The FCB is Firgelli's proprietary synchronization component. This device will maintain synchronous control over all attached feedback actuators; keeping them within 1/8" over the course of motion. All attached actuators will operate as one unit without individual actuator control.
The FCB units are not our first attempt at Synchronizing control boxes; we've had similar products for years. The FCB is the next generation - these units have superseded all previous control boxes and provide more features and electrical capability.
FCB Setup & Wiring (All FCBs)
Wiring Guide (Feedback Actuators)
Setup Video [All FCBs]
The Homing and Calibration routines do not use any FCB settings. They will not listen to limit settings or speed settings. Both of these set-up steps will run all attached actuators at full speed to the physical limit switches at each end of the actuators; any unit-to-unit speed differences will not be accounted for. We recommend running initial homing and calibration on a bench.
FCB Settings & Functions [All FCBs]
The FCB will allow you to limit each end of the actuator’s stroke, as well as set a speed for extension and retraction. These settings are a percentage of the actuator’s maximum capabilities, as controlled by the “actuator settings” on the board. The FCB will not increase the speed of actuators.
The FCB also has 5 weekly timers and one interval timer built in. Each "weekly timer" allows you to set a time of day to extend and a time to retract. It will follow this time schedule to operate on specific days of the week, as set by the user. To use the weekly delay timers, you will need to set the date and time on the FCB in System Settings. Note the date is not a standard format - it is in YY / MM / DD format. (Example: February 3rd, 2001 would be 01/02/03)
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. [At time of writing, you most likely have a second-edition FCB or newer model]
Feedback: On or Off? What's the upside? [All FCBs]
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.
RF Remote Pairing & Unpairing [FCB-2]
The Newest Firgelli Control Box with Integrated RF (model FCB-2) has all the best features of previous FCB 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.
FCB restrictions and workarounds (All FCBs)
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).
FCBs will operate on 12v or 24v DC power; however, there is a control chip inside the unit that cannot go over 25v. If you are using an FCB on a 24vDC system, you want to ensure constant voltage to the FCB.
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-) - Potentiometer Feedback not processed by FCB.
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.
Situational Example:
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 should leave the speed settings at 100%. This is because power is equal to the voltage multiplied by the amperage (P=i*V); voltage is directly correlated to the speed of the actuator; amperage is directly correlated with force. When the controllers lower the speed (voltage) fed into the motor, it must also raise the current (amps) to ensure the same amount of power is applied. With the 10A draw units, this can cause the FCB to adjust the amps beyond the FCB capabilities, which would result overcurrent errors.
We recommend using a higher-force Bullet .50 with the FCB-system if you are near the load capacity of the 500 lbs. units.
Errors & Troubleshooting
The FCB will give error indications or on-screen messages in the event of operation failure. On screen messages will say Overcurrent or Stuck; failure to operate for other reasons usually results in a flashing red indicator light - a red indicator light itself does not mean there is an issue, as it can also show up during normal operation under certain conditions.
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.
"Overcurrent" simply means that the actuator motors drew too much power - either the units are overloaded, speed settings have been reduced too far, or there may be a short in the system.
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.
FCB Caveats for Use and Solutions:
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. This concept may be applicable to other types of circuit breakers.
