Emotron EMX-B Instruction Manual

Emotron EMX-B
Drive system
for rotary heat exchangers
Instruction manual
English
Emotron EMX-B Drive system
Valid from software version 3.0
Document number: 01-6048-01 Edition: r3 Date of release: 2019-03-27 © Copyright CG Drives & Automation Sweden AB 2015-2019 CG Drives & Automation retain the right to change specifications and illustrations in the text, without prior notification. The contents of this document may not be copied without the explicit permission of CG Drives & Automation Sweden AB.
The product is protected as follows:
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 01-6048-01r3 1
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.
2 CG 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.
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Contents

Safety instructions................................................................... 1
Contents ................................................................................ 5
1. Description ............................................................................ 7
1.1 Introduction................................................................................................. 7
1.2 Delivery and unpacking .............................................................................. 8
1.3 Warranty ...................................................................................................... 8
1.4 General description .................................................................................... 9
1.5 Operating indicators ............................................................................... 10
2. Mounting and installation ..................................................... 13
2.1 Basic mounting ........................................................................................ 13
2.2 External sensor for rotation monitor (optional) ..................................... 14
2.3 Cable connections ................................................................................... 15
2.4 Control board ........................................................................................... 16
2.5 Select type of control signal.................................................................... 22
3. Built-in functions .................................................................. 23
3.1 Holding torque ......................................................................................... 23
3.2 Automatic purging.................................................................................... 23
3.3 Rotation monitor (DIP switch 6).............................................................. 24
3.4 Protection of the control unit .................................................................. 26
3.5 Defrosting................................................................................................. 27
3.6 Manual control using a 10 kOhm potentiometer .................................. 27
3.7 Test Switch ............................................................................................... 27
3.8 Cooling recovery....................................................................................... 27
3.9 DIP switches............................................................................................. 28
3.10 Communication through Modbus ........................................................... 32
3.11 Built-in configurable non-linearity ........................................................... 39
4. Troubleshooting ................................................................... 41
4.1 Trip conditions, causes and remedial action ......................................... 41
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5. Maintenance........................................................................ 46
5.1 Motor diagnosis........................................................................................ 46
6. Technical Data..................................................................... 47
6.1 Dimensions ............................................................................................... 48
6.2 Part numbers ............................................................................................ 51
7. Appendix ............................................................................. 53
7.1 Connection label....................................................................................... 53
7.2 Front label................................................................................................. 54
6 CG Drives & Automation 01-6048-01r3

1. Description

1.1 Introduction

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. 1 EMX-B motor and control unit mounted on rotary heat exchanger
CG Drives & Automation 01-6048-01r3 Description 7

1.2 Delivery 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

1.3 Warranty

The warranty applies when the equipment is installed, operated and maintained according to instructions in this instruction manual.
8Description CG Drives & Automation 01-6048-01r3

1.4 General 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.
Built-in functions:
Automatic purging operation/Continuous purging operation
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 01-6048-01r3 Description 9

1.5 Operating indicators

LED window
Fig. 2 Control 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 1 Operating indication
*)Exception Belt test, see page 44
All possible combinations of LED indication is described in detail in Table 13, page 43.
10 Description CG 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.

1.5.1 Dismantling 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 01-6048-01r3 Description 11
12 Description CG Drives & Automation 01-6048-01r3

2. Mounting and installation

Heat exchanger rotor
Control unit
Motor

2.1 Basic 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. 3 Emotron motor and Control unit for rotary heat exchangers
CG Drives & Automation 01-6048-01r3 Mounting and installation 13
2.2 External sensor for rotation monitor
Rotation sensor
Magnet
5-8 mm
Heat exchanger rotor
(optional)
Fig. 4 Rotation 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 installation CG Drives & Automation 01-6048-01r3

2.3 Cable connections

2.3.1 Motor

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.

2.3.2 Mains 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.

2.3.3 Communication 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 01-6048-01r3 Mounting and installation 15

2.4 Control 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. 5 Control board layout EMX-B15.
Table 2 Location of terminals and components EMX-B15.
No. Designation
1 Three LED operation indicators
2 DIP switches
3 Test switch
4 Jumper SW2 to select signal type, voltage or current (K/I)
5 Control signal terminals and RS485 interface (31-40)
6 Alarm terminals (41-43)
7 Hall sensor terminals (1-5)
8 Motor terminals ( -R-Y-B)
9 Mains supply terminals (L-N- )
10 PE connector
16 Mounting and installation CG Drives & Automation 01-6048-01r3
Fig. 6 Control board layout EMX-B25/B35.
EMX -B25/B35
1
2
3
4
9
8
7
6
5
Table 3 Location of terminals and components, EMX-B25/B35.
No. Designation
1 Three LED operation indicators
2 Test switch
3 DIP switches
4 Jumper X3 to select signal type, voltage or current (K/I)
5 Control signal terminals and RS485 interface (31-40)
6 Alarm terminals (41-43)
7 Hall sensor terminals (1-5)
8 Motor terminals ( -R-Y-B)
9 Mains 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 01-6048-01r3 Mounting and installation 17

2.4.1 Terminals

0 V
Mains
Motor
Hallsensors
Alarm
relay
Modbus
Ext.
CR
DF
monitor
Motor
rotation
+12 VDC
potentiometer
only
Fig. 7 Terminals on control board.
Table 4 Terminals and connections description.
Control board External
Mains supply
Te rm in al Name/no
L Line
N Neutral
Connection
Earth
Earth
Remark
Mount the Ferrite (included in delivery) on the mains cable acc. to Fig. 8, page 20
Motor
Hallsensor
Alarm
R R
Y Y
B B
1 1
2 2
3 3
4 4
5 5
41 NC
42 Common
43 NO
Motor power connections
Motor sensor connection
42 - 43 closed on alarm Reset alarm possible by shorten terminals 33, 34 and 35
18 Mounting and installation CG Drives & Automation 01-6048-01r3
Table 4 Terminals and connections description.
Control board External
Te rm in al Name/no
35 One end of pot.
Control signals
External rotation monitor
DF­Defrosting
CR-Cooling recovery
RS485/ Modbus
37 Other end of pot.
35 0 V
36 + signal
31 RM -
32 RM +
33, 35
34, 35
38 A +
39 B -
40 0 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

2.4.2 Mains supply voltage cables

Dimension the mains cables according to local regulations. The cable must be able to carry the load current.
CG Drives & Automation 01-6048-01r3 Mounting and installation 19
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. 8 Mount the Ferrite on the Mains supply cable.
Fig. 8.
20 Mounting and installation CG Drives & Automation 01-6048-01r3

2.4.3 Recommendations 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. 9 Excess 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 01-6048-01r3 Mounting and installation 21

2.5 Select 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 installation CG Drives & Automation 01-6048-01r3

3. Built-in functions

3.1 Holding 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.

3.2 Automatic 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.

3.2.1 Normal purging mode

In normal purging mode, when the dip-switch DIP8 is disabled (Off) the motor shaft turns two revolutions every 5 minutes.

3.2.2 Continuous 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
CG Drives & Automation 01-6048-01r3 Built-in functions 23
DC
.

3.3 Rotation monitor (DIP switch 6)

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
3.3.1 Internal 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.
Further, since the operating reference speed is
TM
24 Built-in functions CG Drives & Automation 01-6048-01r3
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.

3.3.2 External 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.
CG Drives & Automation 01-6048-01r3 Built-in functions 25

3.4 Protection of the control unit

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 5 Protection 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, immediately Automatic Automatic
Yes, immediately
Yes, immediately Motor not stopped
Yes, immediately Motor not stopped
Restart Alarm 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.
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3.5 Defrosting

Control unit
10 kOhm
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.
3.6 Manual 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

3.7 Test 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.

3.8 Cooling 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.
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3.9 DIP switches

By default, all 10 DIP switches are set to “Off”.
Clarification
= DIP Off = DIP On

3.9.1 Choice of 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
28 Built-in functions CG Drives & Automation 01-6048-01r3
Table 6 DIP switch combinations and speed
% of maximum
speed
100 % 500 0 0 0 0
95 % 475 1 0 0 0
90 % 450 0 1 0 0
85 % 425 1 1 0 0
80 % 400 0 0 1 0
75 % 375 1 0 1 0
70 % 350 0 1 1 0
65 % 325 1 1 1 0
60 % 300 0 0 0 1
55 % 275 1 0 0 1
50 % 250 0 1 0 1
45 % 225 1 1 0 1
40 % 200 0 0 1 1
35 % 175 1 0 1 1
30 % 150 0 1 1 1
25 % 125 1 1 1 1
Speed
rpm
DIP 1 DIP 2 DIP 3 DIP 4
CG Drives & Automation 01-6048-01r3 Built-in functions 29

3.9.2 Setting DIP switches

WARNING!
Disconnect the voltage supply before changing the DIP switch setting.
NOTE: After changing DIP settings the control unit must be power cycled before the new settings become active.
Table 7 DIP switch setting
Speed
Please refer to section chapter 3.9.1 page 28
for different speed presetting
Direction of rotation, DIP 5
Clockwise from shaft end (Default setting).
DIP 5=Off
Counter clockwise from shaft end.
DIP 5=On
Rotation monitor, DIP 6
Internal rotation monitor (Default setting)
External rotation monitor (External sensor required)
Control signal, DIP 7
0-10 V / 0-20 mA (Default setting)
DIP 6=Off
DIP 6=On
DIP 7=Off
2-10 V / 4-20 mA
DIP 7=On
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Table 7 DIP switch setting
Type of purging mode, DIP 8
Normal purging (Default setting)
Modbus baud rate, DIP 9
Not changeable via Modbus
Not changeable via Modbus
Modbus Off/On, DIP 10
Modbus communication disabled (Default setting)
Modbus communication enabled
DIP 8=Off
Continuous purging
DIP 8=On
Default: 19200, 8, N, 1
(Default setting)
DIP 9=Off
Default: 9600, 8, N, 1
DIP 9=On
DIP 10=Off
DIP 10=On
CG Drives & Automation 01-6048-01r3 Built-in functions 31

3.10 Communication through Modbus

WARNING!
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 8 Tw o se ts o f b a ud -ra te
Dip 9 = On Dip 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
32 Built-in functions CG Drives & Automation 01-6048-01r3

3.10.1 Modbus register list

Table 9 Input Register read access (function code 04)
Register
30002 1 Mbus Ver
30003 2 HW
30004 3 SW
30006 5 Nrem
30007 6 Nlocked
30008 7 Nsp
30010 9 M1 Motor Type R
30011 10 n1
30013 12 n
30015 14 Switch
Starting
Name Description R/W Comment Memory* Min Max Default
address
Protocol version
Hardware version
Software version
Tot a l N o. of alarms for belt failure
Tot a l N o. of alarms for motor failure
Tot a l N o. of alarms for voltage failure
DIP setting for Max speed
Actual speed motor
Dip switch setting
Changes when there is a Modbus
R
version change
R ** V 1 65535
R ** V 1 65535
Tota l N o . of alarms for belt
R
failure
Tota l N o . of alarms for motor
R
failure
Tota l N o . of alarms for voltage
R
failure
EMX-B version of the motor 15, 25, 35
Reads DIP value for 16 speed
R
presets. 0 (100%) to 15 (25%)
Motor speed in RPM. +ve clockwise & -ve
R
counter­clockwise
Reads all 10 DIP
R
switches
V 1 256
NV 0 65535 0
NV 0 65535 0
NV 0 65535 0
V 15 35 -
0 15 0
V -600 600 0
0 1024 0
* 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
CG Drives & Automation 01-6048-01r3 Built-in functions 33
Table 9 Input Register read access (function code 04)
Register
Starting
Name Description R/W Comment Memory* Min Max Default
address
30016 15 Mode
30017 16 Signal
30027 26 Current
30028 27 Power
30029 28
DC­Voltage
30030 29 Oper
30031 30 Vdrive
30032 31 Pdrive
30034 33 To t al a la r m
Actual Operating mode
Control signal / Prc Set
Input current to motor
Input power. Motor (W)
DC link Voltage (V)
Days of operation
Input voltage to drive (V)
Input power
- drive (W)
Tot a l N o. of alarms
0 = Normal
operation 1 = Defrosting 2 = Purging 4 = Test button
R
8 = Belt test 16= Error except
voltage error 32= Voltage error 64= Standstill
Control signal in
R
percentage
Input current drawn by motor;
R
1 = 1 mA
Power consumed by motor;
R
1 = 1 W
Input DCbus voltage to the
R
motor; 1 = 1 V
No of days of operation of the
R
motor
Input AC voltage to the drive;
R
1 = 1 V
Power consumed
R
by the drive
Tota l N o . of
R
alarms
0 256 0
V 0 100 0
V 0 10000 0
V 0 500 0
V 0 400 0
NV 0 65535 0
V 0 400 0
V 0 500 0
NV 0 65535 0
* V = Volatile memory
NV =Non volatile memory
34 Built-in functions CG Drives & Automation 01-6048-01r3
Table 10 Holding Register read/write access (function code 03, 06)
Register
40003 2 Dir
Starting address
Name Description R/W Comment Memory* Min Max
Sets/reads motor direction
R/W
40007 6 Config Linearisation R/W
Reads alarm/ resets alarm
40008 7 Larm
Reset alarm by
R/W
writing 0 to the register.
Compensation,
Comp
40010 9
40011 10
40012 11
E1
Comp E2
Comp E3
1 (5% signal) [%*10]
Compensation, 2 (10% signal) [%*10]
Compensation, 3 (15% signal) [%*10]
R/W
R/W
R/W
Depending on DIP5.
DIP5=0 gives 0 = clockwise 1 = counter
clockwise DIP5=1 gives 0= counter
clockwise 1 = clockwise
Speed variation 0 - Linear variation 1 - Non linear
variation
0 = No error/Reset
error 1 = Under Voltage
error 2 = Over Voltage
error 4 = Belt error 8 = Overload
protection 16=Short Circuit/
Earth fault 32=External
rotation sensor
error / broken
belt 64=Modbus
timeout error
Compensation, 1 (5% signal) [%*10]
Compensation, 2 (10% signal) [%*10]
Compensation, 3 (15% signal) [%*10]
Default
0 1 0
NV 0 1 1
V 0 65535 0
NV 0 1000 2
NV 0 1000 5
NV 0 1000 9
CG Drives & Automation 01-6048-01r3 Built-in functions 35
Table 10 Holding Register read/write access (function code 03, 06)
Register
Starting address
40013 12
40014 13
40015 14
40016 15
40017 16
40018 17
40019 18
40020 19
40021 20
40022 21
40023 22
40024 23
40025 24
Name Description R/W Comment Memory* Min Max
Comp E4
Comp E5
Comp E6
Comp E7
Comp E8
Comp E9
Comp E10
Comp E11
Comp E12
Comp E13
Comp E14
Comp E15
Comp E16
Compensation, 4 (20% signal) [%*10]
Compensation, 5 (25% signal) [%*10]
Compensation, 6 (30% signal) [%*10]
Compensation, 7 (35% signal) [%*10]
Compensation, 8 (40% signal) [%*10]
Compensation, 9 (45% signal) [%*10]
Compensation, 10 (50% signal) [%*10]
Compensation, 11 (55% signal) [%*10]
Compensation, 12 (60% signal) [%*10]
Compensation, 13 (65% signal) [%*10]
Compensation, 14 (70% signal) [%*10]
Compensation, 15 (75% signal) [%*10]
Compensation, 16 (80% signal) [%*10]
Compensation, 4
R/W
(20% signal) [%*10]
Compensation, 5
R/W
(25% signal) [%*10]
Compensation, 6
R/W
(30% signal) [%*10]
Compensation, 7
R/W
(35% signal) [%*10]
Compensation, 8
R/W
(40% signal) [%*10]
Compensation, 9
R/W
(45% signal) [%*10]
Compensation, 10
R/W
(50% signal) [%*10]
Compensation, 11
R/W
(55% signal) [%*10]
Compensation, 12
R/W
(60% signal) [%*10]
Compensation, 13
R/W
(65% signal) [%*10]
Compensation, 14
R/W
(70% signal) [%*10]
Compensation, 15
R/W
(75% signal) [%*10]
Compensation, 16
R/W
(80% signal) [%*10]
NV 0 1000 15
NV 0 1000 23
NV 0 1000 33
NV 0 1000 47
NV 0 1000 66
NV 0 1000 91
NV 0 1000 122
NV 0 1000 159
NV 0 1000 199
NV 0 1000 248
NV 0 1000 296
NV 0 1000 351
NV 0 1000 408
Default
36 Built-in functions CG Drives & Automation 01-6048-01r3
Table 10 Holding Register read/write access (function code 03, 06)
Register
40026 25
40027 26
40028 27
40029 28
40031 30 Te s t
40034 33 Ctrl
40035 34
40036 35 Baud
Starting address
Name Description R/W Comment Memory* Min Max
Compensation,
Comp
17 (85% signal)
E17
[%*10]
Compensation,
Comp
18 (90% signal)
E18
[%*10]
Compensation,
Comp
19 (95% signal)
E19
[%*10]
Compensation,
Comp
20 (100%
E20
signal) [%*10]
Sets/reads unit into test mode
Control signal/ PrcSet
Address
Address R/W Slave ID NV 1 256 30
Modbus baudrate
40037 36 Par Parity R
40038 37
40040 39 Defrost
Stop bits
Stop bits R
Enable/Disable Defrost mode
Compensation, 17
R/W
(85% signal) [%*10]
Compensation, 18
R/W
(90% signal) [%*10]
Compensation, 19
R/W
(95% signal) [%*10]
Compensation, 20
R/W
(100% signal) [%*10]
0 = Not test mode 1 = Test mode
R/W
Same operation as test switch
Control signal via
R/W
MODBUS
Modbus Baud rate. Read only Baudrate divided
R
by 100, ex, 96, 192, 384, 576, 1152
Modbus parity Read only 0=N 1=E 2=O
Sets Modbus Stop bits 0 = one stop bit 1 = two stop bits
0 = Normal
R/W
operation 1= Defrosting
Default
NV 0 1000 497
NV 0 1000 620
NV 0 1000 800
NV 0 1000 1000
V 0 1 0
V 0 1000 0
NV 96 192 96
NV 0 2 0
U / NV 0 1 0
V 0 1 0
CG Drives & Automation 01-6048-01r3 Built-in functions 37
Table 10 Holding Register read/write access (function code 03, 06)
Register
Starting address
40046 45
40047 46
40048 47
40049 48
40050 49
40051 50
Name Description R/W Comment Memory* Min Max
Default is 0 i.e. Motor is in normal operation. When written into the register, all the
R/W
other functions are disabled and motor will run at
V 0 500 0
Motor Te st speed
Put in the test speed request in rpm (motor)
Note: Only for testing motor
the specified speed.
Min speed
Cool heat mode
Minimum speed (rpm)
Cooling or heating mode
Minimum value of
R/W
the speed
0 = Cooling mode
R/W
1= Heating mode
NV 4 500 4
V 0 1 0
Maximum speed of the motor is decided here when in heating mode.
R/W
Only active when DIP 1-4 are all Off
NV 0
Dep. on DIP 1-4 setting
Max heat
Maximum speed in heating mode (rpm)
and when modbus enabled.
Maximum speed of the motor is decided here when in cooling mode.
R/W
Only active when DIP 1-4 are all Off
NV 0
Dep. on DIP 1-4 setting
Max cool
Maximum speed in cooling mode (rpm)
and when modbus enabled.
0 = go back to
Force
Stop motor R/W
Stop
normal
operation 1= Force Motor to
V 0 1 0
stop.
Default
500
500
* V = Volatile memory
NV =Non volatile memory
38 Built-in functions CG Drives & Automation 01-6048-01r3

3.11 Built-in configurable non-linearity

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.
Table 11 Non-linear speed.
Control signal
%
Speed reference
%
Motor shaft speed *
0 1.6 4
5 1.6 4 10 1.6 4 15 1.6 4 20 1.6 4 25 2.3 11 30 3.3 16 35 4.7 23 40 6.6 33 45 9.1 45 50 12.2 61 55 15.9 79 60 19.9 99 65 24.8 124 70 29.6 148 75 35.1 175 80 40.8 204 85 49.7 248 90 62 310 95 80 400
100 100 500
rpm
*) With DIP 1-4 set in Off position.
CG Drives & Automation 01-6048-01r3 Built-in functions 39
Table 12 Control signals and speed
Control signal Purging Maximum speed
0 - 10 V 0.5-0.6 V 10.0 V
2 - 10 V 2.5 V 10.0 V
0 - 20 mA 1.0 mA 20.0 mA
4 - 20 mA 5.0 mA 20.0 mA
NOTE: A small hysteresis window is used to avoid setting the controller to jump between state Purge and state Normal operation (avoiding state jumping).
40 Built-in functions CG Drives & Automation 01-6048-01r3

4. Troubleshooting

4.1 Trip conditions, causes and remedial action

Check that:
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
replacing both motor and control unit.
CG Drives & Automation 01-6048-01r3 Troubleshooting 41
Motor diagnosis:
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.
42 Troubleshooting CG Drives & Automation 01-6048-01r3
Table 13 Trip 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
AC
AC
alternately
CG Drives & Automation 01-6048-01r3 Troubleshooting 43
Table 13 Trip 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.
44 Troubleshooting CG Drives & Automation 01-6048-01r3
Table 13 Trip 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.
CG Drives & Automation 01-6048-01r3 Troubleshooting 45

5. Maintenance

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.

5.1 Motor 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.
46 Maintenance CG Drives & Automation 01-6048-01r3

6. Technical Data

EMX-B15 EMX-B25 EMX-B35
Output data
Rotation speed
Rated tourque
Continuous Power 42 W 100 W 160 W Starting & max tourque 1.8 Nm 4.8 Nm 7.5 Nm Direction of rotation Selectable Purging mode Built-in function Motor protection Built-in function Alarm output Alternating contact, max 3 A, 230 VAC or 24 VDC
0.8 Nm @ 500 rpm
1.3 Nm @ 300 rpm
Input DATA
Mains supply VOLTAGE 230 VAC +10/ -15%, 50/60 Hz Maximum Fuse 4 A 6 A 6 A Maximum current 1.0 A 3.0 A 3.0 A
Control signal
0-10 VDC, 2 - 10 VDC, 0 - 20 mA, 4-20 mA, 10 kΩ potentiometer.
General DATA
Protection class IP 54 Weight, control unit 0.5 kg 1.5 kg 1.5 kg Weight, motor 4.5 kg 6.0 kg 8.0 kg Ambient temperature -40° to +40°C EMC, emission EN61800-3
EN 61000-6-3:2004/6100-6-4, A1:2012EMC- product standard
Standards
Cable type
Cable glands
EN 6100-6-2 EMC emission EN 61800-5-1:2007 Safety requirements – Electrical, thermal and energy Motorcable: Insulated with 3 individually isolated leads- 0.5 mm2 + PE- 2.5 mm Sensor cable: 5 leads- 0.75 mm2 with pin type crimp lugs. Cable length - 2500mm. 2 pcs M12 glands (Motor) 1 pc M20 and 4 pcs M16 glands (Control unit)
2
with pin type crimp lugs.
4 - 500 rpm
2.0 Nm @ 500 rpm
3.3 Nm @ 300 rpm
2 pcs M12 glands (Motor) 2 pcs M20 and 3 pcs M16 glands (Control unit)
3.0 Nm @ 500 rpm
5.0 Nm @ 300 rpm
CG Drives & Automation 01-6048-01r3 Technical Data 47

6.1 Dimensions

200
150
113
18.5
188
6
56
43.5
180
4.5
(x4)

6.1.1 Control units

Fig. 12 Dimensions, EMX-B15 control unit (mm).
48 Technical Data CG Drives & Automation 01-6048-01r3
200
150
113
29.5
188
6
67
4.5 (x4)
180
7.5
Fig. 13 Dimensions, EMX-B25/35 control unit (mm).
CG Drives & Automation 01-6048-01r3 Technical Data 49

6.1.2 Motors

F
FA
K2
K1
K
FC
FB
LC
H
LA
L
HD
M
HA
HB
Fig. 14 Dimensions, motor.
Fig. 15 Motor dimensions, mm.
EMX-B F FA FB FC H HA HB HD
15 88 96 10
14
+0/-0.1
140 12
29 114 37 153 110
4
30
115.6 39 180 160
25 82
35 109 90 3.0 222 NA
EMX-B K K1 K2 L LA LC M
15
25
35 5 142 42.5 238.4 177
50 Technical Data CG Drives & Automation 01-6048-01r3
66.9
7
75.9 147 159
2.5
130 138

6.2 Part numbers

Part number Designation
01-5731-00 Motor EMX-B15 01-5732-00 Motor EMX-B25 01-5733-00 Motor EMX-B35 01-5762-00 Control unit EMX-B15 01-5764-00 Control unit EMX-B25 01--5766-00 Control unit EMX-B35 01-3549-00 Rotation sensor with magnet M12 x 35 mm
CG Drives & Automation 01-6048-01r3 Technical Data 51
52 Technical Data CG Drives & Automation 01-6048-01r3

7. Appendix

-
0V

7.1 Connection label

Fig. 16 Connection label placed inside front cover of control unit.
CG Drives & Automation 01-6048-01r3 Appendix 53

7.2 Front label

Fig. 17 Front label
54 Appendix CG Drives & Automation 01-6048-01r3
CG Drives & Automation Sweden AB
Mörsaregatan 12 Box 222 25 SE-250 24 Helsingborg Sweden T +46 42 16 99 00 F +46 42 16 99 49 www.cgglobal.com / www.emotron.com
CG Drives & Automation, 01-6048-01r3, 2019-03-27
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