Rodix FEEDER CUBE FC-90 Plus Series User manual

PNP
NPN
TB2
MODEL – FC- 94 Plus
PlusPlus
Plus
P/N 121-000-8240
SUB PANEL MOUNT
Including Model
CFR-94
Plus
PlusPlus
Plus , 121-100-8240
Listed, File No. E183233
Input: 120 VAC
50/60 HZ.
Output: 0-120 VAC
Single Unit Fuse Size: 15 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-94 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



RODIX INC.
FEEDER CUBE


FC-90 Plus Series
Plus SeriesPlus Series
Plus Series
OPEN FRAME
ADJUSTMENTS AND
SET UP




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 Series
Plus SeriesPlus Series
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-94 Plus B.doc 4/8/05 Page 2

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 INCORPORATED
4904 COLT ROAD, ROCKFORD IL 61109-2644
TOLL FREE [phone], FAX [phone]
E-mail [email protected]
www.rodix.com
FEEDER CUBE


FC-94
Plus
PlusPlus
Plus
PARTS SENSING
OPEN FRAME MODEL
IMPORTANT: APPLICATION NOTE
MODEL INPUT VAC AMPS OUTPUT
FC-94
Plus
PlusPlus
Plus
120VAC 15A 0-120



TRIAC REFERENCE GUIDE
A2
A1 GATE
FC-94 PlusW B.doc 5/6/03 page 3
53
1468 9 11
910 511
12
14 2
7
2
7
10
8 612 3
OPTIC SENSOR
-
P/N 111-500
120
INPUT POWER
-
LOAD
CHASSIS
+
TRANSFORMER
-
60
HOT
SOFT
TB1
TB2
AC HOT
+
INV
S2
POWER
+
AC COMMON
TERM. STRIP
SIG
OUTPUT POWER
WHT
NORM
JUMPER
-
CONNECT SINK OR SOURCE WIRE TO "SIG" INPUT
SM312FP1H
SENSOR
GATE
BLU
HOT
A1
CHASSIS
TB2
OPTICS
COM
OFF DELAY
ACCEPTS BOTH OPTIC AND PROX SENSORS, NPN OR PNP.
CONTROL CARD
-
TERM. STRIP
TB1
GND
SIG
AUX FEATURE
(SMALL)
ON DELAY
4-20mA
P/N 24-476 J1
RUN
GND
A2 TRIAC
+
COM
G
BANNERBRN
S
+
FC-90 PLUS
MAX
(TALL)
LINE VOLTAGE
BOWL/HOPPER
1
POT
CONTROL
INTERLOCK OUTPUT
S1
MASTER CONTROL
100K
1/8WMIN
MAIN
cw
FUSE
TIE SHIELD WIRE TO
CHASSIS GROUND
AT THE POT END.
SHIELD
CHASSIS
SENSOR OPTION
CUSTOMER WIRING
SHOWN WITH
DASHED LINES
OPTIONAL POT
Or #14
Wh #14
Bl #14 Bl #14 Vi#20
Bl #14
Wh #14
Gr/Yl #20
Wh
Bl
Rd

FC-90
Plus
PlusPlus
Plus Series
SeriesSeries
Series
ADVANCED
APPLICATION NOTE
OVERVIEW
The FC-90
Plus
PlusPlus
Plus Series
SeriesSeries
Series
of feeder controls is built
around circuit boards 24-476 (120VAC) and 24-
477 (230VAC). The input voltage tolerance for the
24-476 board is 90-120VAC +/- 10%. The input
voltage tolerance for the 24-477 board is 180-
240VAC +/- 10%. Note: vibratory feeders may not
feed well at low line conditions. Each board
contains two power supplies, phase-angle firing
control for the triac, a Sensor input, a "Run" input,
one or two speed inputs, one auxiliary output, and
logic circuitry to perform on-delays and off-delays.
POWER SUPPLIES
The 5 VDC power supply is for internal use only.
The 12 VDC power supply is available for external
use having a maximum current capacityof 100mA.
Both supplies share the same ground.
0-5VDC & 4-20mA ANALOG INPUTS
The FC-90
Plus
PlusPlus
Plus Series
SeriesSeries
Series
feeder control has a
0-5VDC analog signal input and a 4-20mA analog
signal input for controlling the vibration level of the
feeder bowl.
0-5VDC input: Either a potentiometer or a 0-
5VDC input signal can be used to control the
output level of the control.
A potentiometer (Main control pot) normally is
connected to the analog input of J1 to vary the
output level of the control. This pot acts as a
voltage divider across the 5VDC power supply
providing a 0-5VDC signal.
Remote pot operation can be achieved by using a
3-wire shielded cable connected to J1, the analog
input. The shield (drain wire) should be connected
to the chassis ground only at the Rodix end of the
cable. See the wiring diagram for pot wiring
connections.
A 0-5VDC signal can be applied to J1, the analog
input instead of using the Main pot. The 0-5VDC
analog input signal may be applied between
terminals 2 and 3 of header J1. Connect the
ground to terminal 3 and the signal to terminal 2.
To improve noise immunity, remove the wire from
pin 1 of connector J1.
A 0-10VDC signal can be applied to the analog
input by using a voltage divider circuit to scale the
input voltage to 0-5VDC. See figure below.
The J1 cable is provided with the FC-94
Plus
PlusPlus
Plus
control. The cable, P/N 123-145 may be used
anytime a remote signal or a remote pot is used.
The shield of the “J1” cable should be tied to
chassis ground at the Rodix end of the cable.
4-20mA input: a 4-20mA signal is the second
type of input signal that can control the output
vibration level. This method has a better signal to
noise ratio than the 0-5VDC input control.
Connect the 4-20mA signal to TB2-11 (GND) and
TB2-12 (SIG) to allow the bowl's vibration level to
be adjusted remotely.
The Main control pot is automatically disabled
whenever the 4-20mA input current is above 4mA.
When the 4-20mA input current is at 0mA, control
of the vibration level goes back to the J1 Main pot
input.
Application Hints:
For Local/Remote control of the vibration level,
use a switch to toggle between the 4-20mA input
and the control pot. The switch is used to interrupt
the 4-20mA current at TB2-12.
To use only the 4-20mA input to control the
vibration level, disconnect the pot cable connected
to J1.
When an analog input signal is used, the analog
input signal should be applied after line power has
been applied to the control.
The control produces a special logarithmic-tapered
power output curve from the information given by
the Main pot or 4-20mA input. The special taper
spreads the power curve broadly across the pot
range, helping to give maximum fine control over
the control's output. For extra fine pot control, five
and ten-turn pot kits are available from RODIX.
Please note, on revision B or higher circuit boards
the 4-20mA feature is de-activated when the
Constant Feed Rate (CFR) feature is used.
Step Up/Down Remote Speed Interface P/N
123-120 allows remote control of output power
level, and replaces the Main control pot on the FC-
40
Plus
PlusPlus
Plus and FC-90 Plus Series
Plus SeriesPlus Series
Plus Series
Feeder Cube®
controls. When used, two customer provided push
buttons increase or decrease the output power
level of the control. This add-on option is available
from Rodix. FC-90 ADV APP B.doc 4/3/03 page 1
RODIX INC.
FEEDER CUBE


FC-90 Plus Series
Plus SeriesPlus Series
Plus Series



J1
1
CONTROL
cw
MAIN
100K
POT
1/8WMIN
-
+
SIG
J1
1
CONTROL
POT
cw
MAIN
1/8WMIN
100K
CHASSIS
SHIELD
TIE SHIELD WIRE TO
CHASSIS GROUND AT
THE CONTROL END.
OPTIONAL POT
TB2
1
J1
+
-
0-5VDC Input Diagram
v
CHASSIS
4.7K
4.7K
1
J1
+
-
0-10VDC Input Diagram
v
1/4W
1/4W
CHASSIS

RUN INPUT
Remote OFF/ON control normally can be
accomplished by using a dry relay contact at
terminals TB2-7 and TB2-8. When a contact is
unavailable, one of the following can be used.
A PLC having an NPN (current sinking) output can
provide remote OFF/ON control to the control’s
Run input. Connect the PLC’s NPN output to TB2-
8 (SIG). Connect the PLC’s power supply (5-
30VDC to TB2-9 (Pos). Apply the signal whenever
the control should be enabled. To prevent
damage when using this feature, resistors R24
and R25 must be removed from the FC-90
Plus
PlusPlus
Plus
circuit board. Use pliers to twist and snap off
resistors.
A PLC having a PNP (current sourcing) output can
provide remote OFF/ON control to the control’s
Run input. Connect the PLC’s PNP output (5-
30VDC) to TB2-8 (SIG). Connect the PLC’s
ground to TB2-7 (Gnd). Applythe signal whenever
the control should be enabled. To prevent damage
when using this feature, resistors R24 and R25
must be removed from the FC-90
Plus
PlusPlus
Plus
circuit
board. Use pliers to twist and snap off resistors.
If no power supply is available for a Run input
signal, the “on-board” power supply can be used.
A current sinking output (NPN) from a PLC can be
connected to TB2-8 and ground wire from the PLC
connects to TB2-7. Do not remove resistors R24
and R25 when using the “on-board” power supply.
AUXILIARY OUTPUT
The auxiliary output is useful for controlling other
feeder controls, solid-state relays, small DC
solenoids, and PLC inputs. The auxiliary (interlock)
output turns ON whenever the control output is
ON.
The AUX output comes from the factory
configured to sink current from the internal power
supply: see the “typical relay wiring” drawing. The
AUX output can be configured to sink or source
current from the internal power supply which is
rated at 100mA or from an external power supply.
Typical relay wiring
The AUX output can be reconfigured to source
current by modifying the jumper positions of JMP1.
JMP1 is a group of five solder pads, and it is
located behind TB2 terminals 1 through 3.
Terminal 1 of JMP1 is indicated by a square pad.
To source current, cut the printed circuit board
traces between pads 1 and 2 and between 3 and
4 of JMP1. Then, use 20 gauge or smaller wire to
connect solder pads 2 and 3. Next, solder a wire
into pads 4 and 5.
Note: the interlock connections change if the AUX
output has been modified to source current. The
interlock connections need to be changed from
terminal TB2-2 to terminal TB2-1, and from
terminal TB2-3 to terminal TB2-2.
The AUX output is capable of switching 500mA at
24VDC when an external power supply is used. To
prevent damage when using this feature, resistors
R20 and R21 must be removed from the circuit
board. Use pliers to twist and snap off resistors.
Inductive loads or loads with a relay coil connected
to the auxiliary output produce a negative voltage
spike when the coil is de-energized. In order to
protect the on board semi-conductors from a
negative voltage, connect a reverse biased diode
across the inductive load. A rectifier diode can be
connected across the coil by connecting the side
of the diode with a band to the positive side of the
coil, and connect the side without the band to the
negative side of the coil. A 1N4006 diode, P/N
115-31 is available from Rodix.
ISOLATION
The FC-90
Plus
PlusPlus
Plus Series
SeriesSeries
Series
control is transformer
isolated from the line, the isolation is rated at
2500V. The chassis to ground isolation is 1000V.
The sensor input, run input, analog (pot) input and
interlock output all share the same power supply
common. The sensor input can be optically
isolated if resistors R22 and R23 are removed
from the circuit board. The sensor power must
then be supplied from an external 5-30VDC
source. The run input and interlock output are
optically isolated only when resistors R20, R21,
R24 and R25 are removed, please read all
directions before removing them. Use pliers to
twist and snap off resistors.
NOISE IMMUNITY
For further details about noise immunity, see the
Feeder Cube®application note for your model
and the Rodix Solution titled Good Wiring
Practices for Avoiding Electrical Noise Problems.
Technical Support
Application notes, troubleshooting guides, and
Rodix solution guides are available at
www.rodix.com.
RODIX, INC.
4904 Colt Road, Rockford, IL 61109
Toll Free [phone]
E-mail custserv[email protected]
FAX [phone]
www.rodix.com
FC-90 Plus ADV B.doc 4/3/03 page 2
321
RECTIFIER DIODE
-
TB2
+
JMP 1
INDUCTIVE
LOAD
321
JMP 1
LOAD
-
+
JUMPERS RECONFIGURED FOR SOURCING CURRENT

FC-90 Plus ADV B.doc 4/3/03 page 3
+5 Vdc
+12 Vdc
+
25
USE 3 WIRE NPN
OR PNP SENSOR
12
4-20mA INPUT
0 OHM
6
4
(TALL)
4.7 KOHM
SENSOR
ADJUSTMENT
POTS
R23
-
120
4.7 KOHM
10
USE ONLY)
12 -
R21
1
HAVE CHANGED FROM PRIOR MODELS.
OHMS
75
OFF DELAY
A
C HOT / L1
TERMINALS 1, 2, 3
GND
5 VDC
INPUT RESISTANCE
> 200K OHMS
+
CIRCUIT BOARD P/N 24-476/24-477
LOW
VOLTAGE
A
C HOT
A
RE WIRED IN
PARALLEL
INV
A
RUN JUMPER IS
4.7 KOHM
R25
SENSOR INPUT
SERIES APPLICATION NOTE FOR INTERCONNECT WIRING.
TB1
0 OHM
R4
R20
11
R24
S2
A
C COMMON / L2
2
+12 Vdc
TB1
R3
R1
TRANSFORMER
3
SOFT
ISOLATED DRIVE
8 7
A
T TERMINALS 7 & 8
+12 Vdc
0 OHM
TERM. STRIP
USUALLY INSTALLED
2
REFERENCE DIAGRAM INCLUDES POTS, SWITCHES,
A
ND A PARTIAL SCHEMATIC DIAGRAM.
A
TTENTION: SENSOR AND/OR FIELD CONNECTIONS
A
NALOG
INPUT R22
NORM
9
A
UX OUTPUT USED TO INTERLOCK ANOTHER
CONTROLLER OR TO DRIVE AUXILLARY EQUIP.
ON DELAY
S1
THIS DIAGRAM IS FOR REFERENCE ONLY, SEE FC-90 PLUS
RUN INPUT
GATE
11
(100 MA MAX) 3
0 OHM
LOAD
5
(SMALL)
MAX
FC-90 PLUS INTERFACE DIAGRAM
(INTERNAL
12 VDC
TERM. STRIP
J1
1 9
ISOLATED
DETECTOR
RECONFIGURABLE
LINE VOLTAGE
A
UX
8
TERMINALS 11 AND 12
COPYRIGHT 1997, 2003 RODIX INC.
A
RE WIRED IN
PARALLEL
SUPPLY
TB2
+5 Vdc
10
0 OHM
FC-90 PLUS SERIES EQUIVALENT CIRCUIT
SUPPLY
G
1
TERMINALS 5, 6, 7, 8
TO SOURCE CURRENT USE: 3 (+) & 2 (SIG)
TO SINK CURRENT USE: 2 (SIG) & 1 (COM)
4.7 KOHM
3
0 OHM
A
UX FEATURE
1
+12 Vdc
R2
A
RE WIRED IN PARALLEL
JUMPERS ARE
S
6
LOAD
ISOLATED
DETECTOR
4
A
C COMMON
TB2
4
60
RUN
249 OR
221
CFR "-"
OR
CFR "+"

Optional software features of the
24-476 / 24-477 Rev. B circuit board
OVERVIEW: The FC-90
Plus
PlusPlus
Plus Series
SeriesSeries
Series
of feeder
controls are built around the circuit boards P/N 24-
476 (120VAC) and 24-477 (230VAC). This section
covers the advanced program features of the
revision B circuit boards. The revision B circuit
boards contain five (5) program jumpers that can
be cut in order to enable alternate program
features. The program features should be chosen
based on the customer application. When the
"CFR" program is ordered from Rodix, the circuit
board is relabeled 24-502 or 24-503.
PROGRAMMING: By cutting the correct jumper
combination, it is possible to run a desired
program instead of the "standard program." The
five program jumpers on the circuit board are
labeled “J8,” “H,” “POL,” “CO,” and “CFR.” The
program jumpers are actually circuit board traces
located between two through-hole pads (feed-
throughs). The jumpers can be cut through with a
sharp knife. Care should be taken to cut the
correct jumper or combination of jumpers to
enable the desired program feature(s). Record
which jumpers were cut for future reference by
circling their letters on the label that reads
PROGRAM: “J8,” “H,” “POL,” “CO,” and “CFR.”
The control comes from the factory configured with
the “standard program.” The different program
variations and their descriptions are enclosed:
Caution: If more than one software function is
desired, please check Table 1 to find the exact
programming selections needed; otherwise, the
board may run a software program that does not fit
the application.
Jumper Programming Chart Jumper Positions
Program Description “J8”“H” “POL” “CO” “CFR”
Standard Program (Factory Default) Norm or Cut Normal Normal Normal Normal
Standard Program and CFR Norm or Cut Normal Normal Normal Cut
Constant ON feeding, Aux. output changes Normal Normal Normal Cut Normal
Constant ON and CFR Normal Normal Normal Cut Cut
Low Pulse rate - 30 or 15 Pulse per second output Cut Normal Normal Cut Normal
Low Pulse rate - 20 or 10 Pulse per second output Cut Normal Cut Cut Normal
60 Pulse Polarity Reversal Norm or Cut Normal Cut Normal Normal
60 Pulse Polarity Reversal and CFR Norm or Cut Normal Cut Normal Cut
Power conservation mode with Soft pot Timer Normal Normal Cut Cut Normal
Power conservation mode with Soft pot Timer and CFR Norm or Cut Normal Cut Cut Cut
High and Low track sensors Norm or Cut Cut Normal Normal Normal
High and Low track sensors and CFR Norm or Cut Cut Normal Normal Cut
Minimum power (Soft) pot with fixed soft-start Norm or Cut Cut Normal Cut Normal
Minimum power (Soft) pot with fixed soft-start and CFR Norm or Cut Cut Normal Cut Cut
High and Low track sensors and Polarity Reversal Norm or Cut Cut Cut Normal Normal
Two Speed Pots with Soft pot as 2nd speed Norm or Cut Cut Cut Normal Cut
Minimum power and output turns off if Main Pot is zero Norm or Cut Cut Cut Cut Normal
Revert to Standard Program Norm or Cut Cut Cut Cut Cut
Table 1
Program Jumper Locations:
CFR
TB1
TB2
POL
437659812 11 10 12
89106734512 1211
Bottom Side of Board
INV
60Norm
120
J1
43658710 91112
91067845123 12
11
OFF SOFT
ON MAX



J8
CFR
CO
TB1
TB2
12
J8 H POL CO CFR
H
CO
H
J8
POL
F
C
-
90
Pl
us
ADV B
So
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t
w
a
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.
doc
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2
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page
4
RODIX INC.
FEEDER CUBE


FC-90 Plus Series
Plus SeriesPlus Series
Plus Series




1. Constant Feed Rate (CFR): A Rodix vibration
sensor P/N 123-170 can be added to allow the control
to regulate the vibration level of a vibratory feeder.
The regulation provides a constant feed rate of parts
to the machine process. Activating the “CFR”
program converts the 4-20mA speed-control input
feature to the CFR input feature. See the “Jumper
Programming Chart” for programming details. The
CFR sensor attaches to the feeder and its
connections are shown in Figure 1. For more
information about the CFR feature, call Rodix or
download the CFR application note.
Figure 1
If the 4-20mA analog speed control is needed along
with the constant feed rate feature, convert the board
to the constant feed rate feature. Then use a P/N
123-164, 4-20mA accessory board to bring the 4-
20mA signal into the pot input J1 of the circuit board.
2. Constant On: This software feature allows a high
feed rate application to keep the feeder running all of
the time (ON). The part sensor is used to switch an
auxiliary device like an air valve ON and OFF through
the Auxiliary output (TB2-1, 2, & 3). The air valve then
blows unwanted parts back into the bowl when the
inline has enough parts. An air valve can be operated
by the Aux. output by using one of the two connection
schemes shown below in Figures 2 & 3. The Constant
On feature automatically disables the Line Voltage
Compensation feature.
Figure 2
3. 60 Pulse Polarity Reversal:Normally in the 60
Pulse (half-wave rectified) mode, the output
voltage is turned on only during the bottom half of
the sine wave. However with the 60 Pulse Polarity
Reversal software feature, the top half of the sine
wave is used instead of the bottom half.
Use this feature to reduce mechanical interaction
between two vibratory feeders. Mechanical
interaction can occur when both feeders use the 60
Pulse mode and they share the same machine base.
Mechanical interaction can cause the vibration from
one feeder to effect the other feeder. A typical
symptom of this is when turning one feeder’s
vibration up causes the vibration to increase or
decrease on the other feeder. To solve this problem,
more mass can be added to the machine base, or
use the Polarity Reversal feature. This feature alters
the timing on one feeder so that each feeder is
pushing against the machine base at a different time.
A second reason for reversing the polarity of the 60
pulse waveform is to reduce the apparent power
when two or more feeders are connected to the
same branch of an electrical power distribution
circuit. An example is a vibratory feeder system
where each unit is set to 60 pulse mode. If there is
a hopper feeding at 1.5 Amps, a bowl feeding at 5
Amps, and an inline feeding at 1 Amp, then the
measured current of the branch would be 7.5 Amps.
But if the 60 pulse waveform were reversed on the
bowl, then the apparent current of the branch would
be reduced some because the current flows in both
directions instead of only one. This would cause the
branch step down transformer to operate a little
cooler and the measured wattage at the utility meter
to decrease. See the “Jumper Programming Chart”
for programming details.
Figure 3
4. High and Low Track Sensors: This option
maintains the parts level between a high-level
sensor and a low-level sensor on the track. One
purpose for this is to keep a consistent reservoir of
parts on the track so the machine process does
not run out of parts without causing too much back
pressure. This feature also can be used to make
a feeder bowl run more efficiently because it only
turns ON when parts are needed, and it only turns
OFF when the track is full of parts. Better
efficiency reduces the amount of wear on the
tooling of the feeder bowl.
When the parts level drops below the low-level
parts sensor, the feeder turns ON after any time
delay. The feeder runs until the parts reach the
high-level shut off sensor and the timer times out.
The feeder stays off until the low-level is reached
again. See the “Jumper Programming Chart” for
programming details.
Two parts sensors are required. The first sensor
connects as normal to the Sensor input. It does
not matter whether the high or low level sensor is
connected to the Sensor input or the Run input.
The wiring for Sensor input is as follows: TB2-4 is
ground. TB2-5 is the Signal. TB2-6 is +12VDC.
The second parts sensor connects to the Run
input. The wiring for the Run input is as follows:
TB2-7 is ground. TB2-8 is the Signal. TB2-9 is
+12VDC.
FC-90 Plus ADV B Software.doc 2/26/03 page 5
10 912
123-170
TB2
11
+
Br
Bu
-
CFR
MAX
J8
CFR
SENSOR
CO
HBR1
C11
3 12
+
T
B2
-
JMP 1
1N4006 RECTIFIER DIODE
A
IR VALVE
(12VDC, 0.6 WATTS)
2 1
T
B2
-
+
JMP1
3
SSR
A
IR VALVE
109-11 ~
VAC

5. Power Conservation Mode: Wasted power and
unnecessary wear on feeder tooling is the result of
“parts jams” and “feeder out of parts” conditions. The
“power conservation mode” can turn the feeder OFF,
and turn the auxiliary output ON when these
conditions occur. Turning the auxiliary output ON
allows operators to be notified through a solid-state
relay and a light stand or by communicating to a
24VDC PLC input. Note: The auxiliary output must be
isolated when connecting it to a 24VDC PLC input.
See the FC-90 Plus Advanced Application note for
further information.
In the power conservation mode, the Soft-Start
trimpot serves as the power conservation timer. It has
an adjustable time delay setting of 2 seconds (CCW)
to 8.5 minutes (CW). The soft-start function becomes
fixed at 1/4 Second. When the power conservation
timer expires, the control shuts OFF because it has
been running for too long. The conservation timer set
point should adjusted so that nuisance time outs do
not occur.
Note: When the power conservation timer is used, the
Hopper/Bowl Interlock feature no longer functions
correctly.
To restart the control after the conservation timer has
timed out, cycle it OFF and then back ON again. Use
one of the following methods: cycle it at either the
Run input (TB2-7, 8, & 9) or the Sensor input (TB2-4,
5 & 6), or turn the power switch OFF and ON, or turn
the Main pot to zero and back up again. One easy
restart method is to use a momentary Reset Switch
(normally closed) wired in series with the Run input at
TB2-7. See the “Jumper Programming Chart” for
programming details.
6. Two-Speed Pot Operation: Some vibratory feeder
applications need to operate at two different speeds.
For example: Nail feeders operate on low speed while
starting up the machine, and then switch to high
speed for normal operation. Packaging machines
operate at high speed while filling the package. When
the package is nearly full, it switches to low speed to
accurately finish filling it.
For the two-speed operation, the Main Pot sets the
one speed, and the SOFT trimpot sets the other
speed. The soft-start function becomes fixed at 1/4
second. The part sensor is used to switch between
the two speeds. See the “Jumper Programming
Chart” for programming details.
7. Minimum Power Trimpot: The Minimum Power
trimpot feature allows the vibratory feeder to operate
at the minimum acceptable feed rate when the Main
Pot is at “0”. The Soft-Start trimpot serves as the
Minimum Power trimpot, and the soft-start function
becomes fixed at 1/4 second.
When very precise adjustment of the Main Pot is
needed, increase the MIN trimpot setting and/or
decrease the MAX trimpot setting so that the range
of the Main Pot is reduced. When this feature is
used in conjunction with the CFR feature, the precise
Main Pot adjustment aids the operator in setting the
desired feed rate. See the “Jumper Programming
Chart” for programming details.
8. Min pot and Output turns off if Main pot is
zero:
The Minimum Power trimpot feature allows the
vibratory feeder to operate at the minimum
acceptable feed rate when the Main Pot is set above
“0”. The Minimum Power trimpot is only operational
when the Main Pot is set higher then “0”. The Soft-
Start trimpot serves as the Minimum Power trimpot,
and the soft-start function becomes fixed at 1/4
second.
When very precise adjustment of Main Pot is
needed, increase the MIN trimpot setting and/or
decrease the MAX trimpot setting so that the range
of the Main Pot is reduced. When this feature is
used in conjunction with the CFR feature, the precise
Main Pot adjustment aids the operator in setting the
desired feed rate. See the “Jumper Programming
Chart” for programming details.
9. Revert to Standard Program: It is possible to
revert back to the “Standard Program” if a program
variation is attempted and does not work out as
expected. If needed, wire jumpers can also be
installed at the Rodix factory to bypass undesired
cuts. See the “Jumper Programming Chart” for
programming details.
RODIX, INC.
4904 Colt Road, Rockford, IL 61109
Toll Free [phone]
E-mail custserv[email protected]
FAX [phone]
www.rodix.com
FC-90 Plus ADV B Software.doc 2/26/03 page 6

10. Low Pulse Rate: 30, 20, 15, or 10 PPS (Pulse-
Per-Second) Output: With 60 Hz input power, this
option allows the control to produce frequencies of
30, 20, 15, and 10 PPS. (For 50 Hz input power, the
frequencies are 25, 16.6, 12.5, and 8.3 PPS).
Vibratory feeders with large parts, large tray feeders
and a few inline track applications may operate below
60 PPS. A vibratory feeder that is converted to a
lower pulse mode will require fewer springs.
The theory behind the “Low Pulse Rate” option is that
the output of the control can be turned ON and OFF
to simulate the desired low frequency waveform.
Current flows through the vibratory feeder
electromagnet coils during the ON time, and the coils
are OFF the rest of the cycle. The output frequency
depends on how low long it takes to complete one ON
and OFF cycle. To simulate the desired frequency,
the output is turned on (ON time) for a series of 60 Hz
pulses, and then it is turned off (OFF time) for the
same amount of time. An example of this is shown in
the waveform titled “Current Waveform, 10Hz. One
second is shown in this window”. Since the vibratory
feeder is tuned to a resonate frequency, it is
stimulated by the desired frequency, but it is unable to
respond to the higher 60 Hz modulating frequency.
Simulating 30 Hz or lower with Alternating Current
(AC) instead of using Direct Current (DC) will
decrease the amount of work that is done by the
vibratory feeder coils, which will decrease the feed
rate of the machine. This is because the output of the
control provides AC, and not DC. DC provides more
power than AC during the same amount of time. This
is because Direct Current is flowing during the entire
ON time, however Alternating Current isn’t flowing as
much of the time because it periodically goes to 0
amps. The coil size and the coil gap determine the
maximum current draw of the vibratory feeder
system. When sizing a distribution transformer for
this control, the transformer will need to be oversized.
Operation: See the “Jumper Programming Chart” for
programming details. Jumper "D" selects which
frequency range to use, 30/15 Hz or 20/10 Hz. Next,
the pulse mode is selected with the 60/120 switch.
Note: The Low Pulse Rate feature disables the Line
Voltage Compensation feature.
Pulse mode selection:
When using the 30 Hz/15 Hz range, select "120" on
the 60/120 switch for 30 Hz and "60" for 15 Hz.
For the 20 Hz/10 Hz range, select "120" on the
60/120 switch for 20 Hz and "60" for 10 Hz.
During the initial operation of the control on the
machine it is important to monitor the temperature of
the coils on the vibratory feeder. If the coils become
too hot to touch, the coil current is too high.
Decrease the MAX pot setting and re-apply power
when the coils have cooled. Overheating the coils
will eventually cause them to short circuit and fail.
Low Pulse Rate Waveforms
that produce 10HZ
Current Waveform, 10Hz.
One second is shown in this window. The Off/On
cycle repeats 10 times per second to provide
10Hz.
Enlarged Current Waveform, 10Hz.
0.1 Second is shown in this window. The current is
on for 3 sine waves then off for 3 sine waves.
FC-90 Plus ADV B Software.doc 2/26/03 page 7