IBC control VariMax50 User manual

IBC
control
NG
MANUAL
CONTROL UNIT FOR ROTARY HEAT EXCHANGER
VariMax50
M
a
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e
i
n
S
w
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Since 1983Since 1983
Ska vara 25 mm i diameter på höjden
Article no. F21050305

TABLE OF CONTENTS
Installation Instructions 2
Mounting 2
Safety instructions 3
Manufacturer's declaration 3
Description of functions 4-5
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
2
MOUNTING
Installations hole 5 ø
Installations hole 5 ø

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.
3
MANUFACTURER'S DECLARATION
Manufacturer IBC control AB
Brännerigatan 5 A, SE-263 37 Höganäs, Sweden
Product Control unit for rotary heat exchanger
Type designation VariMax50 NG
Directives applicable to
the product
e Manufacturer's Declaration of Conformity for the Product.
All control units are approved according to the requirements of EMC
Directive 2014/30/EU and are tested according to standard
EN 61800-3:2018, emission category C1, immunity; second environment.
All control units comply with the Low Voltage Directive 2014/35/EU,
standard EN 61800-5-1:2007/A1:2017.
All control units are intended for installation in pollution degree 2
environments.
is product also complies with RoHS Directive 2011/65/EU,
including Commission Delegated Directive EU2015/863.
Höganäs 2020-10-01
IBC control AB
Christer Persson
MD

4
• e VariMax50 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 VariMax50 NG is intended for rotors up to 2500 mm with a max rotor speed of
12 rpm. If the rotor requires a higher rotor speed, rotor diameter should be reduced.
• e VariMax50 NG has internal Modbus functions.
For more information, see the manual on our website, www.ibccontrol.se
• e VariMax50 NG has an integrated input signal oset, which means rotor eciency is
proportional to the input signal.
• e VariMax50 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 VariMax50 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 VariMax50 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 VariMax50 NG has a built-in cleaning function.
e function can be disconnected via DIP switches.
• VariMax50 NG only needs a shielded cable and EMC gland to the motor. Other
cables do not need to be shielded or EMC glands.
• e VariMax50 NG starts automatically following a power failure,
and resets all alarms upon restarting.
• e VariMax50 NG is a stepper motor with high torque throughout its speed range.
• The VariMax50 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 3 m cable as standard.
-----------------------------------------------------------------------------------------
We use FreeRTOS v6.1.0 (http://www.freertos.org) in this product; we are
able to provide the source code.
5
4
Continued from previous page

6
Output frequency 0-312 Hz
Acceleration and
retardation time
30 sec
Ambient temperature,
non condensing
-40 - +45 OC
Protection form IP44
Weight 0.8 kg
Dimensions, H×W×D 162×195×56 mm
Connection voltage 1×230-240 V +/-15%
50/60 Hz
Power input max 222 W
Input current max 1.65 A
External fuse, max 10 A
Output voltage*) 3×0-260 V
Output current, max 2.0 A
*) Exact value cannot be obtained with a digital measuring
instrument
TECHNICAL DATA, CONTROL UNIT
Max moment 4 Nm
Min rpm 1 rpm
Max. speed (rpm) 375 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
4 kg
Dimensions incl. sha
and motor bracket
H×W×L
130×130×171 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.
Low speed *) e rotor rotates at the pre-set min speed (1 rpm) when the DIP switch is
set to ON.
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 wheel
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 375 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 wheel
- 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

9
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 375 rpm.
e rotor rotates at the set speed, whatever the value of the input signal.
Factory setting at 11 o’clock (1 rpm on motor sha).
Max rpm Potentiometer for adjusting max. speed.
Regulates between 50 and 375 rpm.
Factory setting at 11 o’clock (50 rpm on motor sha).
RESET
Reset Push 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.
Motor temperature e control unit regulates power and makes sure the motor will not
overheat.
Short circuit
Probable cause of fault
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 the motor resistance; should be equal on all windings.
Motor fault
Internal fault Alarms and trips if an internal fault occurs in the control unit.
Internal fault

CONNECTIONS
Switch o power before working on the equipment.
NOTE: Dangerous voltage may be present in the control unit for up to 15 seconds aer disconnection and the
motor has stopped rotating.
Connection voltage
(L-N-PE)
1×230-240 V +/-15%, 50/60 Hz.
NOTE! Protective earth must always be connected.
If the VariMax50 NG is connected phase/phase, no type A residual
current circuit breaker may be connected.
Motor
(U-V-W)
A VariMax50 NG motor must be used.
Direction of rotation is changed by switching two of the phases.
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.
CONNECTION DIAGRAM
N
1 x 230 V
2 3
+
9 10
v
A1 A2
S
br
Manual
speed
External
rotation
monitor
11 12
Reset
L
B C A
Modbus
D+ D+ Com
Input
signal
0 - 10 V
M
U V W
Stepper motor
3-phase
123
13
(Max 0,5 A 30 V AC/DC)
Alarm relay
14 15 B C A
D0 D1 Com
Modbus
15 s.
10
Continued on next page

12 V output
(3-11)
Output for 12 V DC. Terminal connection 3 is minus (-),
terminal connection 11 is plus (+).
Max 50 mA.
External rotation
monitor
(9-10)
If an external rotation monitor is used, this is connected as shown below.
White cable connected to terminal 9, brown to terminal 10.
e magnet is installed with south side (S) towards the sensor.
Max. gap 15 mm.
Reset
(11-12)
Remote reset in the event of alarm.
e control unit is reset automatically in the event of voltage drop-out.
Alarm relay
(13-14-15
Closes between 14-15 in the event of an alarm or voltage drop-out.
Max 0.5 A resistive load / 30 V AC/DC.
Modbus
(A-B-C)
If Modbus must be used, refer to the separate manual on our website,
www.ibccontrol.se.
11
Continued from previous page
INPUT SIGNAL/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.
Input signal - rotation speed
Input signal 0 - 10 V
Rotation speed (%)

12
Check that the control unit is connected as per instructions on page 10.
Connection voltage 1x230-240 V +/-15%, 50/60 Hz.
Check that the input signal is 0-10 V.
Check that rotation monitor and cleaning function are connected.
CHECKS BEFORE POWERING UP 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 “High Speed” DIP switch to the ON position.
Adjust “Max rpm” until the rotor rotates at 10-12 rpm (or as directed by
the rotor manufacturer).
Aer a test run, make sure the DIP switch is set to OFF.
Checking minimum
speed
Set the “Low Speed” DIP switch to ON.
Check that the wheel starts.
e minimum speed is pre-set.
Aer a test run, make sure the DIP switch is set to OFF.
Checking the
cleaning function
Switch o the voltage.
Make sure the “Cleaning function” DIP switch is set to ON and the input
signal is disconnected.
Aer switching on the voltage, the cleaning function starts by the rotor
rotating for 6 seconds with a motor speed of 5 rpm, aer 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
Checking the
Internal rotation
monitor
External rotation
monitor
e yellow “Rotation” LED will ash following an approved measure-
ment. For more information, see “Description of functions” on page 4.
e yellow “Rotation” LED will ash when the magnet passes the
rotation monitor, regardless of 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

EMC-INSTALLATION
EMC GLAND
External rotation monitor
LiYY 2×0.34
Not shielded
Connection voltage
3G1.5
Not shielded
Motor
NCY-HAR/UL/CSA 4G0,75
Shielded
Input signal
2×0.34/0.5
Does not need 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.
13

IBC control AB
Brännerigatan 5 A
SE-263 37 Höganäs
Sweden
Tel. [phone]
www.ibccontrol.se
[email protected]
IBC
cont
rol
F21050905GB VERSION 1.0 2020-10-01