Evco Syncro Series User manual

Syncro series inverter
Inverter for high power synchronous motors
WARNING
Make sure you read and fully
understand the user manual
before using this device.
Non-observance of these
instructions will result in death
or serious injury.
114EIXKE4.00 - 02/2022
Hardware Manual

114EIXKE4.00 ·Syncro series inverter
CONTENTS
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IMPORTANT INFORMATION.............................................................................................................. 4
IMPORTANT SAFETY INFORMATION................................................................................................ 5
SAFETY INFORMATION RELATING TO THE PRODUCT..................................................................... 6
1. INTRODUCTION .............................................................................................................................. 8
1.1 Description ............................................................................................................................................. 8
1.2 Product overview................................................................................................................................... 8
1.3 Features .................................................................................................................................................. 8
1.4 General Compliance............................................................................................................................... 8
2. PURCHASING CODES...................................................................................................................... 9
2.1 Purchasing codes table ......................................................................................................................... 9
3. RECEIVING THE PRODUCT ........................................................................................................... 10
2.2 Checking the packaging.......................................................................................................................10
2.2.1 Opening the packaging..............................................................................................................................10
2.2.2 Checking the packaging contents............................................................................................................10
4. TECHNICAL DATA.......................................................................................................................... 11
4.1 Technical specications......................................................................................................................11
4.2 Other technical information................................................................................................................11
5. MECHANICAL ASSEMBLY............................................................................................................ 12
5.1 Introduction to installation.................................................................................................................12
5.2 Permitted installation positioning ......................................................................................................13
5.3 Minimum installation distances..........................................................................................................13
5.4 Installation method..............................................................................................................................15
5.5 Dimensions and weight........................................................................................................................16
6. ELECTRICAL CONNECTIONS........................................................................................................ 17
6.1 Connection best practice ....................................................................................................................17
6.1.1 Wiring best practices................................................................................................................................18
6.1.2 Sizing safety interlocks.............................................................................................................................18
6.2 Wiring diagram.....................................................................................................................................19
6.2.1 Safety digital input STO wiring diagram..................................................................................................20
7. REGULATORS ................................................................................................................................. 21
7.1 Control types ........................................................................................................................................21
7.2 Protection .............................................................................................................................................21
7.3 LED interface ........................................................................................................................................21
7.4 Operation ..............................................................................................................................................22
7.4.1 Rotation direction reversal......................................................................................................................22
7.4.2 Compressor heating .................................................................................................................................22
7.4.3 Motor control at start-up .........................................................................................................................22
7.4.4 Motor pole pairings...................................................................................................................................22

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CONTENTS
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7.4.5 Speed jump.................................................................................................................................................23
7.4.6 Speed prole..............................................................................................................................................23
7.4.7 Reducing the PWM carrier frequency and/or speed............................................................................24
7.4.8 Motor phase loss alarm sensitivity .........................................................................................................24
7.4.9 Motor stall alarm sensitivity ....................................................................................................................25
8. MANUAL TUNING MODE / AUTOTUNING.................................................................................... 26
8.1 Manual tuning mode ............................................................................................................................26
8.2 Autotuning mode ..................................................................................................................................27
8.2.1 Autotuning procedure ..............................................................................................................................27
9. CONFIGURATIONS........................................................................................................................ 29
9.1 Control via analogue and digital input ...............................................................................................29
9.1.1 Wiring diagram ..........................................................................................................................................29
9.1.2 Parameter conguration..........................................................................................................................29
9.2 Control via Slave Serial port ...............................................................................................................30
9.2.1 Wiring diagram ..........................................................................................................................................30
9.2.2 Parameter conguration..........................................................................................................................30
10. PARAMETERS.............................................................................................................................. 31
10.1 Table of conguration parameters ..................................................................................................31
10.2 Table of Modbus commands .............................................................................................................34
10.3 Serial communication settings.........................................................................................................34
10.4 Table of Modbus variables................................................................................................................34
10.5 Table of monitor data.........................................................................................................................36
11. ALARMS ....................................................................................................................................... 37
11.1 Table of alarms...................................................................................................................................37
12. PARAMETERS MANAGER........................................................................................................... 38

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IMPORTANT INFORMATION
Liability and residual risks
EVCO assumes no liability for any damage caused by the following (by way of example; this is not an exhaustive list):
• Installation/useforpurposesotherthanthosespeciedand,inparticular,notadheringtothesafetyprovisionssetout
by current regulations in the country in which the product is installed and/or contained in this manual;
• Useinappliancesthatdonotguaranteesufcientprotectionagainstelectricshocks,wateranddustwithinthe
installation conditions created;
• Useinappliancesthatallowaccesstohazardouspartswithouttheuseofakeyedortooledlockingmechanismwhen
accessing the instrument;
• Tampering and/or modifying the product;
• Installation/use in appliances which do not comply with current regulations in the country in which the product is
installed.
The customer/manufacturer is responsible for ensuring their machine complies with these regulations.
EVCO’s responsibility is limited to the correct and professional use of the product in accordance with regulations and the
instructions contained in this manual and other product support documents.
TocomplywithEMCstandards,observealltheelectricalconnectioninstructions.Asitdependsonthewiringconfigurationas
wellastheloadandtheinstallationtype,compliancemustbeverifiedforthefinalmachineasspecifiedbytherelevantproduct
standard.
Disclaimer
This document is the exclusive property of EVCO. It contains a general description and/or a description of the technical
specifications for the services offered by the products listed herein. This document should not be used to determine the
suitability or reliability of these products in relation to specific user applications. Each user or integration specialist should
conducttheirowncompleteandappropriateriskanalysis,inadditiontocarryingoutaproductevaluationandtestinrelation
to its specific application or use. Users can send us comments and suggestions on how to improve or correct this publication.
Neither EVCO nor any of its associates or subsidiaries shall be held responsible or liable for improper use of the information
contained herein.
EVCOhasapolicyofcontinuousdevelopment.Therefore,EVCOreservestherighttomakechangesandimprovementstoany
product described in this document without prior notice.
The images in this document and other documentation supplied with the product are provided for illustrative purposes only and
may differ from the product itself.
The technical data in this manual is subject to change without prior notice.
Terms and Conditions of use
Permitted use
Thedevicemustbeinstalledandusedinaccordancewiththeinstructionsprovidedand,inparticular,hazardousliveparts
must not be accessible under normal conditions.
The device must be suitably protected from water and dust with regard to its application and must also only be accessible with
the aid of a tool.
Only qualified personnel may install the product or perform technical support procedures on it.
The customer must only use the product as described in the documentation relating to that product.
Prohibited use
Anyuseotherthanthosedescribedinthe"Permitted use"sectionandintheproductsupportdocumentationisprohibited.
The product must be installed outside hazardous ATEX areas.
Disposal
The device must be disposed of in accordance with local regulations regarding the collection of electrical and
electronic appliances.
Consider the environment
Withaviewtorespectingtheenvironment,westrivetoadheretotheenvironmentalperformanceofthecompany,
whiletakingaccountofcustomerrequirements,technologicalinnovationsintermsofmaterialsandtheexpectations
ofthecommunitytowhichwebelong.EVCOplacesgreatimportanceonrespectingtheenvironment,encouragingall
associatestobecomeinvolvedwithcompanyvaluesandguaranteeingsafe,healthyandfunctionalworkingconditions
andworkplaces.
Please consider the environment before printing this document.

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IMPORTANT SAFETY INFORMATION
Please read this document carefully before installation; study all the warnings before using the device. Only use the device in
accordance with the methods described in this document. The following safety messages may be repeated several times in
thedocument,toprovideinformationregardingpotentialhazardsortoattractattentiontoinformationwhichmaybeusefulin
explaining or clarifying a procedure.
Thissymbolisusedtoindicateariskofelectricshock.
Itisasafetyindicationandassuch,shouldbeobservedtoavoidpotentialaccidentsorfatalities.
Thissymbolisusedtoindicateariskofseriouspersonalinjury.
Itisasafetyindicationandassuch,shouldbeobservedtoavoidpotentialaccidentsorfatalities.
DANGER
DANGER indicatesasituationofimminentdangerwhich,ifnotavoided,will lead to death or serious injury.
WARNING
WARNING indicatesasituationofimminentdangerwhich,ifnotavoided,may lead to death or serious injury.
CAUTION
CAUTION indicatesapotentiallyhazardoussituationwhich,ifnotavoided,could cause minor or moderate injury.
NOTICE
NOTICE indicates a situation not related to physical injuries but which ,ifnotavoided, could damage the equipment.
NOTE:themaintenance,repair,installationanduseofelectricalequipmentmustonlybeentrustedtoqualifiedpersonnel.
QUALIFIED PERSONNEL
Only suitably trained and experienced personnel capable of understanding the content of this manual and all documentation
regardingtheproductareauthorisedtoworkonandwiththisequipment.Furthermore,thepersonnelmusthavecompleted
coursesinsafetyandmustbeabletorecogniseandpreventtheimplieddangers.Thepersonnelmusthavesuitabletraining,
knowledgeandexperienceatatechnicallevel,andbecapableofanticipatinganddetectingpotentialriskscausedbyusing
theproduct,aswellaschangingthesettingsandmodifyingthemechanical,electricandelectronicequipmentfortheentire
systeminwhichtheproductisused.Allpersonnelworkingonandwiththeproductmustbeentirelyfamiliarwiththerelevant
standardsanddirectives,aswellassafetyregulations.

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SAFETY INFORMATION RELATING TO THE PRODUCT
Beforecarryingoutanyworkontheequipment,readtheseinstructionscarefully,makingsureyouunderstandeverything.
DANGER
RISK OF ELECTRIC SHOCK, EXPLOSION OR ELECTRIC ARC
• Onlysuitablytrainedpersonnel,familiarwithandcapableofunderstandingthecontentofthemanualandallrelevant
documentation,areauthorisedtoworkonandwiththisinverter.Furthermore,thepersonnelmusthavecompletedcourses
insafetyandmustbeabletorecogniseandpreventtheimplieddangers.Installation,adjustmentandmaintenancemust
only be carried out by qualified personnel.
• Variousproductcomponents,includingtheprintedcircuits,runathazardousvoltagelevels.
• Only use electrically insulated and suitably calibrated measuring devices and equipment.
• Do not handle the equipment while the power supply is connected.
• Do not touch the unshielded components or the terminals while they are live.
• Themotorsmaygeneratevoltageiftheshaftisrotated.Beforecarryingoutanyworkontheinverter,lockthemotorshaft
to prevent it from rotating.
• Beforeworkingontheinverter:
• Disconnect the power supply.
• UseasuitablycalibratedandelectricallyinsulatedVoltmetertomakesurethepowersupplyisdisconnected.
• Waitfor5minutedafterdisconnectingthepowersupplybeforeinstalling/uninstallingaccessories,hardware,cablesor
wires,toallowthecondenserstodischargeanyresidualvoltage.
• Donotopen,disassemble,repairormodifytheproduct.
• Beforehandlingtheproduct,makesureyouarewearingallthenecessarypersonalprotectiveequipment(PPE).
• Do not expose the equipment to liquids or chemicals.
• Before applying voltage to the inverter:
• Makesuretherunningperiodhasbeencompletedandnopartsofthesystemcanbecomehazardous.
• Ifthemainspowersupplyterminalsandthemotoroutputterminalshavebeenearthedandcircuited,removetheearth
and short circuits on these terminals.
• Makesurealltheequipmentisproperlyearthed.
• Makesureallprotectiveelements,suchascovers,hatchesandgrilles,arefittedand/orclosed.
• Checkallwiringconnections.
ForinstallationinaccordancewithstandardEN61800-5-1,adevicecuttingoffthecircuitbetweenthepowersupplyandthe
inverter is required.
DANGER
RISK OF ELECTRIC SHOCK
Usetherequiredsafetyinterlocks(fusesand/ormagnetothermalswitches)ofasuitablesizebetweenthepowersupplyand
the inverter.
DANGER
RISK OF ELECTRIC SHOCK AND FIRE
• Do not use the device with loads greater than those indicated in the technical data section.
• Do not exceed the temperature and humidity ranges indicated in the technical data section.
DANGER
RISK OF ELECTRIC SHOCK OR MALFUNCTIONING OF THE EQUIPMENT
Do not use damaged products or accessories.
Thisdevicewasdesignedtooperateinnon-hazardousenvironments,excludingapplicationsthatgenerate,orcouldpotentially
generate,hazardousatmospheres.Onlyinstallthisdeviceinareasandforapplicationswhicharereliablyfreefromhazardous
atmospheres.
DANGER
RISK OF EXPLOSION
• Onlyinstallandusethisdeviceinsitesthatarenotatrisk.
• Donotinstallorusethisdeviceinapplicationswhicharecapableofgeneratinghazardousatmospheres,suchas
applications that use flammable refrigerants.

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Theendapplicationutilisesawiderangeofmechanical,electricalandelectroniccomponentsconnectedtooneanotherandthe
inverter is only one part of the application.
Theinverter,asanindividualmachine,isnotcapableofprovidingallthefunctionsnecessarytosatisfyallthesafety
requirementsrelatingtotheendapplication.Dependingontheapplicationandthecorrespondingriskanalysistobeperformed,
a series of additional equipment will be required.
Asamachinedesigner/manufacturer,itisnecessarytobefamiliarwithandobserveallstandardsapplicabletothemachine.
ItisalsoessentialtocarryoutariskassessmentandtodeterminetheappropriatePerformanceLevel(PL)and/orSafety
IntegrityLevel(SIL)inordertodesignandconstructthemachineincompliancewithallapplicablestandards.Theinteraction
betweenallmachinecomponentsmustbeconsidered,anditisessentialtoprovideoperatinginstructionswhichallowtheuser
(qualifiedpersonnel)tosafelycarryoutanytypeofworkonthemachine,suchasoperationandmaintenance.
Thisdocumentassumesfamiliaritywithallstandardsandregulatoryrequirementsrelatingtotheapplication.Astheinverteris
notcapableofprovidingallsafety-relatedfunctionsfortheentireapplication,itisessentialthattherequiredperformancelevel
and/or safety integrity level is guaranteed through the installation of all necessary additional equipment.
WARNING
INSUFFICIENT PERFORMANCE LEVEL AND/OR SAFETY INTEGRITY LEVEL AND/OR MALFUNCTIONING OF THE EQUIPMENT
• Carryoutariskassessmentinaccordancewithallotherstandardsrelatingtoyourapplication.
• Useredundantcomponentsand/orcontrollinesforallcriticalcontrolfunctionsidentifiedintheriskassessment.
• Makesurethattheusefullifeofallcomponentsusedintheapplicationissufficientfortheanticipateddurationoftheentire
application.
• Carryoutin-depthstart-uptestsforallpotentialerrorsituationsinordertochecktheeffectivenessofthesafetyand
monitoringfunctionsimplemented,suchasspeedmonitoringviaencoder,short-circuitmonitoringforallconnected
equipmentandcorrectbrakeandprotectivedeviceoperation.
• Carryoutin-depthstart-uptestsforallpotentialerrorsituationsinordertomakesuretheloadcanbesafelybroughttoa
stop in all conditions.
The Syncro inverter must be installed in a suitably ventilated environment to allow heat to dissipate.
Thetemperatureofthedevicecanexceed80°C(176°F)duringoperation.
WARNING
HOT SURFACES
• Avoidallcontactwithhotsurfaces.
• Donotleaveflammableorheat-sensitivecomponentsonornearhotsurfaces.
• Makesuretheproducthascooledsufficientlybeforehandlingit.
• Makesuresufficientheatdissipationtakesplacebyperformingatestundermaximumloadconditions.
WARNING
MALFUNCTIONING OF THE EQUIPMENT
• Performthewiringcarefully,incompliancewithelectromagneticcompatibilityrequirements.
• Donotoperatetheproductwithunknownorincorrectsettingsordata.
• Carryoutafullstart-uptest.
• Makesurethewiringiscorrectforthesettings.
• Use shielded cables for all I/O signal and communication cables.
• Usedouble-shieldedcablesformotorwiring.
• Minimisethelengthoftheconnectionsasmuchaspossible,toavoidwindingthecablesaroundelectricallyconnectedparts.
• The signal (communication and corresponding power supplies) and power cables for the device must be routed in separate
ducts.
• Use ferrite couplings for the connection cables running to the motor and for the earth connection cable.
• Beforeapplyingthepowersupply,checkallthewiringconnections.
• Donotconnectwirestounusedterminalsand/orterminalsmarkedwiththetext“Noconnection”(N.C.).

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1.1 DESCRIPTION
The series of Syncroinvertersisdesignedtocontrolthree-phasepermanentmagnetsynchronousmotorswithapowerofupto6kW.
Operating environments for the Syncro series of products are:
• Three-phasepermanentmagnetsynchronousmotors(BLDC);
• Three-phaseasynchronousmotors;
• ControllingHVAC-Rcompressors.
Itusesscalarorvectormotorcontrol,dependingonapplicationrequirements.
1.2 PRODUCT OVERVIEW
1
6
7
2
3
4
5
Ref. Description
1Power supply input
2Motor output
3I/O connections
4Digital Output
5Cooler fans
6
PCB fan
7ServiceUSBinput
Fig. 1. Syncro Inverter overview
1.3 FEATURES
The main features of the Syncro series inverter are:
• 3 digital inputs;
• 1safetydigitalinput(forSIL2/SIL3systems);
• 1analogueinput:
• CanbeconguredasanNTC/PTCprobeor0...10Vinput;
• 1digitaloutput;
• 112Vdcoutput;
• 1RS-485Modbusslavecommunicationserialport;
• Availablepowerlevels:
• 4.8kW;
• 6kW.
• Invertercoolingsystemviabuilt-inventilation.
1.4 GENERAL COMPLIANCE
Directive Harmonised standard
LVD Directive 2014/35/EU EN61800-5-1:2007-09:Adjustablespeedelectricalpowerdrivesystems.
Part 5-1:Safetyrequirements–Electrical,thermalandenergysafety.
EMC Directive 2014/30/EU
EN61800-3 (EMC):Adjustablespeedelectricalpowerdrivesystems.ClassC2.
EN61000-3-12 (EMC):Limitsforharmoniccurrentsproducedbyequipmentconnectedto
publiclow-voltagesystemswithinputcurrent>16Aand≤75Aperphase.
Machine Directive 2006/42/EC EN61800-5-2:Adjustablespeedelectricalpowerdrivesystems.Safetyrequirements–
Functionalsafety.
1. INTRODUCTION

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2. PURCHASING CODES
2.1 PURCHASING CODES TABLE
The table below illustrates the main features of available Syncro series inverters and the corresponding purchasing codes:
Features Syncro
Power supply 230Vac±10% •
Power levels 4.8kW EI4K8M2Y04O0VXX
6kW EI6K0M2Y04O0VXX
Digital inputs NPN(*) 3
Analogueinputs 0...10V 1
Digital outputs
1Arelayat230Vac 1
Powered outputs
12Vdcoutput,100mA
(reinforced insulation)
1
IndicatorLED
YellowLED 1
RedLED 1
GreenLED 1
Installation Panel •
Terminalblocks Quick-disconnectscrew
type •
Communication
ports RS-485MODBUSSLAVE •
NOTE: for further information, consult chapter "Chapter 4. Technical data" on page 11.
(*) = PNP on request; contact the sales ofce for more information.

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NOTICE
MALFUNCTIONING OF THE EQUIPMENT
• Droppagesandshockscandamagetheproductbeyondrepair.
• Tamperingwithorremovingtheidentificationstickersinvalidatesthewarranty.
2.2 CHECKING THE PACKAGING
• Makesurethepackagingisintact;
• Makesuretheinverterisintactupondeliveryandinformthecourierimmediately,inwriting,ofanyproblemscausedby
carelessorimpropertransportation(acceptthepackageconditionally).
2.2.1 Opening the packaging
• Takethepackagetotheinstallationsite;
• Openthecardboardbox,removingthepolystyrenecornerprotectors;
• Slideouttheinverter.
2.2.2 Checking the packaging contents
Thestandardproductpackagecontains:
• Syncro series inverter;
• Instruction sheet for installation and assembly.
3. RECEIVING THE PRODUCT