Instruction Manual MODEL AC FLOW CONTROLLER Electronics Inc. 56790 Magnetic Drive Mishawaka, Indiana 46545 1-800-832-5653 (Toll Free) Phone: 1-574-256-5001 Fax: 1-574-256-5222 E-mail: sales@electronics-inc.com Made in the USA Website: www.electronics-inc.
Table of Contents PRODUCT DESCRIPTION 3 THEORY OF OPERATION 3 PRELIMINARY ADJUSTMENTS 3 OPERATION 4 STABILITY ADJUSTMENT 5 MOTOR CURRENT CALIBRATION 5 MOTOR AMPS FULL SCALE DISPLAY 5 SPARE PARTS LISTS 6 WARRANTY 6 UPGRADES-REVISIONS 7 AUTO-ZERO FEATURE 7 TROUBLE-SHOOTING GUIDE 7 CALCULATING FLOW RATE (Pounds per minute) 13 FIGURE 1: FRONT PANEL (Operator Controls) 14 FIGURE 2: FRONT PANEL (Technical Adjustments) 16 WIRING CONNECTIONS for P/N 999201 18 SPECIFICATIONS for P/N
1. PRODUCT DESCRIPTION The Model AC Amperage Controller is used with wheel-type shot peening and blast cleaning machines. It is designed to 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 motor amps. A 0-10Vdc output signal is available for a remote indicator or a stripchart recorder. High and low alarms are set to bracket the requested amperage setting.
. OPERATION Operation consists of controlling motor current by modulating the shot flow rate through the MagnaValve and transmitting an alarm signal when motor current is above or below the desired flow range (amperage). The servo loop controls output voltage for the MagnaValve by comparing the setpoint command with the actual motor amps a. SETPOINT (1-9) - To set the desired motor current, turn the setpoint knob and push display switch to the right to read desired amperage in the digital display.
signal source. An internal reference 10 Vdc excitation voltage for a remote potentiometer (10K OHM) is available at Terminal #4. h. MODE SWITCH (1-11) - The mode switch is used to turn the control “on” or “off” or enable the remote “Ready” mode. i. RECORDER OUTPUT- A recorder output analog voltage signal at terminal #20 with a 0 10 Vdc range is available to operate a strip-chart recorder or analog input card in data loggers. The minimum load on this output is 10K Ohms.
b. Set the servo switch (2-11) to the off (down) position. c. Turn the motor off. d. Turn the “setpoint” knob on the front panel full clockwise. Push and hold the “display switch” to right. Adjust "display range coarse/fine" trimpots (2-8) and (2-9) to set the display to equal the current transformer amp rating (not motor full load amps). e. Rotate the setpoint knob fully counterclockwise. Start the motor. f. Start the valve (apply Enable signal-or use on/off/ready mode switch (1-11) on front). g.
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. 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.
blocked. 2. Setpoint does not control motor current a. Green LED (1 - 7) “Local” should be on for local setpoint knob operation. b. Enable signal must be present (Terminal #3). The “Enable” LED must be lighted (1-2). c. MagnaValves operate using a magnetic field and have no moving parts. Large air suction in some wheel designs may pull shot through the valve. This symptom is characterized by having shot flowing when valve is off (red valve LED=off).
reading is not within 10%, then the valve driver is defective or not adjusted properly. Be sure the replacement valve driver is pre-calibrated to the same value as the original module. If the reading is within 10% of the original valve driver calibration, the valve driver module is okay but the valve is defective. 5. Motor amps are erratic or unstable. a. New installations - refer to servo adjustments. b. Old installations - machine worked fine until recently. i.
iv. FAX this information to Electronics Incorporated for assistance. (1-574-256-5222) This test is performed with the “SERVO” switch turned OFF. Plot the data on the following tables and Setpoint Knob Motor Information FL Amps=________ H.P.
Motor Amps Profile (0-50 A) 50 45 40 Motor Amps 35 30 25 20 15 10 5 0 0 10 20 30 40 50 % Setpoint 11 60 70 80 90 100
The following graphs show the results from two types of shot flow rate conditions. The first shows a condition where the maximum amperage is too low due to restricted maximum shot flow rate. This can be caused by inadequate sizing of the openings in the shot hopper or contamination (blockage) either above or below the MagnaValve. This could also be caused by restrictions at the wheel inlet due to pipe size or the wheel not being sized properly to discharge enough media at a given motor RMP.
. CALCULATING FLOW RATE IN POUNDS/MINUTE To determine the pounds per minute flow rate perform a catch and weigh test. A large container in which to catch the shot for at least 15 seconds of flow will be needed. Since the AC controller is a current controller and not a flow rate controller, some extra steps to determine the effective shot flow rate will be required. a. Select an amperage setting that is typical of the operation. Place the servo switch in the off (down) position.
FIGURE 1. FRONT PANEL DESCRIPTION - (Operator Controls) 1. AUTO-ZERO - This LED indicator is on when the auto-zero function is forcing the display to zero. The “enable” and the wheel motor must be off for this function to operate. The Auto-zero may be disabled, (2-2) 2. ENABLE - This LED indicator will be on if the mode switch is "on" or if mode switch is in "ready" mode and costumer applies 120VAC to Terminal #3 (control enable). 3.
FIGURE 1.
FIGURE 2. FRONT PANEL DESCRIPTION - (Technical Adjustments) 1. SPAN ADJUST - Please do not adjust the Span. This is a factory setting. Do not remove the calibration sticker. 2. ZERO ADJUST - Please do not adjust the Zero. This is a factory setting. Do not remove the calibration sticker. 3. AUTO-ZERO SWITCH - Used to activate or deactivate the auto-zero function. Auto-zero forces the digital display to zero whenever the enable signal and the motor are off.
FIGURE 2.
14. WIRING CONNECTIONS FOR P/N 999201 1. Power Neutral (120VAC) 2. Power Hot (120VAC, 50/60 Hz, 25VA) 3. Input Enable (120VAC) 4. (+) 10 Vdc Reference Output for external remote setpoint command excitation 5. (+) 12 Vdc Excitation Output for MagnaValve preamp (not used with VLP MagnaValve) 6. (-) 12 Vdc Excitation Output for MagnaValve preamp (not used with VLP MagnaValve) 7. (+) MagnaValve Output (in conduit or SO cord, does not have to be shielded) 8.
15. SPECIFICATIONS (P/N 999201) Power: (90-120VAC @ 60Hz) (110-120VAC @ 50Hz), 25VA Inputs: Current Shunt Input (0-5A). Electronics Inc. P/N 999200 (included) Voltage Signal Input (0-5 Vdc) Remote Command Setpoint Input (0-10 Vdc) Enable (90-120VAC @ 60Hz) (110-120VAC @ 50Hz) Alarm Reset (90-120VAC @ 60Hz) (110-120VAC @ 50Hz) Outputs: Valve Power: 60 Vdc PWM at 8 Hertz Alarm Relay Contacts: 120VAC @ 1A Excitation Voltage: +/-12Vdc @ 100mA Reference Voltage: +10Vdc @ 10mA Weight: 4 Lbs. (1.
16. WIRING CONNECTIONS FOR P/N 999201.B 1. Power Neutral (90-240VAC) 2. Power Hot (90-240VAC, 50/60 Hz, 50VA) 3. Input Enable (80-240VAC) 4. (+) 10 Vdc Reference Output for external remote setpoint command excitation 5. (+) 12 Vdc Excitation Output for MagnaValve preamp (not used with VLP MagnaValve) 6. (-) 12 Vdc Excitation Output for MagnaValve preamp (not used with VLP MagnaValve) 7. (+) MagnaValve Output (in conduit or SO cord, does not have to be shielded) 8.
17. SPECIFICATIONS (P/N 999201.B) Power: 90-240VAC, 50/60 Hertz, 50VA No internal fuse (1A recommended) Inputs: Current Shunt Input (0-5A). Electronics Inc. P/N 999200 (included) Voltage Signal Input (0-5Vdc) Remote Command Setpoint Input (0 -10Vdc) Enable (80-240VAC) Alarm Reset (80-240VAC) Outputs: Valve Power: 50Vdc PWM at 8 Hertz Recorder Analog Output: 0-10Vdc Alarm Relay Contacts: MAX. (125VAC/60Vdc @ 1A) Excitation Voltage: +/- 12Vdc @ 100mA Reference Voltage: +10Vdc @ 10mA Weight: 3 Lbs. (1.
18. WIRING CONNECTIONS FOR P/N 999201.C 1. Power Neutral (115VAC) 2. Power Hot (115VAC, 50/60 Hz, 25VA) 3. Input Enable (115VAC) 4. (+) 10 Vdc Reference Output for external remote setpoint command excitation 5. (+) 12 Vdc Excitation Output for MagnaValve preamp (not used with VLP MagnaValve) 6. (-) 12 Vdc Excitation Output for MagnaValve preamp (not used with VLP MagnaValve) 7. (+) MagnaValve Output (in conduit or SO cord, does not have to be shielded) 8.
19. SPECIFICATIONS (P/N 999201.C) Power: 115 VAC, 50/60 Hertz, 50VA No internal fuse (1amp recommended) Inputs: Current Shunt Input (0-5A). Electronics Inc. P/N 999200 (included) Voltage Signal Input (0-5Vdc) Remote Command Setpoint Input (0 -10Vdc) Enable (90 -115VAC) Alarm Reset (90 -115VAC) Outputs: Valve Power: 60 Vdc PWM at 8 Hertz Alarm Relay Contacts: 115VAC @ 1A Excitation Voltage: +/- 12Vdc @ 100mA Reference Voltage: +10Vdc @ 10mA Weight: 4 Lbs. (1.
20. CONTROLLER POWER REQUIREMENTS The model AC, FC and MC controllers were originally designed to operate from 120VAC (version A). In late 2001 a design change was made to accommodate 90-240VAC European applications (version B). Then, in 2002, for USA requirements, we upgraded the domestic version only, to version C. See notes below for the serial number ranges.
21. HOW TO RETURN A CONTROLLER FOR REPAIR 1 2 Installed in panel. Turn “Off” all power sources to controller before going to step 2. Remove terminal blocks and leave wires attached. 3 4 Remove Rails and Rail Mounting Screws. Slide controller forwards. Slide Rails back on and install the Rail Mounting Screws. 5 6 Call 1-574-256-5001 ask for a Returns Goods (RG) Number (#) Ship controller with RG # to: Electronics Incorporated 56790 Magnetic Drive Mishawaka, IN 46545 Controller is ready to return.
