Emerson EVH Series Installation Manual Download

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Copeland

™

Commercial HVACR

Variable Frequency Drive – EVH Series

Installation Manual

Summary of Contents for EVH Series

Page 1: ...Copeland Commercial HVACR Variable Frequency Drive EVH Series Installation Manual ...

Page 2: ... 18 Branch Circuit Short Circuit Protection 19 Cable and Fuse Guidelines 22 Panel Mounting 27 EMC Installation 28 International EMC Installation 29 Install in corner grounded network 30 Verifying Rotation 30 Step 3 Control Board Layout 31 I O Terminal Connections 32 Step 4 Drive Startup and Setup 33 Main Menu Navigation 33 Startup Wizard 34 PID and Advanced App Startup 34 Bypass Unit Information 3...

Page 3: ...en to ensure the proper restart of programs interrupted after a voltage dip or failure This should not cause dangerous operating states even for a short time If necessary emergency stop devices should be implemented Wherever faults in the automation system may cause injury or material damage external measures must be implemented to ensure a safe operating state in the event of a fault or malfuncti...

Page 4: ...nt After receiving your Copeland VFD please check for the following Check to make sure that the package includes the install manual quick start guide and accessory packet The accessory packet includes Rubber grommets Control cable grounding clamps Additional groundingscrew Inspect the unit to ensure it was not damaged during shipment Make sure that the part number indicated on the nameplate corres...

Page 5: ...5 Rating Label Carton Label Keypad Button Overview ...

Page 6: ...A 261 261A 310 310A 525 600V 4D5 4 5A 7D5 7 5A 010 10A 013 13A 018 18A 022 22A 027 27A 034 34A 041 41A 052 52A 062 62A 080 80A 100 100A 125 125A 144 144A 208 208A 250 250A Platform H Gen Duty HVACR Input Voltage 2 200 240V 4 380 480V 5 525 600V Onboard Comms B BACnet Modbus Option Spot N None B Bypass Output Voltage 2 200 240V 3Ø 4 380 480V 3Ø 5 525 600V 3Ø Product type V Variable Frequency Drive ...

Page 7: ...23 37 244 7 419 0 406 0 380 0 167 8 134 0 90 0 90 0 7 0 10 6 FR3 10 44 21 97 21 46 20 41 8 06 7 24 4 92 4 92 0 35 49 82 265 1 558 0 545 0 518 5 204 6 184 0 125 0 125 0 9 0 22 6 FR4 11 57 24 80 24 31 23 26 9 36 9 13 8 07 8 07 0 35 77 60 294 0 630 0 617 5 590 7 237 7 232 0 205 0 205 0 9 0 35 2 FR5 13 41 34 98 29 65 27 83 11 34 11 10 8 66 8 66 0 35 154 32 340 7 888 5 753 0 707 0 288 0 282 0 220 0 220...

Page 8: ...ize mounting instructions Minimum clearances A and B for drives with Type 12 IP54 enclosure is 0mm in for FR1 FR2 FR3 FR4 The below guidelines apply unless testing has been completed to validate a design outside of these recommendations This work must be done in collaboration with Emerson Application Engineering ...

Page 9: ... should follow required dimensions refer to the drive mounting template printed on the outside carton FR2 Mounting Instructions Step 1 Lift the drive out from the carton Remove the packaging Step 2 Attach the drive to the mounting plate with four M5x15 or 3 16 inch screws and four M5 or 3 16 inch nuts The opening dimensions on the mounting plate should follow required dimensions refer to the drive...

Page 10: ...e should follow required dimensions refer to the drive mounting template printed on the outside carton FR4 Mounting Instructions Step 1 Lift the drive out from the carton Remove the packaging Step 2 Attach the drive to the mounting plate with four M8x15 or 3 8 inch screws and four M8 or 3 8 inch nuts The opening dimensions on the mounting plate should follow required dimensions refer to the drive ...

Page 11: ... M8 or 3 8 inch wrench Step 3 Use a hook to lift the drive Step 4 Attach the drive to the mounting plate with four M8x20 or 3 8 inch screws and four M8 or 3 8 inch nuts with an M8 or 3 8 inch wrench The opening dimensions on the mounting plate should follow required dimensions refer to the drive mounting template printed on the outside carton ...

Page 12: ... M8 or 3 8 inch wrench Step 3 Use a hook to lift the drive Step 4 Attach the drive to the mounting plate with four M8x20 or 3 8 inch screws and four M8 or 3 8 inch nuts with an M8 or 2 8 inch wrench The opening dimensions on the mounting plate should follow required dimensions refer to the drive mounting template printed on the outside carton ...

Page 13: ...13 Rubber Grommet Installation Instructions Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 ...

Page 14: ...nd output current If motor temperature sensing is used for overload protection the output cable size may be selected based on the motor specifications Maximum symmetrical supply current is 100 000 A RMS for all size EVH Drives Input protection Input protection devices are rated based on the EVH drive rated input and output current For UL and cUL CSA refer to Appendix D for proper sizing For gG gL ...

Page 15: ... 25 120 25 65 25 120 FR5 1 10 6 10 1 10 9 45 1 10 6 10 1 10 9 45 28 155 28 240 28 155 28 240 FR6 0 98 4 72 0 98 7 87 0 98 4 72 0 98 7 87 25 120 25 200 25 120 25 200 Power Connection Tightening Torque Frame Size Power wire in lb Nm Ground wire in lb Nm Control wire in lb Nm FR1 5 3 0 6 10 1 1 4 5 0 5 FR2 15 6 1 8 10 1 1 4 5 0 5 FR3 40 4 5 10 1 1 4 5 0 5 FR4 95 10 7 14 1 6 4 5 0 5 FR5 354 40 0 35 4 ...

Page 16: ...ot discard the plastic bag containing the wiring hardware 1 Remove the A cover by removing 4 screws then lifting the A cover away from the base 2 Remove power wiring protection plate Use power motor cable tables 3 Add attachable grounding clamps qty 2 one on each side of drive 4 Pass motor input power wires cables through base wiring plate 5 If shielded cable is used connect the shields of input p...

Page 17: ...y vary slightly by frame Ground Wiring Run motor cables in separate conduit DO NOT RUN CONTROL WIRES in same conduit Cables sized per below tables for Cables Fuses Provide dedicated wire for low impedance ground between drive and motor DO NOT USE conduit as ground Improper grounding could result in damage to the motor and or drive and could void warranty ...

Page 18: ... 210 20 215 3 and 430 address the NEC requirements in more detail For safety reasons it is recommended to assume all loads are continuous To explain the process for finding the minimum breaker size necessary please complete the following 1 Find your total current load of the circuit ex 13 7 2 Multiply your current load by 1 25 to find your minimum breaker size ex 13 7 1 25 17 125 3 Find the correc...

Page 19: ...rotects your wire sizing Frame size EVH Base Model Maximum fuse rating magnetic breaker rating Maximum magnetic breaker rating 1 EVH 3443D3 R 600 V 10 A 480 V 15 A 480 V 7 A EVH 3444D3 R 600 V 10 A 480 V 15 A 480 V 15 A EVH 3445D6 R 600 V 15 A 480 V 15 A 480 V 15 A EVH 3447D6 R 600 V 15 A 480 V 15 A 480 V 25 A EVH 344009 R 600 V 15 A 480 V 15 A 480 V 25 A EVH 344012 R 600 V 15 A 480 V 15 A 480 V 2...

Page 20: ...ating Maximum magnetic breaker rating 1 EVH 3224D8 R 600 V 15 A 480 V 15 A 480 V 15 A EVH 3226D6 R 600 V 20 A 480 V 20 A 480 V 25 A EVH 3227D8 R 600 V 20 A 480 V 20 A 480 V 25 A EVH 322011 R 600 V 30 A 480 V 30 A 480 V 30 A EVH 322012 R 600 V 30 A 480 V 30 A 480 V 30 A 2 EVH 322017 R 600 V 40 A 480 V 40 A 480 V 50 A EVH 322025 R 600 V 40 A 480 V 40 A 480 V 50 A EVH 322031 R 600 V 40 A 480 V 40 A 4...

Page 21: ...ion protects your wire sizing Field wiring The field installed conductors for this drive should be 75 C or higher copper wire The enclosure openings provided for conduit connections in the field shall be closed by UL Listed conduit fittings with same type rating as the enclosure Type 1 Type 12 Frame size EVH Base Model Maximum fuse rating Maximum thermal magnetic breaker rating Maximum current lim...

Page 22: ... is recommended Frame size VT IL at 230 V at 208 V VT IL at 40 C Recommend fuse rating Line and motor Ground Line and motor Ground FR1 4 4 4 2 4 6 4 8 10 14 14 24 10 18 10 6 1 6 6 6 6 6 10 14 14 24 10 18 10 7 2 6 8 7 5 7 8 10 14 14 24 10 18 10 10 2 9 6 10 6 11 15 14 14 24 10 18 10 11 6 12 5 15 12 12 24 10 18 10 FR2 16 3 15 2 16 7 17 5 20 10 10 20 6 12 6 23 2 22 24 2 25 30 8 10 20 6 12 6 29 28 30 8...

Page 23: ...s recommended Frame size 208 V input current VT IL Current VT IL at 40 C Fuse rating gG gL Mains and motor cable Cu mm2 Terminal cable size Main terminal Cu mm2 Earth terminal Cu mm2 FR1 4 4 4 8 6 3 1 5 1 5 0 2 6 solid or 0 2 4 stranded 0 75 6 6 1 6 6 10 3 1 5 1 5 0 2 6 solid or 0 2 4 stranded 0 75 6 7 2 7 8 16 3 1 5 1 5 0 2 6 solid or 0 2 4 stranded 0 75 6 10 2 11 16 3 1 5 1 5 0 2 6 solid or 0 2 ...

Page 24: ...otor Ground motor Ground FR1 3D3 2 8 3 3 10 14 14 26 10 18 10 4D3 3 2 3 4 3 4 10 14 14 26 10 18 10 5D6 4 5 4 8 4 8 10 14 14 26 10 18 10 7D6 7 1 7 6 7 6 10 14 14 26 10 18 10 9D0 8 4 7 6 15 14 14 26 10 18 10 012 10 2 11 11 15 14 14 26 10 18 10 FR2 016 13 14 14 20 12 12 20 6 12 6 023 19 6 21 21 30 10 10 20 6 12 6 031 25 2 27 27 35 8 8 20 6 12 6 FR3 038 31 7 34 34 50 6 8 6 2 14 4 046 37 40 40 60 6 8 6...

Page 25: ... 3 35 16 16 50 6 50 105 97 105 125 3 50 25 16 50 6 50 FR5 140 129 140 160 3 70 35 50 185 10 120 170 157 170 200 3 95 50 50 185 10 120 205 189 205 250 3 120 70 50 185 10 120 FR6 261 246 2 261 400 2 3 70 35 2 50 150 35 150 310 292 4 310 400 2 3 95 50 2 50 150 35 150 Notes Line and motor cable size is selected according to IEC 60364 5 52 2009 Table B 52 4 for copper conductor with PVC insulation with...

Page 26: ...rrent Frame size current VT IL rating at 575 V Recommended 40 C fuse rating c Line and motor Ground Terminal connection size AWG Line and motor Ground FR1 4 2 3 9 4 5 10 14 14 26 10 18 10 7 6 1 7 5 10 14 12 26 10 18 10 9 3 9 10 15 14 10 26 10 18 10 FR2 12 5 11 13 5 20 12 10 20 6 12 6 16 7 17 18 30 10 10 20 6 12 6 20 4 22 22 35 10 8 20 6 12 6 FR3 25 2 27 27 40 6 8 6 2 14 4 31 7 32 34 45 6 8 6 2 14 ...

Page 27: ...ection Large area connection of all metallic control panel components Mounting surfaces of frequency inverter and cable shielding must be free from paint Connect the cable shielding in the output of the frequency inverter with a large surface area contact to the ground potential PES Large area cable shield contacts with motor Large area earth connection of all metallic parts ...

Page 28: ... and be connected with short HF braided cables It is recommended to avoid using painted surfaces anodized chromized An overview of all EMC measures is provided in the figure on Previous Page Install the frequency inverter as directly as possible without spacers on a metal plate mounting plate Route input and motor cables in the switch cabinet as close to the ground potential as possible This is be...

Page 29: ...ree or four wire cable is recommended for the motor cables The green yellow line of a four wire cable connects the protective ground connections from the motor and the variable frequency drive and therefore minimizes the equalizing current loads on the shielding braid If there are additional subassemblies in a motor feeder such as motor contactors overload relays motor reactor sinusoidal filters o...

Page 30: ... cover to allow the intermediate circuit capacitors to discharge Locations of EMC and MOV Screws for Frame 2 and Frame 4 Locations of the EMC Screws in Frame 5 and Frame 6 Failure to follow these instructions will result in death or serious injury Remove the main cover of the AC drive and remove the EMC MOV screws depending on frame size see Following Figures Once the screw is removed it can be re...

Page 31: ...31 Step 3 Control Board Layout ...

Page 32: ...Motor Current Shows Motor current of motor 0 FLA 4 20mA 19 24Vi 24VDC Input External control voltage input 20 DIN1 Digital Input 1 Run Forward Input starts drive in forward direction start enable 21 DIN2 Digital Input 2 Run Reverse Input starts drive in reverse direction start enable 22 DIN3 Digital Input 3 External Fault Input causes drive to fault 23 DIN4 Digital Input 4 Fault Reset Input resets...

Page 33: ...ocess In the Wizard you will need the following keypad buttons Up Down Buttons Use these to change value OK Button Confirm selection and enter into next question Back Reset Button If this was pressed at the first question the startup wizard will be cancelled Once you have connected power to your Copeland EVH frequency converter and the Startup Wizard is enabled follow these instructions to easily ...

Page 34: ...AI2 17 PID1 Control Output 5 AI2 Joystick 6 Keypad 18 PID2 Control Output 7 Feildbus 9 MaxFrequency 10 AI1 AI2 11 AI1 AI2 12 AI2 AI1 2 Slot A AI1 3 Slot B AI1 4 AI1 Joystick 5 AI2 Joystick 6 Keypad 7 Feildbus 9 Max Frequency 10 AI1 AI2 11 AI1 AI2 12 AI2 AI1 13 AI1 AI2 14 AI1 or AI2 15 Min AI1 AI2 16 Max AI1 AI2 17 PID1 Control Output 18 PID2ControlOutput 20 BypassEnabled 0 Disabled 1 Enabled 21 Ap...

Page 35: ...lection programming is available A bypass unit contains a VFD drive with a 24 Vdc bypass control circuit It also includes 24 Vdc power supply and 24 Vdc VFD output and bypass contactors Input Device Choices MMP CB Non fusible disconnect with separately mounted fuses Operator Controls VFD Keypad only Optional 3 position VFD OFF BYPASS selector switch and VFD Keypad Operation Modes Without the selec...

Page 36: ...ifting eyes as sharp edges may cause excessive wear and possible failure Select or adjust rigging lengths to compensate for unequal weight distribution of the load to keep unit in the upright position Spreader bar recommended for installation Mounting hardware Mounting hardware is shown on the drawing supplied with the unit Dimensional Drawings For drives with bypass option there are 9 possible en...

Page 37: ...37 H1 H1S Approximate dimensions in inches mm ...

Page 38: ...38 H2 H2S Approximate dimensions in inches mm ...

Page 39: ...39 H3 H3X IP54 Approximate dimensions in inches mm ...

Page 40: ...40 H4 CX IP54 Approximate dimensions in inches mm ...

Page 41: ...41 DX IP21 DX IP54 Approximate dimensions in inches mm ...

Page 42: ...ng power wiring Remote auto start contact and 4 20 mA auto speed signal connections are made directly to VFD control module Component size and locations may be slightly different than shown Motor connections that are made to VFD power terminals U V and W ground using clamp supplied Conduit plates Some models have removable conduit plate for wiring ease See outline drawing supplied with unit to det...

Page 43: ...43 Some examples are shown below Actual connection points are shown on the connection diagram provided with the unit ...

Page 44: ...44 ...

Page 45: ...45 ...

Page 46: ... motor leads directly to the output contactor M overload OL or output power TB All bypass models have labels to help locate Actual connections points are shown on the connection diagram provided with the unit Some examples are shown below ...

Page 47: ...ol transformer CPT All bypass units have a separate 24 V power supply that provides control circuit power as well as backup power to the VFD logic This backup power feature allows the VFD logic and keypad to remain operational when the main input power has been removed when the Isolation Contactor or Switch option is provided For 208 230 and 480 V models the power supply is powered directly from t...

Page 48: ...3 1 3 the bypass control circuit may not operate properly The key bypass design parameters are P2 2 3 IO terminal 1 Start Signal 2 must be set to DigIN NormallyOpen P2 2 6 IO terminal 2 Start Signal 2 must be set to DigIN NormallyOpen P2 2 9 Ext Fault 1 NO must be set to DigIN 3 P2 2 19 Run Enable must be set to DigIN 2 P2 2 34 Bypass Start must be set to DigIN 7 P3 1 2 RO1 Function must be set to...

Page 49: ...sconnect Keypad should power and display Startup Wizard The Keypad display should show BYPASS above the left keypad soft button Pressing the button should give you the message Switch to Bypass Press OK Note The BYPASS VFD mode selection using the Soft Key on the keypad will only appear if the BYPASS mode has been enabled in software by using the startup wizard or direct entry using parameter P10 1...

Page 50: ... running in the bypass mode and the VFD logic provides the overload protection when the motor is running on the VFD Type E CMC Motor protection is provided by the following depending on the mode The CMC input device provides the motor overload protection when in running in the bypass mode and the VFD logic provides the overload protection when the motor is running on the VFD Note The VFD logic pro...

Page 51: ...n pressing the reset button on the OL relay The overload relay is set for manual reset operation Auto reset is not used or recommended THE BYPASS DESIGN HAVE AN OPTIONAL VFD OFF BYP SWITCH LOCATED ON THE COVER OR DOOR OF THE UNIT IF THE SWITCH IS LEFT IN THE BYPASS POSITION THE MOTOR WILL AUTOMATICALLY RESTART IN BYPASS AS SOON AS POWER IS REAPPLIED AFTER THE OVERLOAD RELAY HAS BEEN RESET IT IS RE...

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