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
Made in the USA
E-mail: sales@electronics-inc.com
Website: www.electronics-inc.com

Model AC Controller
IM:0048 Revision: T Date: 11/1/2007
 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 999201 19
WIRING CONNECTIONS for P/N 999201.B 20
SPECIFICATIONS for P/N 999201.B 21
WIRING CONNECTIONS for P/N 999201.C 22
SPECIFICATIONS for P/N 999201.C 23
MODEL AC, MC AND FC CONTROLLER POWER REQUIREMENTS 24
HOW TO RETURN CONTROLLERS FOR REPAIR 25

2
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 in-
dications of motor amps. A 0-10Vdc output signal is available for a remote indicator or a strip-
chart recorder. High and low alarms are set to bracket the requested amperage setting. The
alarm bandwidth is adjustable from the front panel. Either local (front panel) or remote 0-10Vdc
setpoint commands may be used.

Caution: The length of the motor amps current transformer wiring to the 50 mV
current shunt at terminals #16 and #18 must be less than 10 feet (3 M) of
16AWG wire, otherwise the digital display reading will show lower than actual
amps. Terminal #17 can be used to receive an input signal from motors with
variable-speed drives equipped with a 0-5Vdc output. This signal is used for
current/load monitoring. See section 14 for additional wiring information.

2. THEORY OF OPERATION

The AC Controller compares the motor current setpoint with the actual motor current sends a
power signal to the MagnaValve. If the desired amperage is not achieved within an adjustable
period, a high/low alarm relay will be triggered, outputting a signal that may be used to inhibit
further machine operations and signal the operator.

3. PRELIMINARY ADJUSTMENTS

Refer to Figures 1 & 2..

a. Apply power to the AC controller.

b. The digital display (1-4) should read 0.0 when the motor is off.

c. Verify that the controller full-scale range matches the current transformer. Push and hold
the display toggle switch (1-10) to the right and turn the setpoint knob (1-9) fully clockwise.
The typical factory setting is 100.0A. To change this value, see section 6. MOTOR CUR-
RENT CALIBRATION (Span).

d. For automatic machine cycle, place the mode switch (1-11) to the left for the “Ready
“mode. When an enable signal is received, the "ENABLE" LED indicator (1-2) on the front
panel will light and activate the valve output. The red LED (1-3) for "valve" will blink. Adjust
the motor amps setpoint to desired motor amperage level.

e. Adjust the alarm bandwidth (2-7), typically 5A. By pushing the display switch (1-10) to
the left to exhibit the alarm bandwidth in the display, and turning the adjustment Pot to the
desired setting.

f. Adjust the alarm delay time (2-6) from 0-10 seconds. Typically 5 seconds.

3
4. 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 de-
sired 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 dis-
play switch to the right to read desired amperage in the digital display. This will show the
setpoint for either local or remote modes of operation. Release the display switch and the
actual motor current will again be displayed. The setpoint may be adjusted during use.
Pushing the display switch to the right is optional and not necessary while changing the
setpoint during shot flow.

b. ENABLE (1-2) - The AC controller can be automatically activated by a remote enable sig-
nal when the mode switch (1-11) is in the “READY” position. The mode switch can be
placed in the “off” position, to inhibit automatic operation or it can be placed in the “on” po-
sition for manual operation.

c. ALARM (1-5) - The alarm bandwidth is adjustable from 0 to 50% of full-scale and is fac-
tory set at 10%. The alarm circuit is activated when the servo is "on" and the control is en-
abled. When the control is enabled, the "ENABLE" LED (1-2), on the front panel, will be
lighted. The midpoint of the alarm band automatically follows the setpoint setting. The
servo switch (2-11) must be on (up) for the alarms to function.

d. ALARM BAND (2-7) - The flow setpoint is also the alarm midpoint. The alarm bandwidth,
usually set at 5%, will track the setpoint . For example: a setpoint of 30A will have alarms
set at 25 and 35A. Moving the setpoint to 45A will cause the alarms to move to 40 and
50A.

e. ALARM DELAY (2-6) - When the control is enabled and in servo mode, the "high" (1-5) or
"low" (1-6) alarm light will come on if motor current is above or below the alarm limits. An
adjustable timer, labeled "ALARM DELAY” (2-6) which is adjustable from 0 - 10 seconds,
will start each time the "high" or "low" light comes on. If the fault lasts longer than the timer
setting, the high (or low) light will get brighter and the high (or low) alarm relay contact will
transfer and latch. The alarm will stay on after the “Enable” signal is removed until the
alarm is reset.

f. ALARM RESET - Activating the alarm-reset circuit (115VAC applied to Terminal #14) will
cancel the alarm relay and the alarm "high" or "low" LED's will go off. Continuous applica-
tion of the reset signal will disable or inhibit the alarm output signal. The alarms are auto-
matically reset upon receipt of each new "Enable" command and therefore using the man-
ual alarm reset function is not necessary.

g. REMOTE MODE (1-6) - A remote setpoint command may be used in place of the front
panel setpoint knob. To use this feature, the setpoint local/remote switch (2-12) must be
down in the “REMOTE” mode. A yellow LED (1-8) on the front panel indicates operation in
the remote mode. Apply a 0 - 10Vdc analog signal to the remote input, Terminal #10. A
0Vdc signal will correspond to 0% motor current command; and 10Vdc signal will corre-
spond to 100% motor current. To verify the setpoint command, push and hold the display
switch to the right. The remote command may come from a remote pot or any 0 – 10Vdc
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 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 log-
gers. The minimum load on this output is 10K Ohms. Shielded cable should be used and
the shield should be connected to AC® controller’s chassis ground. Additional noise filter-
ing may be necessary at the input terminals of the analog input card to prevent erroneous
readings from the recorder output.
5. STABILITY ADJUSTMENTS - (SERVO STABILITY)

The servo adjustments have been factory set to typical settings but the customer may fine-tune
these settings to optimize the speed of response. Since many factors determine system stability,
these adjustments should be made slowly.

SERVO GAIN - This adjustment sets the gain of the error amplifier over a range of 1% to
100%. Most systems may operate at 50%. If the motor current is unstable, then reduce the
gain to 25%.

SERVO RESET - This adjustment determines the speed at which the output signal increases
to achieve desired motor current. A 50% value is set at factory for typical applications. Turning
the servo reset clockwise will make it faster and turning it counter clockwise will make it
slower.

If the shot flow rate and motor current are not steady, it will be necessary to perform a simple sta-
bility test. Place the servo switch (2-11) in its off position. Enable the control and slowly increase
the setpoint from 0% until the display reads the desired operating value. If the operation at this
time is unstable, then it is the system that is unstable. Since the control is in manual mode, if mo-
tor current is unstable, then the machine itself is causing a problem, not the servo adjustments
(because the servo is off). Refer to the Trouble-Shooting Section 12.

6. MOTOR CURRENT CALIBRATION (Span)

Caution: The factory has preset the span adjustment so that 5 A AC input will result in a full-
scale display reading. To accommodate different ranges of current transformers, such as 100:5
or 50:5, change the Display Full-Scale Adjustments, not the span setting. See section 7.
DO NOT ADJUST THE AC® CONTROLLER SPAN, IT HAS BEEN FACTORY SET AND
SEALED.

7. MOTOR CURRENT FULL SCALE DISPLAY

The standard factory setting is for 100:5 current transformers. To use other current transformer
ratios proceed as follows:

a. Apply power to AC controller.

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 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 dis-
play 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. Slowly turn setpoint knob clockwise until desired motor current is achieved.

h. NOTE: The factory calibration of the 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. If the digital amps display is compared to a clamp-on type ammeter
and is accurate at the low amps but not at higher operating amps, then the 5-amp loop
wire is too small. Use a larger gage wire or re-locate the current shunt from the rear termi-
nal strip closer to the current transformer and connect the shunt to the AC controller using
18 AWG or larger shield cable.

i. If the digital amps display reading is unstable, then a system problem exists. Do not make
any servo adjustments (the servo is off) until the cause of unstable operation in manual
mode is corrected. See Trouble-Shooting Section XIII.

j. Turn Enable off.

k. Place servo switch (2-11) on.

l. Push display switch to right and adjust setpoint to typical motor amps.

m. Enable the control and note the motor amps response time and stability. If the response
time is too fast (unstable) or too slow (sluggish), refer to Section 5 for stability adjustment.

8. SPARE PARTS LIST

There are no spare parts recommended for the AC controller. Contact the factory for assistance.

9. WARRANTY

Electronics Incorporated warrants this product to be free from defect in material and workman-
ship for a period of two years from date of original shipment. Defective units must be returned to
Electronics Incorporated with shipping costs prepaid. Electronics Incorporated will repair or re-
place defective unit at its option. No consequential liability is assumed. No other warranty, includ-
ing merchantability or fitness for purpose, applies or is expressed or implied.

Warranty work is only available at the factory. On-site service or start-up assistance is available
at extra cost to customer.

6
 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 In-
corporated for details. When ordering spare units, please refer to model number and serial num-
ber of each unit.

11. AUTO-ZERO FEATURE

An auto-zero feature is available to maintain a true zero reading during the motor-off condition.
This circuit monitors the motor current signal and forces it to zero whenever the motor is off and
the Enable signal is absent. A blue LED on the front panel indicates the auto-zero is active.
When the valve Enable signal is present the auto-zero function is disabled.

12. TROUBLESHOOTING GUIDE

1. Unstable operation

a. Several conditions can affect motor current stability. It is important to determine if the
problem is caused by the machine or by the MagnaValve.
i. Place the servo switch (2 - 11) to the off (down) position.
ii. Turn the machine on and apply the Enable signal to Terminal #3 or place mode
switch to on (right) position.
iii. Slowly turn the setpoint control (1-9) clockwise to increase the motor amps until ei-
ther the panel display reading is at desired value or the motor amps display is at
the desired value. The motor amps feedback signal does not affect the controller
stability in this mode (servo off). Therefore, the wheel is the only cause for instabil-
ity.

b. To demonstrate this further, another test can be performed.

i. 1. Close the slide gate above the MagnaValve.
ii. 2. Start the wheel and apply the Enable signal.
iii. 3. Turn the setpoint control (1-9) to 100% or full clockwise position. The red LED
valve light will be constantly on and the MagnaValve will be in its maximum flow
condition. Slowly open the slide gate and observe the wheel ammeter for stability.
iv. 4. If the motor current is unstable, the problem is due to the machine, not the Am-
perage Controller or MagnaValve.

c. If the machine uses a variable speed drive, check it for stability or bypass it with a con-
ventional motor starter. The instability may be caused by flooding/choking the wheel or
demanding more shot than the wheel can supply.
i. Check for obstructions or restrictions or unnecessary bends in the flow path.
ii. Worn blades or damaged control cages will not pass as much shot as new blades,
therefore, as blades wear, the maximum motor amperage is reduced.
iii. Shot condition is very important. Unclean shot due to oil, water or dust, can cause
erratic flow performance. Dust can be generated by shot deterioration, or by abra-
sion of parts being peened, the cabinet, or the tooling. Dust will tend to cake and
clog the flow. Under severe conditions, the MagnaValve may become completely

7
 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 suc-
tion in some wheel designs may pull shot through the valve. This symptom is character-
ized by having shot flowing when valve is off (red valve LED=off). Providing an aspiration
air inlet below the MagnaValve may be necessary. Contact factory for assistance.
d. MagnaValve valve driver module may be defective. The output current setting is listed on
the valve driver module. Check the valve current at 100% duty cycle (Red LED con-
stantly on) with an ammeter in series, with wire lead from the controller to the valve
driver module. Contact factory for assistance.

3. No alarm relay contact output.

a. Enable must be on (1 - 2).

b. Servo switch must be on (2 - 11).
c. High (1-5) or low (1 - 6) Alarm LED must be on and in the bright mode for alarm relay
contact to transfer.
d. Check alarm bandwidth; it may be too large.
e. Check wiring from the terminals:
i. High Alarm Relay Contact = #11
ii. Common Alarm Relay Contact = #12
iii. Low Alarm Relay Contact = #13
f. Alarm Reset signal (120VAC) should be absent from terminal #14. (NOTE: Alarms are
cleared or reset each time a new Enable signal is received; therefore, using the manual
alarm reset feature is not necessary.)

4. Cannot achieve any flow, or motor amps are very low.

a. Enable light must be on (1 - 2).

b. Setpoint command must be present (check setpoint 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 reapply the Enable signal.
d. Check Red LED at MagnaValve junction box. If it is not off, check for a wiring problem. If
it is on, verify that the current going to the valve driver module matches the value written
on the label of the valve driver module.
e. Check for contamination in or above the MagnaValve, especially check for water, oil, or
dust mixture in the shot, or other obstructions.
f. The MagnaValve or valve driver module may be defective. To check, remove the Mag-
naValve from machine (keep wires attached). Enable the output and get red LED valve
on at 100% duty cycle. When the Valve LED is on, the magnetic field inside the Magna-
Valve should be perfectly canceled. No shot should stick inside the MagnaValve. If any
shot sticks to the valve, then either the valve driver module or the MagnaValve is defec-
tive. Measure the dc current going to the valve driver module in the red wire. Compare
your measurement with the value written on the label of the valve driver module. If your

8
 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. Check shot for cleanliness (dust, oil, and water).
ii. Check shot for obstructions.
iii. Check shot hopper, is it low or out of shot?
iv. Do not adjust servo adjustments.
v. Check for worn wheel blades or worn control cage.
vi. Check valve driver module and MagnaValve® current.
vii. Call the factory for advice.

NOTE: This category is the most challenging to trouble shoot. We have found that shot
cleanliness and foreign objects are usually responsible. Items such as: wire (from identifi-
cation tags), welding rod, nuts and bolts from machine or screen separators, masking
tape, razor blades, milk cartons, cigarette butts, etc., seem to find their way to the valve.

6. Calibration Accuracy at low and high amps

If the amperage on the digital display matches the actual motor current at a low setting but
not at a higher setting, compare the motor amps with a clamp-on type ammeter to the cur-
rent transformer output. If it is not proportional then the wire size for the current loop is too
small and must be increased. Up to 5-foot long wire loops can use 16 AWG wire. Longer
runs should use 14 AWG or 12 AWG wire.

7. Technical Support

If you cannot achieve expected high motor amperage or the system “just isn’t right”, then
perform the following profile before calling for technical support. This procedure will pro-
vide the information needed for corrective action.
i. Place the Servo switch “off” in the manual mode.
ii. Use the Display Toggle switch to set the setpoints in the following table.
iii. Read and record the amperage reading for each of the above setpoints.

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 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
Motor Information Company Name: _____________________________________
FL Amps=________ Technicians Name: ___________________________________
H.P.=___________ Call back Phone ___________________________________
RPM=__________ Date: _______________Notes:
Setpoint
Motor Amps Comments:
Knob
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%

Motor Amps Profile (0-100 A)

100

90

80

70

60
Motor Amps

50

40

30

20

10

0
0 10 20 30 40 50 60 70 80 90 100

% Setpoint

10
 Motor Amps Profile (0-50 A)

50

45

40

35

30
Motor Amps

25

20

15

10

0
0 10 20 30 40 50 60 70 80 90 100

% Setpoint

11
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.

50

45

40
Motor Amps

35

30

25

20

15

10

0
0 10 20 30 40 50 60 70 80 90 100

% Setpoint

The second example shows a typical installation where the full load (FL) motor current of 35 A is
achieved at approximately 70% of MagnaValve capacity with the wheel running at 3000 RPM. This in-
dicates that the valve is able to supply all the shot needed and has a reserve capacity of 30%.
Caution: Do not allow operation above the full load rating of the motor.

50

45

40
Motor Amps

35

30

25
20

15

10

0
0 10 20 30 40 50 60 70 80 90 100

% Setpoint

12
13. CALCULATING FLOW RATE IN POUNDS/MINUTE

To determine the pounds per minute flow rate perform a catch and weigh test. A large con-
tainer 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. Place the setpoint knob at its minimum setting. Start the wheel and
slowly increase the output using the setpoint knob until the desired amperage is achieved.
b. Stop the wheel and remove the feed hose from the wheel feed spout and aim it at the
catch bucket.
c. Caution: Do not start the wheel.
d. Enable the controller, flow shot for 15 seconds and catch it in the bucket.
e. Weigh the shot, subtract the (empty) bucket weight, and multiply by 4 to get pounds/
minute.
f. Repeat the test to assure accuracy.
g. Reassemble the hose to the feed spout and return the servo switch to the ON position
(up).

NOTE: The above procedure only works because the servo is turned off. In this mode the set-
point knob sets the output manually and ignores the motor amperage feedback signal, which
during the catch and weigh test is zero. The procedure works because the flow rate is estab-
lished manually with the wheel motor current. In order to select another flow rate it will be nec-
essary to have the feed spout in place and manually set the output to a new condition.

13
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. VALVE - This LED indicator shows power output to the MagnaValve at fixed 8-Hertz rate and vari-
able duty cycle.

4. DIGITAL DISPLAY - Indicates the motor amps. Pushing the display switch (1-11) to the right dis-
plays the amperage setpoint. Pushing display switch to the left will display the alarm bandwidth (in
amps).

5. HIGH ALARM - This LED indicator will be on when the control is enabled and the motor amps ex-
ceed the high alarm trip point [setpoint + alarm band]. When the Alarm Time “Times Out” the LED
will get brighter and the High Alarm Relay Contact will close.

6. LOW ALARM - This LED indicator will be on when the control is enabled and the motor amps are
less than the low alarm trip point [setpoint-alarm band]. When the Alarm Time Relay “Times Out”
the LED will et brighter and the Low Alarm Relay Contact will close

7. LOCAL - This LED indicator shows that the control is in the “local” mode and the setpoint knob be-
low it will command the motor amps. When this indicator is “on” the remote mode indicator is “off”.

8. REMOTE - This LED indicator shows that the control is in the “remote” mode and a remote analog
0-10 Vdc command is expected at terminal #10. The “setpoint” knob is not active when the remote
LED is on.

9. SETPOINT KNOB - This knob will set the desired motor amps and the midpoint of the alarm band-
width when the control is in local mode (local LED indicator must be on). Push the display switch to
the right to see amperage setpoint in the digital display.

10. DISPLAY SWITCH - Push to the left to read the alarm bandwidth. Push to the right to read set-
point command. When the switch is in the center position, the actual motor amps are displayed.

11. MODE SWITCH - This switch determines the controller mode of operation.
a. Right = Forced on
b. Middle = Forced off
c. Left = Ready (waiting for 120VAC "Enable" signal from machine at terminal #3)

12. DECAL - Model Number and revision level is shown on this decal. Space is provided for customer
annotation.

13. CALIBRATION DECAL - Customer may place a calibration decal here to restrict access to the in-
ternal adjustments normally made by technicians only.

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FIGURE 1. FRONT PANEL - Operator Controls

15
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 cali-
bration sticker.

2. ZERO ADJUST - Please do not adjust the Zero. This is a factory setting. Do not remove the cali-
bration 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. The Auto-zero blue
LED indicator will show that it is active.

4. SERVO GAIN - Used to adjust the gain of the error amplifier in the servo. High gain requires less
error to cause servo correction. Turn clockwise for more gain. If the gain is too high, the servo
may be unstable.

5. SERVO RESET - Used to adjust the speed of the servo response. Faster reset allows faster re-
sponse to an error condition. Turn clockwise for faster reset. If the reset is too fast, the servo may
be unstable.

6. ALARM DELAY TIME - Used to set the time allowed before the alarm relay contact will operate.
The high or low alarm LED's will go to a bright condition when this timer expires. The range is 0-
10 seconds.

7. ALARM BANDWIDTH - Used to set the amps width of the alarm zone. The Alarm Bandwidth
is adjustable from 0% to 50%. The alarm midpoint follows the command Setpoint. Push the dis-
play switch left to display alarm bandwidth.

8. DISPLAY RANGE FINE - Used to adjust the digital display range to the full scale (current trans-
former) range desired.

9. DISPLAY RANGE COARSE - Used to select the digital display range to the full-scale range
(current transformer) desired.

10. DIGITAL DISPLAY DECIMAL POINT - Used to select the decimal point position on the digital
display. Choices are: 1000 / 100.0 / 10.00.

11. SERVO SWITCH - Used to control the servo. Up is "on” for automatic servo control. Down is "off”
for manual operation. The alarms do not function and no motor amps servo correction is provided
when the servo is off.

12. SETPOINT LOCAL / REMOTE - Used to select the Setpoint command from the front panel knob
or from an external remote analog 0-10 Vdc command.

13. FREQUENCY ADJUST - Factory set at 8 Hertz. Adjusts the frequency of the pulse output signal
to the MagnaValve. The new 1xxx series MagnaValves can be set to 15-25 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.

16
FIGURE 2. FRONT PANEL - Technician Adjustments

17
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. (-) MagnaValve Output (in conduit or SO cord, does not have to be shielded)
9. Common Remote Setpoint (0Vdc)
10. Input Remote Setpoint (0-10 Vdc) (shielded cable)
11. High Alarm Relay Contact
12. Common Alarm Relay Contact
13. Low Alarm Relay Contact
14. Alarm Reset Input (120VAC)
15. (Not used)
16. Input Current Shunt (0-5A ac) E.I. current shunt P/N 999200
17. Input Voltage (0-5 Vdc) (shielded cable)
18. Common Current Shunt or Voltage ( 0Vdc)
19. Common Recorder Signal ( 0Vdc)
20. Output Recorder Signal (0-10 Vdc) (shielded cable)

NOTE: Connect 100:5 current transformer leads to current shunt at terminals #16 and #18. Use
16AWG wire and keep it shorter than 10 feet to avoid losing signal strength. If the current trans-
former is further away than 10 feet it may be necessary to use larger wire size or mount the current
shunt next to the current transformer and then connect the shunt to the AC controller using #18AWG
shielded cable.

Motor speed controllers with 0-5 Vdc output load monitor may be connected to terminals #17 and
#18 using shielded cable.

A small, 10μF, capacitor may be needed at the far end of the cable for recorder output to suppress
electrical noise signals. The near end of the shield (screen) should be connected to the rear of the
AC chassis green screw terminal.

18
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. (1.8 kg)

Display Range: 0 - 1999 counts

Decimal Places: 1000 / 100.0 / 10.00

Alarm Band: 0 - 50% of full scale

Alarm Delay: 0 - 10 Seconds

19
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. (-) MagnaValve Output (in conduit or SO cord, does not have to be shielded)
9. Common Remote Setpoint (0Vdc)
10. Input Remote Setpoint (0-10Vdc) (shielded cable)
11. High Alarm Relay Contact
12. Common Alarm Relay Contact
13. Low Alarm Relay Contact
14. Alarm Reset Input (80-240VAC)
15. (Not used)
16. Input Current Shunt (0-5A ac) E.I. current shunt P/N 999200
17. Input Voltage (0-5Vdc) (shielded cable)
18. Common Current Shunt or Voltage (0Vdc)
19. Common Recorder Signal (0Vdc)
20. Output Recorder Signal (0-10Vdc) (shielded cable)

NOTE: Connect 100:5 current transformer leads to current shunt at terminals #16 and #18. Use
16AWG wire and keep it shorter than 10 feet to avoid losing signal strength. If the current trans-
former is further away than 10 feet it may be necessary to use larger wire size or mount the current
shunt next to the current transformer and then connect the shunt to the AC controller using #18AWG
shielded cable.

Motor speed controllers with 0-5 Vdc output load monitor may be connected to terminals #17 and
#18 using shielded cable.

A small, 10μF, capacitor may be needed at the far end of the cable for recorder output to suppress
electrical noise signals. The near end of the shield (screen) should be connected to the rear of the
AC chassis green screw terminal.

20
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. (1.4 kg)

Display
0 - 1999 counts
Range:

Decimal
1000 / 100.0 / 10.00
Places:

Alarm Band: 0 - 50% of full scale

Alarm Delay: 0 - 10 Seconds

21
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. (-) MagnaValve Output (in conduit or SO cord, does not have to be shielded)
9. Common Remote Setpoint (0Vdc)
10. Input Remote Setpoint (0-10Vdc) (shielded cable)
11. High Alarm Relay Contact
12. Common Alarm Relay Contact
13. Low Alarm Relay Contact
14. Alarm Reset Input (90 -115VAC)
15. (Not used)
16. Input Current Shunt (0-5A ac) E.I. current shunt P/N 999200
17. Input Voltage (0-5Vdc) (shielded cable)
18. Common Current Shunt or Voltage (0Vdc)
19. Common Recorder Signal (0Vdc)
20. Output Recorder Signal (0-10Vdc) (shielded cable)

NOTE: Connect 100:5 current transformer leads to current shunt at terminals #16 and #18. Use
16AWG wire and keep it shorter than 10 feet to avoid losing signal strength. If the current trans-
former is further away than 10 feet it may be necessary to use larger wire size or mount the current
shunt next to the current transformer and then connect the shunt to the AC controller using #18AWG
shielded cable.

Motor speed controllers with 0-5 Vdc output load monitor may be connected to terminals #17 and
#18 using shielded cable.

A small, 10μF, capacitor may be needed at the far end of the cable for recorder output to suppress
electrical noise signals. The near end of the shield (screen) should be connected to the rear of the
AC chassis green screw terminal.

22
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. (1.8 kg)

Display Range: 0 - 1999 counts

Decimal Places: 1000 / 100.0 / 10.00

Alarm Band: 0 - 50% of full scale

Alarm Delay: 0 - 10 Seconds

23
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 ver-
sion C. See notes below for the serial number ranges.

Version A Version B Version C

120VAC 90-240VAC Range
115VAC
(replaced by version C)
ONLY
NOT AVAILABLE NOT AVAILABLE

S/N prior to 01219 S/N 01219-001 to 02279-129 S/N 02279-130 and up

NOTE: Relay contacts are NOTE: Relay contacts are NOTE: Relay contacts are
rated 120VAC rated 120VAC rated 115VAC

Serial Number description: S/N 12345-678

Digits 1-2 are for year, (01=2001, 02=2002,etc.)

Digits 3-5 are manufacturing batch lot number
Digits 6-8 are sequence number within batch lot

24
21. HOW TO RETURN A CONTROLLER FOR REPAIR

1 2

Installed in panel. Turn “Off” all power Remove terminal blocks and
sources to controller before going to step 2. leave wires attached.

3 4

Remove Rails and Rail Mounting Screws. Slide Rails back on and install the
Slide controller forwards. 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.

END OF MANUAL

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