Emerson EV3 Series Instruction Manual

EV3 Inverter Drive for
ZPV* Variable Speed Compressors
EV3015B & EV3185B
Application Guidelines

AGL_Sol_EV3_E_Rev_01
About these guidelines ...................................................................................................1
1Safety instructions...............................................................................................1
1.1 Icon explanation....................................................................................................................1
1.2 Safety statements.................................................................................................................1
1.3 General instructions..............................................................................................................2
1.4 Use with A2L refrigerants......................................................................................................2
2Product description .............................................................................................4
2.1 General information about the EV3 drive..............................................................................4
2.2 Drive highlights .....................................................................................................................4
2.3 Models...................................................................................................................................4
2.4 Advanced technical information............................................................................................4
2.5 Conformity to directives and standards ................................................................................5
2.6 Nomenclature........................................................................................................................5
2.7 Identification..........................................................................................................................5
3Installation............................................................................................................6
3.1 Handling................................................................................................................................6
3.2 Terminals and LED’s.............................................................................................................6
3.3Mounting ...............................................................................................................................7
3.4 Electrical installation .............................................................................................................7
3.4.1 Earth leakage protection ...........................................................................................7
3.4.2Grid 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
4Start-up & operation...........................................................................................11
4.1 #OneEmerson Modbus®Map............................................................................................ 11
4.2 Drive configuration............................................................................................................. 11
4.3 Drive operation modes....................................................................................................... 11
4.3.1 Compressor Run mode.......................................................................................... 11
4.3.2 Stator Heating mode .............................................................................................. 11
4.4 Envelope control ................................................................................................................ 12
4.4.1 Passive Envelope Protection ................................................................................. 12
4.4.2 Active Envelope Protection .................................................................................... 13
4.5 Clearing faults.................................................................................................................... 14
4.6 Compressor start-up.......................................................................................................... 14

AGL_Sol_EV3_E_Rev_01
4.7 Compressor shutdown....................................................................................................... 15
5Optional analog board .......................................................................................16
5.1 Terminal and LED description ........................................................................................... 16
5.2 Control and configuration................................................................................................... 17
5.2.1 Selection of drive compressor code....................................................................... 17
5.2.2 Clearing faults ........................................................................................................ 18
5.2.3 Control signals........................................................................................................ 18
5.2.4 Stator heating control............................................................................................. 18
5.2.5Speed control ......................................................................................................... 18
5.2.6 Shutdown conditions .............................................................................................. 19
5.2.7 Compressor speed range selection ....................................................................... 19
5.2.8 Onboard 7-segment display................................................................................... 19
6Protections 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
7Maintenance & repair.........................................................................................24
7.1 General statements............................................................................................................ 24
7.2 Fan replacement................................................................................................................ 24
8Frequently asked questions..............................................................................25
Appendix 1: Drive dimensions and mounting instructions (EV3185B / EV3150B)....26
Appendix 2: Choke dimensions....................................................................................27
Appendix 3: Analog control board description and dimensions................................28
Appendix 4: Envelopes .................................................................................................29
Appendix 5: Advanced user interface..........................................................................30
DISCLAIMER ..................................................................................................................30

AGL_Sol_EV3_E_Rev_01 1
About these guidelines
The purpose of these guidelines is to provide guidance in the application of Emerson drives in users’
systems. They are intended to answer the questions raised while designing, assembling and
operating a system with these products.
Besides the support they provide, the instructions listed herein are also critical for the proper and
safe functioning of the compressors. Emerson cannot guarantee the performance and reliability of
the product if it is misused in regard of these guidelines.
These application guidelines cover stationary applications only. For mobile applications, please
contact the Application Engineering department at Emerson as other considerations may apply.
1 Safety instructions
Copeland Scroll compressors are manufactured according to the latest European and US safety
standards. Particular emphasis has been placed on the user’s safety.
These drives are intended for installation in systems in accordance with EN 60335-1. They may be
put to service only if they have been installed in these systems according to instructions and conform
to the corresponding provisions of legislation. 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-electrical damage or injury. Take
necessary protections to avoid injury!
General warning about risk of burning on hot surfaces. Take necessary
precautions to avoid injury!
General warning about risk of explosion. Take necessary precautions to avoid
injury!
Table 1: Explanation of used symbols
1.2 Safety statements
This product is designed to be used in HVAC/R systems and can only be installed, operated or
maintained by an electrically qualified person with additional system-related expertise. Please
immediately contact the manufacturer for support if the user is uncertain with any safety-related
issue.
This product operates at hazardous voltages which can cause severe personal injury or equipment
damage. Extreme care and precautions must be taken when handling the product.
In this publication, the safety warnings are classified into four types based on the risk and nature of
injury and/or damage which can occur if the warnings are neglected.

2 AGL_Sol_EV3_E_Rev_01
1.3 General instructions
Safety risks (read carefully!)
After disconnecting power, wait 10 minutes before removing the drive
enclosure.
Before operating and maintenance work always check that all voltages at the
terminals are zero or at levels which are harmless.
Always make sure the compressor has stopped completely before removing
the drive enclosure.
As soon as the drive is connected to the power supply the input terminals will
be at line voltage even when the compressor is not rotating.
Do not measure insulation resistance or dielectric rigidity directly via the
input terminals with power supply connected.
Review relevant safety standards concerning installation of high voltage
devices, as well as the regulations for the correct use of personal protective
equipment.
The drive can only be used for purposes specified by the manufacturer.
This product can cause both AC and DC earth leakage current. To protect
against both kinds of leakage current an AC/DC sensitive RCD must be
installed in front of the EV3 drive.
Do not make any modifications or replace any components as these actions
may lead to consequences including but not limited to fire and electric shock
and will void the warranty. Product modifications are not allowed. The
manufacturer is not responsible for any unauthorized modification made to
the product by the user.
A proper earth connection of the drive must be ensured to avoid the risk of
electric shock.
The IP20 protection 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 safety shoes to avoid foot injury.
Handle the drive carefully.
Protect the drive from dust. During installation make sure to clean off the
debris caused by drilling. Remove any conductive debris inside the drive
which can cause damage or malfunction.
Before touching the heatsink or unpowered chokes, make sure that the
temperatures are within safe limits to avoid burn injury.
In general, the drive cannot be used in an environment where a direct
contact with flammable or explosive substances can occur. Furthermore, use
in a transcritical system is not allowed. Use with A2L flammable refrigerants
is only foreseen in systems based on the IEC 60335-2-40:2018-05 standard
with some restrictions shown in these guidelines.
Table 2: Safety risks
1.4 Use with A2L refrigerants
The EV3 drive is not designed or qualified based on the ATEX directive! Use
with A2L flammable refrigerants is possible if the system design is based on
the IEC 60335-2-40:2018-05 standard.
The EV3 drive has been assessed in accordance with IEC 60335-2-40, and does not represent a
source of ignition for A2L if the following points are respected:
▪The drive mounting area must be in Zone 2 or outside any ATEX zone and in line with "Pollution
Degree 2" classification.
▪No airstream guided over the drive itself.

AGL_Sol_EV3_E_Rev_01 3
▪Ensure that the airstream over the heatsink does not influence 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.

4 AGL_Sol_EV3_E_Rev_01
2 Product description
2.1 General information about the EV3 drive
The EV3 inverter drive has been developed specifically for Copeland Scroll™compressor models
ZPV066 and ZPV096. These are variable speed compressors with permanent magnet synchronous
motors. The drive will power the compressor, control the compressor running speed, provide
compressor and drive protection and communicate with the master controller. The drive has
integrated fans for cooling and is typically installed in a system near the compressor.
2.2 Drive highlights
The EV3 drive at a glance:
▪Control of Copeland variable speed compressors (ZPV models) in commercial environments
▪Predefined selection for compressor
▪Active envelope protection
▪Special envelope related overload protection
▪Compressor crankcase heater functionality
▪Operation ambient temperatures -25 to 60°C
▪Controllable via RS485 and Modbus® RTU
▪Automatic baud rate detection (19.200 bps)
▪Designed and qualified based on EN 60335-1 for the European market
▪UL 60730-1 approval for the North American market
▪Safety Input to wire a high-pressure limiter
▪Discharge line temperature sensor 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
3~ 380 to 460 VAC
38 A
38 A
18.5 kW
Table 3: Voltage, current and power range
NOTE: The power range in Table 3 is to be considered as an indication depending on the
system design and the compressor motor. The rated voltage to run ZPV compressors in the
full dedicated envelope and to pass EN 60335-2-34 tests is 400 VAC for three-phase drives.
2.4 Advanced technical information
Storage temperature
-40 to +85°C
Max. operating temperature
-25 to +65°C
Max. full performance operating temperature
-20 to +50°C
Humidity
0 to 95% rH non-condensing
Altitude
Max. 2000 m above sea level
Pollution degree
2
Drive enclosure protection
IP20
DC choke protection
IP00
Communication
RS485 Modbus®(RTU)
Baud rate 19.200 bps
Slave ID: 45
Sensor input
Discharge line temperature
DLT / NTC 10 kΩ
Safety torque off input
Designed to connect a safety high-pressure limiter
Max. efficiency
~98%
Max. power factor
~0.94 w/ integrated PPFC
Table 4: Advanced technical information

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2.5 Conformity to directives and standards
The EV3 drive has been designed and developed especially for the European commercial market
based on applicable European Directives. The design is qualified by main safety standards
EN 60335-1 (Safety for household and similar electrical appliances, Part 1: General requirements),
EN 60335-2-34 (Part 2-34: Particular requirements for motor-compressor) and EN 60730-1
(Automatic electrical controls for household and similar use).
The EV3 drive complies with EMC standard EN 61800-3 Category C3. Depending on the unit design,
the drive may comply with Category C2 as well. However, if C2 cannot be achieved with the drive
alone, an external filter may be used. Recommended ferrites are shown in Chapter 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 (Electronics Variable speed)
3
Third generation
185
Input power
Format: XX.X [kW]
eg, 18.5 [kW]
B
Communication: RS485 5V Modbus RTU
-
K
3-Phase, 380-460 VAC
1
Power output codes: 1-9
X
Type of module:
1-4: OEM
5-6: Export
8-9: Aftermarket
XX
Software/hardware variations
Table 5: Nomenclature
2.7 Identification
The rating plate on the drive gives information about the drive, including model, serial number, rated
input and output, and certificate approval.
Figure 1: Rating plate
It is advised to check and confirm the rating plate before installing or operating the equipment.

6 AGL_Sol_EV3_E_Rev_01
3 Installation
3.1 Handling
▪Correct handling and storage of the drive is essential in preventing mechanical damage.
▪The box and the protection bag inside the box have to be opened with care. Do not use any sharp
object to open the protection bag or cut across the drive.
▪Once opened do not stack the drives.
▪Do not use chemicals or solvents to clean the drive.
▪Do not drop any mechanical tools on the drive.
▪Check that the cooling slots, fans and heatsink are free of dust to guarantee efficient cooling.
3.2 Terminals and LED’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: B / Modbus data channel B (physical RS485)
6: A / Modbus data channel A (physical RS485)
7: GND / Modbus ground (physical RS485)
8: 5 V / 5 VDC optional for the RS485 communication
9: 24 V / N/A
D
Service port for updating software with a special tool
E
Power LED (green)
F
Fault LED (red)
Table 6: Terminals and LED's
Figure 2: EV3185B, EV3150B, side and front views

AGL_Sol_EV3_E_Rev_01 7
3.3 Mounting
The drive should be located as close to the compressor as possible, preferably within 1 meter of the
compressor. To avoid electromagnetic interference please ensure that the motor cables do not cross
or attach to any other connecting cables.
There should be at least a natural air stream inside the cabinet and around the drive to keep the
temperature below 65°C.
There are holes in the drive mounting flange for mounting purposes. These holes will accommodate
M6 sized screws.
The drive should be positioned in a way that the input and output terminals are on the bottom side.
After connecting the input and output cables, one must not forget to place back the protection cover
for the terminals.
Caution: Respect the maximum screw torque to avoid any damage to 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, bottom, left and right sides
A [mm]
B [mm]
C [mm]
100
30
100
Table 7: Clearance to other components
NOTE: For more information about drive dimensions and mounting please refer to Appendix
1: Drive dimensions and mounting instructions (EV3185B / EV3150B)".
3.4 Electrical installation
Please read carefully the safety
instructions in Chapter 1 and Table 1!
3.4.1 Earth leakage protection
In all inverter devices like the EV3 drive, earth leakage current (DC, AC) may occur. To protect
against both kinds of leakage currents, an AC/DC-sensitive residual current circuit breaker must be
installed in front of the EV3 drive.

8 AGL_Sol_EV3_E_Rev_01
3.4.2 Grid supply and compressor wiring
Figure 4 shows the general wiring to the power grid and to the compressor. This wiring diagram
does not show any system-related components like fuse breaker, RCD and the additional ferrites for
EMC.
Paragraph 3.4.6 "Control terminal" shows how to wire control-related components like DLT-sensor,
high-pressure limiter and the RS485 serial communication (Modbus®) to the drive.
Figure 4: Wiring EV3185B, EV3150B
3.4.3 DC chokes
The integrated DC choke has protection class IP00 and temperature class H. The choke is positioned
between the heatsink of the drive and the drilled metal sheet, within the lower metal case. The fan
provides the necessary airstream for proper cooling. The chokes are fully covered to protect against
direct touching. Short connecting cables are used to minimize the possibility of EMI issues. The
choke dimensions are shown in Appendix 2: "Choke dimensions".
Drive model
Choke model
Number of
chokes
Electrical parameters
EV3185B
LE105-5002
1 x DC
2 mH ± 10%, 50 A
EV3015B
R4002RJ
1 x DC
2 mH ± 10%, 40 A
Safety protection: IP00, Class 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 screw terminals should be done with 5 mm ring terminals. The
drives are IP20 protection class; therefore, make sure to re-screw the terminal protection after wiring
the drive in order to maintain the standard. Also, the use of isolated ring and isolated blade terminals
is mandatory for all terminals to maintain the IP20 class.
Power grid
3-Phase grid: 400 VAC 50/60 Hz (L1, L2, L3, PE)
Drive model / choke
Max input
current [A]
Fuse or circuit
breaker [A]
@ 30°C
Cable cross
section [mm²]1)
@ 60°C ambient
Usable Ferrite(s) to
reduce EMC noise
EV3185B
1 x DC choke
38
50
Type B
10
H63x38x25 KH10
(3 turns)
EV3150B
1 x DC choke
27
32
Type B
6
H63x38-25 KH10
(3 turns)
1) Based on: DIN VDE 0298-4 (conductor temperature 90°C, laying method E)
Table 9: Connection to the input power grid
The grid must provide a RSCE ≥250 Ω, together with a system input current greater than 16 A on
each phase to be in line with standard EN 61000-3-12.

AGL_Sol_EV3_E_Rev_01 9
For users who are unable to qualify for EN 61800-3 Category C2, an external EMI filter can be fitted
in front of the drive.
3.4.5 Compressor connection
Table 10 shows information on how to connect the drive to the compressor. The connecting cables
are rated at 90°C. The cable cross-section is rated for a maximum ambient temperature of 60°C.
Drive model
Max output
current [A]
Cable cross-
section [mm²]1)
@ 60°C ambient
Usable ferrite(s) to
reduce EMC noise
EV3185B
38
10
H63x38x25 KH10
(3 turns)
EV3150B
27
6
H63x38x25 KH10
(3 turns)
1) Based on: DIN VDE 0298-4 (conductor temperature 90°C, laying method E)
Table 10: Compressor connection
The drive output terminals are named U, V, W. In addition to this, there is a PE terminal which must
be wired directly to the compressor earth point. The cables should be as short and the ferrites as
close to the drive as possible. In any case the motor cables should not cross any other cables to
avoid EMI issues. By using a shielded cable, which is in general not 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 the DLT input, the STO input, ie,
high-pressure limiter (see paragraph 3.4.8 "STO input"), and if necessary to the RS485 serial
communication circuit. No other usage of these 5 V and 24 V power supplies is allowed.
Figure 5: Control terminal
3.4.7 DLT input
To protect the compressor against high discharge temperatures it is possible to connect a discharge
line temperature sensor (DLT) between the control terminals 1 and 2. This sensor input is
configurable via register [207]. By default, it is disabled.
Sensor specifications:
▪Type: NTC 10 kΩ@ 25°C
▪Accuracy: ± 1%
▪Powered by: Internal 5 VDC (terminal 2)
▪Temp. range: -40 to +155°C
▪Reference: Emerson ECN-G series
The sensor should be mounted on the discharge line approx. 120 mm away from the compressor
outlet.
Caution: Consider the total maximum output
currents:
▪Terminal 5 V (2, 8) < 150mA

10 AGL_Sol_EV3_E_Rev_01
After starting the compressor, the drive observes the temperature from the DLT sensor. The
observable temperature range is between -40 and 155°C.
3.4.8 STO input
An STO input (Safety Torque Off) is available between terminals 3 and 4 to connect a safety high-
pressure limiter. The input is designed as a protected electronic circuit (PEC) based on the safety
standard EN 60335-1. In case of a high-pressure situation the drive will let the compressor stop
immediately. The drive will remain in a safe state until the controller sends a clear fault command to
the drive.
NOTE: It is not allowed to use any other external power supply with a higher voltage rating to
avoid damaging the STO input!
High-pressure limiter specifications:
▪Type: Safety switch (NC, ie, normally closed; based on latest version of EN 12263)
▪Contacts: Golden plated contacts
▪Powered by: Internal 24 VDC (terminal 4)
▪Current flow: Typically ~10mA
▪Reference: Emerson PS4 series
Caution: Connect the safety limiter directly to terminals 6 and 7 without any relay etc. in
between. Otherwise the safety will probably not be guaranteed any longer.
3.4.9 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-adaptive function is enabled, the drive can automatically detect the
baud rate and parity. If communication auto-adaptive function is not enabled, the drive will use baud
rate and parity read from EEPROM. Further information is provided in the Modbus®Map.
3.4.10 Drive cooling control
The drive provides temperature values from the power modules mounted on the heatsink. These
values should be used to monitor and control proper drive cooling from system side.
Dedicated registers for temperature sensing:
▪[70]: PIM Temperature
▪[22]: PIM Overtemperature
▪[42]: PIM Speed-drop protection limit
Exceeding the overtemperature limit (register [22]) the drive will immediately shut down the
compressor. When the temperature of the power module reaches 80°C (stored in register [42]), the
fan starts close to full-speed and then gradually reduces its speed, while the temperature of the
module decreases. The fan will stop only if the drive is turned off.

AGL_Sol_EV3_E_Rev_01 11
4 Start-up & operation
The configuration and control of the drive are based on the #OneEmerson Modbus®Map.
4.1 #OneEmerson Modbus®Map
The #OneEmerson Modbus Map is provided as a separate document which shows also the status,
alarm, configuration and control registers. Furthermore, it provides an advanced register description.
For the latest version of the Modbus map, please contact the Application Engineering department at
Emerson.
4.2 Drive configuration
The drives were specially designed for the ZPV066 and ZPV096 compressors. The compressor code
will be set by default, so it will not have to be introduced by the user. The standard default
configuration may be used, or it may be adapted to the user’s requirements.
Before starting the configuration, the user has to introduce the password 9029 (decimal value) in
register [200], in order to have access to registers [201] to [234]. Error! Reference source not found. d
escribes the first steps in configuring the drive.
Step
Action
1
DLT sensor used?
▪Yes: Connect the sensor to pins 1 and 2 of the communication terminal. By default,
the DLT is enabled.
▪No: Introduce the value 0 in register [207] or connect a resistor between pins 1 and
2.
2
STO sensor used?
▪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 Heating mode
While selecting both control modes at the same time the compressor run mode has the highest
priority. While stator heating is already on, sending a compressor run command will terminate the
stator heating mode and start the compressor.
4.3.1 Compressor Run mode
Go through the following sequence:
▪Make sure that there are no faults
▪Turn the compressor on by selecting Enable in the list, register [100]
▪Introduce the speed demand in register [101]
The drive will accelerate and decelerate by the rates defined in [211] and [212].
4.3.2 Stator Heating mode
Go through the following sequence:
▪If the compressor is running, set the value of the speed demand in register [101] to 0
▪Make sure the compressor is enabled (select Enable in the list, register [100])
▪Introduce the percentage of power needed in register [102], based on the algorithm below. Note
that once a value is introduced in register [102], stator heating mode is automatically enabled.
There is no separate register for turning on and off the stator heating mode.

12 AGL_Sol_EV3_E_Rev_01
The power demand must be written in register [102]. The value represents the percentage of power
(0%-100%). The maximum power that can be commanded on the stator is readable via register [52].
The relation between the power and the value introduced in register [102] is the following:
▪If the value is a multiple of 10:
𝑃𝑜𝑤𝑒𝑟~150 × ([102]
100 )
▪If the value is not a multiple of 10:
𝑃𝑜𝑤𝑒𝑟 ~ 150 × ([102] 𝑑𝑖𝑣 10 + 1)×10
100
(Stator Heating Demand = value stored in register [102])
The power commanded on the stator is interpreted by the drive according to Table 12:
User demand
Drive received
1 - 10%
10%
11 - 20%
20%
21 - 30%
30%
31 - 40%
40%
…
…
81 - 90%
90%
91 - 100%
100%
Table 12: User commanded power
4.4 Envelope control
The drive offers 4 different envelope control modes allowing the compressor to operate at four
different safety levels within the dedicated envelopes. Two conceptually different methods are
provided to achieve this:
▪Passive Envelope Control (modes 0, 1, 2) which is based on the internal current/speed curve
of the drive;
▪Active Envelope Control (mode 3) which takes actions based on the evaporating and
condensing temperatures/pressures received from the system controller via Modbus.
The 4 modes can be selected from a list through register [231]:
o0: Full Envelope Protection
o1: High-Speed Envelope Protection
o2: Advanced Speed-Drop Protection Mode
o3: Active Envelope Protection
4.4.1 Passive Envelope Protection
The passive envelope control implies the so-called Overload Protection. Based on the compressor
operation envelope, which is transferred in a speed-current curve, the drive will compute and adjust
frequently the output current threshold. Once the output current exceeds this calculated threshold
the drive will go in the Speed-Drop Protection (SDP) mode, ie, a kind of power limitation to protect
the drive and the stator windings against overload. The difference between the three modes from the
user’s point of view, consists in the access to different speed ranges and the speed at which the
drive folds back in case of speed-drop protection:
0: Full Envelope Protection
▪Overload Protection enabled.
▪Normal Operation Mode: the minimum speed is the speed available for the whole envelope.
Taken from the EEPROM and stored in register [109].
▪SDP mode: the speed at which the drive drops is the same as the minimum speed from the
Normal Operation mode.
▪In this mode the user provides only the speed demand.

AGL_Sol_EV3_E_Rev_01 13
1: High-Speed Envelope Protection
▪Overload Protection enabled.
▪Normal Operation: the minimum speed is the minimum speed of the envelope. Value taken from
the EEPROM and updated frequently based on the operating point. The user must take care to
run the compressor within the envelope at all times.
▪SDP mode: the minimum speed is the speed available for the whole envelope. Taken from the
EEPROM and stored in register [109].
▪In this mode, besides the speed demand, the user must send the minimum speed for each
operating point.
2: Advanced Speed-Drop Protection Mode
▪Overload Protection enabled.
▪Normal Operation: the minimum speed is the minimum speed of the envelope. The value is stored
and updated frequently in register [109].
▪SDP mode: the speed at which the drive drops is the minimum speed of the envelope. The value
is stored and updated frequently in register [109].
▪In this mode, besides the speed demand, the user must also provide the minimum speed
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 point is within the envelope. If the operating point is
out of the envelope for 30 seconds an alarm is sent to the system controller.
If the compressor is not running inside the envelope, the drive acts differently based on the region in
which the running point is. The outer part of the envelope is spread into two parts: the grey zone
below the envelope and the white zone. This particular feature is based on the different behaviour of
the installation during start-up. In this way the compressor is allowed to run below the envelope
during start-up and defrost, until the setpoint stabilizes within the envelope.
Figure 6: Application envelope of ZPV0962E with R410A (20°F SH, 15°F SC, 95°F ambient)
White zone:
▪Speed range: 2600-6000 rpm
▪Allowed running time: 30 seconds

14 AGL_Sol_EV3_E_Rev_01
Grey zone:
▪Speed range: 2600-6000 rpm
▪Allowed running time based on the evaporating temperature:
oif less than -15C: 15 minutes
oif higher than -15C: 30 minutes
If the speed demand is less than 2600 rpm or higher than 6000 rpm, the speed is increased or
decreased automatically to respect the speed range. The time and temperature thresholds are
readable through registers [318], [319], [320] and [321]. The time remaining for running outside of
the envelope is readable through register [47]. The DLT feature is enabled while Active Envelope
Protection is in place.
Stage II: Speed limits within an envelope sub-region
If the working point is within the envelope, the drive will limit the speed range of each sub-region of
the envelope (minimum speed stored in register [44] and maximum speed stored in register [45]).
The coordinates of the point are compared with several predefined lines, for a proper localization of
the sub-region.
If the compressor is running outside the allowed speed limits, a warning is given and the speed is
changed accordingly.
In case of Speed-Drop Protection, the drive may reduce the speed as low as the minimum allowed
speed for the envelope region.
Outside the qualified application envelope, the speed limits are restricted to the 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 only be cleared if their triggering cause
is gone. The Clear Fault command remains active until the last remaining fault has been
cleared. If all the faults have been cleared, the Clear Fault command will automatically be
reset.
4.6 Compressor start-up
The start-up control is divided into four stages:
▪Stage I: (~2 seconds) The compressor will run from 0 to 1500 rpm at a default acceleration rate
of 600 rpm/s.
▪Stage II: (T1) The compressor continues to increase its speed from 1500 to 3600 rpm with an
acceleration rate of 1000 rpm/s.
▪Stage III: (T2~120 seconds) The compressor will remain at 3600 rpm for 120 seconds. The speed
from region III is set to 3600 rpm by default, but it can be configured through register [213]. Also,
the time (default value = 120 seconds) is configurable via register [234].
▪Stage IV: After 120 seconds, the compressor will reach the commanded speed by a default
acceleration/deceleration rate of 200 rpm/s. The acceleration and deceleration rates can be
changed by introducing different values into registers [211], [212] (the maximum allowed value is
600 rpm/s).

AGL_Sol_EV3_E_Rev_01 15
Figure 7: Start-up sequence
4.7 Compressor shutdown
The user has the possibility to perform an immediate shutdown or a controlled shutdown. By setting
the compressor Enable register [100] to Disabled, while the speed demand is greater than 0, the
drive will perform an immediate stop. Otherwise if the user sends a Disable command as well as 0
speed 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 decelerate automatically with more than
1000 rpm/s. The deceleration rate may be configured through register [210] in the range of 30 to
600 rpm/s.
Figure 8: Shutdown sequence

16 AGL_Sol_EV3_E_Rev_01
5 Optional analog board
The analog board is foreseen for users who do not have the possibility to control the EV3 drive via
an RS485 communication and the Modbus®protocol. To control the EV3 drive the analog board
needs a digital enable signal and an analog signal to set the speed or heating demand. The drive
compressor package must be selected by a 6-Digit DIP-switch. The 7-segment display shows the
status, failure codes as well the software version. The board also provides the system controller with
a PWMfeedback signal with the main information. To protect the compressor a DLT sensor as shown
in paragraph 3.4.6 "Control terminal"must be wired to the drive control terminal.
If a DLT protection is already part of the system controller a wired resistance of 10 kΩcan bypass
this protection on the drive side. In normal operation it is possible to select limited or full speed range
via terminal L (CN104). Using the full speed range, the main controller must take care that in each
sub-envelope the speed does not go below the allowed speed. Using the limited speed range, 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 the terminals shown in Figure 9 which are supported by the EV3 drive.
Code
Description and comments
A
DIP-switch:
Selection of drive compressor package code
B
PWM-output feedback-signal:
▪Pin 1: 5 VDC > NA
▪Pin 2: PWM signal > Ext. controller digital input
▪Pin 3: GND > Ext. controller GND
▪Duty cycle [%]:
0: Error (general error, miswiring)
25: Wrong compressor code (power cycle needed)
50: Standby (waiting for enable and 0…10 V signal)
75: SDP mode (Speed-Drop-Protection mode)
100: Running or heating mode
C
Analog input:
▪Pin 1: AD (0...10 V) > Ext. controller analog output
▪Pin 2: GND > Ext. controller GND
D
RS485 communication / power supply:
▪Pin 1: RS485- (B) > EV3 drive control terminal: 5
▪Pin 2: RS485+ (A) > EV3 drive control terminal: 4
▪Pin 3: GND > EV3 drive control terminal: 3
▪Pin 4: 5 VDC > EV3 drive control terminal: 2
E
PWM input
F
Enable signal:
▪Pin 1: (12 VDC or 24 VDC/AC)
▪12 VDC / 24 VDC/AC > Ext. controller enable signal
▪Pin 2: GND > Ext. controller GND

AGL_Sol_EV3_E_Rev_01 17
Code
Description and comments
G
Programming port:
▪Used for software updates via Renesas Emulators together with a special PCB board
from Emerson
H
Status LED (green):
▪Flashing fast: Fault state
▪Flashing slow: Standby
▪Constantly on: Compressor running / heating
I
Not used
J
Not used
K
Used to select the type of feedback on port B:
▪Without jumper (variable duty cycle [%]):
0:.........Tripped
100: ....OK
▪With jumper (variable duty cycle [%]):
0:..........Error (general error, miswiring)
25: .......Wrong compressor code (power cycle needed)
50: .......Standby (waiting for enable and 0…10 V signal)
75:........SDP mode (Speed-Drop-Protection mode)
100:......Running or heating mode
L
Used for selection of the compressor speed range:
▪Without bridge between pin 1 and 3
oLimited speed range in normal operation (Mode 0: Full Envelope Protection selected
–see paragraph 4.4 "Envelope control"for more details)
▪Bridge between pin 1 and 3
oFull speed range in normal operation (Mode 1: High Speed Envelope Protection
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 case of a wrong configuration the 7-Segment Display shows
the error code E-39. The PWM output shows a duty cycle of 25%. In this case a power cycle is
needed to reset this fault. The DIP-switch will only be analysed once after a power cycle. During the
start-up cycle the 7-segment display will show the compressor as per the DIP-switch configuration –
see Table 14.
ZPV066-4X9
ZPV096-4X9
Package code
44
45
Binary code
001101
101101
Nixie tube
C044
C045
Table 14: Package codes for ZPV/ compressors
The binary code reflects the DIP-switch positions from left to right (from 1 to 6), "1" meaningON state
for the switch, "0" meaning OFF state for the switch.
Example:
▪Drive version: EV3185B-K1-294
▪Compressor version:ZPV096-4X9
▪Package code: 45
▪Binary code: 101101