Honeywell SmartVFD HVAC MR4 User manual

Honeywell
User Manual
SmartVFD HVAC
Variable Frequency Drives
for Constant and Variable
Torque Applications
63-2692-08

Honeywell • 0
INDEX
Document: DPD00323C
Version release date: 1.4.10
1. Safety ..................................................................................................................2
1.1 Danger ............................................................................................................................ 2
1.2 Warnings......................................................................................................................... 3
1.3 Grounding and ground fault protection ........................................................................... 3
1.4 Running the motor .......................................................................................................... 4
2. Receipt of delivery.............................................................................................6
2.1 ‘Product modified’ sticker ................................................................................................ 6
2.2 Unpacking and lifting the drive........................................................................................ 6
2.2.1 Lifting frames MR8 and MR9 .......................................................................................... 7
2.3 Type designation code.................................................................................................... 8
2.4 Accessories..................................................................................................................... 9
3. Mounting...........................................................................................................10
3.1 Dimensions ...................................................................................................................10
3.1.1 Wall mount, MR4-MR7.................................................................................................. 10
3.1.2 Wall mount, MR8 and MR9........................................................................................... 12
3.1.3 Flush mount .................................................................................................................. 13
3.2 Cooling.......................................................................................................................... 18
4. Power cabling ..................................................................................................20
4.1 UL standards on cabling ............................................................................................... 21
4.1.1 Cable dimensioning and selection ................................................................................ 21
4.2 Brake resistor cables .................................................................................................... 23
4.3 Control cables ...............................................................................................................23
4.4 Cable installation...........................................................................................................24
4.4.1 Frames MR4 to MR7..................................................................................................... 24
4.4.2 Frames MR8 and MR9.................................................................................................. 31
4.4.3 Cable and motor insulation checks............................................................................... 39
5. Commissioning................................................................................................40
5.1 Commissioning of the SmartVFD HVAC....................................................................... 41
5.2 Changing EMC protection class.................................................................................... 42
5.2.1 Frames MR4 to MR7..................................................................................................... 42
5.2.2 Frame MR8 ................................................................................................................... 44
5.2.3 Frame MR9 ................................................................................................................... 45
6. Control unit ......................................................................................................48
6.1 Control unit cabling ....................................................................................................... 49
6.1.1 Control cable sizing.......................................................................................................49
6.1.2 Control terminals and DIP switches .............................................................................. 50
6.2 Fieldbus connection ...................................................................................................... 53
6.2.1 Prepare for use through ethernet.................................................................................. 53
6.2.2 Prepare for use through MS/TP.................................................................................... 55
6.2.3 RS485 cable data ......................................................................................................... 58
6.3 Battery installation for Real Time Clock (RTC) ............................................................. 59
6.4 Galvanic isolation barriers............................................................................................. 60
7. Product data.....................................................................................................61
7.1 Power ratings ................................................................................................................61
7.1.1 Mains voltage 208-240 V .............................................................................................. 61
7.1.2 Mains voltage 380-480V ............................................................................................... 62

Honeywell • 1
7.1.3 Definitions of overloadability ......................................................................................... 63
7.2 SmartVFD HVAC - technical data................................................................................. 64
7.2.1 Technical information on control connections............................................................... 66

SAFETY Honeywell • 2
1
1. SAFETY
This manual contains clearly marked cautions and warnings which are intended for your per-
sonal safety and to avoid any unintentional damage to the product or connected appliances.
Please read the information included in cautions and warnings carefully.
The cautions and warnings are marked as follows:
Table 1. Warning signs
1.1 Danger
= DANGEROUS VOLTAGE!
= WARNING or CAUTION
The components of the power unit of the Smart VFD HVAC are live when the
drive is connected to mains potential. Coming into contact with this voltage is
extremely dangerous and may cause death or severe injury.
The motor terminals U, V, W and the brake resistor terminals are live when
the drive is connected to mains, even if the motor is not running.
After disconnecting the drive from the mains, wait until the indicators on the
keypad go out (if no keypad is attached see the indicators on the cover). Wait 5
more minutes before doing any work on the connections of the drive. Do not open
the cover before this time has expired. After expiration of this time, use a measur-
ing equipment to absolutely ensure that no
voltage is present. Always ensure
absence of voltage before starting any electrical work!
The control I/O-terminals are isolated from the mains potential. However, the
relay outputs and other I/O-terminals may have a dangerous control voltage
present even when the drive is disconnected from mains.
Before connecting the drive to mains make sure that the front and cable covers
of the drive are closed.
During a ramp stop (see the Application Manual), the motor is still generating
voltage to the drive. Therefore, do not touch the components of the drive before
the motor has completely stopped. Wait until the indicators on the keypad go out
(if no keypad is attached see the indicators on the cover). Wait additional 5 min-
utes before starting any work on the drive.

Honeywell • 3 SAFETY
1.2 Warnings
1.3 Grounding and ground fault protection
The Honeywell Smart VFD HVAC AC drive must always be grounded with an grounding con-
ductor connected to the grounding terminal marked with .
The touch current of the drive exceeds 3.5mA AC. According to EN61800-5-1, one or more of
the following conditions for the associated protective circuit shall be satisfied:
1. A fixed connection and
a) the protective earthing conductor has a cross-sectional area of at least 10 mm2Cu
or 16 mm2Al through its total run.
b) an automatic disconnection of the supply in case of loss of continuity of the protective
conductor. See chapter 4.
The Honeywell Smart VFD HVAC is meant for fixed installations only.
Do not perform any measurements when the drive is connected to the mains.
The touch current of the Honeywell Smart VFD HVAC exceeds 3.5mA AC.
According to standard EN61800-5-1, a reinforced protective ground connec-
tion must be ensured. See chapter 1.3.
If the drive is used as a part of a machine, the machine manufacturer is
responsible for providing the machine with a supply disconnecting device (EN
60204-1).
Only spare parts delivered by Honeywell can be used.
At power-up, power brake or fault reset the motor will start immediately if the
start signal is active, unless the pulse control for
Start/Stop logic has been selected .
Futhermore, the I/O functionalities (including start inputs) may change if parame-
ters, applications or software are changed.Disconnect, therefore, the motor if an
unexpected start can cause danger.
The motor starts automatically after automatic fault reset if the autoreset func-
tion is activated. See the Application Manual for more detailed information.
Prior to measurements on the motor or the motor cable, disconnect the
motor cable from the drive.
Do not touch the components on the circuit boards. Static voltage discharge
may damage the components.
Check that the EMC level of the drive corresponds to the requirements of your
supply network. See chapter 5.2.
In a domestic environment, this product may cause radio interference in which
case supplementary mitigation measures may be required.
CAUTION!

SAFETY Honeywell • 4
1
c) provision of an additional terminal for a second protective earthing conductor of the
same cross-sectional area as the original protective earthing conductor.
OR
2. Connection with an industrial connector according to IEC 60309 and a minimum protec-
tive earthing connector cross-section of 2.5mm2as part of a multi-conductor power
cable. Adequate strain relief shall be provided.
NOTE: Due to the high capacitive currents present in the drive, fault current protective switches
may not function properly.
1.4 Running the motor
MOTOR RUN CHECK LIST
Do not perform any voltage withstand tests on any part of the drive. There is a
certain procedure according to which the tests shall be performed. Ignoring this
procedure may result in damaged product.
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 make sure that this can be done safely.
Make sure that no power correction capacitors are connected to the motor cable.
Make sure that the motor terminals are not connected to mains potential.

Honeywell • 5 SAFETY

RECEIPT OF DELIVERY Honeywell • 6
2
2. RECEIPT OF DELIVERY
Check the correctness of delivery by comparing your order data to the drive information found
on the package label. If the delivery does not correspond to your order, contact the supplier
immediately. See chapter 2.3.
2.1 ‘Product modified’ sticker
In the small plastic bag included with delivery you will find a silver Product modified sticker.
The purpose of the sticker is to notify the service personnel about the modifications made in
the drive. Attach the sticker on the side of the drive to avoid losing it. Should the drive be later
modified mark the change on the sticker.
Figure 1. ‘Product modified’ sticker
2.2 Unpacking and lifting the drive
The weights of the drives vary greatly according to the size. You may need to use a piece of
special lifting equipment to remove the drive from its package. Note the weights of each indi-
vidual frame size in Table 2 below.
Table 2. Frame weights
If you decide to use a piece of lifting equipment see picture below for recommendations to lift
the drive.
Frame Weight [kg] Weight [lb.]
MR4 6.0 13.2
MR5 10.0 22.0
MR6 20.0 44.1
MR7 37.5 82.7
MR8 70.0 154.3
MR9 108.0 238.1
Product modified
Date:
Date:
Date:

Honeywell • 7 RECEIPT OF DELIVERY
2.2.1 Lifting frames MR8 and MR9
Figure 2. Lifting bigger frames
The Honeywell Smart VFD HVAC undergoes scrupulous tests and quality checks at the factory
before it is delivered to the customer. However, after unpacking the product, check that no
signs of transport damages are to be found on the product and that the delivery is complete.
Should the drive have been damaged during the shipping, please contact primarily the cargo
insurance company or the carrier.
NOTE: Place the lifting hooks symmetrically in at least two
holes.The lifting device must be able to carry weight of the
drive.
NOTE: The maximum allowed lifting angle is 45 degrees.

RECEIPT OF DELIVERY Honeywell • 8
2
2.3 Type designation code
Honeywell type designation code is formed of a four-segment code. Each segment of the type
designation code uniquely corresponds to the product and options you have ordered. The code
is of the following format:
HVFDSD 3 C 0100 G 1 0 0
Product Family Options
HVFDSD = Honeywell SmartVFD HVAC 0 = Drive Only or No Special Options
HVFDSB = Honeywell SmartVFD BYPASS 1 = Auto-Bypass
2 = Auto-Bypass and HOA
Input Phase
3 = Three Phase (3~in, 3~out) Contactors
0 = Drive Only
Nominal Voltage 1 = Disconnect Only
A= 208/230 Vac Drive Alone, 208 Vac Bypass 2 = Two Contactor Bypass
B = 230 Vac Bypass 3 = Three Contactor Bypass
C = 480 Vac
D = 575 Vac Enclosure Type
1 = NEMA 1
Nominal Horsepower 2 = NEMA 12
0007 = .75 Horse Power 3 = NEMA 3R
0010 = 1 Horse Power
0100 = 10 Horse Power Interface
T = Text KeyPad
G = Graphic KeyPad

Honeywell • 9 RECEIPT OF DELIVERY
2.4 Accessories
After having opened the transport package and lifted the converter out, check immediately that
these various accessories were included in the delivery:
• Rubber grommets (sizes vary according to frame)
• Power cable clamps for EMC grounding
• Screws for fixing the power cable clamps
• Control cable grounding clamps
• M4 screw for EMC level change in frame MR7
• Additional grounding screw (if necessary, see chapter 1.3)
• Ferrite holder
• Optional plastic shield to prevent unintended contact with live parts from front (MR8 and
MR9, IP00)

MOUNTING Honeywell • 10
3
3. MOUNTING
The drive must be mounted in vertical position on the wall. Ensure that the mounting plane is
relatively even.
The drive shall be fixed with four screws (or bolts, depending on the unit size).
3.1 Dimensions
3.1.1 Wall mount, MR4-MR7
Figure 3. SmartVFD HVAC dimensions, MR4, wall mount
5.04
3.94
Ø.28
Ø.51
2.83
.55
3.94
2.4 4
7.48
NEMA1
Ø.98
1.30
1.26
1.26
NEMA12
1.26
1.30 1.26
Ø.98

Honeywell • 11 MOUNTING
Figure 4. SmartVFD HVAC dimensions, MR5, wall mount
Figure 5. SmartVFD HVAC dimensions, MR6, wall mount
*Optional mounting holes (for NX replacement)
8.43
5.67
4.53.5 7
Ø.28
Ø.55 Ø.28
2.83
3.94*
.57 4.53
Ø.28
3.94*
NEMA1
1.38 1.46 1.46
Ø1.30 Ø1.30Ø.98
NEMA12
1.36 1.48 1.48
1.38 1.46 1.46
7.68
5.83
Ø.61
Ø.35
2.83
Ø.35 5.83
9.02
2.01 1.83 1.83
NEMA1
Ø1.57Ø1.30 Ø1.57
1.42 1.42
2.40
2.01 1.83
NEMA12

MOUNTING Honeywell • 12
3
Figure 6. SmartVFD HVAC dimensions, MR7, wall mount
3.1.2 Wall mount, MR8 and MR9
Figure 7. AC drive dimensions, MR8 NEMA1 and NEMA12
10.20
Ø.79
9.33
7.48 Ø.35
Ø.63
Ø2.01
NEMA1
2.72 2.72
1.381.38
NEMA12
Ø.98
Ø1.97
2.72 2.72
1.77 1.77
Ø.98 3 x 1.50
Ø2.36
2.46 6.46
11.42
Ø.87
Ø.43
Ø.35
13.50 8.54
Ø.35
Ø.35
26.46
27.32
8.50
37.64
9.25

Honeywell • 13 MOUNTING
Figure 8. AC drive dimensions, MR9 NEMA1 and NEMA12 (preliminary)
3.1.3 Flush mount
The AC drive can also be recessed into the cabinet wall or similar surface. A special flush
mount option is available for this purpose. For an example of a flush-mounted drive, see Figure
9.
Figure 9. Example of flush mount (frame MR9)
Ø.35 18.90
15.75
Ø.35 14.17 11.50
Ø.87
14.37
13.98
14.17
Ø.35
Ø.35
Cabinet wall
(or similar)
IP21 IP54
Cabinet wall
(or similar)

MOUNTING Honeywell • 14
3
3.1.3.1 Flush mount - Frames MR4 to MR6
Figure 10. presents the dimensions of the mounting opening and Figure 11. the depth dimen-
sions of the drives with the flush mount option.
Figure 10. Flush mount cutout dimensions for MR4 to MR6
Table 3. Flush mount cutout dimensions for MR4 to MR6 [in]
Frame A B C D E F
MR4 12.20 5.39 13.27 5.67 4.33 12.44
MR5 16.06 5.98 17.09 6.30 5.20 16.30
MR6 21.02 7.99 22.05 8.31 7.24 21.30
A
C
F
Opening outline
Drive outline
TOP

Honeywell • 15 MOUNTING
Figure 11. MR4 to MR6, flush mount, depth dimensions
MR4 MR5 MR6
3.03 4.45
7.48 8.43
4. 49
3.94
4.17 4.84
9.02

MOUNTING Honeywell • 16
3
3.1.3.2 Flush mount MR7 to MR9
Figure 12. presents the dimensions of the mounting opening and Figure 13. the dimensions of
the drives with the flush mount option.
Figure 12. Flush mount cutout dimensions for MR7 to MR9
Table 4. Flush mount cutout dimensions for MR7 to MR9 [in]
Frame A B C D E
MR7 25.79 9.45 26.85 10.55 .53
MR8 33.82 11.73 34.96 14.13 .67
MR9 38.39 19.09 41.34 20.87 2.13
C
A E
Drive outline
Opening outline
TOP

Honeywell • 17 MOUNTING
Figure 13. MR7 to MR9, flush mount, depth dimensions
4. 33 5 .8 7
MR7 MR8
9.17
MR9
Ø.87
4.25 9.72

MOUNTING Honeywell • 18
3
3.2 Cooling
The drive produces heat in operation and is cooled by air circulated by a fan. Enough free
space needs to be left around the drive to ensure sufficient air circulation and cooling. Different
acts of maintenance also require a certain amount of free space.
Make sure that the temperature of the cooling air does not exceed the maximum ambient tem-
perature of the converter.
Table 5. Min. clearances around drive
Figure 14. Installation space
A= clearance around the drive (see also B)
B= distance from one drive to another or distance to cabinet wall
C= free space above the drive
D= free space underneath the drive
Min clearance [in], NEMA1
Type A*
*. Min clearances A and B for
drives with IP54 enclosure is 0
in.
B*C D
MR4 .79 .79 3.94 1.97
MR5 .79 .79 4.72 2.36
MR6 .79 .79 6.30 3.15
MR7 .79 .79 9.84 3.94
MR8 .79 .79 11.8 5.91
MR9 .79 .79 13.78 7.87
C
A
NK5_ 2
D
B
A
B