Rockwell Automation CNMD180W0ENNNC1 User manual

Instruction Manual
Reach Drive User Manual
Manufactured for DBT
D2-3561

Copyright © 2006 Rockwell Automation. All rights reserved.
The information in this manual is subject to change without notice.
Throughout this manual, the following notes are used to alert you to safety considerations:
Important: Identifies information that is critical for successful application and understanding of the product.
!
ATTENTION: Identifies information about practices or circumstances that can lead to personal
injury or death, property damage, or economic loss.
!
ATTENTION: Only qualified electrical personnel familiar with the construction and operation of
this equipment and the hazards involved should install, adjust, operate, or service this equipment.
Read and understand this manual and other applicable manuals in their entirety before
proceeding. Failure to observe this precaution could result in severe bodily injury or loss of life.
ATTENTION: DC bus capacitors retain hazardous voltages after input power has been
disconnected. After disconnecting input power, wait five (5) minutes for the DC bus capacitors to
discharge and then check the voltage with a voltmeter to ensure the DC bus capacitors are
discharged before touching any internal components. Failure to observe this precaution could
result in severe bodily injury or loss of life.
ATTENTION: The drive can operate at and maintain zero speed. The user is responsible for
assuring safe conditions for operating personnel by providing suitable guards, audible or visual
alarms, or other devices to indicate that the drive is operating or may operate at or near zero
speed. Failure to observe this precaution could result in severe bodily injury or loss of life.
ATTENTION: Do not install modification kits with power applied to the drive. Disconnect and lock
out incoming power before attempting such installation or removal. Failure to observe this
precaution could result in severe bodily injury or loss of life.
ATTENTION: The drive start/stop/enable control circuitry includes solid state components. If
hazards due to accidental contact with moving machinery or unintentional flow of liquid, gas or
solids exist, an additional hardwired stop circuit may be required to remove the AC line to the
drive. An auxiliary braking method may be required.
ATTENTION: The drive contains ESD- (Electrostatic Discharge) sensitive parts and assemblies.
Static control precautions are required when installing, testing, servicing, or repairing the drive.
Erratic machine operation and damage to, or destruction of, equipment can result if this procedure
is not followed. Failure to observe this precaution can result in bodily injury.
ATTENTION: The user is responsible for conforming with all applicable local, national, and
international codes. Failure to observe this precaution could result in damage to, or destruction
of, the equipment.

Contents 1
CONTENTS
Chapter 1
Introduction
1.1 Who Should Use this Manual? ........................................................................ 1-1
1.2 Manual Conventions........................................................................................ 1-1
1.3 Identifying the Drive by Nameplate.................................................................. 1-1
1.4 Identifying the Drive by Model Number ........................................................... 1-2
Chapter 2
Installation/Wiring
2.1 AC Supply Source Considerations .................................................................. 2-1
2.1.1 Unbalanced or Ungrounded Distribution Systems ................................ 2-2
2.1.2 Input Power Conditioning ...................................................................... 2-2
2.2 General Grounding Requirements................................................................... 2-3
2.2.1 Safety Ground - PE ............................................................................... 2-4
2.2.2 Shield Termination - SHLD.................................................................... 2-4
2.2.3 RFI Filter Grounding.............................................................................. 2-5
2.3 Fuses and Circuit Breakers ............................................................................. 2-5
2.4 Power Wiring ................................................................................................... 2-5
2.4.1 Cable Types Acceptable for 200-600 Volt Installations......................... 2-5
2.4.2 Motor Cable Lengths ............................................................................. 2-5
2.4.3 Power Termination Location Notes ....................................................... 2-6
2.5 I/O Wiring......................................................................................................... 2-7
2.5.1 I/O Terminal Designations..................................................................... 2-8
2.5.2 Encoder Terminal Block ...................................................................... 2-11
2.5.3 Signal and Control Wire Types............................................................ 2-12
2.5.4 The I/O Control Board ......................................................................... 2-14
2.5.5 I/O Terminal Blocks............................................................................. 2-14
2.5.6 Hardware Enable Circuitry .................................................................. 2-15
2.5.7 Resistance Temperature Detector (RTD) Board ................................. 2-15
2.5.7.1 Connections .......................................................................... 2-17
2.5.7.2 Hardware .............................................................................. 2-17
2.5.7.3 Microcontroller Software ....................................................... 2-19
Chapter 3
Parameter Descriptions
3.1 Parameters ...................................................................................................... 3-2
3.2 Advanced Tuning Parameters (Vector Control Only) .................................. 3-141
Chapter 4
Troubleshooting
4.1 About Alarms ................................................................................................... 4-2
4.1.1 Alarm Descriptions ................................................................................ 4-3
4.2 About Faults .................................................................................................... 4-7
4.2.1 About the Fault Queue .......................................................................... 4-7
4.2.2 Clearing Faults ...................................................................................... 4-8
4.2.3 Fault Descriptions and Corrective Actions ............................................ 4-9
4.3 Testpoint Parameter ...................................................................................... 4-15
4.4 Troubleshooting the Drive Using the LCD HIM ............................................. 4-16
4.4.1 Accessing the Fault Queue ................................................................. 4-16

2 DBT Reach Drive User Manual
Appendix A
Technical Specifications........................................................................................... A-1
Appendix B
Logic Command/Status Words ................................................................................ B-1
Appendix C
HIM Overview........................................................................................................... C-1
Appendix D
Application Notes ..................................................................................................... D-1

Introduction 1-1
CHAPTER 1
Introduction
The purpose of this manual is to provide you with the basic information needed to
install, start-up, and troubleshoot the Reach Drive.
1.1 Who Should Use this Manual?
This manual is intended for qualified personnel. You must be able to program and
operate adjustable frequency AC drives devices. In addition, you must have an
understanding of the parameter settings and functions.
1.2 Manual Conventions
Parameter names: In most instances, parameter names are shown as the parameter
name followed by the parameter number.
For example: Ramped Speed (22).
1.3 Identifying the Drive by Nameplate
Each Reach Drive can be identified by its nameplate.
Figure 1.1 – Identifying the Drive by Nameplate
198
270
432-528
Nom. Coolant Pressure: 25psig
Input: 3 Phase, 47-63 Hz
MFD. in 2006 on AUG 15
3 Sec. Overload Amps
1 Min. Overload Amps
Continuous Amps
Base Hz (default)
AC Voltage Range
Output: 3 Phase, 0-400Hz
AC Voltage Range
Normal Duty Power
Amps
60 Hz
180
0-460
169
480V
150 HP
Serial Number: MEAZ0NNO
Original Firmware V. 1.001
Series: A
Cat No.
Made in the U.S.A. by Rockwell Automation Co. (FAC1C)
I/O:
Frame: 1
DBT
CNMD180W0ENNNC1
CNMD180W0ENNNC1

1-2 DBT Reach Drive User Manual
1.4 Identifying the Drive by Model Number
Each Reach Drive and Reach Drive Kit can be identified by its model number. The
model number is on the shipping label and drive nameplate. The model number
includes the drive and any factory-installed options.
Table 1.1 – Reach Drive Model Numbers
Part Model Number
Reach Drive CNMD180W0ENNNC1
ControNet Comm
Adapter Fiber Kit
CNM-CNETGF-11
Pump Control
Adapter Kit
CNM-PCTRL-11
Dynamic Brake
Resistor Kit
CNM-R2-019P600

Installation/Wiring 2-1
CHAPTER 2
Installation/Wiring
This chapter provides information on mounting and wiring the Reach Drive.
Most start-up difficulties are the result of incorrect wiring. Every precaution must be
taken to assure that the wiring is done as instructed. All items must be read and
understood before the actual installation begins
2.1 AC Supply Source Considerations
Reach Drives are suitable for use on a circuit capable of delivering up to a maximum
of 200,000 rms symmetrical amperes and a maximum of 600 volts.
If a system ground fault monitor (RCD) is to be used, only Type B (adjustable) devices
should be used to avoid nuisance tripping.
!
ATTENTION: The following information is merely a guide for proper
installation. Rockwell Automation cannot assume responsibility for the
compliance or the noncompliance to any code, national, local or
otherwise for the proper installation of this drive or associated equipment.
A hazard of personal injury and/or equipment damage exists if codes are
ignored during installation.
!
ATTENTION: To guard against personal injury and/or equipment
damage caused by improper fusing or circuit breaker selection, use only
the recommended line fuses/circuit breakers specified in Appendix A.

2-2 DBT Reach Drive User Manual
2.1.1 Unbalanced or Ungrounded Distribution Systems
2.1.2 Input Power Conditioning
Certain events on the power system supplying a drive can cause component damage
or shortened product life. The following events can cause such damage.
•The power system has power factor correction capacitors switched in and out of
the system, either by the user or by the power company.
•The power source has intermittent voltage spikes in excess of 6000 volts. These
spikes could be caused by other equipment on the line or by events such as
lightning strikes.
!
ATTENTION: Power distribution to Reach Drives is intended to be from
the ungrounded secondary of the system’s step down transformer.
Protective MOVs, the EMI Snubber Board, and common mode capacitors
(3 places) in the drive have been disconnected. They should typically be
reconnected in any application where the power distribution at the drive
is grounded. Refer to Figure 2.1
Figure 2.1 – Protective Circuit Connections for Grounded Drive Systems
SEE CONNECTION
DETAILS
CUT TY-WRAP
PULL INSULATED LEADS FREE
REMOVE INSULATED COVER
SEPARATE LEADS
REMOVE SCREW
FASTEN LUGS WITH SCREW TO FLANGE
TIGHTEN SCREW TO 28 in-lbs
TUCK LEADS BACK INTO UNIT
STEP 1
STEP 2

Installation/Wiring 2-3
•The power source has frequent interruptions.
If these conditions exist, it is recommended that the user install a minimum amount of
impedance between the drive and the source. This impedance could come from the
supply transformer itself, the cable between the transformer and drive or an additional
transformer or reactor.
2.2 General Grounding Requirements
The drive Safety Ground - PE must be connected to system ground. Ground
impedance must conform to the requirements of national and local industrial safety
regulations and/or electrical codes. The integrity of all ground connections should be
periodically checked.
For installations within a cabinet, a single safety ground point or ground bus bar
connected directly to building steel should be used. All circuits including the AC input
ground conductor should be grounded independently and directly to this point/bar.
Refer to Figure 2.2 and Table 2.1.
Figure 2.2 – Recommended Ground Locations
GROUNDPOINT
GROUNDPOINT
GROUNDPOINT

2-4 DBT Reach Drive User Manual
2.2.1 Safety Ground - PE
This is the safety ground for the drive that is required by code. This point must be
connected to adjacent building steel (girder, joist), a floor ground rod or bus bar (see
above). Grounding points must comply with national and local industrial safety
regulations and/or electrical codes.
2.2.2 Shield Termination - SHLD
The Shield terminal provides a grounding point for the motor cable shield. The motor
cable shield should be connected to this terminal on the drive (drive end) and the
motor frame (motor end). A shield terminating cable gland may also be used.
When shielded cable is used for control and signal wiring, the shield should be
grounded at the source end only, not at the drive end.
Table 2.1 – Power Termination Locations Notes
Terminal Description Notes
BR1 DC Brake (+) DB Resistor Connection
BR2 DC Brake (-)
DC+ DC Bus (+)
DC- DC Bus (-)
PE PE Ground
Motor Ground
U U (T1) To motor
V V (T2) To motor
W W (T3) To motor
R R (L1) AC Line Input Power
S S (L2) AC Line Input Power
T T (L3) AC Line Input Power
PS+ AUX (+) Auxiliary Control Voltage
PS- AUX (-) Auxiliary Control Voltage

Installation/Wiring 2-5
2.2.3 RFI Filter Grounding
Using an optional RFI filter may result in relatively high ground leakage currents.
Therefore, the filter must only be used in installations with grounded AC supply
systems and be permanently installed and solidly grounded (bonded) to the
building power distribution ground. Ensure that the incoming supply neutral is solidly
connected (bonded) to the same building power distribution ground. Grounding must
not rely on flexible cables and should not include any form of plug or socket that would
permit inadvertent disconnection. Some local codes may require redundant ground
connections. The integrity of all connections should be periodically checked. Refer to
the instructions supplied with the filter.
2.3 Fuses and Circuit Breakers
The Reach Drive includes input fuses. National and local industrial safety regulations
and/or electrical codes may determine additional requirements for these installations.
Refer to Appendix A for recommended fuses/circuit breakers.
2.4 Power Wiring
2.4.1 Cable Types Acceptable for 200-600 Volt Installations
A variety of cable types are acceptable for drive installations. For many installations,
unshielded cable is adequate, provided it can be separated from sensitive circuits. As
an approximate guide, allow a spacing of 0.3 meters (1 foot) for every 10 meters (32.8
feet) of length. In all cases, long parallel runs must be avoided. Do not use cable with
an insulation thickness less than or equal to 15 mils (0.4mm/0.015 in.). Use Copper
wire only. Wire gauge requirements and recommendations are based on 75 degrees
C. Do not reduce wire gauge when using higher temperature wire.
Unshielded
THHN, THWN or similar wire is acceptable for drive installation in dry environments
provided adequate free air space and/or conduit fill rates limits are provided. Do not
use THHN or similarly coated wire in wet areas. Any wire chosen must have a
minimum insulation thickness of 15 Mils and should not have large variations in
insulation concentricity.
2.4.2 Motor Cable Lengths
Typically, motor lead lengths less than 91 meters (300 feet) are acceptable.
!
ATTENTION: The Reach Drive does not provide branch short circuit
protection. Specifications for the recommended fuse or circuit breaker to
provide protection against short circuits are provided in Appendix A.
!
ATTENTION: National Codes and standards (NEC, VDE, BSI etc.) and
local codes outline provisions for safely installing electrical equipment.
Installation must comply with specifications regarding wire types,
conductor sizes, branch circuit protection and disconnect devices. Failure
to do so may result in personal injury and/or equipment damage.

2-6 DBT Reach Drive User Manual
2.4.3 Power Termination Location Notes
Figure 2.3 – Power Termination Locations (DC+ and DC-)
(+) DC BUS
TEST POINT
(-) DC BUS
TEST POINT
Figure 2.4 – Power Termination Locations (BR1 and BR2)
BR1
BR2

Installation/Wiring 2-7
2.5 I/O Wiring
Important points to remember about I/O wiring:
•Use Copper wire only. Wire gauge requirements and recommendations are based
on 75 degrees C. Do not reduce wire gauge when using higher temperature wire.
•Wire with an insulation rating of 600V or greater is recommended.
•Control and signal wires should be separated from power wires by at least 0.3
meters (1 foot).
Important: I/O terminals labeled “(–)” or “Common” are not referenced to earth
ground and are designed to greatly reduce common mode interference.
Grounding these terminals can cause signal noise.
Figure 2.5 – Power Termination Locations (U, V, W, R, S, T)
T
S
R
!
ATTENTION: Configuring an analog input for 0-20mA operation and
driving it from a voltage source could cause component damage. Verify
proper configuration prior to applying input signals.
ATTENTION: Hazard of personal injury or equipment damage exists
when using bipolar input sources. Noise and drift in sensitive input circuits
can cause unpredictable changes in motor speed and direction. Use
speed command parameters to help reduce input source sensitivity.

2-8 DBT Reach Drive User Manual
2.5.1 I/O Terminal Designations
Table 2.2 – I/O Terminal Designations
No. Signal
Factory
Default Description
Rel.
Param.
1Analog In 1 (-)12
Isolated3, bipolar, differential
+/- 10V/4-20mA, 11 bit and
sign, 88k ohm input
impedance. For 4-20mA, a
jumper must be installed at
terminals 17 and 18 (or 19
and 20).
320-
327
2Analog In 1 (+)1
3Analog In 2 (-)1
4Analog In 2 (+)1
5 Port Common - For (+) and (-) 10V port
references.
6 Analog Out 1 (-) 2Bipolar (current output is not
bipolar), +/- 10V/4-20mA, 11
bit and sign, voltage mode -
limit current to 5 mA. Current
mode - maxz load resistance
is 400 ohms.
340-
347
7 Analog Out 1 (+)
8 Analog Out 2 (-)
9 Analog Out 2 (+)
10 HW PTC Input 1 - 1.8k ohm PTC, Internal 3.32k
ohm pull-up resistor
238
259
11 Digital Out 1 - N.C.4Fault Max. Resistive Load:
240V AC/30V DC -- 1200VA,
150W
Max. Current: 5A, Min. Load
10mA
Max. Inductive Load:
240V AC/30V DC - 840VA,
105W
Max. Current: 3.5A, Min.
Load: 10mA
380-
391
12 Digital Out 1 Common
13 Digital Out 1 - N.O.4NOT
Fault
14 Digital Out 2 - N.C.4NOT
Run
15 Digital Out 2/3 Com
16 Digital Out 3 - N.O.4Run
1
16 32

Installation/Wiring 2-9
17 Current In Jumper1 - Analog
In 1
Placing a jumper across
terminals 17 and 18 (or 19
and 20) will configure that
analog input for current.
(Parameter 320 must be set
ON.)
18
19 Current In Jumper1–
Analog In 2
20
21 –10V Pot Reference – 2k ohm minimum load.
22 +10V Pot Reference –
23 HW PTC Input 1 – See above
24 +24VDC5– Drive supplied logic input
power. 5
25 Digital In Common –
26 24V Common(5) – Common for internal power
supply.
27 Digital In 1 Stop -
CF
115V AC, 50/60 Hz - Opto
isolated
Low State: less than 30V AC
High State: greater than 100V
AC
24V DC - Opto isolated
Low State: less than 5V DC
High State: greater than 20V
DC
11.2 mA DC
361-
366
28 Digital In 2 Start
29 Digital In 3 Auto/M
an.
30 Digital In 4 Speed
Sel 1
31 Digital In 5 Speed
Sel 2
32 Digital In 6/Hardware Enable Speed
Sel 3
1.Important: 4-20mA operation requires a jumper at terminals 17 and 18 (or 19 and 20). Drive damage may
occur if jumper is not installed.
2.These inputs/outputs are dependant on a number of parameters (see “Rel. Param.).
3.Differential Isolation - External source must be maintained at less than 160V with respect to PE. Input
provides high common mode immunity.
4.Contacts in unpowered state. Any relay programmed as Fault or Alarm will energize (pick up) when power
is applied to drive and deengergize (drop out) when a fault or alarm exists. Relays selected for other
functions will energize only when that condition exists and will deenergize when condition is removed.
5.150mA maximum load. Not present on 115V versions.
Table 2.2 – I/O Terminal Designations
No. Signal
Factory
Default Description
Rel.
Param.

2-10 DBT Reach Drive User Manual
Figure 2.6 – I/O Plug
32 POSITION I/O PLUG
REMOVE FROM CONTROL PCB
TERMINATE WIRE HARNESS TO PLUG
THEN MATE PLUG TO HEADER AND
FASTEN SCREWS TO 7 in-lbs
SCREW ON PLUG
NUT ON PCB HEADER

Installation/Wiring 2-11
2.5.2 Encoder Terminal Block
Table 2.3 – Encoder Terminal Designations
No. Description
8+12V1DC Power
1. Jumper selectable +5/12V is available on 20B-ENC-2 Encoder Boards only.
Internal power
source
250 mA.
7 +12V<Footnote>(1) DC
Return (Common)
6 Encoder Z (NOT) Pulse, marker or
registration
input.2
2. Z channel can be used as a pulse input while A & B are used for encoder.
5 Encoder Z
4 Encoder B (NOT) Quadrature B
input.
3 Encoder B
2 Encoder A (NOT) Single channel
or quadrature A
input.
1 Encoder A
Table 2.4 – Sample Encoder Wiring
I/O Connection Example I/O Connection Example
Encoder
Power
–1Internal
Drive Power
Internal
(drive) 12V
DC, 250mA
1.SHLD connection is on drive chassis.
Encoder
Power
–External
Power
Source
Encoder
Signal
–Single-
Ended, Dual
Channel
Encoder
Signal
–Differential,
Dual Channel
8
1
Common
+12V DC
(250 mA)
1
2
3
4
5
6
7
8
to SHLD
+
Common
External
Power
Supply
to
SHLD
B
B NOT
A NOT
A
Z
Z NOT to SHLD
to Power Supply
Common
1
2
3
4
5
6
7
8
to SHLD
1
2
3
4
5
6
7
8
B
Z
A NOT
B NOT
Z NOT
A

2-12 DBT Reach Drive User Manual
2.5.3 Signal and Control Wire Types
Table 2.5 – Recommended Signal Wire
Signal Type/
Where Used
B e l d e n W i r e T y p e ( s )
(or equivalent) Description
Minimum
Insulation
Rating
Analog I/O
and PTC
8760/9460 0.750 mm2(18AWG),
twisted pair, 100% shield
with drain1.
1. If the wires are short and contained within a cabinet which has no sensitive circuits, the use of shielded
wire may not be necessary, but is always recommended.
300V,
75-90
degrees C
(167-194
degrees F)
8770 0.750 mm2(18AWG), 3
cond., shielded for remote
pot only.
Encoder/
Pulse I/O
<30 m (100
ft.)
Combined: 97302
2. 9730 is 3 individually shielded pairs (2 channel + power). If 3 channel is required, use 9728.
0.196 mm2(24AWG),
individually shielded.
Encoder/
Pulse I/O
30 to 152 m
(100 to 500
ft.)
Signal: 9730/972820.196 mm2(24AWG),
individually shielded.
Power: 87903
3. 8790 is 1 shielded pair.
0.750 mm2(18 AWG)
Combined: 98924
4. 9892 is 3 individually shielded pairs (3 channel), 0.332 (22 AWG) + 1 shielded pair 0.5 mm2 (20 AWG)
for power.
0.330 mm2or 0.500 mm2
4
Encoder/
Pulse I/O
152 to 259 m
(500 to 850
ft.)
Signal: 9730/972820.196 mm2(24AWG),
individually shielded.
Power: 879030.750 mm2(18 AWG)
Combined: 9773/97745
5. 9773 is 3 individually shielded pairs (2 channel + power). If channel 3 is required, use 9774.
0.750 mm2(18 AWG) or
0.500 mm2, individually
shielded pair

Installation/Wiring 2-13
Table 2.6 – Recommended Control Wire for Digital I/O
Type Wire Type(s) Description
Minimum Insulation
Rating
Unshielded Per US NEC or applicable
national or local code
– 300V,
60 degrees C
(140 degrees F)
Shielded Multi-conductor shielded
cable such as Belden
8770(or equiv.)
0.750
mm2(18AWG), 3
conductor,
shielded.

2-14 DBT Reach Drive User Manual
2.5.4 The I/O Control Board
Figure 2.2 shows the I/O control board and terminal block locations. The control board
provides a mounting point for the various Reach Drive I/O options. To remove the
cassette, loosen the two screw latches as shown in Figure 2.7. (A).
2.5.5 I/O Terminal Blocks
!
ATTENTION: You must stay within the minimum and maximum wire size
range. Failure to observe this precaution can result in severe equipment
damage, bodily injury, or loss of life.
Table 2.7 – I/O Terminal Block Specifications
No. Name Description Wire Size Range4 Torque
Maximum Minimum Maximum Recommended
1I/O
Terminal
Block
Signal &
control
connections
2.1 mm2
(14 AWG)
0.30
mm2
(22
AWG)
0.6 N-m
(5.2 lb.-in.)
0.6 N-m
(5.2 lb.-in.)
2Encoder
Terminal
Block
Encoder
power &
signal
connections
0.75 mm2
(18 AWG)
0.196
mm2
(24
AWG)
0.6 N-m
(5.2 lb.-in.)
0.6 N-m
(5.2 lb.-in.)
Figure 2.7 – Reach Drive Typical Control Board and I/O Terminal Blocks
PIN 1
PIN 1
1
2
A
JUMPER
4. Maximum/minimum sizes that the terminal block will accept - these are not recommendations.
4