boot 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

16

Trip Limits (Read)

Compressor Phase Over

Current

N/A

Amps (RMS)

2 Bytes

12.4 Ex. If Value = 512, then Conversion = 512/(2^4)

17 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


20 AC Input Over Voltage


21 AC Input Under Voltage


22 Power Module Over Temp

N/A Celsius 2 Bytes 11.5 Ex. If Value = 512, then Conversion = 512/(2^5)

23 PFC-IGBT Over Temp


32 DC Bus Voltage Low


35 Power Module Temp High


36 PFC-IGBT Temp High


38 Sensor 2 (Thermistor, DLT)

High Temp Limit


48

Drive Status/Readings

(Read)

Compressor Torque/Phase Current Fold Back Status

N/A N/A 2 Bytes 0 = No ; 1 = Yes

49 Power Module Temp Fold Back Status


50 AC Input Current Fold Back Status


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 Torque/Phase Current

N/A Nm/Amps (RMS)

2 Bytes 7.9 Ex. If Value = 512, then Conversion = 512/(2^9)

62 Torque Limit/Phase Current

Limit

N/A Nm/Amps (RMS)


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


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)

70

Power Module Temp


73

PFC-IGBT 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


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


DC Bus Under Voltage Immediate


AC Input Over Voltage Controlled


AC Input Under Voltage Controlled


Sensor 1 (High Pressure Switch Open)

Immediate Shutdown

N/A Bit 8 0 = No ; 1 = Yes

Power Module Over Temp Immediate


PFC-IGBT Over Temp Immediate


Lost Rotor Position Immediate


Lockout (After 10 fault occurrences*)

DC Bus Voltage Low N/A N/A Bit 0 0 = No ; 1 = Yes

Compressor Phase Over Current (Intermediate)

Controlled Shutdown

N/A Bit 1 0 = No ; 1 = Yes

Compressor Torque/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

79


Auto Config Communication Timeout

N/A N/A Bit 6 0 = No ; 1 = Yes

Modbus Communication Lost Controlled


Sensor 2 (Thermistor, DLT) High Temp

Immediate Shutdown

N/A Bit 8 0 = No ; 1 = Yes

Board Temp High Controlled Shutdown

N/A Bit 10 0 = No ; 1 = Yes

Power Module Temp High Controlled Shutdown

N/A Bit 11 0 = No ; 1 = Yes

PFC-IGBT Temp High Controlled Shutdown

N/A Bit 12 0 = No ; 1 = Yes

80

Multiple Faults Occurred (Read)


Immediate Shutdown


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

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

PFC-IGBT Over Temp Immediate Shutdown

N/A Bit 12 0 = No ; 1 = Yes

Lost Rotor Position

Immediate Shutdown

N/A

Bit 13

0 = No ; 1 = Yes Lockout (After 10 fault occurrences*)

81


DC Bus Voltage Low

N/A

N/A

Bit 0

0 = No ; 1 = Yes

Compressor Phase Over Current (Intermediate)

Controlled Shutdown

N/A Bit 1 0 = No ; 1 = Yes

Compressor Torque/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

Board Temp High Controlled Shutdown

N/A Bit 10 0 = No ; 1 = Yes

Power Module Temp High Controlled Shutdown

N/A Bit 11 0 = No ; 1 = Yes

PFC-IGBT Temp High Controlled Shutdown

N/A Bit 12 0 = No ; 1 = Yes

82


Compressor Phase Current Imbalance

Immediate Shutdown

N/A Bit 0 0 = No ; 1 = Yes

Micro Electronic Fault or Drive EEPROM Fault

Immediate Shutdown


Motor Over-speed Intermediate Shutdown

N/A Bit 3 0 = No ; 1 = Yes

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

Sensor 2 (Thermistor, DLT) Low Temp or Open

Immediate Shutdown

N/A Bit 2 0 = No ; 1 = Yes

83


Power Module Temp Low or Sensor Open fault

Immediate Shutdown

N/A Bit 5 0 = No ; 1 = Yes

PFC-IGBT Temp Low or Sensor Open fault

Immediate Shutdown

N/A Bit 6 0 = No ; 1 = Yes

Fault Limit Lockout N/A N/A Bit 15 Lockout Status 0 = No ; 1 = Yes

84


Compressor Phase Current Imbalance

Immediate Shutdown

N/A Bit 0 0 = No ; 1 = Yes

Micro Electronic Fault or Drive EEPROM Fault

Immediate Shutdown


Motor Over-speed Intermediate Shutdown

N/A Bit 3 0 = No ; 1 = Yes

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


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

PFC-IGBT Temp Low or Sensor Open fault

Immediate Shutdown

N/A Bit 6 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)

Map access Password

2 Bytes Password = 0x2345 Customer access to 201~213

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

260 = ZHV0211U-3E9 (900 –

7200RPM)

261 = ZBV0211U-3E9 (2000 –

5000RPM)

311 = ZPV0212E-2E9 (900 -

7200RPM) Rev.1

0

313 = ZHV0212P-2E9 (900 -

7200RPM) Rev.1

360 = ZHV0291U-3E9 (900 –

7200RPM)

361 = ZBV0291U-3E9 (2000 –

5000RPM)

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.

208

Customer Configuration

Parameter (Read/Write)

PFC Config Option

2 Bytes

0 = PFC Threshold for US 100 = PFC Thresholds for EU

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


20

212

Speed Ramp-down Rate Config Option

2 Bytes


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

*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 0x to Register 200.

Read Registers 201 to 213

(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 213

Operate drive

Troubleshoot according to

the fault

YE

S

YES

NO

NO

5 TROUBLESHOOTING GUIDE

Item Fault/Protection Check and Handling Registers Bit Blink Code LED2=YELLOW

LED3 = RED

1


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

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 if it is < 187VAC.

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 line voltage if it is > 265VAC. 2. Check the DC bus voltage if it is >385VDC 3. Check the compressor is operating with in specified limits.

78

80

2

7

5

DC Bus Under Voltage

1. Check the line voltage if it is < 187VAC. 2. Check the DC bus voltage if it is < 385VDC 3. 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 > 265VAC. 2. Check the DC bus voltage if it is > 385VDC 3. 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 < 187VAC. 2. Check the DC bus voltage if it is < 385VDC 3. 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 PFC-IGBT Over Temp

78 80 12 5

10

Lost Rotor Position 1. Check the U/V/W connections on drive

side & compressor side.

2. Check the compressor motor windings

78

80

13

2

11 Compressor Phase

Current Imbalance 82 84 0 14

12

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

13 Power Module Temp Low or Sensor Open

fault

Temperature sensing device on the drive are possibly defective. If problem persists, replace the drive.

83 85 5 2

14

DC Bus Voltage Low

1. Check the line voltage if it is < 187VAC. 2. Check the DC bus voltage if it is < 385VDC. 3. Check the compressor is operating with in specified limits.

79 81 0 17

15

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

16

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


High Temp

1. Check the DLT/Scroll Thermistor connection. 2. Check the compressor is operating with in specified limits.

79 81 8 6

18

Power Module Temp High


79

81

11

18

19 PFC-IGBT High Temp

79 81 12 19

22 PFC-IGBT Temp Low or Sensor Open

fault


83 85 6 1

23 Power Module Temp. Fold Back

Timeout

79 81 3 21

24 Sensor 1 (High Pressure Switch

Open)

Condensing Pressure beyond limit, system issue.

78 80 8 20

25 Sensor 1 (High Pressure Sensor)

Low or Open

Condensing Pressure below limit, system issue.

82 84 5 N/A

26 Compressor Model Configuration Error

Compressor model and configuration code do not match

82 84 6 22

27 High Pressure Sensor Type

Configuration Error

Pressure sensor and configuration code do not match

82 84 7 23


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

29 AC Input Voltage Sampling Fault

Sensor on Drive not reading properly N/A N/A N/A 6

30 DC BUS Voltage Sampling Fault”

Sensor on Drive not reading properly N/A N/A N/A 7

31 Fault Limit Lockout Certain faults have a trip limit, see modbus map for details

82 84 15 N/A

32 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

33 Compressor AA5 Phase Over Current

(Intermediate)

Check the compressor is operating within specified limits.

79 81 1 27

34 Board 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 10 26

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

Test Procedure:

• Setup test on a clean and dry non-conductive surface.

• Ensure samples are handled properly and using ESD precautions.

• Verify the dielectric tester is configured per “Recommended test settings”.

• 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.

7 ACCESSORIES

Accessory Assembly P/N Drive Models Compressor Models

Compressor Molded Plug Cable 12 AWG, Fork Terminal (OEM)

529-0275-00 3.3kW All Compressors

Compressor Molded Plug Cable (Service)1

529-0243-03 3.3kW All Compressors

Communication Cable 529-0249-00 3.3kW All Compressors

1 Service cable will require field mounting of proper connector type on drive end of power cable

Documents

AE8-1422 - EV2 Single Phase Series Variable Speed Drives ......2 AE8-1422 Safety Instructions Copeland Scroll™ variable speed drives are manufactured according to the latest U.S