Instruction Manual
MagnaValve Shot Flow Controller
Electronics Inc.
56790 Magnetic Drive
Mishawaka, Indiana 46545
1-800-832-5653 (Toll Free) |
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Phone: |
1-574-256-5001 |
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Fax: |
1-574-256-5222 |
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Made in the USA |
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E-mail: |
sales@electronics-inc.com |
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Website: |
www.electronics-inc.com |
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Model FC-24 Control
IM:0079 Revision: E Date: 1/22/2014
Table of Contents
PRODUCT DESCRIPTION |
3 |
THEORY OF OPERATION |
3 |
LOCATION OF ADJUSTMENTS |
3 |
PRELIMINARY ADJUSTMENTS |
3 |
CALIBRATION |
4 |
OPERATION |
4 |
STABILITY ADJUSTMENTS |
5 |
SPARE PARTS LISTS |
6 |
TROUBLE-SHOOTING GUIDE |
6 |
MAINTENANCE |
7 |
Figure 1 Upper Front Panel |
8 |
Figure 2 Lower Front Panel |
9 |
SPECIFICATIONS |
10 |
WIRING CONNECTIONS |
10 |
HOW TO RETURN CONTROLLERS FOR REPAIR |
12 |
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1.PRODUCT DESCRIPTION
The Model FC-24 Shot Flow Controller will measure and control the rate of flow 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 0-10 Volt dc 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, for either percent of full scale or percent of setpoint, 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 MagnaValve uses permanent magnets to hold the shot and electro-magnets to cancel the magnetic field. When power is applied to electro-magnets the shot is free to flow. The desired flow rate command or setpoint is compared to the actual flow rate and a control 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 can be used with any MagnaValve with built-in flow rate sensors, which have a 0- 10 Vdc output signal.
3.LOCATION OF ADJUSTMENTS
For location of adjustments see Figures 1 and 2. Numbers in parenthesis (figure-balloon) represent figure number and balloon call-out number. For example, digital display is (1-3), meaning figure 1 and balloon number 3. Notice that the yellow buttons also require the use of the ▲or ▼ buttons to change the display readings. The black buttons act alone to change the status of a function.
4.PRELIMINARY ADJUSTMENTS
A.Apply 24Vdc power.
B.Zero: The display (1-1) should read 0.0 during no-flow condition. If the digital display does not show zero then push the “Zero” button (2-26).
C.Calibration of the display range may be required. Use the arrow buttons to adjust the display to read 0.0 Other full-scale values may be used with different MagnaValves. Push the “Display Coarse” button (2-28) to show the current value of full scale range. To change the range use the ▲or ▼ buttons. The following table shows available scaled settings.
MagnaValve |
Flow Range |
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576-24 |
2 Lbs/min |
1 Kg/min |
577-24 |
10 Lbs/min |
5 Kg/min |
578-24 |
20 or 30 Lbs/min |
10 or 15 Kg/min |
579-24 |
100 Lbs/min |
45 Kg/min |
580-24 |
200 Lbs/min |
100 Kg/min |
590-24 |
300 Lbs/min |
150 Kg/min |
500-24 |
700-1200 Lbs/min |
300-600 Kg/min |
Note: MagnaValves are calibrated to give a 0-10 Vdc output signal at rated flow. Because of calibration differences caused by shot type and size, custom factory calibration is recommended .Please state type of shot, size of shot and desired flow range from the table above.
Multiple shot sizes may be used with one valve with slight degradation of accuracy. Adjustments for different flow ranges can be made by adjusting the “Span” at the MagnaValve or at the FC-24 control.
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D.For automatic machine cycle, push the “Mode” button (2-22) until the “Ready” LED (1-6) is on. When a 24Vdc "Enable" signal is received the "On" LED indicator (1-7) will come on and activate the valve output. The bar graph display (2-13) will indicate the relative signal strength sent to the MagnaValve. Adjust the flow rate setpoint with button (1-8) and ▲or ▼ buttons to the desired flow rate. The display is usually scaled in pounds/minute, but may be scaled in Kg/minute.
E.Display the alarm bandwidth by pushing button (1-4) and using ▲or ▼ to change the settings. A typical setting is 5% of full scale.
F.Select either percent of point (PT) or percent of full scale (FS) for the alarm band by pushing button (2-16). Typical setting is percent of full scale (FS). The alarm bandwidth is +/- this value and follows the set point command.
G.Adjust the alarm delay time (2-17) from 0-10 seconds. A typical setting is 5 seconds.
5.CALIBRATION
A.The MagnaValve has been factory calibrated to provide a 10 Vdc signal output at its rated flow If a different type or size of shot is used it maybe necessary to re-calibrate the system. The span setting can be changed at the MagnaValve or at the FC 24 controller. The calibration change should be made at the FC 24 controller for convenience, since replacement MagnaValves will have the same calibration as the original and the span setting at the FC-24 controller can easily be displayed as described below.
B.Push the “Span” button (2-19) to display the current span setting. The factory standard setting is 1.000 for unity gain. The range of the span function is between .750 and 1.500.
C.To check the flow accuracy, perform a catch and weigh test. Run shot through the MagnaValve for 1 minute and catch it in a container. Weigh the shot. Use the ▲or ▼ buttons to increase or decrease the flow rate. Repeat the trial to confirm calibration. Keep a record of the span setting to be used in case the FC-24 controller is replaced.
6.OPERATION
A.Operation consists of controlling the shot flow rate through the MagnaValve and transmitting an alarm signal when the flow rate is above or below the desired flow range. The shot flow rate for the MagnaValve is controlled by a servo loop that compares the setpoint command to the actual shot flow rate.
B.SETPOINT - To read the current setpoint push the “Setpoint” button (1-8). To change the value use the ▲or ▼ buttons.
C.MODE - The FC controller has three mode settings: “Off”, “Ready” and “On” as indicated by LEDs (1-5, 6, 7). The “Off” mode prevents any shot flow. The “On” mode will activate the MagnaValve manually. The “Ready” mode will only activate the MagnaValve upon receipt of a 24 Vdc “Enable” signal. The “On” LED will come on upon receipt of the enable signal and will get brighter upon expiration of the “Enable Delay”.
D.ENABLE DELAY – The “Enable Delay” feature is set by button (2-21) and is used to allow the air pressure to stabilize prior to activating the MagnaValve output. A typical setting is 3 seconds. Without this delay the air blast system may exhibit unstable flow conditions for 15 or more seconds.
E.ALARM BANDWIDTH - The alarm bandwidth is adjustable from 0 to 50% of full scale or of setpoint and is factory set at 5% of full scale (FS). The alarm circuit is available only when the servo is "on" and the control is enabled. The flow set point is also the alarm mid-point.
The alarm bandwidth, usually set at 5%, will track the flow set point setting.
F.If the Alarm Mode is set for percent of full scale (FS) as indicated by LED (2-14) then, with
5% of full scale and a full scale of 20 lb/min, the alarm band is ± 1 lb/min. For a setpoint of
12 pounds/minute the alarms would be active below 11 and above 13 pounds/minute.
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