Emotron DCM User manual

Emotron DCM
Control Unit
Instruction manual
English

CG Drives & Automation 01-5965-01r1 1
Contents
1 Inside the Box............................................................................. 1
2 Safety .......................................................................................... 3
3 Introduction ................................................................................ 5
3.1 Description .................................................................................................. 5
4 Getting Started ........................................................................... 7
4.1 Please note the safety section .................................................................. 7
4.2 Connection and setup before start ........................................................... 7
4.3 Auto set performed at normal pumping - pumping water........................ 9
4.4 Auto set performed at snoring – pumping a mix of air and water ....... 10
4.5 Quick setup - flow chart........................................................................... 11
5 Installation................................................................................ 13
5.1 Choice of current transformer ................................................................ 13
5.2 The operator’s panel ............................................................................... 17
5.3 Description of functions .......................................................................... 19
5.4 Connection terminals .............................................................................. 23
6 Single-Pump System Installation ............................................ 25
6.1 Single-pump system connection............................................................. 26
6.2 Detailed setup for single-pump system ................................................. 28
6.3 Adjustment of stop level.......................................................................... 30
6.4 Start conditions and pause time adjustment ........................................ 30
6.5 Returning to the default settings............................................................ 31
7 Dual-Pump System Installation............................................... 33
7.1 Dual-pump system connection ............................................................... 34
7.2 Detailed setup for dual-pump system (always use two
Emotron DCMs)........................................................................................ 36
7.3 Returning to the default settings............................................................ 38

2CG Drives & Automation 01-5965-01r1
8 Protection and Alarm............................................................... 39
8.1 Phase sequence (F1) ............................................................................... 39
8.2 Phase asymmetry (F2) ............................................................................. 39
8.3 Checking the current (F3) ........................................................................ 40
8.4 Operating fault (F4) .................................................................................. 40
8.5 Temperature input (F5)............................................................................ 40
8.6 Undervoltage (LU)/Overvoltage (OU) alarm ............................................ 41
9 Troubleshooting ....................................................................... 43
10 Technical Data ......................................................................... 45
10.1 EU (European Union) specifications........................................................ 48
10.2 US specifications...................................................................................... 49
10.3 Canada specifications.............................................................................. 49
11 Window Parameters................................................................. 51
12 Service ...................................................................................... 57
13 Appendix ................................................................................... 59

CG Drives & Automation 01-5965-01r1 Inside the Box 1
1 Inside the Box
Please check the delivery. Despite the fact that all products from CG Drives &
Automation are carefully inspected and packed, transport damage may occur:
• Your shipment should contain the Emotron DCM, a current transformer,
2x terminal covers (option*) and this instruction manual.
• Check carefully that the equipment ordered complies with the pump
motor’s input voltage and that the current transformer rating is as stated on
the delivery note.
• Check that the contents have not been damaged during transport.
• If something is missing, or has been damaged, contact the supplier as well as
the forwarding agent within 48 hours of receipt.
NOTE: If in doubt contact your supplier before installing or commissioning
the product.

2 Inside the Box CG Drives & Automation 01-5965-01r1

CG Drives & Automation 01-5965-01r1 Safety 3
2Safety
• Study this manual thoroughly before installing and using the Emotron
DCM.
• The Emotron DCM must be installed by qualified personnel.
• Always disconnect supply circuits prior to installing.
• The installation must comply with standard and local regulations.
• Pay special attention to the information in this chapter and the parts marked
WARNING and CAUTION in the chapter on operation.
• Check that the Emotron DCM and the equipment are correctly connected
before being taken into use.
• Should questions or uncertainties arise, please contact your local sales outlet
or see Chapter 12 page 57, Service.
• Faults that arise due to faulty installation or operation are not covered by the
warranty.
NOTE: Removing or tampering with the seal on the housing will invalidate
the warranty.

4Safety CG Drives & Automation 01-5965-01r1

CG Drives & Automation 01-5965-01r1 Introduction 5
3 Introduction
This instruction manual describes the installation and commissioning of the
Emotron DCM. The Emotron DCM is a control unit that remotely controls
submersible pump equipment. Level sensors are not needed to initiate start and
stop. The pump stops automatically when it begins to snore (draw air), when
the pit has been pumped free from water. During a pumping operation, the
Emotron DCM measures the length of the run period and uses this to
determine the length of the rest period. The longer the run period, the shorter
the rest period. As a result the run and the rest periods are continuously adapted
to the rate of flow.
Two Emotron DCM can be connected in parallel to control two submersible
pumps and allow independent operation and display of monitored values (see
Chapter 7).
This instruction manual contains complete instructions for the installation and
use of the Emotron DCM. Please read the entire manual before installing or
using the DCM. Pay special attention to the Safety chapter in this manual and
the parts marked WARNING and CAUTION.
3.1 Description
The Emotron DCM measures the input power by measuring voltage and
current. This gives a reliable measurement of pump motor load over the total
load range.
As an option a level switch can be used to trigger a start; either to override the
pause time in case of high level or as the sole means to trigger a start.
The Emotron DCM is connected to the pump motor supply cable with a type
CTM current transformer. The same Emotron DCM is suitable for small and
large induction pump motors and the only accessory needed is the CTM
current transformer (a primary standard current transformer is also necessary
when the motor current is greater than 100 A).
The Emotron DCM is enclosed in a recyclable PC/ABS plastic housing. At the
front is the operator’s panel which comprises an LCD display and a set of six
keys. The connection terminals are at the top and bottom of the unit front
panel. The unit should be mounted on a standard DIN-rail.
The Emotron DCM is very easy to use. The “Auto set” function makes it
possible to adjust the unit (stop level) automatically by pressing just one key.

6Introduction CG Drives & Automation 01-5965-01r1
The Emotron DCM always stops the pump as soon as it starts to snore (draw
air) and restarts it after a calculated pause time or in response to a high-level
switch-over.
The Emotron DCM is able to check:
• Phase sequence.
•Phasevoltageasymmetry.
• Current from current transformer(s).
• Temperature on pump motor.
• Undervoltage and Overvoltage (at start up).
The Emotron DCM gives information about:
• Delay time before restarting after the pump has stopped.
• Pumping time since the latest pump start.
• High-level pumping time since the pump started as a result of high-level
switch-over.
• Measured power as a percentage of the DCM’s measurement range.
• Measured voltage.
• Measured peak power as a percentage of the DCM’s measurement range.
• Time counter for total pumping time.
• Start counter - total number of times pump has started.
The Emotron DCM can be connected in parallel for a dual-pump system:
•Alternating
•MASTER/SLAVEfunction
• If there is a breakdown in one of the pumps, the other pump starts to
operate.

CG Drives & Automation 01-5965-01r1 Getting Started 7
4 Getting Started
4.1 Please note the safety section
1. Pay special attention to the safety section in this manual and parts marked
WARNING and CAUTION.
2. Check that the pump motor/supply voltage corresponds to the values on the
Emotron DCM product label at the side of the unit.
3. Make a note of the pump motor’s rated current from its nameplate. Confirm
that the current transformer(s) supplied is of the correct size according to
Table 1, on page13 and Table 2, on page15 in this manual.
4.2 Connection and setup before start
1. Connect the Emotron DCM according to Chapters 5 and 6 and Fig. 13
(alternatively, for dual-pumps, Chapter 7 and Fig. 15 and 16).
2. Make sure all safety measures have been implemented and switch on the
supply voltage.
3. Follow Quick setup - flow chart Fig. 4, page 11 for single-pump system and
Fig. 5, page 12 for dual pumps.
The purpose of Getting Started is to achieve quick setup and to initiate the stop
function. The Emotron DCM stops the pump when the water level has
dropped to such a low level that the pump begins to snore (draw air). On intake
of air the pump motor power drops below the stop level (see Fig. 1, page 8 and
Fig. 2, page 9) and then the Emotron DCM stops the pump.

8 Getting Started CG Drives & Automation 01-5965-01r1
Fig. 1 Pump operation
If the Emotron DCM has been used previously, some parameters may have been
changed. In such a case, go to Chapter 6 and perform a complete setup for
single-pump system installation (alternatively, Chapter 7 for dual-pump system
installation).
On the following pages is a description for the single-pump setup in general. In
the event of an alarm during setup, see Chapters 8 and 9. For dual-pump setup,
see Chapter 7, Dual-Pump System Installation.
Power pump motor
Set power level
Normal pump load power
Stop level
Pump begins to
draw air (snore)
Time

CG Drives & Automation 01-5965-01r1 Getting Started 9
4.3 Auto set performed at normal pumping -
pumping water
1. Check that the amount of water is sufficient for pumping about 30 seconds
without snoring.
2. Switch on the supply voltage to the Emotron DCM and set any pump
system control equipment to the on position, “1” or Auto. The pump
should now be pumping water without snoring. If the pump does not start,
press the button on the Emotron DCM.
3. Step with the button to window 13 and check that the line is shown at
the top of the display (¯). If not, press , then press to confirm.
4. When the pump is working in steady state, press until “SEt” is shown
on the display. The stop level is now set.
The stop function is now initiated and the Emotron DCM controls the pump.
Adjustments can be made according to Section 6.2, page 30. See also section 6.3
and 6.4.
Fig. 2 Auto set performed at normal pumping
NEXT
ENTERENTER
SET
AUTO
SET
AUTO
Power pump motor
Auto set is pressed
Normal pump load power (window 04)
Stop level (window 11)
Power level
when snoring
Time
Snore margin (window 12)

10 Getting Started CG Drives & Automation 01-5965-01r1
4.4 Auto set performed at snoring – pumping a
mix of air and water
1. Set the pump system control equipment to the off position or “0”, and
switch on the supply voltage to the Emotron DCM.
2. Step to window 13 with the button and press so that the line is
shown at the bottom of the display (_). Then press to confirm the
setting. The Emotron DCM is now ready for Auto set at snoring.
3. Set the pump system control equipment to the on position, “1” or Auto to
start the pump. If necessary, press to start the pump.
4. Run the pump until it starts to snore.
5. Press until “SEt” is shown on the display. The stop level is now set, thus
stopping the pump when snoring.
The stop function is now initiated and the Emotron DCM controls the pump.
Adjustments can be made according to Section 6.2, page 30. See also Sections
6.3 and 6.4.
Fig. 3 Auto set performed at snoring
NEXT
ENTERENTER
SET
AUTO
SET
AUTO
Power pump
Auto set is pressed
Normal pump load power (window 04)
Stop level (window 11)
Power level
when snoring
Time
Snore margin (window 12)

CG Drives & Automation 01-5965-01r1 Getting Started 11
4.5 Quick setup - flow chart
Fig. 4 Quick setup for single-pump system (the pump will start and stop during
setup)
Place the pump in the pit
Set window 13 to ( ),
Is pump
snoring?
NO
Is pump
running?
Press the
button for 3
seconds (while the
pump is stopped)
until SEt is shown
in the window.
NO
YES
Press the
Does window
00 indicate
an alarm?
NO
Check the
troubleshooting
procedure, see
YES
Set window 13
Press the key for 3 s until
SEt is shown in the window . The stop
level (window 11) is set automatically .
YES
and switch the power on.
The stop level
(window 11) is
set to 0.
button
SET
AUTO
SET
AUTO
Chapter 9.
to ( ), see Table
8.
see Table 8.
SET
AUTO
SET
AUTO
Assuming all settings are
in default

12 Getting Started CG Drives & Automation 01-5965-01r1
Fig. 5 Quick setup for dual-pump system (the pumps will start and stop during
setup).
Place both pumps in the pit and
switch the power on.
Both pumps will start running now.
Set the Emotron MASTER DCM
window 71 to 2, see Table 8.
Set the Emotron SLAVE DCM
window 71 to 3.
Continue from here with the
Quick Setup for Single Pump on
the MASTER, see Fig. 4.
Press the key on the SLAVE.
Continue from here with the
Quick Setup for Single Pump
on the SLAVE, see Fig. 4.

CG Drives & Automation 01-5965-01r1 Installation 13
5 Installation
The Emotron DCM may only be installed and commissioned by an authorized
person according to standard and local regulations. Pay special attention also to
the Safety chapter in this manual and the parts marked WARNING and
CAUTION.
The Emotron DCM should be mounted on a standard DIN rail 46277,
35 mm. See “Technical Data” for maximum operating temperature range,
dimensions etc. Before installing, make sure that no voltage is applied to the
equipment and that the voltage rating of the Emotron DCM, as shown on the
rating plate on the side of the unit, corresponds to the motor/line voltage.
5.1 Choice of current transformer
Depending on pump motor size, the Emotron DCM should be used with one
or two current transformers. For pump motors with a rated current up to
100 A, use a single CTM current transformer. The possible combinations of
CTM current transformers and the number of windings are listed in Table 1.
Table 1 Table for selection of current transformer for motors with a rated current
up to 100 A
Rated motor
current
Choice of current transformer and number of windings for
different pump motor sizes.
CTM010 CTM025 CTM050 CTM0100
0.4 to 1.0 A 10
1.01 to 2.00 A 5
2.01 to 3.0 A 3
3.1 to 5.0 A 2
5.1 to 10 A 1
10.1 to 12.5 A 2 4
12.6 to 25 A 1 2
26 to 50 A 1
51 to 100 A 1

14 Installation CG Drives & Automation 01-5965-01r1
Fig. 6 Example: CTM 025 with 2 windings for a 12 A pump motor
Fig. 7 Example: 1, 2 and 3 windings, see also note on page 14
NOTE: The current transformer must be linked to the phase connected to
terminal 9 (L1).
L1
L2
L3
12
S1 S2
M
3
DCM
2 windings
CTM025
12

CG Drives & Automation 01-5965-01r1 Installation 15
For larger motors (rated current > 100 A), use two current transformers - one
outer, standard transformer, and one CTM010 with two windings. Table 2
shows the choice of transformers (standard + CTM010) and number of
windings for currents exceeding 100 A.
The following examples illustrate the choice of current transformer(s):
Example A. Pump motor has a rated current of 6.9 A. According to Table 1,
choose CTM010 with one (1) winding.
Example B. Pump motor has a rated current of 108 A. According to Table 2,
choose a standard current transformer 150:5 with one (1) winding and a
CTM010 with two (2) windings.
In order to ensure accurate calibration of the Emotron DCM, it is essential that
you use the correct CTM (and, additionally, a standard current transformer)
and apply the exact number of wirings in accordance with the tables above.
Table 2 Table for selection of current transformers for motors with a rated current
greater than 100 A
Rated motor current Current transformers
Number of windings
101 to 150 A 150:5 + CTM010
1 + 2
151 to 250 A 250:5 + CTM010
1 + 2
251 to 500 A 500:5 + CTM010
1 + 2
501 to 999 A 1000:5 + CTM010
1 +2
NOTE: The current transformer must be linked to the phase connected to
terminal 9 (L1).

16 Installation CG Drives & Automation 01-5965-01r1
Fig. 8 Example of a CTM 010 with 2 windings and a primary transformer
500:5 with 1 winding for a 260 A pump motor. See also note on page 15
NOTE: The current transformer(s) must be used according to Table 1 or
Table 2. Make sure to apply the correct number of winding to the
transformers.
L1
L2
L3
12
S1 S2
M
3
DCM
2 windings
CTM010
500:5
S1 S2
1 winding