Electronics FC User Manual

Instruction Manual

MODEL FC FLOW CONTROLLER

Electronics Inc.

56790 Magnetic Drive

Mishawaka, Indiana 46545

1-800-832-5653 (Toll Free)

Phone: [phone]
Fax: [phone]
E-mail: [e-mail]
Website: www.electronics-inc.com

FC Controller

IM:0056 Revision: N Date: 6/27/2011

Made in the USA

Table of Contents

PRODUCT DESCRIPTION 3
THEORY OF OPERATION 3
PRELIMINARY ADJUSTMENTS 3
FLOW RATE CALIBRATION 3
OPERATION 4
STABILITY ADJUSTMENTS 5
SPARE PARTS LISTS 6
WARRANTY 6
SERVICE/START-UP ASSISTANCE 6
UPGRADES-REVISIONS 6
AUTO-ZERO FEATURE 6
TROUBLE-SHOOTING GUIDE 7
MAINTENANCE 9
FIGURE 1 FRONT PANEL (Operator Controls) 9
FIGURE 2 FRONT PANEL (Technician Adjustments) 11
SPECIFICATIONS for P/N 999234 13
WIRING CONNECTIONS for P/N 999234 14
SPECIFICATIONS for P/N 999234.B 15
WIRING CONNECTIONS for P/N 999234.B 16
SPECIFICATIONS for P/N 999234.C 17
WIRING CONNECTIONS for P/N 999234.C 18
REAR TERMINAL STRIP LEGEND 19
CONTROLLER POWER REQUIREMENTS 20
HOW TO RETURN CONTROLLERS FOR REPAIR 21

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1. PRODUCT DESCRIPTION

The Model FC Shot Flow Controller will measure and control the flow rate of steel shot passing
through a special, normally-closed, magnetic valve called a MagnaValve. A digital display is pro­vided for indications of shot flow rate. A 0-10Vdc output signal, representing flow rate, is available
for remote indication or strip-chart recording. High and low alarms are set to bracket the requested
shot flow rate. The alarm bandwidth is adjustable from the front panel. Either local (front panel), or
remote (0-10Vdc) set point commands may be used.

2. THEORY OF OPERATION

The desired flow rate command, or “set point”, is compared to the actual flow rate and a power sig­nal is sent to the MagnaValve to achieve desired flow rate. If the desired flow rate is not achieved
within an adjustable time period, then a high/low alarm relay will be triggered. This output signal may
be used to inhibit further machine operations and signal the operator. The FC Controller is used with
a MagnaValve that has a built-in flow rate sensor. This MagnaValve incorporates a preamplifier cir­cuit that provides a 0-5Vdc output signal back to the FC Controller.

3. PRELIMINARY ADJUSTMENTS

For location of adjustments see (Figure-Item) as noted.

a. Apply power to unit.
b. The display should read 00 during a no-flow condition. Check the signal input at Terminals 17

& 18 for the flow sensor input from the MagnaValve. Confirm 0Vdc at the no-flow condition. If
the input signal is 0Vdc but the display does not show “00”, adjust the “ZERO” trimpot until
“00” appears on the display

c. For automatic machine cycle, place the “Mode” switch to the left for the ready mode (1-11).

When a 115VAC "Enable" signal is received, the ENABLE LED indicator (1-2) on the front
panel will light and activate the valve output. The red VALVE (1-3) LED will blink at 8-Hertz
(8 times per second). Adjust the flow rate SETPOINT knob (1-9) to desired flow rate. The
display (1-4) is usually scaled in pounds/minute, but may be scaled in Kg/minute.

d. Adjust the ALARM BAND (2-7), typically 10% of full scale by pushing the DISPLAY SWITCH

(1-10) to the left to exhibit the alarm bandwidth in the display. The alarm bandwidth is +/- of
this value and it follows the set point command.

e. Adjust the ALARM DELAY time (2-6) from 0-10 seconds. A typical setting is 5 seconds.

4. FLOW RATE CALIBRATION

Calibration of the display range may be required. The standard factory setting is 20.0-pounds/minute
full scale to match the model 578 MagnaValve. Other full-scale values may be used with different
MagnaValves.

MagnaValve Model Maximum Flow Rate FC Display Full Scale

477 or 577 2 pounds/minute 2.00
478 or 578 20 pounds/minute 20.0
479 or 579 100 pounds/minute 100.0
480 or 580 200 pounds/minute 200
490 or 590 300 pounds/minute 300

VLP+ (with sensor option) 1000 pounds/minute 1000

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a. To change the full-scale range of the digital display place the control into the local mode of

operation. (1-7)
b. Turn SETPOINT knob (1-9) on the front panel counter-clockwise to 0%.
c. Push and hold the display switch (1-10) to right. The display should read zero. If it does not

read zero, contact the factory for assistance.
d. Turn the set point knob (1-9) on the front panel full clockwise to 100%.
e. Push and hold the display switch (1-10) to right. Adjust "Display Range-Coarse/Fine" trim

pots (2-8) and (2-9), to achieve the desired full-scale flow rate range for the display to match

the MagnaValve rating.
f. To check the flow accuracy you must perform a catch and weigh test. Run shot through the

MagnaValve for 1 minute and catch it in a container. Weigh the shot. This is the pounds/

minute flow rate. If shot weighs more than the display amount, turn the span trim pot at the

MagnaValve clockwise. If shot weighs less than indicated amount, turn the span trim pot at

the MagnaValve counter-clockwise. Repeat the trial to confirm calibration.

The FC Controller span is factory set to translate the 0-5Vdc MagnaValve signal to 0-10Vdc levels
for the controller. Shot flow rate calibrations should be made at the MagnaValve, not at the

controller.

DO NOT ADJUST THE FC CONTROLLER SPAN. CALL THE FACTORY FOR ASSISTANCE!

5. OPERATION

Operation consists of controlling shot flow rate through the MagnaValve and transmitting an alarm
signal when flow rate is above or below the desired flow range. The output voltage for the Magna­Valve is controlled by a servo loop by comparing the set point command to the actual shot flow rate.

a. SETPOINT - To set desired flow rate, turn the set point knob and push Display Switch (1-10)

to the right to read desired set point in the digital display. This will show the set point for either
“Local” or “Remote” modes of operation. Release the Display Switch and the actual flow rate
will again be displayed. The set point may be adjusted during use. It is optional (not neces­sary) to push the Display Switch to the right while changing the set point during normal opera­tion.

b. ENABLE - The FC controller can be automatically activated by a 90-115VAC remote "enable"

signal when the mode switch (1-11) is in the "Ready" position (push to the left). The mode
switch can be placed in the "off" position, the "On" position for manual operation, or the
“Ready” position for automatic operation.

c. ALARM - The alarm bandwidth is adjustable from 0 to 50% of full scale and is factory set at

5%. The customer may readjust to another value if desired. The alarm circuit is activated
when the servo is "on" and the control is “Enabled”. When the control is enabled the "Enable"
LED.(1-2) will be lighted). The mid-point of the alarm band automatically follows the set point
setting. The servo switch (1-11) must be on (up) for the alarms to function.

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d. ALARM BAND - The flow set point is also the ± alarm mid-point. The alarm bandwidth, usu-

ally set at ± 5%, will track the flow set point. For example: with 1 pound/minute alarm band-

width and a set point of 12 pounds/minute the alarms would be active below 11 and above 13

pounds/minute. Changing the set point to 15 would change the alarms to 14 and 16 pounds/

minute automatically. The alarm bandwidth of ±1 stays fixed until the alarm bandwidth is

changed (see figure 2-7).
e. ALARM TIMER - When the control is "enabled" and in automatic servo mode, the "High" (1-

5) or "Low" (1-6) alarm light will come on if flow rate goes above or below the alarm limits. An

adjustable timer, labeled "ALARM DELAY” (2-6) which is adjustable from 0 - 10 seconds, will

start each time the "High" or (Low) lights come on. If the fault lasts longer than the timer set-

ting the “High” (or "Low”) lights will get brighter and the “High” (or “Low”) alarm relay contacts

will transfer and latch. The alarm will stay on after the “Enable” signal is removed until the

alarm is reset.
f. ALARM RESET - Activating the alarm-reset circuit (90-115VAC applied to Terminal #14) will

cancel the alarm relay and the alarm "High" or (“Low”) LED will go off. Continuous applica-

tion of the reset signal will disable or inhibit the alarm output signal. The alarms are automati-

cally reset upon receipt of each new "Enable" command.

g. REMOTE SETPOINT - There are two conditions required for use of the remote setpoint. The

set point “Local/Remote” switch (2-12) must be down in the remote mode. A yellow LED (1-

8) on the front panel indicates operation in the remote mode. Apply a 0 - 10 Vdc analog re-

mote set point command signal to the remote input, Terminal #10. A 0Vdc signal will corre-

spond to a 0% flow rate command and 10 Vdc signal will correspond to a 100% flow rate. To

verify the set point command, push and hold the display switch (1-10) to the right. The re-

mote command may come from a remote pot or any 0 - 10Vdc signal source. An internal ref-

erence 10Vdc voltage for a (customer supplied) remote potentiometer (10k OHM) is available

at Terminal #4.
h. MODE SWITCH - The mode switch, (1-11) is used to turn the control "on" or "off" or to accept

a remote “Enable” while in the "Ready" mode.
i. RECORDER OUTPUT- An analog voltage recorder output signal Terminal #20 with a 0 -

10Vdc range is available to operate a strip-chart recorder or analog input card in data log-

gers. The minimum load on this output is 10K Ohms. Shielded cable (20AWG or larger

gage) should be used and the shield should be connected to rear chassis of the FC control.

This analog output signal is heavily filtered with a capacitor to provide noise immunity. Addi-

tional noise filtering may be necessary at the input terminals of your analog input card to pre-

vent erroneous readings.
j. MAGNAVALVE - During operation of the MagnaValve a red LED labeled Valve (1-3) will be

on, showing that power is sent to the MagnaValve. The MagnaValve also has an LED on the

valve driver junction box to show this function. This LED will pulse with the duty cycle (on

time to off time ratio). A low duty cycle will provide a low flow rate and the Valve LED will be

relatively dim. A long, or continuously on, duty cycle will provide for a high flow rate. At

100% duty cycle the Valve LED is constantly on and the permanent magnet field is com-

pletely canceled and no magnetic field exists in the MagnaValve and shot will fall freely

through the valve. The MagnaValve has no moving parts.

6. STABILITY ADJUSTMENTS - (SERVO STABILITY)

The servo adjustments have been factory set to typical settings and the customer may fine-tune to
optimize the speed of response if desired. Since there are many factors that determine system sta­bility, these adjustments should be made slowly.

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a. SERVO GAIN - This adjustment sets the gain of the error amplifier over a range of 1% to

100%. Most systems may operate at 50% (full clockwise) for high gain. If a system is unsta­ble, then reduce the gain to 25%.

b. SERVO RESET - This adjustment determines the speed at which the output signal increases

to achieve desired flow rate. A 75% value is set at factory for typical applications. Turning
the servo reset clockwise will make it respond faster and turning it counter-clockwise will
make it respond slower.

If the shot flow rate is not steady it will be necessary to perform a simple test. Place the “Servo”
switch (2-11) down in its "off" position. Enable the control and slowly increase the set point from 0%
until flow display reads your desired value. If the shot flow rate is still unstable then system itself is
unstable. Since the control is in manual mode, if flow rate is unstable, then the machine itself is
causing a problem, not the servo adjustments (The servo is off.). Refer to the Trouble-Shooting
Section 12.

7. SPARE PARTS LIST

There are no spare parts for the FC controller. A spare controller should be purchased for an emer­gency or Electronics Inc. should be contacted for repair service.

8. WARRANTY

a. Electronics Incorporated warrants this product to be free from defect in material and work-

manship for a period of two years from the date of shipment. Defective units must be re­turned to Electronics Incorporated with shipping costs prepaid. Call for a Return Authoriza­tion Number and shipping instructions. Electronics Incorporated will repair or replace a defec­tive unit at its option. No consequential liability is assumed. No other warranty, including
merchantability or fitness for purpose, applies or is expressed or implied.

b. Warranty work is only available at the factory. On-site service or start-up assistance is avail-

able at extra cost to the customer. See Section IX.

c. Caution: Any customer attempts to modify or repair the product during the warranty period will

terminate the warranty. Standard technician labor rates will be quoted prior to repair work.

9. SERVICE / START-UP ASSISTANCE

Service is an option available at the time of purchase or as required by customer. A purchase order
is required prior to making a service call.

10. UPGRADES - REVISIONS

Design improvements are constantly being made to our products. Please contact Electronics Incor­porated for details. When ordering spare units, please refer to model number and serial number of
each unit.

11. AUTO-ZERO FEATURE

An auto-zero feature is available to maintain a true zero reading during the no-flow condition. This
circuit monitors the flow signal and forces it to zero whenever the "Enable" is absent. A blue LED
indicates that the auto-zero is active.

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12. TROUBLE-SHOOTING GUIDE

1. SYMPTOM: Unstable operation.
If display indicates flow rate variations of more than 5%, check for the following:

a) Air leaks - nozzle, hose, valve, etc.
b) Pressure regulator malfunction (may be pulsing).
c) Contaminated shot (dust, oil, water, and broken shot).
d) Blast hose restricted during nozzle movement.

To determine if instability is caused by the shot peening machine or by the controller, put the
servo switch (2-11) down in the off position. Turn on the machine and slowly increase the set­point until the display reads the desired flow rate. Since the servo mode is off, the controller is
acting like a power supply to the MagnaValve with no flow rate feedback information. If the flow
rate is unstable, the cause originates in the machine. If the flow rate is stable with the servo off,
then the servo needs to be readjusted. Refer to Section VI Stability Adjustments.

2. SYMPTOM: Display reads high value and does not change.
a) Wiring defect in the cable to the MagnaValve pre-amps. Check voltages at Terminals #17

and #18 for proper connection to MagnaValve.
b) Be sure MagnaValve is installed right side up (see flow arrow).
c) Check to see if the lower portion of the MagnaValve is full of shot due to hose blockage etc.

3. SYMPTOM: Set point (front panel SETKNOB) does not control flow rate.
a) Green LED (1 - 7) "Local" should be on for local set point knob operation.

b) “Enable” signal must be present (Terminal #3). Also, the "Enable" LED must be
lighted (1-2).
c) MagnaValves operate using a magnetic field and have no moving parts. High differential air
pressure in air peening applications or suction in wheel peening applications, may force shot
through the valve. This symptom is characterized by having shot flowing when valve is off
(red valve LED=off). For direct pressure air-peening systems, be sure air pressure in the
pressure pot is equal to boost air supply. This will eliminate the differential air pressure that
can force shot through the MagnaValve.
d) MagnaValve valve driver module may be defective. The output current setting is listed on the
valve driver module. Check the valve current with an ammeter in series with the wire lead
from the controller to the valve driver module. Contact factory for assistance.

4. SYMPTOM: No alarm relay contact output.
a) “Enable” must be on (1 - 2).

b) “Servo” switch must be on (up) (2 - 11).
c) “High” (1-5) or low (1-6) Alarm LED must be on (bright) for alarm relay contact to transfer.
d) Check ± alarm bandwidth; it may be too large.
e) Check wiring from the terminals:
f) “High” Alarm Relay Contact
g) “Common” Alarm Relay Contact
h) “Low” Alarm Relay Contact
i) “Alarm Reset” signal, (115VAC) should be absent from terminal #14.

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