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EV3 Inverter Drive for

ZPV* Variable Speed Compressors

EV3015B & EV3185B

Application Guidelines

Summary of Contents for EV3 Series

Page 1: ...EV3 Inverter Drive for ZPV Variable Speed Compressors EV3015B EV3185B Application Guidelines ...

Page 2: ...s and LED s 6 3 3 Mounting 7 3 4 Electrical installation 7 3 4 1 Earth leakage protection 7 3 4 2 Grid supply and compressor wiring 8 3 4 3 DC chokes 8 3 4 4 Power grid connection 8 3 4 5 Compressor connection 9 3 4 6 Control terminal 9 3 4 7 DLT input 9 3 4 8 STO input 10 3 4 9 Modbus communication 10 3 4 10 Drive cooling control 10 4 Start up operation 11 4 1 OneEmerson Modbus Map 11 4 2 Drive c...

Page 3: ...7 segment display 19 6 Protections and alerts 20 6 1 Speed Drop Protection mode 20 6 2 Power module speed drop protection 21 6 3 Discharge line temperature protection 21 6 4 Speed drop protection limits LED and analog board codes 22 7 Maintenance repair 24 7 1 General statements 24 7 2 Fan replacement 24 8 Frequently asked questions 25 Appendix 1 Drive dimensions and mounting instructions EV3185B ...

Page 4: ...ation For relevant standards please refer to the Manufacturers Declaration available on request These instructions should be retained throughout the lifetime of the compressor and the drive You are strongly advised to follow these safety instructions 1 1 Icon explanation Explanation of used symbols Electric shock hazard May cause severe injury or death General warning about a possibility of non el...

Page 5: ...ion is only given after all terminals are connected with isolated ring and isolated blade terminals In special cases of using the drive without the IP20 enclosure which is in general forbidden the protection against direct and indirect touching must be part of the system design to avoid any risk of electric shock DC AC chokes must be covered on system side to avoid any risk of electric shock Use s...

Page 6: ...nfluence the environment of the drive keep pollution degree 2 No condensation under normal operation Ensure that the cool plate for flat plate versions does not create condensation inside the drive The IP class of the drive mounting area must be in line with the system standard ...

Page 7: ...sor input DLT Integrated passive power factor correction Integrated EMI filter Inrush current limitation Rated currents 50 C Enclosure with integrated heatsink and fan for cooling Speed Drop Protection mode for increased system stability 2 3 Models Drive model Power supply 50 60Hz Max input current 50 C Max output current 50 C Max input power 380 V EV3150B 3 380 to 460 VAC 27 A 27 A 15 kW EV3185B ...

Page 8: ... 3 Installation Furthermore the EV3 drives models comply with standard EN 61000 3 12 for harmonic currents higher than 16A Further system related requirements for compliance with the above mentioned standards are detailed in Chapter 3 Installation 2 6 Nomenclature Table 5 hereunder explains the nomenclature based on the drive model EV3185B K1 XXX EV 3 185 B K 1 XXX Definition EV Product family Ele...

Page 9: ...ED s Table 6 and additional illustrations explain the function and location of the drive terminals and LED s Terminal LED Function A Power input terminals 3 Phase L1 L2 L3 PE B Compressor terminals U V W C Control terminal 1 DLT Discharge line temp sensor NTC 10k 2 5 V 5 VDC powering the DLT sensor 3 STO Safety torque Off high pressure limiter 4 24 V 24 VDC STO powering the high pressure limiter 5...

Page 10: ...the frame M5 screws 3 9 Nm M6 screws 6 7 Nm To achieve better cooling it is recommended to mount the drive in the lower or middle part of the cabinet Ensure that the drive is mounted in such a way that good natural convection is possible Figure 3 shows the minimum clearances to other components near the drive Figure 3 Minimum mounting clearances Recommended minimum clearance space on the top botto...

Page 11: ...ass 0 Temperature class H Table 8 DC chokes 3 4 4 Power grid connection Table 9 includes information on how to connect the drive to the grid The maximum input current is based on a power factor of approximately 0 9 The ferrites fuses and cable cross sections should be considered as a recommendation and can be different based on the system design The connection between the cables and the drive scre...

Page 12: ...designed for cable lengths less than 2 meters ensure proper shielding on both sides to get best results The use of isolated ring and isolated blade terminals is mandatory for all terminals to maintain the IP20 class 3 4 6 Control terminal Each drive has a 9 pin control terminal including the 9 pin plug counterpart JITE PTB750B 00 1 09 3 The 5 V terminals are designed to provide voltage supply to t...

Page 13: ...9 Modbus communication The drive acts as a Modbus slave with a pre selected address 45 The serial communication between drive and any kind of controller or user interface is physically driven via RS485 control terminals 5 6 and 7 and logically via the Modbus RTU protocol If a master controller needs to be supplied with 5 VDC the control terminal 8 can be used During start up cycle if the auto adap...

Page 14: ... Yes Connect the sensor to pins 3 4 of the communication terminal No Place a jumper between pins 3 4 of the communication terminal Table 11 Configuration steps NOTE The drive remembers the configuration from registers 200 213 after each power cycle Wrong configuration will not be cleared with a power cycle 4 3 Drive operation modes There are two main operation modes Compressor Run mode Stator Heat...

Page 15: ...g temperatures pressures received from the system controller via Modbus The 4 modes can be selected from a list through register 231 o 0 Full Envelope Protection o 1 High Speed Envelope Protection o 2 Advanced Speed Drop Protection Mode o 3 Active Envelope Protection 4 4 1 Passive Envelope Protection The passive envelope control implies the so called Overload Protection Based on the compressor ope...

Page 16: ... depending on the operating point for the Normal Operation and SDP modes in register 109 4 4 2 Active Envelope Protection The Active Envelope Control selectable via register 231 mode 3 comprises of two stages Stage I Out of maximum application envelope detection The drive receives the evaporating and condensing temperatures via Modbus from the system controller Then it checks whether the operating...

Page 17: ... whole envelope speed band ie 2600 6000 rpm There are 6 sub regions in total which can be identified in the envelopes as per Appendix 4 4 5 Clearing faults Faults can be cleared after 30 seconds To do this follow the steps below 1 Set Compressor Speed Demand to zero 101 2 Set Compressor Enable command to zero 100 3 Set Clear Fault command 103 NOTE Once a Clear Fault command is sent faults will onl...

Page 18: ...d demand insert 0 in Compressor Speed Demand register 101 the drive will issue a controlled stop During the controlled shutdown if the speed is lower than 3600 rpm the drive will automatically decelerate towards 0 with more than 1000 rpm s However if the speed is higher than the platform speed 3600 rpm it will decelerate with a default rate of 200 rpm s until it reaches the platform speed then dec...

Page 19: ...nge the compressor lowest speed is the one which is valid for the whole envelope and is called MMS Maximum Minimum Speed In this case running at high load the compressor is well protected against too low and too high speeds In the Speed Drop Protection mode the drive will only use the limited speed range Figure 9 Analog control board 5 1 Terminal and LED description Table 13 describes in detail th...

Page 20: ...tion selected see paragraph 4 4 Envelope control for more details M 7 segment display Displaying status speed error code software version Table 13 Terminals and LED s of the analog control board 5 2 Control and configuration 5 2 1 Selection of drive compressor code The drive compressor code must be selected by a 6 digit binary coded DIP switch which has to be done before connecting to the drive In...

Page 21: ...To control the speed and the stator heating demand a 0 10 VDC signal is required at terminal C A PWM feedback signal is available at terminal B 5 2 4 Stator heating control To control the stator heating of the compressor the analog control board considers the range between 1 and 1 9 V see Table 15 The actual heating power depends on the type of compressor Voltage V Heating power 1 0 10 1 1 20 1 2 ...

Page 22: ...ed to MMS Figure 11 Analog board speed range selection In speed drop protection mode the drive will only use the limited speed range In this case the speed will not go below the MMS speed 5 2 8 Onboard 7 segment display The onboard 7 segment display shows the main information about the drive compressor status failure and warning codes which are part of Table 19 Board state Description Power on 5 s...

Page 23: ...gion in which it operates stored and frequently updated depending on the region in registers 44 and 109 If running in Full Envelope Control mode the foldback speed will be the minimum allowed compressor speed valid for the whole envelope stored in register 109 An immediate shutdown will occur if the Maximum Allowed Values limit is exceeded Going downwards the speed drop protection axis If the curr...

Page 24: ...down the compressor However if the temperature decreases below 108oC the drive will enter in the Speed Holding area where the speed is kept constant until the temperature goes below the recovery value ie below 103oC If the temperature goes below the recovery value the drive will return to the speed commanded initially 6 3 Discharge line temperature protection If a discharge line temperature sensor...

Page 25: ... E39 16 84 6 10 Output U phase current sampling fault N A Compressor trip E44 17 84 11 11 Output V phase current sampling fault N A Compressor trip E10 18 80 10 12 Output W phase current sampling fault N A Compressor trip E10 19 80 10 13 Input current sampling fault Input current AD 1658 or input current AD 2487 Compressor trip 20 14 Drive module temperature sampling fault If the module temperatur...

Page 26: ...pressor loss W phase 56 31 Compressor start up fault The compressor fails starting 3 times Compressor trip E14 57 80 13 32 High pressure protection N A Compressor trip E09 58 80 8 33 Compressor motor phase current imbalance The difference between the maximum and minimum of the compressor phase currents RMS value exceeds 4 A Compressor trip E07 59 80 6 34 AC input loss of phase The maximum value of...

Page 27: ... heatsink are free of dust to guarantee efficient cooling 7 2 Fan replacement In case the fan breaks it can be easily replaced Use the following installation procedure to replace it 1 Identify the fan position on the drive below the input and output terminals of the drive 2 Press on the clips on the left and right sides of the plastic housing and take the fan out The housing being attached to the ...

Page 28: ... the configuration based on registers 201 213 after a power cycle In order for the faults to be cleared the right parameters must be introduced 3 Why has the DLT sensor short open fault been triggered If the DLT sensor has been enabled and nothing is connected to the communication terminal on the positions of the sensors DLT pins 1 2 then a fault will trigger 4 The drive ignores the speed command ...

Page 29: ...26 AGL_Sol_EV3_E_Rev_01 Appendix 1 Drive dimensions and mounting instructions EV3185B EV3150B ...

Page 30: ...AGL_Sol_EV3_E_Rev_01 27 Appendix 2 Choke dimensions Figure 14 DC choke 40A 2mH for EV3150B Figure 15 DC choke 50A 2mH for EV3185B ...

Page 31: ...28 AGL_Sol_EV3_E_Rev_01 Appendix 3 Analog control board description and dimensions Figure 16 ...

Page 32: ...AGL_Sol_EV3_E_Rev_01 29 Appendix 4 Envelopes Figure 17 ZPV066 compressor envelope with R410A 20 F SH 15 F SC 95 F ambient Figure 18 ZPV096 compressor envelope with R410A 20 F SH 15 F SC 95 F ambient ...

Page 33: ...not to be construed as warranties or guarantees express or implied regarding the products or services described herein or their use or applicability 2 Emerson Climate Technologies GmbH 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 3 Emerson does not assume responsibility for the selectio...

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