IBC control VariMax100 User manual

IBC
control
Made in Sweden
MANUAL
CONTROL UNIT FOR ROTATING HEAT EXCHANGER
VariMax100
Art. no. F21100201

PAGE REFERENCE
Installation instructions 2
Mounting 2
Safety instructions 3
Manufacturer's declaration 4
Description of functions 5
Technical data 6
Functions 6-8
DIP switches 7
- Operational indications 7
- Alarms 7
- Adjustments via
potentiometer 8
- Push buttons 8
Connection diagram 9
Connections 9
Input signal/Rotation speed 10
Checks before switching on
the control unit
10
Putting the equipment into
operation
10
EMC installation 11
EMC gland 11
Personal notes 12-13

MOUNTING
Warning indication e control unit must only be used in perfect technical condition.
Any damage that may aect safety must be dealt with
immediately.
Maintenance/Repairs e function of the control unit should be checked regularly.
Troubleshooting and repairs must only be performed by trained
personnel.
Prescribed electrical protection must be implemented.
Disposal and recycling When replacing components or when the control unit in its
entirety need replacing, 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 as environment-friendly as the technology
allows in terms of environmental protection and recycling.
INSTALLATION INSTRUCTIONS
Mounting hole 5 ø
32
Mounting hole 5 ø

SAFETY INSTRUCTIONS
"Safety instruction" represents instructions that are intended to
avoid the risk of personal injury and to prevent damage to
equipment.
Danger! Electrical current to electrical components!
Note! Switch o the main current 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 important instructions apply to personal protection and technical safety during
operation.
32

MANUFACTURER'S DECLARATION
Manufacturer IBC control AB
Brännerigatan 5 A, SE-263 37 Höganäs, Sweden
Product Control unit for rotating heat exchanger
Type designation VariMax100
Article number F21100201
EU directive
applied to the
product
e manufacturer's declaration of conformity with the requirements of the
EMC Directive 2004/108/EC.
All control units are approved according to the requirements of the
EMC Directive 2004/108/EC and are tested according to standard
EN 61800-3:2004, emission category C1 and immunity category C2.
All control units comply with the Low Voltage Directive 2006/95/EC,
standard EN 61800-5-1.
All control units are designed for installation in environments subject to
pollution degree 2.
is product also complies with the RoHS Directive 2011/65/EU.
Höganäs 2015-07-01
IBC control AB
Christer Persson
MD
-------------------------------------------------------------------------------------------
We use FreeRTOS v6.1.0 (http://www.freertos.org) in this product and this source
code can be supplied by us.
54

•e VariMax100 is part of a range of control units adapted for optimum control of
rotating heat exchangers, with the necessary additional functions.
e range consists of three sizes: VariMax25, VariMax50 and VariMax100. All control
units run a 3-phase stepper motor. All control units have an input signal of 0-10 V.
•VariMax100 is designed for wheels up to 3900 mm with a wheel speed of max. 12 rpm.
If the wheel requires a faster wheel speed, the rotor diameter should be reduced.
•VariMax100 has built-in shi of the input signal, which means that the wheel's eciency
is proportional to the input signal.
•VariMax100 has a preset threshold value of 0,1 V (hysteresis 0,13–0,07 V). If the input
signal falls below this value, the wheel stops.
•VariMax100 has a rotation monitor (magnet mounted on the wheel with associated
magnetic sensor) and built-in cleaning function. e functions can be disconnected via
DIP switches.
•VariMax100 starts automatically aer voltage drop-out,
and resets all alarms on restart.
•e VariMax-motor100 is a stepper motor with substantial moment over the entire speed
range.
•When the motor is stationary, holding moment is activated, which means that the wheel
always remains still. e holding moment disappears if the voltage to the control unit is
lost.
•e motor is mounted with a 3 m cable as standard.
•If total cable length exceeds 3 m, external EMC lters should be used.
DESCRIPTION OF FUNCTIONS
54

Output frequency 0-333 Hz
Acceleration and
retardation time
30 sec
Ambient temperature,
non condensing
-30 - +45 OC
Protection form Type 1/IP54
Weight 2,6 kg
Dimensions, HxWxD 233x205x104 mm
Connection voltage 1x230-240 V +/-15%
50/60 Hz
Power input, max. 500 W
Input current, max. 2,2 A
External fuse, max. 10 A
Output voltage*) 3x0-280 V
Motor current/phase 3,2 A
Internal fuse **) 4 AT *) Exact value cannot be obtained with a digital measuring instrument
**) e fuse protects both motor and electronics
TECHNICAL DATA CONTROL UNIT
Max. moment 10 Nm
Min. rotation speed 1 rpm
Max. rotation speed 400 rpm
Motor temperature, mantle max. 110 OC
Sha diameter 19 mm
Sha length 35 mm
Ambient temperature -30 - +45 OC
Protection form IP54
Weight incl. motor bracket 8,4 kg
Dimensions incl. sha and
motor bracket HxWxL
142x150x180 mm
TECHNICAL DATA MOTOR
Operational indications
Alarm indications
Push button for Reset
DIP switches
ON to le
Adjustments
FUNCTIONS
4 1 2 35
76

DIP SWITCHES
Cleaning Cleaning function connected in ON position.
When the wheel has been still for 30 minutes, the cleaning function is
activated and the wheel rotates for 20 seconds at 12 rpm.
Rotation monitor Rotation monitor connected in ON position.
High speed *) e wheel rotates at the set max. rpm when the switch is set to ON.
Low speed *) e wheel rotates at the preset min. speed (1 rpm) when the switch is set
to ON.
*) Manual running (test mode)
OPERATIONAL INDICATIONS
On/Alarm "Voltage on" comes on with a xed light.
Flashes 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.
Rotation Flashes when the magnet passes the magnetic sensor, whatever the setting
of the "Rotation monitor" DIP switch.
Flashes even if the input signal is lower than the threshold value.
ALARMS
In the event of an alarm the control unit restarts aer 30 seconds. e respective red light diode comes
on for the same duration (30 seconds).
Aer restart the light diode goes out, this happens twice. e third time, the alarm relay closes and
the alarm "moves on". In order for the alarm relay to close and the alarm to "move on", the above
three alarm signals must occur within 90 minutes, otherwise the sequence is reset.
e green light diode comes on with a xed light for the rst and second alarm and begins to ash on
the third alarm. All alarms subsequently remain.
Rotation monitor Alarms and trips if a pulse is not received every 30 minutes at min.
rotation speed (1 rpm) and every 20 seconds at max. rotation speed
(400 rpm).
e time between these speeds is linear.
e function can be disconnected via DIP switches.
Continued on next page
76

Continued from previous page
Probable fault cause on
installation
Probable fault cause in
operation
- Magnet turned the wrong way
- Magnet transmitter incorrectly connected (wrong polarity),
see CONNECTIONS on page 9
- Too big a gap between magnet transmitter and magnet, max. 15 mm
- Broken belt
- Belt slipping
- Stuck wheel
- e magnet transmitter or magnet is not intact
Motor temperature Alarms and trips if the coil temperature in the motor is too high.
e thermal contact in the motor returns to normal mode once the
temperature falls.
Over-voltage Alarms and trips if the input voltage exceeds 265 V.
Under-voltage Alarms and trips if the input voltage falls below 190 V.
Over/under temperature Alarms and trips if the temperature in the control unit goes above/below
safe temperature level (+85 - -30 OC).
Short circuit
Probable fault cause
Alarms and trips in the event of short circuit phase-phase or phase-earth.
- Short circuit between phases in cable or motor
- Short circuit between phase-earth in cable or motor
- Interruption to one phase in cable or motor
Measure motor resistance; it should be identical on all coils.
Internal fault Alarms and trips if an internal fault in the control system has occurred.
ADJUSTMENTS VIA POTENTIOMETER
Manual speed By closing A1-A2 the speed is controlled via the potentiometer marked
"Manual speed". Can be regulated between 1-400 rpm.
e wheel rotates at the set speed, whatever the value of the input signal.
Factory setting: 1 rpm on motor sha.
Max. speed Potentiometer for adjusting max. speed.
Regulates between 50-400 rpm.
Factory setting: 50 rpm on motor sha.
PUSH BUTTON
Reset Reset button for resetting the control unit. e control unit is also reset in
the event of voltage drop-out and closure between terminal 11 and 12.
98

CONNECTIONS
e voltage must be switched o before undertaking any work on the equipment.
Recommended tightening moment 0,5 Nm, max. tightening moment 0,8 Nm.
Connection voltage
(L-N-PE)
1x230-240 V +/-15 %, 50/60 Hz.
NOTE! Protective earth must always be connected.
Alarm relay
(13-14-15)
Closes between 14-15 in the event of an alarm or voltage drop-out.
Max. 2 A resistive load/250 V AC.
Manual speed
(A1-A2)
Produces set rotation speed on closure.
Input signal
(2-3)
0-10 V.
Plus connected to terminal 2, minus to terminal 3.
Rotation monitor
(9-10)
White cable connected to terminal 9, brown to terminal 10.
e magnet is installed with south side (S) towards the transmitter.
Max. distance 15 mm.
12 V output
(3-11)
Output for 12 V DC. Terminal 3 is minus, terminal 11 is plus.
Max. 50 mA.
Reset
(11-12)
Remote reset in the event of alarm.
e control unit is reset automatically in the event of voltage drop-out.
ermal contact
(T-T)
is must be connected to protect the motor against overheating.
Motor
(U-V-W)
VariMax-motor100 must be used.
Direction of rotation is changed by switching two of the phases.
CONNECTION DIAGRAM
(Max 2 A / 250 V AC)
L N 14 15
M
13
2 3
+
9 10
w
A1 A2
S
br
11 12
T T U V W
1 x 230 V
Alarm relay
Man.
speed
Input
signal
0 - 10 V
Reset
Rotation
monitor
Thermal
contact
Stepper motor 3-phase
3
5 2
4 1
98

10
Check that the control unit is connected as per instructions on page 9.
Connection voltage 230-240 V +/-15%, 50/60 Hz.
Check that the input signal is 0-10 V.
Check that rotation monitor and cleaning function are connected.
INPUT SIGNALS/ROTATION SPEED
e input signal is directly proportional
to the eciency of the wheel, which
means that input signal and rotation
speed are as per adjoining diagram.
CHECKS BEFORE SWITCHING ON THE CONTROL UNIT
Check that the motor rotates in the right direction in relation to the wheel's direction
of rotation.
In the event of a fault, switch two phases to the motor.
Adjustment of max.
speed
Set the DIP switch to "High speed" in the ON position.
Adjust "Max. speed" so that the wheel rotates at 10-12 rpm (or as per
directions from wheel manufacturer).
Checking minimum
speed
Set the DIP switch to "Low speed" in the ON position.
Check that the wheel starts.
e minimum speed is preset.
Checking the cleaning
function
Switch o the voltage.
Make sure that the "Cleaning" DIP switch is set to ON, and that the input
signal is disconnected.
Aer switching on the voltage the wheel rotates for 20 seconds at 12 rpm.
Checking the rotation
monitor
e yellow "Rotation" light diode should ash when the magnet passes
the magnetic sensor, whatever the DIP switch position.
Finish by having the control unit drive the wheel at maximum and minimum
rotation speed and checking that the wheel speed is correct.
PUTTING THE EQUIPMENT INTO OPERATION
Should be done in sequence
11
Input signal 0-10 V
Input signal - rotation speedRotation speed [%]

EMC INSTALLATION
EMC GLAND
Magnet transmitter, LiYCY 2x0.34
Shielded
Incoming EKK 3G1.5
Not shielded
Motor cable
Ölex Classic 110 CY/7G0.75
Shielded
Input signal, LiYCY 2x0.34/0.5
Shielded
EMC glands must be used for shielded cables.
e above cables, or equivalent, must be used to comply with the terms of the EMC Directive.
NOTE!
When connecting the shielding to the EMC gland, it is important to connect as shown above.
10 11

12
PERSONAL NOTES

12 13
PERSONAL NOTES

IBC control AB
Brännerigatan 5 A
SE-263 37 Höganäs
Sweden
Tel. [phone]
Fax [phone]
www.ibccontrol.se
[email protected]
IBC
control
F21100901 GB VERSION 2.0 2015-07-01