Honeywell SmartVFD HVAC Installation Instructions

Honeywell

Installation manual

SmartVFD HVAC

Variable Frequency Drives

for Variable Torque Applications

%\XVLQJWKLV+RQH\ZHOOOLWHUDWXUH\RXDJUHHWKDW+RQH\ZHOOZLOOKDYHQROLDELOLW\
IRUDQ\GDPDJHVDULVLQJRXWRI\RXUXVHRUPRGLILFDWLRQWRWKHOLWHUDWXUH<RXZLOO
GHIHQGDQGLQGHPQLI\+RQH\ZHOOLWVDIILOLDWHVDQGVXEVLGLDULHVIURPDQGDJDLQVW
DQ\OLDELOLW\FRVWRUGDPDJHVLQFOXGLQJDWWRUQH\V¶IHHVDULVLQJRXWRIRUUHVXOWLQJ
IURPDQ\PRGLILFDWLRQWRWKHOLWHUDWXUHE\\RX

38-00007-03

Honeywell • 0

INDEX

Document: DPD00323D

Version release date: 18.1.18

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.............................................................................................5

2.1 ‘Product modified’ sticker ................................................................................................ 5

2.2 Unpacking and lifting the drive........................................................................................ 5

2.2.1 Lifting frames MR8 and MR9 .......................................................................................... 6

2.3 Type designation code.................................................................................................... 7

2.4 Accessories..................................................................................................................... 8

3. Mounting.............................................................................................................9

3.1 Dimensions ..................................................................................................................... 9

3.1.1 Wall mount, MR4-MR7.................................................................................................... 9

3.1.2 Wall mount, MR8 and MR9........................................................................................... 11

3.1.3 Flange mount................................................................................................................ 12

3.2 Cooling.......................................................................................................................... 17

4. Power cabling ..................................................................................................19

4.1 UL standards on cabling ............................................................................................... 20

4.1.1 Cable dimensioning and selection ................................................................................ 20

4.2 Control cables ...............................................................................................................22

4.3 Cable installation...........................................................................................................23

4.3.1 Frames MR4 to MR7..................................................................................................... 23

4.3.2 Frames MR8 and MR9.................................................................................................. 30

4.3.3 Cable and motor insulation checks............................................................................... 38

4.4 Installation in corner-grounded network........................................................................ 38

5. Commissioning................................................................................................39

5.1 Commissioning of the SmartVFD HVAC....................................................................... 40

5.2 Changing EMC protection class.................................................................................... 41

5.2.1 Frames MR4 to MR6..................................................................................................... 41

5.2.2 Frames MR7 and MR8.................................................................................................. 43

5.2.3 Frame MR9 ................................................................................................................... 45

6. Control unit ......................................................................................................47

6.1 Control Unit Cabling...................................................................................................... 48

6.1.1 Selection of the Control Cables .................................................................................... 48

6.1.2 Control Terminals and Dip Switches............................................................................. 48

6.2 Fieldbus Connection ..................................................................................................... 52

6.2.1 Using Fieldbus Through an Ethernet Cable.................................................................. 53

6.2.2 Using Fieldbus Through an RS485 Cable .................................................................... 55

6.3 Installation of Option Boards......................................................................................... 59

6.4 Installation of a Battery for the Real Time Clock (RTC)................................................ 61

6.5 Galvanic Isolation Barriers............................................................................................ 62

7. Maintenance .....................................................................................................63

8. Product data.....................................................................................................64

8.1 Power ratings................................................................................................................64

Honeywell • 1

8.1.1 Mains voltage 208-240 V .............................................................................................. 64

8.1.2 Mains voltage 380-480V ............................................................................................... 65

8.1.3 Mains voltage 525-600V ............................................................................................... 66

8.1.4 Definitions of overloadability ......................................................................................... 67

8.2 SmartVFD HVAC - technical data................................................................................. 68

8.2.1 Technical information on control connections............................................................... 71

SAFETY Honeywell • 2

1. SAFETY

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.

Please read the information included in cautions and warnings carefully.

The cautions and warnings are marked as follows:

= DANGEROUS VOLTAGE!

= WARNING or CAUTION

Table 1. Warning signs

1.1 Danger

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 measur­ing equipment to absolutely ensure that no

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 min­utes before starting any work on the drive.

voltage is present.

Always ensure

1

Honeywell • 3 SAFETY

1.2 Warnings

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
Futhermore, the I/O functionalities (including start inputs) may change if parame­ters, 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 func­tion is activated. See the Application Manual for more detailed information.

Start/Stop logic has been selected

.

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.

1.3 Grounding and ground fault protection

CAUTION!

The Honeywell Smart VFD HVAC AC drive must always be grounded with an grounding con­ductor 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 6 AWG

(10 mm

2

) Cu or 4 AWG (16 mm2) Al through its total run.

b) an automatic disconnection of the supply in case of loss of continuity of the protective

conductor. See chapter 4.

SAFETY Honeywell • 4

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 12 AWG (2.5 mm
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.

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.

2

) as part of a multi-conductor

1.4 Running the motor

MOTOR RUN CHECK LIST

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.

NOTE! You can download the English and French product manuals with applicable safety,
warning and caution information from https:// en-US/Pages/de-

fault.aspx.

REMARQUE Vous pouvez télécharger les versions anglaise et française des manuels produit

contenant l’ensemble des informations de sécurité, avertissements et mises en garde applica­bles sur le site https:// en-US/Pages/default.aspx

.

1

Honeywell • 5 RECEIPT OF DELIVERY

Product modified

Date:

Date:

Date:

9004.emf

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 indi­vidual frame size in Table 2 below.

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

Table 2. Frame weights

If you decide to use a piece of lifting equipment see picture below for recommendations to lift
the drive.

RECEIPT OF DELIVERY Honeywell • 6

Max. 45°

9012.emf

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.

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.

2

Honeywell • 7 RECEIPT OF DELIVERY

11447_uk

A = Updated Control Board
No A = Legacy Control Board

T = Text KeyPad
G = Graphic KeyPad

Interface

1 = NEMA 1
2 = NEMA 12
3 = NEMA 3R

Enclosure Type

0 = Drive Only
1 = Disconnect Only
2 = Two Contactor Bypass
3 = Three Contactor Bypass

Contactors

0 = Drive Only or No Special Options
1 = Auto-Bypass
3 = Auto-Bypass and HOA

Options

0007 = .75 Horse Power

0010 = 1 Horse Power

0100 = 10 Horse Power

Nominal Horsepower

A= 208/230 Vac Drive Alone, 208 Vac Bypass

B = 230 Vac Bypass

C = 480 Vac
D = 600 Vac

Nominal Voltage

3 = Three Phase (3~in, 3~out)

Input Phase

HVFDSD = Honeywell SmartVFD HVAC

HVFDSB = Honeywell SmartVFD BYPASS

Product Family

HVFDSD 3 C 0100 G 1 0 0 A

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:

RECEIPT OF DELIVERY Honeywell • 8

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)

2

Honeywell • 9 MOUNTING

5.04

3.94

Ø.28

Ø.51

2.83

.55

3.94

2.44

7.48

NEMA 1

Ø.98

1.30

1.26

1.26

NE MA12

1.26

1.30

1.26

Ø.9 8

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

MOUNTING Honeywell • 10

*Optional mounting holes (for NX replacement)

8.43

5.67

4.53.5 7
Ø.2 8
Ø.5 5

Ø.28

2.83

3.94*

.57 4.53

Ø.2 8

3.94*

NEMA1

1.38 1 .46 1.46

Ø1.30 Ø1.3 0Ø.98

NEMA12

1.36 1.48 1.48

1.38 1.46 1. 46

11449_uk

7.68

5.83

Ø.61

Ø.3 5

2.83

Ø.35

5.83

9.02

2.01 1.83 1.83

NEMA1

Ø1.57Ø1.30Ø1.57

1.42 1.42

2.40

2.01 1.83

NEMA12

Figure 4. SmartVFD HVAC dimensions, MR5, wall mount

Figure 5. SmartVFD HVAC dimensions, MR6, wall mount

3

Honeywell • 11 MOUNTING

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

11451 00

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

11452 00

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

MOUNTING Honeywell • 12

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)

11453_00

Figure 8. AC drive dimensions, MR9 NEMA1 and NEMA12 (preliminary)

3.1.3 Flange mount

The AC drive can also be recessed into the cabinet wall or similar surface. A special flange
mount option is available for this purpose. For an example of a flange-mounted drive, see Fig­ure 9.

Figure 9. Example of flange mount (frame MR9)

11454_uk

3

Honeywell • 13 MOUNTING

A

C

F

11455 00

3.1.3.1 Flange mount - Frames MR4 to MR6

Figure 10. presents the dimensions of the mounting opening and Figure 11. the depth dimen­sions of the drives with the flange mount option.

Drive outline

Opening outline

TOP

Figure 10. Flange mount cutout dimensions for MR4 to MR6

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

MOUNTING Honeywell • 14

MR4 MR5 MR6

3.03 4.45

7.48

8.43

4. 49

3.94

4.17 4.84

9.02

Table 3. Flange mount cutout dimensions for MR4 to MR6 [in]

Figure 11. MR4 to MR6, flange mount, depth dimensions

3

Honeywell • 15 MOUNTING

C

A E

11482_00

3.1.3.2 Flange mount MR7 to MR9

Figure 12. presents the dimensions of the mounting opening and Figure 13. the dimensions of
the drives with the flange mount option.

Drive outline

TOP

Figure 12. Flange mount cutout dimensions for MR7 to MR9

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

Table 4. Flange mount cutout dimensions for MR7 to MR9 [in]

Opening outline

MOUNTING Honeywell • 16

3.03 4.45

7.48

8.43

4. 49

3.94

4.17 4.84

9.02

11456_00

Figure 13. MR7 to MR9, flange mount, depth dimensions

3

Honeywell • 17 MOUNTING

C

A

9013.emf

D

B

A

B

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 tem­perature of the converter.

Min clearance [in], NEMA1

Type A

*

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

*. Min clearances A and B for

drives with IP54 enclosure is 0
in.

*

B

C D

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

MOUNTING Honeywell • 18

C+D

9014.emf

FRONT SIDE

Note that if several units are mounted above one another the
required free space equals C + D (see Figure 15.). Moreover,
the outlet air used for cooling by the lower unit must be direct­ed away from the air intake of the upper unit.

Figure 15. Installation space when drives are

Type

Cooling air required

[cfm]

MR4 26
MR5 44
MR6 112
MR7 109
MR8 197
MR9 366

Table 6. Required cooling air

mounted on top of each other

3

Honeywell • 19 POWER CABLING

9007.emf

PE conductor
and shield

PE conductors

Shield

4. POWER CABLING

The mains cables are connected to terminals L1, L2 and L3 and the motor cables to terminals
marked with U, V and W. See Table 7 for the cable recommmendations for different EMC lev­els.

Use cables with heat resistance of at least +158°F. The cables and the fuses must be dimen­sioned according to the drive nominal OUTPUT current which you can find on the rating plate.

1st environment 2nd environment

EMC levels

Cable type

Mains cable 1 1 1
Motor cable 3* 2 2
Control cable 4 4 4

Table 7. Cable types required to meet standards

According to EN61800-3 (2004)

Category C2 Category C3 Level T

1 = Power cable intended for fixed installation and the specific mains voltage. Shielded

cable not required. (MCMK or similar recommended).

2 = Symmetrical power cable equipped with concentric protection wire and intended for the

specific mains voltage. (MCMK or similar recommended). See Figure 16.

3 = Symmetrical power cable equipped with compact low-impedance shield and intended

for the specific mains voltage. [MCCMK, EMCMK or similar recommended; Recom­mended cable transfer impedance (1...30MHz) max. 100mohm/m]. See Figure 16.
*360º grounding of the shield with cable glands in motor end needed for EMC level C2.

4 =Screened cable equipped with compact low-impedance shield (JAMAK, SAB/ÖZCuY-

O or similar).

Figure 16.

NOTE: The EMC requirements are fulfilled at factory defaults of switching frequencies (all
frames).
NOTE: If safety switch is connected the EMC protection shall be continuous over the whole ca­ble installation.

POWER CABLING Honeywell • 20

4.1 UL standards on cabling

To meet the UL (Underwriters Laboratories) regulations, use a UL-approved copper cable with
a minimum heat-resistance of +140/167°F. Use Class 1 wire only.

The units are suitable for use on a circuit capable of delivering not more than 100,000 rms sym­metrical amperes, 600V maximum.

4.1.1 Cable dimensioning and selection

Table 8 shows the minimum dimensions of the Cu/Al-cables and the corresponding fuse sizes.
Recommended fuse types are gG/gL.

These instructions apply only to cases with one motor and one cable connection from the drive
to the motor. In any other case, ask the factory for more information.

4.1.1.1 Cable and fuse sizes, frames MR4 to MR6, North America

The recommended fuse types are gG/gL (IEC 60269-1) or class T (UL & CSA). The fuse volt­age rating should be selected according to the supply network. The final selection should be
made according to local regulations, cable installation conditions and cable specification. Big­ger fuses than what is recommended below shall not be used.

Check that the fuse operating time is less than 0.4 seconds. Operating time depends on used
fuse type and impedance of the supply circuit. Consult the factory about faster fuses. Honey­well offers recommendations also for high speed J (UL & CSA), aR (UL recognized, IEC 60269-

4) and gS (IEC 60269-4) fuse ranges.

Frame Type

A007 3.7 6 AWG14 AWG24-AWG10 AWG17-AWG10
A0010 4.8 6 AWG14 AWG24-AWG10 AWG17-AWG10
A0015 6.6 10 AWG14 AWG24-AWG10 AWG17-AWG10
A0020 8 10 AWG14 AWG24-AWG10 AWG17-AWG10
A0030 11 15 AWG14 AWG24-AWG10 AWG17-AWG10

MR4

A0040 12.5 20 AWG14 AWG24-AWG10 AWG17-AWG10
C 0015 3.4 6 AWG14 AWG24-AWG10 AWG17-AWG10
C 0020 4.8 6 AWG14 AWG24-AWG10 AWG17-AWG10
C 0030 5.6 10 AWG14 AWG24-AWG10 AWG17-AWG10
C 0040 8.0 10 AWG14 AWG24-AWG10 AWG17-AWG10
C 0050 9.6 15 AWG14 AWG24-AWG10 AWG17-AWG10
C 0075 12.0 20 AWG14 AWG24-AWG10 AWG17-AWG10

*

I

[A]

L

Fuse

(class T)

[A]

Mains, motor and

ground cable

Cu

Terminal cable size

Main terminal

Ground

terminal

4

Honeywell • 21 POWER CABLING

Frame Type

A0050 18 25 AWG10 AWG20-AWG5 AWG17-AWG8
A0075 24.2 30 AWG10 AWG20-AWG5 AWG17-AWG8
A0100 31 40 AWG8 AWG20-AWG5 AWG17-AWG8
C 0100 16.0 25 AWG10 AWG20-AWG5 AWG17-AWG8
C 0150 23.0 30 AWG10 AWG20-AWG5 AWG17-AWG8

MR5

C 0200 31.0 40 AWG8 AWG20-AWG5 AWG17-AWG8
D0030 3.9 6 AWG14 AWG20-AWG5 AWG17-AWG8
D0050 6.1 10 AWG14 AWG20-AWG5 AWG17-AWG8
D0075 9 10 AWG14 AWG20-AWG5 AWG17-AWG8
D0100 11 15 AWG14 AWG20-AWG5 AWG17-AWG8
A0150 48 60 AWG4 AWG13-AWG0 AWG13-AWG2
A0200 62 80 AWG4 AWG13-AWG0 AWG13-AWG2
C 0250 38.0 50 AWG4 AWG13-AWG0 AWG13-AWG2
C 0300 46.0 60 AWG4 AWG13-AWG0 AWG13-AWG2

MR6

C 0400
D0150 18 20 AWG10 AWG13-AWG0 AWG13-AWG2
D0200 22 25 AWG10 AWG13-AWG0 AWG13-AWG2
D0250 27 30 AWG8 AWG13-AWG0 AWG13-AWG2
D0300 34 40 AWG8 AWG13-AWG0 AWG13-AWG2

*

I

L

[A]

**

61.0 80 AWG4 AWG13-AWG0 AWG13-AWG2

Fuse

(class T)

[A]

Mains, motor and

ground cable

Cu

Terminal cable size

Main terminal

Ground

terminal

*. For more information on type code, see page 7.
**. The 460V models require 90-degree wire to meet UL regulations

Table 8. Cable and fuse sizes for Honeywell Smart VFD HVAC (MR4 to MR6)

The cable dimensioning is based on the criteria of the Underwriters’ Laboratories UL508C:Cables must
be PVC-isolated; Max ambient temperature +86°F, max temperature of cable surface +158°F; Use only
cables with concentric copper shield; Max number of parallel cables is 9.
When using cables in parallel,
area and the max number of cables must be observed.
For important information on the requirements of the grounding conductor, see standard Underwriters’
Laboratories UL508C.

For the correction factors for each temperature, see the instructions of standard Underwriters’ Labora­tories UL508C.

NOTE HOWEVER that the requirements of both the cross-sectional

4.1.1.2 Cable and fuse sizes, frames MR7 to MR9, North America

The recommended fuse types are gG/gL (IEC 60269-1) or class T (UL & CSA). The fuse volt­age rating should be selected according to the supply network. The final selection should be
made according to local regulations, cable installation conditions and cable specification. Big­ger fuses than what is recommended below shall not be used.

Check that the fuse operating time is less than 0.4 seconds. Operating time depends on used
fuse type and impedance of the supply circuit. Consult the factory about faster fuses. Honey­well offers recommendations also for high speed J (UL & CSA), aR (UL recognized, IEC 60269-

4) and gS (IEC 60269-4) fuse ranges.

POWER CABLING Honeywell • 22

Frame Type

A0250 75 100 AWG2 AWG9-AWG2/0 AWG9-AWG2/0
A0300 88 110 AWG1 AWG9-AWG2/0 AWG9-AWG2/0
A0400 105 150 AWG1/0 AWG9-AWG2/0 AWG9-AWG2/0
C 0500 72.0 100 AWG2 AWG9-AWG2/0 AWG9-AWG2/0

MR7

MR8

MR9

C 0600 87.0 110 AWG1 AWG9-AWG2/0 AWG9-AWG2/0
C 0750 105.0 150 AWG1/0 AWG9-AWG2/0 AWG9-AWG2/0
D0400 41 50 AWG6 AWG9-AWG2/0 AWG9-AWG2/0
D0500 52 60 AWG6 AWG9-AWG2/0 AWG9-AWG2/0
D0600 62 70 AWG4 AWG9-AWG2/0 AWG9-AWG2/0
A0500 143 200 AWG3/0 AWG1-350kcmil AWG1-350kcmil
A0600 170 225 250kcmil AWG1-350kcmil AWG1-350kcmil
A0750 208 250 350kcmil AWG1-350kcmil AWG1-350kcmil
C 1000 140.0 200 AWG3/0 AWG1-350 kcmil AWG1-350 kcmil
C 1250 170.0 225 250 kcmil AWG1-350 kcmil AWG1-350 kcmil
C 1500 205.0 250 350 kcmil AWG1-350 kcmil AWG1-350 kcmil
D0750 80 90 AWG1/0 AWG1-350kcmil AWG1-350kcmil
D1000 100 110 AWG1/0 AWG1-350kcmil AWG1-350kcmil
D1250 125 150 AWG2/0 AWG1-350kcmil AWG1-350kcmil
A1000 261 350 2x250kcmil AWG1-350kcmil AWG1-350kcmil
A1250 310 400 2x350kcmil AWG1-350kcmil AWG1-350kcmil
C 2000 261.0 350 2*250 kcmil AWG1-350 kcmil AWG1-350 kcmil
C 2500 310.0 400 2*350 kcmil AWG1-350 kcmil AWG1-350 kcmil
D1500 144 175 AWG3/0 AWG1-350kcmil AWG1-350kcmil
D2000 208 250 300kcmil AWG1-350kcmil AWG1-350kcmil

I

L

[A]

Fuse

(class T)

[A]

Mains, motor

and ground

cable

Cu

Terminal cable size

Main terminal Ground terminal

Table 9. Cable and fuse sizes for Honeywell Smart VFD HVAC (MR7 to MR9)

The cable dimensioning is based on the criteria of the Underwriters’ Laboratories UL508C:Cables must
be PVC-isolated; Max ambient temperature +86°F, max temperature of cable surface +158°F; Use only
cables with concentric copper shield; Max number of parallel cables is 9.
When using cables in parallel,
area and the max number of cables must be observed.
For important information on the requirements of the grounding conductor, see standard Underwriters’
Laboratories UL508C.

For the correction factors for each temperature, see the instructions of standard Underwriters’ Labora­tories UL508C.

NOTE HOWEVER that the requirements of both the cross-sectional

4.2 Control cables

For information on control cables see chapter 6.

4

Honeywell • 23 POWER CABLING

9019.emf

D1

B1

C1

A1

D2

C2

E

Earth conductor

MAINS MOTOR

Earth conductor

4.3 Cable installation

• Before starting, check that none of the components of the drive is live. Read carefully
the warnings in chapter 1.

• Place the motor cables sufficiently far from other cables

• Avoid placing the motor cables in long parallel lines with other cables.

• If the motor cables run in parallel with other cables note the minimum distances
between the motor cables and other cables given in table below.

Distance between

cables, [in]

Shielded

cable, [ft]

11.8 ≤ 164

39.4 ≤ 656

• The given distances also apply between the motor cables and signal cables of other
systems.

• The maximum lengths of motor cables are 328 ft. (MR4), 492 ft. (MR5 and MR6) and
656 ft. (MR7 to MR9).

• The motor cables should cross other cables at an angle of 90 degrees.

• If cable insulation checks are needed, see chapter Cable and motor insulation checks.

Start the cable installation according to the instructions below:

4.3.1 Frames MR4 to MR7

1

Strip the motor and mains cables as advised below.

Figure 17. Stripping of cables

POWER CABLING Honeywell • 24

M4x55

Frame A1 B1 C1 D1 C2 D2 E

MR4 .59 1.38 .39 .79 .28 1.38

MR5 .79 1.57 .39 1.18 .39 1.57

MR6 .79 3.54 .59 2.36 .59 2.36

MR7 .79 3.15 .79 3.15 .79 3.15

Table 10. Cables stripping lengths [in]

Leave

as short

as pos-

sible

2

Open the cover of the drive.

Figure 18.

4

Honeywell • 25 POWER CABLING

M4x8

9022.emf

11457_00

3

Remove the screws of the cable protection plate. Do not open the cover of the

power unit!

4

Figure 19.

Insert the cable grommets (included in the delivery) in the openings of the cable
entry plate (included) as shown in the picture.

Figure 20.

POWER CABLING Honeywell • 26

9217.emf

Insert the cables - supply cable, motor cable - in the openings of the cable entry
plate. Then cut the rubber grommets open to slide the cables through. Do not cut
the grommet openings wider than what is necessary for the cables you are
using.

5

IMPORTANT NOTE FOR NEMA12 INSTALLATION:

To meet the requirements of the enclosure class NEMA12, the connection
between the grommet and the cable must be tight. Therefore, lead the first bit of
the cable out of the grommet straight before letting it bend. If this is not possible,
the tightness

of the connection must be ensured with insulation

tape or a

cable

tie

.

Figure 21.

4

Honeywell • 27 POWER CABLING

M4x16
(2.2 Nm)

9024.emf

11458 00

6

Detach the cable clamps and the grounding clamps (Figure 22) and place the
cable entry plate with the cables in the groove on the drive frame (Figure 23).

Figure 22.

Figure 23.

POWER CABLING Honeywell • 28

1

2

3

3

11459_uk

Connect the stripped cables (see Figure 17 and Table 10) as shown in
Figure 24.

• Expose the shield of all three cables in order to make a 360-degree con­nection with the cable clamp (1).

7

• Connect the (phase) conductors of the supply and motor cables into their
respective terminals (2).

• Form the rest of the cable shield of all three cables into “pigtails” and make
a grounding connection with a clamp as shown in Figure 24 (3).
Make the pigtails just long enough to reach and be fixed to the terminal ­not longer.

Tightening torques of cable terminals:

Tightening torque

Frame Type

A 0007-A 0040
C 0015-C 0075

A 0050-A 0100
C 0100-C 0200
D 0030-D 0100

A 0150-A 0200
C 0250-C 0400
D 0150-D 0300

A 0250-A 0400
C 0500-C 0750
D 0400-D 0600

*. Cable clamping (Ouneva Pressure Terminal Connector)

MR4

MR5

MR6

MR7

[Nm]/[lb-in.]

Power and motor

terminals

[Nm] lb-in. [Nm] lb-in. [Nm] lb-in.

0.5—0.6 4.5—5.3 1.5 13.3 2.0 17.7

1.2—1.5 10.6—13.3 1.5 13.3 2.0 17.7

10 88.5 1.5 13.3 2.0 17.7

*

8/15

Table 11. Tightening torques of terminals

70.8/132.8* 1.5 13.3 8/15* 70.8/132.8*

Figure 24.

Tightening torque

[Nm]/[lb-in.]

EMC grounding

clamps

Tightening torque,

[Nm]/[lb-in.]

Grounding terminals

4

Honeywell • 29 POWER CABLING

11460_00

9220.emf

Check the connection of the grounding cable to the motor and the drive terminals
marked with .

8

NOTE: Two protective conductors are required according to standard EN61800-

5-1. See Figure 25 and chapter Grounding and ground fault protection. Use an
M5 size screw and tighten it to 2.0 Nm (17.7 lb-in.).

= M5; 2Nm

9

Figure 25. Additional protective grounding connector

Re-mount the cable protection plate (Figure 26) and the cover of the drive.

1

,

5

1

,

5

N

m

Figure 26. Re-mounting of cover components

N

m

POWER CABLING Honeywell • 30

9019.emf

D1

B1

C1

A1

D2

C2

E

Earth conductor

Earth conductor

4.3.2 Frames MR8 and MR9

1

Strip the motor and mains cables as advised below.

Figure 27. Stripping of cables

Frame A1 B1 C1 D1 C2 D2 E

MR8 1.57 7.09 .98 11.81 .98 11.81

Leave as

short as

MR9 1.57 7.09 .98 11.81 .98 11.81

Table 12. Cables stripping lengths [in]

possible

4

Honeywell • 31 POWER CABLING

9046.emf

M4 x 10

1

2

11461_00

2

MR9 only: Remove the main cover of the AC drive.

3

Figure 28.

Remove the cable cover (1) and the cable fitting plate (2).

MR9

Figure 29.

POWER CABLING Honeywell • 32

4

MR9 only: Loosen the screws and remove the sealing plate.

MR9

11462_00

Figure 30.

5

Locate the terminals. OBSERVE the exceptional placement of motor cable ter­minals in MR8!

11463_00

Figure 31.

4

Honeywell • 33 POWER CABLING

11464_00

11465_00

Cut the rubber grommets open to slide the cables through. Should the grommets

6

fold in while inserting the cable, just draw the cable back a bit to straighten the
grommets up. Do not cut the grommet openings wider than what is necessary for
the cables you are using.

Figure 32.

7

Place the grommet with the cable so that the frame end plate fits in the groove
on the grommet, see Figure 33.
To meet the requirements of the enclosure class NEMA12, the connection
between the grommet and the cable must be tight. Therefore, lead the first bit of
the cable out of the grommet straight before letting it bend. If this is not possible,
the tightness
As an example,see Figure 21.

of the connection must be ensured with insulation

tape or a

cable

tie.

Figure 33.

POWER CABLING Honeywell • 34

11466_00

8

9

If you use thick cables insert the cable separators in between the terminals in
order to avoid contact between the cables.

Figure 34.

Connect the cables stripped as shown in Figure 27.

• Connect the (phase) conductors of the supply and motor cables into their
respective terminals (a).

• Form the rest of the cable shield of all cables into “pigtails” and make a
grounding connection as shown in Figure 35 (b) using the clamp from the

Accessories bag.

• Note also correct position of the ferrite holder (c) AFTER the cable strip­ping (in MR8 and EMC class C2 only).

• Note: If you use several cables on one connector observe the position of
cable lugs on top of each other. See Figure 36 below.

4

Honeywell • 35 POWER CABLING

L1 L2 L3

DC-

DC+

R+

R-

b

a

MR8

c

UWV

11467_00

Cable lug

Cable lug

Connector

Figure 35.

Figure 36. Placing two cable lugs on top of each other

Tightening torques of cable terminals:

Tightening torque

Frame Type

A 0500-A 0750

MR8

MR9

C 1000-C 1500
D 0750-D 1250

A 1000-A 1250
C 2000-C 2500
D 1500-D 2000

*. Cable clamping (Ouneva Pressure Terminal Connector)

[Nm]/[lb-in.]

Power and motor

terminals

[Nm] lb-in. [Nm] lb-in. [Nm] lb-in.

*

20/40

20/40* 177/354* 1.5 13.3 20 177

Table 13. Tightening torques of terminals

177/354* 1.5 13.3 20 177

Tightening torque

[Nm]/[lb-in.]

EMC grounding

clamps

Tightening torque,

[Nm]/[lb-in.]

Grounding terminals

POWER CABLING Honeywell • 36

9035.emf

M4x8

M4x8

9223.emf

10

Expose the shield of all three cables in order to make a 360-degree connection
with the cable clamp.

Figure 37.

11

Re-attach first the cable fitting plate and then the cable cover.

Figure 38.

4

Honeywell • 37 POWER CABLING

11468_00

12

MR9 only: Now re-mount the main cover (unless you want to make the control

connections first).

13

Figure 39.

Check the connection of the earth cable to the motor and the AC drive terminals
marked with .

NOTE: Two protective conductors are required according to standard EN61800­5-1. See chapter Grounding and ground fault protection.

Connect the protective conductor using a cable shoe and an M8 screw (included
in the

Accessories bag) on either of the screw connectors as advised in

Figure 40.

POWER CABLING Honeywell • 38

11469_00

Figure 40.

4.3.3 Cable and motor insulation checks

1. Motor cable insulation checks
Disconnect the motor cable from terminals U, V and W of the drive and from the motor.
Measure the insulation resistance of the motor cable between each phase conductor as
well as between each phase conductor and the protective ground conductor. The insula­tion resistance must be >1MΩ at ambient temperature of 68°F.

2. Mains cable insulation checks
Disconnect the mains cable from terminals L1, L2 and L3 of the drive and from the mains.
Measure the insulation resistance of the mains cable between each phase conductor as
well as between each phase conductor and the protective ground conductor. The insula­tion resistance must be >1MΩ at ambient temperature of 68°F.

3. Motor insulation checks
Disconnect the motor cable from the motor and open the bridging connections in the
motor connection box. Measure the insulation resistance of each motor winding. The
measurement voltage must equal at least the motor nominal voltage but not exceed 1000
V. The insulation resistance must be >1MΩ at ambient temperature of 68°F.

4.4 Installation in corner-grounded network

Corner grounding is allowed for the drive types rating from 72 A to 310 A at 380...480 V supply
and from 75 A to 310 A at 208...240 V supply.

In these circumstances the EMC protection class must be changed to level C4 following the
instructions in Chapter 5.2 of this manual.

Corner grounding is not allowed for the drive types with rating from 3.4 A to 61 A at 380...480
V supply and 3.7 A to 62 A with 208...240 V supply.

4

Honeywell • 39 COMMISSIONING

5. COMMISSIONING

Before commissioning, note the following directions and warnings:

Internal components and circuit boards of the drive (except for the galvanically
isolated I/O terminals) are live when it 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 B-/B+ are live
when the drive is connected to mains, even if the motor is not running.

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.

Do not make any connections to or from the drive when it is connected to the
mains.

After disconnecting the drive from the mains, wait until the fan stops and 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 measuring equipment to absolutely ensure that no voltage is present.

Always ensure abscence of voltage before electrical work!
Before connecting the frequency converter to mains make sure that the front

and cable covers of the drive are closed.

COMMISSIONING Honeywell • 40

5.1 Commissioning of the SmartVFD HVAC

1

2

3
4
5

6

7

Read carefully the safety instructions in Chapter 1 and above and follow them.

After the installation, make sure that:

• both the drive and the motor are grounded.

• the mains and motor cables comply with the requirements given in chapter

4.1.1.

• the control cables are located as far as possible from the power cables,
see chapter 4.3.

• the shields of the shielded cables are connected to protective ground

marked with .

• check the tightening torques of all terminals

• the wires do not touch the electrical components of the drive.

• the common inputs of digital input groups are connected to +24V or
ground of the I/O terminal or the external supply.

Check the quality and quantity of cooling air (chapter 3.2 and Table 6).

Check the inside of the drive for condensation.

Check that all Start/Stop switches connected to the I/O terminals are in
Stop-position.

Before connecting the AC drive to mains:

• check mounting and condition of all fuses and other protective devices

Run the Startup Wizard (see the Application Manual).

5

Honeywell • 41 COMMISSIONING

MR4

9064.emf

MR5

MR6

5.2 Changing EMC protection class

I

f your supply network is an IT (impedance-grounded) system but your AC drive is EMC-protected accord­ing to class C2 you need to modify the EMC protection of the AC drive to EMC-level T. This is done by
removing the built-in EMC jumpers with a simple procedure described b

Warning! Do not perform any modifications on the drive when it is con­nected to mains.

5.2.1 Frames MR4 to MR6

elow:

1

connecting the built-in RFI-filters to ground. See Figure 41. and Figure 42.

NOTE: The locations of the EMC-jumpers have changed in frames MR5 and MR6. Figure 41.
shows the old locations and Figure 42. the new locations in frames MR5 and MR6.

Remove the main cover of the drive (see pages 24 and 31) and locate the jumpers

Figure 41. Current locations of the EMC-jumpers in frame MR4, old locations in frames MR5
and MR6

COMMISSIONING Honeywell • 42

9099.emf

MR 5

MR 6

Figure 42.Current locations of the EMC-jumpers in frames MR5 and MR6

2

Figure 43. Removing the jumper, MR5 as example

Disconnect the RFI-filters from ground by removing the EMC-jumpers using long­nose pliers or similar. See Figure 43.

5

Honeywell • 43 COMMISSIONING

9066.emf

9065.emf

5.2.2 Frames MR7 and MR8

Follow the procedure described above to modify the EMC protection of the drive of frames MR7
and MR8 to EMC-level C4.

1

Figure 44.

2

Remove the main cover of the drive and locate the jumper. MR8 only: Push down
the grounding arm. See Figure 44.

MR7 and MR8: Locate the EMC box under the cover. Remove the screws of the
box cover to expose the EMC-jumper. Detach the jumper and re-fix the box cover.

Figure 45.

COMMISSIONING Honeywell • 44

9062.emf

3

Figure 46. MR7: Detaching the DC grounding busbar from frame

MR7 only: locate the DC grounding busbar between connectors R- and U and
detach the busbar from the frame by undoing the M4 screw.

5

Honeywell • 45 COMMISSIONING

11470_00

5.2.3 Frame MR9

Follow the procedure described above to modify the EMC protection of the AC drive of frame
MR9 to EMC-level T.

Find the Molex connector in the accessories bag. Remove the main cover of the

1

Molex connector

AC drive and locate the place for the connector next to the fan. Push the Molex
connector in its place. See Figure 47.

2

Figure 47.

Further remove the extension box cover (1), the touch shield (2) the I/O plate (4)
with I/O grommet plate (3). Locate the EMC jumper on the EMC board (see mag­nification below) and remove it.

Figure 48.

11471_00

COMMISSIONING Honeywell • 46

CAUTION! Before connecting the AC drive to mains make sure that the EMC pro­tection class settings of the drive are appropriately made.

NOTE! After having performed the change write ‘EMC level modified’ on the stick-
er included with the drive delivery (see below) and note the date. Unless already
done, attach the sticker close to the name plate of the drive.

5

Honeywell • 47 CONTROL UNIT

STO JMP

L

I

M

K

H

G

F

J

E

D

A

B

C

6. CONTROL UNIT

The control unit of the AC drive contains the standard boards and the option boards. The option
boards are connected to the slots of the control board (see 6.3 Installation of Option Boards).

Figure 49.The components of the control unit

A. The control terminals for the standard I/O

B. The Ethernet connection

connections

C. The relay board terminals for 3 relay out-

D. The option boards

puts or 2 relay outputs and a thermistor

E. A DIP switch for the RS485 bus termina-

tion

G. A DIP switch for the isolation of the digital

inputs from ground

I. A DIP switch for the signal selection of

Analogue Input 1

K. A fan (only in IP54 of MR4 and of MR5) L. The battery for the RTC

F. A DIP switch for the signal selection of

Analogue Output

H. A DIP switch for the signal selection of

Analogue Input 2

J. The status indicator of the Ethernet con-

nection

M. The location and the default position of

the Safe Torque Off (STO) jumper
(feature not available, do not touch)

CONTROL UNIT Honeywell • 48

When you receive the AC drive, the control unit contains the standard control interface. If you
included special options in your order, the AC drive will be as in your order. On the next pages,
you will find information on the terminals and general wiring examples.

It is possible to use the drive with an external power source with these properties: +24 VDC
±10%, minimum 1000 mA. Connect the external power source to terminal 30. This voltage is
sufficient to keep the control unit on and for you to set the parameters. The measurements of
the main circuit (for example, the DC link voltage, and the unit temperature) are not available
when the drive is not connected to mains.

The status LED of the drive shows the status of the drive. The status LED is located in the con­trol panel, below the keypad, and it can show 5 different statuses.

Colour of the LED light Status of the drive

Blinking slowly Ready
Green Run
Red Fault
Orange Alarm
Blinking fast Downloading software

Table 14. The statuses of the status LED of the drive

6.1 Control Unit Cabling

The standard I/O board has 22 fixed control terminals and 8 relay board terminals. You can see
the standard connections of the control unit and the descriptions of signals in Fig. 39.

6.1.1 Selection of the Control Cables

The control cables must be a minimum of 20 AWG (0.5 mm
more on the cable types in Table 7 on page 19. The terminal wires must be a maximum of
12 AWG (2.5 mm

The terminal The terminal screw

All the terminals of the I/O
board and the relay board

6.1.2 Control Terminals and Dip Switches

Here you see the basic description of the terminals of the standard I/O board and the relay
board. For more information, see 8.2.1 Technical information on control connections.

2

) for the relay board terminals and other terminals.

M3 0.5 4.5

Table 15. Control cable tightening torques

2

) screened multicore cables. See

Tightening torque

Nm lb-in.

Some terminals are assigned for signals that have optional functions that you can use with the
DIP switches. See more in 6.1.2.1 Selection of terminal functions with DIP switches.

6

Honeywell • 49 CONTROL UNIT

RUN

FAULT

READY

*)

*)

Reference output

+10 Vref

Terminal

Standard I/O board

Signal

1

24V auxiliary voltage

24Vout6

Analogue input,
voltage or current

Reference

potentiometer

1...10kΩ

Actual value

2-wire transmitter

I = (0)4...20mA

AI1+2

Analogue input
common, (current)

AI1-3

Analogue input,
voltage or current

AI2+4

Analogue input
common, (current)

AI2-5

Analogue signal
(+output)

AO1+

RUN

18

Analogue output
common / I/O ground

AO1-/GND19

24V auxiliary
input voltage

+24Vin30

24V auxiliary voltage

24Vout

12

I/O ground

GND7

I/O ground

GND13

Digital input 1

DI18

Digital input 2

DI29

Digital input 3

DI310

Digital input 4

DI414

Digital input 5

DI515

Digital input 6

DI616

Relay output 1

RO1 NC21

22

RO1 CM

RO1 NO23

Common for DI1-DI6

CM11

Common for DI1-DI6

CM

17

Serial bus, negative

RS485A

Serial bus, positive

RS485

B

Relay output 2

Relay output 3

RO2 NC24

25

RO2 CM

RO2 NO26

32

RO3 CM

RO3 NO33

Description

Frequency reference

Frequency reference

Start forward

Start reverse

External fault

DI4 DI5 Freq. ref.
Open
Closed

Open
Closed

Open
Open
Closed
Closed

Analog input 1
Preset Freq. 1
Preset Freq. 2
Preset Freq. 3

Fault reset

Output frequency

Modbus RTU
BACnet, N2

mA

Figure 50.The signals of the control terminals on the standard I/O board, and a connection

example. If you include the optional code +SBF4 in your order, the relay output 3 is re-

placed with a thermistor input.

CONTROL UNIT Honeywell • 50

RO1 NC
RO1 CM
RO1 NO

RO2 NC

RO2 CM

RO2 NO

RO3 CM

RO3 NO

21
22

23
24

25

26

32

33

RUN

RUN

FAULT

READY

Relay output 1

Relay output 2

Relay output 3

From Standard I/O board

Terminal Signal

Default

Relay board 1

From term.

#6 or 12

From term.

#13

Figure 51.The standard relay board

6.1.2.1 Selection of terminal functions with DIP switches

You can make 2 selections with the DIP switches for specified terminals. The switches have 2
positions: up and down. You can see the location of the DIP switches and the possible selec­tions in Figure 52.

6

Honeywell • 51 CONTROL UNIT

A B

A

B

C

D

E

AI2

U
I

AI1

U
I

RS-485

OFF
ON

AO1

U
I

Figure 52.The selections of the DIP switches

A. The voltage signal (U), 0-10 V input B. The current signal (I), 0-20 mA input
C. OFF D. ON
E. The RS-485 bus termination

The DIP switch The default position

AI1 U
AI2 I
AO1 I
RS485 bus termination OFF

Table 16. The default positions of the DIP switches

CONTROL UNIT Honeywell • 52

C

D

B

A

6.1.2.2 Isolation of digital inputs from ground

It is possible to isolate from ground the digital inputs (terminals 8-10 and 14-16) on the standard
I/O board. To do this, change the position of a DIP switch on the control board.

A

B

C

Figure 53.Change the position of this switch to isolate the digital inputs from ground

A. The digital inputs B. Floating
C. Connected to GND (default)

6.2 Fieldbus Connection

You can connect the drive to fieldbus with an RS485 or an Ethernet cable. If you use an RS485
cable, connect it to terminal A and B of the standard I/O board. If you use an Ethernet cable,
connect it to the Ethernet terminal below the cover of the drive.

A. RS485 terminal A = Data - B. RS485 terminal B = Data +
C. The Ethernet terminal D. The control terminals

Figure 54.The Ethernet and RS485 connections

6

Honeywell • 53 CONTROL UNIT

IP54

6.2.1 Using Fieldbus Through an Ethernet Cable

Item Description

The plug type A shielded RJ45 plug, maximum length 40 mm (1.57 in)
The cable type CAT5e STP
The cable length Maximum 100 m (328 ft)

Table 17. Ethernet cable data

6.2.1.1 ETHERNET CABLING

1

2

Connect the Ethernet cable to its terminal.

In IP21, cut free the opening on the cover
of the AC drive for the Ethernet cable. In
IP54, cut a hole in a grommet and move
the cable through it.

a. If the grommet folds in when you

put the cable, pull the cable back
to make the grommet straight.

b. The hole in the grommet must

not be wider than your cable.

c. Pull the first bit of the cable out

of the grommet so that it stays
straight. If this is not possible,
make the connection tight with
some insulation tape or a cable
tie.

IP21

CONTROL UNIT Honeywell • 54

A

A. The Ethernet cable in IP21

A

A. The Ethernet cable in IP54

Put the cover of the drive back. Keep the
distance between the Ethernet cable and
the motor cable at a minimum of 30 cm
(11.81 in).

See more in the Installation Manual of the
fieldbus that you have.

3

6

Honeywell • 55 CONTROL UNIT

10

5

15 mm

6.2.2 Using Fieldbus Through an RS485 Cable

Item Description

The plug type
The cable type STP (shielded twisted pair), Belden 9841 or almost the same

The cable length So that it agrees with the fieldbus. See the fieldbus manual.

RS485 CABLING

Remove approximately 15 mm (0.59 in)
of the grey shield of the RS485 cable. Do
this for the 2 fieldbus cables.

a. Strip the cables for approxi-

mately 5 mm (0.20 in) to put
them in the terminals. Do not
keep more than 10 mm (0.39 in)
of the cable outside the termi-

1

nals.

b. Strip the cable at such a dis-

tance from the terminal that you
can attach it to the frame with
the grounding clamp for control
cable. Strip the cable at a maxi­mum length of 15 mm (0.59 in).
Do not remove the aluminium
shield of the cable.

2.5 mm

2

Table 18. RS485 cable data

CONTROL UNIT Honeywell • 56

Connect the cable to the standard I/O
board of the drive, in terminals A and B.

• A = negative

• B = positive

2

3

Attach the shield of the cable to the
frame of the drive with a grounding
clamp for control cable to make a
grounding connection.

6

Honeywell • 57 CONTROL UNIT

If the drive is the last device on the field­bus line, set the bus termination.

a. Find the DIP switches on the left

side of the control unit of the
drive.

b. Set the DIP switch of the RS485

bus termination to the ON posi­tion.

c. Biasing is built in the bus termi-

nation resistor. The termination
resistance is 220 ȍ.

4

5

In IP21, unless you have cut the openings
for other cables, cut an opening on the
cover of the drive for the RS485 cable.

CONTROL UNIT Honeywell • 58

A

A. The fieldbus cables

Put the cover of the drive back. Pull the
RS485 cables to the side.

a. Keep the distance of the Ether-

net, I/O and Fieldbus cables
from the motor cable at a mini­mum of 30 cm (11.81 in).

b. Move the fieldbus cables away

from the motor cable.

6

7

Set the bus termination for the first and the last device of the fieldbus line. We rec­ommend that the first device on the fieldbus is the master device.

D

A

D

E

A. The termination is activated B. The termination is deactivated
C. The termination is activated with a

DIP switch

E. The fieldbus

B

D. The bus termination. The resistance

is 220 ȍ.

C

6

Honeywell • 59 CONTROL UNIT

M4x55

Note: If you do power-down to the last device, there is no bus termination.

6.3 Installation of Option Boards

CAUTION!

Do not install, remove, or replace option boards on the drive when the power is on. Doing this
can cause damage to the boards.

Install the option boards into the option board slots of the drive. Refer to Table 19.

Type of the option
board

HVFDSDOPT6DI
HVFDSDOPT2RO1T The Thermistor relay board C, D, E

HVFDSDOPT1AI2AO The I/O expander board C, D, E
HVFDSDOPT3RO The Relay board C, D, E
HVFDSDOPT1RO5DI The I/O expander board C, D, E

HVFDOPTTMP

32006630-001 The LonWorks fieldbus board D, E

Table 19. The option boards and their correct option board slots

THE INSTALLATION PROCEDURE

Open the cover of the AC drive.

WARNING

Do not touch the control terminals.
They can have a dangerous volt­age also when the drive is discon-

1

nected from mains.

Description of the option board The correct slot or slots

The I/O expander board

The Temperature measurement
board

C, D, E

C, D, E

CONTROL UNIT Honeywell • 60

A. The slot coding

If you have an HVFDSDOPT or an
32006630-001 option board, make sure
that the label on it says "dv" (dual volt­age). This shows that the option board is

2

compatible with the drive.

Note: It is not possible to install option
boards that are not compatible with the
drive.

To get access to the option board slots,
open the cover of the control unit.

dv

OPT

A

3

6

Honeywell • 61 CONTROL UNIT

A. The slot coding
B. The option board slots

Install the option board into the correct
slot: C, D or E. See Table 19.

a. The option board has a slot cod-

ing, because of which it is not
possible to install the option
board in an incorrect slot.

A

4

B

5

6.4 Installation of a Battery for the Real Time Clock (RTC)

To use the Real Time Clock (RTC), you must install a battery in the drive.

1

2

The battery will last approximately 10 years. See more about the functions of the RTC in the
Application Manual.

Close the cover of the control unit. Put the cover of the AC drive back.

Use a ½ AA battery with 3.6 V and a capacity of 1000-1200 mAh. You can use,
for example, a Panasonic BR-1/2 AA or a Vitzrocell SB-AA02.

Install the battery on the left side of the control panel. See Figure 49 on page 47.

CONTROL UNIT Honeywell • 62

6.5 Galvanic Isolation Barriers

The control connections are isolated from mains. The GND terminals are permanently connect­ed to I/O ground.

The digital inputs on the standard I/O board can be galvanically isolated from the I/O ground.
To isolate the digital inputs, use the DIP switch that has the positions FLOAT and GND.

A

10Vref
GND
+24V
GND
AI1+
AI1-

AI2+
AI2­DI1...
DI6
CM
AO1+
AO1­+24Vin

RS485

RO1/1
RO1/2
RO1/3
RO2/1
RO2/2
RO2/3
TI1+
TI1-

L1

L2

L3

DC- DC+/R+ R-

Table 20. The galvanic isolation barriers

A. The control unit B. The power unit

B

U

V

W

6

Honeywell • 63 MAINTENANCE

7. MAINTENANCE

In normal conditions, the AC drive is maintenance-free. However, regular maintenance is rec­ommended to ensure a trouble-free operation and a long lifetime of the drive. We recommend
to follow the table below for maintenance intervals.

NOTE: Because of capacitor type (thin film capacitors), reforming of capacitors is not neces­sary.

Maintenance interval Maintenance action

Regularly and according to gen­eral maintenance interval

6–24 months (depending on
environment)

24 months Clean heatsink and cooling tunnel
3–6 years Change internal IP54 fan
6–10 years Change main fan

• Check tightening torques of terminals

• Check input and output terminals and control I/O
terminals.

• Check operation of cooling fan

• Check for corrosion on terminals, busbars and other
surfaces

Table 1. Maintenance

Honeywell • 64 PRODUCT DATA

8. PRODUCT DATA

8.1 Power ratings

8.1.1 Mains voltage 208-240 V

Mains voltage 208-240V, 50-60 Hz, 3~

Loadability Motor shaft power

*

[A]

Low

L

10% overload

current

[A]

Converter

type

Rated continuous

current I

A 0007 3.7 4.1 0.55 0.75

A 0010 4.8 5.3 0.75 1.0

A 0015 6.6 7.3 1.1 1.5

A 0020 8.0 8.8 1.5 2.0

MR4

A 0030 11.0 12.1 2.2 3.0

A 0040 12.5 13.8 3.0 4.0

A 0050 18.0 19.8 4.0 5.0

A 0075 24.2 26.4 5.5 7.5

MR5

A 0100

**

31.0 34.1 7.5 10.0

A 0150 48.0 52.8 11.0 15.0

230 supply 208-240V supply

10% overload

40°C
[kW]

10% overload

40°C

[hp]

A 0200** 62.0 68.2 15.0 20.0

MR6

A 0250 75.0 82.5 18.5 25.0

A 0300 88.0 96.8 22.0 30.0

MR7

A 0400 105.0 115.5 30.0 40.0

A 0500 143.0 154.0 37.0 50.0

A 0600 170.0 187.0 45.0 60.0

MR8

A 0750 208.0 225.5 55.0 75.0

A 1000 261.0 287.1 75.0 100.0

A 1250 310.0 341.0 90.0 125.0

MR9

*

See chapter 8.1.4.

**

Given low loadabilities valid for 230V drives at a switching frequency of

4kHz

Table 20. Power ratings, supply voltage 208-240V.

NOTE: The rated currents in given ambient temperatures (in Table 3) are
achieved only when the switching frequency is equal to or less than the fac­tory default.

PRODUCT DATA Honeywell • 65

8.1.2 Mains voltage 380-480V

Mains voltage 380-480V, 50-60 Hz, 3~

Loadability Motor shaft power

*

[A]

Low

L

10% overload

current

[A]

Converter

type

Rated continuous

current I

C 0015 3.4 3.7 1.1 1.5

C 0020 4.8 5.3 1.5 2.0

C 0030 5.6 6.2 2.2 3.0

C 0040 8.0 8.8 3.0 4.0

MR4

C 0050 9.6 10.6 4.0 5.0

C 0075

**

12.0 13.2 5.5 7.5

C 0100 16.0 17.6 7.5 10

C 0150 23.0 25.3 11.0 15.0

MR5

C 0200** 31.0 34.1 15.0 20.0

C 0250 38.0 41.8 18.5 25.0

C 0300 46.0 50.6 22.0 30.0

MR6

C 0400** 61.0 67.1 30.0 40.0

C 0500 72.0 79.2 37.0 50.0

C 0600 87.0 95.7 45.0 60.0

MR7

C 0750 105.0 115.5 55.0 75.0

C 1000 140.0 154.0 75 100

C 1250 170.0 187.0 90 125

MR8

C 1500 205.0 225.5 110 150

C 2000 261.0 287.1 132 200

400V supply 480V supply

10% overload

104°F

[kW]

10% overload

104°F

[HP]

C 2500 310.0 341.0 160 250

MR9

*

See chapter 8.1.4

**

Given low loadabilities valid for 480V drives at a switching frequency of

4kHz

Table 1. Power ratings, supply voltage 380-480V.

NOTE: The rated currents in given ambient temperatures (in Table 3) are achieved only when
the switching frequency is equal to or less than the factory default.

8

Honeywell • 66 PRODUCT DATA

8.1.3 Mains voltage 525-600V

Mains voltage 525-600V, 50-60 Hz,
3~

Loadability

Converter

type

Rated continuous

current I

[A]

Low

L

*

10% overload

current

[A]

D0030 3.9 4.3 3.0

D0050 6.1 6.7 5.0

D0075 9.0 9.9 7.5

MR5

D0100 11.0 12.1 10.0

D0150 18.0 19.8 15.0

D0200 22.0 24.2 20.0

D0250 27.0 29.7 25.0

MR6

D0300 34.0 37.4 30.0

D0400 41.0 45.3 40.0

D0500 52.0 57.2 50.0

MR7

D0600 62.0 68.2 60.0

D0750 88.0 154.0 75.0

D1000 110.0 187.0 100.0

MR8

D1250 137.5 225.5 125.0

D1500 144.0 158.4 150.0

Motor shaft

power

600V supply

10% overload

104°F

[HP]

D2000 208.0 228.8 200.0

MR9

*

See chapter 8.1.4

Table 2. Power ratings, supply voltage 525-600V.

PRODUCT DATA Honeywell • 67

I

L

I

L* 11 0%

1 min 9 min

I

L*11 0%

Current

Time

8.1.4 Definitions of overloadability

Low overload

Example: If the duty cycle requires 110% rated current I

=Following continuous operation at rated output current IL, the converter is fed with

110% * I

9 min must be at rated current or less.

for 1 min, followed by a period of IL.

L

Figure 1. Low overload

for 1 min in every 10 min, the remaining

L

11481_uk

8

Honeywell • 68 PRODUCT DATA

8.2 SmartVFD HVAC - technical data

Mains connection

Motor connection

Control

characteristics

Input voltage U

in

208...240V; 380…480V; 525…600V;

-10%…+10%

Input frequency 47…66 Hz

Connection to mains Once per minute or less

Starting delay 4 s (MR4 to MR6); 6 s (MR7 to MR9)

Output voltage

Continuous output
current

Starting current

0-U

in

IL:Ambient temperature max. +104°F,
overload 1.1 x I

(1 min./10 min.)

L

IS for 2 s every 20 s

Output frequency 0…320 Hz (standard)

Frequency resolution 0.01 Hz

200-500 V

• MR4-MR6:

• 1.5-10 kHz

• Default: 6 kHz (except for A 0040,
A 0100, A 0200, C 0075, C 0200 and
C 0400: 4 kHz)

• MR7-MR9:

•1.5-6 kHz

• Default: MR7: 4 kHz, MR8: 3 kHz, MR9:

Switching frequency

2kHz

(see parameter
M3.1.2.1)

600 V

• MR5-MR9:

•1.5-6 kHz

• Default: 2 kHz

• For a product that is configured for a C4
installation on IT network the maximum
switching frequency is limited to default
2kHz.

Automatic switching frequency derating in
case of overload.

Frequency reference
Analogue input
Panel reference

Resolution 0.1% (10-bit), accuracy ±1%
Resolution 0.01 Hz

Field weakening point 8…320 Hz

Acceleration time 0.1…3000 sec

Deceleration time 0.1…3000 sec

PRODUCT DATA Honeywell • 69

IL : -10°C (no frost)…+40°C,
Ambient operating
temperature

14 (no frost) ... 104 F

Up to 50 °C with derating (1.5%/1°C)

Ambient conditions

Ambient conditions

(cont.)

Storage temperature

Relative humidity

Air quality:
chemical vapours
mechanical particles

Altitude

Vibration
EN61800-5-1/
EN60068-2-6

Shock
EN61800-5-1
EN60068-2-27

-40°C ... +70°C

-40°F…+158°F

0 to 95% RH, non-condensing, non-corro-

sive

IEC 60721-3-3, unit in operation, class 3C2

IEC 60721-3-3, unit in operation, class 3S2

100% load capacity (no derating) up to

1,000 m / 3280 ft

1-% derating for each 100m/328ft above

1,000m/3280ft

Max. altitudes:

208...240V: 4,500m/14763 ft

tems)

380...480V:

tems)

525...690 V: 2,000m/6562 ft (TN and IT

systems, no corner grounding)

Voltage for I/O signals:

Up to 2,000m/6561ft : Allowed up to 240V

2,000m...4,500m / 6561...14763ft: Allowed

up to 120V

5…150 Hz

Displacement amplitude 1 mm (peak) at

5…15.8 Hz (MR4…MR9)

Max acceleration amplitude 1 G at

15.8…150 Hz (MR4…MR9)

UPS Drop Test (for applicable UPS weights)

Storage and shipping: max 15 G, 11 ms (in

package)

4,500m/14763 ft (TN and IT sys-

(TN and IT sys-

Enclosure class

IP21/NEMA 1 standard in entire kW/HP range

IP54/NEMA12 option

Note! Keypad required for IP54/NEMA12

8

Honeywell • 70 PRODUCT DATA

EMC (at default

settings)

Emissions

Safety

Immunity

Emissions

Average noise level
(cooling fan) sound
power level in dB(A)

Fulfils EN61800-3 (2004), first and second

environment

Depend on EMC level.

+EMC2: EN61800-3 (2004), Category C2

Honeywell Smart VFD HVAC will be deliv-

ered with class C2 EMC filtering, if not oth-

erwise specified.

Honeywell Smart VFD HVAC can be modi-

fied for IT-networks. See chapter 5.2.

• 200-500 V: EN 61800-3 (2004), category
C2.

• 600 V: EN 61800-3 (2004), category C3.

• All: The product is configurable to cate­gory C4 for installation on IT networks.
The drive can be modified for IT type
mains. See chapter 7.6 Installation in an
IT system. The IP00 / UL Open Type
drive has by default category C4.

MR4: 65 MR7: 77
MR5: 70 MR8: 86
MR6: 77 MR9: 87

EN 61800-5-1 (2007), CE, cUL; (see unit
nameplate for more detailed approvals)

Control connections See chapter 8.2.1.

Protections

Overvoltage trip limit
Undervoltage trip limit

Ground fault protection

Mains supervision Ye s

Motor phase supervision

Yes
Yes

In case of ground fault in motor or motor
cable, only the drive is protected

Trips if any of the output phases is missing

Overcurrent protection Yes

Unit overtemperature
protection

Motor overload protection

Yes

Yes

Motor stall protection Yes

Protections (cont.)

Motor underload
protection

Yes

Short-circuit protection
of +24V and +10V

Yes

reference voltages

Table 3. Smart VFD HVAC technical data

PRODUCT DATA Honeywell • 71

8.2.1 Technical information on control connections

Basic I/O board

Terminal Signal Technical information

Reference output +10V, +3%; Maximum current 10 mA

1

Analogue input channel 1
0- +10V (Ri = 200 kΩ)
4-20 mA (Ri =250 Ω)
Resolution 0.1 %, accuracy ±1 %
Selection V/mA with dip-switches (see page 50)

Differential input if not connected to ground;
Allows ±20V differential mode voltage to GND

Analogue input channel 1
Defauit:4-20 mA (Ri =250 Ω)
0-10 V (Ri=200kΩ)
Resolution 0.1 %, accuracy ±1 %
Selection V/mA with dip-switches (see page 50)

Differential input if not connected to ground;
Allows 20V differential mode voltage to GND

+24VDC, ±10%, max volt. ripple < 100mVrms; max. 250mA
Dimensioning: max. 1000mA/control box.
Short-circuit protected

Ground for reference and controls (connected internally to
frame ground through 1MΩ)

Positive or negative logic
Ri = min. 5kΩ
18…30V = "1"

Digital inputs can be disconnected from ground, see chapter

6.1.2.2.
+24VDC, ±10%, max volt. ripple < 100mVrms; max. 250mA

Dimensioning: max. 1000mA/control box.
Short-circuit protected

Ground for reference and controls (connected internally to
frame ground through 1MΩ)

Positive or negative logic
Ri = min. 5kΩ
18…30V = "1"

Digital inputs can be disconnected from ground, see chapter

6.1.2.2.
Analogue output channel 1, selection 0 -20mA,

load <500 Ω
Default:0-20 mA
0-10V
Resolution 0.1 %, accuracy ±2 %
Selection V/mA with dip-switches (see page 50)

Can be used as external power backup for the control unit
(and fieldbus)

Differential receiver/transmitter
Set bus termination with dip switches (see page 50)

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

30

A

B

Analogue input,
voltage or current

Analogue input common (cur­rent)

Analogue input,
voltage or current

Analogue input common (cur­rent)

24V aux. voltage

I/O ground

Digital input 1

Digital input 2

Digital input 3

Common A for DIN1-DIN6

24V aux. voltage

I/O ground

Digital input 4

Digital input 5

Digital input 6

Common A for DIN1-DIN6

Analogue signal (+output)

Analogue output common

24V auxiliary input voltage

RS485

RS485

Table 4. Technical information on basic I/O board

8

Honeywell • 72 PRODUCT DATA

Relay board with two Type 8A/STST and one Type 8A/STDT relays.

Relay

board 1

Terminal Signal Technical information

5,5 mm isolation between channels.
External interface connector
See chapter 6.

21

22

Relay output 1

23

24

25

Relay output 2*

26

32

33

Relay output 3*

*

If 230VAC is used as control voltage from the output relays, the control

Switching capacity24VDC/8A
250VAC/8A

*

125VDC/0.4A
Min.switching load5V/10mA

Switching capacity24VDC/8A
250VAC/8A
125VDC/0.4A
Min.switching load5V/10mA

Switching capacity24VDC/8A
250VAC/8A
125VDC/0.4A
Min.switching load5V/10mA

circuitry must be powered with a separate isolation transformer to limit
short circuit current and overvoltage spikes. This is to prevent welding on
the relay contacts. Refer to standard EN 60204-1, section 7.2.9

Table 5. Technical information on Relay board 1

+RPHDQG%XLOGLQJ7HFKQRORJLHV

,QWKH86

+RQH\ZHOO

3HDFKWUHH6WUHHW1(

$WODQWD*$

FXVWRPHUKRQH\ZHOOFRP

® U.S. Registered Trademark
© 2018 Honeywell International Inc.
38-00007—03 M.S. Rev. 01-18
Printed in U.S.A.

Subject to change without notice