Emerson Copeland EV2 Series, Copeland EV2080M-L1, Copeland EV2080M-L2 Application Engineering Bulletin

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

............................................... 5

Hi-pot Procedure / Set-up ...................................... 5

Temperature & Humidity ......................................... 6

Pre-operation Checks ............................................. 6

Power On/Off ......................................................... 6

Communication Setting ......................................... 6

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

Dynamic DC Bus Voltage Control by Buck ............ 6

Speed Control ......................................................... 6

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

Shutdown ................................................................ 6

Fault Clearing ......................................................... 6

Lockout Faults ........................................................ 6

Stator Heat Control ................................................ 6

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

4 States of RGB LED (DS1-LED) ....................... 7

Rolling LED ......................................................... 7

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

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

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

Drive Cooling .......................................................... 7

Drive Over Temperature Protection ....................... 7

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

Cold Plate Heat Exchanger .................................... 8

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

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

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

Figures

Drive Assembly 3D Wiring Diagram ....................... 9

Drive Assembly 2D Wiring Diagram ..................... 10

Tables

Communication Connector Pin Definition ............ 11

Sensor Connector Pin Definition .......................... 11

Addendum

AE8-1429 R1

January 2018

EV2 Three Phase Series Variable Speed Drives

517-625V, 8.0 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

AE8-1429

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

AE8-1429

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.

AE8-1429

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.

• Personal safety equipment must be used.

• 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.

• Personal safety equipment must be used.

• 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.

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 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

Nomenclature

The model number of the drive includes the power rating and nominal voltage input to the drive. Contact

Application Engineering

for all the alpha and numeric

characters in the drive model number.

INSTALLATION Drive Handling

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.

•

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 by 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.

•

Do not drop any mechanical tools on the drive or

drive accessories.

•

It is always recommended to use ESD control

wristbands while touching any part of the drive.

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

Mounting

The drive should be located 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 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 mating 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

Contact

Application Engineering

for all the drawings

and detailed dimensions with tolerances.

Wiring Diagram

Refer to

Figures 1-2

for a detailed description of the

drive wiring diagrams. Refer to

Tables 1-2

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.

AE8-1429

Temperature & Humidity

Drive operating temperature range: -20°C to 55°C Drive storage temperature range: -40°C to 85°C Humidity: Maximum Relative Humidity 95%

Pre-operation Checks

Check the drive carefully before use it. 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, 517-625V on EV20XXM-LX-XXX models.

Use of incorrect power supply may damage the drive. The 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 60 seconds 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. Standard Modbus protocol RTU is available.

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, 517-625V on EV20XXM-LX-XXX drive models. 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 specified range as above.

Drive

Max AC Input Current

EV2080L 11A RMS

Dynamic DC Bus Voltage Control by Buck

The drive has dynamic DC bus voltage control function, which is capable of improving efficiency.

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

In the Modbus relationship, the drive is considered a slave, and the system controller is the master. Faults will not clear unless they are commanded to.

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 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.

AE8-1429

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 is one control chip on the drive board. And drive board has both RGB LED (DS1), and Rolling 7segment LED for drive status display.

4 states of RGB LED (DS1-LED)

1. PURPLE: When the drive is in programming mode via bootloader.

2. GREEN Solid: When the drive is in normal state (no faults) in standby mode and the compressor is not running. The LED will be solid GREEN.

3. GREEN Blinking: When the compressor is running, LED will blink at 1Hz in GREEN.

4. RED: When the drive has any active faults or protections.

Rolling LED

There is also a Rolling LED for drive status display. For further information, refer to Tables 7 & 8 for detailed functionality and display status modes.

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 210 -213 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.

•

Registers 206 & 207 are for sensor type

configurations.

•

configuration.

•

ramp-up and ramp-down rate configuration.

•

during compressor 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

CN5 on EV2080X-LX-XXX is a 2-port connector on drive model. The output is a 3.3VDC signal. The highpressure cutout switch must be normally closed. If the switch is open, the drive will not operate. The output current for the high-pressure contact will range from 300uA to 400uA. 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.

This port is hardware Protected Electronic Circuit (PEC), and software is Class-B according to UL60730-1.

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 131°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.

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 Section 2 in the

Addendum

for more information.

AE8-1429

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 the 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 TC-5022 silicone heat sink compound or a similar product is recommended. Contact

Application Engineering

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 or 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 Section 2 in the

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:

•

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 ground

•

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.

Figure 1 – Drive Assembly 3D Wiring Diagram

+ 18 hidden pages

Emerson Copeland EV2 Series, Copeland EV2080M-L1, Copeland EV2080M-L2 Application Engineering Bulletin

Specifications and Main Features

Frequently Asked Questions

User Manual