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Honeywell SmartDrive HVAC Installation Manual

Variable frequency drive for heating, ventilation and air conditioning applications

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Honeywell
Installation manual
SmartDrive HVAC
Variable Frequency Drive for
Heating, Ventilation and
Air conditioning applications

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Summary of Contents for Honeywell SmartDrive HVAC

  • Page 1 Honeywell Installation manual SmartDrive HVAC Variable Frequency Drive for Heating, Ventilation and Air conditioning applications...
  • Page 2: Table Of Contents

    Honeywell • 0 INDEX Document: DPD00487D Version release date: 10.6.11 Safety ........................2 Danger ..........................2 Warnings......................... 3 Earthing and earth fault protection.................. 3 EMC levels........................4 1.4.1 Total Harmonic Distortion (THD)..................5 Receipt of delivery.....................6 Type designation code....................7 Unpacking and lifting the drive..................8 2.2.1 Lifting frames MR8 and MR9 ..................
  • Page 3 Honeywell • 1 Maintenance ......................... 65 Technical data....................67 Drive power ratings ....................... 67 7.1.1 Mains voltage 208-240 V ....................67 7.1.2 Mains voltage 380-480 V ....................68 7.1.3 Definitions of overloadability ..................69 Technical data....................... 70 7.2.1 Technical information on control connections............... 73...
  • Page 4: Safety

    Honeywell • 2 AFETY AFETY 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.
  • Page 5: Warnings

    (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.
  • Page 6: Emc Levels

    EMC levels SmartDrive HVAC inverters are divided into three classes according to the level of electromag- netic disturbances emitted, the requirements of a power system network and the installation environment (see below). The EMC class of each product is defined in the type designation code.
  • Page 7: Total Harmonic Distortion (Thd)

    T-class. This class is very typical requirement also in installations in ships. Also the 230V SmartDrive HVAC products can be ordered as ready configured to this class by adding a T to the end of standard product code (HVAC230-xxx-xxT).
  • Page 8: Receipt Of Delivery

    Honeywell • 6 ECEIPT OF DELIVERY ECEIPT 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.
  • Page 9: Type Designation Code

    ECEIPT OF DELIVERY 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:...
  • Page 10: Unpacking And Lifting The Drive

    Honeywell • 8 ECEIPT OF DELIVERY 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 move the converter from its package. Note the weights of each in- dividual frame size in Table 4 below.
  • Page 11 Honeywell • 9 ECEIPT OF DELIVERY Should the drive have been damaged during the shipping, please contact primarily the cargo insurance company or the carrier.
  • Page 12: Accessories

    Honeywell • 10 ECEIPT OF DELIVERY Accessories After having opened the transport package and lifted the converter out, check immediately that these various accessories were included in the delivery. The contents of the accessories bag differ by drive size and IP protections class: 2.3.1...
  • Page 13: Size Mr6

    Honeywell • 11 ECEIPT OF DELIVERY 2.3.3 Size MR6 Item Quantity Purpose Screws for power cable clamps (6) M4x20 screw and grounding clamps (4) M4x16 screw Screws for control cable clamps M4x8 screw Screw for optional grounding M5x12 screw Screw for drive external grounding...
  • Page 14: Size Mr8

    Honeywell • 12 ECEIPT OF DELIVERY 2.3.5 Size MR8 Item Quantity Purpose M4x16 screw Screws for control cable clamps Control cable grounding lamella Control cable grounding Cable lugs KP34 Clamping power cables Cable insulator Avoiding contact between cables Cable grommet, hole diameter 25.3 mm...
  • Page 15: Product Modified' Sticker

    Honeywell • 13 ECEIPT OF DELIVERY ‘Product modified’ sticker In the small plastic bag included in the 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.
  • Page 16: Mounting

    Honeywell • 14 OUNTING OUNTING The drive must be mounted in vertical position on the wall or on the back plane of a cubicle. Ensure that the mounting plane is relatively even. The drive shall be fixed with four screws (or bolts, depending on the unit size).
  • Page 17 Honeywell • 15 OUNTING Ø7 100* Ø14 Ø7 IP21 IP54 Ø33 Ø25 Ø33 Ø25 Ø7 100* *Optional mounting holes (for NX replacement) Figure 5. SmartDrive dimensions, MR5 IP21 Ø40 Ø33 Ø40 Ø9 Ø 15,5 Ø25 Ø25 IP54 Ø9 Figure 6. SmartDrive dimensions, MR6...
  • Page 18 Honeywell • 16 OUNTING Ø9 IP21 Ø20 Ø16 Ø51 IP54 Ø25 Ø50 Figure 7. SmartDrive dimensions, MR7 Ø9 Ø22 3 x 38 Ø25 Ø60 62,5 Ø11 Ø9 Figure 8. SmartDrive dimensions, MR8 IP21 and IP54...
  • Page 19 Honeywell • 17 OUNTING 3 x 42 = 126 Ø25 Ø59 4 x 81,5 = 326 Figure 9. SmartDrive dimensions, MR9 IP21 and IP54...
  • Page 20: Cooling

    Honeywell • 18 OUNTING Cooling The drives produce heat in operation and are cooled down by air circulated by a fan. Enough free space shall therefore be left around the drive to ensure sufficient air circulation and cooling. Different acts of maintenance also require certain amount of free space.
  • Page 21 Honeywell • 19 OUNTING Note that if several units are mounted above each other the required free space equals C + D (see Fig- ure 11.). Moreover, the outlet air used for cooling by the lower unit must be directed away from the air in- take of the upper unit by means of e.g.
  • Page 22: Power Cabling

    Honeywell • 20 OWER CABLING OWER 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 principal connection diagram in Figure 12. See also Table 13 for the cable recommmendations for different EMC levels.
  • Page 23: Ul Standards On Cabling

    Honeywell • 21 OWER CABLING *360º earthing 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). PE conductor PE conductors and shield Shield Figure 13.
  • Page 24 Honeywell • 22 OWER CABLING 4.1.1.1 Cable and fuse sizes, frames MR4 to MR6 The recommended fuse types are gG/gL (IEC 60269-1) or class T (UL & CSA). The fuse volt- age 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.
  • Page 25 Honeywell • 23 OWER CABLING 4.1.1.2 Cable and fuse sizes, frames MR7 to MR9 The recommended fuse types are gG/gL (IEC 60269-1) or class T (UL & CSA). The fuse volt- age 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.
  • Page 26 Honeywell • 24 OWER CABLING 4.1.1.3 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 volt- age 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.
  • Page 27 Honeywell • 25 OWER CABLING 4.1.1.4 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 volt- age 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.
  • Page 28: Cable Installation

    Honeywell • 26 OWER CABLING 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.
  • Page 29: Frames Mr4 To Mr7

    Honeywell • 27 OWER CABLING 4.2.1 Frames MR4 to MR7 Strip the motor and mains cables as advised below. Earth conductor Earth conductor MAINS MOTOR Figure 14. Stripping of cables Frame Leave as short as pos- sible Table 18. Cables stripping lengths [mm]...
  • Page 30 Honeywell • 28 OWER CABLING M4x55 Figure 15. Remove the screws of the cable protection plate. Do not open the cover of the power unit! M4x8 Figure 16.
  • Page 31 Honeywell • 29 OWER CABLING Insert the cable grommets (included in the delivery) in the openings of the cable entry plate (included) as shown in the picture (upper pictures EU version, lower pictures US version). Figure 17. • Insert the cables - supply cable, motor cable and optional brake cable - in the openings of the cable entry plate.
  • Page 32 Honeywell • 30 OWER CABLING Figure 18. Detach the cable clamps and the grounding clamps (Figure 19) and place the cable entry plate with the cables in the groove on the drive frame (Figure 20). M4x16 (2.2 Nm) Figure 19.
  • Page 33 Honeywell • 31 OWER CABLING Figure 20. Connect the stripped cables (see Figure 14 and Figure 18) as shown in Figure 21. • Expose the shield of all three cables in order to make a 360-degree con- nection with the cable clamp (1).
  • Page 34 Honeywell • 32 OWER CABLING Tightening torques of cable terminals: Tightening torque Tightening torque Tightening torque, [Nm]/[lb-in.] [Nm]/[lb-in.] [Nm]/[lb-in.] Power and motor EMC grounding Grounding Frame Type terminals clamps terminals [Nm] lb-in. [Nm] lb-in. [Nm] lb-in. 230 P55—230 3P0 0.5—0.6 4.5—5.3 13.3...
  • Page 35: Frames Mr8 And Mr9

    Honeywell • 33 OWER CABLING Re-mount the cable protection plate (Figure 23) and the cover of the drive. Figure 23. Re-mounting of cover components 4.2.2 Frames MR8 and MR9 Strip the motor and mains cables as advised below. Earth conductor...
  • Page 36 Honeywell • 34 OWER CABLING Frame Leave as short as possible Table 20. Cables stripping lengths [mm] MR9 only: Remove the main cover of the drive. M4 x 10 Figure 25. Remove the cable cover (1) and the cable fitting plate (2).
  • Page 37 Honeywell • 35 OWER CABLING M4 x 8 M5 x 10 Figure 27. Removing cable cover and cable fitting plate (MR9). MR9 only: Loosen the screws and remove the sealing plate. Figure 28.
  • Page 38 Honeywell • 36 OWER CABLING Remove the EMC shield plate. M4x8 Figure 29. Locate the terminals. OBSERVE the exceptional placement of motor cable ter- minals in MR8! Figure 30.
  • Page 39 Honeywell • 37 OWER CABLING Cut the rubber grommets open to slide the cables through. Should the grommets 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.
  • Page 40 Honeywell • 38 OWER CABLING If you use thick cables insert the cable insulators in between the terminals in order to avoid contact between the cables. Figure 33. Connect the cables stripped as shown in Figure 24. • Connect the (phase) conductors of the supply, brake and motor cables into their respective terminals (a).
  • Page 41 Honeywell • 39 OWER CABLING L1 L2 L3 R+ R- L1 L2 L3 DC-DC+ U V W Figure 34. Connector Cable lug Cable lug Figure 35. Placing two cable lugs on top of each other Tightening torques of cable terminals:...
  • Page 42 Honeywell • 40 OWER CABLING Expose the shield of all three cables in order to make a 360-degree connection with the cable clamp. Figure 36. Remount now first the EMC shield plate (see Figure 30) and then the sealing plate for MR9 (see Figure 29).
  • Page 43 Honeywell • 41 OWER CABLING MR9 only: Now re-mount the main cover (unless you want to make the control connections first). M4x10 Figure 38. Check the connection of the earth cable to the motor and the drive terminals marked with NOTE: Two protective conductors are required according to standard EN61800- 5-1.
  • Page 44 Honeywell • 42 OWER CABLING Figure 39.
  • Page 45: Installation In Corner-Grounded Network

    Honeywell • 43 OWER CABLING 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 6.3 of this manual.
  • Page 46: Control Unit

    Honeywell • 44 ONTROL UNIT ONTROL UNIT The control unit of the drive consists of the control board and additional boards (option boards) connected to the slot connectors of the control board. Locations of essential control unit components: 1 = Control terminals of the control board...
  • Page 47: Control Unit Cabling

    Honeywell • 45 ONTROL UNIT Control unit cabling The basic control unit connections are presented in Figure 41 below. The control board is equipped with 30 fixed control I/O terminals. All signal descriptions are given in Tables 23 to 24.
  • Page 48: Control Terminals And Dip Switches

    Honeywell • 46 ONTROL UNIT 5.1.2 Control terminals and DIP switches The terminals of the Standard I/O board and the Relay board are described below. For more information on the connections, see chapter 7.2.1. The terminals shown on shadowed background are assigned for signals with optional functions selectable with DIP switches.
  • Page 49 Honeywell • 47 ONTROL UNIT From Relay board Standard I/O board From term. From term. Terminal Signal Relay output 1 RO1/1 RO1/2 RO1/3 Relay output 2 RO2/1 RO2/2 RO2/3 TI1+ Thermistor input TI1- Table 24. Control I/O terminal signals on relay board and connection example 5.1.2.1...
  • Page 50 Honeywell • 48 ONTROL UNIT 5.1.2.2 Isolating digital inputs from ground The digital inputs (terminals 8-10 and 14-16) on the standard I/O board can be isolated from ground by removing a jumper on the control board. See Figure 43. Lift the plastic lid to expose the jumper and apply long-nose pliers or similar to remove it.
  • Page 51: I/O Cabling And Fieldbus Connection

    Honeywell • 49 ONTROL UNIT I/O cabling and fieldbus connection The drive can be connected to fieldbus either through RS485 or Ethernet. The connection for RS485 is on the standard I/O board (terminals A and B) and the connection for Ethernet is un- der the drive cover, left to the control keypad.
  • Page 52 Honeywell • 50 ONTROL UNIT max. 40 mm Ethernet cable Figure 45. Protection class IP21: Cut free the opening on the drive cover for the Ethernet cable. Protection class IP54: Cut the rubber grommets open to slide the cables through. Should the grommets fold in while inserting the cable, just draw the cable back a bit to straighten the grommets up.
  • Page 53: Prepare For Use Through Ms/Tp

    Honeywell • 51 ONTROL UNIT Remount the drive cover. NOTE: When planning the cable runs, remember to keep the distance between the Ethernet cable and the motor cable at a minimum of 30 cm. Ethernet cable IP54 IP21 Figure 47.
  • Page 54 Honeywell • 52 ONTROL UNIT Strip about 15 mm of the RS485 cable (see specification on page 55) and cut off the grey cable shield. Remember to do this for both bus cables. Leave no more than 10 mm of the cable outside the terminal block and strip the cables at about 5 mm to fit in the terminals.
  • Page 55 Honeywell • 53 ONTROL UNIT Using the cable clamp included in the delivery of the drive, ground the shield of the RS485 cable to the frame of the drive. Cable clamp If the drive is the last device on the bus, the bus termination must be set. Locate the DIP switches to the right of the control keypad of the drive and turn the switch for the RS485 bus termination resistor to position ON.
  • Page 56 Honeywell • 54 ONTROL UNIT Unless already done for the other control cables, cut free the opening on the drive cover for the RS485 cable (protection class IP21). Remount the drive cover and run the RS485 cables as shown in picture.
  • Page 57: Rs485 Cable Data

    Honeywell • 55 ONTROL UNIT 5.2.3 RS485 cable data Connector 2.5 mm STP (Shielded Twisted Pair), type Cable type Belden 9841 or similar Depends on the used fieldbus. See Cable length respective bus manual. Table 27. RS485 cable data...
  • Page 58: Changing The Battery For Real Time Clock (Rtc)

    Honeywell • 56 ONTROL UNIT Changing the battery for Real Time Clock (RTC) Enabling the functions of the Real Time Clock (RTC) requires that a battery is installed in the drive. The place for the battery can be found in all frames left to the control keypad (see Figure 49).
  • Page 59: Galvanic Isolation Barriers

    Honeywell • 57 ONTROL UNIT Galvanic isolation barriers The control connections are isolated from the mains potential and the GND terminals are per- manently connected to ground. See Figure 50. The digital inputs are galvanically isolated from the I/O ground. The relay outputs are addition- ally double-isolated from each other at 300VAC (EN-50178).
  • Page 60: Commissioning

    Honeywell • 58 OMMISSIONING OMMISSIONING 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.
  • Page 61: Commissioning Of The Drive

    Honeywell • 59 OMMISSIONING Commissioning of the drive Read carefully the safety instructions in Chapter 1 and above and follow them. After the installation:  Check that both the drive and the motor are grounded.  Check that the mains and motor cables comply with the requirements given in chap- ter 4.1.1.
  • Page 62 Honeywell • 60 OMMISSIONING 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.
  • Page 63: Installation In It System

    C2 you need to modify the EMC protection of the drive to EMC-level C4. This is done by removing the built-in EMC jumpers with a simple procedure described below. NOTE: Honeywell SmartDrive HVAC 230V products with letter ‘T’ in the end of the product code (HVAC230-xxx-xxT) are as standard configured to IT-networks and do not need any mod- ifications.
  • Page 64: Frames Mr7 And Mr8

    Honeywell • 62 OMMISSIONING 6.3.2 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. Remove the main cover of the drive and locate the jumper. MR8 only: Push down the grounding arm.
  • Page 65: Frame Mr9

    Honeywell • 63 OMMISSIONING MR7 only: locate the DC grounding busbar between connectors R- and U and detach the busbar from the frame by undoing the M4 screw. Figure 55. MR7: Detaching the DC grounding busbar from frame 6.3.3 Frame MR9 Follow the procedure described below to modify the EMC protection of the drive of frame MR9 to EMC-level C4.
  • Page 66 Honeywell • 64 OMMISSIONING Further remove the extension box cover, the touch shield the I/O plate with I/O grommet plate. Locate the EMC jumper on the EMC board (see magnification be- low) and remove it. Figure 57. CAUTION! Before connecting the drive to mains make sure that the EMC protec- tion class settings of the drive are appropriately made.
  • Page 67: Maintenance

    Honeywell • 65 OMMISSIONING Maintenance In normal conditions, the drive is maintenance-free. However, regular maintenance is recom- mended to ensure a trouble-free operation and a long lifetime of the drive. We recommend to follow the table below for maintenance intervals.
  • Page 68 Honeywell • 66 OMMISSIONING...
  • Page 69: Drive Power Ratings

    Honeywell • 67 ECHNICAL DATA ECHNICAL DATA Drive power ratings 7.1.1 Mains voltage 208-240 V Mains voltage 208-240V, 50-60 Hz, 3~ Loadability Motor shaft power 230 supply 208-240V supply Product type Rated continuous Input 10% overload 10% overload 10% overload...
  • Page 70: Technical Data

    Honeywell • 68 ECHNICAL DATA 7.1.2 Mains voltage 380-480 V Mains voltage 380-480V, 50-60 Hz, 3~ Loadability Motor shaft power 400V supply 480V supply Product type Rated continuous 10% overload 10% overload 10% overload Input current I L current 40°C 40°C...
  • Page 71: Definitions Of Overloadability

    Honeywell • 69 ECHNICAL DATA 7.1.3 Definitions of overloadability Low overload =Following continuous operation at rated output current I , the converter is fed with 110% * I for 1 min, followed by a period of I Example: If the duty cycle requires 110% rated current I for 1 min in every 10 min, the remaining 9 min must be at rated current or less.
  • Page 72: Technical Data

    Honeywell • 70 ECHNICAL DATA Technical data Input voltage U 208...240V; 380…480V; -10%…+10% Input frequency 50…60 Hz -5...+10% Mains connection Connection to mains Once per minute or less Starting delay 4 s (MR4 to MR6); 6 s (MR7 to MR9) Output voltage :Ambient temperature max.
  • Page 73 Honeywell • 71 ECHNICAL DATA : -10°C (no frost)…+40°C; up to +50°C Ambient operating temperature with derating Storage temperature -40°C…+70°C Relative humidity 0...95% RH, non-condensing, non-corrosive Tested according to IEC 60068-2-60 Test Ke: Flowing mixed gas corrosion test, Method 1 (H...
  • Page 74 Honeywell • 72 ECHNICAL DATA Overvoltage trip limit 240-volt drives: 456 VDC 480-volt drives: 911 VDC Depends on supply voltage (0,8775*sup- ply voltage): Undervoltage trip limit Supply voltage 240 V: Trip limit 211 VDC Supply voltage 400 V: Trip limit 351 VDC...
  • Page 75: Technical Information On Control Connections

    Honeywell • 73 ECHNICAL DATA 7.2.1 Technical information on control connections Standard I/O board Terminal Signal Technical information Reference output +10VDC, +3%; Maximum current 10 mA Analogue input channel 1; Short-circuited protected  0- +10VDC (Ri = 200 k Analogue input, ...
  • Page 76 Honeywell • 74 ECHNICAL DATA Relay board with two change-over contact (SPDT) relays and one Relay relay with normally-open (NO or SPST) contact. board 5,5 mm isolation between channels. Terminal Signal Technical information Switching capacity24VDC/8A 250VAC/8A Relay output 1 125VDC/0.4A Min.switching load5V/10mA...
  • Page 77 DPD00487D Find out more For more information on Honeywell’s variable frequency drives and other Honeywell products, visit us online at http://ecc.emea.honeywell.com Automation and Control Solutions Honeywell GmbH Böblinger Str. 17 71101 Schönaich, Germany Telephone (49) 7031 637 01 EN1B-0489GE51 R1210...

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