table of contents - electronics inc

IM00812018-01

2 ElectronicsInc.•(574)256-5001•www.electronics-inc.com

TableofContents

ProductOverview........................................................................................................................................................3

PrincipleofOperation.................................................................................................................................................3

Closed-LoopServoControlwiththeFC-24Controller................................................................................................4

Adjustments.................................................................................................................................................................5

LEDStatusIndicators...................................................................................................................................................6

Installation……………………………………………………………………………………………………………………………………………………………...7

CriticalRequirementsforDirectPressureMachineApplications..........................................................................8

CriticalRequirementsforSuctionBlastMachineApplications..............................................................................9

WiringDiagrams........................................................................................................................................................10

Calibration..................................................................................................................................................................12

Specifications.............................................................................................................................................................13

24VdcMagnaValveSelectorGuideBasedonFlowRate.........................................................................................13

ProductDimensions...................................................................................................................................................14

TroubleshootingGuide..............................................................................................................................................15

ReplacementParts.....................................................................................................................................................16

Maintenance..............................................................................................................................................................16

ContactingElectronicsInc..........................................................................................................................................16

LimitedWarranty.......................................................................................................................................................17

SafetyNoticesGood safety practices must be followed when operating and handling theMagnaValve. Improper usage couldresultindamagetotheproductorpersonalinjury.

• Pleasenote:TheMagnaValveemitsmagneticfieldsthatcanbeharmfultopeoplewhowearpacemakers.• TheMagnaValveoperateswithinternalairpressure.Referallservicingtoqualifiedpersonnel.• PowerofftheFC-24ControllerbeforeconnectingordisconnectingtheMagnaValve.

ElectronicsInc.•(574)256-5001•www.electronics-inc.com 3

ProductOverviewThe 24Vdc seriesMagnaValves regulate the flowof ferrousmedia in shot peening and abrasive blast cleaningmachines.Thesevalveshaveamagneticcontrolsection(upperportion)andashotflowratesensingsection(lowerportion).24VdcMagnaValvesareusedindirectpressure,gravity-fedandsuction-blast(venturi-stylenozzles)air-blastmachines.

PrincipleofOperationThe low-maintenance construction of the MagnaValve features a rare earth permanent magnet for normallyclosedoperationandanelectromagnetforcontrollingshotflowrates.Withpowerapplied,themagneticfield isneutralized and shot is allowed to flow through the valve.When no power is applied to theMagnaValve, thepermanentmagnetstopsallflow.Ifthepowerisinterruptedforanyreason,thepermanentmagnetsecurelyholdstheshot.TheMagnaValveisfactorycalibratedandresultsaresupplieduponrequest.Note: TheMagnaValve is factory calibrated for themedia type, size and flow rate as specifiedon thepurchaseorder.Refertothecalibrationlabelonthesideofthevalveforthisinformation.


Closed-LoopServoControlwiththeFC-24ControllerToachieveclosed-loopservocontrol,the24VdcMagnaValveispairedwiththeFC-24MediaFlowController(soldseparately).Hereishowtheclosed-loopsystemprovidesaccurateanddependablemediaflowcontrol:

• ThedesiredmediaflowratesignalisprocessedbytheFC-24Controller(0-10Vdc)• AcontrolsignalissenttotheMagnaValve• ThemediaflowratesignalissenttotheFC-24Controllerforcomparisontothedesiredmediaflowrateand

thecontrolsignalisadjustedasrequiredtomaintainthedesiredflowrate• Thealarmcircuitwilltriggerahigh-floworlow-flowalarmiftheflowrateisnotwithinthealarmbandwidth

FeaturesoftheFC-24Controller(soldseparately)•Monitorsflowrateinlb/minandkg/min•Enableinputandoutput(24Vdc)•Remoteanalogsetpoint(0-10Vdc)•Recorderanalogoutput(0-10Vdc)•Digitaldisplay•High-lowalarmcontacts•Easypanelmonitoring•CEcompliant•24VdcFormoreinformationontheFC-24Controller,pleasecallourCustomerServicedepartmentat1-800-832-5653(toll-freeinUSAandCanada)or(574)256-5001.


AdjustmentsThevalveiscalibratedwiththeshottypeandsizespecifiedonthepurchaseorder.Thevalveshouldnotneedanyadjustments upon installation unless a different media type or size will be used. The MagnaValve must berecalibratedifadifferentmediatypeorsizeisused.Severaladjustments,however,canbemadeatthepanelbehindtheMagnaValve’sprotectivecoverplate.TheseadjustmentsareZero,PulseRateandGainAdjust.

FrontPanel

A)ValvePulse–Therateatwhichthevalvedispensesshot,similartoaheartbeatrate.Itisfactorysettomatchthebestflowcharacteristicsofthemedia(caststeel,cutwireormicro-bead).Typicaloperationissetat8Hertz.B)Zero–TurnknobuntilbothLEDs(belowthe(-)and(+)signs)areOFF.Thiswillsettheoutputsignalvoltagetozero±.050Vdcduringno-flow.C) Gain – Controls the amplification or gain of the sensor signal. It has been factory set to provide a full-scaleoutputsignalof10Vdcforthetypeandsizeofmediarequestedinthepurchaseorder.(Seethecalibrationlabelonthevalveforflowrange,mediatypeandsize.)Note: Be sure only one Gain Select switch is selected (up position). Use the “Gain Adjust” knob for fineadjustments.Gainadjustmentsmayberequiredifadifferenttypeorsizeofmediaisused.Standardaccuracyis5%offullvalue.TheMagnaValvemustberecalibratedifadifferentmediatypeorsizeisused.D)TestConnector–FordiagnosisbyFactoryorFieldServiceTechnician.E) ProgramPort –Connectionport toa computer for calibration.Aprogrammingcable is required. Foramoreinformation on the programming cable and the calibration of a 24 VdcMagnaValve, please call our CustomerServicedepartmentat1-800-832-5653(toll-freeinUSAandCanada)or(574)256-5001.


LEDStatusIndicators

FrontPanel

1)VALVEON–GreenLEDindicatesthevalveflowstatus

• OFF=Noflow• ON=Thevalveisopenedtofullcapacityandthemediaisallowedtoflow• Blinking = The valve is pulsing and dispensing the amount of shot flow as determined by the FC-24

Controller2)Vin>0.25Vdc–AmberLEDindicatesthestatusoftheservoinputanalogsignal

• ON=Servosignalexceedsthe0.25Vdcthresholdandmediawillflow• OFF=Servosignalislessthentherequired0.25Vdcthresholdsignalandnomediawillflow

3)24VdcENABLE–AmberLEDindicatestheoperatingstatus

• ON=Valveisenabledandmediawillflow• OFF=Thevalveisnotenabledandnomediaisallowedtoflow

4)24VdcPower–Red/GreenLEDsindicatethestatusof24Vdcpower

• OFF=No24Vdcpowerisavailable• RedON=24Vdcpowerisavailable(withintolerance)• RedBlinking=Powerisavailablebutnotwithinthetoleranceband±2Vdc• GreenON=Microprocessorfailure-returnvalvetoElectronicsIncorporatedforservice


InstallationThefollowingitemsarerequiredfortheinstallationofa24VdcMagnaValve:

• Threadsealant(Teflon®tape)• Otherfittingsasrequired• A150%capacitymanualshut-offvalvemountedabovetheMagnaValveformaintenance• Fordirectpressureapplicationsonly-anautomaticshut-offvalvemountedbelowtheMagnaValve.

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"


CriticalRequirementsforDirectPressureMachineApplications

The followingare critical requirements for the installationandoperationof the24VdcMagnaValveonadirectpressuremachine.FailuretofollowthesestepscouldresultindamagetotheMagnaValveandvoiditswarranty.InstallationTocorrectlyinstalla24VdcMagnaValveonadirectpressuremachine,performthefollowingsteps.

• InstallamechanicalmaintenancevalveabovetheMagnaValve• InstallapinchtubevalvebelowtheMagnaValve• Themechanicalmaintenancevalveandpinchtubevalvemustberatedat150%ofthemaximum

anticipatedmediaflowrate

OperationThefollowingstepsmustbefollowedinsequencewhenstartingandstoppingablastcleaningorshotpeeningcycle.Tostarttheblast/peencycle Tostoptheblast/peencycle1.Turnontheairvalve(s) 1.TurnofftheMagnaValve2.Wait10secondsforairtostabilize 2.Closethepinchtubevalve3.Openthepinchtubevalve 3.Wait10secondswhilemediaclearstheblastinghose4.TurnontheMagnaValve 4.Turnofftheairvalve(s)


CriticalRequirementsforSuctionBlastMachineApplications

Thefollowingarecriticalrequirementsfortheinstallationandoperationofthe24VdcMagnaValveonasuctionblastmachine.FailuretofollowthesestepscouldresultindamagetotheMagnaValveandvoiditswarranty.Installation

• InstallamechanicalmaintenancevalveabovetheMagnaValve.• Theaspirationair inletmustbelargeenoughtosupplyadequateairvolumetoallowconveyanceofthe

mediatothenozzle.

OperationThefollowingstepsmustbefollowedinsequencewhenstartingandstoppingablastcleaningorshotpeeningcycle.Tostarttheblast/peencycle Tostoptheblast/peencycle1.Turnontheairvalve(s) 1.TurnofftheMagnaValve2.Wait10secondsforairtostabilize 2.Wait10secondswhilemediaclearstheblastinghose3.TurnontheMagnaValve 3.Turnofftheairvalve


WiringDiagramsThefollowingpagesillustratethewiringdiagramsforthe24VdcMagnaValves.RoutingofgroundwiresfromtheMagnaValve back to the power supply will prevent interference from the high current pulses that can placedisturbancesonthegroundwires(seeFigure2onthenextpage).

• Figure1illustratesroutingofwiresforchassisgrounding(separatefromSignalGround)• Figure 2 illustrates the routing of signalwires between the FC-24 Controller and theMagnaValve that is

acceptableformostapplications• Figure3illustratesthepreferredroutingofsignalwiresbetweentheFC-24ControllerandMagnaValve

Formoreinformation,downloadtheFC-24ControllerInstallationManualatwww.electronics-inc.com.

Figure1.RoutingofWiresforChassisGrounding

GroundingNotesTheFC-24Controller chassis green screwonbackmustbe connected toagoodearthground.TheMagnaValvemustbegrounded,usingtheGroundClampshownaboveandconnectedtoagoodearthground.Note:The24Vdcpowersupplymustbecapableofsupplying2Ampstoeachvalve.Theblack(ground)wirefromtheMagnaValvemustberouteddirectlytothenegativelead(ground)ofthepowersupply.Eachvalvemusthaveaseparatewiretothisnegativeterminal.Donotdaisy-chainvalvegroundcommons.


Figure2.MagnaValveandFC-24ControllerWiringAcceptableformostapplications

Figure3.MagnaValveandFC-24ControllerWiringPreferredfornoiseimmunityandground-loopissues

A6-ft.longconductorcableand6-pinplugissuppliedwitheachMagnaValve.Thecableshouldberuninaprivatemetal conduit with no other wires to prevent noise interference. If additional wire length is needed, the wireshouldbeaminimumof16AWG.ContactElectronicsInc.foralternatelengths.For higher electrical noise immunity, do not connect the MagnaValve ground wires to the FC-24 Controllerterminals.TheGreenandBlackwiresmustbetakendirectlytothenegativeterminalofthepowersupplyortoacopperbusbarconnecteddirectlytothenegativeterminalofthepowersupply.Thesewiresconducthighcurrentpulsesthatmayinterferewiththeflowratesignalortheservocommandsignals.


CalibrationAnannualcalibrationofthe24VdcMagnaValveisrecommended.Theannualcalibrationshouldbebasedonthefirstdateofuse,notthefactorydateofcalibrationontheMagnaValve’scalibrationlabel.Detailedinstructionsonhowtocalibratea24VdcMagnaValveareavailableinour“CalibrationInstructionManualforthe24VdcMagnaValve®.”Themanualisavailablefordownloadfromourwebsiteatwww.electronics-inc.com.


SpecificationsPower +24Vdc@2A(50VA)Adjustments Zero,Span,PulseRateMaximumPressure 100PSIMaximumDifferentialPressure 5PSIMode NormallyClosedMedia SteelShotTemperatureRange 40˚F-110°F(5˚C-43°C)EnableInputSignal 24VdcFlowSignalOutput 0-10VdcServoInputSignal 0-10Vdc

24VdcMagnaValveSelectorGuideBasedonFlowRate

MaximumFlowRate(poundsperminute/kilogramsperminute)

Shot 576-24 577-24 578-24 579-24 580-24 590-24Size lb kg lb kg lb kg lb kg lb kg lb kgS-70 2 1 10 5 30 15 100 45 200 90 300 150S-110 2 1 10 5 30 15 100 45 200 90 300 150S-170 2 1 10 5 30 15 100 45 200 90 300 150S-230 2 1 10 5 30 15 100 45 200 90 300 150S-280 - - 10 5 28 13 100 45 200 90 300 135S-330 - - - - 26 12 100 45 200 90 300 135S-390 - - - - 25 11 100 45 200 90 250 125S-460 - - - - 25 11 85 38 200 90 250 125S-550 - - - - - - 70 32 200 90 250 110S-660 - - - - - - 70 32 200 90 240 105S-930 - - - - - - 45 20 200 90 225 100

CCW-14 2 1 10 5 30 15 100 45 200 90 300 150CCW-23 2 1 10 5 30 15 100 45 200 90 300 150CCW-28 2 1 10 5 30 15 100 45 200 90 300 150CCW-32 - - 10 5 30 13.5 100 45 200 90 300 135CCW-35 - - - - 26 12 88 40 200 90 300 135


ProductDimensions

6.5” (165.1 mm)

4.2’’(106.7 mm)

Top View Side View

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)


TroubleshootingGuideIfalloftheLEDsareonbutthereisnomediaflow,pleasecheckthefollowing:1. IsthemechanicalvalveaboveorbelowtheMagnaValvefullyopen?2. Ismediaavailablefromthehopper?3. IsthereablockageaboveorbelowtheMagnaValve?4. Arethereairleaks,especiallyabovetheMagnaValveoratthenozzle?5. IsthemagneticfieldcompletelycanceledwhentheGreen“ValveOn”LEDison?Checkthisbyremovingthe

valve from themachine and applying the proper signals for 100% flow. Did all of the shot fall from thevalve?"

Iftheproblemcan’tbeidentified,contactElectronicsInc.Pleasehavethefollowinginformationready.1. Typeofsystem:__AirBlast__SuctionBlast__GravityBlast2. Numberofvalvesonthemachine3. Controllermodel4. Valvemodel____________________Valveserialnumber________________________5. Mediatype__CastSteel__CutWire__Grit__Other6. Mediasize7. Blastpressure(PSI)8. Flowrate(lb/minorkg/min)9. Cycletime

10. Timebetweencycles11. NozzlesizeID12. BlasthoseID13. Blasthoselength14. Isthereashut-offvalve?__Aboveor__belowtheMagnaValve?15. Numberofvalvesononepowersupply16. Valvegeneration:__First__Second__Third

MakenoteofLEDindicatorsontheMagnaValve:1. HowdotheMagnaValveLEDindicatorsreactduringtheblastcycle?2. MakenoteofLEDindicatorsontheFC-24Controller(ifused):3. DoestheFC-24Controllerdisplay“0”(zero)attheendoftheblastcycle?

Toexpediteasolution,pleasesendimagesofyourvalveinstallation,thevalve’sCalibrationLabeland/oravideoofthecontrollerandvalvedriverduringoperation.Telephone:(574)256-5001or1-800-832-5653(USAandCanada)Fax:(574)256-5222


ReplacementPartsTherearenouserserviceableparts.

MaintenanceAnannualcalibrationisrecommendedforthe24VdcMagnaValve.

ContactingElectronicsInc.MailingandShippingAddress:

ElectronicsInc.56790MagneticDrive

Mishawaka,IN46545USA

Telephone:1-800-832-5653(Toll-freeinUSAandCanada)or(574)256-5001Fax:(574)256-5222

Email:[email protected]:www.electronics-inc.com


LimitedWarranty24VdcMagnaValve®

ThewarrantyobligationsofElectronicsInc.forthisproductarelimitedtothetermssetforthbelow.LengthofWarrantyPeriodThislimitedwarrantylastsone(1)yearfromtheshippingdateofthisproduct.WhatisCoveredThislimitedwarrantycoversdefectsinmaterialsandworkmanshipinthisproduct.WhatisNotCoveredThis limited warranty does not cover any damage, deterioration or malfunction resulting from any alteration,modification,improperorunreasonableuseormaintenanceoruseofamediaforwhichtheMagnaValvewasnotcalibrated, misuse, abuse, accident, neglect, exposure to excess moisture, fire, improper packing and shipping(such claims must be presented to the carrier), lightning, power surges, or other acts of nature. This limitedwarrantydoesnotcoveranydamage,deteriorationormalfunction resulting fromthe installationor removalofthisproductfromanyinstallation,anyunauthorizedtamperingwiththisproduct,anyrepairsattemptedbyanyoneunauthorizedbyElectronicsInc.tomakesuchrepairs,oranyothercausewhichdoesnotrelatedirectlytoadefectinmaterials and/or workmanship of this product. This limited warranty does not cover equipment enclosures,cablesoraccessoriesusedinconjunctionwiththisproduct.HowtoObtainaRemedyUnderthisLimitedWarrantyToobtainaremedyunderthislimitedwarranty,contactElectronicsIncorporatedbyletter,email,faxortelephonewiththefollowinginformation:

• Productnameandmodel• Productserialnumber• Originalshippingdate(seelabelonproduct)• Companynameandlocation• Nameofcontactpersonfordescriptionofsymptoms• Returnshippingaddressandanyspecialinstructions

Ifitisdeterminedthattheproductmustbereturnedunderthislimitedwarranty,aReturnedGoods(RG)number,obtained from Electronics Inc., will be required. This product should be properly packed to prevent damage intransit. Cartons not bearing a RG number will require additional processing time and repair service may bedelayed.WhatElectronicsInc.WillDoUnderThisLimitedWarrantyElectronicsInc.will,atitssolediscretion,provideoneofthefollowingremediestowhateverextentitshalldeemnecessarytosatisfyaproperclaimunderthislimitedwarranty:1. Electtorepairorfacilitatetherepairofanydefectivepartswithinareasonableperiodoftime,freeofany

charge for the necessary parts and labor to complete the repair and restore this product to its properoperatingcondition.Electronics Inc.willpay theshippingcostsnecessary to return thisproductoncetherepairiscomplete.


2. If thedefectiveproductcannotberepaired, itwillbereplacedwithanewunitandtheoriginalwarrantyperiodwillbeextendedbysix(6)months.ElectronicsInc.willpaytheshippingcostsnecessarytoreplacethisproduct.

IfthisproductisreturnedtoElectronicsInc.,theproductmustbeinsuredduringshipment,withtheinsuranceandshippingchargesprepaid.Ifthisproductisreturneduninsured,ElectronicsInc.doesnotassumeanyriskoflossordamage during shipment. Electronics Inc. will not be responsible for any costs related to the removal or re-installationofthisproduct.Out-of-WarrantyProductProductthatisout-of-warrantywillberepairedatcustomer’srequestandthecostofrepairwillbedisclosedpriorto proceeding with the repair. A purchase order must be received prior to repair. If the product cannot berepaired,ElectronicsInc.willprovideoneofthefollowingremedies:1)Newunitatcurrentpricingwithaone(1)yearLimitedWarrantyfromtheshippingdateofproduct.2)Refurbishedunit (if available) at adiscountedpricewitha six (6)month LimitedWarranty from the shippingdateofproduct.LimitationonLiabilityThemaximum liabilityof Electronics Inc. under this limitedwarranty shall notexceed theactual purchasepricepaid for the product. Electronics Inc. is not responsible for direct, special, incidental or consequential damagesresulting from any breach of warranty or condition, or under any other legal theory to the maximum extentpermittedbylaw.ExclusiveRemedyTo themaximumextentpermittedby law, this limitedwarrantyand the remediesset forthaboveareexclusiveand in lieuofallotherwarranties, remediesandconditions,whetheroralorwritten,expressor implied.To themaximumextentpermittedbylaw,ElectronicsInc.specificallydisclaimsanyandallimpliedwarranties,including,without limitation, warranties ofmerchantability and fitness for a particular purpose. If Electronics Inc. cannotlawfully disclaim or exclude implied warranties under applicable law, then all implied warranties covering thisproduct,includingwarrantiesofmerchantabilityandfitnessforaparticularpurpose,shallapplytothisproductasprovidedunderapplicablelaw.RightsUnderStateLawThiswarrantydefinesspecific legalrightsrelativetotheseproductsprovidedbyElectronics Inc.Legalrightsmayalsovaryfromstatetostate.

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