Emotron EMX-B Instruction Manual
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Emotron EMX-B Instruction Manual

Emotron EMX-B Instruction Manual

Drive system for rotary heat exchangers
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Emotron EMX-B
Drive system
for rotary heat exchangers
Instruction manual
English

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  • Page 1 Emotron EMX-B Drive system for rotary heat exchangers Instruction manual English...
  • Page 3 Emotron EMX-B Drive system Instruction manual 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.
  • Page 4 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 UltraRotoSense : EP17171733.3...

  • Page 5: Safety Instructions

    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.
  • Page 6 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.
  • Page 7 Transport To avoid damage, keep the drive system in its original packaging during transport. This packaging is specially designed to absorb shocks during transport. CG Drives & Automation 01-6048-01r3...
  • Page 8 CG Drives & Automation 01-6048-01r3...

  • Page 9: Table Of Contents

    Contents Safety instructions..............1 Contents ................5 Description ................7 Introduction....................7 Delivery and unpacking................8 Warranty ...................... 8 General description ..................9 Operating indicators ................10 Mounting and installation ............. 13 Basic mounting ..................13 External sensor for rotation monitor (optional) ........14 Cable connections ...................
  • Page 10 Maintenance................ 46 Motor diagnosis..................46 Technical Data..............47 Dimensions ....................48 Part numbers .................... 51 Appendix ................53 Connection label..................53 Front label....................54 CG Drives & Automation 01-6048-01r...

  • Page 11: Description

    Description 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.

  • Page 12: Delivery And Unpacking

    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 Warranty The warranty applies when the equipment is installed, operated and maintained according to instructions in this instruction manual. Description...

  • Page 13: General Description

    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.

  • Page 14: Operating Indicators

    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 Slow flashing (1 time/s) – Purging mode/Low control signal Rapid flashing (10 times/s) –...
  • Page 15 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. Description CG Drives & Automation 01-6048-01r3...
  • Page 16 Description CG Drives & Automation 01-6048-01r3...

  • Page 17: Mounting And Installation

    Heat exchanger rotor Control unit Motor Fig. 3 Emotron motor and Control unit for rotary heat exchangers Mounting and installation CG Drives & Automation 01-6048-01r3...

  • Page 18: External Sensor For Rotation Monitor (Optional)

    External sensor for rotation monitor (optional) Magnet Heat exchanger rotor Rotation sensor 5-8 mm Fig. 4 Rotation monitor Two different rotation monitors can be selected. The first, which is an integrated UltraRotoSense rotation monitor, and secondly a rotation monitor using an external rotation sensor (optional) see also further info in chapter 3.3 page 24.

  • Page 19: Cable Connections

    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. Mounting and installation CG Drives & Automation 01-6048-01r3...

  • Page 20: Control Board

    Control board 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”...
  • Page 21 EMX -B25/B35 Control board layout EMX-B25/B35. Fig. 6 Location of terminals and components, EMX-B25/B35. Table 3 Designation Three LED operation indicators Test switch DIP switches Jumper X3 to select signal type, voltage or current (K/I) Control signal terminals and RS485 interface (31-40) Alarm terminals (41-43) Hall sensor terminals (1-5) Motor terminals (...
  • Page 22 2.4.1 Terminals Alarm relay Mains Hallsensors Modbus Motor Motor +12 VDC Ext. potentiometer rotation only monitor Fig. 7 Terminals on control board. Table 4 Terminals and connections description. Control board External Remark Terminal Connection Name/no Line Mount the Ferrite Mains (included in delivery) on Neutral supply...
  • Page 23 Table 4 Terminals and connections description. Control board External Remark Terminal Connection Name/no One end of pot. Variable point of If potentiometer is used pot. Control Other end of pot. signals When external control signal is used + signal External RM - Ext.
  • Page 24 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.
  • Page 25 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. Mounting and installation CG Drives & Automation 01-6048-01r3...

  • Page 26: Select Type Of Control Signal

    Select type of control signal (EMX-B15) Voltage (default) Current (EMX-B25/35) Current Voltage (default) 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”.

  • Page 27: Built-In Functions

    Built-in functions 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.

  • Page 28: Rotation Monitor (Dip Switch 6)

    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).
  • Page 29 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.

  • Page 30: Protection Of The Control Unit

    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.

  • Page 31: Defrosting

    Defrosting 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. 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.

  • Page 32: Dip Switches

    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 dips- witches are off the maximum speed will be 100% of the maximum speed of the drive (500 rpm).
  • Page 33 Table 6 DIP switch combinations and speed % of maximum Speed DIP 1 DIP 2 DIP 3 DIP 4 speed 100 % 95 % 90 % 85 % 80 % 75 % 70 % 65 % 60 % 55 % 50 % 45 % 40 %...
  • Page 34 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).
  • Page 35 Table 7 DIP switch setting Type of purging mode, DIP 8 Normal purging (Default setting) DIP 8=Off Continuous purging DIP 8=On Modbus baud rate, DIP 9 Default: 19200, 8, N, 1 Not changeable via Modbus (Default setting) DIP 9=Off Default: 9600, 8, N, 1 Not changeable via Modbus DIP 9=On Modbus Off/On, DIP 10...

  • Page 36: Communication Through Modbus

    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: Table 8...
  • Page 37 Total No. of Total No. of alarms for 30008 alarms for voltage 65535 0 voltage failure failure EMX-B version of 30010 Motor Type the motor 15, 25, Reads DIP value DIP setting for 16 speed 30011 for Max presets. 0 (100%)
  • Page 38 Table 9 Input Register read access (function code 04) Starting Register Name Description R/W Comment Memory* Min Max Default address 0 = Normal operation 1 = Defrosting 2 = Purging Actual 4 = Test button 30016 Mode Operating 8 = Belt test mode 16= Error except voltage error...
  • Page 39 Table 10 Holding Register read/write access (function code 03, 06) Starting Register Name Description Comment Memory* Min Max Default address Depending on DIP5. DIP5=0 gives 0 = clockwise Sets/reads 1 = counter 40003 motor direction clockwise DIP5=1 gives 0= counter clockwise 1 = clockwise Speed variation...
  • Page 40 Table 10 Holding Register read/write access (function code 03, 06) Starting Register Name Description Comment Memory* Min Max Default address Compensation, Compensation, 4 Comp 40013 4 (20% signal) (20% signal) 1000 [%*10] [%*10] Compensation, Compensation, 5 Comp 40014 5 (25% signal) (25% signal) 1000 [%*10]...
  • Page 41 Table 10 Holding Register read/write access (function code 03, 06) Starting Register Name Description Comment Memory* Min Max Default address Compensation, Compensation, 17 Comp 40026 17 (85% signal) (85% signal) 1000 [%*10] [%*10] Compensation, Compensation, 18 Comp 40027 18 (90% signal) (90% signal) 1000 [%*10]...
  • Page 42 Table 10 Holding Register read/write access (function code 03, 06) Starting Register Name Description Comment Memory* Min Max Default address Default is 0 i.e. Motor is in normal operation. When Put in the test written into the Motor speed request register, all the 40046 Test...

  • Page 43: Built-In Configurable Non-Linearity

    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.
  • Page 44 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...

  • Page 45: Troubleshooting

    Troubleshooting 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.
  • Page 46 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.
  • Page 47 Table 13 Trip condition, their possible causes and remedial action Alarm indication Possible LED indication Remedy cause Flash slowly = about 1 time/s Flash rapidly= about 10 times/s - If the motor is not running and Green LED flashes slowly, check the drive system with the test switch.
  • Page 48 Table 13 Trip condition, their possible causes and remedial action Alarm indication Possible LED indication Remedy cause Flash slowly = about 1 time/s Flash rapidly= about 10 times/s - Disconnect the supply voltage, check the connection of the motor cable and check that Red and green Earth fault in the correct motor is connected.
  • Page 49 Table 13 Trip condition, their possible causes and remedial action Alarm indication Possible LED indication Remedy cause Flash slowly = about 1 time/s Flash rapidly= about 10 times/s When there is no communication for more than MODBUS 60 seconds, the yellow LED will be lit. As soon Yellow LED is lit timeout error as communication reappears it will start...

  • Page 50: Maintenance

    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.

  • Page 51: Technical Data

    Technical Data EMX-B15 EMX-B25 EMX-B35 Output data 4 - 500 rpm Rotation speed 0.8 Nm @ 500 rpm 2.0 Nm @ 500 rpm 3.0 Nm @ 500 rpm Rated tourque 1.3 Nm @ 300 rpm 3.3 Nm @ 300 rpm 5.0 Nm @ 300 rpm Continuous Power 42 W...

  • Page 52: Dimensions

    Dimensions 6.1.1 Control units 43.5 (x4) Fig. 12 Dimensions, EMX-B15 control unit (mm). Technical Data CG Drives & Automation 01-6048-01r3...
  • Page 53 (x4) Fig. 13 Dimensions, EMX-B25/35 control unit (mm). Technical Data CG Drives & Automation 01-6048-01r3...
  • Page 54 6.1.2 Motors Fig. 14 Dimensions, motor. Fig. 15 Motor dimensions, mm. EMX-B 66.9 75.9 EMX-B 115.6 +0/-0.1 42.5 238.4 Technical Data CG Drives & Automation 01-6048-01r3...

  • Page 55: Part Numbers

    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 Technical Data CG Drives & Automation 01-6048-01r3...
  • Page 56 Technical Data CG Drives & Automation 01-6048-01r3...

  • Page 57: Appendix

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

  • Page 58: Front Label

    Front label Fig. 17 Front label Appendix CG Drives & Automation 01-6048-01r3...
  • Page 60 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...

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