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

CONNECTIONS
e voltage must be switched o before undertaking any work on the equipment.
Recommended torque 0,5 Nm, max. torque 0,8 Nm.
Connected power supply
(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 / 50 V AC.
Manual speed
(A1-A2)
Produces set rotation speed on connection.
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. gap 15 mm.
12 V output
(3-11)
Output for 12 V DC. Terminal connection 3 is minus (-),
terminal connection 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
N 14 15
1 x 230 V
M
13
(Max 2 A / 50 V AC)
Alarm relay
2 3
+
9 10
v
A1 A2
S
br
Manual
speed
Rotation
monitor
11 12
T T U V W
Reset Thermal
contact
Stepping motor 3-phase
45123
L
B C A
Modbus
D+ D+ Com
Input
signal
0 - 10 V
98

10
Check that the control unit is connected as per instructions on page 9.
Power supply 230-240 V +/-15%, 50/60 Hz.
Check that the input signal is 0-10 V.
Check that the rotation monitor and blow-clean function are connected.
INPUT SIGNAL/ROTATION SPEED
e input signal is directly
proportional to the ecacy of the
rotor, which implies that input signal
and rotation speed are as per the
adjacent diagram.
CHECKS BEFORE POWERING UP THE CONTROL UNIT
Check that the motor rotates in the right direction in relation to the rotor's direction
of rotation. In the event of a fault, switch two phases to the motor.
Adjustment of max.
speed
Set the High Speed DIP switch to the ON position.
Adjust "Max rpm" so that the rotor rotates at 10-12 rpm
(or as per rotor manufacturer's directions).
Checking minimum
speed
Set the Low Speed DIP switch to ON.
Check that the rotor starts.
e minimum speed is preset.
Checking the blow-clean
function
Switch o the voltage.
Make sure the blow-clean DIP switch is set to ON and the input signal is
disconnected.
Aer switching on the voltage the rotor rotates for 20 seconds at 12 rpm
on the motor.
Checking the rotation
monitor
e yellow Rotation LED will ash when the magnet passes the magnetic
sensor, regardless of DIP switch position.
Finish by having the control unit drive the rotor at maximum and minimum
rotation speeds and checking that the operating rotor speed is correct.
COMMISSIONING THE EQUIPMENT
Should be accomplished in sequence
11
Input signal - rotation speed
Rotation speed (%)
Input signal 0-10 V

EMC INSTALLATION
EMC GLAND
LiYCY 2x0,34, UL recognized,
Shielded
Incoming EKK 3G1.5
Unshielded
NCY-HAR/UL/CSA 7G0,75
Shielded
Input signal,
LiYCY 2x0,34/0,5 UL recognized
Shielded
EMC glands must be used for shielded cables.
e above cables or equivalent must be used to comply with the EMC Directive.
NOTE!
When connecting the shielding to the EMC gland, it is important to connect as shown above.
10 11

12 13
Modbus

12 13
Modbus

14 15

TECHNICAL DATA, MODBUS
Communication
protocol
MODBUS RTU
Interface RS485, half-duplex
Data rate 9 600, 19 200, 38 400, 56 000 bits per second
Bit format 8 databits, 1 stop bit, even parity
8 databits, 1 stop bit, no parity
8 databits, 2 stop bits, no parity
8 databits, 1 stop bit, odd parity
Address 8 unique addresses, refer to the table "Addressing" page 18
Termination Embedded terminal resistance 120 Ω
Inputs 3-pole screw plinth marked A (D+), B (D-), C=common
CONNECTION
A D+, positive data channel
B D-, negative data channel
C Common, signal earth
B C A
Modbus
D+ D- Com
14 15

Blow-clean and rotation
monitor
e function will start in the manually selected position on the control
unit's DIP switch (refer to picture on page 18), but it is possible to change
this via Modbus. When the Modbus communication is activated the
manual settings give the settings for blow-clean and rotation monitor a
start value, but Modbus has priority.
High speed/Low speed High speed/Low speed are not controlled via Modbus.
Refer also to "High speed/Low speed" on page 7.
Manual speed
A1-A2
A1-A2 has priority over Modbus and is controlled independently of
other units. Manual sped can be read and activated via Modbus if A1-A2
are not connected. Refer also to "Manual Speed" on page 8.
Max speed Max speed is set via the potentiometer. e DUC is congured so that
100 % of the reference value equates to the set rpm speed. Refer also to
"Max Speed" on page 8.
Resetting Resetting can be made via Modbus, via the Reset button or via Remote
Reset. Refer also to "Resetting" on page 8 and "Remote Reset" on page 9.
Input signal is is controlled via Modbus.
Rotor speed e rotor speed can be read via Modbus.
Activation of Modbus communication and conguration of address, data transfer rate, parity and
termination are achieved through a 9-pole DIP switch. On delivery of the unit all DIP switches are set to
their OFF position. For setting and conguration of the DIP switches refer to the table on page 18.
Modbus communication is activated through DIP switches. A constant red LED starts to light straight
away if no message with the speed reference value has been received. is goes out once the message
with the speed reference value has been received. A green LED starts ashing if there is data trac
present in the bus.
Settings made via Modbus are not saved in VariMax100M. When VariMax100M is restarted the setting
from the DUC has to be re-transmitted.
16 17
FUNCTION SETTINGS, MODBUS

OPERATIONAL INDICATIONS, MODBUS
Green LED Indication of communication ow
Steady green - It will extinguish if the red LED is activated during a 90 second period if
a transfer error has occurred.
Flashing green - Indicates all trac in the bus
- Flashes if the red LED indicates a fault
Red LED Indication of communication error.
Steady red - Not connected to the bus
- Connected to a bus without trac
- Incorrect address set via the DIP switch
- In the event of no data if the reference value is received within
90 seconds
Flashing red - Incorrect bus speed connection
- Other communication fault
TIMEOUT
If messages with reference values stop coming, VariMax100M will continue using the latest received
reference value. Aer 90 seconds the red LED will activate.
Green LED Red LED DIP switch
17

123456789
Modbus communication To 1
Addressing
Hexadecimal Decimal
10 16 0 0 0
11 17 1 0 0
28 40 0 1 0
29 41 1 1 0
90 144 0 0 1
91 145 1 0 1
A8 168 0 1 1
A9 169 1 1 1
Rate
9,600 0 0
19,200 1 0
38,400 0 1
56,000 1 1
Package
1 stop bit, even parity 0 0
1 stop bit, no parity 0 1
2 stop bits, no parity 1 0
1 stop bit, odd parity 1 1
Termination To 1
DIP SWITCH
18 19