Instruction Manual MagnaValve Amperage 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 LOCATION OF ADJUSTMENTS 3 PRELIMINARY ADJUSTMENTS 3 OPERATION 4 STABILITY ADJUSTMENT 6 MOTOR AMPS FULL SCALE DISPLAY 6 MOTOR AMPS CALIBRATION 7 WARRANTY 7 UPGRADES — REVISIONS 7 TROUBLE-SHOOTING GUIDE 7 EXAMPLES 9 CALCULATING FLOW RATE (Pounds per minute) 10 SPECIFICATIONS 11 WIRING CONNECTIONS 11 FIGURE 1: FRONT PANEL (Operator Controls) 12 FIGURE 2: FRONT PANEL (Technical Adjustments) 13 TABLES FOR CALCULATING
1. PRODUCT DESCRIPTION The Model AC-24 Amperage Controller is used with wheel-type shot peening and blast cleaning machines 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 0-10 Volt dc output signal proportional to motor amps is available for remote indication or strip-chart recorder. High and low alarms are set to bracket the requested amperage setting.
I. To set the alarm bandwidth push (1-4) and ▼ or ▲. The alarm bandwidth is relative to this value and is centered at the setpoint command. Typical setting is 5% of Full Scale (FS). J. Adjust the alarm delay time by pushing (2-17) and ▼ or ▲. Typically setting is 5 seconds. 5. OPERATION Operation consists of controlling motor amps by modulating the shot flow rate through the MagnaValve and transmitting an alarm signal when motor amps is above or below the desired amperage.
ting. For example: for an alarm band of 5 Amps and a setpoint of 30 Amps will have alarms set at 25 and 35 amps. Moving the setpoint to 45 Amps will cause the alarms to move to 40 and 50 Amps. E. ALARM DELAY: An adjustable time delay of 1-10 seconds is set by the alarm delay button (2-17) and the ▼ or ▲ buttons. The delay timer will start each time the “high” or “low” light comes on.
K. CALIBRATION SPAN AND ZERO 1. The digital display (1-1) should show zero when the motor is turned off. If it does not show zero then push the “zero” button (2-26) to achieve a zero reading. 2. The factory setting of input “Span” is 1000 (gain of 1.000). This represents the condition of 5.00 Amps as input signal and for a 100:5 current transformer the display should show 100.0. This setting probably should not need customer adjustment.
E. Use the Display Range Fine button (2-29) for slower adjustment speed. 8. MOTOR AMPS CALIBRATION A. The factory calibration of input span should not need any adjustment. Verify that the wire size is adequate in the 5-amp loop of the current transformer secondary. It should be a minimum of 16 AWG for short runs of 5 feet or less. Longer runs should use 14 AWG or 12 AWG wire size.
. Adjust the setpoint command to 100%. The red LED bar graph will be fully on (all 10 elements on) and the MagnaValve will be in its maximum flow condition. Slowly open the slide gate and observe the wheel ammeter for stability. 9. If the motor current is unstable, the problem is due to the wheel condition, not the AC controller or MagnaValve. 10. If the machine uses a variable speed drive, check it for stability or bypass it with a conventional motor starter. 11.
E. Motor amps are erratic or unstable. 1. New installations - refer to servo adjustments. 2. Old installations - machine worked fine until recently. 3. Check shot for cleanliness (dust, oil, water). 4. Check shot for obstructions. 5. Check shot hopper, are you low or out of shot? 6. Do not adjust servo adjustments. 7. Check for worn wheel blades or worn control cage. 8. Call the factory for advice. F. Amperage calibration not accurate at low or high amps 1.
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. B. The first example shows a typical installation where the maximum full load (FL) motor amps is achieved at approximately 70% of MagnaValve capacity with the wheel running at 3000 RPM.
I. Note: The above procedure only works because the servo is turned off. In this mode the setpoint sets the output manually and ignores the motor amperage feedback signal, which during the catch and weigh test is will be zero. The procedure works because you manually establish a flow rate with the wheel motor amps and then, without changing the manual output setting, perform a catch and weigh test.
FIGURE 1: FRONT PANEL (Operator Controls) 1-12 1-11 1-1 1-10 1-2 1-9 1-3 1-8 1-4 1-5 1-7 1-6 Black switches toggle sequence Yellow switches require up/down ▲▼ FRONT PANEL (upper portion) (1-1) Digital Display (1-7) Mode status “On” LED (1-2) High Alarm LED (1-8) Setpoint button (1-3) Low Alarm LED (1-9) Remote Setpoint LED (1-4) Alarm Band button (1-10) Local Setpoint LED (1-5) Mode status “Off” LED (1-11) (1-6) Mode status “Ready” LED (1-12) Increment button ▲ 12 Decrement button ▼
FIGURE 2: FRONT PANEL (Technical Adjustments) 2-13 2-14 2-15 2-27 2-16 2-22 2-17 2-25 2-23 2-18 2-19 2-28 2-29 2-20 2-30 2-21 2-24 2-26 FRONT PANEL (lower portion with plate removed) 2-13 MagnaValve output signal level 2-22 Control Mode button 2-14 Alarm bandwidth % of full scale 2-23 Servo Gain button 2-15 Alarm bandwidth % of setpoint 2-24 Servo Speed button 2-16 Alarm mode button 2-25 Span button for amperage calibrate 2-17 Alarm delay button 2-26 Zero button for zero amp
Tables for Calculating Flow in Pounds/minute Set Point Knob Wheel RPM 1750 Wheel RPM 2400 Wheel RPM 3000 Wheel RPM 1750 Wheel RPM 2400 Wheel RPM 3000 0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% Set Point Knob 0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% 14
FAX this information back to Electronics Incorporated for assistance. (1-574-256-5222) Motor Information Motor Horse Power HP Motor Full Load Amps Wheel Size (diameter) Wheel Speed (RPM) Requested motor Amps Control and Valve Information Valve Model (see label for modification information) Valve Serial Number Control Model (see label for modification information) Control Serial Number Misc.
. HOW TO RETURN CONTROLLERS 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.
