Patents: US 6 628 100; SE 9902821-9
SE 0100814-3; SE 0100814-3; EP 1 366 346; US 7 083 544
Registered design: US 462 937; DE 400 05 393.4; SE 66 630
Patent pending for UltraRotoSenseTM: EP17171733.3
Safety instructions
Instruction manual
Read this instruction manual before installing and running the drive system.
The following symbols can appear in this manual. Always read these first before
continuing:
NOTE: Additional information as an aid to avoid problems.
CAUTION! Failure to follow these instructions can result in malfunction
or damage to the drive system.
!
WARNING! Failure to follow these instructions can result in serious
injury to the user in addition to serious damage to the drive system.
Users
This instruction manual is intended for:
•installation engineers
•maintenance engineers
•operators
•service engineers
Handling the drive system
Installation, commissioning, demounting, taking
measurements, etc, of or on the drive system may only be carried out by
personnel technically qualified for the task. The installation must be carried out
in accordance with local standards.
CG Drives & Automation 01-6048-01r31
Opening the control unit
WARNING! Always switch off the mains voltage before opening
the control unit.
Wait at least 5 minutes before starting work.
Always take adequate precautions before opening the control unit. Although the
connections for the control signals and the switches are isolated from the mains
voltage, do not touch the control board when the drive system is switched on.
Precautions to be taken with a connected motor
If work must be carried out on a connected motor or on the driven machine,
the mains voltage must always be disconnected from the drive system first.
Earthing
The control unit must always be earthed via the mains safety earth connection.
EMC Regulations
In order to comply with the EMC Directive, it is absolutely necessary to follow
the installation instructions. All installation descriptions in this manual follow
the EMC Directive.
Voltage tests (Megger)
Do not carry out voltage tests (Megger) on the motor, before all the motor
cables have been disconnected from the drive system.
Condensation
If the control unit is moved from a cold (storage) room to a room where it will
be installed, condensation can occur. This can result in sensitive components
becoming damp. Do not connect the mains voltage until all visible dampness
has evaporated.
Incorrect connection
The control unit is not protected against incorrect connection of the mains
voltage, and in particular against connection of the mains voltage to the motor
outlets R, Y and B. The control unit can be damaged in this way.
2CG Drives & Automation 01-6048-01r3
Transport
To avoid damage, keep the drive system in its original packaging during
transport. This packaging is specially designed to absorb shocks during
transport.
Emotron EMX-B is a speed controlled drive system specially designed for
driving rotary heat exchangers. The drive system consists of a motor and its
associated control unit with a wide speed range from 4 to 500 rpm.
Emotron EMX-B motor is based on permanent magnet brush-less DC (PM
BLDC) motor technology. These motors make it possible to drive heat
exchanger rotors without gears, making the system very silent.
The system can be controlled either via terminals/analogue and digital inputs or
via RS485/Modbus RTU communication protocol.
Emotron EMX-B drive system completely replaces Emotron EMX-R drive
systems.
Fig. 1EMX-B motor and control unit mounted on rotary heat exchanger
CG Drives & Automation 01-6048-01r3Description7
1.2Delivery and unpacking
Check for any visible signs of damage. Inform your supplier immediately of any
damage found. Do not install the equipment if damaged.
The shipment of a complete drive system consists of two boxes containing:
Box 1:
•Emotron EMX-B Control unit
•One Ferrite core
Box 2:
Emotron EMX-B motor with connected cables
1.3Warranty
The warranty applies when the equipment is installed, operated and maintained
according to instructions in this instruction manual.
8DescriptionCG Drives & Automation 01-6048-01r3
1.4General description
Emotron EMX-B is a silent speed-controlled drive system specially designed for
driving rotary heat-exchangers. Emotron EMX-B is available in different sizes
suitable for different sizes of rotors. The system supports a wide speed range
from 4 up to 500 rpm. The drive system consists of a motor and its associated
control unit which are linked by two cables. The control unit is connected to
single-phase power supply, 230 VAC, 50/60 Hz.
•Rotation monitor - integrated UltraRotoSenseTM or with external rotation
sensor
•Active holding torque
•Alarm relay
•Defrosting
•Cooling recovery
•Full speed Test switch
•Short circuit/earth fault protection
•Under voltage, over voltage and over current/overload protection
•Sixteen (16) speed selections through DIP switches
•Direction of rotation through DIP switch
•Soft start/soft stop
•Non-linearity function that gives a non-linear relationship between the control signal and the efficiency
•RS485 interface with industrial Modbus RTU communication protocol
CG Drives & Automation 01-6048-01r3Description9
1.5Operating indicators
LED window
Fig. 2Control unit with LED´s for operation indication
Three LEDs, one red, one green and one yellow, are used for indication
purpose, which are as follows:
Table 1Operating indication
*)Exception Belt test, see page 44
All possible combinations of LED indication is described in detail in Table 13,
page 43.
10DescriptionCG Drives & Automation 01-6048-01r3
Green *
Red *
Yellow
Slow flashing (1 time/s) – Purging mode/Low control signal
Rapid flashing (10 times/s) – Operation, the motor rotates
continuously.
Lit 1 second - External rotosense magnet passes sensor
Constantly Lit or flashing LED indicates alarm, see also in
chapter
Flashing – Modbus incoming message addressed to unit active
and CRC correct.
Constantly Lit - Modbus timeout
“Troubleshooting” on page 41.
1.5.1Dismantling and scrapping
The enclosures of the drives are made from recyclable material. Each drive
contains a number of components demanding special treatment, for example
capacitors. The circuit boards contain small amounts of tin and lead. Any local
or national regulations in force for the disposal and recycling of these materials
must be complied with.
Disposal of old electrical and electronic equipment
The product is designed to comply with the RoHS and REACH directives, and
shall be handled and recycled in accordance with local legislations.
This symbol on the product or on its packaging indicates that this
product shall be taken to the applicable collection point for the
recycling of electrical and electronic equipment. By ensuring this
product is disposed of correctly, you will help prevent potentially
negative consequences for the environment and human health,
which could otherwise be caused by inappropriate waste handling
of this product. The recycling of materials will help to conserve natural
resources. For more detailed information about recycling this product, please
contact the local distributor of the product or visit our home page
www.cgglobal.com/www.emotron.com.
CG Drives & Automation 01-6048-01r3Description11
12DescriptionCG Drives & Automation 01-6048-01r3
2.Mounting and installation
Heat exchanger rotor
Control unit
Motor
2.1Basic mounting
Both the motor and the control unit are usually mounted in the heat exchanger
housing. In this way, they do not occupy any space outside of the heat
exchanger housing and are well protected during transport. Furthermore, it is
often advantageous from the point of view of interference (EMC) to place the
motor and control unit in the rotor housing.
Larger motors are usually mounted on a sprung motor support when a V-belt is
used. In this way, problems arising if non-circular rotors are used can be
prevented.
Vibration dampers should be mounted between the motor and the motor
support so that any vibration from the motor is not transmitted to the rotor
housing.
Fig. 3Emotron motor and Control unit for rotary heat exchangers
CG Drives & Automation 01-6048-01r3Mounting and installation13
2.2External sensor for rotation monitor
Rotation sensor
Magnet
5-8 mm
Heat exchanger rotor
(optional)
Fig. 4Rotation monitor
Two different rotation monitors can be selected. The first, which is an
integrated UltraRotoSense
TM
rotation monitor, and secondly a rotation
monitor using an external rotation sensor (optional) see also further info in
chapter 3.3 page 24.
The magnet for the external rotation monitor is mounted tight on the periphery
or in the body of the heat-exchanger. It is recommended to place the sensor
magnet close to the axis of the rotary heat exchanger. If the housing around the
rotor is magnetic itself then the sensor magnet must be isolated from the
housing. The rotation sensor is mounted to ensure that the magnet passes over
it at a distance of 5-8 mm, see
Fig. 4.
14 Mounting and installationCG Drives & Automation 01-6048-01r3
2.3Cable connections
2.3.1Motor
The motor is delivered with fixed connected motor cables to simplify
installation of the drive system. The length of the cables is 2.5m.
In order to secure the function of the drive system, do not change the length of
the motor cables.
WARNING! Do not install a switch between the motor and the
control unit.
2.3.2Mains supply
An external slow-blow fuse rated at <6 A must always be installed on mains
supply. The drive system does not contain a fuse. Electronic motor protection is
built into the control unit, and monitors the motor at all times. The control
unit is protected from short circuit within the motor.
Connect the mains cables according to Fig. 7 and Table 4.
2.3.3Communication connections
For communication signals, the used RS485 cable type should preferably be
screened and of twisted pair type to avoid EMI. The cable should be placed at
least 20 cm away from any power cables. Drop cables shall be avoided to the
extent possible. It is recommended to connect the screen of the cable to chassis/
mounting plate near to the EMX-B gland.
CG Drives & Automation 01-6048-01r3Mounting and installation15
2.4Control board
1
2
3
4
9
8
7
6
5
10
Fig. 5 and Fig. 6 shows the layout of the control board and where the parts most
important to the user are located.
For safety reasons do not make changes while the mains supply is on, see also
“Safety instructions” on page 1.
Fig. 5Control board layout EMX-B15.
Table 2Location of terminals and components EMX-B15.
No.Designation
1Three LED operation indicators
2DIP switches
3Test switch
4Jumper SW2 to select signal type, voltage or current (K/I)
5Control signal terminals and RS485 interface (31-40)
6Alarm terminals (41-43)
7Hall sensor terminals (1-5)
8Motor terminals (-R-Y-B)
9Mains supply terminals (L-N-)
10PE connector
16 Mounting and installationCG Drives & Automation 01-6048-01r3
Fig. 6Control board layout EMX-B25/B35.
EMX -B25/B35
1
2
3
4
9
8
7
6
5
Table 3Location of terminals and components, EMX-B25/B35.
No.Designation
1Three LED operation indicators
2Test switch
3DIP switches
4Jumper X3 to select signal type, voltage or current (K/I)
5Control signal terminals and RS485 interface (31-40)
6Alarm terminals (41-43)
7Hall sensor terminals (1-5)
8Motor terminals (-R-Y-B)
9Mains supply terminals (L-N-)
NOTE! Minimum recommended conductor size area for the connection
terminal is 0.5 mm2.This is to achieve proper electrical contact.
CG Drives & Automation 01-6048-01r3Mounting and installation17
2.4.1Terminals
0 V
Mains
Motor
Hallsensors
Alarm
relay
Modbus
Ext.
CR
DF
monitor
Motor
rotation
+12 VDC
potentiometer
only
Fig. 7Terminals on control board.
Table 4Terminals and connections description.
Control boardExternal
Mains
supply
Te rm in al
Name/no
LLine
NNeutral
Connection
Earth
Earth
Remark
Mount the Ferrite
(included in delivery) on
the mains cable acc. to
Fig. 8, page 20
Motor
Hallsensor
Alarm
RR
YY
BB
11
22
33
44
55
41NC
42Common
43NO
Motor power
connections
Motor sensor connection
42 - 43 closed on alarm
Reset alarm possible by
shorten terminals 33, 34
and 35
18 Mounting and installationCG Drives & Automation 01-6048-01r3
Table 4Terminals and connections description.
Control boardExternal
Te rm in al
Name/no
35One end of pot.
Control
signals
External
rotation
monitor
DFDefrosting
CR-Cooling
recovery
RS485/
Modbus
37Other end of pot.
350 V
36+ signal
31RM -
32RM +
33, 35
34, 35
38A +
39B -
400 V
NOTE: It is wire marking, not colour marking, that is valid.
Connection
Variable point of
pot.
Remark
If potentiometer is used36
When external control
signal is used
Ext. rotation sensor
(optional)
Activate by shorting 33
and 35
Activate by shorting 34
and 35
2.4.2Mains supply voltage cables
Dimension the mains cables according to local regulations. The cable must be
able to carry the load current.
CG Drives & Automation 01-6048-01r3Mounting and installation19
2.4.2.1 Ferrite core
The ferrite core is used to reduce disturbances and to fulfill the EMC standards.
Mount the ferrite core (included in delivery) on the mains supply cable for
EMX-B15 (L, N and PE) and on the motor cable for EMX-B25/35 close to the
Control unit according to
Fig. 8Mount the Ferrite on the Mains supply cable.
Fig. 8.
20 Mounting and installationCG Drives & Automation 01-6048-01r3
2.4.3Recommendations with respect to EMC
Wrong
Correct
In order to fulfil the European EMC Directive regarding electromagnetic
compatibility, the following precautions must be taken:
The motor cable must be mounted as close to the heat exchanger housing as
possible. If the cable is too long, the excess should be collected together in the
form of, for example, a figure “8”. The area enclosed by the cable should be as
small as possible. Electrical tape or cable ties can be used to achieve this.
Fig. 9Excess motor cable should be arranged such that the area enclosed is as
Special EMC couplings/glands are not necessary. An EMC filter is built into the
EMX-B control unit.
For communication signals, the used RS485 cable type should preferably be
screened and of twisted pair type to avoid EMI. The cable should be placed at
least 20 cm away from any power cables. Drop cables shall be avoided the extent
possible.
It is recommended to connect the screen of the cable to chassis/mounting plate
near to the EMX-B gland.
small as possible
CG Drives & Automation 01-6048-01r3Mounting and installation21
2.5Select type of control signal
Voltage
Current
V
I
V
I
(default)
Voltage
Current
V
I
V
I
(default)
SW2
X3
(EMX-B15)
(EMX-B25/35)
Fig. 10 Jumper connection
When SW2/X3 on the controller board is in V position then the control signal
type is ‘voltage’ and when SW2/X3 is in I position the control signal type is
“current”. As default it is set to voltage.
22 Mounting and installationCG Drives & Automation 01-6048-01r3
3.Built-in functions
3.1Holding torque
Most of the time the heat exchanger rotor seals keep the rotor stationary, but if
the rotor seals are not touching the rotor and the air flow is not perpendicular to
the rotor, the air flow may cause the rotor to rotate. To prevent unintentional
heat recovery in this situation the motor is automatically used to provide a
holding torque to keep the rotor stationary.
A rotor that does require a holding torque will try to turn slowly. The drive
system immediately brakes this motion, reducing the speed to zero, and then
applies a constant holding torque to keep the rotor stationary. The holding
torque is at least 50% higher than the torque required for operation just before
stand still.
If a holding torque has been applied and you grasp the drive belt and try to turn
the heat exchanger rotor by hand, the torque will progressively increase.
The holding torque is generated by passing current through the motor phases.
The higher the torque that is required, the higher the current. This holding
current may create a sound which is perfectly normal.
3.2Automatic purging
When the control signal is low, <0.5-0.6 VDC at 0–10 VDC (or <2.5 VDC at
2 - 10VDC depending on DIP7), the drive system switches to purging mode.
This slow rotation does not provide any significant heat transfer, but simply
serves to keep the heat exchanger rotor clean. There are two purging modes as
described below.
3.2.1Normal purging mode
In normal purging mode, when the dip-switch DIP8 is disabled (Off) the
motor shaft turns two revolutions every 5 minutes.
3.2.2Continuous purging mode
This purging mode is activated by dip-switch DIP 8 in the controller. When
this dip-switch is activated the normal purge mode is not valid anymore. Instead
the system will run at the lowest possible speed all the time (4 rpm or
equivalent) when the control signal is below 0.5-0.6 V
Two different kinds of rotation monitors can be selected. These are used to
secure that the belt is not damaged and in other case notify the user via Rotation
alarm.
The first, UltraRotoSense™ (patent pending) is a unique, ultra-sensitive method
for detecting light load variations w/o even affecting the set operating speed of
the motor using only smart built in software algorithm in the micro controller
(no external equipment needed).
The second method, external rotation monitoring is using a more traditional
solution with external sensor and magnet mounted on the heat exchanger. This
is an alternative to UltraRotoSense™ and may be used when applicable for e.g.
the very most light weight / smallest rotors.
The rotation monitors give alarms through operating indications (LED) and via
the alarm relay (external signal) See
with this alarm.
Table 1, page 10. The motor does not stop
3.3.1Internal UltraRotoSense
Activated by setting DIP6 to Off.
DIP switch 6 (see chapter 3.9.2 page 30) in position “OFF” (downwards),
means that the built in UltraRotoSense™ algorithm is enabled.
This method is using the motor as a sensor which means that no external
hardware is necessary for belt detection. Further, it is designed to measure load
variations even without changing the operating speed which allows continuous
belt supervision (~every other minute). This allows a very fast alarm response in
case of broken belt which may be critical for the system operating in cold
outdoor temperatures.
maintained during the belt test it will not affect the heat recovery process/room
temperature.
UltraRotoSense™ belt testing is automatically activated every other minute in all
operating states with the exception of intermittent purge mode but only if the
motor current is below a value considered as a possible no-load condition.
The controller indicates that this sequence is initiated by setting both green and
red led on at the same time. During this test the current set point speed is
maintained. The test is ongoing only for as long as necessary to detect the
presence of a load (belt intact) but for a maximum of 40 seconds. The controller
then goes directly back to normal operation.
In the case where UltraRotoSense™ cannot detect a load it performs a very short
ramp as a second stage check before activating rotation alarm. During this ramp
it senses the complete motor load coming e.g. from inertia of the rotor as well as
mechanical and brush friction, air flow though rotor etc. When/If a second
stage ramp up check is performed the controller will wait for 5 minutes before
activating the next belt test. The first belt test will be performed 1 minute after
power up if the motor current is below the considered no-load level.
NOTE: In order to use internal UltraRotoSenseTM the load on the motor
should not be too low with the smallest heat exchangers.
If the load is too low for detection, use external rotation monitor instead.
3.3.2External rotation monitor
Activated by setting DIP6 to On.
DIP switch 6 in position “ON” (upwards), means rotation monitor uses an
external rotation sensor.
The rotation monitor with external rotation sensor requires a magnet fitted on
the periphery of the rotor or anywhere on the rotor body. The magnet activates
the external rotation sensor once every revolution. Should, for example, a belt
break and the rotor stops, the pulses cease and an alarm is given. The time until
the alarm is given is speed dependent and is 16 seconds at max. speed and 20
minutes at min. speed.
It is recommended to place the sensor magnet close to the rotor axis for accurate
results.
The amplitude of output pulse from the external rotation sensor should have a
value of 8V to 12V.
3.3.2.1 LED indications
When the magnet passes the sensor, this is indicated with Green LED is Lit 1
second and Red LED is Off.
The control unit is monitored for both over-voltage and under voltage. If the
supply voltage goes over or under the allowed limits, an alarm is triggered and
the motor stops. The motor starts again automatically when the supply voltage
returns to its normal value. The alarm is automatically reset.
The control unit has built-in motor protection that protects against overloading
and external motor protection shall not be used. Power supply to the motor is
cut in the event of overload. In order to reset the alarm, when Modbus is not
used, the supply voltage to the control unit must be temporarily disconnected
for at least 30 seconds to let stored voltage discharge. Reset is also possible by
shorten the terminals see
Table 4, page 18.
Built-in short circuit protection protects against short circuits between the
phases of the motor and between the phases and earth. If this fault is
continuously detected can it only be reset by power cycling.
Table 5Protection and alarm functions
Protective
function
Supply fault,
overvoltage
Supply fault,
undervoltage
Motor
protection/
overload
Short circuit/
earth fault
Internal Rotation
monitor
External rotation
monitor
External alarm
with alarm relay
Yes, immediatelyAutomaticAutomatic
Yes, immediately
Yes, immediatelyMotor not stopped
Yes, immediatelyMotor not stopped
RestartAlarm reset
Manual reset, disconnect and reconnect
power supply.*
Manual reset, disconnect and reconnect
power supply.*
Manual reset,
disconnect and
reconnect power
supply.*
Manual reset,
disconnect and
reconnect power
supply.*
*) Possible to reset via Modbus or shorten the terminals 33, 34 and 35 when
Modbus is Off.
Short terminal 33 and terminal 35 to activate defrosting mode. During this
mode the speed on the motor will be 4 rpm. In this case the incoming control
speed is ignored and instead 4 rpm is prioritized.
3.6Manual control using a 10 kOhm
potentiometer
It is easy to control the drive system manually by using a 10 kOhm
potentiometer connected as shown in the figure below.
Fig. 11 Manual control using potentiometer
3.7Test Switch
The control unit is equipped with a test switch, placed on the control board see
Fig. 5, page 16 and Fig. 6, page 17. When this switch is in the “ON” position
(up), the motor soft starts and the speed increases to the maximum,
independently of other signal sources. When in the “OFF” position (down), the
control unit goes back to normal operation.
The test switch can also be used to run the motor at maximum speed if, for
example, an external control signal is missing.
3.8Cooling recovery
By shorting terminal 34 and terminal 35, the system will go into cooling
recovery. This means that the system will run at maximum speed.
DIP switch 1 - 4 are used to set different maximum speeds. When all dipswitches are off the maximum speed will be 100% of the maximum speed of the
drive (500 rpm). When all 4 dips-witches are on (1111) the maximum speed
will be 25% of the possible maximum speed.
NOTE: After changing dip settings the control unit must be power
cycled before the new settings become active.
The other combinations divides the speed range from 25 to 100% into equal
pieces see
rotors smaller in diameters, when it is desired to limit the speed of rotation and/
or when using larger belt pulleys.
Table 6, page 29. This function is primarily intended for use with
Disconnect the voltage supply before changing the DIP switch setting.
The drive unit has built-in Modbus RTU communication via RS485,
terminals 38 (A+), 39 (B-) and 40 (0 V).
Modbus communication is enabled by setting the Dip switch 10 to On.
There are two sets of baud-rate available, selected by Dip switch 9, which are as
follows:
Ta b le 8Tw o se ts o f b a ud -ra te
Dip 9 = OnDip 9 = Off (default)
Address: 30
Baud rate/Speed: 9600
Parity bit: N, none
Stop bit: 1
Data bits: 8
When DIP switch 9 is ‘ON’ then the default parameters are 9600, 8, N, 1 .
When DIP switch 9 is ‘OFF’ then the default parameters are 19200, 8, N, 1.
None of these settings are changeable via Modbus.
Address: 30
Baud rate/Speed: 19200
Parity bit: N, none
Stop bit: 1
Data bits: 8
* V = Volatile memory, NV =Non volatile memory
**) Decoded as “TT.XXXXXXX.YYYYYYY” (16 bits coding)
where TT is type, 0= release, 1=prerelease, 2= beta, 3= alpha
XXXXXXX is main version number
YYYYYYY is minor version number
The drive system has a built-in configurable function that gives a non-linear and
in second case a linear relation between the control signal and the efficiency of
the heat exchanger rather than having the speed of rotation proportional to the
control signal. This provides good conditions for stable temperature control.
NOTE: A small hysteresis window is used to avoid setting the controller to
jump between state Purge and state Normal operation (avoiding state
jumping).
•the equipment has been correctly installed, i.e. the cables are properly
stripped, that there are no loose cables, etc.
•motor and control unit of corresponding type size.
•check that the DIP switches are correctly set before powering the unit on.
Power cables should not be clamped together with e.g. RS485 or analogue
cables to avoid EMI.
It is always possible to test run the drive system using the TEST switch located
on the control board, see
two fixed positions, when it is in the up position, the motor accelerates to its
maximum speed independent of the control signal but dependent on DIP 1-4,
and when it is in the down position the rotation speed is set by the control
signal.
If any of the following is observed, then diagnosis should be performed to
rectify the fault.
•Motor does not reach the intended speed.
•Motor has noisy operation at reduced speed.
•High motor speed and noisy operation.
•Motor does not start to rotate.
•Control unit trips with LEDs indicating overload condition immediately
after power up without heat exchanger wheel connected.
•Control unit trips with LEDs indicating short circuit condition immediately
after power up when no heat exchanger wheel connected.
Fig. 5, page 16 and Fig. 6, page 17. The switch has
Diagnosis:
1. Check the cable connections.
2. If the connections are proper, then replace the motor alone and check for
the performance.
3. If performance is not as intended, replace the control unit.
4. Perform a motor diagnosis if the performance is not as intended after
1. Disconnect power supply to the EMX-B unit and remove all the
connections.
2. Measure the resistance of the motor using a digital multi-meter. Values
should match as provided in
Chapter 5.1 page 46. Any deviations found
indicates damage to the motor.
3. Also check the connectivity between each motor phase and the PE cable.
There should ideally be no connectivity.
If the motor does not reach maximum speed or respond to the control signal,
check DIP switches. If the heat exchanger rotates in the wrong direction, change
the setting of DIP switch 5.
If the control unit is to be exchanged, the complete unit including circuit boards
must be exchanged.
WARNING!
Residual voltage remains for up to 5 minutes after
disconnection of the supply voltage. The test switch and the DIP
switches may only be adjusted when the supply voltage has
been disconnected.
NOTE: After changing dip settings the control unit must be power
cycled before the new settings become active.
Table 13Trip condition, their possible causes and remedial action
Alarm
indication
LED indication
Flash slowly =
about 1 time/s
Flash rapidly=
about 10 times/s
Green LED
flashes slowly
Red LED is lit
Possible
cause
Purging / low
control signal.
Overload/
motor
protection
Remedy
- If the motor is not running and Green LED
flashes slowly, check the drive system with
the test switch.
The motor should accelerate to its maximum
speed. If the motor does accelerate to the
maximum speed when the test switch is
activated, the fault is external.
- Is the control signal between terminals 36(+)
and 35 (-) present?
- Have + and - been swapped?
- The motor protection has been activated due
to excessive load. Check that the motor
cables are connected correctly; see the
chapter on Mounting/Connection.
- Check also that the rotor runs freely and that
the diameters of the rotor and pulley are
correct. If wrong pulley is mounted, change
pulley or change max. speed with DIP-switch
1 to 4 acc. to chapter 3.9.2 page 30.
- If the fault remains, carry out motor diagnosis.
Replace the motor if it is faulty. If the fault
does not lie within the motor, replace the
control unit.
Red and green
LED flashes
slowly and
Over voltage
Under voltage
The supply voltage exceeds 260V
The supply voltage lies below 180V
Table 13Trip condition, their possible causes and remedial action
Alarm
indication
LED indication
Flash slowly =
about 1 time/s
Flash rapidly=
about 10 times/s
Red and green
LED flashes
rapidly and
alternately
Red LED
flashes rapidly
and Green LED
is off
Red LED
flashes
rapidly and
Green
LED is lit
Green LED is lit
and Red LED is
off
Possible
cause
Earth fault in
the motor/
Short circuit in
the motor
Internal
Rotation
monitor
External
Rotation
monitor
Test to check
broken belt in
progress
Remedy
- Disconnect the supply voltage, check the
connection of the motor cable and check that
the correct motor is connected. If the fault
remains, carry out motor diagnosis.
- If the motor is faulty, replace it. If the fault
does not lie within the motor, replace the
control unit.
- The exchanger rotor does not rotate; check
the drive belt.
- If Internal rotation monitor is used, check that
the rotor or belt pulleys are not very small.
External rotation sensor error;
- Check whether the external rotation sensor is
working and providing proper pulses.
- Check function of the rotation sensor:
Measure with a Multimeter between terminal
31 and 32, correct sensor measures:
NO sensor shows > 8 V
NC sensor shows < 1 V
& < 12VDC
DC
DC
when the magnet passes the sensor.
- Check whether the connection of external
rotation sensor is made properly.
- When DIP 6 is in external rotation sensor
position (UP) and if no connection is provided
at terminals 31 and 32 then this alarm is
triggered.
This not any alarm condition. It only indicates
that an internal UltraRotoSense ™ belt test is
currently being performed. For details see
chapter 3.3.1 page 24.
Table 13Trip condition, their possible causes and remedial action
Alarm
indication
LED indication
Flash slowly =
about 1 time/s
Flash rapidly=
about 10 times/s
Yellow LED is lit
Possible
cause
MODBUS
timeout error
Remedy
When there is no communication for more than
60 seconds, the yellow LED will be lit. As soon
as communication reappears it will start
flashing as per received modbus telegram.
WARNING! Residual voltage remains for up to 5 minutes after
disconnection of the supply voltage. The test switch and the DIP
switches may only be adjusted when the supply voltage has
been disconnected.
The motor and the controller do not normally require any maintenance. There
are however some things which we recommend to be checked regularly.
•Check external wiring, connections and control signals.
•Check power and motor cable connections
Preventive maintenance can optimise the product life time and secure trouble
free operation without interruptions.
For more information on maintenance, please contact your CG Drives &
Automation service partner.
5.1Motor diagnosis
•Disconnect the supply voltage.
•Disconnect the motor cables from the control unit.
Measure the motor resistance between R–Y, Y–B and B–R. The values should
be approximately 140 Ohm for EMX-B15, approximately 40 Ohm for
EMX-B25 and approximately 28 Ohm for EMX-B35. The resistance should
not differ by more than 10 Ohm between the phases. Also check the insulation
resistance between R, Y, B terminals shorted and the motor body to ensure that
there is no short circuit to PE.
NOTE: When checking the insulation resistance, it is important to turn the
motor shaft slowly (at least one complete turn) in order to get a correct
measurement.
46MaintenanceCG Drives & Automation 01-6048-01r3
6.Technical Data
EMX-B15EMX-B25EMX-B35
Output data
Rotation speed
Rated tourque
Continuous Power42 W100 W160 W
Starting & max tourque1.8 Nm4.8 Nm7.5 Nm
Direction of rotationSelectable
Purging modeBuilt-in function
Motor protectionBuilt-in function
Alarm outputAlternating contact, max 3 A, 230 VAC or 24 VDC
0.8 Nm @ 500 rpm
1.3 Nm @ 300 rpm
Input DATA
Mains supply VOLTAGE230 VAC +10/ -15%, 50/60 Hz
Maximum Fuse4 A6 A6 A
Maximum current 1.0 A3.0 A3.0 A
01-5731-00Motor EMX-B15
01-5732-00Motor EMX-B25
01-5733-00Motor EMX-B35
01-5762-00Control unit EMX-B15
01-5764-00Control unit EMX-B25
01--5766-00Control unit EMX-B35
01-3549-00Rotation sensor with magnet M12 x 35 mm