Copeland™ Commercial HVACR Variable Frequency Drive – EVM Series
Installation Manual
Safety Precautions
ELECTRICAL SHOCK HAZARD
WARNING: Disconnect and lock out power before servicing. Discharge all capacitors 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.
Before Performing the Installation
It is strongly recommended to read through this entire manual for safe and correct installation.
- Disconnect the power supply of the device.
- Ensure that the devices cannot be accidentally restarted.
- Verify isolation from the supply.
- Earth and short circuit the device.
- Cover or enclose any adjacent live components.
- Only suitably qualified personnel in accordance with EN 50110-1/-2 (VDE 0105 Part 100) may work on this device/system.
- Before installation and before touching the device ensure that you are free of electrostatic charge.
- The functional earth (FE, PES) must be connected to the protective earth (PE) or the potential equalization. The system installer is responsible for implementing this connection.
- Connecting cables and signal lines should be installed so that inductive or capacitive interference does not impair the automation functions.
- Install automation devices and related operating elements in such a way that they are well protected against unintentional operation.
- Suitable safety hardware and software measures should be implemented for the I/O interface so that an open circuit on the signal side does not result in undefined states in the automation devices.
- Ensure a reliable electrical isolation of the extra- low voltage of the 24 V supply. Only use power supply units complying with IEC 60364-4-41 (VDE 0100 Part 410) or HD384.4.41 S2.
- Deviations of the input voltage from the rated value must not exceed the tolerance limits given in the specifications, otherwise this may cause malfunction and dangerous operation.
- Emergency stop devices complying with IEC/EN 60204-1 must be effective in all operating modes of the automation devices. Unlatching the emergency-stop devices must not cause a restart.
- Measures should be taken 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 malfunction (for example, by means of separate limit switches, mechanical interlocks, and so on).
- Depending on their degree of protection, adjustable frequency drives may contain live bright metal parts, moving or rotating components, or hot surfaces during and immediately after operation.
- Removal of the required covers, improper installation, or incorrect operation of motor or adjustable frequency drive may cause the failure of the device and may lead to serious injury or damage.
- The electrical installation must be carried out in accordance with the relevant regulations (for example, with regard to cable cross sections, fuses, PE).
- Installations containing adjustable frequency drives must be provided with additional monitoring and protective devices in accordance with the applicable safety regulations. Modifications to the adjustable frequency drives using the operating software are permitted.
- All covers and doors must be kept closed during operation.
- Never touch live parts or cable connections of the adjustable frequency drive after it has been disconnected from the power supply. Due to the charge in the capacitors, these parts may still be live after disconnection. Fit appropriate warning signs.
Step 1 – Copeland EVM Drive Overview
This chapter describes the purpose and contents of this manual, the receiving inspection recommendations and the Copeland EVM Series open drive.
It is recommended to read through the entire document before attempting to install the drive.
Use QR code on table of contents page to reach our EVH AE bulletin for supporting information that is not included in this manual.
How to Use this Manual
The purpose of this manual is to provide you with information necessary to install, start up, and setup the Emerson Copeland commercial HVACR variable frequency drive (VFD), EVM drive. To provide for safe installation and operation of the equipment, read the safety guidelines at the beginning of this manual and follow the procedures outlined in the following chapters before connecting power to the Copeland EVM VFD. Keep this operating manual handy and distribute to all users, technicians and maintenance personnel for reference.
Receiving and Inspection
The Copeland EVM VFD has met a stringent series of factory quality requirements before shipment. It is possible that packaging or equipment damage may have occurred during shipment. 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 grounding screw
- Inspect the unit to ensure it was not damaged during shipment.
- Make sure that the part number indicated on the nameplate corresponds with the catalog number on your order.
- If shipping damage has occurred, please contact and file a claim with the carrier involved immediately.
- If the delivery does not correspond to your order, please contact your Emerson electrical representative.
Note: Do not destroy the packing. The template printed on the protective cardboard can be used for marking the mounting points of the Copeland VFD on the wall or in a cabinet.
Common Abbreviations
| Abbreviation | Definition |
|---|---|
| VT | Variable torque with low overload rating (110%) |
| H | High Overload(150%) |
| IL | Low Overload (110%) |
| VFD | Variable Frequency Drive |
Rating Label/Carton Label
EMERSON
Cat. No.: EVM-3222D5-E20EFN
Style No.: 3-5001-101A
Copeland™ EVM VFD
Factory ID: Plant 11
| CT/VT | Input | Output |
|---|---|---|
| 0.25HP/ (0.18KW) | U(V~) 200-240 30 50/60 Hz | 0~30A 0-400 Hz |
| 0.5HP (0.37KW) | I (A) 2.1/3.3 | 1.6/2.5 |
Enclosure Rating IP20/NEMA 1/UL Type 1 with NEMA 1 kit installed
User installation manual: 2020ECT-36
Serial No.: XX20J0001
Contains FCC ID: 2ADXE-HY-40R204PC
Field installed conductors must be copper rated at 75°C
20201015 Assembled in Dominican Republic
Keypad Button Overview
Display
Increase value
Scroll menu up
Speed potentiometer
Back/reset
Move cursor left
Stop button
Enter menu
Confirm selection
Change control place between local and remote
Move cursor right
Start button
Decrease value
Scroll menu down
READY RUN REV REM FAULT
KEY
SW MON PAR FLT OPT
OK
RESET
LOCAL
REM
MS
NS
UL CERTIFIED
SAFETY US-CA E518704
20
TÜV Rheinland CERTIFIED www.tuv.com ID 0600000000
CE
Bluetooth
Nomenclature
| Output Amps(single phase) | Output Amps(three phase) | ||||||||
|---|---|---|---|---|---|---|---|---|---|
| 100-120V | 200-240V | 200-240V | 380-480V | ||||||
| 2D5=2.5A | 2D5=2.5A | 2D5=2.5A | 2D2=2.2A | ||||||
| 4D8=4.8A | 4D8=4.8A | 4D8=4.8A | 4D3=4.3A | ||||||
| 6D9=6.9A | 7D8=7.8A | 7D8=7.8A | 5D6=5.6A | ||||||
| 7D8=7.8A | 7D8=7.8A | ||||||||
| 011-11A | 011-11A | 011-11A | 012-12A | ||||||
| 017=17A | 017-17A | 017-17A | 016=16A | ||||||
| 025=25A | 025=25A | 025=25A | 023-23A | ||||||
| 032-32A | 032-32A | 032-32A | 031-31A | ||||||
| 048-48A | 048-48A | 048-48A | 038-38A | ||||||
| 062-62A | 062-62A | 062-62A | 046=46A | ||||||
| Platform: M:Multi-Purpose | Input Voltage: 1:100-120V 2:200-240V 4:380-480V 5:525-600V | Output Voltage: 2:200-240V 30 4:380-480V 30 5:525-600V 30 | Human Interface: N:No screen or keypad E:Embedded 7 segment | Enclosure IP Rating: IP20=20 | Hardware Protections: F:Internal EMI Filter N:No EMI Filter, No Choke | Onboard Comms: M:Modbus RTU E:Ethernet/BACnet/Modbus | Option Spot: N:None | ||
| Product type: V:Variable Frequency Drive | Phases Input: 1:10 3:30 |
EVM - 3 4 4 5 D 6 - E 2 0 E F N
Product Family Basic Sizing Data Critical Features/Options
Step 2 — Copeland EVM Drive Installation
Dimensions and Weights
Approximate mounting dimensions in inches (mm)
| Frame size | D | H1 | H2 | W1 | W2 | W3 | Ø | Weight lb (kg) |
|---|---|---|---|---|---|---|---|---|
| FR1 | 7.09 (180) | 5.98 (152) | 5.51 (140) | 2.83 (72) | 2.26 (57.5) | 2.26 (57.5) | 0.20 (5.2) | 2.6 (1.2) |
| FR2 | 7.09 (180) | 8.66 (220) | 8.15 (207) | 4.29 (109) | 3.56 (90.5) | 3.56 (90.5) | 0.22 (5.5) | 5.7 (2.6) |
| FR3 | 7.09 (180) | 10.24 (260) | 9.72 (247) | 5.12 (130) | 4.57 (116) | 4.57 (116) | 0.22 (5.5) | 8.2 (3.7) |
| FR4 | 7.68 (195) | 11.81 (300) | 11.06 (281) | 7.24 (184) | 6.3 (160) | 6.3 (160) | 0.24 (6) | 13.9 (6.3) |
Mounting
For mounting space guidelines please follow the below diagram and table. Then find the correct frame size mounting instructions.
For EVM Drives utilizing an option card, allow 2.76in. (70mm) for dimension A for the option card enclosure.
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.
Table 2. Approximate Space Requirements in inches (mm)
| Input voltage | Frame size | Mounting clearance | Airflow | ||||
|---|---|---|---|---|---|---|---|
| A in. (mm) | B in. (mm) | C in. (mm) | D in. (mm) | CFM (m3/h) | |||
| 100 Vac to 120 Vac, 50/60 Hz 1 phase | FR1 | 0 | 0 | 1.97 (50) | 1.97 (50) | 14.83 (25.2) | |
| FR2 | 0 | 0 | 1.97 (50) | 1.97 (50) | 24.72 (42) | ||
| 200 Vac to 240 Vac, 50/60 Hz 1 phase | FR1 | 0 | 0 | 1.97 (50) | 1.97 (50) | 14.83 (25.2) | |
| FR2 | 0 | 0 | 1.97 (50) | 1.97 (50) | 37.43 (63.6) | ||
| FR3 | 0 | 0 | 1.97 (50) | 1.97 (50) | 42.37 (72) | ||
| 200 Vac to 240 Vac, 50/60 Hz 3 phase | FR1 | 0 | 0 | 1.97 (50) | 1.97 (50) | 14.83 (25.2) | |
| FR2 | 0 | 0 | 1.97 (50) | 1.97 (50) | 24.72 (42) | ||
| FR3 | 0 | 0 | 1.97 (50) | 1.97 (50) | 42.37 (72) | ||
| FR4 | 0 | 0 | 1.97 (50) | 1.97 (50) | 75.56 (128.4) | ||
| 380 Vac to 480 Vac, 50/60 Hz 3 phase | FR1 | 0 | 0 | 1.97 (50) | 1.97 (50) | 14.83 (25.2) | |
| FR2 | 0 | 0 | 1.97 (50) | 1.97 (50) | 37.43 (63.6) | ||
| FR3 | 0 | 0 | 1.97 (50) | 1.97 (50) | 58.61 (99.6) | ||
| FR4 | 0 | 0 | 1.97 (50) | 1.97 (50) | 57.56 (97.8) | ||
| 525 Vac to 600 Vac, 50/60 Hz 3 phase | FR2 | 0 | 0 | 1.97 (50) | 1.97 (50) | 37.43 (63.6) | |
| FR3 | 0 | 0 | 1.97 (50) | 1.97 (50) | 58.61 (99.6) | ||
| FR4 | 0 | 0 | 1.97 (50) | 1.97 (50) | 57.56 (97.8) | ||
Note: For EVM Drives utilizing an option card, allow 2.76in. (70mm) for dimension A for the option card enclosure.
FR1 Mounting Instructions
Step 1:
Lift the drive out from the carton and remove the packaging. The magnetic cores and cable ties are only included in EMI version drive.
Step 2:
Screw mounting: Attach the drive to the mounting plate with two M5x20 (or 3/16 in.) screws and two M5 (or 3/16 in.) nuts. The opening dimension on the mounting plate should follow required dimensions (refer to the dimension drawing in Table 1 of this document).
DIN Rail mounting: Lift the drive at an angle about 30 degrees. Align the top hooks of drive DIN rail mounting slot with DIN rail top edge. Push down and rotate the drive to clip the bottom hooks on the bottom DIN rail edge.
Step 3: (EMI version only)
Input wiring:
- 1P FR1 EMI version: Run the input wires (two line wires+one grounding wire) through the input magnetic core before connecting to the input terminal block (L2/L3) and grounding hole. Tie the input magnetic core to the input wires with a cable tie.
- 3P 230/480 V FR1 EMI version: Run the input wires (three line wires + one grounding wire) through the input magnetic core before connecting to the input terminal block (L1/L2/L3) and grounding hole. Tie the input magnetic core to the input wires with a cable tie.
Output wiring:
- All 1P/3P FR1 EMI version: Run three motor wires through the output magnetic core before connecting to the output terminal block. The output grounding wire should not run through the output magnetic core. Tie the output magnetic core to the output wires with a cable tie.
The maximum distance between the input/output magnetic core's top surface is 100 mm (3.94 in.). All EVM non-EMI version drives do not have input/output magnetic cores.
FR2 Mounting Instructions
Step 1:
Lift the drive out from the carton and remove the packaging. The magnetic cores and cable ties are only included in EMI version drive.
Step 2:
Screw mounting: Attach the drive to the mounting plate with four M5X20 (or 3/16 in.) screws and four M5 (or 3/16 in.) nuts. The opening dimension on the mounting plate should follow required dimensions (refer to the dimensions in Table 1).
DIN Rail mounting: Lift the drive at an angle about 30 degrees. Align the top hooks of drive DIN rail mounting slot with DIN rail top edge. Push down and rotate the drive to clip the bottom hooks on the bottom DIN rail edge.
Step 3: (EMI version only)
Input wiring:
- 1P FR2 EMI version: Run the input wires (two line wires + one grounding wire) through the input magnetic core before connecting to the input terminal block (L2/L3) and grounding hole. Tie the input magnetic core to the input wires with a cable tie.
- 3P 230/480 V FR2 EMI version: Run the input wires (three line wires + one grounding wire) through the input magnetic core before connecting to the input terminal block (L1/L2/L3) and grounding hole. Tie the input magnetic core to the input wires with a cable tie.
- 3P 575 V FR2 EMI version: Does not have input magnetic core. Connect the three line wires to the input terminal block (L1/L2/L3) directly.
Output wiring:
- All 1P/3P FR2 EMI version: Run three motor wires through the output magnetic core before connecting to the output terminal block. The output grounding wire should not run through the output magnetic core. Tie the output magnetic core to the output wires with a cable tie.
The maximum distance between the input/output magnetic core's top surface is 100 mm (3.94 in.). All EVM non-EMI version drives do not have input/output magnetic cores.
FR3 Mounting Instructions
Step 1:
Lift the drive out from the carton and remove the packaging. The magnetic cores and cable ties are only included in EMI version drive.
Step 2:
Screw mounting: Attach the drive to the mounting plate with four M5X20 (or 3/16 in.) screws and four M5 (or 3/16 in.) nuts. The opening dimension on the mounting plate should follow required dimension (refer to the dimension drawing in Table 1 of this document)
DIN Rail mounting: Lift the drive at an angle about 30 degrees. Align the top hooks of drive DIN rail mounting slot with DIN rail top edge. Push down and rotate the drive to clip the bottom hooks on the bottom DIN rail edge.
Step 3: (EMI Version Only)
Input wiring:
- 1P FR3 EMI version: Run the input wires (two line wires+one grounding wire) through the input magnetic core before connecting to the input terminal block (L2/L3) and grounding hole. Tie the input magnetic core to the input wires with a cable tie.
- 3P 230/480 V FR3 EMI version: Run the input wires (three line wires + one grounding wire) through the input magnetic core before connecting to the input terminal block (L1/L2/L3) and grounding hole. Tie the input magnetic core to the input wires with a cable tie.
- 3P 575 V FR3 EMI version: Run the input wires (three line wires) through the input magnetic core before connecting to input terminal block (L1/L2/L3). The input grounding wire should not run through the input magnetic core. Tie the input magnetic core to the input wires with a cable tie.
Output wiring:
- 1P FR3 EMI Version: Does not have an output magnetic core. Connect three motor wires to the output terminal block directly.
- 3P 230/480/575 V FR3 EMI Version: Run three motor wires through the output magnetic core before connecting to output terminal block. The output grounding wire should not run through the output magnetic core. Tie the output magnetic core to the output wires with a cable tie.
The maximum distance between the input/output magnetic core's top surface is 100 mm (3.94 in.). All EVM non-EMI version drives do not have input/output magnetic cores.
FR4 Mounting Instructions
Step 1:
Lift the drive out from the carton and remove the packaging. The magnetic cores and cable ties are only included in EMI version drive.
Step 2:
Screw mounting: Attach the drive to the mounting plate with four M5x20 (or 3/16 in.) screws and four M5 (or 3/16 in.) nuts. The opening dimension on the mounting plate should follow required dimension (refer to the dimension drawing in the instruction leaflet).
Step 3: (EMI version only)
Input wiring:
- 3P 230/480 V FR4 EMI version: Run the input wires (three line wires + one grounding wire) through the input magnetic core before connecting to the input terminal block (L1/L2/L3) and grounding hole. Tie the input magnetic core to the input wires with a cable tie.
- 3P 575 V FR4 EMI version: Run the input wires (three line wires) through the input magnetic core before connecting to input terminal block (L1/L2/L3). The input grounding wire should not run through the input magnetic core. Tie the input magnetic core to the input wires with a cable tie.
Output wiring:
- 3P 230/480/575 V FR4 EMI Version: Run three motor wires through the output magnetic core before connecting to output terminal block. The output grounding wire should not run through the output magnetic core. Tie the output magnetic core to the output wires with a cable tie.
The maximum distance between the input/output magnetic core's top surface is 100 mm (3.94 in.). All EVM non-EMI version drives do not have input/output magnetic cores.
Mounting Instruction for Option Cards
Step 1:
For enclosed type: Remove the front cover (1) from the NEMA 1 kit then remove the terminal cover (2) from the drive.
For open type: Only remove the terminal cover.
Step 2:
Remove the option card port label and four snap covers from the drive.
Step 3:
Connect the cable to option card connector (3) and MCU board connector (4).
Step 4:
Clamp the cable with the optional card port. Mount the option card to the drive by inserting the four snaps into the slots on drive.
Step 5:
For enclosed type: Install the terminal cover (1) to the drive then install the front cover (2) to the NEMA 1-kit.
For open type: Only install the terminal cover to the drive.
Option Card Wiring Instruction
Termination resistor dip switch
- ON-120 Ω termination resistor On
- OFF-120 Ω termination resistor Off
User terminal
| No Use | CAN_H | Shield | CAN_L | GND | |
|---|---|---|---|---|---|
Grounding terminal
User terminals (DB9 connector)
| 5. DGND | 9. No Use | |||||||
|---|---|---|---|---|---|---|---|---|
| 4. RTS | 8. RXD/TXD-N | |||||||
| 3. RXD/TXD-P | 7. No Use | |||||||
| 2. No Use | 6. VP | |||||||
| 1. No Use | ||||||||
Grounding terminal
Ground Wiring
WARNING: Connect only in voltage-free state!
Input power and motor cable stripping lengths
| Power Wiring in Inches (mm) | Motor Wiring in Inches (mm) | |||||||
|---|---|---|---|---|---|---|---|---|
| Size | A1 | B1 | C1 | D1 | A2 | B2 | C2 | D2 |
| FR1 | 0.39 (10) | 2.76 (70) | 0.3 (10) | 2.76 (70) | 0.39 (10) | 2.76 (70) | 0.39 (10) | 2.76 (70) |
| FR2 | 0.47 (12) | 2.76 (70) | 0.4 (12) | 2.76 (70) | 0.47 (12) | 2.76 (70) | 0.47 (12) | 2.76 (70) |
| FR3 | 0.47 (12) | 3.54 (90) | 0.4 (12) | 3.54 (90) | 0.47 (12) | 3.54 (90) | 0.47 (12) | 3.54 (90) |
| FR4 | 0.79 (20) | 4.53 (115) | 0.7 (20) | 4.53 (115) | 0.79 (20) | 4.53 (115) | 0.79 (20) | 4.53 (115) |
Power Connection Tightening Torque
| Frame Size | Power wire in-lb (Nm) | Ground wire in-lb (Nm) | Control wire in-lb (Nm) |
|---|---|---|---|
| FR1 | 4.4 (0.5) | 7.1 (0.8) | 1.73 (0.2) |
| FR2 | 10.5 (1.2) | 7.1 (0.8) | 1.73 (0.2) |
| FR3 | 10.5 (1.2) | 14.2 (1.6) | 1.73 (0.2) |
| FR4 | 33 (3.73) | 14.2 (1.6) | 1.73 (0.2) |
Notes:
- Strip the motor and power cables as shown above.
- Both UL and IEC tools may be used
- Applies to strained wire, solid wire, or ferrule installations
Circuit Breaker Sizing
The circuit breaker selected must be in accordance with the National Electric Code (NEC) Requirements. The NEC determines that circuit breakers should handle 80% of their rated capacity for continuous loads and 100% for intermittent loads. NEC Articles 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:
- Find your total current load of the circuit (ex: 13.7)
- Multiply your current load by 1.25 to find your minimum breaker size (ex: 13.7*1.25=17.125)
- Find the correct breaker to match the size you found in #2. If it is not a standard size, per the NEC, select the next standard size up. For our example we would select a 20A breaker.
Cable and Fuse Guidelines
UL Cable Fuse Sizes
| Input voltage | Frame size | Output rating | UL application | NEC wire size | Term-inal size | |||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| VT/I current amps | VT/I, current (max amps) | Recom-mended fuse (Class J, T, CF or CC) | Recom-mended miniature inverse-time circuit breaker (max rating) | Recom-mended inverse-time molded-case circuit breaker (max rating) | Type E CMC (open type only for 3-phase) | NEC circuit breaker (max rating) 100 KAIC | Term-inal size motor ground AWG | NEC wire size line AWG | Term-inal size motor ground AWG | |||||||
| 100 KAIC | 65 KAIC | 10/14 | ||||||||||||||
| 100 Vac to 120 Vac 50/60 Hz 1-phase | FR1 | 2.5 | 10 | 30 | 30 | 30 | 14 | 10 | 18-8 | 16-8 | ||||||
| 4.8 | 20 | 70 | 63 | 70 | 10 | 8 | 18-8 | 16-8 | ||||||||
| FR2 | 6.9 | 26.4 | 90 | 63 | 90 | 8 | 8 | 20-6 | 12-6 | |||||||
| 7.8 | 30 | 125 | 63 | 125 | 8 | 6 | 20-6 | 12-6 | ||||||||
| 200 Vac to 240 Vac 50/60 Hz 1-phase | FR1 | 2.5 | 6.5 | 15 | 15 | 15 | 14 | 14 | 18-8 | 16-8 | ||||||
| 4.8 | 11 | 30 | 30 | 30 | 14 | 10 | 18-8 | 16-8 | ||||||||
| 7.8 | 17 | 60 | 63 | 60 | 10 | 8 | 18-8 | 16-8 | ||||||||
| FR2 | 11 | 23 | 80 | 63 | 80 | 10 | 8 | 20-6 | 12-6 | |||||||
| 17.5 | 35 | 125 | 63 | 125 | 8 | 6 | 20-6 | 12-6 | ||||||||
| FR3 | 25.3 | 49.6 | 200 | 200 | 6 | 6 | 20-6 | 8-6 | ||||||||
| 200 Vac to 240 Vac 50/60 Hz 3-phase | FR1 | 2.5 | 3.3 | 6 | 5 | 6.3 | 15 | 14 | 14 | 18-8 | 16-10 | |||||
| 4.8 | 5.8 | 15 | 10 | 6.3 | 15 | 14 | 14 | 18-8 | 16-10 | |||||||
| 7.8 | 9.4 | 20 | 15 | 10 | 15 | 14 | 12 | 18-8 | 16-10 | |||||||
| 11 | 13.2 | 30 | 20 | 16 | 20 | 12 | 10 | 18-8 | 16-10 | |||||||
| FR2 | 17.5 | 20.1 | 40 | 30 | 25 | 30 | 10 | 10 | 20-6 | 12-8 | ||||||
| 25.3 | 29.1 | 60 | 40 | 32 | 45 | 8 | 10 | 20-6 | 12-8 | |||||||
| FR3 | 32.2 | 37 | 70 | 50 | 40 | 50 | 8 | 8 | 20-6 | 10-8 | ||||||
| FR4 | 48.3 | 53.1 | 100 | 80 | 4 | 8 | 20-2 | 8-6 | ||||||||
| 62.1 | 68.3 | 125 | 100 | 3 | 6 | 20-2 | 8-6 | |||||||||
Notes:
- Can be any UL listed types with the same ratings.
UL Cable Fuse Sizes (continued)
| Input voltage | Frame size | Output rating | UL application | NEC wire size | Term-inal size | |||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| VT/I current amps | VT/I, current (max amps) | Recom-mended fuse (Class J, T, CF or CC) | Recom-mended miniature inverse-time circuit breaker (max rating) | Recom-mended inverse-time molded-case circuit breaker (max rating) | Type E CMC (open type only for 3-phase) | NEC circuit breaker (max rating) 100 KAIC | Term-inal size motor ground AWG | NEC wire size line AWG | Term-inal size motor ground AWG | |||||||
| 100 KAIC | 65 KAIC | 10/14 | ||||||||||||||
| 380 Vac to 480 Vac 50/60 Hz 3-Phase | FR1 | 2.2 | 2.6 | 6 | 4 | 6.3 | 15 | 14 | 14 | 18-8 | 16-10 | |||||
| 4.3 | 5.2 | 10 | 8 | 6.3 | 15 | 14 | 14 | 18-8 | 16-10 | |||||||
| 5.6 | 6.7 | 15 | 10 | 10 | 15 | 14 | 14 | 18-8 | 16-10 | |||||||
| 7.6 | 9.1 | 30 | 15 | 10 | 15 | 14 | 10 | 18-8 | 16-10 | |||||||
| FR2 | 12 | 14.4 | 30 | 20 | 16 | 20 | 12 | 10 | 20-6 | 12-8 | ||||||
| 16 | 19.2 | 40 | 25 | 25 | 30 | 10 | 10 | 20-6 | 12-8 | |||||||
| 23 | 27.6 | 60 | 32 | 32 | 40 | 8 | 10 | 20-6 | 12-8 | |||||||
| FR3 | 31 | 35.7 | 70 | 40 | 50 | 8 | 8 | 20-6 | 10-8 | |||||||
| FR4 | 38 | 43.7 | 70 | 50 | 70 | 6 | 8 | 20-2 | 8-6 | |||||||
| 46 | 52.9 | 80 | 58 | 80 | 4 | 8 | 20-2 | 8-6 | ||||||||
| 525 Vac to 600 Vac 50/60 Hz 3-Phase | FR2 | 7.5 | ||||||||||||||
| 10 | ||||||||||||||||
| 13.5 | ||||||||||||||||
| FR3 | 18 | |||||||||||||||
| FR4 | 22 | |||||||||||||||
| 27 | ||||||||||||||||
Notes:
- Can be any UL listed types with the same ratings.
IEC Cable Fuse Sizes
| Input voltage | Frame size | Output rating | IEC application | IEC cable size | Term-inal size | |||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| VT/I current amps | VT/I, current (max amps) | Recom-mended fuse (max rating) | Recom-mended miniature inverse-time circuit breaker (max rating) | Recom-mended inverse-time molded-case circuit breaker (max rating) | Type E CMC (open type only for 3-phase) | IEC circuit breaker (max rating) 100 KAIC | Term-inal size motor ground mm² | IEC wire size line mm² | Term-inal size motor ground mm² | |||||||
| IEC rating | IEC rating | 10/14 | ||||||||||||||
| 100 Vac to 120 Vac 50/60 Hz 1-phase | FR1 | 2.5 | 10 | 30 | 30 | 30 | 2.5 | 2.5 | 0.2-6 | 1-6 | ||||||
| 4.8 | 20 | 70 | 63 | 70 | 6 | 6 | 0.2-6 | 1-6 | ||||||||
| FR2 | 6.9 | 26.4 | 90 | 63 | 90 | 10 | 10 | 0.5-16 | 1-10 | |||||||
| 7.8 | 30 | 125 | 63 | 125 | 10 | 10 | 0.5-16 | 1-10 | ||||||||
| 200 Vac to 240 Vac 50/60 Hz 1-phase | FR1 | 2.5 | 6.5 | 15 | 15 | 15 | 2.5 | 2.5 | 0.2-6 | 1-6 | ||||||
| 4.8 | 11 | 30 | 30 | 30 | 2.5 | 2.5 | 0.2-6 | 1-6 | ||||||||
| 7.8 | 17 | 60 | 63 | 60 | 6 | 6 | 0.2-6 | 1-6 | ||||||||
| FR2 | 11 | 23 | 80 | 63 | 80 | 6 | 6 | 0.5-16 | 1-10 | |||||||
| 17.5 | 35 | 125 | 63 | 125 | 10 | 10 | 0.5-16 | 1-10 | ||||||||
| FR3 | 25.3 | 49.6 | 200 | 200 | 16 | 16 | 0.5-16 | 1.5-6 | ||||||||
| 200 Vac to 240 Vac 50/60 Hz 3-phase | FR1 | 2.5 | 3.3 | 6 | 5 | 6.3 | 15 | 2.5 | 2.5 | 0.2-6 | 1.5-6 | |||||
| 4.8 | 5.8 | 15 | 10 | 6.3 | 15 | 2.5 | 2.5 | 0.2-6 | 1.5-6 | |||||||
| 7.8 | 9.4 | 20 | 15 | 10 | 15 | 2.5 | 2.5 | 0.2-6 | 1.5-6 | |||||||
| 11 | 13.2 | 30 | 20 | 16 | 20 | 4 | 4 | 0.2-6 | 4-10 | |||||||
| FR2 | 17.5 | 20.1 | 40 | 30 | 25 | 30 | 6 | 6 | 0.5-16 | 4-10 | ||||||
| 25.3 | 29.1 | 60 | 40 | 32 | 45 | 10 | 10 | 0.5-16 | 6-10 | |||||||
| FR3 | 32.2 | 37 | 70 | 50 | 40 | 50 | 10 | 10 | 0.5-16 | 10-16 | ||||||
| FR4 | 48.3 | 53.1 | 100 | 80 | 25 | 16 | 0.535 | 10-16 | ||||||||
| 62.1 | 68.3 | 125 | 100 | 35 | 16 | 0.535 | 10-16 | |||||||||
IEC Cable Fuse Sizes (continued)
| Input voltage | Frame size | Output rating | IEC application | IEC cable size | Term-inal size | |||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| VT/I current amps | VT/I, current (max amps) | Recom-mended fuse (max rating) | Recom-mended miniature inverse-time circuit breaker (max rating) | Recom-mended inverse-time molded-case circuit breaker (max rating) | Type E CMC (open type only for 3-phase) | IEC circuit breaker (max rating) 100 KAIC | Term-inal size motor ground mm² | IEC wire size line mm² | Term-inal size motor ground mm² | |||||||
| IEC rating | IEC rating | 10/14 | ||||||||||||||
| 380 Vac to 480 Vac 50/60 Hz 3-Phase | FR1 | 2.2 | 2.6 | 6 | 4 | 6.3 | 15 | 2.5 | 2.5 | 0.2-6 | 1.5-6 | |||||
| 4.3 | 5.2 | 10 | 8 | 6.3 | 15 | 2.5 | 2.5 | 0.2-6 | 1.5-6 | |||||||
| 5.6 | 6.7 | 15 | 10 | 10 | 15 | 2.5 | 2.5 | 0.2-6 | 1.5-6 | |||||||
| 7.6 | 9.1 | 30 | 15 | 10 | 15 | 2.5 | 2.5 | 0.2-6 | 1.5-6 | |||||||
| FR2 | 12 | 14.4 | 30 | 20 | 16 | 20 | 4 | 4 | 0.5-16 | 4-10 | ||||||
| 16 | 19.2 | 40 | 25 | 25 | 30 | 6 | 6 | 0.5-16 | 4-10 | |||||||
| 23 | 27.6 | 60 | 32 | 32 | 40 | 10 | 10 | 0.5-16 | 4-10 | |||||||
| FR3 | 31 | 35.7 | 70 | 40 | 50 | 10 | 10 | 0.5-16 | 6-10 | |||||||
| FR4 | 38 | 43.7 | 70 | 50 | 70 | 16 | 16 | 0.535 | 10-16 | |||||||
| 46 | 52.9 | 80 | 58 | 80 | 25 | 16 | 0.535 | 10-16 | ||||||||
| 525 Vac to 600 Vac 50/60 Hz 3-phase | FR2 | 7.5 | ||||||||||||||
| 10 | ||||||||||||||||
| 13.5 | ||||||||||||||||
| FR3 | 18 | |||||||||||||||
| FR4 | 22 | |||||||||||||||
| 27 | ||||||||||||||||
Drive to Motor Connection Panel Mount
EMC-Compliant setup – 230Vac, 460/480 Vac, 600 Vac
EVM Motor
| U | V | W | |
|---|---|---|---|
| U/T1U1 | V/T2V1 | W/T3W1 |
FWD
REV
400/460YV
S1 11 kW
1410 rpm
COS 0.67
38/22 A
50 Hz
UL-230V (U-400 V)
Cable routing
If conduit is being used for wiring, use separate conduits for line voltage (mains), motor cables, and all interface/control wiring.
To meet the UL requirements, if conduit is being used for wiring, the enclosure openings provided for conduit connections in the field shall be closed by UL listed conduit fittings with the same type rating (Type 1) as the enclosure.
Avoid running motor cables alongside or parallel to any other wiring. If it is necessary to run motor cables with other wiring, then maintain spacing between motor cables and other wiring.
Wiring the VFD
If three or more motor cables are used, each conductor must have its own overcurrent protection.
Note: Do not wire motor leads to R+, R-. This will cause damage to the drive.
Note: Actual layout may vary slightly by frame.
Ground wiring
- Run motor cables in separate conduit
- DO NOT RUN CONTROL WIRES in same conduit
- Cables sized per Appendix B
- Provide dedicated wire for low impedance ground between drive and motor. DO NOT USE conduit as ground
CAUTION Improper grounding could result in damage to the motor and/or drive and could void warranty.
Checking the cable and motor insulation
1. Check the motor cable insulation as follows:
- Disconnect the motor cable from terminals U, V and W of the EVM drive and from the motor
- Measure the insulation resistance of the motor cable between each phase conductor as well as between each phase conductor and the protective ground conductor
- The insulation resistance must be >1M ohm
2. Check the input power cable insulation as follows:
- Disconnect the input power cable from terminals L1, L2 and L3 of the EVM drive and from the utility line feeder
- Measure the insulation resistance of the input power cable between each phase conductor as well as between each phase conductor and the protective ground conductor
- The insulation resistance must be >1M ohm
3. Check the motor insulation as follows:
- Disconnect the motor cable from the motor and open any bridging connections in the motor connection box
- Measure the insulation resistance of each motor winding. The measurement voltage must equal at least the motor nominal voltage but not exceed (1.1 * 2* Sqrt (2) X Vdc).
- The insulation resistance must be >1M ohm
EMC Installation
Note: All following information is strongly recommended but is not necessary if sufficient system design and validation has been completed.
The responsibility to meet the local system EMC limit values and electromagnetic compatibility requirements is the responsibility of the end user or the system operator. This operator must also take measures to minimize or remove emissions in the environment concerned (see Figure below). He must also use means to increase the interference immunity of the system devices.
In a drive system (PDS) with frequency inverters, you should take measures for electromagnetic compatibility (EMC) while doing your planning, because changes or improvements to the installation site, which are required in the installation or while mounting, are normally associated with additional higher costs.
The technology and system of a frequency inverter cause the flow of high frequency leakage current during operation. All grounding measures must therefore be implemented with low impedance connections over a large surface area.
International EMC protection cable requirements
The screened cables between the variable frequency drive and the motor should be as short as possible.
- Connect the screening, on both sides and across a large area (360° overlap), to the protective earth (PE). The power screening protective earth (PES) connection should be in the immediate proximity of the variable frequency drive and directly on the motor terminal box
- Prevent the screening from becoming unbraided, e.g., by pushing the opened plastic sheath over the end of the screening or with a rubber grommet on the end of the screening. As an alternative, in addition to a broad area cable clip, you can also twist the shielding braid at the end and connect to protective ground with a cable clip. To prevent EMC disturbance, this twisted shielding connection should be made as short as possible.
- Screened three- 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 or terminals), the shielding of the motor cable can be interrupted close to these subassemblies and connected to the mounting plate (PES) with a large area connection
- Unsheilded or sheilded connection cables should not be any longer than about 200 mm.
Environment EMC levels
| Cable Type | Category C2 | Category C3 | Category C4 2 |
|---|---|---|---|
| Line voltage/mains 1 | 1 | 1 | 1 |
| Motor cable 3 | 3 | 3 | 3 |
| Control cable | 4 | 4 | 4 |
Motor power cable EMC guidelines.
| Item | Directive | Product | EMC (at default settings) |
|---|---|---|---|
| IEC 61800-2 | UL 61800-5-1, IEC/EN 61800-5-1 Immunity (EMS): IEC/EN 61800-3, 2nd environment Radiated and Conducted emissions (EMI): IEC/EN 61800-3 230/480V Series: | ||
| Category C1: is possible with external filter connected to drive. Please consult factory | |||
| Category C2: with internal filter maximum of 5 m motor cable length | |||
| Category C3: with internal filter maximum of 25 m motor cable length |
Cable categories
| Cable category | Description (All cables are rated for the specific operating voltage) |
|---|---|
| 1 | Intended for fixed installation |
| 2 | Symmetrical power cable equipped with a concentric protection wire. |
| 3 | Symmetrical power cable with compact low-impedance shield. Recommended cable transfer impedance of 1-30 MHz max. See figure below. |
| 4 | Screened cable equipped with compact low-impedance shield |
Cable description
PE Conductor and Shield
PE Conductor Shield
1 For EMC C2&C3 requirements on EVM drive, use provided core with input&output wires going through it once. Refer to section "FR1 mounting instructions", "FR2 mounting instructions", "FR3 mounting instructions", "FR4 mounting instructions"
2 For installations in IT systems, it is necessary to modify the EMC protection to EMC level C4. See the following page for the procedure.
3 360° earthing of the shield with cable glands in motor end needed for EMC Level C2. See the following page for the procedure.
4 Control cable needs to follow the section "screen earth kit" to grounding.
Installation in corner-grounded network and IT system
Corner grounding and IT system are allowed for all the drive types.
In these circumstances the EMC protection class must be changed to level C4. This is done by removing the built-in EMC and MOV screws with a simple procedure described below.
WARNING Do not perform any modifications on the AC drive when it is connected to mains.
WARNING Electric shock hazard-risk of injuries! Carry out wiring work only if the unit is de-energized.
After disconnecting the supply, wait at least five minutes before removing the cover to allow the intermediate circuit capacitors to discharge.
WARNING 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 reconnected to re-engage the EMC protection.
Location of the EMC/MOV screw in frame 1.
Location of the EMC/MOV screws in frame 2-4.
Verifying Rotation
When starting the compressor up for the first time, verify it is running in the correct direction. For pumps or compressors verify your discharge pressure starts to increase and your suction decreases. For fans make sure it is blowing air in the correct direction. If it is running in reverse, please see the box in the above diagram.
Step 3–Control board layouts
EVM PRO wiring illustration
| STO terminals | Relay terminals | ||||||||||||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| 15 TO COM | 16 TO2 | 17 TO1 | 8 Al1+ | 1 DIN | 2 DIN | 9 Al1- | 3 DIN | 10 GN | 18 Y1NO | 11 AO1+ | 19 Y1CM | 4 DIN | 12 GN | 20 Y1NC | 5 CM | 13 +0V | 21 Y2NO | 6 A+ | 14 +24 V | 22 Y2CM | |
I/O terminals
Factory-Set Control Terminal Functions
I/O Connection
| SW1 | SW2 | Default setting | Description | ||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| RES OFF | SW1 | ON | OFF | ON | |||||||||
| External wiring | Terminal | Short name | Name | ||||||||||
| 1 | DI1 | Digital input 1 | Run forward | Starts the motor in the forward direction. | |||||||||
| 2 | DI2 | Digital input 2 | Run reverse | Start the motor in the reverse direction. | |||||||||
| 3 | DI3 | Digital input 3 | External fault | Triggers a fault in the drive. | |||||||||
| 4 | DI4 | Digital input 4 | Fault reset | Resets active faults in the drive. | |||||||||
| 5 | CMA | DI1 to DI4 common | Grounded | Allows for sourced input. | |||||||||
| 6 | A | RS-485 signal A | Fieldbus communication (Modbus RTU, BACNet). | ||||||||||
| 7 | B | RS-485 signal B | Fieldbus communication (Modbus RTU, BACNet). | ||||||||||
| 8 | Al1+ | Analog input 1 | 0-10 V | Voltage speed reference (programmable to 4 mA to 20 mA). | |||||||||
| 9 | Al1- | Analog input 1 ground | Analog input 1 common (ground). | ||||||||||
| 10 | GND | I/O signal ground | 1/0 signal ground for reference and control. | ||||||||||
| 11 | A01+ | Analog output 1 | Output frequency | Shows output frequency to motor 0 - 60 Hz (4 mA to 20 mA). | |||||||||
| 12 | GND | I/O signal ground | 1/0 ground for reference and control. | ||||||||||
| 13 | 10 V | 10 Vdc reference output | 10.3 Vdc +/- 3% | 10 Vdc reference voltage. | |||||||||
| 14 | 24 V | 24 Vdc control output | 24 Vdc In/Out | Control voltage input/output (100 mA max.). | |||||||||
| 15 | STO_com | Safe torque common | Safe torque Off common. | ||||||||||
| 16 | STO2 | Safe torque Off 2 | Safe torque Off 2 input. | ||||||||||
| 17 | ST01 | Safe torque Off 1 | Safe torque Off 1 input. | ||||||||||
| 18 | R1NO | Relay 1 normally open | Run | Changes state when the drive is in the run state. | |||||||||
| 19 | R1CM | Relay 1 common | |||||||||||
| 20 | R1NC | Relay 1 normally closed | |||||||||||
| 21 | R2NO | Relay 2 normally open | Fault | Changes state when the drive is in the fault state. | |||||||||
| 22 | R2CM | Relay 2 common | |||||||||||
Notes:
The above wiring demonstrates a SINK configuration. It is important that CMA is wired to ground (as shown by dashed line). If a SOURCE configuration is desired, wire 24 V to CMA and close the inputs to ground. When using the +10 V for Al1, it is important to wire Al1- to ground (as shown by dashed line).
Al1+ support 10 K potentiometer.
Step 4 –Start-up and Set-up of Drive
Main menu navigation for startup
Startup Wizard
In the Startup Wizard, you will be prompted for essential information needed by the drive so that it can start controlling your process. 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 EVM frequency converter, and the Startup Wizard is enabled, follow these instructions to easily set up your device.
Startup Wizard Instructions
For any further explanations of the below items please see Emerson AE bulletin AE-1456. Information for some items can be found in Copeland Mobile or OPI for the specific compressor model. For general motors, on the nameplate.
| Par. | Par. Name | Min Value | Max Value | Default | Description |
|---|---|---|---|---|---|
| P13.1.7 | Par. Password PIN | 0 | 9999 | 0 | Set a password: By default, the password function is not in use. If you want to activate the password, change the value of this parameter to any number between 1 and 9999. To deactivate the password, reset the parameter value to 0 |
| P1.1 | Minimum Freq | 0.00 Hz | 400 HZ | 0.00 Hz | These define the frequency limits of the drive. These will limit other frequency parameter settings; preset speeds, jog speed, 4 mA fault preset speed, fire mode speed, and brake speed settings. |
| P1.2 | Max Freq. | 0.00 Hz | 400.00 Hz | MaxFreqMFG | These define the frequency limits of the drive. The minimum frequency must be below the maximum frequency level. These will limit other frequency parameter settings; preset speeds, jog speed, 4 mA fault preset speed, fire mode speed, and brake speed settings. |
| P1.6 | Motor Nominal Current | DriveNom CurrCT* 1/10A | DriveNom CurrCT* 2A | DriveNom CurrCT* | Motor nominal nameplate full load current. Find this value on the rating plate of the motor. |
| P1.7 | Motor Nominal Speed | 300 RPM | 20,000 RPM | MotorNomSpeedMFG | Motor nominal nameplate base speed. Find this value on the rating plate of the motor. |
| P1.8 | Motor Power Factor | 0.30 | 1.00 | 0.85 | Motor nominal nameplate full load power factor. Find this value on the rating plate of the motor. |
| P1.9 | Motor Nominal Voltage | 180V | 690V | 487V | Motor nominal nameplate base voltage. Find this value on the rating plate of the motor. |
| P1.10 | Motor Nominal Freq | 8.00 Hz | 400 Hz | MotorNom FreqMFG | Motor nominal nameplate base frequency. Find this value on the rating plate of the motor. This parameter sets the field weakening point (P8.4) to the same value. |
| P1.3 | Accel. Time 1 | 0.10 s | 3000.0 s | 20.0 s | The time required for the output frequency to accelerate from zero frequency to maximum frequency (P1.2). When accelerating from different frequency levels, the acceleration time will be a fraction of the total ramp time. |
| P1.4 | Decel. Time 1 | 0.10 s | 3000.0 s | 20.0 s | The time required for the output frequency to decelerate from maximum frequency (P1.2) to zero frequency. When decelerating from different frequency levels, the deceleration time will be a fraction of the total deceleration time. |
| P1.13 | Remote Control Place | N.A | N.A | 0 | 0 = IO terminal; 1 = Fieldbus; or 3 = Keypad Selects where the drive will look for the start command in the remote location: I/O terminals would be from the digital hard-wired inputs; fieldbus would be a communication bus; and keypad display will indicate what mode is selected |
| P1.14 | Remote Ref. | N.A | N.A | 0 | 0 = Al; 1 = Drive reference pot; 2 = Al joystick; 3 = Motor pot; 4 = Maximum frequency; 5 = PI control output; 6 = Keypad; or 7 = Fieldbus reference. |
| P13.5.3 | Keypad Password PIN | 0 | 9999 | 0 | By default, the password function is not in use. If you want to activate the password, change the value of this parameter to any number between 1 and 9999. To deactivate the password, reset the parameter value to 0. |
| P11.6.1 | Blue Tooth Enable | N.A | N.A | N.A | 0 = Disabled; or 1 = Enable. |
Now the Startup Wizard is done. It won't show again on the next power up. If you want to reset it, please set the Startup Wizard (P13.1.17) or select it from the main menu screen to enable and cycle the power to the drive.
File Info : application/pdf, 31 Pages, 2.49MB
DocumentDocumentReferences
Copeland | Copeland US- Copeland Commercial HVACR Variable Frequency Drives | Emerson US
Emerson Global | Emerson
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