IBC control VariMax100M User manual

IBC
control
Made in Sweden
MANUAL
CONTROL UNIT FOR ROTATING HEAT EXCHANGER WITH MODBUS
VariMax100M
UL/CSA
Article no. F21100304

TABLE OF CONTENTS
Installation instructions 2
Mounting 2
Safety instructions 3
Manufacturer's declaration 4
Description of functions 5
Technical data, control unit 6
Technical data, motor 6
Functions 6
- DIP switch 7
- Operational indications 7
- Alarms 7
- Settings via potentiometer 8
- Push button 8
Connection diagram 9
Connections 9
Input signal/Rotation speed 10
Checks before powering up
the control unit 10
Commissioning the equipment 10
EMC installation 11
EMC gland 11
Modbus 13
Technical data, Modbus 15
Connection 15
Function settings, Modbus 16
Operational indications,
Modbus 17
Timeout 17
DIP switch 18
Modbus Registry Folder 19
Coil 19
Discrete input 20-21
Sub-faults 21-22
Input registry 16-bit 23-24
Input registry 32-bit 25-26
Holding registry 26
Own notes 27-29

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 needs replacing, please follow the advice below:
e aim shall always be to achieve the maximum possible
recycling of raw materials, with the 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
32
MOUNTING
Mounting hole 5 ø
Mounting hole 5 ø

SAFETY INSTRUCTIONS
is safety instruction refers to instructions whose specic intent
is to avoid the risk of personal injury and to prevent damage to
equipment.
Lethal Danger! Electrical components are powered by electrical
current!
NB! Switch o main power before removing the cover.
Never touch electrical components or contacts while main
current is switched on. Risk of electrocution, 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.
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 VariMax100M
Article number F21100304
EU Directive
applicable 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.
UL/CSA ETL 4009131.
All control units are also approved in accordance with UL 508C and CSA C22.2
No. 14.
Associated VariMax motor100 is approved in accordance with UL 1004-1,
UL 1004-3 and CSA C22.2 No. 100.
is product also complies with the RoHS Directive 2011/65/EU.
Höganäs 1/3/2016
IBC control AB
Christer Persson
MD
-----------------------------------------------------------------------------------------
e FreeRTOS v6.1.0 (http://www.freertos.org) soware is used in this
product and this source code can be supplied by us.
54

• e VariMax100M is a control device with embedded Modbus communication.
Technical data for Modbus can be found on page 13-26.
e control function can also be used with a normal 0-10 V input signal.
Refer to page 6-11.
• e VariMax100M 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: VariMax25M, VariMax50M and VariMax100M.
All control units run a 3-phase stepping motor.
All control units have an input signal of 0-10 V.
• e VariMax100M is designed for rotors up to 3900 mm with a rotor speed of max.
12 rpm. If the rotor requires a faster rotor speed, the rotor diameter should be reduced.
• e VariMax100M has built-in input signal shi, which means that the rotor's eciency
is proportional to the input signal.
• e VariMax100M has a preset threshold value of 0,1 V (hysteresis 0,13–0,07 V).
If the input signal falls below this value, the rotor will stop.
• e VariMax100M has a rotation monitor (magnet mounted on the rotor with associated
magnet transmitter) and a built-in blow-cleaning function.
e functions can be disconnected via DIP switches.
• e VariMax100M 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, a holding moment is activated, which means that the rotor
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.
54
DESCRIPTION OF FUNCTIONS

76
Output frequency 0-333 Hz
Acceleration and
retardation time
30 sec
Ambient temperature,
non condensing
-30 - +45 OC
Protection form Type 1
Weight 2,6 kg
Dimensions, HxWxD 233x205x104 mm
External power supply 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. speed (RPM) 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
Measurements incl.
sha and motor bracket
HxWxL
142x150x180 mm
TECHNICAL DATA, MOTOR
Operational indications
Alarm indications
Reset button
DIP switch
ON to le
Settings
FUNCTIONS
4 1 2 35

7
DIP SWITCH
Blow-clean function Blow-clean function connected in ON position.
When the rotor has been still for 30 minutes, the blow-clean function is
activated and the rotor rotates for 20 seconds at 12 rpm.
Rotation monitor Rotation monitor connected in ON position.
High speed *) e rotor rotates at the set max. rpm when the switch is set to ON.
Low speed *) e rotor rotates at the preset min. speed (1 rpm) when the switch is set
to ON.
*) Manual operation (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, regardless of the
rotation sensor DIP switch setting.
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.
A steady green LED is activated for the rst and second alarm and begins to ash on the third alarm.
All alarms subsequently remain active.
Rotation monitor Generates an alarm and trips if a pulse has not been received every 30
minutes at minimum speed (1 rpm) and every 20 seconds at maximum
speed (400 rpm).
e time between these speeds is linear.
e function can be disconnected via DIP switches.
Continued on next page

Continued from previous page
Probable fault cause
during installation
Probable fault cause in
operation
- Magnet turned the wrong way
- Magnet transmitter incorrectly connected (wrong polarity),
refer to "connections" on page 9
- Gap too wide between the magnetic sensor and magnet; max 15 mm
- Broken belt
- Belt slipping
- Stuck rotor
- Magnetic sensor or magnet not intact
Motor temperature Alarms and trips if motor winding temperature is too high. e
temperature switch in the motor reverts to normal mode when the
temperature drops.
Excess voltage Alarms and trips if the input voltage exceeds 265 V.
Under-voltage Alarms and trips if the input voltage falls below 190 V.
Excessive /under-
temperature
Alarms and trips if the temperature in the control unit goes above/below
safe temperature level (+85 - -30 OC).
Short circuit
Probable 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.
SETTINGS VIA POTENTIOMETER
Manual speed By closing A1-A2 the speed is controlled via the potentiometer marked
"Manual speed". Can be regulated between 1 and 350 rpm.
e rotor 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 and 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 terminals 11 and 12.
98