Proportional pressure controller

Introduction

I. Introducing : Proportional Pressure Controller

I or E
Input signal Output pressure

The MAC Proportional Pressure Controller, (PPC) is an innovative product P

which converts an electrical signal into a proportional pneumatic output.
The PPC is unlike conventional I/P or V/P transducers. It offers much more
in terms of performance, features, and reliability. Inlet pressure

The key to the MAC PPCs are two MAC 34, 45, 400, 47, 92 or 93 Series valves that are used to control the
output pressure. The valves are operated by the PPCs closed loop electronic control circuit. Feedback is obtained
from one or two transducers. The balanced poppet, fast response, and high flow of these two MAC Valves
provide outstanding performance characteristics for the PPC.
EXHAUST 2
+ 24 VDC
The PPC controls output pressure by constantly measuring its down
stream pressure and comparing it to the command signal. If a 1
0-10 Volt /
higher pressure is commanded the PPC quickly responds by OUT

actuating the MAC fill valve, increasing the output pressure until it 4-20 mA /
4 or 8 Bit 2
is equal to the pressure represented by the command signal. Circuit Board

Conversely, if a lower pressure is required, the PPC will energize

1
the MAC exhaust valve, decreasing output pressure until the FILL

correct pressure is achieved. All of this happens very quickly to

smoothly maintain the correct pressure. E
P

This approach to pressure control provides a small, light, and

cost effective unit. Unlike voice coil units, the PPC is not affected by vibration or mounting position. Unlike large
direct solenoid proportional units, the PPC is small and light, drawing little power, and producing little heat.
Unlike units that utilize unbalanced air valves, the PPCs balanced valves provide high flow and extremely fast
and repeatable response times as well as eliminating “undershoot” and “overshoot” problems normally
associated with unbalanced valve designed units. Other proportional products often incorporate valves from third
party manufactures. All MAC PPCs utilize only fast shifting, repeatable, high flow, long life MAC Valves as fill
and exhaust valves.

II. Configuration

The PPC is available in many configurations.

The PPC5C can be ordered with a single or dual transducer, with an analog or digital command signal, for pressure or
vacuum service. All other PPCs can be ordered with a single transducer with an analog command signal.
Single transducer PPCs can be configured with internal sensing (stand alone) or with external sensing (e.g. for
Proportional Multi-Pressure Pak®). Dual transducer PPCs are available for controlling other devices such as boosters.
PPCs with analog or digital command signal are chosen following the command device available for the application.
Most PPC Series are available as covered or coverless devices. Coverless PPCs are intended for use in cabinets or areas
protected from moisture while covered PPCs can be used in unprotected environments (Washdown).
MAC offers a multitude of special modifications designed to meet customers specific application requirements. Please
contact your local MAC distributor for consultation if our standard product options do not fulfill your requirements.
3 Consult “Precautions” page 94 before use, installation or service of MAC Valves.
 Introduction

III. Specifications

LINEARITY

The linearity parameter shows the capability of

the unit to follow the input signal according to Input signal
Span
an ideal straight line curve.
MAC PPCs exhibit excellent linearity throughout
the pressure range. The deviation is measured in
± % of full scale.

zero Output pressure

Desired curve
Actual curve

LIMITS OF ADJUSTMENT

For single transducer models, two parameters can be adjusted. Primarily these should be set by the factory but can be
done in the field if absolutely necessary. The first parameter is the ZERO adjust, the second is the SPAN adjust. These
parameters provide the possibility of customizing the PPC according to customers needs. However these adjustments are
limited due to the tolerances of the transducers. If adjustments are necessary, please consult the factory or your local
distributor

Note: Dual transducer models are not field adjustable.

P P

zero adjusted span adjusted

Input Input

4 Consult “Precautions” page 94 before use, installation or service of MAC Valves.

 Proportional pressure controller

Introduction

HYSTERESIS

The hysteresis error, sometimes called “deadband”, is the

amount of output pressure variance required to cause the 120 PSI
PPC to react, making a correction to the output pressure.
It is given in percent of full scale pressure, all MAC PPC
products perform with minimal hysteresis. 60,5 PSI

60 PSI

59,5 PSI

0 PSI

ACCURACY

MAC Valves states accuracy of the MAC PPCs as overall accuracy. Accuracy is expressed in percent of full scale, which
includes hysteresis and linearity. Some suppliers give separate parameters in order to give a better impression. In this
case hysteresis and linearity are added. MAC PPCs are extremely accurate and maintain excellent control of output
pressure well within our stated accuracy.

O V E R S H O OT – U N D E R S H O OT

Two undesirable characteristics of other

proportional control units available on the
market are overshoot and undershoot. OVERSHOT

TARGET
Overshoot is a characteristic of the regulator to PRESSURE
exceed the desired output pressure when the
command signal is given. Undershoot is a PSI
TARGET
PRESSURE
characteristic of the regulator to fail to reach the
desired output pressure. UNDERSHOT

0 TIME
The PPC is based on a closed loop design which
combined with MACs fast responding, very repeatable, high flow, balanced 2-way valves, optimizes response and
accuracy, practically eliminating overshoot and undershoot.

CLOSED END VOLUME

The closed end volume is the amount of volume needed to keep the PPC stable. If the closed volume to be filled is not
appropriate for a particular PPC model (too small in comparison with the flow of air coming from the PPC), it will be
very difficult to control the desired pressure inside this volume. So the PPC will be required to compensate for any small
variation of pressure and the device will be unstable. This instability is sometimes referred to as “motorboating” or the
continuous energizing and de-energizing of the fill and exhaust valves. Minimum volume requirements to prevent
“motorboating” are listed for each PPC in this catalog for your reference.

5 Consult “Precautions” page 94 before use, installation or service of MAC Valves.

 Introduction

IV. Command Signal Options

The PPC can be controlled with either an analog command signal or a digital command signal.

ANALOG COMMAND SIGNAL

The analog command signal can be either 0 – 10 VDC (voltage) or 4 – 20 mA (current).

Two wires are necessary to accept the command signal. The PPC measures the voltage differences between the two
wires to determine the desired pressure output. Along with the command signals, a 24 VDC source must be available to
operate the PPC. The return path for the 24VDC source and the return path for the command signal must not be
isolated from each other. An example of how to wire the
PPC with a differential command signal is shown below. +COMMAND (WHITE)
+

0 TO 10V
The major advantages of the command signal for the -COMMAND (BLUE) CABLE
PPC are : - TO PPC

• Elimination of ground loop noise. POWER (BLACK)

+
• Operation of multiple PPC’s from a single power supply.
• Easy to connect to single-ended equipment.
24VDC
COMMON (GREEN)
-

D I G I TA L C O M M A N D S I G N A L

The PPC, through the use of a converter board, accepts a digital command signal for 4-bit or 8-bit binary logic and
converts this to an analog signal to produce a proportional pressure.

Using a 4-bit digital input, the maximum number of different pressures available at the output is 16. If an 8-bit digital
input is specified, a much finer resolution (256 pressures at the output) can be obtained. For example, in a 100 PSI
output system, using 4-bit logic, each bit is equal to 6.67 PSI. With an 8-bit digital, each bit is equal to .392 PSI

There are four different models available for the 4-bit and 8-bit digital PPC based on the type of input signal :

1. Positive Logic/Sourcing Input 2. Negative Logic/Sourcing Input

3. Positive Logic/Sinking Input 4. Negative Logic/Sinking Input

Positive Logic is defined as a minimum command level (all bits are logic low) controlling a minimum pressure output.
For example, in a 4-bit system, a 0000 digital signal would correspond to zero psi and a 1111 digital signal would
correspond to the maximum pressure.

6 Consult “Precautions” page 94 before use, installation or service of MAC Valves.

 Proportional pressure controller

Introduction

Negative Logic is defined as a maximum command level (all bits are logic high) controlling a minimum pressure
output. For example, in a 4-bit system, a 1111 digital signal would correspond to zero psi and a 0000 digital signal
would correspond to the maximum pressure.

Sinking Input requires the digital voltage to be supplied by the controller connected to the input of the PPC.
A command signal must be supplied by the external controller to the digital input connections. The PLC "drives" the PPC,
by which a digital input (as opposed to analog) will control the output pressure.

Sourcing Input requires the PPC to produce the digital voltage. The controller connected to the input of the PPC is
required to "pull the logic level down to zero" or to "maintain the logic level at one". "Zero" is considered that level of
the signal which corresponds to the minimum value of the digital input supply (logic low). "One" is considered that level
of the signal which corresponds to the maximum positive value of the digital input supply (logic high). In this case, the
PPC "drives" the PLC. Again, a digital input will control the output pressure.

V. Monitor Signal Options

The PPC is available with two optional monitor signals. The Analog Monitor Signal (AMS), and the Logic Monitor
Signal (LMS). The PPC may be ordered with either one or both of these signals. Monitor Signals provide intelligent
feedback to the controlling device.

A N A L O G M O N I TO R S I G N A L -AMS-

The Analog Monitor Signal is a 0 to 10 VDC feedback

signal that provides a voltage proportional to the pressure
output of the PPC or the output of the device it is controlling.
In the case of MACs Proportional Multi-Pressure Pak®, the DIGITAL
AMS signal provides a voltage output proportional to the DISPLAY WITH HIGH

output pressure of the PMPP. IMPEDANCE INPUT

- +

The AMS may be used by the controlling device to verify

that the correct pressure has been achieved. Also, the AMS
may be connected to a voltage meter to display the pressure CABLE

output. In some applications, the AMS is fed into the analog FROM PPC
AMS (RED)
input of a controller to provide data for Statistical Process
Control. In either case, a high impedance input is required COMMON (GREEN)
Fig. 1
for proper operation.

Figure 1, shows how to wire the AMS to a panel meter to display pressure output.

7 Consult “Precautions” page 94 before use, installation or service of MAC Valves.

 Introduction

L O G I C M O N I TO R S I G N A L -LMS-

The Logic Monitor Signal provides digital feedback to confirm

that the PPC has achieved the correct pressure. The LMS
provides standard logic levels such as TTL (5V) or 24 VDC.

TTL INPUT
CONTROLER

With the TTL option, when correct pressure is achieved, the - +

LMS outputs a logic 1, (5 VDC). When the PPC is working,
(Fill or Exhaust valve is in operation) the LMS outputs a
logic 0, 0 VDC.

CABLE

Figure 2 shows how to wire the LMS to a controller’s TTL input. LMS (ORANGE)
FROM PPC

COMMON (GREEN)
Fig. 2
The LMS provides a simple "go/no go" signal back to the
controlling device. The LMS may also be used to turn on an
L.E.D. for remote indication.

There also is a negative logic version (LMS) available. When the correct pressure is achieved, this option outputs a logic 0.
When the PPC is working (fill or exhaust valve is in operation) the output is a logic 1. In either case, the LMS circuit is a
sinking type of output. Thus, the PPC supplies the ground to the reading device.

COVERLESS PPC WIRING PIN OUT

AMS – Analog Monitor Signal

- 0-10 VDC feedback signal that provides a voltage proportional
to the output pressure
LMS 1 – Logic Monitor Signal
- 5 VDC (TTL high), 24 VDC (high), 5 VDC (low), or 24 VDC (low)
“go/no go” feedback signal (depending on requirements)
LMS 2 – Logic Monitor Signal DUMP FILL
- 5VDC (TTL low), 24 VDC (high), or 24 VDC (low) “go/no go” VALVE VALVE

feedback signal (depending on requirements)

CV+ – Positive Command Signal
- Positive lead for the 0 – 10 VDC or 4-20 MA command signal
(depends on requirements)
CV- – Negative Command Signal
- Negative lead for the 0 – 10 VDC or 4-20 MA command signal
(depends on requirements)
COM – Main Power Common
- Common lead for the 24 VDC power
POWER SPAN ZERO
PWR – Main Power COM
CV-
- Positive lead for the 24 VDC power CV+
LMS2
LMS1
AMS

8 Consult “Precautions” page 94 before use, installation or service of MAC Valves.

 Proportional pressure controller

Series PPC400A
Port size Flow (Max) (Cv/Nl/min) Individual mounting Series
coverless
1/4” 1.3/1300 analog
base mount

OPERATIONAL BENEFITS

1. Reliable operation, using two MAC 400 Series

with balanced pilot.
2. Fast response. PPC5C
3. Long life.
4. High flow.
5. Low power consumption.
6. Not affected by vibrations.
7. Accuracy : ± 2.5 % full scale. PPC34B
8. Analog command signal and output.

LCP35A

H O W TO O R D E R PPC45B
BASIC MODEL PPC400A X X X - X X X X - X X X
PPC47A
Type Type of Pressure range Pressure Accuracy Command Logic monitor Cover options
mounting PSI/BAR reference signal signal
A Analog AA Base side port 0A 100/6.7 G Gage pressure E ±2.5% F.S. B 0-10v differential A TTL LMS 1,2 0 No Cover
1/4” NPTF
B
(int. pilot)
Analog AB Base side port
0B 60/4
0C 30/2
D Differential
pressure
D 4-20mA
differential
B 24v LMS High on
TTL LMS 1 Press.
PPC400A
(ext. pilot) 1/4” BSPPL 0N 10/0.66 Achieved
AC Base side port 0T 45/3 C 24v LMS Low on
Caution: differential
1/4” BSPTR
AD Base side 8mm
pressure must not TTL LMS Press.
Achieved
PPC92B
tube receptacle exceed pressure
range.
BA Base bottom port

BB
1/4” NPTF
Base bottom port
PPC93A
1/4” BSPPL
BC Base bottom port
1/4” BSPTR
BD Base bottom 8mm
tube receptacle

EXAMPLE : PPC400A AAA - 0AGE - BA0

400 Series flow valves, analog, side port 1/4” NPTF, 100 psi pressure range,
gage reference, 2.5% accuracy, 0-10v differential, TTL LMS 1,2, no cover.

53 Consult “Precautions” page 94 before use, installation or service of MAC Valves.

 100% WARRANTY

100%
OF
PRODUCTION
TESTED
18
MONTHS

Series PPC400A
G E N E R A L DATA P N E U M AT I C DATA

Ambient temperature : 32 to 120°F/0 to 50°C Inlet pressure* : 120 PSI max (for 10-100 PSI output pres.)
LED indicators : Red : power on - Green : pressure achieved 8 BAR max (for 0.66-6.6 BAR output pres.)

Vibration : Not affected Fluids : Compressed air or inert gases

Port size : G1/4”, 1/4” NPTF - Option : bottom ports Lubrication : Not required. However, if used, a medium aniline point oil
is recommended
Connector : 7 pin terminal block
Output pressure : 0 to 10, 30, 45, 60, 100 PSI
Mounting : Any plane
0 to 0.66, 2, 3, 4, 6.6 BAR
Overall accuracy : ± 2.5% full scale
E L E C T R I C A L DATA
Flow : Cv 1.3/1300 Nl/min
Supply voltage : 20.4 to 26.4 VDC Minimum closed end volume : 50.0 cubic inch - 820 cm3
Supply current : 50 to 350mA * 20 PSI maximum inlet for 10 PSI output pressure - 1.3 BAR maximum inlet for 0.66 BAR output pressure.
Minimum inlet pressure for 400 series internal pilot is 20 PSI/1.3 BAR.
Command signal : 0 to 10V or 4 to 20mA
Command type : Single-ended or differential
Input impedance : 4.99 kΩ ± 1.0% (voltage)
316 Ω ± 0.1% (current)
Analog Monitor Signal (AMS) : 0 to 10 Volt
Logic Monitor Signal (LMS) : 2 types of signals (see How to order) (sinking)
EMI/RFI protection : Common mode and high frequency noise reduction for
electrical inputs

DIMENSIONS

60.2
APPROX.

OPTIONAL EXT. PILOT

M8 TUBE
40.50
RECEPTACLE
1/8"-27 N.P.T.F.

41.00 1/8"-28 [Link]

17.50 1/8"-28 [Link]

M4 - TUBE RECEPTACLE

10.0 97.7
31.25 91.4 APPROX.
SIDE PORT APPROX. BTM PORT
ONLY
EXH OUT
ONLY SIDE PORT
ONLY
1/4"-18 N.P.T.F.
TYP. (3)

37.6 1/4"-19 [Link]

21.75 TYP. (3)
BTM PORT IN 17.75
ONLY
1/4"-19 [Link]
TYP. (3)

9.5 M8 - TUBE RECEPTACLE

TYP(3)
26.6

BASE MOUNT W/
SIDE PORTS

41.00
4.2 DIA. THRU
TYP.(2) MTG. HOLES
17.50

57.00

16.0
12 12

OUT EXH
MODEL

MODEL

68.2 62.7
76.2
12

97.0
AUCKLAND, N.Z.
LIEGE, BELGIUM
WIXOM, MI. USA

APPROX.
3

315
2 4

2 4
14
MODIF

MODIF

IN

4.0 14 14
1/4"-18 N.P.T.F.
TYP. (3)

1/4"-19 [Link]
TYP. (3)

1/4"-19 [Link]
4.0 49.0 TYP. (3) 9.50

M8 - TUBE RECEPTACLE
BASE MOUNT W/
TYP. (3)
BOTTOM PORTS

54 Consult “Precautions” page 94 before use, installation or service of MAC Valves.

 Proportional pressure controller

Series PPC400A
Port size Flow (Max) (Cv/Nl/min) Mounting Series
coverless
1/4” 1.3/1300 analog
DIN rail mount

OPERATIONAL BENEFITS

1. Reliable operation, using two MAC 400 Series

with balanced pilot.
2. Fast response. PPC5C
3. Long life.
4. High flow.
5. Low power consumption.
6. Not affected by vibrations.
7. Accuracy : ± 2.5 % full scale. PPC34B
8. Analog command signal and output.

LCP35A

H O W TO O R D E R PPC45B
BASIC MODEL PPC400A X X X - X X X X - X X X
PPC47A
Type Type of Pressure range Pressure Accuracy Command Logic monitor Cover options
mounting PSI/BAR reference signal signal
A Analog DA Din rail base 0A 100/6.7 G Gage pressure E ±2.5% F.S. B 0-10v differential A TTL LMS 1,2 0 No Cover
1/4” NPTF side port
B
(int. pilot)
Analog DB Din rail base
0B 60/4
0C 30/2
D Differential
pressure
D 4-20mA
differential
B 24v LMS High on
TTL LMS 1 Press.
PPC400A
(ext. pilot) 1/4” BSPPL side port 0N 10/0.66 Achieved
DC Din rail base 0T 45/3 C 24v LMS Low on
Caution: differential
1/4” BSPTR side port
DD Din rail base side
pressure must not TTL LMS Press.
Achieved
PPC92B
8mm tube receptacle exceed pressure
range.

PPC93A
Note: Din rail mount (EN50 022)

EXAMPLE : PPC400A ADA - 0AGE - BA0

400 Series flow valves, analog, din rail 1/4” NPTF side port, 100 psi pressure range,
gage reference, 2.5% accuracy, 0-10v differential, TTL LMS 1,2, no cover.

55 Consult “Precautions” page 94 before use, installation or service of MAC Valves.

 100% WARRANTY

OF
PRODUCTION
TESTED

100%
18 MONTHS

Series PPC400A
G E N E R A L DATA P N E U M AT I C DATA

Ambient temperature : 32 to 120°F/0 to 50°C Inlet pressure* : 120 PSI max (for 10-100 PSI output pres.)
LED indicators : Red : power on - Green : pressure achieved 8 BAR max (for 0.66-6.6 BAR output pres.)

Vibration : Not affected Fluids : Compressed air or inert gases

Port size : G1/4”, 1/4” NPTF - Option : bottom ports Lubrication : Not required. However, if used, a medium aniline point oil
is recommended
Connector : 7 pin terminal block
Output pressure : 0 to 10, 30, 45, 60, 100 PSI
Mounting : Any plane
0 to 0.66, 2, 3, 4, 6.6 BAR
Overall accuracy : ± 2.5% full scale
E L E C T R I C A L DATA
Flow : Cv 1.3/1300 Nl/min
Supply voltage : 20.4 to 26.4 VDC Minimum closed end volume : 50.0 cubic inch - 820 cm3
Supply current : 50 to 350mA * 20 PSI maximum inlet for 10 PSI output pressure - 1.3 BAR maximum inlet for 0.66 BAR output pressure.
Minimum inlet pressure for 400 series internal pilot is 20 PSI/1.3 BAR.
Command signal : 0 to 10V or 4 to 20mA
Command type : Single-ended or differential
Input impedance : 4.99 kΩ ± 1.0% (voltage)
316 Ω ± 0.1% (current)
Analog Monitor Signal (AMS) : 0 to 10 Volt
Logic Monitor Signal (LMS) : 2 types of signals (see How to order) (sinking)
EMI/RFI protection : Common mode and high frequency noise reduction for
electrical inputs

DIMENSIONS
60.2
APPROX.

40.50 M8 TUBE
RECEPTACLE

41.00

17.50

1/4"-18 N.P.T.F.
TYP. (3)
10.0
1/4"-19 [Link]
TYP. (3)
31.25 100.7
EXH OUT APPROX.
1/4"-19 [Link]
TYP. (3)

M8 - TUBE RECEPTACLE
TYP(3)
21.75
IN

9.50

12 12
MODEL

MODEL

76.20
CL
12

AUCKLAND, N.Z.
LIEGE, BELGIUM
WIXOM, MI. USA

DIN RAIL 97.0

3

315
2 4

2 4

APPROX.
14

36.85
MODIF

MODIF

14 14

56 Consult “Precautions” page 94 before use, installation or service of MAC Valves.