576-24 577-24 578-24 579-24 580-24 590-24 24 Vdc MagnaValve® for Air Blast Machines Instruction Manual 56790 Magnetic Drive, Mishawaka, Indiana 46545 USA • 1-800-832-5653 or (574)256-5001 • www.electronics-inc.com Rev 9/14 Table of Contents Product Overview and Principle of Operation ......................................................3 Closed-Loop Servo Control with the FC-24 Media Flow Controller..............4 Adjustments............................................................................................................................5 LED Status Indicators..........................................................................................................6 Installation..............................................................................................................................7 Direct-Pressure Machine Applications.....................................................................8 Gravity-Fed Suction Machine Applications............................................................9 Suction-Blast Machine Applications...................................................................... 10 Wiring Diagrams................................................................................................................. 11 Calibration............................................................................................................................. 13 Specifications...................................................................................................................... 14 MagnaValve Selector Guide......................................................................................... 14 Product Dimensions......................................................................................................... 15 Troubleshooting Guide................................................................................................... 16 Replacement Parts............................................................................................................ 17 Warranty................................................................................................................................. 17 Contacting Electronics Inc............................................................................................. 17 Appendix Notice of Revision......................................................................................................... 18 Remote Table Select (RTS) - Third Generation Only......................................... 19 Safety Notices Warning: Good safety practices must be followed when operating and handling the MagnaValve. Improper usage could result in damage to the product or personal injury. Please note: • The MagnaValve emits magnetic fields which can be harmful to people who wear pacemakers. • The MagnaValve operates with internal air pressure. Refer all servicing to qualified personnel. • Power off the FC-24 Controller before connecting or disconnecting the MagnaValve. • The use of plastic buckets during catch testing can cause a static charge buildup. Be sure to provide a means of preventing electrostatic discharge. Additional safety notices can be found throughout this manual and should be adhered to at all times. 2 Product Overview and Principle of Operation The 24 Vdc series MagnaValves regulate the flow of ferrous media in shot peening and abrasive blast cleaning machines. These valves have a magnetic control section (upper portion) and a shot flow rate sensing section (lower portion). MagnaValves are used in direct pressure, gravityfed and suction-blast (venturi-style nozzles) air-blast machines. A special version of the valve, the RTS series, offers choices of up to five media calibrations (see page 19). Principle of Operation The low-maintenance construction of the MagnaValve features a rare earth permanent magnet for normally closed operation and an electromagnet for controlling shot flow rates. With power applied, the magnetic field is neutralized and shot is allowed to flow through the valve. When no power is applied to the MagnaValve, the permanent magnet stops all flow. If the power is interrupted for any reason, the permanent magnet securely holds the shot. The MagnaValve is factory calibrated and results are supplied upon request. Note: The MagnaValve is factory calibrated for the media type, size and flow rate as specified on the purchase order. Refer to the Calibration Label on the side of the valve for this information. 3 Closed-Loop Servo Control with the FC-24 Media Flow Controller To achieve closed-loop servo control, the 24 Vdc MagnaValve is paired with the FC-24 Media Flow Controller (sold separately). Here is how the closed-loop system provides accurate and dependable media flow control: • The desired media flow rate signal is processed by the FC-24 Controller (0-10 Vdc) • A control signal is sent to the MagnaValve • The media flow rate signal is sent to the FC-24 Controller for comparison to the desired media flow rate and the control signal is adjusted as required to maintain the desired flow rate • The alarm circuit will trigger a high-flow or low-flow alarm if the flow rate is not within the alarm bandwidth Media Hopper Desired Media Flow Rate Control Signal FC-24 Controller 24 Vdc MagnaValve Regulated Media Flow Media Flow Rate Signal from Sensor in MagnaValve Nozzle Media Accelerated Features of the FC-24 Controller (sold separately) • Monitors flow rate in lb/min and kg/min • Enable input and output (24 Vdc) • Remote analog setpoint (0-10 Vdc) • Recorder analog output (0-10 Vdc) • Digital display • High-low alarm contacts • Easy panel mounting • CE compliant • 24 Vdc For more information on the FC-24 Controller, please call our Customer Service department at 1-800-832-5653 (Toll-free in USA and Canada) or (574) 256-5001. 4 Adjustments The valve is calibrated with the shot type and size specified on the Purchase Order. The valve should not need any adjustments upon installation unless a different media type or size will be used. The MagnaValve must be recalibrated if a different media type or size is used. Several adjustments, however, can be made at the panel behind the MagnaValve’s protective cover plate. These adjustments are Zero, Pulse Rate and Gain Adjust. Front Panel B C D A E A) Valve Pulse – The rate at which the valve dispenses shot, similar to a heart beat rate. It is factory set to match the best flow characteristics of the media (cast steel, cut wire or micro-bead). Typical operation is set at 8 Hertz. B) Zero – Turn knob until both LEDs (below the (-) and (+) signs) are OFF. This will set the output signal voltage to zero ± .050 Vdc during no-flow. C) Gain – This adjustment controls the amplification or gain of the sensor signal. It has been factory set to provide a full-scale output signal of 10 Vdc for the type and size of media requested in the Purchase Order. (See Calibration Label on the valve for flow range, media type and size.) Note: Be sure only one Gain Select switch is selected (up position). Use the “Gain Adjust” knob for fine adjustments. Gain adjustments may be required if a different type or size of media is used. Standard accuracy is 5% of full value. The MagnaValve must be recalibrated if a different media type or size is used. D) TEST CONNECTOR - For diagnosis by Factory or Field Service Technician. E) Program Port - For advanced calibration with the Windows HyperTerminal program. Call Electronics Inc. for an instruction manual on these procedures at 1-574-256-5001 or 1-800-8325653 (USA and Canada). A connection cable (PA-24 Program Cable) is needed to use this function. To order, please specify: P/N: 980090 - Flat P/N: 980097 - Round 5 LED Status Indicators Front Panel 1) 2) 4) 830283 3) 1) VALVE ON – Green LED indicates the valve flow status • OFF = No flow • ON = The valve is opened to full capacity and the media is allowed to flow • Blinking = The valve is pulsing and dispensing the amount of shot flow as determined by the FC-24 Control 2) Vin > 0.25 Vdc – Amber LED indicates the status of the servo input analog signal • ON = Servo signal exceeds the 0.25 Vdc threshold and media will flow • OFF = Servo signal is less then the required 0.25 Vdc threshold signal and no media will flow 3) 24 Vdc ENABLE – Amber LED indicates the operating status • ON = Valve is enabled and media will flow • OFF = The valve is not enabled and no media is allowed to flow 4) 24 Vdc Power – Red/Green LEDs indicate the status of 24 Vdc power • OFF = No 24 Vdc power is available • Red ON = 24 Vdc power is available (within tolerance) • Red Blinking = Power is available but not within the tolerance band ±2 Vdc • Green = Microprocessor failure - return valve to Electronics Incorporated for service Note: The 24 Vdc power supply must be capable of supplying 2 Amps to each valve. The black (ground) wire from the MagnaValve must be routed directly to the negative lead (ground) of the power supply. Each valve must have a separate wire to this negative terminal. Do not daisy-chain valve ground commons. 6 Installation The following items are required for the installation of a 24 Vdc MagnaValve: Pipe Fitting Requirements Models 576 - 577 Models 578 - 579 Models 580 - 590 Two (2) NPT Male-Threaded Short Nipple Pipe Fittings 1" 1¼" 2" Two (2) NPT Pipe Unions 1" 1¼" 2" One (1) Mixing Tees 1" 1¼" 2" • Thread sealant (Teflon® tape) • Other fittings as required • A manual shut-off valve mounted above the MagnaValve for maintenance • For direct pressure applications only - an automatic shut-off valve mounted above or below the MagnaValve 7 Direct-Pressure Machine Applications Mount the MagnaValve in a vertical position with an adequate supply of media above it. Install a manual shut-off valve above the MagnaValve for maintenance. Mount a remote-operated valve, such as the pinch-tube type shown here or a mechanical grit valve, below the MagnaValve. This will prevent back pressure from entering the bottom of the MagnaValve. Pipe unions will allow (rotational) alignment of the valve and simplify the removal of the MagnaValve for service. The proper valve opening sequence is needed to assure fast and smooth operation. See tables below. Turning on air supply “A” first is important because the air must completely fill the blast hose (and exit the nozzle) in order to establish a near-laminar flow in the blast hose. If the MagnaValve is allowed to dispense media too early—prior to back pressure stabilization—then the air and media flow rate will be very erratic. Allow at least two seconds during the turn-on sequence for the air supply to stabilize in the blast hose before dispensing media. Allow at least two seconds during the turn-off sequence to purge all media from the blast hose and ready it for the next cycle. Pressure Pot Manual Shut-Off Valve for Maintenance Union (C) 24 Vdc MagnaValve Union (B) Automatic Pinch-Tube Valve (A) to Air Valve Blast Hose to Nozzle Mixing Chamber Turn On Sequence Turn Off Sequence Step 1 Turn on Air Valve (A) Step 1 Turn off MagnaValve (C) Step 2 Wait for system to stabilize Step 2 Turn off Pinch-Tube Valve (B) Step 3 Turn on Pinch-Tube Valve (B) Step 3 Step 4 Turn on MagnaValve (C) Wait for media to purge, then turn off Air Valve (A) 8 Gravity-Fed Suction Machine Applications Mount the MagnaValve in a vertical position with an adequate supply of media above it. Install a manual shut-off valve above the MagnaValve for maintenance. Install a Tee below the MagnaValve to provide aspiration air to convey the media to the suction (venturi) nozzle. Pipe unions will allow (rotational) alignment of the valve and makes removal for service easier. During operation, the nozzle creates a suction to draw the shot into the blast hose and out the nozzle. The shot hopper is at atmospheric pressure. The MagnaValve dispenses shot directly into the nozzle’s blast hose. Aspiration air is available at the Tee below the MagnaValve and this provides the air needed to convey the shot to the nozzle. Aspiration air can be throttled to adjust the correct amount of suction for conveyance of media in the blast hose. Caution: Too much suction will pull media through the MagnaValve. Be sure that the on-off maintenance valve above the MagnaValve can flow at least 150% of the expected media flow rate. Media Vessel Manual Shut-Off Valve for Maintenance Union 24 Vdc MagnaValve Union Aspiration Air Inlet to Venturi Nozzle 9 Suction-Blast Machine Applications Mount the MagnaValve in a vertical position with an adequate supply of media above it. Install a manual shut-off valve above the MagnaValve for maintenance. Install a Tee below the MagnaValve to provide for aspiration air to convey the media to the suction (venturi) nozzle. Pipe unions will allow (rotational) alignment of the valve and make removal for service easier. During operation the nozzle creates a suction to draw the shot into the blast hose and out the nozzle. The shot hopper is at atmospheric pressure. The MagnaValve dispenses shot into a mixing chamber where the aspiration air conveys the shot to the nozzle. Aspiration air can be throttled to adjust the correct amount of suction for conveyance of media in the blast hose. Caution: Too much suction will pull media through the MagnaValve. Be sure that the on-off maintenance valve above the MagnaValve can flow at least 150% of the expected media flow rate. Media Vessel Manual Shut-Off Valve for Maintenance Union 24 Vdc MagnaValve Union Aspiration Air Inlet to Blast Hose Venturi Nozzle Mixing Chamber 10 Wiring Diagrams The following pages illustrate the wiring diagrams for the 24 Vdc MagnaValves. Routing of ground wires from the MagnaValve back to the power supply will prevent interference from the high current pulses that can place disturbances on the ground wires (see Figure 2 on page 12). Figure 1 illustrates routing of wires for chassis grounding (separate from Signal Ground) Figure 2 illustrates the routing of signal wires between the FC-24 Controller and the MagnaValve that is acceptable for most applications Figure 3 illustrates the preferred routing of signal wires between the FC-24 Controller and MagnaValve For more information, download the FC-24 Controller Installation Manual at www.electronicsinc.com. Figure 1. Routing of Wires for Chassis Grounding 24V Series Earth Ground Routing Wire attached to ground clamp Ground Pipe Clamp (Order Separately) Grounding Notes: Ground Buss Bar or Machine Frame 1. Be sure the controler chassis green screw on back is connected to a good earth ground. 2. Be sure the MagnaValve is well grounded to the machine plumbing above and below it. 3. Be sure the MagnaValve is well grounded to machine frame. To ground valve attach wire to valve pipe using a proper clamp. Earth Ground Signal Ground Chassis Ground Ground Buss Bar ELECTRONICS INCORPORATED 56790 MAGNETIC DR. MISHAWAKA IN 46545 Basic wiring connections for 24volt series flow control MagnValves SIZE Grounding Notes CPN B SCALE FILE NAME 1) The FC-24 Controller chassis green screw on back must be connected to a good earth ground. 2) The MagnaValve must be well-grounded above and below to the machine plumbing and wellgrounded to earth ground. 11 REV. S:\Corel\Draw\Appnote\24vdiagram5_5_14.cdr None SHEET 1 0 Figure 2. MagnaValve and FC-24 Controller Wiring Acceptable for most applications MAGNAVALVE and FC-24 Wiring - Preferred Figure578-24 3. MagnaValve and FC-24 Controller Wiring Preferred for noise immunity and ground-loop issues 578-24 3 4 6 5 FC-24 2 FLOW OUTPUT 1 WHITE 6 Flow Signal Input 0-10Vdc FLOW INPUT 4 ORANGE 8 Servo Signal Output 0-10Vdc 24VDC ENABLE INPUT 6 BLUE 9 1 SOCKET Enable Output 24Vdc Power Supply 19 Positive 20 Negative 24Vdc Green Ground Screw on back of Control. Ground Pipe Clamp (Order Separately) 24VDC POSITIVE 2 RED GROUND 3 GREEN GROUND 5 BLACK ELECTRONICS INCORPORATED 56790 MAGNETIC DR. MISHAWAKA IN 46545 Preferred for noise imunity Basic wiring connections for 700-24 FC-24 Control and ground-loop issues. A 6-ft. conductor cable and plug is supplied with each MagnaValve. The cable shouldandbe run in a SIZE CPN FILE NAME REV. 0 private metal conduit with no other wires since they could cause noise interference. If additional wire length is needed, the wire should be a minimum of 16 AWG. B SCALE S:\Corel\Draw\Appnote\24vdiagramnNFMrevb.cdr None SHEET 1 For higher electrical noise immunity, do not connect the MagnaValve ground wires to the FC-24 Controller terminals. The Green and Black wires must be taken directly to the negative terminal of the power supply or to a copper bus bar connected directly to the negative terminal of the power supply. These wires conduct high current pulses which may interfere with the flow rate signal or the servo command signals. 12 Calibration Calibration of the MagnaValve is accomplished by performing catch and weigh tests. Catch the media in a suitable container for a timed period and weigh the results. The valve must be connected to a Model FC-24 Controller in the Servo-On mode (or PLC with servo-loop capability) for timed periods, usually one minute. Factory Calibration: The factory calibration is performed in accordance with the type and size of media listed in the purchase order. The type and size of media affects the calibration. Refer to the Calibration Label on the valve for the type, size and calibration range utilized during the factory calibration procedure. Field Calibration: Field calibrations can be performed by selecting a desired flow amount at the FC-24 Controller and dispensing the media into a suitable catch container for one minute. The amount of media caught should equal the desired media flow rate setting. Either a simple or advanced technique (see below) can be used. Insure that all of the media coming out of the nozzle is captured in the catch device. Since the compressed air must escape the catch vessel, be sure to provide means to keep the media captured. Tight woven screens or fabric may be used at the exhaust port of the catch vessel. Warning: Media blasted into a plastic bucket will generate large static electricity and a severe shock hazard exits. Provide a short metal rod connected to a flexible wire that is firmly attached to the machine frame or other suitable grounding point. Carefully stir the media with the rod to dissipate the electric charge. Spark lengths greater than 3" (76.2 mm) are not uncommon. Calibration Methods Two methods of calibration may be used, simple or advanced. The simple method uses the adjustments on the MagnaValve located behind the cover plate. This is often called a single point calibration. For most applications this provides sufficient accuracy. It is recommended for use only with one or two preferred settings. Simple Calibration (5% Accuracy): Media flow sensor gain adjustments are available on the front of the MagnaValve. A row of six slide switches and a single-turn knob are used to set the sensor gain. Make small gain adjustments using the knob. For bigger gain changes use the slide switches (remember to have only one switch in the “UP” position). Advanced Calibration (1% Accuracy): For higher accuracy over the entire valve flow range, use the advanced technique with a special programming cable connected to the serial port of a laptop computer. This method allows multi-point adjustments and provides a much higher degree of accuracy. Call Electronics Inc. for the Advanced Calibration Manual for this procedure at 1-800-832-5653 (USA and Canada) or 574-256-5001. 13 Specifications Power +24Vdc @ 2A (50VA) Adjustments Zero, Span, Pulse Rate Maximum Pressure 100 PSI Maximum Differential Pressure 5 PSI Mode Normally Closed Media Steel Shot Temperature Range 40-120° F (5-50° C) Enable Input Signal 24 Vdc Flow Signal Output 0-10 Vdc Servo Input Signal 0-10 Vdc 24 Vdc MagnaValve Selector Guide Based on Flow Rate Maximum Flow Rate (pounds per minute/kilograms per minute) Shot 576-24 577-24 578-24 579-24 580-24 590-24 Size lb kg lb kg lb kg lb kg lb kg lb kg S-70 2 1 10 5 30 15 100 45 200 90 300 135 S-110 2 1 10 5 30 15 100 45 200 90 300 135 S-170 2 1 10 5 30 15 100 45 200 90 300 135 S-230 2 1 10 5 30 15 100 45 200 90 300 135 S-280 - 10 5 28 13 100 45 200 90 300 135 S-330 - - - - 26 12 100 45 200 90 300 135 S-390 - - - - 25 11 100 45 200 90 300 135 S-460 - - - - 25 11 85 38 200 90 300 135 S-550 - - - - - - 70 32 200 90 250 113 S-660 - - - - - - 70 32 200 90 240 109 S-930 - - - - - - 45 20 200 90 225 100 CCW-14 2 1 10 5 30 15 100 45 200 90 300 135 CCW-23 2 1 10 5 30 15 100 45 200 90 300 135 CCW-28 2 1 10 5 30 15 100 45 200 90 300 135 CCW-32 - - 10 5 30 13.5 100 45 200 90 300 135 CCW-35 - - - - 26 12 88 40 200 90 300 135 14 Product Dimensions Top View Side View 6.5” (165.1 mm) 4.2’’ (106.7 mm) Model Number Pipe Size (NPT) “A” “B” 576-24 1'' 2.5" (63.5 mm) 6.0" (152.4 mm) 577-24 1" 2.5" (63.5 mm) 6.0" (152.4 mm) 578-24 1.25" 2.5" (63.5 mm) 6.0" (152.4 mm) 579-24 1.25" 2.5" (63.5 mm) 8.0" (203.2 mm) 580-24 2" 2.9" (73.6 mm) 8.0" (203.2 mm) 590-24 2" 2.9" (73.6 mm) 8.0" (203.2 mm) 15 Troubleshooting Guide If all of the LEDs are on but there is no media flow, please check the following: 1) Is the mechanical valve above or below the MagnaValve fully open? 2) Is media available from the hopper? 3) Is there a blockage above or below the MagnaValve? 4) Are there any air leaks, especially above the MagnaValve or at the nozzle? 5)Is the magnetic field completely cancelled when the Red “Valve On” LED is on? Check this by removing the valve from the machine and applying the proper signals for 100% flow. Did all of the shot fall from the valve? If the problem can’t be identified, contact Electronics Inc. Please have the following information ready. 1) Type of system: ☐ Air Blast ☐ Suction Blast ☐ Gravity Blast 2) Number of valves on the machine_____________________________________________ 3) Controller model___________________________________________________________ 4) Valve model____________________Valve serial number___________________________ 5) Media type ☐ cast steel ☐ cut wire ☐ grit ☐ other_____________________________ 6) Media size_________________________________________________________________ 7) Blast pressure (PSI)__________________________________________________________ 8) Flow rate (lb/min or kg/min)__________________________________________________ 9) Cycle time_________________________________________________________________ 10) Time between cycles________________________________________________________ 11) Nozzle size ID______________________________________________________________ 12) Blast hose ID_______________________________________________________________ 13) Blast hose length___________________________________________________________ 14) Is there a shut-off valve? Above or below the MagnaValve: ☐ above ☐ below 15) Number of valves on one power supply_________________________________________ 16) Generation of valve (see Appendix on page 18) ☐ First ☐ Second ☐ Third Make note of LED indicators on the MagnaValve: How do the MagnaValve LED indicators react during the blast cycle? _________________________________________________________________ Make note of LED indicators on the FC-24 Controller (if used): Does the FC-24 Controller display “0” (zero) at the end of the blast cycle? To expedite a solution, please send images of your valve installation, the valve’s Calibration Label and/or a video of the controller and valve driver during operation. Troubleshooting with Skype is also recommended. Electronics Inc. Telephone: (574) 256-5001 or 1-800-832-5653 (USA and Canada) Fax: (574) 256-5222 16 Replacement Parts There are no user serviceable parts. Maintenance An annual calibration is recommended for the MagnaValve. Warranty MagnaValves are covered by a two-year, no-fault warranty. Valves must be returned to Electronics Incorporated (shipping prepaid by customer) for either repair or replacement. Valves returned beyond the warranty period will be evaluated prior to repair or replacement and customer will be advised of costs prior to repair or replacement. Contacting Electronics Inc. Mailing and Shipping Address: Electronics Inc. 56790 Magnetic Drive Mishawaka, IN 46545 USA Telephone: 1-800-832-5653 (Toll-free in USA and Canada) or (574) 256-5001 Fax: (574) 256-5222 Email: [email protected] Website: www.electronics-inc.com For repairs and/or return instructions, please call our Customer Service department at 1-800-832-5653 (Toll-free in USA and Canada) or (574) 256-5001. For a faster resolution to the problem, please email images to [email protected] of your valve installation and/or a video of the MagnaValve during operation. Include an image of the MagnaValve’s Calibration Label. The use of Skype is also recommended. Electronics Inc. makes no representations or warranties, either expressed or implied, with respect to the contents of this publication or the products that it describes, and specifically disclaims any implied warranties of merchantability or fitness for any particular purpose. Electronics Inc. reserves the right to revise this publication and to make changes and improvements to the products described in this publication without the obligation of Electronics Inc. to notify any person or organization of such revisions, changes or improvements. 17 Appendix Notice of Revision Use the following information to determine which generation of MagnaValve is in operation. First Generation No Program Port - obsolete Sensor Gain is set by switches and single-turn knob. Perform a catch and weigh test and adjust the Sensor Gain as needed for accuracy. Only single-point calibrations can be performed with this revision. 1 2 3 4 5 6 www.magnavalve.com (1-574-256-5001)USA Second Generation Oval Program Port added - obsolete Sensor Gain is still set by switches and single-turn knob but additional multi-point calibrations for higher accuracy may also be performed with this revision. www.magnavalve.com (1-574-256-5001)USA 1 2 3 4 5 6 1------5 Oval Program Port Third Generation Round Program Port added Sensor Gain is still set by switches and single-turn knob but additional multi-point calibrations for higher accuracy may be performed with this revision. The Windows program on a laptop computer is needed to access these calibration features. Call Electronics Inc. for an instruction manual at 1-574-2565001 or 1-800-832-5653. A connection cable is needed to use this function (PA-24 Program Cable Order P/N: 980090). Round Program Port 18 Appendix Remote Table Select (RTS) - Third Generation Only The RTS Series MagnaValves have five (5) internal memory tables to store calibration parameters. These tables can be accessed by applying 24 Vdc signal to the proper pins (4, 5 and 6) of the RTS connector located on the bottom of the RTS MagnaValve. Three LEDs indicate the status of the three input ports (A, B and C). A 6-ft (1.83 m) cable with 6-pin plug is supplied with the RTS MagnaValve. Note: Pin 3 (the green wire) of the RTS socket is connected to the MagnaValve ground system inside the MagnaValve. { A, B and C LED Lights Cable Connector (Standard) Remote Table Select (RTS) Connector The Five Internal Memory Tables for the RTS MagnaValve LED A (Pin 4) LED B (Pin 5) LED C (Pin 6) Table 1 ON OFF OFF Table 2 OFF ON OFF Table 3 ON ON OFF Table 4 OFF OFF ON Table 5 ON OFF ON RTS MagnaValve Wiring Pin Number Color Function 1 Red/White N/C 2 Red N/C 3 Green Ground 4 Red/Yellow A 5 Red/Black B 6 Red/Blue C 19
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