Firgelli's popular new Control Boxes are becoming common in the automation world. With their new-found ubiquity, we decided to give our customers as much information about these boxes as we (reasonably) can.
FCB Setup & Wiring (All Models)
Wiring Guide (Feedback Actuators)
The FCB-1 model I was released in 2023. This first version of the control box included all listed features except for the 'feedback off' function described in this article. In 2024, Firgelli released the FCB-1 model II; with that feedback toggle as the only change to the unit. The FCB-2 also has this feature.
Feedback: On or Off? What's the upside?
Feedback is when there is a sensor inside the actuator that gives a feedback signal to the control box or PLC. Feedback is required for any position-based processing done by the system (limits, precisely even ['synchronized'] motion).
The FCB with Feedback Off is a power distributor for a tandem system. You will lose the 1/8" synchronous precision of the attached actuators and be unable to set limits to their motion. It can still reduce the speeds of the actuators, and move them as commanded; timers and manual functions are unaffected.
This feature means the FCB-2 (and most FCB-1s) can run multiple non-feedback actuators at once. Now, all actuators can operate on the FCB control boxes.
[New] FCB Settings & Functions (2024 Model and newer)
The New Firgelli Control Box with Integrated RF (model FCB-2) has all the best features of both previous FCB-1 models, plus a built-in RF Remote Receiver, connected to our standard RC5 remotes (from our 2 channel RF system). This control box can be paired with up to 4 remote transmitters at once, without interference.
FCB restrictions and workarounds (All Models)
If the FCB loses or is removed from power, the board will think that the units are fully retracted when it is plugged back in. The computer 'brain' initializes with the current position set as the 'home' position; which causes this consideration. We have 3 possible work-around/procedures for dealing with this condition:
- If you can fully retract (“home”) the actuators before removing power -or- run the homing sequence immediately after power is restored, your system will resume normal function.
- Customers have used 12v back-up batteries to prevent FCB power loss, which eliminates the need for homing.
- Lastly, The FCB cannot tell the difference between internal limit switches and external limit switches in the actuator's motor circuit; so, in applications that cannot allow a full retraction, an external limit switch can serve as a ‘hard stop’ for the system without confusing the FCB ‘brain’, though some FCB settings may need to be adjusted for precision.
Electrical Considerations
The FCB will tolerate up to 10A per channel, or 40A total. The Board itself will draw up to 3A during operation [proportional to actuator load], and less than 0.1A when idle (screen off).
Compatible Actuators - Pulsing Binary Sensors (Hall Effect)
Non-Compatible Actuators
- Industrial Heavy Duty (HD-2200)
- Power Max (PM-H-900/1500)
- Feedback Rod Linear Actuators (FA-PO-) - Potentimeter Feedback
We have 2 actuator lines with a high current draw, the Power Max and Industrial Heavy Duty actuators. Both of these units can pull 20 amps at full load or during startup – this current draw is too high for most of our out-of-the-box controllers, including the FCB-1. While the sensor will function with these units, the motor's draw is simply too high.
The 12v version of our 500lbs Bullet .50 Actuators can pull 10A at startup or max load – 10A is the maximum allowable current per channel on the FCB. If you are using the 500# units, you must leave the speed settings at 100%. We recommend using a higher force Bullet .50 model instead.
Errors & Troubleshooting
The FCB will display error messages in the event of operation failure. Overcurrent or Stuck.
Usually, issues with the board are because of a sensor-connection error. Most of your sensor-feedback actuator wires are for the sensor circuit, so double check that they are all well connected within the green cradles and there are no cuts or holes in the wire.
The “Stuck” error means that your FCB can’t see the sensor return-signal from the actuators. This could be due to loose or incomplete wire connections, voltage drop over a wire run, a bad port on the board, a bad sensor inside the actuator, or an external component (like the POCT). Your actuator motors are working fine if the unit is moving at all.
Troubleshooting Steps:
- Switch the green terminal connectors around on the board and attempt to home and calibrate again. Note whether the ‘stuck’ code is following the actuator, or the position on the board.
- You may also set all DIP switches to down and test the calibration of one actuator at a time.
- If the problem actuator(s) still say they are “stuck” when it is the only one connected, we know that’s the problem unit. Check the wiring of the problem actuator for damage.
- Then, remove the problem actuator, and re-connect all working units, adjust DIP switches and re-home, re-calibrate, re-test to ensure that the remaining actuators and FCB are communicating with each other.
You will either end up with a specific unit that doesn’t function with your FCB, or none of your units will function correctly (which means the problem lies in the FCB itself). Report back with findings and we can go from there for further TS or Warranty claims.
