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Advanced Application Notes

6000 Series Controllers
OVERVIEW: This document covers the advanced features of the 6000 series controller circuit boards. The
circuit boards contain four (4) program jumpers that can be cut in order to enable alternate program features. The
program features should be chosen based on the customer application.
PROGRAMMING: By cutting the correct jumper combination, it is possible to run a desired program instead of the
"standard program". The four program jumpers on the circuit board are labeled A, B, C, and D. The program
jumpers are actually circuit board traces located between two holes (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 by circling their letters on the label that reads
PROGRAM: A B C D. The control comes from the factory configured with the “standard program.” The different
program variations and their descriptions are listed below:

Jumper Programming Chart Jumper Positions

Program Description “A” “B” “C” “D”
Standard Program Normal Normal Normal Normal
60 Pulse Pol. Rev. (Polarity Reversal) Normal Normal Normal Cut
Main Pot Follows Fixed Curve Normal Normal Cut Normal
Main Pot Follows Fixed Curve & Pol. Rev. Normal Normal Cut Cut
Output turns off at “0” on Main Pot Normal Cut Normal Normal
Output turns off at “0” on Main Pot & Pol. Rev. Normal Cut Normal Cut
Minimum pot is disabled Normal Cut Cut Normal
Minimum pot is disabled & Pol. Rev. Normal Cut Cut Cut
Power conservation mode w/Min pot Timer Cut Normal Normal Normal
Power conservation mode w/Min pot Timer & Pol. Rev. Cut Normal Normal Cut
Two Speed Pots w/Min pot as “Low” speed Cut Normal Cut Normal
Two Speed Pots w/Min pot as “Low” speed & Pol. Rev. Cut Normal Cut Cut
Low Pulse rate - 30 or 15 Pulse per second output Cut Cut Normal Normal
Low Pulse rate - 20 or 10 Pulse per second output Cut Cut Normal Cut
Standard Program Cut Cut Cut Normal
Standard Program Cut Cut Cut Cut
FEATURE DESCRIPTIONS: C13
Revert Back to the Original Program: If a program variation is attempted
which does not function as desired, it is possible to revert back to the
“Standard Program” by cutting jumper locations “A”, “B” and “C”. If BAS
needed, wire jumpers can also be installed at the ADI factory to bypass Automation Devices
undesired cuts. Program: A B C D

“60 Pulse Polarity Reversal”: Normally in the 60 Pulse (half-wave Q3 R33 U3

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 MOV 1
feature, the top half of the sine wave is used instead of the bottom half.
A B C D
Use this feature to reduce mechanical interaction between two vibratory
feeders. Interaction occurs when both feeders use the 60 Pulse mode and TB1
they share the same machine base. This can cause the vibration from one
1 2 3 4 5 6 7 8 9
feeder to effect the other feeder. A typical symptom of this is when turning
one feeder’s vibration up causes the vibration to decrease on the other
one, and vice versa. To solve this problem more mass can be added to
the machine base or use the Polarity Reversal feature to alter the timing on Fig. 1 Program Jumper Location
one feeder so that each feeder is pushing against the machine base at a on 24-480 and 24-481 PCBs
different time. See the “Jumper Programming Chart” to see which
IH08.02 - Advanced App 121906.doc Page 1
jumper(s) needs to be cut to enable this software feature.
“60 Pulse Polarity Reversal continued”: A second “Power conservation mode with Min Pot Timer”
reason for reversing the polarity of the 60 pulse Use this in applications where an interlock output or
waveform is to reduce the apparent power when two a relay contact is used to frequently turn off the
or more feeders are connected to the same branch of output of the control. When the vibratory feeder is
an electrical power distribution circuit. For example, turned on continuously longer than the time delay set
on a vibratory feeder system where each unit is set by the MIN trimpot, a problem exists such as a parts
to 60 pulse mode, if there is one hopper feeding at jam, or the vibratory feeder is out of parts. Since a
1.5 Amps, one bowl feeding at 5 Amps, and one problem exists, the output is turned off after a time
inline feeding at 1 Amp, then the measured current of delay to conserve power or to prevent parts/feeder
the branch would be 7.5 Amps. But if the 60 pulse wear. When this feature is used, the MIN trimpot
waveform were reversed on the bowl, then the function is converted to the “power conservation
apparent current of the branch would be reduced timer.” The MIN trimpot now sets a variable time
some because the current flows in both directions delay for .03 - 8 minutes. To restart the control, cycle
instead of only one. This would cause the branch it OFF and then back ON again at either the RUN
step down transformer to operate a little cooler and input (J1 at terminals 6&7), or the Auxiliary input
the measured wattage at the utility meter would also (TB2-11&12). Or turn the Main pot to zero and back
decrease. See the “Jumper Programming Chart” for up again. See the “Jumper Programming Chart” for
programming details. programming details.

Main Control Dial Follows a Fixed Curve: The “Two-Speed Pot operation”: Some vibratory feeder
output power is controlled by the Main Control Dial. applications need to operate at two different speeds.
With the standard program, a special logarithmic- For example: Nail feeders operate at low speed while
tapered power out curve (non-linear) makes it easier starting up the machine, and then switch to high
to have "Fine Control" over the output speed of the speed for normal operation. Packaging machines
vibratory feeder. Also, the Max trimpot setting alters operate at high speed while filling the package,
the slope of the non-linear curve. when the package is nearly full they switch to low
speed to accurately finish filling it.
When this feature is enabled, the Main Control Dial
follows a fixed curve instead of the standard non- For the two-speed operation, the Main Pot becomes
linear curve. This feature is used when it is desirable the Normal speed pot, and the MIN trimpot becomes
to have the numbers on the Main control dial indicate the Low speed pot. When this feature is used, the
an actual power setting. (Where "7" on the dial is MIN trimpot no longer controls the minimum power
meaningful). level of the control. See the “Jumper Programming
When the fixed curve program is used, the MAX Chart” for programming details. The control can be
trimpot limits the effective range of the Main control signaled by two different methods to switch between
dial. The MAX trimpot creates a dead band at the the Low and Normal speed pots.
top end of the Main control dial so that increasing the
Main control dial does not increase the output power An Electrical contact can signal the control when to
of the control. When the fixed curve program is switch between low and normal speeds. Low speed
used, the MIN trimpot is automatically disabled. is obtained when terminals TB2-5&6 are connected.
Caution – This program makes it harder to precisely Normal speed is used when both TB2-5&6 and TB2-
adjust the Main control dial. See the “Jumper 6&7 are connected. The output is OFF when
Programming Chart” for programming details. terminals TB2-5&6 are not connected.

Output Turns Off at “0” on Main Pot: With this A Voltage signal can signal the control when to
software feature enabled, the Main pot can be set to switch between low and normal speeds. Low speed
zero when no vibration is desired. This can be done is obtained when terminals TB2-5&6 are connected
instead of turning the power switch off. This may be and there is no voltage present at the Interlock Input,
handy when clearing a part jam or when manually TB2-10, 11,12. When a voltage signal is properly
removing parts from a feeder during a change over to applied at the Interlock Input, the Normal speed is
a different part. The MIN trimpot serves to set the enabled. The voltage signal can be 5-30VDC or
minimum power level at “1” on the dial. The Main pot 105-250VAC. See the ON/OFF control guide for
turns up from there until “10” on the dial, which is set TB2-10, 11,12 wiring details. The output is OFF
by the MAX trimpot. when terminals TB2-5&6 are not connected.

MIN Trimpot Disable: When it is not desirable to

use the Minimum trimpot, it can be turned fully
counter clockwise, or its operation can be disabled.
See the MIN trimpot disable on the “Jumper
Programming Chart”.
IH08.02 - Advanced App 121906.doc Page 2
“Low Pulse rate” – 30, 20, 15, or 10 Pulse per Low Pulse Rate Waveforms
second output: With 60 Hz input power, this option that produce 10HZ
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 Current Waveform, 10Hz.
Waveform, 10Hz. One second is shown in this One second is shown in this window. The Off/On
window”. Since the vibratory feeder is tuned to a cycle repeats 10 times per second to provide 10Hz.
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.
Enlarged Current Waveform
Operation: See the “Jumper Programming Chart” for 0.1 Second is shown in this window. The current is
programming details. Jumper "D" selects which on for 3 sine waves then off for 3 sine waves.
frequency range to use, 30/15 Hz or 20/10 Hz. Next,
the pulse mode is selected with the 60/120 switch. INPUT VOLTAGE: The 24-480 circuit board will
operate from 90-120VAC +/- 10%. The 24-481
Pulse mode selection: circuit board will operate from 180-240VAC +/- 10%.
For the 30 Hz/15 Hz range, select 120 on the 60/120
switch for 30 Hz and 60 for 15 Hz. NOISE IMMUNITY: For further details about noise
immunity, see the application note for your model in
For the 20 Hz/10 Hz range, select 120 on the 60/120 the instructions and the Automation Devices Good
switch for 20 Hz and 60 for 10 Hz. Wiring Practices for Avoiding Electrical Noise
Problems.
During the initial operation of the control on the Automation Devices, Inc.
machine it is important to monitor the temperature of 7050 West Ridge Road
the coils on the vibratory feeder. If the coils become Fairview, PA 16415-2099
Phone: 814-474-5561
too hot to touch, the coil current is too high.
FAX: 814-474-2131 or 800-235-9382
Decrease the MAX pot setting and re-apply power Web Site: WWW.AUTODEV.COM
after the coils have cooled. Overheating the coils will E-mail: [email protected]
eventually cause them to short circuit and fail.
IH08.02 - Advanced App 121906.doc Page 3