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Following manual applies to the correct installation and configuration of the stepper motor controller mounted in the Rotary Heat Exchangers. First chapter concerns proper wiring of a controller and explanation of the switches used for controlling motor work mode. Second chapter presents functionality and key features of the controllers dedicated software used for programming and direct loading of the motor parameters presets.Before installation or using a dedicated software, make sure that all the instructions given in the following manual are understandable. In case of any doubts please contact R&D department of Swiss Rotors.Installation and configuration of the stepper motor must be performed by qualified personnel or technician.

Please read the following documentation carefully before performing installation and configuration of the stepper motor controller. This manual presents steps of proper configuration and running up the dedicated driver for the stepper motor. In case of any doubts, please contact Swiss Rotors R&D department.

1.Controller installation:

Installation starts with the proper wiring of the power supply and motor to the controller. Wires are color coded which means all of their jackets have different colors for easier identification. On the inner side of the controller cover you may find a sticker with a description of wire colors and sockets that are used for their installation (see Figure 1).

Before installation make sure that main power supply is shut off. Wires should be plugged firmly inside the dedicated socket of the controller. Double check the correct wiring – wires cannot be plugged into the wrong socket of the controller. Such mistake may lead to major failure or controller damage. Figure 2 presents the properly wired controller. Make sure to put the main cables throughout the glands located at the bottom of the controller. Socket labeled as L, N and PE are meant for 1 phase 230V power supply cable. Use them to provide the proper power supply for the controller and the motor. Sockets labeled as U, V, W and PE are designed for direct motor connection. If the black and blue wires are connected incorrectly then rotor will rotate in the wrong direction. At the first start, make sure that the rotor rotates towards the motor.

Prepared by: Lukasz Knapik Checked by: Approved by:

Stepper motor controller configuration

23th March 2020Page 1 / 3

Figure 1. Sticker located on the inner side of the controller cover

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Stepper motor controller configuration

Controller is designed to operate without necessity of being connected to the computer or any other devices once the preset is uploaded to the device. In order to that, please connect two sockets 0-10V and 12V with each other using a short wire as presented on the Figure 3. This step must be performed before connecting to the computer software.

Connect the controller to the computer (with dedicated software installed) using a MODBUS EIA-485 cable slot. Plug the RS485 cable to the controller modbus socket labeled MODBUS EIA-485 (Figure 3). Sockets A and B are internally parallel and therefore it is optional which connector will be used. RS485 cable has to be plugged between the controller and the converter. One end of the cable need to be plugged in the above mentioned A or B socket (Figure 3) while the second end into the slots of the converter exactly as shown in the Figure 4 – red wire connected with the slot 2 and white wire to the slot number 3. For this configuration it is important to set the converter DIP switches to ON position as shown in Figure 5. Converter is further connected with the computer via standard USB cable.

Figure 3. Connect 0-10V and 12V sockets via short wire.

Figure 4. Proper method of wiring the RS485 cable with the converter. Insert the wires

as shown above. Red wire into the socket 2 and white wire into the socket 3.

Figure 2. Properly wired power supply and motor within the controllers socket

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Before running the controller software make sure that DIP switches on Controller are positioned in the correct manner regarding connected motor. There are 4 DIP switches in the controller (Figure 6) which are also described on the sticker located inside the controller cover.

Speed switches DIP (3 & 4) are set by default to OFF positions on both DIP 3 and DIP 4 switch. Leave them in those positions: controller will get the speed information from the configuration file which will be uploaded. DIP1 and DIP2 must be set according to the Nm values on the label plate of the motor which is being configured. See Figure 6 presenting possible ways of setting the controller.

2. Software settingsWhen the controller and computer are connected together via Rs-485 cable (MODBUS), it is possible to start up the software and start the configuration process. In the beginning you need to make sure that all the connection settings within the software are set properly in the “Setup” tab. See the Figure 8 to copy the correct settings starting with Modbusld value which must be set to “79”.

Figure 5. Proper DIP Switches settings of the converter

Figure 6. Dip switches of the controller

Set the motor switches according to the torque of the motor inside the rotary heat exchanger. Information about the torque should be given on the label plate ofthe motor itself. Default speed settings should be set to OFF on both DIP3 andDIP4.

Stepper motor controller configuration

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Stepper motor controller configuration

Figure 8. Software connection settings

It is very likely that the heat exchanger will start operating the moment in which controller will be connected to the computer. To start or stop the connected heat exchanger operation go to the “Operate” tab within the software and click Start or Stop respectively. See Figure 9.

Figure 9. Start or stop the operation of the rotary heat exchanger

Uploading the file with presets is done via tab labeled Motor/Rotor/User Config (See Figure 9). From this sub menu of the software, user is able to upload the configuration file including the key parameters of the motor, see the already uploaded configs, change them or preview other user data.

Figure 10. User Config tab used for uploading the presets of the motor

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Stepper motor controller configuration

All of the configuration files got the extension “.udf” (See Figure 11). It is the only correct file format in which software is capable of loading the information to the controller. To upload the preset click on the Open config file button shown in Figure 8. Windows browser will pop-up and let the user to choose the desired file (See Figure 9). Choose the correct file and click open.

Figure 11. Choose the correct preset file with the proper „.udf” extension

Note: Configuration files must be downloaded from the exact work localization assigned to specific control station in the facility. Each wheel type of the rotary heat exchanger has its own individual configuration file. File name must comply with the name on the label plate of the exchanger. Configuration file names are ended with letters S, E and C and corresponds to the type of the rotary wheel in the heat exchanger. Be sure to choose the proper file: S – Total,E – Hygroscopic, C – Non-hygroscopic.If everything is set correctly, the next step is to send the configuration data to the controller. To do that click on the Send config to Drive button located at the bottom of the software window (Figure 12).

Figure 12. Load the data by clicking the send config to drive button

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Stepper motor controller configuration

If the chosen file was uploaded correctly, the Configure tab should be filled with the data read from the file (Figure 13). In this point it is crucial to check all the loaded parameters and make sure that everything is set correctly.

Although the whole process is automatic, there are cases in which the loaded data may be incorrect. Check the correctness of the loaded data, go to the Configure tab (Figure 14. Click the Set button if the visible data matches with the parameters visible in the Motor/Rotor/User Config tab.

Figure 13. Preview of the loaded preset in the Configure tab

Figure 14. Configure tab letting the user to verify the uploaded data and set the values

for any given parameter

Go to the Setup tab of the software and click on the Get button at the Alternative device communication settings. See Figure

Figure 15. Preview of the Setup tab

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Stepper motor controller configuration

Note: It is important to wait few additional seconds after clicking the Set button. Software requires some time to upload the predefined preset and send the configuration file to the controller via modbus. Disconnecting the driver from the computer too quickly may result in data corruption and hence configuration failure. Preset is uploaded when the “Ready” notification will be displayed in the software. When such notification appears, the controller is ready to be unplugged and disconnected from the computer safely.

Uploading of the controller configuration is finished. Uploaded data were send to the driver and the motor should work according to the given parameters. Unplug the modbus cable to disconnect from the computer. Unplug the heat exchanger from the power supply and plug back in order to reset the device. Verify the operating mode of the heat exchanger disconnected from the computer. Turn on the rotary heat exchanger powered with the controller. Verify the configured rotational speed of the rotary wheel. Check with the RPM declared on the label plate of the heat exchanger. If everything is correct and the wheel spins with the proper speed without being connected to the computer, configuration of the controller is finished. In any other case, configuration of the controller was carried out incorrectly and should be repeated.

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Swiss Rotors Inc.3535 Gravel Springs Rd Ext, STE 203Buford, GA 30519

3. CONTACT