Honeywell HVAC232 Series Instructions for use

APPLICATION MANUAL
HVAC232/402
27652_ENG06

Application manual HVAC232/402 | Document 27-652 | Issue ENG06 | 2019-08-07 2
Content
0 DOCUMENT HYSTORY.............................................................................................................................. 5
1 SAFETY............................................................................................................................................................ 6
1.1 Warnings ...............................................................................................................................................................................................................................................................7
1.2 Safety instructions............................................................................................................................................................................................................................................8
1.3 Earthing and earth fault protection.........................................................................................................................................................................................................9
1.4 Before running the motor .............................................................................................................................................................................................................................10
2 RECEIPT OF DELIVERY ............................................................................................................................. 10
2.1 Storage ...................................................................................................................................................................................................................................................................10
2.2 Maintenance .......................................................................................................................................................................................................................................................10
2.3 Warranty.................................................................................................................................................................................................................................................................11
3 INSTALLATION............................................................................................................................................. 11
3.1 Mechanical installation .................................................................................................................................................................................................................................11
3.2 HVAC232/402 dimensions  ........................................................................................................................................................................................................................14
3.3 Cooling ...................................................................................................................................................................................................................................................................17
3.4 Power losses ........................................................................................................................................................................................................................................................18
3.5 EMC levels ............................................................................................................................................................................................................................................................21
3.6 Changing the EMC protection class from C2 to C4........................................................................................................................................................................22
3.7 Cabling and connections..............................................................................................................................................................................................................................23
3.8 Screw of cables...................................................................................................................................................................................................................................................28
3.9 Stripping lengths of motor and mains cables.................................................................................................................................................................................... 31
3.10 Cable installation ..............................................................................................................................................................................................................................................32
3.11 Cable and motor insulation checks.........................................................................................................................................................................................................32
4 COMMISSIONING AND
STARTUP WIZARD ..................................................................................................................................... 32
4.1 Commissioning steps of HVAC232/402 ..............................................................................................................................................................................................32
4.2 Startup Wizard.................................................................................................................................................................................................................................................... 34

Application manual HVAC232/402 | Document 27-652 | Issue ENG06 | 2019-08-07 3
5 FAULT TRACING........................................................................................................................................... 35
6 HVAC232/402 APPLICATION INTERFACE ........................................................................................ 41
6.1 Introduction .........................................................................................................................................................................................................................................................41
6.2 Control I/O............................................................................................................................................................................................................................................................42
7 CONTROL PANEL........................................................................................................................................ 44
7.1 General ...................................................................................................................................................................................................................................................................44
7.2 Display .................................................................................................................................................................................................................................................................... 44
7.3 Keypad ....................................................................................................................................................................................................................................................................46
8 NAVIGATION ON THE HVAC232/402 CONTROL PANEL.............................................................. 47
8.1 Main menu ...........................................................................................................................................................................................................................................................47
8.2 Reference menu.................................................................................................................................................................................................................................................49
8.3 Monitoring menu ..............................................................................................................................................................................................................................................50
8.4 Parameter menu................................................................................................................................................................................................................................................53
8.5 System menu.......................................................................................................................................................................................................................................................54
9 Standard application parameters.......................................................................................................... 55
9.1 Quick setup parameters (Virtual menu, shows when par. 16.2 1)...................................................................................................................................56
9.2 Easy usage menu (Control panel: Menu PAR P16).................................................................................................................................................................89
9.3 Fire mode (Control panel: Menu PAR  P18)...............................................................................................................................................................................................90

Application manual HVAC232/402 | Document 27-652 | Issue ENG06 | 2019-08-07 4
10 Parameter description ............................................................................................................................... 96
10.1 Motor settings (Control panel: Menu PAR P1).......................................................................................................................................................................... 96
10.2 Start / stop setup (Control panel: Menu PAR P2)....................................................................................................................................................................101
10.3 Frequency references (Control panel: Menu PAR P3)...........................................................................................................................................................112
10.4 Ramps & brakes setup (Control panel: Menu PAR P4) ......................................................................................................................................................... 114
10.5 Digital inputs (Control panel: Menu PAR P5)............................................................................................................................................................................. 117
10.6 Analogue inputs (Control panel: Menu PAR P6) ......................................................................................................................................................................118
10.7 Digital outputs (Control panel: Menu PAR P7) .........................................................................................................................................................................119
10.8 Analogue outputs (Control panel: Menu PAR P8) ...................................................................................................................................................................120
10.9 Fieldbus DataMapping (Control panel: Menu PAR P9)...................................................................................................................................................... 120
10.10 Prohibited Frequencies (Control panel: Menu PAR P10) ....................................................................................................................................................121
10.11 Protections (Control panel: Menu Par P12) ...............................................................................................................................................................................122
10.12 Automatic reset (Control panel: Menu PAR P13).....................................................................................................................................................................127
10.13 PID control parameters (Control panel: Menu PAR P14).....................................................................................................................................................128
10.14 Application setting (Control panel: Menu PAR P15)..............................................................................................................................................................130
10.15 Application setting (Control panel: Menu PAR P16)..............................................................................................................................................................131
10.16 System parameter ............................................................................................................................................................................................................................................132
10.17 Modbus RTU .......................................................................................................................................................................................................................................................133
10.18 Termination resistor ........................................................................................................................................................................................................................................134
10.19 Modbus address area  ....................................................................................................................................................................................................................................134
10.20 Modbus process data  ....................................................................................................................................................................................................................................134
11 Technical data............................................................................................................................................... 138
11.1 HVAC232/402 technical data.................................................................................................................................................................................................................... 138
12 PART NUMBERS, POWER RATINGS, SIZE, AND WEIGHT ............................................................. 141
12.1 Part Number Options......................................................................................................................................................................................................................................141
12.2 Low overload........................................................................................................................................................................................................................................................142
12.3 High overload......................................................................................................................................................................................................................................................142
12.4 HVAC232/402 – Mains voltage 208240 V........................................................................................................................................................................................143
13 ACCESSORIES .............................................................................................................................................. 145

Application manual HVAC232/402 | Document 27-652 | Issue ENG06 | 2019-08-07 5
0 DOCUMENT HYSTORY
Version Date Modifications
ENG06 20190807 Table 54 : Modbus: Input process data: ID2003
new Name "Frequency reference" and new Type "0…10'000"

Application manual HVAC232/402 | Document 27-652 | Issue ENG06 | 2019-08-07 6
1 SAFETY
Please read the information included in cautions and warnings carefully:
CAUTION
ONLY A COMPETENT ELECTRICIAN IS ALLOWED TO CARRY OUT THE ELECTRICAL INSTALLATION!
This manual contains clearly marked cautions and warnings which are intended for your personal safety and to avoid any unintentional damage
to the product or connected appliances.

Application manual HVAC232/402 | Document 27-652 | Issue ENG06 | 2019-08-07 7
WARNING
The motor can start automatically after a fault situation, if the
autoreset function has been activated.
1.1 Warnings
WARNING
The control I/O-terminals are isolated from the mains
potential. However, the relay output terminals may have a
dangerous control voltage present even when HVAC232/402
is disconnected from mains.
WARNING
The motor terminals U, V, W (T1, T2, T3) and the possible brake
resistor terminals / + are live when HVAC232/402 is connected
to mains, even if the motor is not running.
WARNING
The components of the power unit of the frequency converter
are live when HVAC232/402 is connected to mains. Coming
into contact with this voltage is extremely dangerous and may
cause death or severe injury. The control unit is isolated from
the mains potential.
WARNING
The earth leakage current of HVAC232/402 frequency
converters exceeds 3.5 mA AC. According to standard
EN61800 51, a reinforced protective ground connection
must be ensured.
WARNING
If the frequency converter is used as a part of a machine,
the machine manufacturer is responsible for providing the
machine with a main switch (EN 602041).
WARNING
If HVAC232/402 is disconnected from mains while running the
motor, it remains live if the motor is energized by the process.
In this case the motor functions as a generator feeding energy
to the frequency converter.
WARNING
After disconnecting the frequency converter from the mains,
wait until the fan stops and the indicators on the display
go out. Wait 5 more minutes before doing any work on
HVAC232/402 connections.

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1.2 Safety instructions
CAUTION
The HVAC232/402 frequency converter has been designed for
fixed installations only.
CAUTION
Do not perform any measurements when the frequency
converter is connected to the mains.
CAUTION
Do not perform any voltage withstand tests on any part of
HVAC232/402.
The product safety is fully tested at factory.
CAUTION
Prior to measurements on the motor or the motor cable,
disconnect the motor cable from the frequency converter.
CAUTION
Do not open the cover of HVAC232/402. Static voltage
discharge from your fingers may damage the components.
Opening the cover may also damage the device. If the cover of
HVAC232/402 is opened, warranty becomes void.

Application manual HVAC232/402 | Document 27-652 | Issue ENG06 | 2019-08-07 9
1.3 Earthing and earth fault protection
The Smart HVAC232/402 frequency converter must always be earthed
with an earthing conductor connected to the earthing terminal. See figure
below:
MCR36496
Fig. 1. MI1 - MI3
Fig. 2. MI4
Fig. 3. MI5
1. The earth fault protection inside the frequency converter protects only
the converter itself against earth faults.
2. If residual current devices are used they must be tested with the drive
with earth fault currents that are possible to arise in fault situations.
MCR36497
MCR36498

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1.4 Before running the motor
Checklist:
 Before starting the motor, check that the motor is mounted properly
and ensure that the machine connected to the motor allows the motor
to be started.
 Set the maximum motor speed(frequency) according to the motor and
the machine connected to it.
 Before reversing the motor shaft rotation direction make sure that this
can be done safely.
 Make sure that no power correction capacitors are connected to the
motor cable.
2 RECEIPT OF DELIVERY
After unpacking the product, check that no signs of transport damages are
to be found on the product and that the delivery is complete (compare the
type designation of the product to the code: see chapter 12).
Should the drive have been damaged during the shipping, please contact
primarily the cargo insurance company or the carrier.
If the delivery does not correspond to your order, contact the supplier imme-
diately.
2.1 Storage
If the frequency converter is to be kept in store before use make sure that
the ambient conditions are acceptable:
Storing temperature –40 °F (–40 °C)…+70 °F (21 °C)
Relative humidity < 95%, no condensation
2.2 Maintenance
In normal operating conditions, HVAC232/402 frequency converters are
maintenance- free. However, regular maintenance is recommended to
ensure a trouble-free operating and along lifetime of the drive. We recom-
mended to follow the table below for maintenance intervals.
Table 1.
Maintenance interval Maintenance action
Whenever necessary Clean heat sink*
Regular Check tightening torques of terminals
12 months (If stored) Check input and output terminals and control
I/O terminals.
Clean cooling tunnel.*
Check operation of cooling fan.
Check for corrosion on terminals, bus bars
and other surfaces.*
6 - 24 months (depending
on environment)
Check and clean cooling fans:
• Main fan*
• Internal fan*
* Only for frame 4 and frame 5

Application manual HVAC232/402 | Document 27-652 | Issue ENG06 | 2019-08-07 11
Capacitor recharge
After a longer storage time the capacitors need to be recharge in order to
avoid capacitor damage. Possible high leakage current through the capac-
itors must be limited. The best way to achieve this is to use a DC-power
supply with adjustable current limit.
1. Set the current limit to 300…800 mA according to the size of the drive.
2. Then connect the DC-power supply to the input phase L1 and L2.
3. Then set the DC-voltage to the nominal DC voltage level of the
(1.35 × Un AC) and supply the converter for at least 1h.If DC-voltage
is not available and the unit has been stored much longer than 12
months de-energized, consult the factory before connecting power.
2.3 Warranty
Only manufacturing defects are covered by the warranty. The manufacturer
assumes no responsibility for damages caused during or resulting from
transport, receipt of the delivery, installation, commissioning or use.
The manufacturer shall in no event and under no circumstances be
held responsible for damages and failures resulting from misuse, wrong
installation, unacceptable ambient temperature, dust, corrosive substances
or operation outside the rated specifications. Neither can the manufacturer
be held responsible for consequential damages.
Variable frequency drive devices (VFD) and accessories: new products for
thirty-six (30) months from the date of production.
3 INSTALLATION
3.1 Mechanical installation
There are two possible ways to mount HVAC232/402 in the wall. For
MI1MI3, either screw or DIN-rail mounting; For MI4MI5, screw or flange
mounting.
= M5
MI3
MI1
=M4
MI2
=M5
LOC
REM
BACK
RESET
OK
M36500
LOC
REM
BACK
RESET
OK
LOC
REM
BACK
RESET
OK
Fig. 4. Screw mounting, MI1 - MI3

Application manual HVAC232/402 | Document 27-652 | Issue ENG06 | 2019-08-07 12
MI4
MI5
LOC
REM
BACK
RESET
OK
M36501
=M 6
=M 6
LOC
REM
BACK
RESET
OK
Fig. 5. Screw mounting, MI4 - MI5
NOTE:
See the mounting dimensions on the back of the drive.
1 2
M36502
Fig. 6. DIN-rail mounting, MI1 - MI3
M36503
LOC
REM
BACK
RESET
OK
Fig. 7. Flange mounting, MI4 - MI5

Application manual HVAC232/402 | Document 27-652 | Issue ENG06 | 2019-08-07 13
14-1/2 (370)
14-19/64 (362)
13/64 (6)
6-1/2
(166)
6-51/64
(173)
7-13/32
(189)
TOP 6
(153)
Ø 1/4 (7)
14 (356)
15-7/64 (384) M36504
DRIVE OUTLINE
OPENING OUTLINE
Fig. 8. Flange mounting cutout dimensions for MI4
[Unit: inches (mm)]
OPENING OUTLINE
16 (407)
DRIVE OUTLINE
Ø 1/4 (7)
TOP 6
(153)
14 (356)
15-45/64 (400)
17 (431)
13/64 (6)
6-1/2
(166)
6-51/64
(173)
7-13/32
(189)
M36505
Fig. 9. Flange mounting cutout dimensions for MI5
[Unit: inches (mm)]
MI4
M36507
MI5
1-3/32
(29)
51/64
(20)
13
(332)
15/32
(12) 29/32
(23) 3-1/2
(89)
6-1/2 (165)
3
(77)
5/8
(16)
1-3/32
(29)
15
(379)
19/32
(15)
29/32
(23)
8 (202)
3-45/64
(95)
4-7/32
(107)
Fig. 10. Flange mounting depth dimensions
for MI4 and MI5 [Unit: inches (mm)]

Application manual HVAC232/402 | Document 27-652 | Issue ENG06 | 2019-08-07 14
3.2 HVAC232/402 dimensions
W2
W3
W (W1)
H (H1)
H2
H3
D2
D (D1)
Fig. 11. HVAC232/402 dimensions,
MI1 - MI3
W2
W3
H (H1)
W (W1)
D (D1)
H3
H2
Fig. 12. HVAC232/402 dimensions,
MI4 MI5

Application manual HVAC232/402 | Document 27-652 | Issue ENG06 | 2019-08-07 15
Table 2. HVAC232/402 dimensions in inches (mm).
Type H1 H2 H3 W1 W2 W3 D1 D2
MI1 6.3 (160.1) 5.8 (147) 5.4 (137.3) 2.6 (65.5) 1.5 (37.8) .18 (4.5) 3.9 (98.5) .28 (7)
MI2 7.7 (195) 7.2 (183) 6.7 (170) 3.5 (90) 2.5 (62.5) .22(5.5) 4 (101.5) .28 (7)
MI3 10 (254.3) 9.6 (244) 9.0 (229.3) 3.9 (100) 3.0 (75) .22 (5.5) 4.3 (108.5) .28 (7)
MI4 14.6 (370) 13.8 (350.5) 13.2 (336.5) 6.5 (165) 5.5 (140) .28 (7) 6.5 (165) -
MI5 16.3 (414) 15.7 (398) 15.1 (383) 6.5 (165) 5.5 (140) .28 (7) 8.0 (202) -
Table 3. HVAC232/402 frame dimensions (mm) and weights in lbs (kg)
Frame
Dimensions in inches (mm) Weight in lbs (kg.)*
W H D
MI1 2.6 (66) 6.3 (160) 3.9 (98) 1.1 (0.5)
MI2 3.5 (90) 7.7 (195) 4 (102) 1.6 (0.7)
MI3 3.9 (100) 10 (254.3) 4.3 (109) 2.2 (1)
MI4 6.5 (165) 14.6 (370) 6.5 (165) 17.7 (8)
MI5 6.5 (165) 16.3 (414) 8 (202) 22 (10)
* without shipping package

Application manual HVAC232/402 | Document 27-652 | Issue ENG06 | 2019-08-07 16
Fig. 13. HVAC232/402 dimensions,
MI23 - Display Location
Dimensions in
inches (mm)
Frame
MI2 MI3
A.7 (17) .9 (22.3)
B1.7 (44) 4 (102)
Fig. 14. HVAC232/402 dimensions,
MI45 - Display Location
Dimensions in
inches (mm)
Frame
MI2 MI3
A 8 (205) 9.8 (248.5)
B3.4 (87) 3.4 (87)

Application manual HVAC232/402 | Document 27-652 | Issue ENG06 | 2019-08-07 17
3.3 Cooling
Enough free space shall be left above and below the frequency converter
to ensure sufficient air circulation and cooling. You will find the required
dimensions for free space in the table below.
If several units are mounted above each other, the required free space
equals C + D (see figure below). Moreover, the outlet air used for cooling by
the lower unit must be directed away from the air intake of the upper unit.
The amount of cooling air required is indicated below. Also make sure that
the temperature of the cooling air does not exceed the maximum ambient
temperature of the converter.
Table 4. Min. clearances around AC drive
Min clearance in inches (mm)
Type A* B* C D
MI1 .8 (20) .8 (20) 3.9 (100) 2 (50)
MI2 .8 (20) .8 (20) 3.9 (100) 2 (50)
MI3 .8 (20) .8 (20) 3.9 (100) 2 (50)
MI4 .8 (20) .8 (20) 3.9 (100) 3.9 (100)
MI5 .8 (20) .8 (20) 4.7 (120) 3.9 (100)
* Min clearance A and B for drives for MI1~MI3 can be 0 inches if the ambient temperature
is below 104 °F (40°C).
A = clearance around the freq. converter (see also B)
B = distance from one frequency converter to another or distance to
cabinet wall
C = free space above the frequency converter
D = free space underneath the frequency converter
B
C
B
A
D
A
Fig. 15. Installation space
NOTE:
See the mounting dimensions on the back of the drive.
Leave free space for cooling above (100 mm),below (50 mm), and on the
sides (20 mm) of HVAC232/402! (For MI1 - MI3, side-to-side installation
allowed only if the ambient temperature is below 104 °F (40 °C);
For MI4MI5, side-to-side installation is not allowed.
Table 5. Required cooling air
Type Cooling air required in cfm (m³/h)
MI1 5.886 (10)
MI2 5.886 (10)
MI3 17.65 8 (30)
MI4 26.487 (45)
MI5 44.145 (75)

Application manual HVAC232/402 | Document 27-652 | Issue ENG06 | 2019-08-07 18
3.4 Power losses
If the operator wants to raise the switching frequency of the drive for some
reason (typically e.g. in order to reduce the motor noise), this inevitably
affects the power losses and cooling requirements, for different motor shaft
power, operator can select the switching frequency according to the graphs
below.
MI1 - MI3 1P 230 V POWER LOSS

Application manual HVAC232/402 | Document 27-652 | Issue ENG06 | 2019-08-07 19
MI1 - MI5 3P 400 V POWER LOSS

Application manual HVAC232/402 | Document 27-652 | Issue ENG06 | 2019-08-07 20
MI1 - MI5 3P 400 V POWER LOSS