RODIX, INC.

FC-90 Plus & CFR-90 Plus Series Troubleshooting Guide

for Circuit Board P/Ns 24-490 and 24-491
Control MUST be connected to a known GOOD LOAD prior to testing
Problem: Possible Cause: Solution:
No output from the No AC line voltage Check power to control.
control
No AC voltage on circuit board at Check / Replace Fuse
terminal block TB1: 1, 2 & 3 are HOT Check / Replace Control Switch
5, 6, 7 & 8 are COM
Run Jumper is missing from TB2-8 & 9 Install Run Jumper or close Run Contacts
or Run Contacts are not closed “RUN” LED light lights up when made.
60/120 Pulse switch is in the wrong Change switch setting (If this does not work,
position. (It gives the appearance of no reset the switch to its original setting).
output) Measure output voltage with load connected

**Bad parts sensor or incorrect parts Test: Turn ON delay counter-clockwise.

sensor setup Then, flip “INV/NORM” switch, if control
runs, sensor setup is incorrect. Check
“NPN” and “PNP” status LEDs.
Max Pot on board turned fully counter- Adjust Max Pot per the control’s application
clockwise note.
*Damaged pot/cable assembly Replace pot/cable assembly
***Bad control board Replace control board
Feeder only hums or
moves parts slowly 60/120 pulse switch is in the wrong Change switch setting (If this does not work,
position reset the switch to its original setting)
Max pot set incorrectly Adjust Max pot per the control’s application
note
Potential Feeder problem Download Rodix Solution “Control or Feeder
Problem?”
Electrical noise has disrupted the unit Download Rodix Solution “Good Wiring
Practices”
Electrical noise has disrupted the Turn the main pot fully counter-clockwise,
sensor/control signal and then turn the main pot up to the desired
feed rate. Also, download Rodix Solution
“Good Wiring Practices”
*** Bad control board Replace control board
Full output with no Control is not connected to a known Connect a load to the unit
change in the output good load
when the control knob
is adjusted ****The TRIAC on the unit is shorted Replace TRIAC (P/N 115-32)
Max pot set incorrectly, or Adjust Max Pot per the control’s application
MIN pos set incorrectly note
CFR Sensor detached from feeder Re-attach the sensor to the feeder.
Additional tape is available from Rodix
***Bad control board Replace control board

The output power is The feeder vibration is near 25g of Rotate the CFR sensor about 15 degrees so
reduced automatically acceleration, and it is exceeding the that its sensitive axis gets less vibration.
after the Main pot is range of the sensor. (see unit’s application note)
increased.
FC & CFR-90 Plus T-guide 9/23/2009 Page 1
 FC-90 Plus / CFR-90 Plus Series Control Troubleshooting Guide - Continued
Problem: Possible Cause: Solution:
Erratic output when *Damaged control pot on main lid Check or replace pot/cable assembly
adjusting main
control knob *** Bad control board Replace control board

Erratic output when Potential Feeder problem Download Rodix Solution “Control or
making no Feeder Problem?”
adjustment to the Electrical noise has disrupted the unit Download Rodix Solution “Good Wiring
control. Practices”
50Hz generator produces electrical noise Use utility power when available
transients (where used)
Output is not Delay trimpots set wrong Turn the delay trimpots fully counter-
turning ON and OFF or input INV/NORM switch set wrong clockwise and change switch setting (If
properly or both trimpots and switch set wrong changing switch setting does not work,
reset the switch to its original setting)
Sensor turns aboard LED on and off but Select NPN or PNP sensor type on S1.
the output remains either off or on. Check NPN/PNP status LEDs.
**Bad sensor Replace sensor
***Bad board Replace control board
Interlocked board Run jumper or paddle switch may not be See control’s application note for to
does not turn off across interlock terminals (where used) determine proper interlock connections
with the CFR-90
Plus board

The CFR sensor is CFR switch S1 is set to 4-20mA Set S1 to CFR position to enable CFR
not regulating the Broken or detached CFR sensor cable. Reconnect CFR sensor cable.
feeder speed
CFR Sensor is no longer attached to the Re-attach the sensor to the feeder.
vibratory feeder. Additional tape is available from Rodix.
Main pot is set to “10”. Adjust Max Pot per the control’s
application note.
CFR control settings were changed (Max Readjust the Main Pot to the desired feed
Pot, 60/120 switch, INV/NORM switch). rate.
Or the Main Pot was changed while the
control was idle.

The Vibratory feeder The CFR control is overcompensating for Rotate the CFR sensor about 15 degrees
oscillates by itself changes in vibration. A small amount of so that its sensitive axis gets less
oscillation shows that the feedback from vibration. (see unit’s application note) If
the sensor is working. the part feed rate is acceptable and no
part jams occur, a small amount of
oscillation is acceptable.
* To test if the Main control pot is functioning correctly, use the following method: un-plug the three-pin, pot-wire connector.
Using an Ohmmeter, measure the resistance from the center lead of the Pot to one of the outside leads. The resistance should
vary smoothly from 0 to 100K Ohms as the main control knob is turned. Repeat from the center wire to the other lead.
*** To determine if the problem is in the feeder or the control: down load Rodix Solution “Control, Feeder or Power Line Solution.”

Note: Malfunctioning controls and/or circuit boards can be sent back to Rodix Inc. for repair or to be updated to the
rd
latest revision. Please send in the product to Rodix Inc., 2303 23 Avenue, Rockford IL 61104, Attention Repair
Department. Please include your address, telephone number, name of person to contact and a description of the
symptoms of the control problem. For further assistance visit www.rodix.com or call us at 800-562-1868 extension 22.
 1998, 2009 Rodix Inc. FC & CFR-90 Plus T-guide 9/23/2009 Page 2
 RODIX, INC.
FC-40 Plus Series Control
Troubleshooting Guide for Circuit Board P/Ns 24-480 and 24-481
Control must be connected to a known GOOD LOAD prior to testing

Problem: Possible Cause: Solution:

No output from the No AC line voltage Plug in control.
control
No AC voltage on circuit board at Check / Replace Fuse
terminal block TB1: 1, 2 & 3 are HOT Check / Replace Control Switch
5, 6 & 7 are COM
Run Jumper is missing or Run Contacts Install Run Jumper or close Run
are not closed across TB2-5 & 6 Contacts (See the application note for
OR TB2-6 & 7 the control’s interlock connections)
60/120 Pulse switch is in the wrong Change switch setting (If this does not
position. (It gives the appearance of no work, reset the switch to its original
output) setting)
RTV on pins of Main pot connector J1 Clean J1 pins
(boards manufactured before 1/2000)
Max Pot on board turned fully counter- Adjust Max Pot per the control’s
clockwise application note
Damaged pot/cable assembly Replace pot/cable assembly
**Bad control board Replace control board

Feeder only hums or 60/120 pulse switch is in the wrong Change switch setting (If this does not
moves parts slowly position work, reset the switch to its original
setting)
Max pot set incorrectly Adjust Max pot per the control’s
application note
Potential Feeder problem See Rodix Solution “Control, Feeder or
Power Line Problem?”
Electrical noise has disrupted the unit Download Rodix Solution “Good Wiring
Practices”
** Bad control board Replace control board
Full output with no
change in the output Control is not connected to a known Connect a load to the unit
when the control good load
knob is adjusted ***The TRIAC on the unit is shorted Replace TRIAC (P/N 115-32)
Max pot set incorrectly Adjust Max Pot per the control’s
application note
**Bad control board Replace control board
Erratic output when *Damaged control pot on main lid Check or replace pot/cable assembly
adjusting main
control knob ** Bad control board Replace control board

2/12/01
 FC-40 Plus Series Control Troubleshooting Guide-Continued
Problem: Possible Cause: Solution:
Erratic output when Potential Feeder problem Download Rodix Solution “Control or
making no Feeder Problem?”
adjustment to the
control. Electrical noise has disrupted the unit Download Rodix Solution “Good Wiring
Practices”
50Hz generator produces electrical Use utility power when available
noise transients (where used)
Feeder changes Bowl is overloaded or underloaded Maintain correct depth of parts in bowl
speed by itself or use a Constant Feed Rate control
Line voltage fluctuations See Rodix Solution “Control, Feeder or
Power Line Problem?”
Potential Feeder problem See Rodix Solution “Control, Feeder or
Power Line Problem?”

Interlocked board Run jumper or paddle switch may not be See the application note for the
does not turn ON across interlock terminals TB2-5 & 6 control’s interlock connections
and OFF with the
FC-90 Plus board Paddle switch contacts may not be Adjust switch position
making contact. or Replace switch contacts
No +12VDC across TB2-11(-) & 12(+) FC-90 Plus control is not feeding parts.
Or interlock wiring may be missing or
wrong.
** Bad control board Replace control board

Interlocked board Run jumper or paddle switch may not be See the application note for the
does not turn ON or across interlock terminals (TB2-5 & 6) control’s interlock connections
OFF with a PLC
Interlock signal voltage may be missing See the application note for the
or wired incorrectly. +5-30VDC at TB2- control’s interlock connections
11(-) & 12(+) OR 105-250VAC at TB2-
10 & 12

Problems FC-40 Plus control does not have an Use an FC-90 Plus control to provide
Interlocking two FC- interlock output an interlock output for interlocking to an
40 Plus controls FC-40 Plus control
together

* To test if the Main control pot is functioning correctly, use the following method: un-plug the three-pin, pot-wire
connector. Using an Ohmmeter, measure the resistance from the center lead of the Pot to one of the outside leads.
The resistance should vary smoothly from 0 to 100K Ohms as the main control knob is turned. Repeat from the center
wire to the other lead.

** To determine if the problem is in the feeder or control: see accompanying Rodix Solution “Control, Feeder or
Power Line Problem.”

*** To test if the TRIAC is functioning correctly, down load Rodix Solution “TRIAC Troubleshooting Guide.”

Note: Malfunctioning controls and/or circuit boards can be sent back to Rodix Inc. for repair or to be updated to the
latest revision. Please send in the product to Rodix Inc., 2303 23rd Ave, Rockford IL 61104, Attention Repair
Department. Please include your address, telephone number, name of person to contact and a description of the
symptoms of the control problem. For further assistance visit www.rodix.com or call us at 800-562-1868 extension 22.

 1998, 2001 Rodix Inc. FC-40 Plus T-guide 2/12/01

 RODIX, INC.

Troubleshooting Guide for Three-Wire DC sensors

Control must be connected to a known GOOD LOAD prior to testing
*NOTE: RODIX Plus Series controls work with three-wire DC sensors with either an NPN or PNP output.
Always check for proper wiring of the sensor to the Rodix control. Check the sensor’s application note
and the Rodix control’s application note to determine what the correct sensor wiring should be. (Do not
use a two-wire DC sensor)
Most proximity switches and fiber-optic sensors have a red LED mounted in the back of the sensor which
lights up whenever it is sensing. If this is operational then the sensor is typically good. Occasionally the
vibration movement of a track can interrupt the beam of an optic sensor causing ON/OFF delay problems.
Most fiber-optic sensors, such as the Banner sensors, have a Light/Dark operate switch and a sensing-
distance (gain) adjustment in the rear of the sensor. Turn the gain Pot fully clockwise for maximum
sensing distance. If the sensor is turning On and Off at the desired sensing distance, but not in the
correct sequence (OFF when supposed to be ON, ect.), then flip the "INV/NORM" switch inside the Rodix
control.

The parts sensor’s output may be either NPN or PNP. The NPN/PNP switch on the control must be set to
match the type of sensor being used, NPN or PNP.
Problem: Possible Cause: Solution:
LED will not light End of cables covered with dirt, grease or Clean cable ends
oil Increase Gain adjustment
Clean sensor head with cotton swab
Cracked or broken cables Increase Gain adjustment
Replace broken cables
Test each cable: Plug both ends of one
cable into sensor, LED should light when
cable is good.
Poor alignment of cable ends across the Correct alignment: use a drill rod to verify
track correct alignment
Incorrect sensor wiring Correct the wiring: see the application notes
for the control and the sensor
Optic cables not fully inserted into sensor Insert cables fully into sensor

Sensor bad Replace sensor

LED is always ON Light is bouncing around the parts Decrease the Gain adjustment.
Mount the optics at a 45° angle to the track
and not a 90° angle. This way the beam
gets blocked by 2-3 parts.
Cable not fully seated in the sensor head Loosen screw and push cable ends further
of the Banner sensor in.

RODIX, INC.
rd
2303 23 Avenue, Rockford, IL 61104
Toll Free (800) 562-1868, FAX (815) 316-4701
E-mail custserve@rodix.com
www.rodix.com
FC & CFR-90 Plus T-guide 4/2/2009 Page 4
1994, 2009 Rodix Inc.
 RODIX, INC.
TRIAC Troubleshooting Guide
Use an Ohmmeter to test the TRIAC across the terminals described below (see the TRIAC
Reference Guide below for terminal locations).

Set the Ohmmeter to the highest Meg. Ohm scale for the following resistance
measurements. The resistance noted below is generally greater than 1Meg. Ohm. A
good TRIAC will match the conditions shown in the chart below.
Red Meter Lead Black Meter Lead Correct Result

Anode 1 Anode 2
High resistance in both directions
Anode 2 Anode 1

Measure the resistance between the terminals indicated by the following chart. The
resistance noted below is generally greater than 1Meg. Ohm. A good TRIAC will match
the conditions shown in the chart below.
Red Meter Lead Black Meter Lead Correct Result

Gate Anode 2
High resistance in both directions
Anode 2 Gate

Set the Ohm meter to the 1K Ohm resistance scale. Measure the resistance between the
terminals indicated by the following chart. The resistance noted below is generally 1K
Ohm or less. A good TRIAC will match the conditions shown in the chart below.
Red Meter Lead Black Meter Lead Correct Result

Gate Anode 1
Low resistance in both directions
Anode 1 Gate

If the resistance measurements match all of the above conditions, then the TRIAC is good.
If any measurements do not match all of the above conditions, replace the TRIAC.

TRIAC Reference Guide

Anode 2

RODIX, INC.
rd
2303 23 Avenue, Rockford, IL 61104
Anode 1 Gate Toll Free (800) 562-1868, FAX (815) 316-4701
E-mail custserve@rodix.com
www.rodix.com
1994, 2009 Rodix Inc. FC & CFR-90 Plus T-guide 4/2/2009 Page 3
 No vibration: Connect a volt meter to the The wiring and feeder coil resistance should
RODIX INC. output of the control and monitor the meter while measure well below 200 Ohms. If the resistance is
CONTROL, FEEDER OR adjusting the main control pot up and down. If greater than 200 Ohms, check for bad
POWER LINE PROBLEM? there is no voltage present, follow the connections. Then check with the manufacturer,
RODIX SOLUTION .308 recommendation given in the troubleshooting or replace open (bad) coils.
 guide for your control model. If there is a voltage If the coils check good, the TRIAC may be short
output, follow the procedure below. circuited. Follow the recommendation given in the
CONTROL, FEEDER OR POWER LINE
Not enough vibration and gradually troubleshooting guide for your model. A shorted
PROBLEM?
reduced vibration: Connect a volt meter to TRIAC provides full power in the 120 pulse mode.
Problems with vibratory feed systems generally fall If the vibratory feeder is tuned for 60 pulse, it will
the output of your control and monitor the meter
into three categories: mechanical feeder, power not vibrate.
while turning the main control pot clockwise. For
line fluctuations and control problems. To
controls set to 120 Pulse, the output should If there is still not enough vibration and the 60/120
complicate things, any of the three problems can
increase to within 2VAC of the incoming power. pulse switch and Max pot are set correctly, the
make a feeder vary its parts rate or slow down;
For controls set to 60 Pulse, the voltage problem may be a mechanical tuning problem.
therefore, careful attention needs to be given to
measured depends on the inductance of the Contact the manufacturer of the vibratory feeder
find the root cause of the problem. Let’s
feeder coils. The output voltage should increase for assistance with solving mechanical problems.
determine if the problem is with the control, with
to 80 - 110 volts with a 120VAC supply line or
the feeder’s mechanical tuning or with power line The following is list of some common electro-
160 - 220 volts with a 240VAC utility. If these
fluctuations. mechanical tuning problems:
values are not obtained, see the application note
TEST SET UP FOR TROUBLESHOOTING for setting the Max pot (where applicable). If the 1) Loose bolts, loose toe clamps, a missing bolt at
control is set up properly and it will not supply the center of the feeder bowl, etc. will cause a loss
The control must be in the “run” mode in order to in vibration. When tightening the bolts on the
test the output. If additional information is needed, the correct output voltage, then the control is
malfunctioning. Follow the troubleshooting springs and large toe clamps, use a three-foot-
the application note and troubleshooting guide for long cheater bar over the Allen wrench.
your control is available from our web site. guide’s recommendations.
2) Cracked or broken springs will cause a loss of
If full output voltage is achieved and there is not
Important: When checking the output voltage vibration. To check for a bad spring while the
enough vibration, check the 60/120 pulse switch
of a feeder control with a volt meter, always feeder is operating, lightly grasp a spring holding
set up. The control’s 60/120 pulse switch may
have a known good load connected to the the outside edges of the spring between your
be in the wrong position. If the feeder only hums
output so that the meter does not give false thumb and fingers. A bad spring will move from
and does not feed parts, turn the power off, and
readings due to TRIAC leakage current. side to side and feel different than a good spring.
flip the 60/120 switch on the circuit card. If it still
Repeat this for every spring.
Connect a voltmeter to the output of the feeder does not feed parts, turn the power off, and flip
the 60/120 switch on the circuit card back to the Another test for a cracked or broken spring is to
control. On some models this can be
original position. For an explanation of 60/120 remove the springs from the feeder. Lightly grasp
accomplished by backing the plug out of the outlet
pulse selection, down load the Rodix Solution a spring holding the outside edges of the spring
just a little so that the voltmeter leads can touch
“60/120 Pulses Output Selection." Note: the line between your thumb and fingers. Tap each end of
the flat blades of the plug. Always leave the load
frequency must be correct for the feeder used, the spring with a hammer. A good spring will ring
connected; otherwise, the meter readings will be
see electro-mechanical tuning problems part 7. like a bell. A bad spring will not ring.
incorrect.
For no vibration or low vibration at full output 3) Spring fatigue is a gradual degradation in spring
HOW TO USE THIS GUIDE
voltage, check the following: In rare cases a bad performance that happens over a period of months
The typical symptoms for an existing feed system coil or a bad connection can cause the vibratory or years. Spring fatigue will cause the operator to
are no vibration, low vibration, gradually feeder to stop vibrating, even though the output turn the control up gradually over a long period of
decreasing feed rate, fluctuating feed rate and too of the feeder control is at full voltage. To test for time until there is no more power available from
much vibration with no control. To use this guide, this condition, disconnect the wires going to the the control.
match the vibratory feeder’s symptom to the vibratory feeder, and use an ohmmeter to
corresponding problem listed in bold letters. measure their resistance. Use the lowest Ohms
Control, Feeder or Power Line Problem.doc 2/6/06
scale on the meter.
4) A broken weld on the vibratory feeder or drive is running its fastest and slowest. Also, record No Voltmeter Available?
base will cause a loss in vibration. Visually inspect what time the readings were taken. Find the If there is no voltmeter available, a quick function
and touch each welded joint. The vibration on both difference (in volts) between the readings by check of the feeder control can be made with a
sides of the joint should feel the same. If it feels subtracting the low voltage reading from the high light bulb (incandescent) such as a garage trouble
different, the weld may be cracked. voltage reading. light. Substitute the light bulb for the vibratory
feeder. A good control will act like a light dimmer.
5) The feeder/machine must be securely fastened Secondly, monitor the incoming line voltage to
A bad control will not be adjustable, or it will not
to the floor to avoid any movement of the drive the control where the feeder control power cord
light the light bulb when it is supposed to. For a
base. is connected to the power line. Record the
bad control, follow the recommendation given in
voltage reading when the bowl is running the
6) A bad coil(s) can reduce the vibration to a hum. the troubleshooting guide for the control model.
fastest and the slowest, also record what time
Check for magnetism at the air gap along side of the readings were taken. Find the difference (in
each coil and its pole face. Use the metal shaft of Troubleshooting guides & Application Notes
volts) between the readings by subtracting the
a screwdriver to feel the magnetic pull. Alternately, Rodix has troubleshooting guides available at
low-voltage reading from the high voltage
a clamp-on Amp meter can read the current for www.rodix.com, or call for technical support at 1-
reading.
each coil. If a coil has no pull or current flowing 800-562-1868 extension 22.
through it, it may have a bad connection, or it may Next compare the voltage difference values from
be damaged internally. step 1 and step 2. If they are about the same,
then the problem is with the incoming power
7) If the vibratory feeder is being set up after line. If the incoming power line voltage does not
importation from a foreign country, it may be tuned fluctuate, but the output voltage does, then the
for the wrong power line frequency. problem is in the control. If neither input nor
Too much vibration, with no control: The output fluctuates, but the feed rate fluctuates,
TRIAC has probably short circuited causing the then there is a mechanical problem in the
vibratory feeder to operate only at full power, vibratory feeder system. See the list of electro-
regardless of the Main Pot setting. Please refer to mechanical tuning problems on the previous
the TRIAC troubleshooting guide and the page.
troubleshooting guide for your control. Power line fluctuations can be caused by many
Feed rate fluctuations: The feed rate of a different factors such as too many loads being
vibratory feeder can fluctuate due to one of connected to a power panel branch circuit; a
several possible causes. The common causes are heavy momentary load like a machine nearby
listed here: Loose or broken springs, a bad starting up; too many loads (including the feeder
potentiometer, fluctuating weight of the parts in the control) are supplied by a long extension cord;
feeder bowl, bad DIAC for controls models FC-30 the utility supplied voltage to the plant varies at
different times of the day; a bad or loose fitting
through FC-90 Series (excluding Plus series
power outlet or connection.
controls) and fluctuations in the power line voltage.
Also, electricity produced by a motor–generator Line Voltage fluctuations can be overcome by
can produce variations in voltage and frequency. using a control that has a line-voltage- 1996, 2006 RODIX INC.
compensation feature. The FC-40-PLC Plus,
Power Line problem test: When the output voltage
changes by a few volts, the feed rate of the
FC-90 Plus, CFR-90 Plus series, and VF-9 RODIX, INC.
controls adjust the control’s output voltage to 2303 23rd Ave, Rockford, IL 61104
vibratory feeder will also change. To test for power compensate for power line fluctuations. In Toll Free (800) 562-1868, FAX (815) 316-4701
line problems, connect a voltmeter to the output of addition the CFR-90 Plus series and VF-9 E-mail custserve@rodix.com
the feeder control. First, monitor the meter while controls use a sensor that attaches to the feeder
the vibratory feeder is operating (“run” mode). www.rodix.com
to maintain a constant vibration level providing a
Record the output voltage readings when the bowl Constant Feed Rate to the machine process. Control, Feeder or Power Line Problem.doc 2/6/06