GSi FLX-5260 Bedienungsanleitung

PNEG-1955

Flex-Flo Control Unit

Operation Manual

PNEG-1955

Date: 07-23-14

2PNEG-1955 Flex-Flo Control Unit

Table of Contents

PNEG-1955 Flex-Flo Control Unit 3

Contents

Chapter 1 Safety .....................................................................................................................................................4

Safety Guidelines ...................................................................................................................................4

Chapter 2 Operation and Maintenance of Flex-Flo Control Unit .......................................................................6

Standard Systems ..................................................................................................................................6

Extension Systems .................................................................................................................................6

Indicator Lights Under Toggle Switch ....................................................................................................6

LED Indicator Lights Inside Enclosure ...................................................................................................7

Safety Backup Switch Time Delay .........................................................................................................7

Safety Backup Switch Sensitivity Level Adjustment ...............................................................................7

Replacing Top Circuit Board ..................................................................................................................9

Chapter 3 Parts List .............................................................................................................................................10

Flex-Flo Control Unit (FLX-5260) .........................................................................................................10

Chapter 4 Wiring Diagrams .................................................................................................................................12

Flex-Flo Control Unit Used with 5 Wire Sensor ....................................................................................12

Flex-Flo Control Unit Extension System - Dependent ..........................................................................13

Flex-Flo Control Unit Extension System - Independent .......................................................................14

Flex-Flo Control Unit Used with Hopper Level Controls .......................................................................15

Flex-Flo Control Unit Used with IR Plus Feed Sensor .........................................................................16

Flex-Flo Control Unit Used with IR Plus Feed Sensor as Hopper Level Controls ................................17

Flex-Flo Control Unit Used with Smart IR Sensor ................................................................................18

Flex-Flo Control Unit Used with 3 Phase Power ..................................................................................19

Flex-Flo Control Unit Used with Universal Sensor ...............................................................................20

Chapter 5 Warranty ..............................................................................................................................................21

4PNEG-1955 Flex-Flo Control Unit

1. Safety

Safety Guidelines

This manual contains information that is important for you, the owner/operator, to know and understand.

This information relates to protecting personal safety and preventing equipment problems. It is the

responsibility of the owner/operator to inform anyone operating or working in the area of this equipment

of these safety guidelines. To help you recognize this information, we use the symbols that are defined

below. Please read the manual and pay attention to these sections. Failure to read this manual and its

safety instructions is a misuse of the equipment and may lead to serious injury or death.

DANGER

WARNING

CAUTION

This is the safety alert symbol. It is used to alert you

to potential personal injury hazards. Obey all safety

messages that follow this symbol to avoid possible

injury or death.

This symbol indicates a potentially hazardous situation

which, if not avoided, may result in serious injury or death.

This symbol indicates a potentially hazardous situation which,

if not avoided, may result in minor or moderate injury.

This symbol indicates a potentially hazardous situation

which, if not avoided, may result in property damage.

This symbol indicates an imminently hazardous situation

which, if not avoided, will result in serious injury or death.

1. Safety

PNEG-1955 Flex-Flo Control Unit 5

Install and Operate Electrical Equipment Properly

Electrical controls should be installed by a qualified electrician

and must meet the standards set by the National Electrical Code

and all local and state codes.

Disconnect and lock out all power sources before installing

wires/cables or servicing equipment.

Electric Shock Hazard

Prepare for Emergencies

Be prepared if fire starts.

Keep a first aid kit and fire extinguisher handy.

Keep emergency numbers for doctors, ambulance service,

hospital, and fire department near your telephone. Keep Emergency Equipment

Quickly Accessible

Wear Protective Clothing

Wear close-fitting clothing and safety equipment appropriate

to the job.

Remove all jewelry.

Tie long hair up and back.

Wear safety glasses at all times to protect eyes from debris.

Wear gloves to protect your hands from sharp edges on plastic

or steel parts.

Wear steel-toed boots to help protect your feet from falling

debris. Tuck in any loose or dangling shoestrings.

A respirator may be needed to prevent breathing potentially

toxic fumes and dust.

Wear a hard hat to help protect your head.

Wear appropriate fall protection equipment when working at

elevations greater than six feet (6').

Eye Protection

Gloves

Steel-Toed Boots

Respirator

Hard Hat

Fall Protection

6PNEG-1955 Flex-Flo Control Unit

2. Operation and Maintenance of Flex-Flo Control Unit

Standard Systems

The Flex-Flo Control Unit is primarily controlled by an auxiliary switch, such as a proximity switch or

infraredsensororhopperlevelcontrol. Refertowiringdiagramson Pages 12-20that matches theauxiliary

switch used. The auxiliary switch is installed underneaththe Flex-Flo Control Unit. The Flex-Flo auger can

only run when the auxiliary switch is calling for feed. If the auxiliary switch fails to shut the Flex-Flo auger

OFFwhen the feedisfull, thefeedwill build-upinsidethebox behind thecontrol unitandthesafety backup

switch will be activated. As a result, the Flex-Flo auger will shut off until the feed drops away.

Extension Systems

The Flex-Flo Control Unit may also be used to control a fill system auger that feeds into an extension

systemauger.In thecaseof an extensionsystem, there is no auxiliaryswitchused to controlthefillsystem

auger. If the fill system auger is to be controlled independent of the extension system auger, there must

be a jumper wire across the “Auxiliary” switch terminals marked “Signal IN” and “Signal Out” of the fill

system control unit. Refer to wiring diagram for “Flex-Flo Control Unit Extension System - Independent”

on Page 14. When wired this way, the fill system auger is controlled by the safety backup switch.

If the fill system auger is to be controlled by the extension system auger, there needs to be a two (2)

conductor cord from the fill system control unit “Auxiliary” terminals marked “Signal IN” and “Signal Out”,

to the extension system control unit terminals marked “Relay Output”. Refer to wiring diagram for

“Flex-Flo Control Unit Extension System - Dependent” on Page 13. When wired this way, the fill system

auger is controlled by the extension system control unit.

Indicator Lights Under Toggle Switch

There are two (2) indicator lights on the end of the Flex-Flo Control Unit underneath the toggle switch.The

lower light is green and indicates that the toggle switch is ON and the safety backup switch has not been

activated.TheFlex-Floaugerwill be allowedtorunif theauxiliaryswitchis callingforfeed,whenthis green

light is ON. (See Figure 2A.)

The upper light is red and indicates that the toggle switch is ON and the safety backup switch has been

activated. The Flex-Flo auger will not run when this red light is ON. (See Figure 2B.)

Figure 2A Control on Box - Green Figure 2B Control on Box - Red

2. Operation and Maintenance of Flex-Flo Control Unit

PNEG-1955 Flex-Flo Control Unit 7

LED Indicator Lights Inside Enclosure

There are three (3) LED indicator lights inside the enclosure on the lower left portion of the bottom PC

board. The left LED is red and indicates when the Flex-Flo Control Unit is in “sensitivity level programming

mode” used to adjust the sensitivity level of the safety backup switch.

The center LED is yellow and indicates whenthe safety backup switch has been activated and is detecting

feed. When this light is ON, the Flex-Flo auger will not run.

The right LED is green. When it is on solid, the safety backup switch has not been activated and the

Flex-Flo auger will be allowed to run as long as the auxiliary switch is calling for feed. When the green LED

is flashing, the Flex-Flo auger is in the 30 seconds time delay period prior to being allowed to run.

(See Figure 2C.)

Figure 2C LED Indicator Lights Inside Enclosure

Safety Backup Switch Time Delay

The Flex-Flo Control Unit safety backup switch has a fixed 30 seconds time delay. Once feed falls away

from the safety backup switch, the Flex-Flo Control Unit will begin to count down until the 30 seconds has

expired. At that time, the Flex-Flo auger will be allowed to run as long as the auxiliary switch is calling for

feed. The green LED inside the enclosure on the lower left portion of the bottom PC board will flash during

the 30 seconds timedelay period. Once the 30 seconds time delay period has expired, the green LED will

remain on solid and the Flex-Flo auger will be allowed to run.

Safety Backup Switch Sensitivity Level Adjustment

The safety backup switch inside the Flex-Flo Control Unit does not rely on feed pressure to activate. It

uses a special sensor inside the enclosure that can sense the presence of feed through the back plastic

wall of the enclosure. When feed builds up to a level that is even with the center of the enclosure, it

activates the safety backup switch. This prevents feed pressure from causing a bridging event once the

feed falls away.

NOTE: The safety backup switch is factory adjusted to the proper sensitivity level for most feeds. It should

only require adjusting if it fails to activate when feed builds up inside the box behind the control unit

enclosure and causes the auger motor’s thermal overload protector to kick out.

WARNING

While adjusting the sensitivity level of the Flex-Flo Control Unit’s safety backup

switch, there is live high voltage power inside the enclosure. Use a screwdriver with

an insulated handle to adjust the sensitivity level. While adjusting the sensitivity

level, make sure to never touch any terminals or exposed bare wire ends.

2. Operation and Maintenance of Flex-Flo Control Unit

8PNEG-1955 Flex-Flo Control Unit

IMPORTANT: Before adjusting the sensitivity level, make sure there is no feed inside the box behind the

control unit. Attempting to adjust the sensitivity level with feed inside the box behind the

control unit will result in failure of the safety switch.

Inside the enclosure, located on the lower right portion of the bottom PC board, is a square shaped push

button switch. It is used for programming the sensitivity level of the safety backup switch. To program the

sensitivity level, carefully insert a small screwdriver with an insulated handle and push the switch once,

and then hold down for approximately 5 seconds until the red LED comes ON. Then release the button.

The flashing red LED indicates that the control is in “sensitivity level programming mode”. The red LED

will continue to flash the same number of times equal to the setting, 1 through 6 for several cycles.

Setting 1 is the least sensitive. Setting 6 is the most sensitive. A setting of 3 or 4 works the best for most

types of feed. To advance to the next setting, push and release the switch once. The number of flashes

will then be advanced to the next higher setting. The settings will roll over from 6 back to 1. Once the

desired setting is achieved, wait until the red light stops flashing. All three (3) LED’s will then begin to flash

alternately for 30 seconds. Once the 30 seconds has expired, the control will jump out of “sensitivity level

programming mode” back to normal operation. (See Figures 2D and 2E.)

Figure 2D Delay Adjustment

Figure 2E Delay Red Flash

2. Operation and Maintenance of Flex-Flo Control Unit

PNEG-1955 Flex-Flo Control Unit 9

Replacing Top Circuit Board

Before determining if top circuit board is bad, contact your nearest AP or Cumberland Service

Representative to aid in diagnosis.

To replace the top circuit board, begin by removing the “Incoming Power” and “Flex-Flo Motor” wires from

the left terminal block. Un-plug the “Auxiliary Switch” terminal block plugs on the right side of the top circuit

board. Unplug the “Toggle Switch” spade terminal wires from the top board. Remove the four (4) screws

(S-7393) that secure the top board to the bottom board.

IMPORTANT: The left end of the top circuit board is plugged into a socket on the bottom circuit board, so

you must wiggle the top circuit board back and forth, while applying upward pressure until

the board becomes free.

To attach a new top circuit board, reverse the procedure above. Be sure the plug on the left side of the

circuit board is aligned with the socket on the bottom board before pressing into place. (See Figures 2F

and 2G.)

Figure 2F Remove Connections from Board

Figure 2G Removing Board

10 PNEG-1955 Flex-Flo Control Unit

3. Parts List

Flex-Flo Control Unit (FLX-5260)

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