Rodix FEEDER CUBE FC-90 Plus Series User manual

PNP
NPN
TB2
MODEL - FC-92 Plus
PlusPlus
Plus
P/N 121-000-8450
Including Models
FC-92-4
Plus
PlusPlus
Plus ,P/N 121-000-8460
FC-92-5
Plus
PlusPlus
Plus ,P/N 121-000-8470
CFR-92
Plus
PlusPlus
Plus ,P/N 121-100-8450
CFR-92-4
Plus
PlusPlus
Plus ,P/N 121-100-8460
CFR-92-5
Plus
PlusPlus
Plus ,P/N 121-100-8470
Listed, File No. E183233
Input: 120 VAC
50/60 HZ.
Output: 0-120 VAC
Double Unit Fuse Sizes:
Unit A 10 AMPS and
Unit B 5 AMPS
80% Duty Cycle at Rated AMPS
© 2000, 2005 RODIX INC.
1. SELECTING 60 OR 120 PULSE
OPERATION
A.For 60 pulse output - Set switch (S1) to 60 on the
P.C. card (No. 24-476).
B.For 120 pulse output - Set switch (S1) to 120 on the
P.C. card.
Note: Readjust MAX pot after changing pulse
switch setting.
2. INSTALLING THE PART SENSOR
(Photo-sensor or Proximity Switch)
A. Connect a three wire, current-sinking (NPN) or
current-sourcing (PNP) sensor as shown on the
enclosed wiring diagram. The sensor must be
able to operate on 12VDC and be capable of
switching at least 3.0 mA.
B. Set switch (S2) for the proper logic. When the
switch is in the "NORM" position, the control will
run only when the sensor signal is present. The
"NORM" position is used with Light-Operate
Photoeyes (through beam). When switch (S2) is
in the "INV" position, the control runs only when
the sensor signal is not present. The "INV" switch
position is used with Dark-Operate (reflective)
Photoeyes and with Proximity Sensors.
Troubleshooting Tip: On new sensor installations if the
sensor LED turns ON and OFF, but the control's output
does not turn ON and OFF, turn the time delays all the
way down, counter-clockwise. If this problem persists,
the sensor may have an internal pull-up or pull-down
resistor that is incompatible with the universal sensor
input on the control. Dedicate the control’s part sensor
input to match the sensor’s output type. Remove the
resistor labeled “R4” and “NPN” when using a NPN
sensor. For a PNP sensor remove the resistor labeled
“R3” and “PNP.” The resistors are located near TB2-4.
Use needle-nose pliers to twist and snap the resistor
off. Removing the resistor does not void the warranty.
3. LIMITING THE MAXIMUM
OUTPUT OF CONTROL
The MAX Output trimpot can be adjusted to keep
the vibratory feeder from hammering when the
control is turned up to full power.
When setting up the MAX output of the feeder
control, the output to feeder must be connected
and the control set for the proper output frequency
(60 or 120 pulse) setting. The Run Contact input
must be closed, and the Part Sensor must be
calling for parts.
A. Power input should be OFF or disconnected.
B. Open cover to allow access to printed circuit
card.
C. Adjust the MAX Output trimpot counter-
clockwise to its minimum setting.
D. Using CAUTION, turn power ON (no output
should be present).
E. Rotate the MAIN CONTROL DIAL on front
cover to its highest setting.
F. Adjust the MAX Output trimpot so that the
output to the feeder reaches its desired
maximum level when the MAIN CONTROL
DIAL is turned fully clockwise. Turning the
MAX Output trimpot clockwise increases the
maximum output level.
4. MAIN CONTROL DIAL
The output power is controlled by the MAIN
CONTROL DIAL. A special logarithmic-tapered
power out curve (non-linear) spreads the power
broadly across the MAIN CONTROL DIAL to help
give maximum "Fine Control" over the output
speed of the vibratory feeder.
5. RUN JUMPER INPUT
The Run Jumper comes installed across TB2-7&8.
The Run input may also be controlled by a relay
contact, switch, or an NPN type of PLC output.
Replace the factory-installed jumper with the "Run
Signal" at terminals 7(-) and 8(+) of TB2 (small
terminal strip). A contact must be able to switch
12VDC at 3.0 mA. The control will then run only
when the contact is closed and the part sensor is
calling for parts. The PLC’s PNP output may be
used if it is isolated from the internal power supply.
To isolate it remove R24&25 located on the bottom
side of the circuit board near TB2-5. Isolation for
an NPN PLC output is optional.
FC-92 Plus B.doc 6/17/2005 Page 1
RODIX INC.
FEEDER CUBE


FC-90 Plus Series
Plus SeriesPlus Series
Plus Series
GENERAL PURPOSE
ADJUSTMENTS AND
SET UP FOR UNIT A

6. SETTING THE TIME DELAYS
The sensor time delays can be set for independent
OFF delay and ON delay periods. The time delay
trimpots can be adjusted to provide the best
individual response for the feeder (0 to 12
seconds). By rotating the adjustment clockwise,
the delay will become longer.
7. SETTING THE SOFT-START
The start-up of the control output can be adjusted
to ramp up to the desired output level instead of
starting abruptly. Soft-start keeps parts from
falling off the tooling, reduces spring shock, and
hammering when the control turns ON. Turn the
SOFT Start trimpot clockwise for the gentlest start
(about a 5 sec. ramp up to full output). Turn the
trimpot fully counter-clockwise for no soft start.
8. FEEDER BOWL/HOPPER
INTERLOCK OUTPUT
The Feeder Bowl/Hopper Interlock feature
(terminals 2 & 3 of TB2) can be connected to a
Rodix FC-40 All-Purpose Series control when
control of a bulk material hopper is needed. The
control interlock will prevent the hopper from
operating anytime the bowl is turned OFF or in
"STAND BY" mode. The Interlock output is 12
VDC (70 mA). The 12 VDC output is capable of
switching 500 mA if an external power supply is
used. Download the FC-90 Plus Advanced
Application note for more details. The Interlock
output can also be used to drive a solid state relay.
The solid state relay is then used to operate any
auxiliary equipment such as air valves. Two FC-
90
Plus
PlusPlus
Plus controls can also be interlocked,
download the FC-90-2 Application Note for the
wiring information.
9. POWER SUPPLY
At the rated line voltage, the power supply is
capable of providing a combined total current of
100 mA at 12 VDC. The total current includes the
sensor and any auxiliary output accessories that
are connected to the Bowl/Hopper Interlock
terminals.
10. REMOTE SPEED CONTROL
Remote control of the power level can be
accomplished by the following methods:
A. 4-20mA signal from a PLC can be used to remotely
vary the output of the control instead of the Main
Control Dial. This feature is automatically turned
ON whenever a 4-20mA signal is applied to the
control (terminals 11 & 12 of TB2). The Main
Control dial setting is ignored whenever there is a 4-
20mA signal. The 4-20mA input is transformer
isolated from the power line.
B. 0-5VDC Analog input signal may be applied in place
of the Main Control Dial. For further information
download (or request from RODIX) an FC-90
Plus
PlusPlus
Plus
Series Advanced Application Note.
C. Remote control of the output power level can be
accomplished by using an optional Step Up/Down
Remote Speed Interface P/N 123-148.
11. LINE VOLTAGE COMPENSATION
Fluctuations in the line Voltage can cause a feeder bowl
to vary its feed rate. The line voltage compensation
feature adjusts the control's output to help compensate
for fluctuations in the supply voltage. If it becomes
necessary to disable this feature, cut through the circuit
board trace labeled J8 using side cutter pliers or a knife.
12. SUPPLEMENTARY FEATURES
Special supplementary software features can be
enabled on the 24-476/24-477 circuit boards with
software versions ADV5.0 or greater. The features
include: Constant Feed Rate regulation (CFR vibration
feedback sensor required), Constant On, High/Low
Track level control, 60 pulse polarity reversal, low pulse
rate, power conservation mode, MIN. power trimpot,
and two speed pots. See the FC-90
Plus
PlusPlus
Plus Advanced
Application Note for details. The control comes from the
factory configured with the "standard program". A
different program may be in operation if any of the
letters on the chip label are circled: "J8", "H", "POL",
"CO" and "CFR".
WARNING:
Fuses should be replaced with Littelfuse 3AB
"Fast Acting" type or equivalent of manufacturer's
original value.
Mounting this control on a vibrating surface will
void the warranty.
WARRANTY
Rodix Control Products are Warranted to be
free from defects in material and workmanship
under normal use for a period of two years
from date of shipment. For the full description of
the warranty, terms, and software license, please
contact the factory.
For assistance installing or operating your Rodix
Control please call the factory or visit our web site.
Technical help is available to answer your
questions and Fax any needed information. To
return a control for IN or OUT of Warranty Service,
please ship it prepaid to:
Rodix Inc., ATTN: Repair Department
If under Warranty, Rodix will repair or replace your
control at no charge; If out of Warranty, we will
repair it and you will be billed for the repair charges
(Time and Material) plus the return freight. Quotes
for repairs are available upon request. A brief note
describing the symptoms helps our technicians
address the issue.
Feeder Cube® is a registered TM of Rodix Inc.
Banneris a registered Trademark of Banner Engineering
Corp, 9714 10th Ave, Minneapolis, MN 55441
DIMENSIONS
RODIX, INC.
4904 Colt Road, Rockford, IL 61109
Toll Free [phone], FAX [phone]
E-mail custserv[email protected]
www.rodix.com
FC-92 Plus B.doc 4/8/05 page 2

1. SELECTING 60 OR 120 PULSE
OPERATION
A. For 60 pulse output - Set switch (S1) to 60 on
the P.C. card (No. 24-480).
B. For 120 pulse output - Set switch (S1) to 120
on the P.C. card.
Note: Readjust MAX pot after changing pulse
switch setting.
2. LIMITING THE MAXIMUM
OUTPUT OF CONTROL
Adjust the MAX Output trimpot so that the output
to the feeder reaches its desired maximum level
when the MAIN CONTROL DIAL is turned fully
clockwise. The MAX Output trimpot should be
adjusted to keep the vibratory feeder from
hammering when the control is turned up to full
power.
NOTE: Output to feeder must be connected and
the control set for proper output frequency (60
or 120 pulse) setting. The Run Jumper must be
connected as shown on the wiring diagram.
A. Power input should be OFF or disconnected.
B. Rotate MAIN CONTROL DIAL on front cover
to 0 or its minimum setting.
C. Open cover to allow access to printed circuit
card.
D. Using CAUTION, turn power ON (no output
should be present).
E. Rotate the MAIN CONTROL DIAL on front
cover slowly to its highest setting.
F. Adjust the MAX output trimpot so that the output
to the feeder reaches its desired maximum
level when the MAIN CONTROL DIAL is
turned fully clockwise. Turning the MAX output
trimpot clockwise increases the maximum
output level.
3. SETTING THE MINIMUM
OUTPUT LEVEL OF CONTROL
When the vibratory feeder is nearly empty, turn the
MAIN CONTROL DIAL fully counter-clockwise and
adjust the MIN trimpot to just below the slowest speed
that provides the proper feed rate.
This trimpot is only installed on Rev. D boards.
4. REMOTE OFF/ON CONTROL
A Run Jumper has been installed at the factory as
shown on the enclosed wiring diagram.
Note: TB2 terminals 5-7 are connected to the line
voltage circuit. Therefore any switch or contact must be
isolated from other circuits.
Remote OFF/ON operation of the FC-40 Plus Ser
Plus SerPlus Ser
Plus Series
iesies
ies
Feeder Cube®control can be configured to operate in
one of the following ways.
A. A low current switch such as a paddle switch can
replace the factory-installed Run Jumper "J1." The
"Run Contact" connects to terminals 6 and 7. The
contact must be able to switch 5VDC and 2mA.
The control will then run only when the contact is
closed. Refer to Section A of the OFF/ON
CONTROL GUIDE.
B. Feeder Bowl/Hopper Interlock allows the Hopper
control to operate only when the Bowl is running
and the paddle switch contact is closed. The
interlock input on terminals 11 and 12 of TB2 is
controlled by the interlock output of a "Parts
Sensing Feeder Bowl Control" such as an FC-90
Plus
PlusPlus
Plus .
Remove jumper "J1" of this control from terminals 6
and 7. Connect the Hopper Paddle switch to
alternate terminals 5 and 6. Connect TB2 terminals
11 and 12 of this control to the "Parts Sensing
Control". Refer to Section B of the OFF/ON
CONTROL GUIDE. Check specific instructions for
the "Parts Sensing Control" wiring.
Note: Only use Bowl/Hopper Interlock with a FC-90
and FC-40 Series control. Two FC-40 Series
controls will not interlock to each other since neither
one has an interlock output.
C. Low Voltage DC can be used to turn the control ON
and OFF. Move jumper "J1" from terminal 7, to
terminal 5, (6 remains the same). Then connect
the positive signal (+5 to 30VDC @ 10mA) to
terminal 12 and the negative to terminal 11 of TB2.
The control will now turn ON when the DC signal is
present at terminals 11 and 12 of TB2. This input
is optically isolated. Refer to Section C of the
OFF/ON CONTROL GUIDE.
D. AC Voltage may be used to turn the control
ON and OFF. This requires a 105-250VAC
signal, with 2mA maximum off-state leakage.
Set up the control by moving the jumper "J1"
from terminal 7, to terminal 5, (6 remains the
same). Connect the 105-250VAC Signal to
terminal 12 (L1) and the common (L2) to
terminal 10 of TB2. The FC-40 control will
now turn ON whenever the AC signal is
applied to terminals 10 and 12 of TB2. This
input is optically isolated. Refer to Section D
of the OFF/ON CONTROL GUIDE.
5. MAIN CONTROL DIAL
The output power is controlled by the MAIN
CONTROL DIAL. A special logarithmic-tapered
power-out curve (non-linear) spreads the power
broadly across the MAIN CONTROL DIAL to help
give maximum "Fine Control" over the output
speed of the vibratory feeder. When very precise
adjustment of the MAIN CONTROL DIAL is
needed, increase the MIN trimpot setting and/or
decrease the MAX trimpot setting. Use of an
external analog signal in place of the control
potentiometer is not recommended.
6. SETTING THE SOFT-START
The start-up of the control output can be adjusted
to ramp up to the desired output level instead of
starting abruptly. This keeps parts from falling off
the tooling of a vibratory feeder when it turns on; it
can reduce hammering during turn on; it can also
simulate a paddle switch ON delay. Adjust the
SOFT Start trimpot clockwise for the gentlest start
(about a 10-second ramp up to full output). Turn
the trimpot fully counter-clockwise for no soft start.
7. ADVANCED FEATURE PROGRAMS
Advanced features are available for specialized
applications. These features can be enabled by
the end user: 60 pulse waveform reversal; Main
Control Dial follows a fixed curve; Control output
turns off when the Main Control Dial is at 0; MIN
pot disable, Power conservation mode; High
speed/low speed/off operation; and Low pulse
rates of 30, 20, 15, 10. For a full description of
these features, please download the FC-40 Plus
Advanced Application Note.
FC-92 Plus B.doc 4/8/05 page 3
ADJUST AND SET UP
FOR UNIT B

1. INSTALLING THE CFR SENSOR
Note: Failure to adequately prepare the feeder’s
surface properly may result in a Constant Feed
Rate (CFR) sensor that will not bond to the
feeder. The sensor should not be mounted until
step C-6.
Fig. 2 The arrow shows the direction of vibration
which is at a right angle to the spring pack.
A. ORIENT THE SENSOR so that its sensitive axis
is in the same direction as the vibration of the
feeder. The double-ended arrow in figure 1 shows the
sensor’s sensitive axis. Align the sensitive axis of the
sensor in the same direction as the vibration (see
figure 2). The sensor must be oriented correctly for
proper operation.
B. CHOOSE A LOCATION for mounting the sensor
on the feeder that is smooth and that will allow the
adhesive on the sensor to bond. Avoid mounting the
sensor over ridges and bumps which can reduce the
ability of the adhesive to stick to the feeder. The
correct location will also have enough space for the
sensor’s cable to hang straight down without touching
anything else.
C. SURFACE PREPARATION of the feeder is crucial
for proper bonding between the sensor and the feeder.
Please follow these steps completely.
1) The feeder should be kept between 70°and 100°F
for ideal tape application.
2) Clean a three and one-half inch circular area with a
solvent like isopropyl alcohol that will not leave a
residue. As a rule of thumb, the area can be
considered clean when after cleaning the area with a
solvent-saturated, white paper-towel, the towel is as
clean as it was before wiping.
3) Using a good amount of pressure, polish the
cleaned, circular area of the feeder using a scratch
pad or steel wool. Repeat step 2, and then go to
step 4.
4) Wipe the cleaned surface with an alcohol wipe or
with a 50/50 isopropyl alcohol/water combination.
5) Dry the surface thoroughly using a low lint cloth or a
clean paper towel.
6) Remove the vibration sensor from its protective
packaging. Remove the liner from the adhesive
backing. Avoid touching the tape. Align the sensor
as shown in figures 1 and 2. Apply the vibration
sensor to the prepared area of the feeder. Press the
sensor very firmly onto the feeder surface for at least
10 seconds.
7) Allow the vibration sensor at least 20 minutes to
cure before operation. Note: It takes 72 hours for
the adhesive to fully cure at 70°F.
Alternatively, #8 or M4 screws can be used to mount
the sensor to the feeder. The hole centers are 1.375”
apart.
D. ROUTE THE SENSOR CABLE to protect it from
strain due to vibration. The cable that attaches to the
sensor will not break from normal vibration; however,
some care should be used when routing the sensor
cable from the sensor to the control. The cable should
hang straight down from the sensor without touching
the feeder bowl or anything else. Then, the sensor
cable should curve towards the power control with
a bend radius larger than 3 inches.
Use a cable tie and an adhesive-backed mount to
attach the sensor cable to the side of the drive
base. See Figure 2. Clean the mounting area
before applying the adhesive-backed mount.
E. CONNECT THE SENSOR to the control. The
sensor’s brown wire connects to +12VDC at TB2-
9. The blue wire connects to the signal input at
TB2-12.
10 912
TB2
11
+
-
CFR
MAX
J8
CO
H
C11
BR1
Fig. 3
2. CFR Software Program
The FC-90 Plus, P/N 24-476/24-477 circuit boards
share the same circuitry as the CFR-90 Plus, 24-
502/24-503 circuit boards. The difference for
Revision B.1 and higher boards is the fact that the
CFR program has been enabled to operate by
cutting the CFR jumper on the Board. The CFR
circuit board trace is shown in figure 3. It must be
cut in order for the CFR sensor, P/N 123-170 to
differentiate it from a 4-20mA signal. When
converting a FC-90 Plus to enable the CFR
function, cut through the CFR trace with a sharp
knife. Then circle the CFR designation on the IC’s
label to show that the CFR software feature has
been enabled. If some of the software features
have been circled already, download the FC-90
Plus Advanced Application Note from
www.rodix.com to find out more of the software
installation details.
© 2000, 2005 RODIX INC.
RODIX, INC.
4904 Colt Road, Rockford, IL 61109
Toll Free [phone], FAX [phone]
E-mail custserv[email protected]
www.rodix.com
CFR Sensor.doc 6/22/2005
CFR Sensor
RODIX INC.
FEEDER CUBE


CFR Plus Series
Plus SeriesPlus Series
Plus Series
CONSTANT FEED RATE



Sensitive
Axis of
Vibration
Fig. 1
Actual Size
1.375”
The CFR
circuit board
trace must be
cut through to
work with CFR
sensor.
P/N 123-170

RODIX INC.
FEEDER CUBE


FC-92 Plus Series
Plus SeriesPlus Series
Plus Series
WIRING DIAGRAM
MODEL #121-8450
MODEL INPUT VAC AMPS OUTPUT
FC-92 PLUS 120 VAC 10/5A 0-120
RODIX, INC.
4904 Colt Road, Rockford, IL 61109
Toll Free [phone]
FAX [phone]
E-mail custserv[email protected]
www.rodix.com
FC-92 Plus B.doc 4/8/05 page 4
A1 GATE
TRIAC REFERENCE GUIDE
A
2



5
10
SWITCH
11
5
FC-40 PLUS SERIES TERM STRIP TB-2
11 5
FC-40 PLUS SERIES TERM STRIP TB-2
5
9
PADDLE
FC-40 PLUS SERIES TERM STRIP TB-2, INPUT
12
12
6
J1
FEEDER BOWL/HOPPER INTERLOCK
8
12
OFF/ON CONTROL
5-30 VDC INPUT VOLTAGE
7
See section 4 of the Application Note for more
details.
7
OFF/ON CONTROL
7
-
B)
TERM STRIP TB-2, OUTPUT
+
105-250 VAC INPUT VOLTAGE
86
OFF/ON CONTROL GUIDE
6
AC VOLTAGE INPUT SWITCHING
8
LOW CURRENT
SWITCH
D)
7
9
8
J1
LOW VOLTAGE INPUT SWITCHING
L2
11
9
10
A)
C)
L1
1
11
9
6
10
2
12
3
FC-40 PLUS SERIES TERM STRIP TB-2
FC-90 PLUS SERIES
10
(DC Voltage from PLC or FC-90 Plus)
64
1357
28
7
910 11
689 511 10
12
12
GATE
1
+
-
+
TB1
J1
CHASSIS
(TALL)
HOT
P/N 24-480
GATE
TB2
LOAD
LINE VOLTAGE
JUMPER
COMMON
INTERLOCK INPUT
RUN
TB2
A1
HOT
A2
COM
(SMALL)
TRIAC
TB1
FC -40 PLUS
OUTPUT POWER
POWER
TERM. STRIP
GND
TERM. STRIP
CONTROL CARD
G
AUX FEATURE
Yl
Rd
UNIT BUNIT A
124 3
+
L2
910 812
-
11
100K
POT
7 56
VDC:
1
cw
S1
-
MAIN
J1
+
VAC:L1 60
SIG
MAXSOFT
1/8W MIN
CONTROL
SM312FP1H
A2
COM
SOFT
cw
120
MIN
ACCEPTS BOTH OPTIC AND PROX SENSORS, NPN OR PNP.
INTERLOCK OUTPUT
+
OPTICS
BLU
SENSOR
A1
S2
CONTROL
S1
60
(TALL)
SIG
4-20mA
CONTROL CARD
Vi #20 Or #14 Bl #14 Bl #14 Wh #1 4
-
-
HOT
NORM
LINE VOLTAGE
100K
P/N 111-500
TB1
SENSOR OPTION
COM
G
CONNECT SINK OR SOURCE WIRE TO "SIG" INPUT
1/8W MIN
TB2
AUX FEATURE
+
AC COMMON
FC -90 PLUS
(SMALL)
Bl #14
BRN
RUN
TB1
OFF DELAY
POT
Wh #2 0
INPUT POWER
Wh #1 4
AC HOT
J1
-
LOAD
CHASSIS
HOT
OUTPUT POWER
Bl #14
POWER
Vi #20 Or #14
GND
Wh #1 4 Wh #2 0
120
MAIN
TERM. STRIP
CHASSIS
Wh #1 4
+
ON DELAY
Bl #14
JUMPER
-
BANNER
Bl #14
INV
S
GND
TRIAC
SIGWHT
P/N 24-476
OPTIC SENSOR
TERM. STRIP
106 85
MAX
TRANSFORMER
TB2
3 72 121 94 11