Instruction Manual MODEL FC 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 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 9992
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.
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.
d. ALARM BAND - The flow set point is also the ± alarm mid-point. The alarm bandwidth, usually set at ± 5%, will track the flow set point. For example: with 1 pound/minute alarm bandwidth 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.
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.
12. TROUBLE-SHOOTING GUIDE 1. SYMPTOM: Unstable operation. If display indicates flow rate variations of more than 5%, check for the following: a) b) c) d) Air leaks - nozzle, hose, valve, etc. Pressure regulator malfunction (may be pulsing). Contaminated shot (dust, oil, water, and broken shot). 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.
5. SYMPTOM: Cannot achieve any flow, or flow rate is very low. a) “Enable” light must be on (1 -2). b) Set point command must be present (check set point using toggle switch to right). c) Red LED "Valve" should be bright and blinking or constantly on. An internal circuit breaker has tripped if it is dim, Check for short circuit valve wiring at Terminals #7 and #8. To reset the circuit breaker, remove and re-apply the “Enable” signal.
13. MAINTENANCE: There is no maintenance required for the FC controller other than calibration tests as needed by user. 14. FIGURE 1 FRONT PANEL (Operator Controls) ITEM DESCRIPTION 1. AUTO-ZERO - This LED indicator is on when the Auto-Zero function is forcing the display to zero. The valve “Enable” must be off for this function to operate. The Auto-Zero may be disabled, see figure 2. 2.
13. CALIBRATION DECAL - Customer may place a calibration decal here to restrict access to the internal adjustments normally made by technicians only. FIGURE 1.
15. FIGURE 2 FRONT PANEL (Technician Adjustments) ITEM DESCRIPTION 1. SPAN - Used to adjust the amplitude of the feedback signal and is factory set to convert 0-5Vdc to 0-10Vdc. Flow calibration adjustments for catch and weigh test should be made at the MagnaValve. Please do not adjust the SPAN. This is a factory adjustment. Do not remove the calibration sticker. 2. ZERO - Used to adjust the input signal on the Digital Display to zero during a no flow condition. . 3.
13. FREQUENCY ADJUST- Factory set at 8 Hertz. Used to adjust the frequency of the pulse out put signal to the MagnaValve. The new 1xxx series MagnaValves can be set to 8-20 Hertz. 14. ENABLE DELAY - Used to adjust the time delay (0-10sec.) from receipt of enable signal until valve output. Useful in direct pressure blasting machines to allow air pressure to stabilize prior to starting the valve. For suction blast or wheel-blast machines this should be set to zero or fully counter-clockwise. 15.
16. SPECIFICATIONS for P/N 999234 Power: 115 Vac, 50/60 Hertz, 50VA No internal fuse (1 Amp recommended) Inputs: Flow Sensor Voltage Input (0-5 Vdc) Remote Command setpoint (0-10 Vdc) Enable (115 ±5v 50/60 Hz) Alarm Reset (115 ±5v 50/60 Hz) Output: Valve Power: 50 Vdc PWM at 8-20 Hertz Recorder Analog Output: 0-10 Vdc Alarm Relay Contacts: MAX. (125 Vac 60Vdc @ 1 Amp) Excitation Voltage: +/- 12 Vdc @ 100mAmp Reference Voltage: +10.00 Vdc @ 10mAmp Weight: 5 Lbs. (2.
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18. SPECIFICATIONS for P/N 999234.B Power: (90-120VAC @ 60Hz) (110-120VAC @ 50Hz), 25VA Inputs: 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: 50 Vdc PWM at 6-25 Hertz Recorder Analog Output: 0-10 Vdc Alarm Relay Contacts: 120VAC @ 1A Excitation Voltage: +/-12Vdc @ 100mA Reference Voltage: +10Vdc @ 10mA Weight: 5 Lbs. (1.
19. WIRING CONNECTIONS for 999234.B WIRE CONNECTIONS FOR AN FC FLOW CONTROLLER TO THE FOLLOWING VALVES: 577, 578, 579, 580, 590, AND ALL 15XX SERIES VALVES JUNCTION BOX VD11 Valve Driver (Factory Wired) CABLE TO MAGNAVALVE BELDEN 9773 3 PAIR SHIELDED 18 AWG OR EQUAL FC CONTROLLER BACK VIEW GROUND NEUTRAL HOT 115VAC 1 2 3 4 5 6 NOTE: THE CABLE SHIELDS ARE TO BE TERMINATED AT THE CONTROLLER ONLY.
20. SPECIFICATIONS for P/N 999234.C Power: 115 Vac, 50/60 Hertz, 50VA No internal fuse (1 Amp recommended) Inputs: Flow Sensor Voltage Input (0-5 Vdc) Remote Command setpoint (0-10 Vdc) Enable (115 ±5v 50/60 Hz) Alarm Reset (115 ±5v 50/60 Hz) Output: Valve Power: 50 Vdc PWM at 6-25 Hertz Recorder Analog Output: 0-10 Vdc Alarm Relay Contacts: MAX. (125 Vac 60Vdc @ 1 Amp) Excitation Voltage: +/- 12 Vdc @ 100mAmp Reference Voltage: +10.0 Vdc @ 10mAmp Weight: 5 Lbs. (2.
21. WIRING CONNECTIONS for P/N 999234.C WIRE CONNECTIONS FOR AN FC FLOW CONTROLLER TO THE FOLLOWING VALVES: 577, 578, 579, 580, 590, AND ALL 15XX SERIES VALVES JUNCTION BOX VD11 Valve Driver (Factory Wired) CABLE TO MAGNAVALVE BELDEN 9773 3 PAIR SHIELDED 18 AWG OR EQUAL FC CONTROLLER BACK VIEW GROUND NEUTRAL HOT 115VAC 1 2 3 4 5 6 NOTE: THE CABLE SHIELDS ARE TO BE TERMINATED AT THE CONTROLLER ONLY.
22. REAR TERMINAL STRIP LEGEND 1. Power Neutral (115Vac) 11. High Alarm Relay Contact 2. Power Hot (115Vac) 12. Common Alarm Relay Contact 3. Enable Input (115Vac) 13. Low Alarm Relay Contact 4. (+) 10Vdc Reference Output 14. Alarm Reset Input (115Vac) 5. (+) 12Vdc Excitation Output 15. No Connection 6. (-) 12Vdc Excitation Output 16. No Connection 7. (+) MagnaValve Output 17. Voltage Input (0-5Vdc) 8. (-) MagnaValve Output 18. Input Common 9. Circuit Common 19. Circuit Common 10.
23. 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 90-240 Vac 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.
24. 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.
