Emotron EMX-R-15S User manual

EMX™-R
DRIVE SYSTEM
INSTRUCTION MANUAL - English

Valid for the following models:
EMX-R-15S
EMX-R-15E
EMX-R-25S
EMX-R-25E
EMX-R-35S
EMX-R-35E
Version 2.x
EMX™-R
DRIVE SYSTEM
INSTRUCTION MANUAL - English
Document number: 01-3333-01
Edition: r2
Date of release: 2006-02-15
© Copyright Emotron AB 2005 - 2006
Emotron 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 Emotron AB.

The product is protected as follows:
Patents: US 4 868 478; EP 0 285 637; SE 8604308-0
US 5 315 224; EP 0 507 835; SE 9002217-9
US 6 628 100; SE 9902821-9
SE 0100814-3
Registered design: US 462 937; DE 400 05 393.4; SE 66 630

Emotron AB 01-3333-01r2 1
Safety instructions
During installation
• Read the instruction manual completely before installation and commis-
sioning.
• The installation must be carried out by qualified personnel.
• General conditions and regulations for the installation and operation of
electrical machinery must be observed.
• Measures to protect against personal injury and damage to the machine
must be taken following local rules and regulations.
• The drive system EMX-R is intended for permanent installation.
• Cables may not be connected or disconnected while the supply voltage is
on.
• Check that the equipment is correctly connected before it is taken into use,
see the instructions in the chapter on Mounting/Connection.
• Faults that arise due to faulty installation or operation are not covered by the
guarantee.
During operation
• Measurements in the control unit, during operation, must only be carried
out on the terminals and only by authorized personnel. NOTE! Great care
must be taken.
• The units may not be opened or disassembled during operation.
During disassembly and scrapping
• The housing of the control unit is made from aluminium and steel. The
material must be handled and recycled following the relevant laws.
• The circuit board contains small amounts of tin and lead, which must be
handled and recycled in accordance with the relevant laws.
• The motor is made from copper, plastic, aluminium and iron. These materi-
als must be handled and recycled in accordance with the relevant laws.

2Emotron AB 01-3333-01r2

Emotron AB 01-3333-01r2 3
Contents
1. Description.................................................................................. 5
1.1 Introduction................................................................................................. 5
1.2 Product range ............................................................................................. 5
1.3 Operating indicators / built-in functions ................................................... 6
1.3.1 Automatic purging mode / holding torque................................................ 7
1.3.2 Rotation monitor (DIP switch 4)................................................................. 8
1.3.3 Protection of the control unit ..................................................................... 9
2. Mounting/connection.............................................................. 11
2.1 Mounting .................................................................................................. 11
2.1.1 Sensor for rotation monitor..................................................................... 12
2.2 Connection ............................................................................................... 12
2.2.1 When switching off .................................................................................. 13
2.2.2 Recommendations with respect to EMC................................................ 13
2.2.3 Priority switch / defrosting / manual control......................................... 14
2.2.4 Manual control using a 10 kOhm potentiometer .................................. 14
2.2.5 Test switch ............................................................................................... 15
2.2.6 Choice of maximum speed ..................................................................... 17
2.2.7 Setting DIP switches................................................................................ 18
2.2.8 Speed controller ...................................................................................... 19
2.2.9 Parallel connection .................................................................................. 19
2.2.10 Heat recovery on cooling – summer/winter switch............................... 20
2.2.11 Analogue output signal (only available on Model E) ............................. 20
2.2.12 Potentiometer with low resistance, 100 Ohm to 5 kOhm
(only available on Model E)..................................................................... 20
3. Maintenance/troubleshooting................................................ 21
3.1 Maintenance ............................................................................................ 21
3.2 Motor diagnosis ....................................................................................... 21
3.3 Troubleshooting ....................................................................................... 22

4Emotron AB 01-3333-01r2
4. Technical data ......................................................................... 25
4.1 The drive system’s operation using different control signals................ 26
4.2 Choice for sizes of drive system and belt pulley .................................... 29
4.3 Accessories and documentation ............................................................ 30
5. Appendix ................................................................................... 31

Emotron AB 01-3333-01r2 Description 5
1. Description
1.1 Introduction
EMX-R is a series of speed controlled drive systems specially designed for driv-
ing rotary heat exchangers. The drive system consist of a motor and its associ-
ated control unit.
EMX-R completely replaces drive systems EMS-VVX 1, 2-4N, 2-4N/ET and
2-4EM as well as the drive systems EMS-VVX 15, 25 and 35. All mentioned
drive systems have completely been replaced by EMX-R.
The new drive system EMX-R is based, like its predecessor, on the SR-motors
(SR=Switched Reluctance). These motors make it possible to drive heat
exchanger rotors up to 3.5 metres in diameter without gears.
1.2 Product range
EMX-R is available in three sizes for rotors up to around 3.5 m. They come in
sizes 15, 25 and 35 (for other rotor sizes, please contact the local distributor or
Emotron AB).
The control unit is available in two versions, S and E, where Model E has an
extra circuit board for increased functionality. Built-in functions included in the
Model S are:
• Automatic purging operation
• Rotation monitor - integrated electronics or with external rotation sensor
• Alarm relay
•Testswitch
• Priority switch/defrosting
• Heat recovery on cooling with external differential thermostat
In addition to the functions included in Model S, the Model E includes:
• Display of the rotor speed in r/min when the external rotation sensor is con-
nected.
• Analogue output signal proportional to the speed of rotation of the motor.
• Heat recovery on cooling with external temperature sensors.
• Input for potentiometer with low resistance, 100 Ohm to 5 kOhm.

6Description Emotron AB 01-3333-01r2
• Prepared for serial communication.
1.3 Operating indicators / built-in functions
Two LEDs, one red and one green, are used on the Model S for indication,
while the Model E has an LED display as follows:
Table 1 Operating indication – Model S
Green
Slow flashing – Purging mode/Low control signal
Rapid flashing – Operation, the motor rotates continuously
Lit for two seconds – Magnet passing rotation sensor
Lit - RotoSens measures the load on the motor during acceleration
Red Lit or flashing LED indicates alarm, see also the chapter on troubles-
hooting
Table 2 Operating indication – Model E
Purging mode. Low control signal
The speed of the rotor in rpm. At start a speed is displayed according to
the gear ratio rotor/motor = 1:25. After 2 pulses from the rotation moni-
tor, the correct speed of rotation of the rotor is displayed. Range 0.2–99
rpm.
RotoSens is selected using the DIP-switch (4) and with no rotation sen-
sor connected
Lit for two seconds when the magnet passes the rotation sensor
RotoSens measures the load on the motor during acceleration
Summer operation/heat recovery on cooling
No rotation monitor - DIP 4 in the OFF position and jumper 31-32
An alarm is indicated by the letter F followed by a number. See also the
chapter on troubleshooting.

Emotron AB 01-3333-01r2 Description 7
1.3.1 Automatic purging mode / holding torque
When the control signal is low, <1.5 V at 0–10 V, the drive system switches to
purging mode. In purging mode the motor shaft turns two revolutions every 10
minutes, which is equivalent to around 30 degrees of rotation by the heat
exchanger rotor. This slow rotation does not provide any significant heat trans-
fer, but simply serves to keep the rotor clean.
Most of the time the 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 used to provide a holding torque to keep the rotor
stationary.
The first time the drive system goes into purging mode after the power is
switched on this holding torque is not activated, since many rotors do not
require an active holding torque to keep them stationary. A rotor that does
require a holding torque will then begin to turn slowly. The drive system imme-
diately brakes this motion, reducing the speed to zero, and then applies a con-
stant holding torque to keep the rotor stationary. The drive system has now
learned which rotors require a holding torque, and which do not. The holding
torque is at least 50% higher than the torque required for operation just before
is should stand still.
If a holding torque has been applied and you grasp the drive belt and try to turn
the rotor by hand, the torque will progressively increase.
The holding torque is generated by passing a current through one of the motor
phases. The higher the torque that is required, the higher the current. This cur-
rent produces a noise that gets louder as the current increases. Integrated in the
control unit are three motor protection breakers, one for each motor phase. The
motor protection also protects the motor when the holding torque is activated.

8Description Emotron AB 01-3333-01r2
1.3.2 Rotation monitor (DIP switch 4)
Two different rotation monitors can be selected. The first, RotoSens™, which is
an integrated electronic rotation monitor, and secondly a rotation monitor
using a rotation sensor.
RotoSens uses the motor as the sensor. By allowing the control unit to measure
the load on the motor, you can determine whether the drive belt has broken.
When the drive belt has broken the motor load will be low. As the rotors which
rotate very easily also give a low load on the motor, it is necessary to also meas-
ure the load during acceleration - you then get a measurement of the rotor’s
moment of inertia. After 2 minutes of operation at a low load, a load measure-
ment is made during acceleration. If the drive belt is broken an alarm is given, if
it is undamaged the load measurement during acceleration is repeated again
after 24 hours. In cleaning mode, measurement during acceleration is made
once every 24 hours.
The rotation monitor with sensor has a magnet fitted on the periphery of the
rotor. The magnet activates the sensor once every revolution. Should, for exam-
ple, 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 24 seconds at max.
speed, 20 minutes at min. speed and about 8 hours in purge mode.
The rotation monitors give alarms through operating indications and via the
alarm relay, the motor does not stop with an alarm.
For operation without an external rotation sensor the DIP-switch 4 must be set
in position “OFF” (downwards), which means the built-in electronic rotation
monitor RotoSens is connected.
NOTE: In order to use RotoSens the load on the motor should not be to low.
The minimum diameter for the rotor and belt pulley for each size of the drive
system must be:
EMX-R-15: Belt pulley ≥63 mm, Rotor diameter ≥630 mm
EMX-R-25: Belt pulley ≥63 mm, Rotor diameter ≥ 1200 mm
EMX-R-35: Belt pulley ≥ 100 mm, Rotor diameter ≥ 2000 mm
If the belt pulley or rotor are smaller RotoSens can not be used, however,
the rotation monitor with sensor can always be used.

Emotron AB 01-3333-01r2 Description 9
For operation without both an external and the built-in electronic rotation
monitor RotoSens the DIP-switch 4 also must be set in position “OFF”, but
then a strap must be fitted between terminals 31 and 32.
1.3.3 Protection of the control unit
The control unit is protected by monitoring for both over-voltage and under-
voltage. If the supply voltage goes over or under the allowed limits, the control
unit is disconnected and the motor stops. The motor starts again automatically
when the supply voltage returns to its normal value.
The control unit has built-in motor protection that protects against overload-
ing, and external motor protection is not required. Power supply to the motor is
cut in the event of overload. In order to restart the drive system, the supply volt-
age to the control unit should be temporarily disconnected for at least 5 sec-
onds.
Built-in short circuit protection protects against short circuits between the
phases of the motor and between the phases and earth.
Table 3 Protection and alarm functions
Protective
function
External alarm
with alarm relay Restart Alarm reset
Supply fault, over-
voltage Yes, immediately Automatic
Automatic
Supply fault,
under-voltage
Pre-alarm, rotation
monitor No Motor not stop-
ped
Rotation
monitor Yes 1)
Pre-alarm, motor
protection/over-
load
No
The system tries
to reset three
times
Automatic
Motor protection/
overload Yes, immediately
Manual, discon-
nect and recon-
nect power
supply
Manual, discon-
nect and recon-
nect power
supply
Short circuit
1) RotoSens - manual, disconnect and reconnect the power supply.
Rotation monitor with sensor - automatic.

10 Description Emotron AB 01-3333-01r2

Emotron AB 01-3333-01r2 Mounting/connection 11
2. Mounting/connection
2.1 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. The motor is 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. 1 Rotor and drive system
10-F08
Control unit
Motor

12 Mounting/connection Emotron AB 01-3333-01r2
2.1.1 Sensor for rotation monitor
The magnet for the rotation sensor is screwed onto the periphery of the heat
exchanger. If the rotor cover is magnetic, the magnet must be insulated from the
cover. The rotation sensor is mounted such that the magnet passes at a distance
of 5–8 mm, see below.
Fig. 2 Mounting of the rotation sensor
2.2 Connection
WARNING! Residual voltage remains for up to 1 minute after
disconnection of the supply voltage.
The motor is delivered with a fixed connected motor cable to simplify installa-
tion of the drive system. The length of the cable is 2.0 m for EMX-R 15M and
2.5 m for EMX-R 25M and EMX-R 35M. The motor cable cannot be
extended because this could interfere with the electronic tachometer that is built
into the system.
NOTE: Magnet and rotation sensor must not be mounted when RotoSens is
used, which means the built-in electronic rotation sensor is used, DIP-switch 4
is used. To display the rotor speed an external sensor must be used
(applicable for model E).
Rotation sensor
Magnet
5-8 mm
Heat exchanger rotor

Emotron AB 01-3333-01r2 Mounting/connection 13
An external slow-blow fuse rated at 10 A must always be installed. 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.
A safety switch is to be installed between the mains supply and the control unit.
An alarm for loss of power is given if the mains supply is disconnected.
WARNING! No switch is allowed between the motor and the control
unit.
2.2.1 When switching off
When it is desired to switch off the heat exchanger, for example at night, this
can be done using a relay connected in series with the control signal. This relay
interrupts the signal to control signal terminal number 33. In this way, no alarm
about interruption of power supply is given. The control signal can of course
also be reduced to its minimum value, in order to achieve the same result. If the
control signal is low or absent the drive system switches to purging mode.
2.2.2 Recommendations with respect to EMC
In order to fulfil the European EMC Directive 89/336/ECC regarding electro-
magnetic 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.

14 Mounting/connection Emotron AB 01-3333-01r2
Fig. 3 Excess motor cable should be arranged such that the area enclosed is as
small as possible
Special EMC couplings/glands are not necessary.
An EMC filter is built into all EMX-R models.
2.2.3 Priority switch / defrosting / manual control
A preselected speed of rotation can be specified by a potential-free connection
between the priority inputs 34–35. When terminal 34 is connected to terminal
35, the speed of rotation is determined by the priority potentiometer, which is
located next to the DIP switches in the control unit. The priority switch has
higher priority than the summer/winter switch (only available on Model E) and
the control signal.
The switch can be used, for example, when cleaning the rotor, defrosting using
an external differential pressostat or for manual control of the speed of rotation.
2.2.4 Manual control using a 10 kOhm potentiometer
It is simple to control the drive system manually using a 10 kOhm potentiome-
ter connected as shown in the figure.
WRONG RIGHT
Control unit
33
34
37
10 kOhm

Emotron AB 01-3333-01r2 Mounting/connection 15
2.2.5 Test switch
The control unit is equipped with a test switch, placed under the cover between
terminals 37 and 41. When this switch is in the “ON” position, the motor soft-
starts and the speed increases to the maximum, independently of other signal
sources. When in the “OFF” position (down), the test switch is not operational.
The test switch can also be used to run the motor at maximum speed if, for
example, an external control signal is available.
Fig. 4 Location of terminals, etc.
No. Designation
1 Supply terminal
2Motorterminal
3 Priority potentiometer
4 Control signal terminal
5 DIP switch
10-F05
12345678
ON
31
51
LN32 33 34 35 36 37 41 42 43654321
52 53 54 55 56 57 58
J1
IU
1234 56 7
8
Extra circuit board in
the Model E with LED-
display,
E-terminals 51-58
and jumper J1
ON

16 Mounting/connection Emotron AB 01-3333-01r2
Fig. 5 Wiring diagram
6Testswitch
7Alarmterminal
8 Operating indicator for Model S, two LEDS
No. Designation
10-F11
Modell S
LN
M
51 52 53
41 42 43
54 55 56 57
31 32 33 34 35 36 37
58
J1
IU
123456
LN
Safety switch
Control signal
Heat recover
y
on cooling
Alarm relay 42-43
closed on alarm
Heat recovery on cooling
51-52 incoming air sensor
51-53 exhaust air sensor
Analogue output signal
0-10V/20mA
Model S and E
Extra circuit board in
model E
Rotation
sensor
Potentiometer
control
Priority switch

Emotron AB 01-3333-01r2 Mounting/connection 17
2.2.6 Choice of maximum speed
The maximum speed can be limited to 80% (200 rpm) or 60% (150 rpm). This
function is primarily intended for use with rotors smaller than 1.3 m, when it is
desired to limit the speed of rotation and/or when using larger belt pulleys.