Emotron M20

Shaft power monitor

Instruction manual
English

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 Contents
1 Inside the Box............................................................................. 3

2 Safety .......................................................................................... 4

3 Description.................................................................................. 5

4 Getting Started ........................................................................... 7

4.1 Please note ................................................................................................. 7
4.2 Connection and set-up before first start ................................................... 7
4.3 First start ..................................................................................................... 8
4.4 Manual setting of alarm levels, alternative A ........................................... 9
4.5 Manual setting of alarm levels, alternative B........................................ 10
4.6 Manual setting of alarm levels, alternative C ........................................ 10

5 Wiring ........................................................................................ 11
5.1 Alternative example for single-phase connection ................................. 13
5.2 Example - digital input ............................................................................. 14

6 Selection of Current Transformer ........................................... 14

6.1 Motors less than 100 A........................................................................... 14
6.2 Motors greater than 100 A ..................................................................... 17

7 Operation .................................................................................. 19
7.1 Overview ................................................................................................... 19
7.2 Window menu .......................................................................................... 20
7.3 How to change a value ............................................................................ 21

8 Programming ............................................................................ 22
8.1 Set measurement unit, kW or HP ........................................................... 22
8.2 Setting rated motor power and current (window 41 and 42)............... 24
8.3 Setting number of phases (window 43) ................................................. 25
8.4 Monitor function (window 05)................................................................. 25
8.5 Setting the Start Delay (window 31)....................................................... 27

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 8.6 Setting alarm levels with Auto set........................................................... 28
8.7 Setting the Response Delay (windows 32 and 34)................................ 29

9 Advanced Features .................................................................. 31

9.1 Setting alarm levels manually (windows 11-14) .................................... 31

10 Troubleshooting ....................................................................... 41

11 Technical Data ......................................................................... 43

12 Parameter List.......................................................................... 48

13 Service ...................................................................................... 51

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 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 M20 shaft power monitor,
a current transformer, 2x terminal covers (option*) and this instruction
manual.
• Check carefully that the equipment ordered complies with the motor’s input
voltage and that the current transformer rating is as stated on the delivery
packaging.
• Check that the contents have not been damaged during shipping.
• 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.

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 2 Safety
• Study this manual thoroughly before installing and using the monitor.
• The monitor 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
CAUTION in the Operation and Programming chapters.
• Check that the monitor and the equipment are correctly connected before it
is taken into use.
• Should questions or uncertainties arise, please contact your local sales outlet
or see chapter 13, 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.

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 3 Description
This instruction manual describes the installation and commissioning of the
Emotron M20 shaft power monitor. The Emotron M20 supervises induction
motor driven equipment and provides warnings when abnormal conditions are
detected. It protects for example, pumps and other equipment. The M20’s
ability to provide reliable monitoring and protection ensures that production
equipment is optimized and expensive breakdowns and interruptions are
minimized.
The Emotron M20 uses the motor as its own sensor and no external sensors or
extra cabling are required. Due to the special method of subtracting motor
power losses, the monitor is able to accurately measure the shaft power supplied
by the motor to the application. This advanced technique allows the M20 to
monitor only the “application” load rather than the “total” motor load, which
includes the varying motor losses.
The shaft power is calculated by measuring motor input power, and subtracting
the motor power loss calculated using a unique principle. The shaft power
output is indicated on the monitor display in kW or HP, or as a percentage of
rated power. Calculating shaft power gives more reliable supervision than non-
linear techniques, such as current and phase angle measurements. Current
measurement is only sufficient at high motor loads and phase angle only at low
loads. Input power is sometimes called true or real power. Input power is linear,
but ignores motor power loss.
The M20’s analogue output and two relay outputs allow the combination of
direct and indirect control. The unit offers high accuracy in the event of very
small load variations. The analogue output signal can be used to scale the
machine load to represent the actual working range.
The monitor is very easy to install and set up and should be mounted on a
standard DIN rail. It is also very easy to use. The “Auto set” function makes it
possible to adjust the monitor automatically by pressing just one key.
The M20 provides complete flexibility in terms of the type of protection
required for your application. You may select either overload and underload
protection or simply overload with pre-alarm or underload with pre-alarm.
Independent response delays can be selected for both overload and underload
protection. Additional flexibility is provided in the form of programmable
output relays, number of start attempts, number of reversing attempts etc.

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 The Emotron M20 shaft power monitor offers advanced multi-function
monitoring and a display for load indication and parameter setting. It is ideal
for
protecting many different applications including pumps in general, centrifugal
pumps, magnetic pumps, screw and impeller pumps, mixers, scrapers, crushers,
conveyor systems, etc.
For further information, please see www.emotron.com.

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 4

4.1 Please note

1. Pay special attention to the safety section in this manual and parts marked
CAUTION.
2. Check that motor/supply voltage corresponds to values on the monitor
product label at the side of the unit.
3. Make a note of the motor’s rated power and full load amps from its
nameplate. Confirm that the current transformer supplied is of the correct
size according to tables 1 and 2 in chapter 6 of this manual.

4.2 Connection and set-up before first start

1. Connect the Emotron M20 according to chapter 5 and Fig. 1.
2. Make sure all safety measures have been taken and switch on the supply
voltage.

3. Use the key to scroll through the menu. Press and hold the ENTER key and
press the key to scroll back.
4. Set rated motor power and current in windows 41 and 42. Additional
settings to be programmed are discussed in chapter 8.
5. Set monitor function in window 05, overload and underload or only
underload or only overload. See chapter 12, Parameter list, for range and
default values.
6. Set start delay and response delay in window 31 and 32/34.
7. Compare all set values with the parameter list in chapter 12 to confirm that
all relevant values are set. Advanced features will be found in chapter 9.

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 4.3 First start

CAUTION!
Make sure that all safety measures have been taken before switching on
the supply voltage and starting the motor/machine in order to avoid
personal injury.

1. Start the motor/machine and let it run at normal load, until the Start Delay
has expired.
2. Press AUTO
SET for 3 seconds.

Hint!
Short-circuit the output relays during the set-up; this prevents the equipment
from stopping unintentionally.
More Hints!
The monitor can be set in three different ways:
1. Automatically by pressing the Auto set key as described above. The Auto set
function performs a measurement (momentarily) of the actual load and sets
relevant alarm levels for this actual load plus/minus the “margins” (Default;
Max +16% and Min -16%).
2. If Auto set is used as above, the margins can be re-adjusted manually
(windows 21-24). When the margin values are changed a new Auto set must
always be performed to activate the changes and the new margins. More
information is provided in chapter 9, Advanced Features.
3. Manual setting of alarm levels (windows 11-14). The alarm levels can be set
manually, without using the Auto set. See sections Manual setting of alarm
levels, alternative A, B and C.

NOTE: If any window parameter is manually adjusted, the display will flash
the new value to indicate that a change has been made. The Enter key must
be pressed for the M20 to accept this new value.

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 4.4 Manual setting of alarm levels,
alternative A

Running and setting at normal load

• Start the motor/machine or pump and let it run at normal load, until the
Start Delay (window 31) has expired.
• Read off the load on the monitor display, e.g. 65%, window 01
(or kW/HP).
• Set the max. main alarm level to something between e.g. 70-85% in window
11. This must be set to the actual application requirements, maximum load
for machine/process.
• Set the min. main alarm level to something between e.g. 60-45% in window
14. This must also be set to the actual application requirements.
See also Fig. 7 in section 8.4, Over- and underload monitor.

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 4.5 Manual setting of alarm levels,
alternative B

Running and setting at maximum load as well as at

minimum load
• Start the motor/machine or pump and let it run at maximum load, until the
Start Delay has expired. E.g. fill the conveyor with maximum allowed goods.
• Read off the load on the monitor display, e.g. 85% (window 01).
• Set the max. main alarm level to something between e.g. 90-95% in window
11. This must be set to the actual application requirements, maximum load
for both machine and processes.
• Then run the motor/machine and let it run at minimum load, e.g. idling,
until the Start Delay has expired.
• Read off the load on the monitor display, e.g. 30%.
• Set the min. main alarm level to something between e.g 25-20% in window
14. This must also be set to the actual application requirements.
See also Fig. 7 in section 8.4, Over- and underload monitor.

4.6 Manual setting of alarm levels,

alternative C
It is also possible to approximately calculate or estimate the alarm levels. If e.g.
the motor used is 22 kW, 22 must be set in window 41. This means that each
percentage point corresponds to 220 W (22 kW/100 = 220 W), and the alarm
limits in window 11- 14 can be set in steps of 220 W. If the max. alarm level is
set to 80% in this example, the monitor will emit an alarm and stop the
machine at approx. max. 17.6 kW shaft output power.

If the pre-alarm is not used, the values for Min. pre-alarm and Max.
pre-alarm can be set to 0 (window 13) and 125% (window 12) respectively.
This will eliminate pre-alarm warning indications in the monitor display
when not in use.

See also Setting alarm levels manually in chapter 9, Advanced Features.

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 5 Wiring
The following wiring diagram provides an example of how the M20 can be
connected to control the start/stop circuit of a three-phase motor, Fig. 1.
Connections to a single-phase motor are described later in this manual (Fig. 2)
as are the programming changes necessary for such applications. The default
setting for the M20 is 3-phase.
1. The current transformer CTMxxx must be placed in the same phase that is
connected to terminal 9, phase L1, see Fig. 1. Failure to follow this
requirement will result in the monitor failing to function.
2. For single-phase connection see fig 2.
When using DC voltage, terminal 6 should be connected to negative polarity
(ground) and terminal 5 to positive polarity (max. 48 VDC). See also
Alternative auxiliary circuit (Fig. 16) in chapter 9.

Note: The current transformer (CTMxxx) must be placed in the same phase
that is connected to terminal 9, phase L1, see Fig. 1.

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 L1
L2
L3

NOTE: in power down,

both relays are alwas
N.O.

9 L1 6 Max. 240 VAC (alt. 0 VDC-)

4
A+ A- C
11 7
L2 R1
M20
13 8
L3 R2
S1 S2
DIG 5

2
Stop
Please see CTM
K1 information
on Page 11.

K1 Start

{
NOTE: Monitor
voltage see K1
Note below.
W
U
V

M N (alt. 48 VDC+)

Fig. 1 Connection example

NOTE: If the START/STOP is connected as per Fig. 1, it is recommended that

terminals 6 and 7 be bypassed during programming. After the programming
is completed the bypass must be taken out. Make sure that the monitor
voltage range e.g. 3x380-500 VAC matches the connected motor/line
voltage, e.g. 3x 400 V.

Please use the enclosed plastic (rubber) insert (if ordered, optional) to cover the
monitor terminals.

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 5.1 Alternative example for single-phase
connection
This wiring example shows the connections required for single-phase
applications. Refer to Fig. 1 for the remaining wiring.

L1
N

9 6

3
L1

4
A+ A- C
11 7
L2 R1
M20
13 8
L3 R2
S1 S2
5
1

CTMxxx DIG

K1 NOTE: Monitor
voltage, see
note below.
N
L

Fig. 2 Single-phase connection example.

NOTE: In Fig. 2 make sure that the monitor voltage range e.g. 1x100-240 VAC
matches the connected motor/“line – neutral” voltage, e.g. 1x 230 V.

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 5.2 Example - digital input
The digital input uses terminals 5 (DIG) and 6 (C - reference). Either a VAC or
a VDC signal may be used. Connect + to terminal 5 (DIG) and - to terminal 6
for VDC signal. Please note the polarity when DC voltage is used. See also Fig1
and terminal 6: Max. 240 VAC (or 0 VDC-) and on terminal 5: N
(or 48 VDC+). See also chapter 9, Advanced Features.

VAC VDC
6

M20
C
5
~
Max 240 VAC M20
C
6

5
- Max 48 VDC
DI G ~ DI G +
Note polarity!

Fig. 3 Wiring example for digital input.

6 Selection of Current Transformer

6.1 Motors less than 100 A

1. Check the rated motor current on the motor plate.
2. Compare this value with the current in Table 1.
3. From Table 1, select the current transformer and the appropriate number of
windings.
Fig. 5 shows the different types of current transformer (CT) windings. In Fig.
5:1 the motor wire is just drawn through the CT, in the text and tables below
this is described as 1 (one) winding. Fig. 5:2 shows a CT with 2 windings and
Fig. 5:3, 3 windings. In other words the number windings is equal to the
number of times the motor wire “L1” is drawn through the hole of the current
transformer.

NOTE: Maximum length of the CTM cable is 1 m (39 inches).

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 Example
• Rated motor current = 12 A.
• Select 10.1-12.5 A from the first column in Table 1.
• This gives:
CTM025 with 2 windings (the motor wire is drawn through the CT’s hole
twice).

Table 1 Motors and CT less than 100 A

CURRENT TRANSFORMER TYPE and

RATED MOTOR NUMBER OF WINDINGS
CURRENT [A]
CTM 010 CTM 025 CTM 050 CTM 100

0.4 – 1.0 10
1.01 – 2.0 5
2.01 – 3.0 3
3.1 – 5.0 2
5.1 – 10.0 1
10.1 – 12.5 2
12.6 –25 1
26 – 50 1
51 – 100 1

In order to ensure an accurate calibration of the M20, it is essential that you use
the correct CTM and apply the exact number of windings in accordance with
the above table.

NOTE: Normally the appropriate Current Transformer will have been ordered
and shipped with the M20. Check that this is the case; contact the supplier
if in doubt.

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 L1
L2
L3

CTM025 2 windings

P2

1 2

S1 S2

M20

M
3

Fig. 4 Example CTM 025 with 2 windings for a 12 A motor

NOTE: The current transformer connection and orientation are not polarity
sensitive, but must be connected to the same phase that is being
referenced for terminal 9 of the M20.

P2

1 2

5:1 5:2 5:3

Fig. 5 Example 1, 2 and 3 windings.

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 6.2 Motors greater than 100 A
1. Check the rated motor current on the motor plate.
2. Compare this value with the current in Table 2.
3. Select the primary and secondary current transformer and the appropriate
number of windings from the columns in Table 2.
Please note that the ratio of the primary transformer must be exactly as provided
in the table below, otherwise the monitor power calculations will be inaccurate.
This will affect power readings, settings etc.

Example
• Rated motor current = 260 A.
• Select 251-500 A from the first column in Table 2.
• This gives:
- Primary transformer 500:5, 1 winding. (The motor wire is drawn through
the primary transformer once).
- CTM010 with 2 windings. (The wire from the primary transformer is
drawn through the hole in the CT, "CTM10", twice).

Table 2 CT greater than 100 A.

RATED MOTOR CURRENT TRANSFORMER TYPE and

CURRENT [A] NUMBER OF PRIMARY WINDINGS

150:5 + CTM 010

101 – 150
1 + 2
250:5 + CTM 010
151 – 250
1 + 2
500:5 + CTM 010
251 – 500
1 + 2
1000:5 + CTM 010
501 – 999
1 + 2

NOTE: Check that the appropriate Current Transformers has been ordered
and shipped with the M20. Contact the supplier if in doubt.

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 L1
L2
L3

CTM010 2 windings

P2

1 winding

1 2 S1 S2

500:5
S1 S2

M20

M
3

Fig. 6 Example of a CTM 010 with 2 windings and a primary transformer

500:5 with 1 winding for a 260 A motor.

NOTE: The transformer connection and orientation are not polarity sensi-
tive, but must be connected to the same phase that is being referenced for
terminal 9 of the M20.

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 7 Operation
Make sure the enclosed plastic (rubber) insert (if ordered, optional) covers the
monitor terminals before you start programming.

7.1 Overview
1 S1 Current transformer input 122 Function (window) number
2 S2 Current transformer input 123 Function Value
3 + Analogue output ! Warning signal
4 - Analogue output  Start, response delay or
5 DIG External RESET or AUTO SET block timer active
or Block Pre-Alarm  Parameter locked
6 C Common: RELAY, DIG V Voltage indicator
7 R1 Main Alarm Relay 1* A Current indicator
8 R2 Pre-Alarm Relay 2 mA Milliampere indicator
kW Kilowatt indicator
S Second indicator
% Per cent indicator

Press for 3 seconds during Proceeds to next window. If no

normal and stable load to key is pressed for 1 minute the
apply the automatic setting of display returns to window 01
the alarm levels. Not avail- automatically. Scroll back by
able if Parameter Locked. pressing and holding ENTER at
the same time as the NEXT key
is pressed.

Confirm (save) changes.

To reset ALARM After Power up window 01
appears, the actual load value
is shown.
Default view (example shows
For increasing and 54% load):
decreasing value 9 L1 Motor phase
11 L2 Motor phase
13 L3 Motor phase 01 54 %

* For alternative relay function, see Special functions Use the NEXT key to scroll
through the function menu.
in chapter 9.

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 7.2 Window menu

Start window
Alarm indication 00 01 Measured shaft power

02 Measured line voltage

03 Measured current

04 Parameter Lock

05 Monitor Function

Factory defaults 99 11 11 MAX Main Alarm

Analogue Output 91 12 12 MAX Pre-Alarm

OVER- and UNDERLOAD

13 13 MIN Pre-Alarm
Block Timer 82
14 14 MIN Main Alarm
UNDERLOAD
OVERLOAD

Digital Input 81
21 21 MAX Main Alarm margin

Relay function 65* 22 MAX Pre-Alarm margin

22
Pre-Alarm Relay 2 64 23 23 MIN Pre-Alarm margin
Main Alarm Relay 1 63 24 24 MIN Main Alarm margin
Alarm at no motor 62
current
Main Alarm Latch 61
31 Start Delay

Number Of Phases 43 32 Response Delay Max

Rated Current 42 33 Hysteresis

Rated Motor Power 41 34 Response Delay Min

35* Pause/Reverse time

36* Autoreset (start attempts)

* See Special functions in chapter 9, Advanced Features

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 • The Alarm window 00 only appears if an Alarm output is active.
• The Actual Load window 01 appears after power up.

• Use the key to scroll through the menu. Scroll back by pressing and
holding ENTER at the same time as the key is pressed.
• The Actual Load window (or alternative alarm window) will appear auto-
matically if no keys are pressed for longer than 1 minute.
• If the Parameter Lock is on, only windows 00 (if alarm active)
01 02 03 04 are visible.

• Window 05 selects the monitor function, see section 8.4.

7.3 How to change a value

Example: setting the rated motor current in window 42.

1. Press until the window number 42 appears.

42
A
5.6
2. Press or until the desired value is reached (e.g. 23 A), value flashes.

42
A
23
3. Press to confirm and save the change, value stops flashing.

NOTE: If the value is NOT to be changed, press the NEXT key.

CAUTION!
In order to avoid personal injury, make sure that all safety measures have
been taken before switching on the supply voltage and starting the motor/
machine.

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 8 Programming

8.1 Set measurement unit, kW or HP

8.1.1 Selecting the unit of measurement

The unit of measurement can be set to kilowatts or horsepower both as absolute
or relative values. This setting is valid for the alarm levels, rated motor power
and the actual load read-out in window 01.

Read-out Alarm levels

Measurement Rated power
load windows
unit window 41
window 01 11, 12, 13, 14

Kilowatt relative value (def.)* % kW %

Horsepower absolute value HP HP HP
Horsepower relative value* % HP %
Kilowatt absolute value kW kW kW

* Measured shaft power as % of rated power.

CAUTION!
In order to avoid personal injury, make sure that all safety measures have
been taken before switching on the supply voltage and starting the motor/
machine.

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 Programming
1. Go to window 01.
2. Press and hold RESET and simultaneously for 3 seconds.
3. The next unit of measurement is set and appears for 2 sec (see examples).
Repeat to select the desired measurement unit according to the table.

For 2 seconds Read-out example

:
absolute value HP 01 3.52
:
relative value* HP %
01 12 %

:
absolute value
kW
01 4.62
kW

:
relative value*
(default) kW %
01 12 %

* Measured shaft power as % of rated power.

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 8.2 Setting rated motor power and current
(window 41 and 42)
The rated motor power and the rated motor current must be set in windows 41
and 42.
Example motor plate:

TYPE: T56BN/4 NR: 948287 Prot. IP: 54

Serv: S1 Cos : 0.78 Is. Cl:F

V:Y/ Hz HP kW RPM A:Y/

240/415 50 3 2.2 1400 5.6/9.4

260/440 60 3 2.2 1680 5.8/9.1
ASYNCHRONOUS THREE-PHASE MOTORS

8.2.1 Programming
1. Go to window 41 (default = 2.2 kW).
2. Press or to set the rated motor power as indicated on the motor
plate (see example).

3. Press to confirm the change.

4. Go to window 42 (default = 5.6 A).
5. Press or to set the rated motor current as indicated on the motor
plate (see example).

6. Press to confirm the change.

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 8.3 Setting number of phases (window 43)
The number of phases must be set according to the number of motor phases.
Default is 3 phases, see also chapter 5, Wiring.

8.3.1 Programming
1. Go to window 43 (default = 3PH).

43 3PH
2. Press or to set the number of phases to 1 if a single-phase motor is
used.

3. Press to confirm the change.

43 1PH

8.4 Monitor function (window 05)

Monitor Indication in Output Relay

Alarm
(Protection) window 05 (default)

MAX Main Alarm Relay 1 (NC): 6-7

OVER- and UNDER- MAX Pre-Alarm Relay 2 (NO): 6-8

LOAD (default) MIN Pre-Alarm Relay 2 (NO): 6-8
MIN Main Alarm Relay 1 (NC): 6-7
MAX Main Alarm Relay 1 (NC): 6-7
OVERLOAD
MAX Pre-Alarm Relay 2 (NO): 6-8
MIN Pre-Alarm Relay 2 (NO): 6-8
UNDERLOAD
MIN Main Alarm Relay 1 (NC): 6-7

If separate output relays are required for overload and underload alarms, please
refer to chapter 9 and chapter 12.

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 Overload and underload Monitor

P/%
START UNDERLOAD OVERLOAD

MAX Main alarm

[11]
MAX Pre-alarm
MAX Main
[12]
alarm margin
MAX Pre-alarm [21]
OPERATION AREA margin [22]
Auto set level
Normal load

MIN Pre-alarm
margin [23] MIN Main
MIN Pre-alarm alarm margin
[13] [24]

MIN Main alarm

[14] Response
delay
[34] [32]

t/s

Start delay [31]

Main Alarm latch=ON [61]

Relay 1
Main alarm

Relay 2
Pre-alarm

Fig. 7 Overload and underload monitor.

Programming
1. Go to window 05. The default selection is Overload and Underload
monitor.
2. Press or to select underload or overload monitor.

_ _
05 _ 05 _ 05

OVER- and UNDERLOAD UNDERLOAD OVERLOAD

3. Press to confirm the change.

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 8.5 Setting the Start Delay (window 31)
To avoid false alarms during start up a Start Delay must be set to allow the
motor and machine to speed up and to allow the power in-rush currents.

Programming
1. Determine in seconds how long it takes for the motor and machine to reach
speed and for the power in-rush to pass. This will be the Start Delay.
2. Go to window 31 (default = 2.0 s).
3. Press or to set the determined Start Delay time in seconds.

4. Press to confirm the change.

If the monitor is being used on a self-priming pump, it may also be necessary to
set the Start Delay long enough to allow the pump to become fully primed.

P
Example: Start Delay 2.0 s

31 2.0 S

t
Start Delay [31]

Fig. 8 Start Delay.

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 8.6 Setting alarm levels with Auto set
The Auto set command performs a measurement (momentarily) of the actual
motor load and automatically sets the relevant alarm levels depending on the
selected monitor function.

Protection Margin
(Monitor Value Margins Alarm Level at
Alarm
function (Default (Windows) Auto set
window 05) margins)

MAX Main 21: MAX Main Normal machine

16%
Alarm Alarm margin load + Window 21
MAX Pre- 22: MAX Pre- Normal machine
OVER- and 8%
Alarm Alarm margin load + Window 22
UNDERLOAD
(Default) MIN Pre- 23: MIN Pre- Normal machine
8%
Alarm Alarm margin load - Window 23
MIN Main 24: MIN Main Normal machine
16%
Alarm Alarm margin load - Window 24
MAX Main 21: MAX Main Normal machine
16%
Alarm Alarm margin load + Window 21
OVERLOAD
MAX Pre- 22: MAX Pre- Normal machine
8%
Alarm Alarm margin load + Window 22
MIN Pre- 23: MIN Pre- Normal machine
8%
Alarm Alarm margin load - Window 23
UNDERLOAD
MIN Main 24: MIN Main Normal machine
16%
Alarm Alarm margin load - Window 24

Programming
1. Start the motor and let it run at the normal machine load until the Start
Delay has expired.
2. Press AUTO
SET for 3 seconds. This can be done in any window.

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 3. The display shows “SEt”, to confirm that the Auto set level has been
measured and the alarm levels have been set. The display reverts to window
01.

3 seconds
AUTO
SET SEE 01 40 %

4. If the alarm levels are too high or too low, readjust the appropriate
MARGINS (see table) and perform a new Auto set. Alternatively, alarm
levels can be set manually, see chapter 9.

8.7 Setting the Response Delay (windows 32

and 34)
A Response Delay allows the machine to remain in an over- or underload
condition for a specific time before the alarm relays are activated. Set the
response delay for the overload condition in window 32 (max.), and set the
response delay for the underload condition in window 34 (min.). The default
value for both windows are 0.5 s. The valves may be adjusted upwards to avoid
triggering a “false alarm”.

Programming
1. Determine in seconds the response delay required for both overload and
underload conditions. This is normally determined by the unique properties
and behaviour of each application.
2. Go to window 32 (overload, default = 0.5 s).
3. Press or to set the determined Response Delay time in seconds.

4. Press to confirm the change.

The response delay for the underload condition (min.) is set in window 34 in a
similar way.

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 Example: Response Delay

32 0.5 S
34 0.5 S

Alarm level

t
Response Delay [32]

Alarm

Fig. 9 Response Delay.

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 9 Advanced Features

9.1 Setting alarm levels manually (windows

11-14)
The alarm levels can be set manually, without using the Auto set. These levels
can also be readjusted, e.g. for fine-turning, after an Auto set has been
performed. See also section 4.3 to 4.6.

Protection (Monitor function

Alarm levels (Window) Default
window 05)

11: MAX Main Alarm 100%

OVER- and UNDERLOAD 12: MAX Pre-Alarm 100%

(Default) 13: MIN Pre-Alarm 0%
14: MIN Main Alarm 0%
11: MAX Main Alarm 100%
OVERLOAD
12: MAX Pre-Alarm 100%
13: MIN Pre-Alarm 0%
UNDERLOAD
14: MIN Main Alarm 0%

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 Setting margins (windows 21-24)
The margins for the Auto set can be changed manually. After the adjustment,
the Auto set action must be performed again.

Protection (Monitor function

Window Default
window 05)

21: MAX Main Alarm margin 16%

OVER- and UNDERLOAD 22: MAX Pre-Alarm margin 8%

(Default) 23: MIN Pre-Alarm margin 8%
24: MIN Main Alarm margin 16%
21: MAX Main Alarm margin 16%
OVERLOAD
22: MAX Pre-Alarm margin 8%
23: MIN Pre-Alarm margin 8%
UNDERLOAD
24: MIN Main Alarm margin 16%

Setting hysteresis (window 33)

The hysteresis of an alarm level prevents the alarm relay “chattering” if the load
fluctuates even in a normal “stable” condition. This also applies to a pre-alarm.
This feature is normally only used if the main alarm latch (window 61) is set to
Off. Default = 0%.

P/%

Hysteresis [33]
MAX Main Alarm level [11]

MIN Main Alarm level [14]

t/s

Relay 1 MAIN Alarm

Fig. 10 Hysteresis

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 Setting main alarm latch (window 61)
The main alarm latch keeps the main alarm output active, even if the alarm
condition has been removed. A latched alarm output can be reset by:
• The reset key
• External reset via digital input (see window 81).
• Switching off the power to the monitor (see also Wiring).
Default = Off.

Setting alarm at no motor current (window 62)

The alarm at no motor current gives an alarm if the motor current goes down to
zero (62 = on). Default = Off (No alarm at no motor current).

Setting relay output (window 63 and 64 alt. 65)

The relay outputs R1 and R2 can be set to NO or NC contacts.

NOTE: If the power to the load monitor is switched off, the relay contacts
are always in position NO.

If separate output relays are required for overload (max., relay R1) and
underload (min., relay R2), see Special functions in chapter 9 and chapter 12.

Setting digital input (window 81)

The digital input can be set for:

RES: External RESET

To reset an alarm.
(Default)
AU: External Auto set To perform an Auto set with an external signal.
To block the Pre-Alarm function and start the Block
bLo: Block Pre-Alarm timer. If the input is high a Pre-Alarm is blocked, i.e. it is
neglected. See also window 82.

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 Setting block timer (Window 82)
To set the timer for the blocking time after the Block command is released (see
also window 81). Default = 0.0 sec.

P/%

MAX Main Alarm level [11]

MAX Pre-Alarm level [12]

Auto set level

t/s

Relay 1 Main alarm

Relay 2 Pre-alarm

Pre-Alarm Blocked

Block signal high on terminal 5 DIG [81] Block timer [82]

Fig. 11 Block timer

Setting analogue output (window 91)

The analogue output provides an analogue signal of either 0-20 mA or 4-20 mA
which represents the motor shaft power. The signal can be inverted (20-0 or 20-
4 mA). Full scale: rated motor power, see Fig. 12. To set P-span/scaling (full
scale) see Fig. 13.

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 91 4.20
PSHAFT
100% 20.4

20.0

0.20

4.20
0% Output
0 4 20 mA

Fig. 12

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 Setting analogue output load range: P-span (window
92-93)
With windows 92 and 93 the full scale of the analogue output can be set
according to the minimum and maximum load (P-span).
1. In window 91, press RESET and + for two seconds until “on” shows.
Windows 92 and 93 are now active.

P shaft
100%
92= 20%
70%
93= 70%

92= 0%
93= 100%

20%

0 Output
0 6 14 20 mA

Fig. 13

2. Set the lowest load value in window 92 (e.g. 20%)

3. Set the highest load value in window 93 (e.g. 70%)
The full scale of the analogue output is now set between 20% and 70% load.
See Fig. 13. To deactivate: Press RESET and + for two seconds until “Off ”
shows in window 91.Windows 92 and 93 are now inactive.

Locking parameters (window 04)

To avoid the parameter settings being changed unintentionally, the
programming can be locked by entering the code “369” in window 04. Now
only Load [01], Voltage [02] and Current [03] can be checked. Follow the same
procedure to unlock the monitor. The Auto set key is disabled when parameters
are locked. Auto set via digital input is always active if window 81 is set to AU
(Auto set).

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 01

24 %

NOTE: The  symbol appears in all windows.

Resetting to factory defaults (window 99)
The factory defaults are reset by entering “dEF” in window 99. If window 99
shows “USr” it indicates that the settings have been changed to user specific
settings.

View alarm message (window 00)

In an alarm condition, the window 00 appears automatically. The window
indicates the following alarm conditions. Window 00 flashes at all times.

Undervoltage,
!
Pre-Alarm MAX !
switch off the
level reached
00 F^ 00 LU supply!

Overvoltage,
!
Alarm MAX !
switch off the
level reached
00 F^ 00 0U supply!

! ! No motor current
Pre-Alarm MIN Window 62 = on
00 FO level reached 00 F0

Out Of Range. This message

!
Alarm MIN
!
appears only in window 01 (actual
00 FO level reached 01 OOO load) or 03 (actual current)

When the monitor is switched on (power up), the voltage on phases L1, L2 and
L3 is checked. If the wrong voltage is detected, an LU (undervoltage) or OU
(overvoltage) alarm is generated. No relay alarm will be indicated or activated.

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 Special functions (windows 35, 36 and 65)
Special functions are separate relays for overload and underload alarm/stop, start
attempts and a reverse function with start attempts:
• Window 65 = 0, Normal M20
• Window 65 = 1, Separate relays for overload and underload alarm (DLM)
• Window 65 = 2, Reverse function

Window 65 = 0 Window 65 = 1 Window 65 = 2

“Normal M20” “Separate relays “Reverse function”
over-/underload
alarm” (max/min)
Max/Min Max
R1 Main alarm R1 Main alarm R1 Forward

Max/Min Min Reverse

R2 R2 R2
Pre-alarm Main alarm

Fig. 14 Window 65 and relay functions

In all three cases the number of start attempts after a main alarm may be set in
window 36. The pause time between start attempts may be set in window 35.
This time is also used as the time to run the motor in the reverse direction when
window 65=2.
The reverse function can be used to reverse e.g. a screw conveyor or pump when
a “jam” occurs. Reversing the motor may remove the blockage. Should one
reverse cycle not be enough to release the material, the M20 will repeat this
operation up to a maximum of 5 cycles (window 36, 0-5 start attempts). Relay
R1 = forward, relay R2 = reverse.

NOTE: For special handling of analogue output in reverse mode, see below.

The analogue output will go to its maximum e.g. 20 mA when the number of
allowed start attempts has elapsed.
Resetting an alarm
A reset will cause the start attempt counter to be reset (new start attempts may
be performed).

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 NOTE: In order to accomplish the above result, it will be necessary for a
forward and reversing motor starter to be installed. See Fig. 15 Example of
connection with a forward and reversing motor starter (contactor).

For more information contact your local sales outlet or visit us at:
www.emotron.com

L1
L2
L3

Alarm/Stop
} 20 mA
(Blocking)

Max 240 VAC (alt. 0 VDC-)

9 6
3

L1 A+ A- C
11 7
L2 R1
M20
13 8
L3 R2
S1 S2
DIG 5
1

CTMxxx

K1 K2 K1 K2 Reset

FWD REV

N (alt. 48 VDC+)

Window Function Range

35 Reverse time 3-511 s

W
U
V

36 Start attempts 0-5

M
65 Relay function 2=reverse

Fig. 15 Example of connection with a forward and reversing motor starter (contac-
tor).

NOTE: In Fig. 15, R1 and R2 (K1 and K2) must not be energized/on at the
same time as this will generate a short circuit. Therefore it is important
that window 65 = 2 before the relays are connected to the contactors.

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 Alternative auxiliary circuit

L1
L2
L3

9 6 0VDC-

4
L1 A+ A- C
11 7 OUT
L2 R1
M20
13 8
L3 R2
S1 S2
5
1

2
DIG
CTMxxx

24VDC+
W
U
V

Fig. 16 Example of auxiliary circuit when VDC is used.

The example above can be used when a high VDC signal output is required.

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 10 Troubleshooting
Ensure that the installation has been correctly carried out, e.g. check the
terminals and that the cables are properly stripped. The monitor is
maintenance-free. However, you should regularly check wirings and terminals
etc.

Problem Solution

- Check the connection of the current

transformer(s).
- Check that the value of the rated motor power in
Window 01 always
window 41 is the same as the rated motor power on
shows zero load, even if
the motor plate.
the motor is running
- Check that window 03 shows a phase current
value that agrees with with the rated motor
current.
- Check that the motor is not oversized for its applica-
tion, check power transmission and gear ratio.
Window 01 shows an - Check that there is a load on the motor during
improper power value normal operation.
when the motor is run- - Check that the change in motor load is greater than
ning about 3% (window 01).
- Check that the current transformer is connected in
phase L1.
- Check that the current transformer has been
selected as per Tables 1 and 2.
Window 03 shows an - Check that the number of windings is as per Tables
improper value for the 1 and 2.
phase current - Check that the value of the motor current in
window 42 is the same as the value of the motor
current on the motor plate.
- Check that window 01 shows a value greater than
The monitor never gives zero.
an alarm - Check the alarm levels in windows 11 to 14. If in-
correct readjust the levels or perform an Auto set.

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 Problem Solution
- Check the alarm levels in windows 11 to 14.
If incorrect readjust the levels or perform an
The monitor always Auto set.
gives an alarm - Check if the monitor is programmed for “latched
alarm” (window 61=on). If so reset the monitor by
pressing the reset key.
Window 00 shows “LU” Switch off the supply:
or “OU”. Under- or over- - Check that the supply voltage agrees
voltage alarm. with the voltage range on the monitor type plate.
Window 01 shows
- The measured shaft power is higher than 125% of
“oor”. “Out Of Range”
the rated motor power programmed in window 41.
alarm.
Window 03 shows - The measured motor current is higher than 125%
“oor”. “Out Of Range” of the rated motor current programmed in window
alarm. 42.
This is only detected at monitor power up and not dur-
Over and undervoltage
ing continued operation. The relays will not trip, only
is not detected
indication in the display.
The alarm relays are not - Check that the wire links between terminals 6
switching and 7 are removed as per “Wiring”.
Not all windows are When the special functions are used (windows 35, 65
shown etc.) blocked windows for settings are not shown.

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 11 Technical Data

45x90x115 mm (1.77" x 3.54" x 4.53")

90mm(3.54) ’‘
Dimensions

(1.02)’‘ (1.38)’‘
26mm 35mm
(WxHxD)

45mm (1.77’‘) 115mm(4.53) ’‘

Mounting 35 mm DIN rail 46277

Weight 0.30 kg (10.5 oz)
Supply voltage 1x100-240 VAC, 3x100-240 VAC, 3x380-500 VAC or 3x525-
(±10%) 690 VAC
Frequency 50 or 60 Hz
Current transformer; CTM 010, 025, 050 and 100. Input 0-
Current input
55 mA. (>100 A extra transformer needed)
Power consump-
Max. 6 VA
tion
Start-up delay 1-999 s
Hysteresis 0-50% of rated motor power
Response delay
0.1-500 s
max
Response delay
0.1-500 s
min
Relay output 5 A/240 VAC Resistive, 1.5 A/240 VAC Pilot duty/AC12
Analogue output Max. load 500 ohm
Max. 240 VAC or 48 VDC. High: 24 VAC/DC,
Digital input
Low: <1 VAC/DC. Reset >50 ms
Fuse Max. 10 A
Use 75°C copper (CU) wire only. 0.2-4.0 mm2 single core
Terminal wire size (AWG12). 0.2-2.5 mm2 flexible core (AWG14), stripped
length 8 mm (0.32")

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 Terminal tighten-
0.56-0.79 Nm (5-7 lb-in)
ing torque
±2%, ±1 unit cos phi>0.5; excl. current transformer; +20°C
Accuracy
(+68°F)
Repeatability ±1 unit 24h; +20°C (+68°F)
Temperature toler-
max 0.1%/°C
ance
Operating temper-
-20 to +50°C (-4°F to +122°F)
ature
Storage tempera-
-30 to +80°C (-22°F to +176°F)
ture
Protection class IP20
RoHS directive 2002/95/EC
Approved to CE (up to 690VAC), UL and cUL (up to 600 VAC)

Article
Designation
number

01-2520-25 Emotron M20 1x100-240/3x100-240 VAC

01-2520-45 Emotron M20 3x380-500 VAC
01-2520-55 Emotron M20 3x525-690 VAC

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 Technical Data for Current Transformer (CT)
Dimensions
Type Weight* Mounting
(WxØ)
CTM 010 27 (35) x Ø48 mm 0.20 kg 35mm DIN rail 46277
CTM 025 27 (35) x Ø48 mm 0.20 kg 35mm DIN rail 46277
CTM 050 27 (35) x Ø48 mm 0.20 kg 35mm DIN rail 46277
CTM 100 45 (58) x Ø78 mm 0.50 kg 35mm DIN rail 46277

* Weight including 1m (39 inch) cable. Please note that max. length of the
CTM cable is 1 m and this cable cannot be extended.

4.3 10.3

17

48
27 42

35
78

45

35

Fig. 17 Current Transformer CTM xxx.

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 Accessories and documentation

Article
Designation
number
01-2471-10 Current Transformer (CT) CTM010, max. 10 A
01-2471-20 Current Transformer (CT) CTM025, max. 25 A
01-2471-30 Current Transformer (CT) CTM050, max. 50 A
01-2471-40 Current Transformer (CT) CTM100, max. 100 A
01-2368-00 Front Panel Kit 1 (2x terminal covers included)
01-4136-01 2x Terminal covers
01-5958-00 Instruction manual (Swedish)
01-5958-01 Instruction manual (English)
01-5958-02 Instruction manual (German)
01-5958-03 Instruction manual (Dutch)
01-5958-04 Instruction manual (Spanish)
01-5958-08 Instruction manual (French)
01-5958-09 Instruction manual (Russian)

Dismantling and disposal

The product is designed to comply with the RoHS directive, and shall be
handled and recycled in accordance with local legislations.

EU (European Union) specifications

EMC EN 61000-6-3, EN 61000-6-2
EN 61000-4-5
Electrical safety EN 60947-5-1
Rated insulated voltage 690 V
Rated impulse withstand voltage 4000 V
Pollution degree 2
Terminals 3, 4, 5, 6, 7 and 8 are basic insulated from the line.
Terminals 3 and 4 are basic insulated from terminals 5, 6, 7 and 8.

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 US specifications
FCC (Federal Communications Commission). This equipment has been tested
and found to comply with the limits for a Class A digital device pursuant to Part
15 of the FCC Rules. These limits are designed to provide reasonable protection
against harmful interference when the equipment is operated in a commercial
environment. This equipment generates, uses and can radiate radio frequency
energy and, if not installed and used in accordance with the instruction manual,
may cause harmful interference, in which case the user will be required to
correct the interference at their own expense.

Canadian specifications
DOC (Department of Communications). This digital apparatus does not
exceed the Class A limits for radio noise emissions from digital apparatus as set
out in the Canadian Interference-Causing Equipment Regulations. Le présent
appareil numérique n'ément pas de bruits radio-électriques dépassant les limites
applicables aux appareils numériques de la Classe A prestite dans le Régelement
sur le brouillage radioélectrique édicté du Canada.

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 12 Parameter List

Window Function Range Default Custom Symbol

00 Alarm indication
Measured shaft
power in % of rated 0-125 %
power
Measured shaft
0-745 kW
power in kW
01
Measured shaft
power in % of rated 0-125 %
power
Measured shaft
0-999
power in HP
02 Measured line voltage 90-760 V V
03 Measured current 0.00-999 A A
04 Parameter lock 0-999 
OVER- and
OVERLOAD
UNDERLOAD,
05 Monitor function and UNDER-
OVERLOAD,
LOAD
UNDERLOAD
0-125 100 %

MAX Main Alarm (relay 0-745 2.2 kW

11
R1) 0-125 100 %
0-999 3
0-125 100 %

MAX Pre-Alarm (relay 0-745 2.2 kW

12
R2) 0-125 100 %
0-999 3

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 Window Function Range Default Custom Symbol
0-125 0 %

MIN Pre-Alarm (relay 0-745 0 kW

13
R2) 0-125 0 %
0-999 0
0-125 0 %

MIN Main Alarm 0-745 0 kW

14
(relay R1) 0-125 0 %
0-999 0
MAX Main Alarm
21 0-100 16 %
margin
MAX Pre-Alarm
22 0-100 8 %
margin
MIN Pre-Alarm
23 0-100 8 %
margin
MIN Main Alarm
24 0-100 16 %
margin
31 Start delay 1-999 2 s
Response delay over-
32 0.1-500 0.5 s
load
33 Hysteresis 0-50 0 %
Response delay
34 0.1-500s 0.5 s
underload
35* Pause/Reverse time 3-511 5 s
Autoreset (start
36* 0-5 0
attempts)
0.10-745 2.2 kW
41 Rated motor power
0.13-999 3
42 Rated current 0.01-999 5.6 A
43 Number of phases 1PH/3PH 3PH
61 Main alarm latch on/OFF OFF

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 Window Function Range Default Custom Symbol

Alarm at no motor
62 on/OFF OFF
current
63 Main Alarm relay R1 nc/no nc
64 Pre-Alarm relay R2 nc/no no
0 = M20
65* Relay function 1 = DLM 0
2 = Reverse
81 Digital input rES/AU/bLo rES
82 Block timer 0.0-90 0.0 s
0.20/4.20/
91 Analogue output 0.20
20.0/20.4
Analogue output low
92** 0-100
value
Analogue output high
93** 0-125
value
99 Factory defaults dEF/USr dEF

* See Special functions in chapter 9.

** See Set analogue output range in chapter 9.

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 13 Service
This manual is valid for the following model:
Emotron M20 (from software version R3b)

Document number: 01-5958-01

Document version: r0
Date of release: 2012-04-02

CG Drives & Automation Sweden AB reserves the right to alter product

specifications without prior notification. No part of this document may be
reproduced without permission from CG Drives & Automation Sweden AB.
For more information contact your local sales outlet or visit us at:
www.emotron.com / www.cgglobal.com

Protected by utility patents EP 1027759 and US 6879260

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 CG Drives & Automation 01-5958-01r0

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 CG Drives & Automation, 01-5958-01r0, 20123-04-02

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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