BLAUPUNKT B UK256 Twin EC Fan Speed Controller and Auto Change Over Panel User Manual

B UK256 Twin EC Fan Speed Controller and Auto Change Over Panel
User Manual

Twin EC Fan Speed Controller & Auto Change Over Panel

INTRODUCTION

This user’s manual is a main operating document intended for technical, maintenance, and operating staff. The manual contains information about purpose, technical details, operating principle, design, and installation of the Blauberg Twin EC Fan Speed Controller & Auto Change Over Panel and all its modifications.
Technical and maintenance staff must have theoretical and practical training in the field of automation control of ventilation systems and should be able to work in accordance with workplace safety rules as well as construction norms and standards applicable in the territory of the country.

SAFETY REQUIREMENTS

• Please read the user’s manual carefully prior to installing and operating the unit.
• All user’s manual requirements as well as the provisions of all the applicable local and national construction, electrical, and technical norms and standards must be observed when installing and operating the unit.
• The warnings contained in the user’s manual must be considered most seriously since they contain vital personal safety information.
• Failure to follow the rules and safety precautions noted in this user’s manual may result in an injury or unit damage.
• After a careful reading of the manual, keep it for the entire service life of the unit.
• While transferring the unit control, the user’s manual must be turned over to the receiving operator.

UNIT MOUNTING AND OPERATION SAFETY PRECAUTIONS

• Disconnect the unit from power mains prior to any installation operations.
• Do not lay the power cable of the unit in close proximity to heating equipment.
• Do not change the power cable length at your own discretion.
• Do not bend the power cable.
• Avoid damaging the power cable.
• Do not put any foreign objects on the power cable.
• Do not use damaged equipment or cables when connecting the unit to power mains.
• Do not touch the unit controls with wet hands.
• Do not carry out the installation and maintenance operations with wet hands.
• Do not allow children to operate the unit.
• Do not operate the unit outside the temperature range stated in the user’s manual.
• Do not operate the unit in aggressive or explosive environments.
• While installing the unit follow the safety regulations specific to the use of electric tools.
• Unpack the unit with care.
• When the unit generates unusual sounds, odour or emits smoke disconnect it from power supply and contact the Seller.
• Do not wash the unit with water.
• Protect the electric parts of the unit against ingress of water.
• Disconnect the unit from power mains prior to any technical maintenance.

THE PRODUCT MUST BE DISPOSED SEPARATELY AT THE END OF ITS SERVICE LIFE.
DO NOT DISPOSE THE UNIT AS UNSORTED DOMESTIC WASTE.

PURPOSE

**** THE UNIT SHOULD NOT BE OPERATED BY CHILDREN OR PERSONS WITH REDUCED PHYSICAL, MENTAL, OR SENSORY CAPACITIES, OR THOSE WITHOUT THE APPROPRIATE TRAINING.
THE UNIT MUST BE INSTALLED AND CONNECTED ONLY BY PROPERLY QUALIFIED PERSONNEL AFTER THE APPROPRIATE BRIEFING.
THE CHOICE OF UNIT INSTALLATION LOCATION MUST PREVENT UNAUTHORISED ACCESS BY UNATTENDED CHILDREN.
The Blauberg Twin EC Fan Speed Controller & Auto Change Over Panel is designed to work with Blauberg TwinBox Fans with EC Motors of domestic, public, and industrial premises.
The controller is not designed for standalone operation. It is rated for continuous operation.
The controller provides constant faults monitoring with automatic fan change over on fan failure and a number of other control options described in this manual.

TECHNICAL DATA

Al! 4 on bottom edge of case.
Supply/ Fan motor nominal Voltage, (V)| AC 220-240 V
Supply/ Fan motor nominal Frequency, (Hz)| 50 Hz
Fan motor nominal Current (each channel), (A)| up to 4 A
Fan motor supply out fuse current rate, (A)| 4 A
Additional supply out fuse current rate, (A)| 1 A
Case protection class, (IP)| IP68, if cable glands with the same or higher level of protection are used.
Operating Ambient Temperature range [t]| +1 °C up to +40 °C
Humidity range [96]| up to 80 % at 25 °C

NOTE If you need to control fans with 4A or higher nominal currents, then you should use external contactors controlled by the unit.

INPUT / OUTPUT / OPTIONS / FUNCTION SETTINGS

Mains Supply in

• 3 way mains terminal block (unit will need a fused supply)

Mains supply out (Auxiliary)

• 3 way mains supply out terminal block, via a 1 Amp fuse.

Fan 1

• 3 way mains feed terminal block (L,N & E) (Live supply only switched by relay via 4A Fuse)
• Speed control signal output (0 to 100% PWM)
• Tacho monitoring input (RPM signal)

Fan 2

• 3 way mains feed terminal block (L,N & E) (Live supply only switched by relay via 4A Fuse)
• Speed control signal output (0 to 100% PWM)
• Tacho monitoring input (RPM signal)

PCB control setting potentiometers

• Trickle fan speed……………………….. (0 to 100% PWM)
• Medium Boost speed…………………………… (0 to 100% PWM)
• High Boost speed…………………………………………. (0 to 100% PWM)
• Min RPM fan speed (for monitoring) ……………………(50 to 250 RPM)
• Fan C/O (changeover) Time …………………….(1 to 12 hours)
• Run On Time (for both Boost speeds)…………………………… (0 to 15 mins)

Low Voltage Switch Inputs

• VFC for BMS Enable (volt free contacts Closed = Run, Open = Stop)
• VFCa Medium Boost Speed (volt free contacts Closed = Med, Open = Trickle)
• VFCb High Boost Speed (volt free contact Closed = High speed, Open = Trickle or Medium) 240V AC Medium Boost input
• Isolated 240V AC input will select Medium Boost speed (works in parallel with VFCa switch input) 0 > 10V IN
• External speed control (0 to 10V DC) will control fan speed scaled from 0V = Trickle Speed to 10V = maximum fan speed.

Outputs

• Fault Output relay (voltage free contacts, Closed = no fault, Open = fault) Fail safe I.E. will go into fault condition for no power and/or fan fault (rated at 48 V 1A).
• 10V Out DC supply for external user speed control pot (10k potentiometer).
• Nominal 24V DC for powering external sensor unit (maximum 80 mA)

NOTE This is an unregulated supply. Output voltage level depends upon mains supply/loading etc.
Power LED 1 [Yellow] PCB mounted

• When on indicates power is present

Status LED 2 [Green] PCB mounted

• Off = no power
• Steady On = all OK
• Flashing (Slow) = BMS enable off
• Flashing (Fast) = fan fault [Fan 1 or Fan 2]

PCB Mode switches
There is the 4-way DIL PCB mounted slide switch providing the following options:

• Fan 1 Override (On = runs Fan 1 continually and disables Fan 2*).
• Fan 2 Override (On = runs Fan 2 continually and disables Fan 1*).
• MED/HIGH R-ON (Selects whether Run On time applies to Medium Boost only or to Medium Boost and High Boost inputs).
• Field Test Mode (see Software operation / Field test mode section below)

*If both Fan 1 Override and Fan 2 Override are on at the same time, both fans run continually (duplex mode).
See note at the end of Software operation / Power up section.
PCB terminals and controls location        

OPERATING PRINCIPLE

Power up checks
On initial power up the fault output relay will be energized into the normal “No Fault” condition.
Fan No 2 will be run for 30 seconds, to allow the controller to monitor the correct running of the fan.
If no fan fault is detected the controller will switch off No 2 fan and bring on fan No 1.
If fan No 2 is found to be faulty the fault relay output will go into fault condition, and the LED will fast flash and fan No 1 will be turned on.
OR
If fan No 1 is found to be faulty the fault relay output will go into fault condition, and the LED will fast flash and fan No2 will be turned on.
NOTE If the installation only has one fan, then set “Fan 1 to override” mode and wire into Fan 1 terminals. Fan 2 will be ignored and the Power Up test mode will not occur.
If both fans are to run continually then put Fan 1 & Fan 2 into override mode.
Both fans will now be monitored for correct operation. The Power Up test mode will not occur.
Fan fault monitoring
Any fan that should be running will be monitored, and if its RPM falls below the Minimum RPM speed setting the Fault Output relay will switch to Fault.
NOTE A fault output will also be generated for lack of mains power.
To ensure that false alarm outputs are not produced the controller will monitor the fan/s for 30 seconds of continuous fault condition before producing a fault output. This time period is used to ensure that the Fault Output relay is stable in its operation, and will not be affected by different start up times of fans or windy days slowing the air flow down etc.
If a fan is found to be faulty the status LED will fast flash and the fault relay remains in the fault condition until such time as the system is turned off then back on. No automatic fault reset occurs.
Field Test mode
Field Test mode reduces the Changeover Time range to 1 to 12 minutes and the Run On Time range to 0 to 15 seconds, for quicker testing during commissioning.
Fan Speed setting
The Low, Medium & High fan speeds should be set as required for each installation.
The speed setting pots will have a basic scaling of 0, 2.5, 5, 7.5 & 10, corresponding to 0 to 100% PWM (0 to 10V).
Changeover mode
After the initial power up checks fan No 1 will run for the pre-set time. At the end of the run period Fan No 2 will be turned on and Fan No 1 will be turned off. If no fan faults are detected this sequence will be repeated.
If a fan fault is detected the Fault Output relay will switch to the fault condition and the status LED will start fast flashing. The fan being run will be turned off and the other fan will be turned on until the controller is powered down then back on to reset the unit.
If both fans develop faults then both will be turned off until the controller is powered down, then back on to reset the unit.
0 to 10V external control (User Control)
The unit will normally drive the fans at the Trickle Speed setting (when the VFCa and VFCb inputs are open and there is no 240V Medium Boost signal). Once the 0 to 10V input goes above circa 0.5V the fan speed/s will be increased in proportion to the input voltage.
I.E.
A) If the Trickle Speed setting is 10% PWM then the 0-10V input will control the fan speed/s from 10% to 100% PWM.
B) If the Trickle Speed setting is 20% PWM then the 0-10V input will control the fan speed/s from 20% to 100% PWM etc.
Boost inputs
If switch inputs VFCa (or the 240V Medium Boost input) or VFCb operate, the fan/s will run at the selected Boost speed. Whilst any boost signal is present the 0 to 10V input will be ignored, and the fan/s will run at the boost speed.
The fan/s will always run at the highest boost speed if Medium Boost and High Boost inputs are present at the same time.
There will be two “Boost” modes:
1) MEDIUM BOOST SPEED
Volts free contact input (referenced to units 0V/Neg) When the contacts close the Medium Boost speed will be selected.
Isolated 240V AC input. When applied the Medium Fan speed will be selected.
NOTE If both Medium Boost inputs are active, then Medium Boost will apply until the last Medium Boost input is removed.
RUN ON TIME
Whenever the last medium boost signal is removed the Fan/s will continue to run for the period set by the “Run ON Time” control.
NOTE If a boost signal has been removed and the fans are still being driven at the boost speed then during the Run On Time, “any” new boost signals will be ignored until the Run On Time has expired.
2) HIGH BOOST SPEED
Volts free contact input VFCb (referenced to 0V/Neg). When the contacts close the High Boost speed will be selected.
NOTE The High Boost can also trigger the Run In Timer if selected by the appropriate mode switch
PRIORITY OF BOOST SIGNALS
Medium Boost will override the Trickle fan speed setting and the 0 to 10V input.
High Boost will override Medium Boost, the Trickle fan speed and the 0 to10V input.
A boost signal will take control of the fan speed whether the boost speed is higher or lower than the fan speed it is overriding.
BMS Enable input
The VFC BMS Enable input must be connected or linked for the controller to operate. This is for remote control by a Building Management System or other control system.
If the Enable input is opened whilst running then the fan/s will be turned off and the Fault Output relay will switch to the fault condition.

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