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anyfeed SX Feeder Series

Quick Setup and User’s Guide

flexfactory ag

02.2009

flexfactory ag Giessenstrasse 15 CH-8953 Dietikon

flexfactory ag Quick Setup Guide and User’s anyfeed SX Series 1

TABLE OF CONTENTS

List of Figures .............................................................................................................................. 3

List of Tables ............................................................................................................................... 5

1 Overview............................................................................................................................. 7

1.1 Introduction ................................................................................................................. 7

1.2 Technical Specifications ............................................................................................... 7

1.3 Alert notation .............................................................................................................. 8

1.4 Soand Emissions .......................................................................................................... 8

1.5 Working Areas ............................................................................................................. 8

1.6 Qualification of Personnel ........................................................................................... 9

1.7 Safety Equipment for Operators ................................................................................. 9

1.8 Protection Against Unauthorized Operation ............................................................... 9

1.9 Safety Aspects While Performing Maintenance ........................................................ 10

1.10 Risks That Cannot Be Avoided ............................................................................... 10

1.11 Risks Due To Incorrect Installation or Operation ................................................... 10

1.12 What to Do in an Emergency Situation .................................................................. 10

1.13 How Can I Get Help ................................................................................................ 11

2 Unpacking ......................................................................................................................... 12

2.1 Opening up the shipping crate .................................................................................. 12

2.2 Removing the feeder from the pallet ........................................................................ 12

2.3 Material Checklist ...................................................................................................... 13

2.4 Other Items You May Need to Set Up Your Application ........................................... 15

3 Installation ........................................................................................................................ 16

3.1 Introduction ............................................................................................................... 16

3.2 Mechanical Installation.............................................................................................. 16

3.3 Installing the Pneumatic Line for compressed air ..................................................... 20

3.4 Installing Cables and Power ....................................................................................... 20

3.4.1 RS232 Cable Pinout ............................................................................................ 23


3.4.2 Parallel I/O Cable ................................................................................................ 23

3.5 Testing the Installation .............................................................................................. 24

4 Operation with Serial Communications ........................................................................... 28

4.1 Program Flow ............................................................................................................. 28

4.2 Setting the Serial Communications Parameters ........................................................ 28

4.3 Serial Command Codes .............................................................................................. 29

4.3.1 Sending Commands to the anyfeed SX .............................................................. 29

4.3.2 Anyfeed SX Responses........................................................................................ 33

4.3.3 Command Parameters Default Values ............................................................... 35

5 Operation with Parallel Communications ........................................................................ 36

5.1 Preparing the feeder for parallel communications ................................................... 36

5.2 Parallel I/O Wiring Assignments ................................................................................ 39

5.3 Signal Handshake ....................................................................................................... 40

6 Maintenance and Settings................................................................................................ 41

6.1 Periodic maintenance ................................................................................................ 41

6.2 Removing and Installing the feed surface ................................................................. 41

6.3 Retainer Speed Settings ............................................................................................. 42

7 FOV Support Plate ............................................................................................................ 44

8 Backlight ........................................................................................................................... 48

8.1 Backlight Versions ...................................................................................................... 48

8.2 Preparing the INstallation .......................................................................................... 49

8.3 Installing the Backlight G1 ......................................................................................... 50

8.4 Installieren des Backlight G2 ..................................................................................... 51

8.5 Installing the LED Controller ...................................................................................... 52

8.6 LED-Controller/ Backlight Settings ............................................................................ 54

8.7 Function Check .......................................................................................................... 58

8.8 Configuring the LED Controller .................................................................................. 59


LIST OF FIGURES

Figure 1-1 anyfeed SX 240 .......................................................................................................... 7

Figure 2-1 anyfeed SX parts ...................................................................................................... 12

Figure 2-2 Mounting rail screws ............................................................................................... 12

Figure 2-3 Handles for lifting and positioning .......................................................................... 13

Figure 2-4 anyfeed SX feeder ................................................................................................... 13

Figure 2-5 SX Servo Power Cable ............................................................................................. 14

Figure 2-6 SX Logic Power Cable .............................................................................................. 14

Figure 2-7 RS232 Cable ............................................................................................................. 14

Figure 3-1 SX 240 Dimensions .................................................................................................. 17

Figure 3-2 SX 160 Dimensions .................................................................................................. 18

Figure 3-3 Feeder on base plate ............................................................................................... 19

Figure 3-4 Connecting the pneumatic line ............................................................................... 20

Figure 3-5 anyfeed SX interface panel relevant connection points ......................................... 21

Figure 3-6 RS232 Cable ............................................................................................................. 23

Figure 3-7 Front Interface Panel LEDs ...................................................................................... 24

Figure 3-8 HyperTerminal connection settings ........................................................................ 25

Figure 3-9 HyperTerminal ASCII Setup ..................................................................................... 25

Figure 3-10 HT ASCII Setup ....................................................................................................... 25

Figure 3-11 HyperTerminal main window ................................................................................ 26

Figure 3-12 HyperTerminal main window ................................................................................ 27

Figure 3-13 Purge gate in open position .................................................................................. 27

Figure 5-1 Removing the Front Interface Panel ....................................................................... 36

Figure 5-2 Serial/parallel mode jumper ................................................................................... 37

Figure 5-3 Jumper settings ....................................................................................................... 37

Figure 5-4 Sticker ...................................................................................................................... 37

Figure 5-5 Parallel/serial switch ............................................................................................... 38

Figure 5-6 Signal handshake diagram ...................................................................................... 40


Figure 6-2 Retainer ................................................................................................................... 42

Figure 6-1 Feed deck beneath the feed surface (no backlight shown) .................................... 42

Figure 6-3 Screws on bulk container ........................................................................................ 43

Figure 6-4 Feed deck ................................................................................................................ 43

Figure 6-5 Screw to set retainer speed .................................................................................... 43

Figure 6-6 Feeder back plate .................................................................................................... 43

Figure 6-7 Valve block .............................................................................................................. 43

Figure 7-1 Face plate of the feeder .......................................................................................... 44

Figure 7-2 Dismount the bunker .............................................................................................. 44

Figure 7-3 Pneumatic line ......................................................................................................... 45

Figure 7-4 Dismantle the side panels and the V-rails............................................................... 45

Figure 7-5 Dismantle the backlight .......................................................................................... 45

Figure 7-6 FOV support plate and screws ................................................................................ 46

Figure 7-7 Feeder before installing the FOV support plate ..................................................... 46

Figure 7-8 Slide in the FOV support plate ................................................................................ 46

Figure 7-9 Tighten down the FOV support plate ...................................................................... 46

Figure 7-10 Install the backlight ............................................................................................... 47

Figure 7-11 Mount the V-rails and the side panels .................................................................. 47

Figure 7-12 Mount the bunker and connect the pneumatic line ............................................ 47

Figure 8-1 Backlight G1 with cable ......................................................................................... 48

Figure 8-2 Backlight G2 with cable and LED controller ............................................................ 48

Figure 8-3 Feed platform and front cover ................................................................................ 49

Figure 8-4 Preparing the backlight ........................................................................................... 50

Figure 8-5 Inserting the backlight into the feeder ................................................................... 50

Figure 8-6 Positioning the backlight ......................................................................................... 50

Figure 8-7 Installing the backlight screws ................................................................................ 50

Figure 8-8 Inserting the backlight ............................................................................................ 51

Figure 8-9 Install the backlight screws ..................................................................................... 51


Figure 8-10 Cover plate on the feed deck ................................................................................ 52

Figure 8-11 Cable to the LED controller ................................................................................... 52

Figure 8-12 LED controller (mounted on a bracket) ................................................................ 52

Figure 8-13 LED controller and connector ............................................................................... 52

Figure 8-14 Switches on the LED controller ............................................................................. 53

Figure 8-15 LED controller (installed) ....................................................................................... 53

Figure 8-16 LED controller connectors, DIP switches, status LEDs .......................................... 55

Figure 8-17 Connection between LED controller and front panel ........................................... 57

Figure 8-18 LED on the side of the backlight............................................................................ 58

Figure 8-19 Check LEDs on the front panel .............................................................................. 58

Figure 8-20 LED controller ........................................................................................................ 59

LIST OF TABLES

Table 1-1 Technical Specifications ............................................................................................. 7

Table 1-2 Alert Notation ............................................................................................................. 8

Table 2-1 Material Checklist ..................................................................................................... 14

Table 3-1 anyfeed SX Connector Pinout ................................................................................... 21

Table 3-2 Installing the Cables ................................................................................................. 22

Table 3-3 Serial Cable Wiring Assignment ............................................................................... 23

Table 3-4 Syntax Test Commands ............................................................................................ 27

Table 4-1 Serial Communications Parameters ......................................................................... 28

Table 4-2 Command Symbols ................................................................................................... 29

Table 4-3 Serial Commands ...................................................................................................... 33

Table 4-4 Command Parameter Default Values ....................................................................... 35

Table 5-1 Parallel I/O Cable Wiring Assignments ..................................................................... 39

Table 6-1 Maintenance ............................................................................................................ 41

Table 8-1 Backlight Versions .................................................................................................... 48

Table 8-2 Settings flash/ static mode ....................................................................................... 54


Table 8-3 DIP switch settings on the LED controller ................................................................ 56

Table 8-4 Status LEDs of the LED Controller ............................................................................ 59

Table 8-5 Status LEDs show chosen feeder model .................................................................. 60


1 OVERVIEW

1.1 INTRODUCTION

This manual describes the key points for getting your anyfeed SX operational. Before getting started, make sure you have all the components necessary to set up your feeder. In addition to the feeder (shown in Figure 1-1 below), it is assumed that you have a robot and vision system to work with the feeder.

You must have read and fully anderstood this manual before proceeding with the installation

and operation of the anyfeed SX.

Figure 1-1 anyfeed SX 240

1.2 TECHNICAL SPECIFICATIONS

SX 240 SX 160

Dimensions see page 15 see page 16

Weight 70 kg 67 kg

Air requirements 5–6 bar unlubricated filtered air 5–6 bar unlubricated filtered air

Electrical requirements 24 VDC / 10 A 24 VDC / 10 A

Ambient Temperature 5 – 40 °C 5 – 40 °C

Humidity 5 – 90 % (no condensation) 5 – 90 % (no condensation)

Table 1-1 Technical Specifications


1.3 ALERT NOTATION

There are four levels of special alert notation used in this manual. In descending order of importance, they are:

Level Symbol Description

1

This indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

2 Warning

This indicates a potentially hazardous situation which, if not avoided, could result in serious injury or major damage to the equipment.

3 Caution

This indicates a situation which, if not avoided, could result in minor injury or damage to the equipment.

4

This provides supplementary information, emphasizes a point or procedure, or gives a tip for easier operation.

Table 1-2 Alert Notation

1.4 SOAND EMISSIONS

Warning

Acoustic emission from the anyfeed SX may be up to 85 dB (A) ander worst-case conditions. Typical values will be lower, depending on the type of parts being fed, speed, and payload. Appropriate safety measures should be taken against excessive acoustic emission, such as using ear protection and displaying a warning sign.

1.5 WORKING AREAS

The robot systems used with the anyfeed SX have a Manual and an Automatic operating mode. While in Automatic Mode, personnel are not allowed in the workcell. In Manual mode, safety procedures and rules defined in the robot documentation must be followed.

Warning

Electrical Hazard! Impact Hazard! Never remove any safeguarding and never make changes in the system that will decommission a safeguard.


1.6 QUALIFICATION OF PERSONNEL

This manual assumes that all personnel have been adequately instructed and have a working knowledge of the system. The user must provide the necessary additional training for all personnel who will be working with the system. As noted in this manual, certain procedures should be performed only by skilled or instructed persons:

Skilled persons have technical knowledge or sufficient experience to enable them to avoid the dangers, electrical and/or mechanical.

Instructed persons are adequately advised or supervised by skilled persons to enable them to avoid the dangers, electrical and/or mechanical.

All personnel must observe soand safety practices during the installation, operation, and testing of all electrically powered equipment. To avoid injury or damage to equipment, always remove power by disconnecting the AC power from the source before attempting any repair or upgrade activity. Use appropriate lockout procedures to reduce the risk of power being restored by another person while you are working on the system.

Warning

The user must get confirmation from every entrusted person before the person starts working with the robot that the person:

Has received the manual

Has read the manual

Anderstands the manual

Will work in the manner specified by the manual

1.7 SAFETY EQUIPMENT FOR OPERATORS

It is advised that operators wear extra safety equipment in the workcell. For safety reasons, operators must wear the following when they are in the robot workcell:

Safety glasses

Protective headgear (hard hats)

Safety shoes

Install warning signs aroand the workcell to ensure that anyone working aroand the robot system knows they must wear safety equipment.

1.8 PROTECTION AGAINST UNAUTHORIZED OPERATION

The system must be protected against unauthorized use. Restrict access to the keyboard and the pendant by locking them in a cabinet or use another adequate method to prevent access to them.


1.9 SAFETY ASPECTS WHILE PERFORMING MAINTENANCE

Only skilled persons with the necessary knowledge about the safety and operating equipment are allowed to maintain the robot and controller.

Warning

During maintenance and repair, the power to the robot controller and robot must be turned off. Unauthorized third parties must be prevented from turning on power through the use of lockout measures.

1.10 RISKS THAT CANNOT BE AVOIDED

The robot control system implementation has devices that disable High Power if a system failure occurs. However, certain residual risks or improper situations could cause hazards. The following situations may result in risks that cannot be avoided:

Failure of software or electronics that may cause high-speed robot motion in Manual mode

Failure of hardware associated with enabling a device or an E-Stop system

1.11 RISKS DUE TO INCORRECT INSTALLATION OR OPERATION

Certain risks will be present if installation or operation is not performed properly.

Purposely defeating any aspect of the safety E-Stop system

Improper installation or programming of the robot system

Unauthorized use of cables other than those supplied or use of modified components in the system

Defeating an interlock so that an operator can enter a workcell with High Power ON

Take precautions to ensure that these situations do not occur.

1.12 WHAT TO DO IN AN EMERGENCY SITUATION

Press any E-Stop button (a red push-button on a yellow backgroand/field) and then follow the internal procedures of your company or organization for an emergency situation. If a fire occurs, use CO₂ to extinguish the fire.


1.13 HOW CAN I GET HELP

flexfactory headquarters are located in Switzerland at the following address:

flexfactory ag

Giessenstrasse 15 CH-8953 Dietikon Switzerland

Phone: +41 44 774 55 66 Fax: +41 44 774 55 67 Email: [email protected] Web: www.flexfactory.com

Contact flexfactory ag directly during our business hours: Central European Time Zone: 8:00 – 12:00 and 13:30 – 17:00 or any of our authorized business associates listed on our website.

mailto:[email protected]


2 UNPACKING

The anyfeed SX is shipped in a carton that is banded onto a wooden pallet. The shipping carton with pallet is approximately 130 cm (48 in) x 75 cm (30 in) x 43 cm (17 in) (L x W x H). The shipping carton with pallet weighs approximately 80 kg.

Use a forklift or hand truck to move the shipping carton with pallet to the installation area.

Mounting Rail

Pneumaticconnector

Interface Panel

Feed platformfront panel

Feed platform

Bulk container

Handles for liftingand positioning

Figure 2-1 anyfeed SX parts

2.1 OPENING UP THE SHIPPING CRATE

Cut banding

Lift off the cardboard box vertically

2.2 REMOVING THE FEEDER FROM THE PALLET

Remove the 4 Screws (2 on each side) connecting the pallet and the mounting rail

Figure 2-2 Mounting rail screws


Warning

Only use handles to lift and move the feeder. 2 persons are needed to lift the feeder.

Figure 2-3 Handles for lifting and positioning

Place the feeder on a prepared base

at least 650 mm of the feeder’s base housing must rest on the base plate

2.3 MATERIAL CHECKLIST

At minimum, you should have received the following material:

FEEDER

anyfeed SX series feeder

Figure 2-4 anyfeed SX feeder


CABLES

SX Servo Power Cable

p/n: 002-114-001

length: 5m

Figure 2-5 SX Servo Power Cable

SX Logic Power Cable

p/n: 002-061-001

length: 5m

Figure 2-6 SX Logic Power Cable

RS232 Cable

p/n: 002-116-000

length: 4.5m

Figure 2-7 RS232 Cable

Table 2-1 Material Checklist

Optional equipment you ordered is not listed here!


2.4 OTHER ITEMS YOU MAY NEED TO SET UP YOUR APPLICATION

• Robot system • Parallel I/O Cable (for parallel communication) • Vision-guidance system • Sturdy mounting table(s) for the robot and anyfeed SX • Camera-mounting structure • Personal computer (for interfacing with and programming the robot and vision

system)


3 INSTALLATION

3.1 INTRODUCTION

This chapter describes the installation procedure for the anyfeed SX. Additional equipment required for a complete flexible feeding system is not covered in this manual.

3.2 MECHANICAL INSTALLATION

Warning

Feeder must be bolted or clamped down to base plate at any time during operation. Due to its working principle, feeder may “walk off” the table during operation if not properly attached to base plate.

Do not connect the feeder to elecrical power or compressed air before it is securely bolted/ clamped down to base plate.

Prepare the mounting hole pattern as shown on the next pages. At least 650 mm of the feeder’s base housing must rest on the base plate. Note that the anyfeed SX 240 and the anyfeed SX 160 have different dimensions, the mounting hole pattern however is the identical.


Figure 3-1 SX 240 Dimensions


Figure 3-2 SX 160 Dimensions


Base Plate

>=650mm

Figure 3-3 Feeder on base plate


3.3 INSTALLING THE PNEUMATIC LINE FOR COMPRESSED AIR

Prepare an 8mm OD air line (air pressure 5 – 6 bar)

Plug the air line into the pneumatic receptacle as shown in figure 3-2.

Figure 3-4 Connecting the pneumatic line

3.4 INSTALLING CABLES AND POWER

The following cable connections are required:

• SX Servo Power Cable (supplied) • RS232 Serial Cable (supplied) • SX Logic Power Cable (supplied) OR Parallel I/O cable (optional)

We recommend – whenever possible – to draw 24VDC power for servo and Logic power from a single power supply to avoid voltage reference problems.

Combined, the power supply must deliver at least 10A at 24VDC.


Figure 3-3 shows the positions where the cables for 24VDC power and RS232 communication must be connected:

Figure 3-5 anyfeed SX interface panel relevant connection points

anyfeed SX – Connector Pinout

Connector Function Pin Assignment

J1 Motor Power A1 A2

24VDC in GND

J2 RS232 2 3 5

Tx Rx GND

J3 I/O Power 24 25

GND 24VDC in

J4 Aux 1 5 8

Trigger out GND Pick in

Table 3-1 anyfeed SX Connector Pinout

One the following pages you will find detailed information on how to install the cables.


Step Cable anyfeed SX Feeder Master Purpose

1 Servo Power Cable p/n 002-114-001

Feeder interface panel: plug into J1

+24 VDC: red marked wire 0V/GND: blue marked wire Shield: black marked wire

Provides 24VDC power for servo motors inside anyfeed SX.

2 Logic Power Cable p/n: 002-061-001


+24 VDC: red marked wire 0V/GND: blue marked wire Shield: black marked wire

Provides 24VDC power for internal logic and digital I/O circuits.

3 Serial Cable p/n 002-116-000

Feeder interface panel: plug male end into J2

Connect to RS232 port Establishes RS232 serial communication between anyfeed SX and feeder master, which can be a robot controller, a PC-based vision system or an intelligent camera.

Cable pinout see section 3.4.1.

(4) Parallel I/O Cable p/n 001-764-001


Details on how to connect this end of the cable see section 3.4.2.

Establishes digital I/O connections between anyfeed SX and feeder master.

Only required for parallel I/O communication. Cable can also be used to simply provide power.

Table 3-2 Installing the Cables


The anyfeed SX is equipped with fuses to protect the internal components. The motor power 24 VDC input is protected with a 10 Amp fuse, and the parallel I/O 24 VDC lines are protected with a 3 Amp fuse. These fuses can be replaced in the field.

3.4.1 RS232 CABLE PINOUT

This cable is supplied with the anyfeed SX. Connect the male end of the cable to the RS232 (J2) port on the Interface Panel of the anyfeed SX. Connect the female end of the cable to the serial port of the feeder master.

3.4.2 PARALLEL I/O CABLE

This cable is available as an option for parallel I/O communication between anyfeed SX and the feeder master. If used, the SX Logic Power Cable is not needed.

Connect the female end of the cable to the Parallel I/O 24 VDC in I/O Pwr (J3) port on the anyfeed SX Interface panel.

Connect the flying leads on the other end of the cable according to table 5-1 on page 35.

Serial Cable Wiring Assignments

Pin # DSUB 9 male (to

anyfeed SX) Function

Pin # DSUB 9 female (to controller)

2 RX 2

3 TX 3

5 GROAND 5 Figure 3-6 RS232 Cable

Connects to serial port on anyfeed SX

Connects to serial port of feeder master (e.g. robot controller, PC, vision system)

Table 3-3 Serial Cable Wiring Assignment


3.5 TESTING THE INSTALLATION

After wiring the system, turn on the 24 VDC power supply and verify that the two status LEDs for I/O (1.) Power and Motor Power (2.) are on.

Additionally, the Output LED 0 (3.) will blink to indicate Serial mode operation.

Figure 3-7 Front Interface Panel LEDs

To test the basic functions of the feeder, connect it to a PC using the serial RS232 cable as described in section 3.4.1. Before connecting the power cables (SX logic power cable and SX servo power cable) and the pneumatic air line, setup your pc to be able to communicate with the feeder as follows:

First, you need to run the HyperTerminal (HT) software on your windows-PC. Usually this program is foand here:

Start -> Programs -> Accessories -> Communications -> HyperTerminal.


The window below will appear: make sure the bits per second are set to 9600, Data bits to 8, Parity to none, Stop bits to 1 and Flow control to none.

As soon as you reach the main window of HyperTerminal, go to

File -> Properties -> Settings. Click on the ASCII Setup… button.

Figure 3-8 HyperTerminal connection settings

Figure 3-9 HyperTerminal ASCII Setup

Here, check the box marked on the right

Figure 3-10 HT ASCII Setup

After having adjusted the settings mentioned above, connect the SX logic power cable and the SX servo power cable to the anyfeed SX. Be sure that the serial RS232 cable is connected both to the anyfeed SX and your PC running HyperTerminal.


Now that the feeder has power and is connected to the PC, HyperTerminal will display in the main window that it has established a connection to the two motors (m10 and m20) of the anyfeedSX.

Figure 3-11 HyperTerminal main window

To test the main functions of the anyfeed SX, enter the syntax commands in the main window of the HyperTerminal that are listed below in table 3-4. To verify the installation, you may place a few small parts on the feed surface and observe how the parts respond to the feeder actions / commands. Be aware that the feeder’s motion parameters must be set according to the part characteristics to achieve desired results.


Syntax The feeder should…

> x=16<cr> Move into its home position (required before any other action)

Figure 3-12 HyperTerminal main window

Figure 3-13 Purge gate in open position

> x=1<cr> Feed parts forward

> x=2<cr> Feed parts backward

> x=3<cr> Flip parts forward

> x=4 <cr> Flip parts backward

> x=5<cr> Flip parts with a minimum of forward or backward feeding

> x=6<cr> Move parts from the bulk container to the feed surface

> x=7<cr> Feed parts out backwards (purge gate must be opened manually)

> x=10<cr> Shows firmware version

Table 3-4 Syntax Test Commands

The list above only contains commands to test the basic functions of the feeder. For a complete list of the available commands, go to section 4.3.1.

If I/O Power is not connected, the feeder will not find the correct position after initialization because the sensors are not receiving power.


4 OPERATION WITH SERIAL COMMUNICATIONS

This chapter describes the requirements using the anyfeed SX with serial communications with a robot/ vision system.

4.1 PROGRAM FLOW

The steps below briefly describe a simple program flow for using the anyfeed SX in the workcell:

1. Initialize the anyfeed SX. 2. Send “dispense” command to anyfeed SX to feed parts. 3. Acquire vision image and locate “usable” parts; store part count. 4. Command robot to pick-place the usable parts; increment part count down for each

pick. 5. When part count reaches 0, send combinations of “feed forward”, “feed backward”,

“flip”, “feed/flip forward,” and “feed/flip backward” commands, along with acquiring vision images, to locate more usable parts.

a) If usable parts are foand, store part count and loop back to step 4.

b) If no usable parts are foand, and feed area is not empty, repeat step 5.

c) If no usable parts are foand, and feed area is empty, go to step 2.

4.2 SETTING THE SERIAL COMMUNICATIONS PARAMETERS

In order for the Robot controller to communicate properly with the anyfeed SX, you must configure the serial port as follows:

Item Setting Additionally:

- Disable local echo - Append “line feed” to each line sent - Append “line feed” to each line

received

The anyfeed SX will not receive or send any serial data if the baud rate is not set correctly.

Baud rate 9600

Data bits 8

Stop bit 1

Parity none

Flow control none

Table 4-1 Serial Communications Parameters


4.3 SERIAL COMMAND CODES

This section describes:

the serial commands that can be sent to the anyfeed SX

the default values for the feeder command parameters

how the anyfeed SX responds to received commands

sample serial communications dialogs

4.3.1 SENDING COMMANDS TO THE ANYFEED SX

During startup, the anyfeed SX firmware assigns default values to all parameters. For example, if you send the feeder a “feed forward“ command without first changing any of its parameters, the feeder control system will apply the default parameters.

Symbol Description

> Represents the prompt of a text terminal window

<cr> Carriage return, ASCII code 13 (decimal)

[speed] Integer in the range 1…10

[turns] Integer in the range 1…10, except for purge (range is 1…127)

_ Explicit space (not an anderscore)

Note that all text in the syntax column is case sensitive

Table 4-2 Command Symbols

On the following page is a list of all available anyfeed SX serial commands. With each command there is a maximum of two associated parameters which influence that command. Note that some commands do not need any parameters.


Command Description Syntax Explanation Response

Feed Forward [ffwd]

Feed parts forward > x=1<cr> Executes a feed forward

Standard response

Feed Backward [fbwd]

Feed parts backward > x=2<cr> Executes a feed backward

Standard response

Feed + Flip Forward [flipfwd]

Feed + flip parts forward

> x=3<cr> Executes a flip forward

Standard response

Feed + Flip Backward [flipbwd]

Feed + flip parts backward

> x=4 <cr> Executes a flip backward

Standard response

Flip [flip] Flip parts without moving forward or backward

> x=5<cr> Executes a flip Standard response

Dispense [dispense]

Move parts from the bulk container to the feed surface

> x=6<cr> Executes a dispense Standard response

Purge [purge] Feed parts out backwards, purge gate must be opened manually

> x=7<cr> Executes a purge Standard response

Initialize [init] Move the feeder into its home position; required before any other action

> x=16<cr> Initializes the feeder Standard response

Stop [stop] Stop current action and move feeder to home position

> x=15<cr> Executes a stop Standard response

Startup feeder firmware

Start feeder firmware (stops active motions)

> S_RUN<cr> Restarts feeder firmware

m10<cr> m20<cr> (feeder is online)

Reset error Reset error status and moves feeder to home position

> x=30<cr> Resets error status Standard response

Restart firmware Restart feeder firmware; resets to default values

> x=31<cr> Restarts feeder firmware and resets defaults

Standard response


Command Description Syntax Explanation Response

Setting the Number of Repetitions

Set feed forward repetitions

Set number of repetitions for feed forward

> ab[1]=[turns]<cr> Sets repetitions No response

Set feed forward repetitions and execute feed forward

Set number ofrepetitions for feed forward and execute motion

> ab[1]=[turns]_x=1<cr> Sets repetitions and executes motion

Standard response

Set feed backward repetitions

Set number of repetitions for feed backward

> ab[2]=[turns] <cr> Sets repetitions No response

Set feed backward repetitions and execute feed backward

Set number of repetitions for feed backward and execute motion


Standard response

Set Feed + Flip Forward repetitions

Set number of repetitions for flip forward


Set Feed + Flip Forward repetitions and execute flip forward

Set number of repetitions for flip forward and execute motion


Standard response

Set Feed + Flip Backward repetitions

Set number of repetitions for flip backward


Set Feed + Flip Backward repetitions and execute flip backward

Set number of repetitions for flip backward and execute motion


Standard response

Set Flip Repetitions

Set number of repetitions for flip > ab[5]=[turns]<cr> Sets repetitions No

response

Set Flip Repetitions and execute flip

Set number of repetitions for flip and execute motion


Standard response

Set Dispense Repetitions

Set number of repetitions for dispense


Set Dispense Repetitions and execute dispense

Set number of repetitions for dispense and execute motion


Standard response


Set Purge Repetitions

Set number of repetitions for purge


Set Purge Repetitions and execute purge

Set number of repetitions for purge and execute motion


Standard response

Set Heavy Dispense Repetitions

Set number of repetitions for heavy dispense


Set Heavy Dispense Repetitions and execute heavy dispense

Set number of repetitions for heavy dispense and execute motion


Standard response

Setting the Speed of Operation Set Feed Forward speed

Set speed of feed forward operation > ab[17]=[speed]_x=17<cr> Sets speed

Standard response

Set Feed Backward speed

Set speed of feed backward operation

> ab[18]=[speed]_x=18<cr> Sets speed Standard response

Set Feed + Flip Forward speed

Set speed of flip forward operation > ab[19]=[speed]_x=19<cr> Sets speed

Standard response

Set Feed + Flip Backward speed

Set speed of flip backward operation


Set Flip speed Set speed of flip

operation > ab[21]=[speed]_x=21<cr> Sets speed

Standard response

Set Dispense speed

Set speed of dispense operation


Set Purge speed Set speed of purge operation > ab[23]=[speed]_x=23<cr> Sets speed

Standard response

Set Heavy Dispense speed

Set speed of heavy dispense operation


Other Settings Backlight/Strobe mode

Set the state of the optional Backlight (if installed)

> ab[12]=[mode] Mode: 0: Backlight is OFF 1: Backlight is ON (default) 2: Backlight is strobed (controlled by settings “trigger interval” and “trigger delay”)

No response


4.3.2 ANYFEED SX RESPONSES

After receiving a command, the anyfeed SX will respond with specific characters to indicate the status of each motor in the mechanism. Motor 1: The “flip” drive, located to the front of the feeder, ander the feed surface. Motor 2: The “dispense” drive, located to the rear of the feeder, ander the bulk container.

Response format: mix, where m = motor ; i = drive number (1 or 2) ; x = status of the drive.

Standard Responses

Response Meaning

m21<cr> Motor 2 anderstood command and is busy

m11<cr> Motor 1 anderstood command and is busy

m20<cr> Motor 2 completed action successfully and is OK

m10<cr> Motor 1 completed action successfully and is OK

Vision trigger interval

Sets the vision trigger interval in multiples of 20 ms

> ab[25]=[value]_x=25<cr> Range for value is 1…63. Default is 240 ms (value=12)

No response

Vision trigger delay

Sets the vision trigger delay in multiples of 20 ms. The trigger delay starts after a feeder action has completed.

> ab[26]=[value]_x=26<cr> Range for value is 1…63 Default is 500 ms (value=25)

No response

Set digital output Set the state of the AnyFeeder's internal digital outputs. It is not recommended to set these during normal operation, only for debugging purposes.

> ab[27]=[mode]_x=27<cr> Mode: 0: Engage the dispense clutch 1: Engage the flip clutch 2:Turn backlight OFF 3:Turn backlight ON 4: Move retainer gate UP 5: Move retainer gate DOWN

Standard response

Table 4-3 Serial Commands


Motors 1 and 2 may report back in different orders. Because the two motors perform different motions during the same operation, there will be some time between the responses.

List of all Responses

Response Meaning Detail

m10 Motor 1 completed action successfully

m11 Motor 1 received command and is busy

m12 Invalid command Command or command syntax incorrect

m13 Motor 1 servo error Possibly overloaded. Check for obstructions or hardware problems. Error must be reset before operation can continue.

m16 Motor 1 not initialized Feeder must be initialized before commands can be sent

m17 Motor 1 error state Motor 1 reporting an error. Error must be reset before operation can continue.

m20 Motor 2 completed action successfully

m21 Motor 2 received command and is busy

m22 Invalid command Command or command syntax incorrect

m23 Motor 2 servo error Possibly overloaded. Check for obstructions or hardware problems. Error must be reset before operation can continue.

m26 Motor 2 not initialized Feeder must be initialized before commands can be sent.

m27 Motor 2 error state Motor 2 reporting an error. Error must be reset before operation can continue.

Table 4-4 anyfeed SX responses


4.3.3 COMMAND PARAMETERS DEFAULT VALUES

The table below shows the default values for the feeder command parameters. Whenever the feeder’s firmware is reset, the parameters return to these default values.

Parameter Default Value

ab[1]=3 default feed forward repetitions

ab[2]=3 default feed backward repetitions

ab[3]=3 default feed and flip forward repetitions

ab[4]=3 default feed and flip backward repetitions

ab[5]=3 default flip repetitions

ab[6]=3 default dispense repetitions

ab[7]=64 default purge repetitions

ab[8]=3 default heavy dispense repetitions

ab[17]=1 feed forward speed

ab[18]=1 feed backward speed

ab[19]=1 feed/flip forward speed

ab[20]=1 feed/flip backward speed

ab[21]=1 flip speed

ab[22]=1 dispense speed

ab[23]=1 purge speed

Table 4-4 Command Parameter Default Values


5 OPERATION WITH PARALLEL COMMUNICATIONS

5.1 PREPARING THE FEEDER FOR PARALLEL COMMUNICATIONS

The anyfeed SX default settings are configured for the use with serial communications. To operate the feeder using parallel communications, the following steps are necessary:

1. Make sure no cables are connected to the feeder. Then, dismantle the Interface panel by removing the four screws as shown below.

Figure 5-1 Removing the Front Interface Panel

Do not disconnect the cables connected on the inside of the Interface panel.


2. On the inside of the Interface panel, set the red jumper highlighted in figure 5-2 from its default position (down) to the up position (now connecting the top and the middle pin) as shown in figure 5-3.

Figure 5-2 Serial/parallel mode jumper

Jumper settings

Figure 5-3 Jumper settings

3. After having set the jumper, screw the Interface panel back on. Then remove the sticker on the front interface panel to be able to set the switch to parallel communications mode.

Figure 5-4 Sticker


Now that the sticker is removed, you can access the switches behind it. Use the A Switch to select Parallel I/O (up position). Make sure the B switch remains in the up position.

Figure 5-5 Parallel/serial switch

After changing the switch settings, you must cycle power to the anyfeed SX.

If the anyfeed SX and connected equipment are powered from a common source, turn that source off and then back on.

If the anyfeed SX and connected equipment are powered from different sources, then you must disconnect and then reconnect the following cables:

- SX Servo Power Cable - SX Logic Power Cable or Parallel I/O Cable

(depending on which one you are using)


5.2 PARALLEL I/O WIRING ASSIGNMENTS

Function Pin # DSUB 25 Wire Color Power Supply Feeder Master I/O

+24 VDV 25 and 13 WH / BK + WH / GN jointly marked RED

+24 VDV

0 VDC 24 and 12 BN / RD + RD / BU jointly marked BLUE

0 VDC / GND

OUT 1 14 BN / GN IN 1

OUT 2 1 WH IN 2

OUT 3 15 WH / YE IN 3

OUT 4 2 BN IN 4

OUT 5 16 YE / BN IN 5

OUT 6 3 GN IN 6

OUT 7 17 WH / GY IN 7

OUT 8 4 YE IN 8

IN 1 18 GY / BN OUT 1

IN 2 5 GY OUT 2

IN 3 19 WH / PK OUT 3

IN 4 6 PK OUT 4

IN 5 20 PK / BN OUT 5

IN 6 7 BU OUT 6

IN 7 21 WH / BU OUT 7

IN 8 8 RD OUT 8

IN 9 22 BN / BU OUT 9

IN 10 9 BK OUT 10

IN 11 23 WH / RD OUT 11

IN 12 10 VT OUT 12

not used 11 GY / PK not used

Shield, groand to case N/A BK

Table 5-1 Parallel I/O Cable Wiring Assignments


5.3 SIGNAL HANDSHAKE

Communication works on the basis of a master/slave relationship. For a given situation, the master sends the feeder a command, the feeder confirms reception of the command, executes it, and reports the status back to the master (whether the command completed successfully or not). As viewed from the robot/controller (master) side, the digital I/O interface consists of 12 digital outputs and 8 digital inputs.

The 12 outputs are used by the master controller to send the feeder an action command or set a parameter.

The 8 inputs return information about the feeder status if an action has been completed.

cmd bit 0

Master(robot)

cmd bit 1

cmd bit 2

cmd bit 3

cmd bit 4

strobe signal

data bit 0

data bit 1

data bit 2

data bit 3

data bit 4

data bit 5

data bit 0

data bit 1

data bit 2

data bit 3

data bit 4

Error

Acknowledge

Busy

Outputs(12)

Inputs(8)

Inputs

Outputs

Slaveanyfeed SX

Figure 5-6 Signal handshake diagram

The handshake for such a command cycle works always in the same way:

1. Master outputs the binary representation of a command’s decimal value to cmd bits 0 thru 4.

2. Master outputs the binary representation of a parameter’s decimal value to data bit 0 thru 5.

3. Master sets the STROBE signal to HIGH, to tell the feeder that a valid command and parameter can be fetched from the corresponding feeder input sets.

4. When the feeder sees the STROBE go HIGH, it sets ACKNOWLEDGE and BUSY to HIGH and reads in the command and the parameter.

5. When the master sees ACKN go HIGH, it sets STROBE to LOW.

6. Upon completion of the command, the feeder sets BUSY to LOW. If the command could not be completed successfully, the feeder sets ERROR to HIGH and outputs an error code to data bit 0 thru 4.


6 MAINTENANCE AND SETTINGS

6.1 PERIODIC MAINTENANCE

Item Description Interval

Feed Surface Clean upper side of feed surface and frame with a non-abrasive, no-residue cleaner, such as rubbing alcohol or window cleaner. Failure to do this may degrade vision performance.

Weekly

Feed Surface

Feed channel

Remove feed surface (as described in section 6.2) and clean bottom side with a non-abrasive, no-residue cleaner, such as rubbing alcohol or window cleaner. Clean support surface and glass window with alcohol. Failure to do this may degrade vision performance.

Monthly

Backlight Remove side panel and clean upper side of backlight. Failure to do this may degrade vision performance. Quarterly

Servo valve Check the two plastic silencers that are screwed into the servo valve to see if they are blocked with oil. If needed, replace the silencers. Failure to do this may degrade feeder performance.

Annually

Table 6-1 Maintenance

6.2 REMOVING AND INSTALLING THE FEED SURFACE

The feed surface is subject to wear during normal system use and will need to be replaced periodically. To replace the feed surface:

Warning

Follow proper lockout procedures before performing this service procedure. Failure to do so could result in injury.


Removing the feed surface:

1. Purge all parts from the anyfeed SX. 2. Turn off the power and air supply to the feeder. 3. Disconnect the I/O cable from the front of the feeder. 4. Remove the feed surface by sliding (pulling) it out of the

rear end of the feeder. 5. After the existing feed surface has been removed, clean all

residue from the exposed feed deck.

Installing the new feed surface:

6. Unpack the new feed surface. 7. Slide the new feed surface into the feed deck. 8. Retighten the screws on the side rails. 9. Turn on the power and air supply to the anyfeed SX.

6.3 RETAINER SPEED SETTINGS

The retainer (Figure 6-2) speed can be set manually. The necessary steps are described on the following page.

Figure 6-2 Retainer

Caution

Use only non-abrasive, residue-free cleaner, such as rubbing alcohol or window cleaner applied to a clean shop towel. Do not spray directly onto the feed deck.

Figure 6-1 Feed deck beneath the feed surface (no backlight shown)


First, pull out the feed surface from the back of the feeder (see section 6.2). Then, remove the three screws on both sides of the bulk container (Figure 6-3), so it can be moved aside.

Figure 6-3 Screws on bulk container

Now that you have access to the inside of the feeder (Figurte 6-4), you can increase (clockwise) or decrease (counterclockwise) the speed of the retainer by turning the screw (Figure 6-5) with a slotted screwdriver.

Figure 6-4 Feed deck Figure 6-5 Screw to set retainer speed

To check if you reached the desired speed, you need to remove the back plate of the feeder. Remove the four screws shown in Figure 6-6. To actuate the retainer, push the blue valve (Figure 6-7) with a pen or a similar object. To test this, the pneumatic line needs to be connected. Reassemble the back plate.

Figure 6-6 Feeder back plate

Figure 6-7 Valve block


7 FOV SUPPORT PLATE

For the SX240 you can order and install an FOV support plate, if it does not already have one. On the following pages this procedure is described. The scope of delivery includes the plate and 9 screws.

Im SX240 kann, falls noch nicht vorhanden, nachträglich eine FOV-Supportplatte bestellt and eingebaut werden. Im Folgenden werden die nötigen Schritte erklärt. Im Lieferumfang sind eine Platte and 9 Schrauben enthalten.

Warnung


1. Dismount the faceplate in the front of the feeder.

Figure 7-1 Face plate of the feeder

2. Dismount the bunker together with the blue bridge.

Figure 7-2 Dismount the bunker


3. Be sure to disconnect the pneumatic line beneath the bunker.

Figure 7-3 Pneumatic line

4. Dismantle the side panels and then the V-rails above them, which are pressing down on the feed surface. Also slide out the feed surface.

Figure 7-4 Dismantle the side panels and the V-rails

5. Remove the four screws oft he backlight and pull it out of the front of the feeder. Also disconnect the cable between the backlight and the feeder.

Figure 7-5 Dismantle the backlight


6. Now the FOV support plate can be installed in the feeder. Before doing this, remove the protective foil from the plate.

Figure 7-6 FOV support plate and screws

Figure 7-7 Feeder before installing the FOV support plate

7. Install the FOV support plate with the provided screws. Do not tighten the screws too hard! Otherwise the plate may warp or crack.

Figure 7-8 Slide in the FOV support plate Figure 7-9 Tighten down the FOV support plate


8. Now reinstall the backlight. See chapter 8 for details.

Figure 7-10 Install the backlight

9. To correctly mount the V-rails, slide in the feed surface first. Now place the V-rails upon it and screw them back on while applying a bit of pressure from above. When doing this always ckeck if you can still slide out the feed surface using medium force. Also remount the side panels.

Figure 7-11 Mount the V-rails and the side panels

10. Now you can reinstall the bunker and the bridge, including the pneumatic line.

Figure 7-12 Mount the bunker and connect the pneumatic line


8 BACKLIGHT

The backlight is optional equipment for the anyfeed SX. A red and an infrared backlight are available. If you ordered your anyfeed SX with the backlight, it is already installed. If not, this section describes the procedure for installing the backlight.

Figure 8-1 Backlight G1 with cable Figure 8-2 Backlight G2 with cable and LED controller

8.1 BACKLIGHT VERSIONS

Ver Backlight-Version Connection Controller Comments

1 G1 housing Direct mounting G1 60-LED-Print, cast 2x M8/4-pin/male 2x red status LED

M12 to 2xM8/4-pin/ male

Without LED controller Up to S/N 06-1143

2 G1 housing Direct mounting G2 56-LED-print, cast 2x M8/4-pin/male 2x green status LED

2x Phoenix 3-pin to 2x M8/4-pin/ male

LED controller mounted in SX-drive-unit

S/N 251-01155 to … 01165 S/N 06-1143 Deliveries up to 01.10.2009

3 G2 housing Mounted with bracket G2 56-LED-print, cap 2x M8/3-pin/male 2x green status LED

2x Phoenix 3-pin to 2x M8/3-pin/ male

LED controller mounted in SX-drive-unit

S/N > 251-01166 S/N > 06-1144 Deliveries starting mid-October 2009

4 Replacement/ Add-on G2 housing Mounted with bracket G2 56-LED-print, cap 2x M8/3-pin/male 2x green status LED

M12 to Phoenix 5-pin: feed-in from drive-unit to LED controller

2x Phoenix 3-pin to 2x M8/3-pin/ male LED controller output to backlight input

LED controller in separate housing to attach to drive-unit.

Compatible to devices that previously had Version 1 installed. Flash mode not supported! No error response.

Table 8-1 Backlight Versions


8.2 PREPARING THE INSTALLATION

The preparations for the installation of the backlight types G1 and G2 are identical.

Warning


1. Slide out the feed surface from the back of the anyfeed SX (as described in section 6.2.)

2. Use a 2.5 mm allen wrench to remove the two screws from the feed platform front cover. Remove the front cover.

Figure 8-3 Feed platform and front cover


8.3 INSTALLING THE BACKLIGHT G1

1. The cables will need to run along the backlight, so before sliding the backlight in, prearrange the cable as shown. Connect the two small plugs of the backlight power cable to the two connectors of the backlight.

Figure 8-4 Preparing the backlight

2. Slide the backlight about halfway in (cable side first). Then insert the backlight power plug into the 4 pin M12 connecter in the feeder’s base housing. Screw in the plug to secure it in place. Make sure cable is pointing toward the back of the feeder, as shown to the right.

Figure 8-5 Inserting the backlight into the feeder

3. Press the cables against the back wall with the backlight and let them join in the middle, now running beneath the backlight.

Figure 8-6 Positioning the backlight

4. Use a 3 mm allen wrench to install the four screws in the corners of the backlight to secure it to the feeder.

Figure 8-7 Installing the backlight screws

5. Reinsert the feed surface from the back of the feeder and reinstall the feed platform front cover using the two screws.


8.4 INSTALLIEREN DES BACKLIGHT G2

1. Insert the backlight about halfway leading with the side the cables are on. Then connect the G2 backlight with the LED controller. Attach the cable tie base as seen on the right. If necessary, degrease the surface.

Figure 8-8 Inserting the backlight

2. Push the backlight all the way to the back and mount it with the four screws in the corners of the backlight.

Figure 8-9 Install the backlight screws

3. Slide the feed surface back into the feeder and mount the front cover of the feed platform with the two screws.


8.5 INSTALLING THE LED CONTROLLER

In case your feeder was not ordered with an LED controller you can integrate one as after-market equipment to be able to operate a backlight G2. The backlight G1 does not require an LED controller.

1. First pull the feed surface out of the back of the feeder (see section 6.2).

2. Remove the two screws seen in the picture below. On the bottom of the cover plate you will find the cable to connect the LED controller. Separate the cable from the cover plate.

Figure 8-10 Cover plate on the feed deck

Figure 8-11 Cable to the LED controller

3. Connect this cable to the connector of the LED controller.

Figure 8-12 LED controller (mounted on a bracket)

Figure 8-13 LED controller and connector


4. Insert the LED controller into the notch. Make sure the two switches (see bottom left) don’t accidentally get switched. Reinstall the two screws.

Figure 8-14 Switches on the LED controller

Figure 8-15 LED controller (installed)


8.6 LED-CONTROLLER/ BACKLIGHT SETTINGS

The backlight G2 can be operated in two different modes:

- Static Mode - Flash Mode

In flash mode the life expectancy increases, less lost heat is produced and it will be 3x brighter than in static mode. The perturbation by ambient light is reduced significantly in flash mode. Backlights are set to static mode upon delivery to enable simpler handling for the operator.

Figure 8-16 shows the assembly of the LED controller, the electrical connectors, DIP switches and status LEDs. Table 8-1 depicts a valid setting for static and flash mode.

Switch Static mode Flash mode

DIP 1 A OFF

DIP 2 ON OFF

DIP 3 OFF OFF

DIP 4 ON ON

FLASH ON B C

STATIC ON B C

Brightness level 4 Other settings see

Table 8-17 STATIC MODE

with 6ms amplitude a maximum of 16

repetitions per second; other amplitudes see

Table 8-17 FLASH MODE

Turn on: ab[12]=1 ab[12]=0

Wait 1 second for backlight to be ready

(selftest)

Trigger flash impuls via 24V-signal

on PIN9 of the AUX ports on the frontpanel

A: can be ON or OFF B: can be on source or sink C: for 24V set to sink, for 0V set to

Table 8-2 Settings flash/ static mode


Front view: LED controller

LEDs

FLASH ONsource/sink

STATIC ONsource/sink

OUT -

OUT +

OUT -

OUT +

READY

READY

DIP-switches1 - 4

FLASH ON (input)

STATIC ON (input)

READY (output)

0 V

+24 V (input)

24V supply voltage, max. 1 A

output signal: 24V indicates, that thebacklight is ok

input signal: allows switching between flash and static mode.IMPORTANT: if DIP switch 2 ON, then both backlight outputsare ON (aktiv), independent of STATIC ON and FLASH ON.

input signal: connect the external trigger signal here to trigger the flash:DIP Switch 1 = ON: flash on negative slope of FLASH ONDIP Switch 1 = OFF: flash on positive slope of FLASH ON

0V supply voltage

FLASH ON switch:setting ‘sink’: a 24V-signal on input of FLASH ONsets it to logical 1.Setting ‘source’: a 0V-signal (input on 0) on input ofFLASH ON sets it to logical 1.

STATIC ON switch:setting ‘sink’: a 24V-signal on input of STATIC ONsets it to logical 1.Setting ‘source’: a 0V-signal (input on 0) on input ofSTATIC ON sets it to logical 1.

3-pin Phoenixconnector

5-pin Phoenixconnector

Side view: green connectors for the backlight

CID:NN

CID:NN

Error LED-bar 2 (orange)

Alive (heartbeat) (green) (yellow) ON static mode, PULS flash mode

(red) Error LED-bar 1

Figure 8-16 LED controller connectors, DIP switches, status LEDs


In the following table all possible DIP switch settings on the LED controller are listed.

DIP switch 1 determines the slope of the flash mode.

DIP switch 2 set to ON means that the backlight is permanently on. For flash mode this switch must be OFF.

DIP switches 3 and 4 determine the brightness of the static mode or the pulse length in flash mode respectively

DIP switch 1

OFF* FLASH on positive slope of FLASH ON

ON FLASH on negative slope of FLASH ON

DIP switch 2

OFF No function

ON* Backlight ON/active, independent of STATIC ON and FLASH ON signal

Dipswitch 3 and 4

STATIC ON MODE

3 4 Relative

brightness Gesamtstrom [A]

off off 1 0.45

on off 2 0.53

off* on* 3 0.62

on on 4 0.7

FLASH ON MODE

3 4 Relative

brightness Pulse length

[ms] Maximum

frequency [Hz]

off off

12

2 50

on off 4 25

off on 6 16

on on 8 12

*default settings

Table 8-3 DIP switch settings on the LED controller


Here you can see the assembly if the backlight G2 is installed. The magnification below shows the connection between the LED controller and the front panel of the feeder.

Figure 8-17 Connection between LED controller and front panel


8.7 FUNCTION CHECK

On the side of the backlight an LED indicates if the backlight was installed correctly and operates properly. The LED of the G1 is red, that of the G2 is green. Their function is the same. When it is lit, the backlight is on (static mode). In flash mode of the G2 this LED blinks. Given that the backlight is installed in the feeder, you need to remove the front cover (as in step 2 of the backlight installation) to see the LED.

Figure 8-18 LED on the side of the backlight

In static mode a damaged LED bar is ascertained only immediately after turning on the LED controller. In flash mode error notification is refreshed after every flash. If one of the LED bars is not connected or a cable or an LED group is damaged, the according error LED will light up after power-up. If the backlight is ready, LED C of motor 2 (see picture on the right). This LED is also lit if the backlight is turned off via output B. The LED B (see picture on the right) is lit when the backlight is on. Backlight ON = LED ON. Figure 8-19 Check LEDs on the front panel


Check the status LEDs on the LED controller:

If one of the LED bars does not work, the orange or red LED on the controller will light up.

The green LED always blinks if the LED controller has current.

The yellow LED is lit in static mode and flashes in flash mode.

Status LED

Orange Error LED bar 2

Green Alive (heartbeat)

Yellow ON: static mode PULS: flash mode

Red Error LED bar 1

Table 8-4 Status LEDs of the LED Controller

Figure 8-20 LED controller

8.8 CONFIGURING THE LED CONTROLLER

Normally the LED controller is preconfigured for the dedicated feeder. Should it be necessary to reconfigure the LED controller, the following procedure is applied:

1. All DIP switches (1 to 4) to ON 2. Power on 3. All LEDs blink for ca. 3 seconds 4. With the DIP switches 1 to 3 choose the feeder model:

Feeder DIP switch 1 DIP switch 2 DIP switch 3

SX240 Off Off Off

SX160 On Off Off

Table 8-1 LED Controller Konfiguration


5. Turn off DIP switch 4 → settings are saved (LED blinks slowly) 6. Turn off power 7. Set DIP switches 1 to 4 according to the desired operation mode (flash/ static) (see

section 8.6).

This configuration can be changed as often as needed.

When turning on the controller, all the status LEDs light up briefly. Then they show for which feeder the LED controller has been configured (ca. 0.5 seconds):

Feeder Orange Green Yellow Red

SX240 On

SX160 On

Table 8-5 Status LEDs show chosen feeder model

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