IBC control F21025305 User manual

IBC
control
NG
MANUAL
CONTROL UNIT FOR ROTARY HEAT EXCHANGER
VariMax25
M
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Since 1983Since 1983
Ska vara 25 mm i diameter på höjden
Article no. F21025305

TABLE OF CONTENTS
Installation Instructions 2
Safety instructions 2
Manufacturer’s declaration
Declaration of conformity 3
Description of functions 4-5
Mounting 5
Technical data, control unit 6
Technical data, motor 6
Functions 6
- DIP switch 7
- Operational indications 7
- Alarms 8-9
- Settings via potentiometer 9
- Reset 9
Connection diagram 10
Connections 10-11
Input signal/Rotation speed 11
Checks before powering up the
control unit 12
Putting the equipment into operation 12
EMC installation 13
EMC gland 13

Warning indication e control unit must be in perfect technical condition before
use.
Damage that can aect safety must be remedied immediately .
Maintenance/Repairs Control unit function should be checked regularly.
Troubleshooting and repairs may only be done by trained
personnel.
e prescribed electrical protection must be met.
Disposal and recycling When replacing components or when the control unit must be
replaced in its entirety, please follow the advice below:
e aim should always be maximum possible recycling of raw
materials, with minimum possible environmental impact.
Never dispose of electrical components with ordinary waste,
always use the designated collection points.
Disposal should be eected as environment-friendly as the
technology allows in terms of environmental protection and
recycling.
INSTALLATION INSTRUCTIONS
SAFETY INSTRUCTIONS
Safety instruction refers to instructions whose specic intent is
to avoid the risk of personal injury and to prevent damage to
equipment.
Danger! Electrical current to electrical components!
NB! Switch o main power before removing the cover.
Never touch electrical components or contacts while main
current is switched on. Risk of electric shock, resulting in serious
injury or death.
Connected terminals contain residual voltage even aer the main
current has been switched o.
e following symbols and references will be used in this description.
ese instructions are important; they apply to personal and technical safety during
operation.
2

MANUFACTURER'S DECLARATION
DECLARATION OF CONFORMITY
Manufacturer IBC control AB
Brännerigatan 5 A
SE-263 37 Höganäs
Sweden
Tel: [phone]
Product Control unit for rotary heat exchanger
Type designation VariMax25 NG
Applicable
EU Directives
EMC Directive 2014/30/EU
Low Voltage Directive 2014/35/EU
RoHS Directive 2011/65/EU including Delegated Directive EU2015/863
Applicable
UK Directives
e Electromagnetic Compatibility Regulations 2016
e Electrical Equipment (Safety) Regulations 2016
e Restriction of the Use of Certain Hazardous Substances in Electrical and
Electronic Equipment Regulations 2012
Harmonizing
standards for
EU/UK Directives
BS EN 61800-3:2018 - Emission kategori C1, Immunitet second environment
BS EN 61800-5-1:2007/A1:2017 - e control unit is intended
for installation in environments with a pollution rating of 2
(Pollution degree 2)
is declaration of conformity is issued under the full responsibility of the
manufacturer
Höganäs 2021-09-01
IBC control AB
Christer Persson
MD
-----------------------------------------------------------------------------------------
We use FreeRTOS v6.1.0 (http://www.freertos.org) in this product; we are
able to provide the source code.
3

4
• e VariMax25 NG is part of a new range of control units that, with the necessary
additional functions, are suitable for the optimum control of rotary heat exchangers.
e series comes in two sizes, the VariMax25 NG and VariMax50 NG.
Both the control units operate 3-phase stepper motors.
e control units have a 0-10 V input signal.
• e VariMax25 NG is intended for rotors up to 1500 mm with a max rotor speed of
12 rpm. If the rotor requires a higher rotor speed, rotor diameter should be reduced.
• e VariMax25 NG has internal Modbus functions.
For more information, see the manual on our website, www.ibccontrol.se
• e VariMax25 NG has an integrated input signal oset, which means rotor eciency is
proportional to the input signal.
• e VariMax25 NG threshold is set at 0.1 V (hysteresis 0.13 - 0.07 V). If the input signal
drops below this value, the rotor will stop.
• e VariMax25 NG has an internal rotation monitor. e rotation monitor is patent
pending.
is is activated when the DIP switch for the “External rotation monitor” is in the OFF
position.
e internal rotation monitor performs measurements at dierent times, depending on
whether the speed of the motor is above or below 37 rpm.
At a motor speed above 37 rpm, the measurement begins when the speed is stable,
normally starting aer about 30 seconds, aer which measurements are carried out
continually. e yellow “Rotation” LED ashes aer each completed, approved
measurement. e time between the measurements varies from 22 seconds to nearly two
minutes.
At a motor speed below 37 rpm, the control unit will increase the speed to 37 rpm at
two-hour intervals. At start-up, this measurement will start aer 10 minutes.
e speed will remain steady for 2 minutes, while the actual measurement is being
performed. To verify the measurement, an additional measurement is conducted
10 minutes later. If both of these measurements are positive, i.e. everything is normal,
the next measurement will not take place until two hours later.
is sequence is then repeated with the same time intervals, provided the motor speed is
below 37 rpm.
DESCRIPTION OF FUNCTIONS
Continued on next page

• As an alternative, the VariMax25 NG can have an external rotation monitor (magnet
mounted on the rotor with an associated rotation monitor). is is connected at terminal
connections 9 and 10, and the DIP switch for the “External rotation monitor” should be
in the ON position.
• If both types of rotation monitor are to be deactivated, an 820 ohm resistor (1% ¼ W) is
installed between terminal connections 9 and 10.
• e VariMax25 NG has a built-in cleaning function.
e function can be disconnected via DIP switches.
• VariMax25 NG only needs a shielded cable and EMC gland to the motor. Other
cables do not need to be shielded or EMC glands.
• e VariMax25 NG starts automatically following a power failure,
and resets all alarms upon restarting.
• e VariMax25 NG is a stepper motor with high torque throughout its speed range.
• The VariMax25 NG motor has no built-in thermal contact. e control unit
regulates power and makes sure the motor will not overheat.
• A holding torque is activated when the motors is stopped, which makes sure the rotor
remain static. e holding torque is lost if power to the control unit is cut.
• e motor is mounted with a 2 m cable as standard.
5
4
Continued from previous page
MOUNTING
Installations hole 5 ø
Installations hole 5 ø

6
Output frequency 0-291 Hz
Acceleration and
retardation time
30 sec
Ambient temperature,
non condensing
-40 - +45 OC
Protection form IP44
Weight 0.6 kg
Dimensions, H×W×D 132×195×56 mm
Connection voltage 1×230-240 V +/-15%
50/60 Hz
Power input max 97 W
Input current max 0.8 A
External fuse, max 10 A
Output voltage*) 3×0-260 V
Output current, max 0.7 A
*) Exact value cannot be obtained with a digital measuring
instrument
TECHNICAL DATA, CONTROL UNIT
Max moment 2 Nm
Min rpm 1 rpm
Max. speed (rpm) 350 rpm
Motor temperature mantle max 110 OC
Sha diameter 14 mm
Sha length 40 mm
Ambient temperature -30 - +45 OC
-40 - +45 OC *)
Protection form IP54
Weight incl. motor
bracket
2.6 kg
Dimensions incl. sha
and motor bracket
H×W×L
130×130×141 mm
TECHNICAL DATA, MOTOR
Operational indications
Alarm indications
Reset
Settings
FUNCTIONS
*) Note, e control unit must be connected to power all the time
DIP switch

7
DIP SWITCH
Cleaning function Cleaning function connected in ON position.
When the rotor has stopped for 10 minutes, the cleaning function is
activated and the rotor starts to rotate. As advance warning, the rotor
rotates with a motor speed of 5 rpm for the rst 6 seconds,
following which the rotor stops for 3 seconds. Aer this, the actual
cleaning function starts, for a random time, between 10 to 20 seconds
with the motor at 20 rpm.
External rotation
monitor
e internal rotation monitor is normally used, in which case the
DIP switch must be in the OFF position. If the external rotation monitor
is used, this is connected at terminal connections 9 and 10, in which case
the DIP switch must be in the ON position.
High speed *) e rotor rotates at the set max. rpm when the DIP switch is set to ON.
Aer a test run, make sure the DIP switch is set to OFF.
Low speed *) e rotor rotates at the pre-set min speed (1 rpm) when the DIP switch is
set to ON. Aer a test run, make sure the DIP switch is set to OFF.
Modbus termination If the control unit is last in the Modbus loop, the DIP switch must be in
the ON position.
*) Manual operation (during test)
OPERATIONAL INDICATIONS
On Lit with xed light
It ashes when the control unit has tripped.
Run Comes on when the motor is to rotate, i.e. when the input signal exceeds
the threshold value.
Flashes during the cleaning function sequence.
Rotation
Internal rotation monitor
External rotation
monitor
Flashes aer each approved measurement, although only when the
“External rotation monitor” DIP switch is in the OFF position; for more
information, see “Description of functions” on page 4
Flashes when the magnet passes the rotation monitor, regardless of the
setting of the “External rotation monitor” DIP switch.
Flashes even if the input signal is lower than the threshold value.
Modbus If Modbus must be used, refer to the separate manual on our website,
www.ibccontrol.se.

8
ALARMS
In the case of an alarm, the control unit will restart aer 30 seconds. e relevant red LED will light up
for the same period of time (30 seconds). Aer restart, the LED is extinguished; this takes place twice.
e third time, the alarm relay closes and the alarm "moves on". For the alarm relay to close and the
alarm to “move on”, the above three alarms must occur within 90 minutes, otherwise the sequence will
be reset. e green LED burns steadily for the rst and second alarms and only begins to ash for the
third alarm. All alarms subsequently remain.
Internal rotation monitor
Probable fault cause
during installation
External rotation
monitor
Probable fault cause
during installation
Probable fault cause in
operation
Generates an alarm and trips if two consecutive measurements
indicate that the rotor is not rotating. For more information,
see “Description of functions” on page 4.
- Broken belt
- Belt slipping
- Stuck rotor
Generates an alarm and trips if a pulse is not received every 30 minutes at
minimum speed (motor 1 rpm), and every 20 seconds at maximum speed
(motor 350 rpm). e time between these speeds is linear. e function
can be disconnected via DIP switches.
- Magnet turned the wrong way
- Rotation monitor incorrectly connected (wrong polarity), refer to
“Connections” on page 10
- Too wide a gap between rotation monitor and magnet; max 15 mm
- Broken belt
- Belt slipping
- Stuck rotor
- Rotation monitor or magnet not intact
Rotation fault
Overvoltage Alarms and trips if the connection voltage exceeds 276 V.
Undervoltage Alarms and trips if the connection voltage drops below 195 V.
Over/under temperature Alarms and trips if the temperature inside the control unit exceeds/drops
below safe limits.
External faults