24 Vdc Cal IM - Electronics Inc · 2020. 6. 14. · Electronics Inc. • (574) 256-5001 • 3 Introduction The Calibration Procedures outlined in this instruction manual can be used

IM00892018-10

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

TableofContentsIntroduction...................................................................................................................................3TerminalProgramOverview.........................................................................................................3 HomeScreen............................................................................................................................3 SetupScreen.............................................................................................................................4 CalibrationScreen....................................................................................................................6 CatchTestScreen.....................................................................................................................8TheCalibrationProcedures...........................................................................................................9 PreparingforCalibration..........................................................................................................9

EquipmentNeeded.............................................................................................................9 SettingUptheWorkstation..............................................................................................10 ZeroingtheSensor............................................................................................................11 UsingaTimer....................................................................................................................12

Single-PointCalibration..........................................................................................................13 CalculatingtheDesiredSetpoint......................................................................................13 Single-PointCalibrationProcedure...................................................................................14 GainAdjustment...............................................................................................................15

Multi-PointCalibration...........................................................................................................17 ConnectingtotheTerminalProgram...............................................................................17 SettingtheUnitsofMeasure............................................................................................20 SettingtheSensorGain....................................................................................................21 StartingtheCalibration....................................................................................................25 ChangingtheFlowLimit...................................................................................................31 NamingtheTable.............................................................................................................33 BackingUptheTable........................................................................................................34 CopyingTableDatatoExcel.............................................................................................35

Closed-LoopCatchTest..........................................................................................................37 CalculatingPercentageError..................................................................................................40

PercentageErrorofFullScale...........................................................................................40 PercentageErrorofPoint.................................................................................................42

ContactingElectronicsInc............................................................................................................44Appendix......................................................................................................................................45 The24VdcMagnaValveswithRemoteTableSelect(RTS).....................................................45

Readthismanualcompletelybeforecalibratinga24VdcMagnaValve®.

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

IntroductionThe Calibration Procedures outlined in this instruction manual can be used to calibrate the following 24 VdcMagnaValves,includingthosewithRemoteTableSelect(RTS):500-24,576-24,577-24,578-24,579-24,580-24and590-24. (For more information on the MagnaValve® with RTS, see the Appendix.) To calibrate the 24 VdcMagnaValve,theMagnaValvemustbeconnectedtoaTerminalprogramviaacomputer.

TerminalProgramOverviewToconnecttotheTerminalprogram,seepage16.

HomeScreenTheHomeScreenprovidesoperationalstatusdataplusaccesstotwootherscreens:2)CalibrationScreenand3)SetupScreen.TheSetupScreenisusedforthebasicsetup.Itsparametersaresetatthefactoryandgenerallydonotrequirechanges.TheCalibrationScreenallowstheusertosetthemaximum(full-scaledeclaration)flowratesandmanipulatetheMagnaValve’sperformance.

HomeScreenFunctionsTableNumber:DisplaystheTableNumbercurrentlyinuse.TheMagnaValvecanstoredatainfivedifferenttables,allowingforfivedifferentcalibrationsofmediasizesandtypes.Flow Limit: Displays the calibration flow rate. In the above example, the output voltage is 10 Vdc when theMagnaValveisflowing100lb/min.ValveCapacity:DisplaysthemaximumflowratewiththeselectedshotsizeCurrentTemperature:DisplayscurrenttemperaturemeasuredbytheMagnaValveMaximumTemperature:DisplaysthemaximumtemperaturerecordedbytheMagnaValveTotalRunTime:DisplaythetotaltimethattheMagnaValvehasbeenpowered.PowerCycles:NumberoftimestheMagnaValvehasbeenpoweredonandoffHomeScreenFunctionsPress2onthekeyboardtoaccesstheCalibrationScreenPress3onthekeyboardtoaccesstheSetupScreenPress ESC todisplayablank screenand terminate the connectionbetween the computer and theMagnaValve.Connection can be re-established by pressing the spacebar on the computer keyboard. At the end of theworksession,terminatetheconnectionbetweenthecomputerandtheMagnaValveandunplugthecables.


SetupScreenPress3onthekeyboardtoaccesstheSetupScreen.TheSetupScreendisplaysMagnaValvesettings.Thefactorysettingsshouldbeusedwheneverpossible.

SetupScreenFunctionsA) Decimal Location: Selects the decimal point in the display of the entered catch weights: 999.99

(recommendedforair-blastmachines)or9999.9(recommendedforwheel-blastmachines).PressingAonthekeyboardwilltogglebetweenthetwovalues.

B) Std/Metric: Selects the display of catch weight either lb/min (default) or kg/min. Pressing B on the

keyboardwilltogglebetweenlbandkg.

C) Auto-Zero Toggle: Activates or deactivates the auto-zero function. The auto-zero routinewill establishzerooutput voltageautomatically thusaccommodatingminoroutput signal voltage changes thatoccurwithtimeortemperature.

Auto-zeroOn:WhentheMagnaValveisnotenabled,thefunctionwillautomaticallyestablishazero outputsignalunlesstheMagnaValve’ssensordetectssignalgreaterthan10%,therebydetectingan abnormalend-of-cyclecondition.Thisindicatesapossiblemalfunctionsuchasthesensornotbeing purgedattheendofacycle.WhentheMagnaValveisenabled,theunitwillholditslastestablished value. Auto-zeroOff:Disablesthefeature. PressingConthekeyboardwilltogglebetweenOnandOff.

D) Sensor Linearization: Activates or deactivates linearization feature. This feature establishes a linear

outputtransferfunctionofthesensorsignal.Apiecewiselinearizationalgorithmisusedtotranslatetheas-receivedsensorsignalintoaccurate(linear)outputsignal.

SensorLinearizationOn:Enablesthepiecewiselinearizationalgorithm SensorLinearizationOff:Disablesthefeature. PressingDonthekeyboardwilltogglebetweenOnandOff.


E) ZeroLock:Activatesordeactivatesthezero lockfeature.Thisfeaturewillestablishandmaintainazerooutputvoltageevenifthesensordetects0-10%signallevelwhennoEnablesignalisapplied.Theoffsetwill reappearwhenanEnable signal isapplied.An invalidoutput signalmayoccurdue tometallicdustaccumulation within the sensor and this can be suppressed when zero lock is on. Pressing E on thekeyboardwilltogglebetweenOnandOff.

ZeroLockon:WhenanEnablesignalisnotpresentandsensorsignalis<10%,theoutputsignalwill be0.0Vdc.WhenanEnablesignalispresentandoutputsignalisnormal,thereisnoinfluenceon outputsignal. ZeroLockoff:Thereisnoeffectontheoutputsignal,whetherornotthereisaPA-24signal.

F) External Table Select: Allows theselectionof thedesired table remotely throughtheexternalRemoteTable Select (RTS) connector. Available on 24 Vdc RTSMagnaValves only. See the Appendix for moreinformation.

G) Enable Terminal while running: Allows continuous communication with the terminal program. The

defaultvalueisON.While“EnableTerminalwhilerunning”isturnedon,theMagnaValvecanbeaccessedat any time.When this function isOFF, thebuttonon thePA-24DataCablemustbeused to start theterminalprogram.


CalibrationScreenPress 2 on the keyboard to access the Calibration Screen. The Calibration Screen allows the user to set themaximum(full-scaledeclaration)flowratesandmanipulatetheMagnaValve’sperformance.

CalibrationScreenFunctionsA) View Setpoint List:Displays the current calibration table.PressingAon thekeyboardwill bringup the

followingscreen.

PWM:Percentageofvalveopening Catchlb/min:Flowrateislb/minorkg/minforthatSetpointmeasuredduringthatcatchtest Sensorsignal:PercentageofsignalmeasuredforthatSetpointduringthatcatchtestThese valuesmay be copy and pasted into aMicrosoft Excel spreadsheet or text file for storage. See “CopyingTabletoExcel”formoreinformation.


B) AddSetpointtoList:Addsupto10additionalSetpointsforcalibration.Thereare10factorySetpointsat10% increments, starting at 15% ending with 100%. If more accuracy is needed, pressing B on thekeyboard will allow additional percentages to be added.When prompted, enter the Setpoint desired.Enterthenumberonly–donotenterapercentagesign.

C) RemoveSetpointfromList:PressConthekeyboardtoremoveunwantedSetpointsfromthecalibration

table.Forexample,ifthevalveisverylinearbetweenmultipleSetpoints,theSetpointsinthelinearrangecanberemovedtospeeduptesting.

D) Edit Catch values: PressDon thekeyboard to change theactual catchweights in the list.Mayalsobe

usedtomanuallyenterdatafromaspreadsheetortextfile.

E) EditSensorvalues:PressEonthekeyboardtochangetheactualsensorreadingsinthelist.Mayalsobeusedtomanuallyenterdatafromaspreadsheetortextfile.

F) ReName Table (6–char): Press F on the keyboard to give each of the five tables a unique name. For

example:S-70orS-230.Thenamehasalimitofsixcharacters.

G) Set Flow Limit: PressGon the keyboard to changemaximumcalibration flow rates. This is howmuchmediaisflowingwhenthevalveoutputs10Vdc.

ValveCapacity:Thisisthemaximumflowthevalvecandowiththeselectedshotsize.Thisvalueis automaticallyfilledinwhenthe100%Setpointcatchtestisconducted.

H) Table Number: The programprovides five separate lookup tables. This allowsuser to store calibrationdataforfivedifferentshottypesorsizes.PressHonthekeyboardtotoggleamongthefivetables.

I) PerformCatchTest:PressGonthekeyboardtoaccesstheCatchTestScreen.

Y) BackupthisTable:PressYonthekeyboardtosavethecurrenttable’sdatatoabackuplocationonthe

MagnaValve.

Z) RestoreTablefromBackup:PressZonthekeyboardtorestorethemostrecentlysavedcalibrationdataforthecurrenttablefromthebackuplocationontheMagnaValve.


CatchTestScreenFromtheCalibrationScreen,PressIonthekeyboardtoaccesstheCatchTestScreen.

CatchTestScreenFunctionsA) TableNumber:PressAonthekeyboardtotoggleamongthefivetables.

B) TestDuration:PressBtotogglethrough10,20,30and60secondflowtests.Makesurethemediacatch

containerwillaccommodatetheamountofmediausedinthecatchtest.Thetestdurationistheamountof time theMagnaValvewill remain onwhen “D) start THIS test” is selected. This function is used toconductatimedcatchtestwhenanexternaltimerisnotused.(See“UsingaTimer.”)

C) Setpoint: Press C to toggle through the Setpoint percentages for the catch test, from the highest

percentage to the lowest. This function also displays the latest catchweight in the list and the sensorsignalmeasuredduringthetest.

D) StartTHIStest:PressDtostartacatchtestattherequestedSetpoint(shownin“C)Setpoint”)savedfor

therequestedamountoftimechosenin“B)TestDuration.” Results:Displaysresultsfromthiscatchtestandtheerrorbetweenthevaluesavedinthetableand thetestresultsfromthiscatchtest.PressFtosavetestresults.

E) Start Remote Test: Press E to start the selected test remotely through the Enable signal to theMagnaValve.Thisallowsthetesttobedoneunderactualflowconditions.

F) EnterCatchData:PressFtosavethetestresults.IFTESTRESULTSARENOTSAVED,THERESULTSWILL

BELOSTIFANEWCATCHTESTISSTARTEDORANEWSCREENISOPENED.

G) ViewTable:PressGtodisplaythecurrentcalibrationtable.


TheCalibrationProceduresAqualifiedtechnicianshouldperformacalibrationprocedure.

PreparingforCalibration

EquipmentNeeded• MagnaValve• Apeening/blastingmachineorteststand(shownabove)• Scalecapableofweighingtotalweightcaughtduringacatchtest• Containertocatchthemedia• Smallflat-headscrewdriver• Timerwithnormallyopencontacts• Media(notshown)

AdditionalEquipmentforMulti-PointCalibration

•PA-24DataCable•USBconvertor•ComputerwithterminalprogramsuchasTeraTermorWindowsHyperTerminal


SettingUptheWorkstationMounttheMagnaValvetotheteststandormachine.

Connect the power cable to the MagnaValve. Follow the wiring instructions in the MagnaValve’s instructionmanual.

Removethe frontcover fromtheMagnaValveby loosening thecaptivescrew.Applypower to theMagnaValve.TheRedPowerLEDonthefrontoftheMagnaValvewillflashfor4secondsbeforeturningtosolidred.


ZeroingtheSensorZerothesensorsignalontheMagnaValvebyusingasmallflatheadscrewdrivertoadjusttheZeropotuntilbothGreenLEDsturnOFF.


UsingaTimerInthisworkstation,atimercontrolstheEnablesignaltotheFC-24Controller.TheFC-24ControllerthenfeedstheEnablesignaltotheMagnaValveasshowninthediagrambelow.Thetimerprovidesprecisecontrolovertheflowduration,thereforeincreasingtheaccuracyoftheflowratecalculation.


Single-PointCalibrationThepurposeofsingle-pointcalibrationistofinetunetheMagnaValve’sperformanceataspecificoperationpointorrange.ThespecificoperatingpointcanbeanypointwithintheoperatingrangeoftheMagnaValve.SomecommonpointsforaSingle-PointCalibrationinclude:

• Full-ScaleValue• Mid-pointoftheanoperatingrange(forexample:8-12lb/min,mid-pointwouldbe10lb/min)• OperatingSetpoint(forexample:8.5lb/min)

Forourexample,theMagnaValvewillbeinstalledonmachinewithaflowratecapabilityof0–12lb/min.Duetothemachine’sflowratecapability,theMagnaValvewasinitiallycalibratedfortherangeof0-12lb/min.However,the application requires a flow rate of 10 lb/min. To ensure the best possible performance, a Single-PointCalibrationwillbeconductedat10lb/min.

CalculatingtheDesiredSetpointTodetermine the Setpoint value (0-10Vdc input to theRemote Setpoint Pin on the FC-24Controller) given thedesiredflowrate,thefollowingequationcanbeused.

𝐼𝑛𝑝𝑢𝑡 𝑉𝑜𝑙𝑡𝑎𝑔𝑒 𝑉𝑑𝑐 = 10 𝑉𝑑𝑐

𝑀𝑎𝑥 𝐹𝑙𝑜𝑤 𝑅𝑎𝑡𝑒 ×𝐷𝑒𝑠𝑖𝑟𝑒𝑑 𝐹𝑙𝑜𝑤 𝑅𝑎𝑡𝑒 (𝑙𝑏𝑠/𝑚𝑖𝑛)

Forthisexample,theSetpoint(inputvoltage)is:

8.33 𝑉𝑑𝑐 = 10 𝑉𝑑𝑐

12 𝑙𝑏𝑠/𝑚𝑖𝑛 ×10 𝑙𝑏𝑠/𝑚𝑖𝑛


Single-PointCalibrationProcedureInaSinglePointCalibrationprocedure,acatchtestmeasurestheflowrateoftheMagnaValveandthenthegainisadjusted to increaseor decrease the flow rate tomeet the tolerance requirement. The Single Point CalibrationmustalwaysbeconductedwiththeServoON(PID-loopenabled).ThefollowingflowchartshowsthenormalstepsofaSinglePointCalibration.


GainAdjustmentThere are two methods of adjusting the gain to increase or decrease the flow rate when the MagnaValve isoperatingwiththeServoON(PID-loopenabled).Thefirstmethod is tochangethegainontheFC-24controller.The secondmethod is toadjust thegainon theMagnaValve.Thismethod isusedwhen theMagnaValve isnotconnectedtoaFC-24.ToadjustthegainontheFC-24controller,pressandholdtheSPANbuttonandusetheupanddownarrowstoincreaseordecrease the span.Decreasing the spanwill cause the flow to increaseand increasing the spanwillcausetheflowtodecrease.


ToadjustthegainontheMagnaValve,adjusttheGAINPot.Todecreasetheflow,turntheGAINPotknobtotheright.Toincreaseflow,turntheGAINPotknobtotheleft.IftheGAINPothasbeenturnedcompletelytotherightorleftandtheMagnaValveisstillnotwithinthetolerancerequirement,theGAINdipswitchescanbeadjusted.Warning:OnlyonedipswitchmustbeintheUPpositionatatime.


Multi-PointCalibrationConnectingtotheTerminalProgram

Equipmentneeded•Windows-basedcomputerwithaccesstoaterminalprogram•ElectronicsInc.PA-24DataCable(Partnumber980097)•AUSBAdaptorifcomputerhasaUSBconnector

RemovethefrontcoverfromtheMagnaValvebylooseningthecaptivescrewonthefrontcover.AttachtheMagnaValveConnector(1)ofthePA-24DataCabletotheProgramPortoftheMagnaValve.Attachthecomputerconnector(2)tothecomputer’sserialportorUSBadaptor(attachtheUSBadaptortothecomputer’sUSBconnector).

Note:DependingontheUSBconvertor,driversmayneedtobeinstalledontothecomputer.


Starttheterminalprogram.Inthisexample,TeraTermistheterminalprogrambuttheprocedureisthesameforanyterminalprogram.Adjustthesettingstomatchthosebelow.Note:ThePortnumbermaynotbe3(COM3)butitmustbegreaterthan1(COM1).

ConnecttheTerminalprogramtotheMagnaValvebypressingtheroundbuttononthePA-24.


AfterpressingthebuttononthePA-24,thefollowingtextwillappearonyourcomputerscreen:PressSPACEBARtoactivateTerminalRoutine…

AfterpressingtheSpacebar,theHomeScreenisdisplayed.

Press3todisplaytheSetupScreen.


SettingtheUnitsofMeasureWhileontheSetupScreen,ensurethattheMagnaValveissettothecorrectunitofmeasurefortheflowrate.Forthisexample lb/min isused. If thecorrectunitofmeasure isnot shown,pressB to togglebetween lb/minandkg/min.

Press2onthekeyboardtodisplaytheCalibrationScreen.


SettingtheSensorGainYouarenowattheCalibrationScreen.

PressItodisplaytheCatchTestScreen.

Check toensure that thecorrect tablenumber is shown. In theexamplebelow,Table#1willbecalibrated. Ifadifferenttableistobecalibrated,pressAonthekeyboardtotoggletothecorrecttablenumber.Note:WhencalibratingmultipletablesinaMagnaValve,theorderinwhichtheshottypeandsizeiscalibratedisimportant.Forexample, if theMagnaValve isbeingcalibratedforcaststeelshotandcutwireshot, thesmallestcaststeelshotmustbecalibratedfirstandthegainadjustedto95%forthatshot.ThegainMUSTNOTbeadjustedforanyothertablecalibration,includingtablecalibrationsforcutwireshot.IfonlycutwireshotwillbeusedintheMagnaValve,thesmallestcutwireshotmustbecalibratedfirstandthegainadjustedto95%forthatshot.EnsurethattheSetpointshownis100%.TheCatchweightandSensorSignalvalueisnotimportantatthistime.IftheSetpointisnot100%,pressConthekeyboardtotogglethroughthedifferentSetpointsuntil100%isdisplayed.


Note:Forthisexample,anexternaltimerandEnablesignalwillbeusedtostartandstopthetest,therefore,“B)TestDuration”isnotimportant.WhenRemoteTestisused,thesystemwillwaituntilanEnablesignal isappliedbeforestartingmediaflowandsamplingthesensor.TheMagnaValvewillcontinuetoflowmediaandsamplethesensoruntiltheEnablesignaldisappears.(Formoreinformation,see“UsingaTimer.”)If“THISTest”isused,thesystemwillstarttoflowmediaandsamplethesensorsignalimmediatelyafterpressingD.Themediawillflowforadurationequaltothe“B)TestDuration.”Tochangethe“B)TestDuration”,pressBtotogglethroughthedifferentTestDurationoptions.


Warning:Don’tforgettoplaceamediacatchcontainerbelowthevalveifusingateststand.PressEonthekeyboard.TheterminalprogramwillindicatethatitiswaitingforanEnablesignal.Pressthestartbuttononthetimer.

Theterminalprogramwillpauseforabout5sec.beforestartingtosamplethesensorsignal.Oncethesamplingstartstheterminalprogramwilldisplaythemeasuredsignalpercentage.


While media is flowing, the Gain dip switch and Gain pot on the MagnaValve must be adjusted to achieveapproximately95%Flowsignal.Warning:OnlyonedipswitchmustbeintheUPpositionatatime.

Warning:Afterthetimerstopstheflow,theterminalprogramwillrequesttheflowrateforthattest.PressENTERonthekeyboardtoskipthis.Sincethesensorgainwasbeingadjustedduringthetest,therecordedsensorsignalisnotaccurate.Note:Ifthetimerstoppedtheflowbeforethegainisproperlyset,thetestcanberunasmanytimesatittakestoproperlyadjustthegain.Itisalsogoodpracticetorunatestonelasttimeafterthegainisadjusted.


StartingtheCalibration

Afterthesensorgainisproperlyadjusted,reclaimthemediaandpressEonthekeyboardtostartthetestfortheactualcalibration.Warning:Fortheactualcatchtest,ensurethatthemediadoesnotrunoutduringthetest.MediamustbeflowingthroughtheMagnaValvethroughouttheentiretest.After the timer stops the flow, place themedia catch container onto the scale andmeasure themedia caughtduringtheflowduration.


Calculatetheflowrateineitherlb/minorkg/mindependingontheunitsofmeasure.EntertheflowrateintotheterminalandpressENTER.

Warning:Thenumberenteredmustbetheflowrate,nottheweightcaught.Iftestdurationwasone(1)minute,thentheweightcaughtwouldbeweightperminute.Ifthetestdurationwassomethingdifferentthanoneminute,thenthefollowingequationcanbeusedtocalculatetheflowrate.

𝐹𝑙𝑜𝑤 𝑅𝑎𝑡𝑒 = 𝑊𝑒𝑖𝑔ℎ𝑡 𝐶𝑎𝑢𝑔ℎ𝑡𝑇𝑒𝑠𝑡 𝑇𝑖𝑚𝑒 (sec. ) ×

60 𝑠𝑒𝑐.1 𝑚𝑖𝑛.

Warning:Thenumberenteredmuststartwithanumber.Forexample:16.69,1.25,or0.97isacceptable..87isnotacceptable.


Aftercompletinga test, theCatchTest screenwill showpercenterrorbetweenwhatwas recordedandwhat iscurrentlyinmemory.Thiserroriscalculatedwiththisformula:

𝐸𝑟𝑟𝑜𝑟 % = 𝑁𝑒𝑤 𝑉𝑎𝑙𝑢𝑒 − 𝐶𝑢𝑟𝑟𝑒𝑛𝑡 𝑉𝑎𝑙𝑢𝑒

𝐶𝑢𝑟𝑟𝑒𝑛𝑡 𝑉𝑎𝑙𝑢𝑒 ×100%

Inthisexample,thecatchweighterroris:

−83.31% = 16.69 𝑙𝑏𝑠/min− 100 𝑙𝑏𝑠/𝑚𝑖𝑛

100 𝑙𝑏𝑠/𝑚𝑖𝑛 × 100%

Thesensorsignalerroris:

−2.47% = 95.26%− 97.68%

97.68% ×100%

PressFonthekeyboardtosavethenewcatchweightandthenewsensorsignal.NoticethatafterpressingF,theErrorwentto0.00%.Warning:IfFisnotpressed,changingtheSetpointorleavingthisscreenwillcausethedatatobelost.


PressConthekeyboardtomovetothenextSetpointinthetable.Repeatthelastfive(5)stepsuntilallSetpointsarecompleted.RemembertopressFaftereachSetpointcatchtest.

Note:After changing theSetpoint, theResults sectionwill stilldisplay theprevious informationand theerror isrecalculatedbasedonthedatastoredinmemoryforthenewSetpoint.Thisisnotanissue.AfterrunningthenewSetpointtest,theResultsdatawillbeoverwrittenwiththenewcatchweightandsensorsignal.

Warning:DONOTrunSetpoint0%.Bydefault,theSetpoint0%issetto0.00lb/minand0.00%sensorsignal.Itisveryimportanttonotoverwritethesevalues.DONOTrunthisSetpoint.


Note: In this example, Setpoints 25% and 15% did not flowmedia. This is not unusual. In the casewhere theMagnaValvewillnotflowmediaforaSetpoint,runthetestandenter0.00fortheflowrate.Bydefaulteverytablehasvalueswrittenintothetableandthesedefaultvalueswillcauseissuesduringruntime.Thescreenshotabove,fora15%Setpoint,showsadefaultvalueof15.00lb/minforthecatchand14.99%forthesensorsignal.Inreality,aSetpointof15%didnotflowanymediaandithada±0.00%sensorsignal.Thisresultsina-100%error.

−100% = 0.00 𝑙𝑏𝑠/min− 15.00 𝑙𝑏𝑠/𝑚𝑖𝑛

15.00 𝑙𝑏𝑠/𝑚𝑖𝑛 × 100%Forexample,ifthistestwasnotconductedand0.00lb/minwasnotenteredforthe25%and15%Setpoints,thedatatablewouldlooklikethegraphonthenextpage.Defaultvaluesinthe25%and15%causesarangeofsensorsignalswithmorethanonepossibleflowrate.ThiscausesconfusionintheprogramandundeterminedvalueswillbeplacedontheAnalogOutputtothecontroller.


Graphshowingdefaultvaluein25%and15%Setpoints

Graphshowingavaluewith0.00 lb/minenteredfor the25%and15%Setpointswhennomediawould flowforthoseSetpoints.


ChangingtheFlowLimit

AfteralltheSetpointshavebeencalibrated,pressGonthekeyboardtoviewthetable.Thistablehasbeensavedinmemory.ThetableaboveshowstheweightcaughtandthesensorsignalmeasuredforeachSetpointduringthecalibration.Thetablenameandmaxflowarealsoshown.Theflowlimitisthescalingoftheanalogoutputvoltage.(Howtonamethetablewillbecoveredinthenextsection.)Note:ThecurrenttableshowstheMaxFlowequalto100.00lb/min,however,the100%Setpointhadaflowrateof16.69lb/min.Notonlyisitimpossibletoflow100.00lb/minofmediathroughthisMagnaValve,butthecurrentapplicationmayrequireonlyamaximumof10lb/min.Thiscaneasilybechangedbyfollowingthesesteps.PressENTERtoreturntotheCatchTestScreen.

PressESCtoreturntotheCalibrationScreen.


OntheCalibrationScreen,theValveCapacityisshownas16.69lb/min.ThisisthemaximumpossibleflowforthisMagnaValve.Theflowlimitshownis100.00lb/min.

Tochangetheflowlimit,pressGonthekeyboardandenterthenewvalue.Forthisexample,theFlowLimitwillbesetto10.00lb/min.TheFlowLimitchangesthescaleofthe0-10VAnalogOutputsuchthat0-10Voutrepresents0-FlowLimit. Inthiscase0-10Voutwillrepresent0-10lb/minofflowrate.IntermediatevaluesoftheAnalogOutputcanbecalculatedbyusingtheflowingequation:

𝑉𝑜𝑢𝑡 = 10𝑉

𝐹𝑙𝑜𝑤 𝐿𝑖𝑚𝑖𝑡 ×𝐼𝑛𝑠𝑡𝑎𝑛𝑡𝑎𝑛𝑒𝑜𝑢𝑠 𝐹𝑙𝑜𝑤 𝑅𝑎𝑡𝑒

PressIonthekeyboardtoreturntotheCatchTestScreenandthenpressGtoviewthetable.


NoticetheMaxFlowhadchangedto10.00lb/min,however,thenameofthetableisablankspace.Tonamethetable,pressENTERtoreturntotheCatchTestScreenandpressESCtoreturntotheCalibrationScreen.

NamingtheTableOntheCalibrationScreen,pressFonthekeyboardtoenteranameforthecurrenttable.EnterthedesiredtablenameandpressEnter.

Inthisexample,S-230willbeenteredbecauseS-230wasusedduringthecalibrationoftheMagnaValve.PressIonthekeyboardtoreturntotheCatchTestScreenandpressGtoviewthetable.


ThetableisnownamedS230.PressENTERtoreturntotheCatchTestScreenandpressESCtoreturntotheCalibrationScreen.

BackingUptheTableWhileontheCalibrationScreen,thecurrenttablecanbebackedupbypressingYonthekeyboard.Thiswillsaveacopyoftheactivetabletomemoryforrecovery.


CopyingTableDatatoExcelTocopythedatafromtheterminalprogram,leftclickbeforethe1in100%,holddowntheleftmousebutton,anddragthemousetojustafterthe%in0.00%.ThenpressCTRL+C.Thiswillselectandcopythewholetable.

TopastethedataintoExcel,clickonthecellinExcelwherethedataistostart.Inthisexample,thedataistostartatD14.Useanormalpastecommand(clickonthecellandpressCTRL+V).Allthedataiscopiedtothatonecolumnand10rows.Tomovethedataacrossthethreecolumns,clickontheDatatabandthenclickonTexttoColumns.


Thiswindowwillpopup,clickFinish.

Thedataisnowpastedintoitsowncells.


Closed-LoopCatchTestAclosed-loopcatchtestisrecommendedaftercalibratingtheMagnaValve.Aclosed-loopcatchtestisacatchtestatseveraldifferentSetpointsacrosstheoperatingrangewheretheMagnaValveiscontrolledbyaPIDloop(servoON). This group of catch tests are then compared to an ideal response of theMagnaValve to ensure that thecalibration isaccuratewithinanexpectedtolerance.Forthisexample,aFC-24ControllerwillbeusedtocontroltheMagnaValve.TheFC-24ControllerwasdesignedtoworkwiththeMagnaValveandithasabuilt-inPID loop.The PID loop, however, will slowly increase the flow through the MagnaValve until the desired flow rate isachieved.Thisslowramp-uptothedesiredflowrateaddserrortothecatchtest.

Theaddederrorcanbecompensatedforbydoingonecatchtestfor1minuteplus15seconds(75seconds)andanothercatchtestfor15seconds.Theresultsfromthecatchtestrunat15secondscanthenbesubtractedfromtheresultsfromthecatchtestrunat75seconds.The following flowchartshowsthenormalstepswhendoingaclosed-loopcatchtestwithoutcompensating fortheramp-upofthePIDloop.


Thefollowingchartshowsthestepsrequiredtoconductacompensatedclosed-loopcatchtest.


The Excel spreadsheet below shows the compensated flow rates (column H, rows 14-23) measured using thecompensated closed-loop catch test technique described earlier. Notice the ideal (expected) catch weight incolumnG,rows14-23.Thepercentageerroristhencalculatedusingtheideal(expected)catchweightandthefinalcatchweight.ThepercentageerroroffullscaleisshownincolumnK,rows14-23andpercentageerrorofpointisshown in column J, rows 14-23. For more information on percentage error, see the next section, “CalculatingPercentageError.”

The results for theMagnaValvecalibrationand theclosed-loopcatch test canbegraphedas shownbelow.ThebluelineisthedatasavedintheMagnaValve’smemory.Theorangelineistheclosed-looptestresults.Noticethemaximumflowrateis16.69lb/minandthecalibratedmaximumflowrateis10.00lb/min.


CalculatingPercentageErrorThe percentage error is the total percentage of all errors in taking a measurement. This error contains theuncertainties in the MagnaValve, the uncertainties in the scale used to measure the flow rate, and theuncertaintiesinthetimerusedtocontroltheflowwhilemeasuringtheflowrate.The%errorcanbecalculatedtwomainways,percentageerrorof full scaleandpercentageerrorofpoint.Thispercentageerrorcanthenbeusedtovalidatethepeeningprocess.

PercentageErrorofFullScalePercentageErroroffullscalecanbedescribedasthepossibleconstanterrorbandacrossthecompleteoperatingrange.Thetoleranceband iscalculatedatthefull-scalevalue(100%Setpoint)andthatpercentage isusedatallpointsalongtheoperatingrange. Inthisexample,theMagnaValvewascalibratedfor10 lb/min. Ifthetoleranceforthisvalvewere+/-5%offullscale,thetolerancebandwouldbe:

±𝑡𝑜𝑙𝑒𝑟𝑎𝑛𝑐𝑒 𝑏𝑎𝑛𝑑 = 𝐹𝑢𝑙𝑙 𝑆𝑐𝑎𝑙𝑒 𝐹𝑙𝑜𝑤 𝑅𝑎𝑡𝑒 ×5%

±0.5 𝑙𝑏𝑠/𝑚𝑖𝑛 = 10 𝑙𝑏𝑠/𝑚𝑖𝑛 ×5%

Theactual%erroroffullscaleataspecificSetpointcanbecalculatedby:

𝐸𝑟𝑟𝑜𝑟 % 𝐹𝑆 = 𝑀𝑒𝑎𝑠𝑢𝑟𝑒 𝐹𝑙𝑜𝑤 𝑅𝑎𝑡𝑒 − 𝐼𝑑𝑒𝑎𝑙 𝐹𝑙𝑜𝑤 𝑅𝑎𝑡𝑒

𝐹𝑢𝑙𝑙 𝑆𝑐𝑎𝑙𝑒 𝑅𝑎𝑛𝑔𝑒 ×100%

Thistolerancebandforpercentageerroroffullscaleisshowninthegraphbelow.


Thefollowingtableshowsthissame+/-5%offull-scaletolerancebandfortheMagnaValveinthisexample.

Red:AmountofvariationforgivenSetpointBlue:MaximumandminimumflowratebasedonthevariationforgivenSetpointGreen:IdealflowrateforgivenSetpoint


PercentageErrorofPointPercentageErrorofpointcanbedescribedasthepossibleamountofvariationatanyspecificSetpointwheretheamountofvariationiscalculatedusingthatspecificSetpoint.Inthisexample,theMagnaValvewascalibratedfor10lb/min,ifthetoleranceforthisvalvewere+/-5%ofpoint,thenthetolerancebandwouldbecalculatedby:

±𝑡𝑜𝑙𝑒𝑟𝑎𝑛𝑐𝑒 𝑓𝑜𝑟 𝑡ℎ𝑎𝑡 𝑆𝑒𝑡𝑝𝑜𝑖𝑛𝑡 = 𝐼𝑑𝑒𝑎𝑙 𝑆𝑒𝑡𝑝𝑜𝑖𝑛𝑡 𝐹𝑙𝑜𝑤 𝑅𝑎𝑡𝑒 ×5%

±0.35 𝑙𝑏𝑠/𝑚𝑖𝑛 = 7 𝑙𝑏𝑠/𝑚𝑖𝑛 (70% 𝑆𝑒𝑡𝑝𝑜𝑖𝑛𝑡)×5%ThepercentageerrorofpointataspecificSetpointcanbecalculatedby:

𝐸𝑟𝑟𝑜𝑟 (%) = 𝑀𝑒𝑎𝑠𝑢𝑟𝑒 𝐹𝑙𝑜𝑤 𝑅𝑎𝑡𝑒 − 𝐼𝑑𝑒𝑎𝑙 𝐹𝑙𝑜𝑤 𝑅𝑎𝑡𝑒

𝐼𝑑𝑒𝑎𝑙 𝐹𝑙𝑜𝑤 𝑅𝑎𝑡𝑒 ×100%


Thistolerancebandforpercentageerrorofpointisshowninthegraphbelow.

Red:AmountofvariationforgivenSetpointBlue:MaximumandminimumflowratebasedonthevariationforgivenSetpointGreen:IdealflowrateforgivenSetpoint


ContactingElectronicsInc.

ElectronicsInc.56790MagneticDriveMishawaka,Indiana46545USA

Telephone

1-800-832-5653(Toll-freeinUSAandCanada)or(574)256-5001

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Website

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AppendixThe24VdcMagnaValveswithRemoteTableSelect(RTS)

Like the other 24VdcMagnaValves, the 24VdcMagnaValveswithRTS have five (5) internalmemory tables tostorecalibrationparameters.However,thetablesintheMagnaValveswithRTScanbeaccessedwithoutgoingintoaTerminalProgram.Thesetablesareaccessedbyapplying24Vdcsignaltotheproperpins(4,5and6)oftheRTSconnectorlocatedonthebottomoftheRTSMagnaValve.Pin3(thegreenwire)oftheRTSsocketisconnectedtotheMagnaValvegroundsysteminsidetheMagnaValve.ThreeLEDsindicatethestatusofthethreeinputports(A,BandC).Note:WhencalibratingmultipletablesinaMagnaValve,theorderinwhichtheshottypeandsizeiscalibratedisimportant.Forexample, if theMagnaValve isbeingcalibratedforcaststeelshotandcutwireshot, thesmallestcaststeelshotmustbecalibratedfirstandthegainadjustedto95%forthatshot.ThegainMUSTNOTbeadjustedforanyothertablecalibration,includingtablecalibrationsforcutwireshot.IfonlycutwireshotwillbeusedintheMagnaValve,thesmallestcutwireshotmustbecalibratedfirstandthegainadjustedto95%forthatshot.

OrderPlug/CableSeparatelyforRTSConnector

• 2MLength–P/N940010• 4MLength–P/N940011• 5MLength–P/N940012


WiringDiagram

Documents

24 Vdc Cal IM - Electronics Inc · 2020. 6. 14. · Electronics Inc. • (574) 256-5001 • 3 Introduction The Calibration Procedures outlined in this instruction manual can be used