Pneg-914 - Automated Production Systems
Contents
1. JUMPER WIRE FLEX FLO FLEX FLO MOTOR MOTOR GND GND 208 230VAC 208 230VAC L2 POWER SUPPLY POWER SUPPLY L1 L1 TAPE FOR PROTECTION AP 2983 UNIVERSAL SENSOR N O ORANGE NOT USED m LINE BROWN G D i N C RED 52 PNEG 914 Installation and Operation of Flex Flo T Wiring Diagrams Flex Flo Control Unit Used with Hopper Level Controls FLEX FLO CONTROL UNIT FLX 5260 7051400 HOPPER LEVEL CONTROL 1 e COM 7 S Q3 N C GND D BLACK S Ko e ces a 7051400 HOPPER LEVEL CONTROL 2 C COM d NC GND D BLACK e e ES J FLEX FLO MOTOR W GND 208 230VAC L2 POWER SUPPLY L1 PNEG 914 Installation and Operation of Flex Flo 53 54 7 VViring Diagrams Flex Flo Control Unit Used vvith IR Plus Feed Sensor FLEX FLO CONTROL UNIT FLX 52602. UNIVERSAL SENSOR AP 2983 GROMMET INSERTION LINE FLEX FLO MOTOR j CY LLI N 5 O Z Lu Z GND z S a L2 208 230VAC T m POWER SUPPLY E o i L1 2 4 Z TAPE FOR PROTECTION PNEG 914 Installation and Operation of Flex Flo 8 VVarranty GSI Group LLC Limited VVarranty The GSI Group LLC GSI warrants products which it manufactures to be free of defects in materials and workmanship under normal usage and conditions for a period of 12 months after sale to the original end user or if a foreign sale 14 months from arrival at port of discharge whichever is earlier The end user s sole remedy and GSI s only obligation is to repair or replace at GSI s option and expense products that in GSI s judgment contain a material defect in materials or workmanship Expenses incurred by or on behalf of the end user without prior written authorization from the GSI Warranty Group shall be the sole responsibility of the end user Warranty Extensions The Limited Warranty period is extended for the following products Performer Series Direct Drive Fan Motor Warranty prorated from list price AP Fans and Flooring All Fiberglass Housings 0 to 3 years no cost to end use
3. FLEX FLO MOTOR GND 208 230VAC L2 POWER SUPPLY L1 SMART IR SENSOR FLX 4951 SMART IR SENSOR O WITH LID REMOVED RELAY OUTPUT ALARM CONTACTS 230VAC ony POWER 599 SUPPLY COM N O GND L1 L2 YELLOW YELLOW PNEG 914 Installation and Operation of Flex Flo T Wiring Diagrams Flex Flo Control Unit Used with 3 Phase Power FLEX FLO CONTROL UNIT FLX 5260 o 9 E 69 W UNIVERSAL SENSOR AP 2983 GROMMET INSERTION LINE FLEX FLO 3 PHASE MOTOR GND e S L3 208 230VAC o d 3 PHASE G L2 POWER SUPPLY m Z L1 8 N O ORANGE NOT USED TAPE FOR PROTECTION PNEG 914 Installation and Operation of Flex Flo 58 7 VViring Diagrams Flex Flo Control Unit Used with Universal Sensor FLEX FLO CONTROL UNIT FLX 5260
4. Figure 5E Part Description 16 60 Hopper Collar 24 Holes 16 60 Hopper Collar 27 Holes 16 60 Hopper Collar 18 Holes 6 BUCIMS SieGueShdd 5 16 x 1 Truss Head Machine Screw sam Wi98NfonnsenNu 9 sse SW ron vashe OOS S 8328 Screw MS 5 16 18 x 1 RHS ZN Grade 2 S 396 Hex Nut 5 16 18 YDP Grade 2 PNEG 914 Installation and Operation of Flex Flo 15 16 5 Installation Inspection Clean Out Plate Installation Once the installation of the auger tubes and auger is complete insert the inspection clean out plate or the optional unloader switch The inspection clean out plate is to be installed per the following instructions See Figure 5F 1 Back off both wing nuts to the stud ends 2 Slide the plate onto the lower side of the unloader opening 3 Move the plate first against the side of the unloader then upward toward the top of the unloader 4 Tighten the wing nuts while holding the plate steady Figure 5F Clean Out Plate Installation PNEG 914 Installation and Operation of Flex Flo 5 Installation Feed Tank Collar The standard bulk feed tank is supplied with a 16 40 64 cm hopper opening If needed 22 55 88 cm hopper openings are also available Consult the dealer for specific ordering instructions Restrictor Adjustment The restrictor may be adjusted to allow more feed flow Do not modify the r
5. IR PLUS FEED SENSOR FLX 5262 GENE e a S O IR PLUS FEED SENSOR e WITH LID REMOVED IT 2 Time Delay 0 Sec PONO EARTH GND LINE 2 LINE 1 30 Sec mu 60 Sec B 90 Sec B FLEX FLO ol BM O 7 MOTOR e E GND 208 230VAC L2 POWER SUPPLY L1 PNEG 914 Installation and Operation of Flex Flo T Wiring Diagrams Flex Flo Control Unit Used with IR Plus Feed Sensor as Hopper Level Controls e ME cepi a Q O Se B 995 06 aa1 e 095 09 Jony 98S 0 aa1 moj S 08S 0 c IN QNO H1HVH Kejaq eui u LJ 9 Q3AONHH QITHLIM O HONG Q33H SfYld Hl O NC Y
6. c928 X 14 HaddoH HOS HOSNIS 4334 SNld HI A1ddnS H3MOd OVAOE c 80c HO LOIN O 14 X3 1h LaNIT dau N3dH9 MOTI3A aa1 199190 m aa1 JeBny el aJl JOMOd a c INI ON H1HV3 995 06 995 09 995 0 995 0 Kejsa eu LO MOTI3A O Q3AON3H GIT HLIM YOSNAS Qq33H SN 1d 0 Re c928 X 14 Z HaddoH HOS HOSN3S Q33H SNId HI JO ON O 4 X9 4 19Mogd Bulwodu SERA i T Li SALLA 9 o 0928 X 13 LINN IOHLNOO O13 X314 55 PNEG 914 Installation and Operation of Flex Flo 56 7 VViring Diagrams Flex Flo Control Unit Used vvith Smart IR Sensor FLEX FLO GONTROL UNIT FLX 5260
7. O M s79 L ns MS 46 32 x TI R K Side ZN Grade2 r 1 seis HeNt632Gudeg TJ 16 pe Ring Terminal 10 Insulated Ja ATI WRABGRN YLW Wire 16 Gauge GreenYelow Stranded Mr 18 FDX2690 J Electrical Se Gei SCs 19 F n TJ Electric Box tia TJ 20 DO108 amp Decal Flex Flo Control Urt 3 m ses SwwMSHORXIPHPSS TJ zz sra HexNuMI0MSS Box 13 3 4 x 5 1 2 x 5 1 2 200C FPF Not Shown RENI I in 48 PNEG 914 Installation and Operation of Flex Flo 6 Parts List Micro Drop Tube Switch Proximity Switch Micro drop tube switch Proximity switch Micro Drop Tube Switch mel me mmm m ENLLNNL LIII Lr uem Tester x ster Lenmsammmnse Proximity Switch ml mm Je Inge FLX 2425 Drop Tube 3 I D x 12 3 65 Meters Ra FLXDF 1172 Capacitive Proximity Switch NC 20 250 VAC en S 7906 1 2 Cord Connector EN PNEG 914 Installation and Operation of Flex Flo 7 VViring Diagrams Flex Flo Control Unit Used vvith 5 VVire Sensor FLEX FLO CONTROL UNIT FLX 5260 Auxiliary Switch GREEN BLACK BROWN 7 LH ki ym II PROXIMITY SWITCH AP 1002 a ee N O ORANGE NOT USED COM GREEN LINE BLACK LINE BROWN FLEX FLO MOTOR GND TAPE FOR PROTECTION 208 230VAC L2 POWER SUPPLY L1 50 PNEG 914 Installation and Operation of Flex Flo T Wiring Diagrams Flex F
8. 300P 350 and HR Unloader and Anchor Assembly 41 Model 500 Unloader and Anchor Assembly aaa aaa ne enen e eee eee ene e eee enet eee eee ee eee eee ee eee eee 42 Direct Drive Driver and Plastic Tube Anchor Package ccccsesecceeesseeeeeeeeeeeeaeeeeeeeseeeeesseeeeeeseeeeeeeas 43 Belt Drive Driver and Plastic Anchor Package aaa aaa aaa anen nane eee kane eee eee petet epet eee kete eee eee tere tepert eee 44 aide sE ee E inte ecifetsc deste vie Se suepesice dane cide ie see is oat eeice need ee anecdote eevee 45 Belt D ve Power H le EE 46 Drop Kit Kwik Attach Drop Kit aa lt 2ivaaadisansactinassivicaausielsitabiesnndsdanancadeniumats 47 Bi ere WC EE 48 Micro Drop Tube Switch Proximity Switch 49 Chapter 7 Wiring Diagrams Ga garuan da 50 Flex Flo Control Unit Used with 5 Wire Sensor aaa aaa aaa near eee e e eee nente pere eee epe nete eee eee ee ede eee tere 50 Flex Flo Control Unit Extension System Dependent aa nana aaa ne eee enn eee e dine eee idene eee idene ee epet eee 51 Flex Flo Control Unit Extension System Independent aaa nana anen nana need enet eee eee e eee ee ee eee eee 52 Flex Flo Control Unit Used with Hopper Level Controls aaa aaa aaa aanane eee na e need eee eee penne e eee eee ee nente 53 Flex Flo Control Unit Used with IR Plus Feed Sensor aaa aaa anen eee kene eee pene 54 Flex Flo Control Unit Used with IR Plus Feed Sensor as Hopper Level Controls 55 Flex Flo Control Unit Used with Sm
9. S Pes mees es oeer ro ser D Deeg OOO 14 See Direct Drive Power Unit Assembly Part Numbers on Pages 37 39 1 2 HP Belt Drive Motor 110 220V 1 PH 60 Hz Farm Duty 012 1 012 1 012 1 012 1 012 1 5 8 Shaft N S 034 1 034 1 034 1 034 1 034 1 3 4 HP Belt Drive Motor 110 220V 1 PH 60 Hz Farm Duty 5 8 Shaft 1 HP Belt Drive Motor 110 220V 1 PH 60 Hz 1750 RPM NS rums Tee oan roca en apen PNEG 914 Installation and Operation of Flex Flo 6 Parts List Direct Drive Power Unit Assemblies I V e Ss LA c i ab m du 9 U N Gearbox orientation PNEG 914 Installation and Operation of Flex Flo 37 6 Parts List Direct Drive Power Unit Assemblies Parts List Direct Drive Power Unit Gearbox Orientation e ene in aot Pin se ru ro Jr os mess ESTEE Prae pmu remore em um m nium rocs nn 38 PNEG 914 Installation and Operation of Flex Flo 6 Parts List Direct Drive Povver Unit Assemblies Parts List Continued Direct Drive Povver Unit Gearbox Orientation e ene wane Tree Pn COC we cme oe ee Prema oor eae vo vezore ae a rosa woe nx PNEG 914 Installation and Operation of Flex Flo 39 6 Parts List Model 220 Unloader and Anchor Assembly Description Qty Ret Model 220 Flex Flo Single through Unloader Body Assembly 6 s449 2 1 4 Tube Clamp Model 220 8 1004042388 Iron
10. Ball 3 Hollow 1 1 2 st s room ese 20 ox Fo ube Soy resoni 1 16 30 Black Plastic Boot 16 30 Clear Plastic Boot PNEG 914 Installation and Operation of Flex Flo 6 Parts List Model 300 300P 350 and HR Unloader and Anchor Assembly Model 300 Model 300P Model 350 Modet300 OO O Le ees ome Seege ege Iron Ball 3 Hollow 1 1 2 Iron Ball 3 Hollow 1 1 2 Iron Ball 3 Hollow 1 1 2 RENI 7 FLX 4648 M 300 Anchor and Bearing FLX 5214 M 300P Anchor and Bearing FLX 4650 M 350 Anchor and Bearing Assembly Assembly Assembly Model 300 Flex Flo Single through Model 300 Flex Flo Single through Model 350 Flex Flo Single Eg pjes Unloader Body Assembly Be Unloader Body Assembly ees through Unloader Body Assembly ES S 9186 3 1 4 Tube Clamp Model 300 S 9186 3 1 4 Tube Clamp Model 300 S 4443 4 Tube Clamp Model 350 FLX 2217 Model 220 300 350 Flex Seal Ring FLX 2217 Model 220 300 350 Flex Seal Ring FLX 2217 A 20 300 S90 Flex rds T FLX 3422 Neoprene Seal FLX 3422 Neoprene Seal FLX 3422 Neoprene Seal 4 Model 300 Flex Flo Tyvin through 1 Model 300 Flex Flo Twin through Model 350 Flex Flo Twin through E Unloader Body Assembly PESE Unlosader Body Assembly DESSEN Unloader Body Assembly 13 FLX 4819 Unloader Brace FLX 4819 Unloader Brace FLX 4819 Unloader Brace PNEG 914 Installation and Operation of Flex Flo 41 42 6 Parts List Model 500 Unloader and Anchor Assembly Pat Peseription 2 5 1 2
11. NOTE Make sure the fiber washer is against the end of the pinion shaft G 6 Re install the gearbox C to the motor J using the bolt A and washer B previously removed See Figure 5W Tighten bolt to 50 in lbs NOTE The space between the back face of the pinion and face of the motor must be 9 16 Figure 5W E S 7409 Flat Washer 3 8 SAE ZN Grade 2 S 7225 Bolt SHCS 5 16 18 x 1 1 4 ER S 1147 Lenin Lock Washer 5 16 ZN FLX 5264 Gasket for Bolt Blue Guard 3000 See Chart Gear Pinion Shaft p Me rep 7 ER S 10293 Bolt HHCS 3 8 16 x 1 2 Grade 5 Zinc PNEG 914 Installation and Operation of Flex Flo 28 5 Installation Belt Drive Power Control Unit 1 Bolt the tube anchor to the control unit body with a flat washer on each of the four 4 5 16 x 3 4 bolts See Figure 5Q on Page 25 for more details 2 Insert the driver shaft through the bearing assembly The bearing mounting plate should be mounted in between Tighten the set screw on the bearing down to the shaft 3 Bolt the two 2 mounting brackets together with the four 4 bolts and washers provided 4 Attach the motor support assembly to the control unit with the four 4 bolts already in the mounting bracket and belt guard Secure with the four 4 lock washers and hex nuts provided If necessary motor orientation can be reversed by rotating the motor mount 180 5 Slide and clamp a tube coupler on the anchor Figure 5X Belt Dri
12. Tube Clamp Model 500 Model 500 Flex Seal Ring 5 Clean Out Plate Assembly e Fixzise M500 Anchor and Bearing Assembly 1 8 FLX 2095 4 5 Control Unit Seal FLX 2194 16 30 Black Plastic Boot E NI FLX 2194C 16 30 Clear Plastic Boot 10 FLX 2195 16 Straight Black Plastic Boot FLX 2195C 16 Straight Clear Plastic Boot PNEG 914 Installation and Operation of Flex Flo 6 Parts List Direct Drive Driver and Plastic Tube Anchor Package emm FLX 5275 Model 220 Direct Drive Driver and Plastic Tube Anchor Package FLX 5279 Model 300 Direct Drive Driver and Plastic Tube Anchor Package FLX 5282 Model 300P Direct Drive Driver and Plastic Tube Anchor Package i FLX 5286 Model 350 Direct Drive Driver and Plastic Tube Anchor Package 2 lt FLX 5293 Model 500 Direct Drive Driver and Plastic Tube Anchor Package Model 300 Positive Lock Direct Drive Spindle Model 300P Positive Lock Direct Drive Spindle Model 350 Positive Lock Direct Drive Spindle Model 500 Positive Lock Direct Drive Spindle Model 300 300P and 350 Auger Lock Clamp Pin Model 500 Auger Lock Clamp Pin Set Screw 5 16 18 x 1 2 SQ HD BK Cup Point Bolt SHCS 5 16 18 x 1 1 2 Type B Cup Point Grade 8 Alloy Steel Model 300 and 350 2 5 16 18 x 2 1 2 Hex Socket Cap Screw Model 500 Ct a LS m 0TubeAnchor Moe 3 M300 and M300P Tube Anchor Molded E 3 4 Lem Mode 600 Tube Anchor Wiel 6 mm J HexNut r16 18 Enge 7 aeos Clamp
13. a direct drive power unit or a belt drive power unit Building Safety If you are intending to install the Flex Flo System at high levels and or suspended from a building structure it is important that you check the structural integrity of the building to carry the additional load For information on the imposed loads on the building by the Flex Flo System please contact the dealer or the GSI Group Installation Sequence This manual outlines the recommended order for the installation of the Flex Flo System Following this guideline will provide the safest and easiest method of installation Above all connection of the system to the electrical mains should be the final stage of installation Failure to observe this could lead to a fatal accident PNEG 914 Installation and Operation of Flex Flo 4 Flex Flo Specifications English Metric Flex Flo Systems Specifications A Model 220 Model 300 Model 300P Model 350 Model 500 Model HR e 2i D 5 nc 3 15 Ibs min 50 Ibs min 50 Ibs min 100 Ibs min 220 Ibs min 50 Ibs min 7 kg min 22 kg min 22 kg min 45 kg min 100 kg min 22 kg min 900 Ibs hr 3000 Ibs hr 3000 Ibs hr 6000 Ibs hr 13200 Ibs hr 3000 Ibs hr 420 kg hr 1400 kg hr 1400 kg hr 2700 kg hr 6000 kg hr 1400 kg hr Carrying Capacity based on 40 Ibs cubic ft High moisture shelled corn up to 27 or ground feed 3 8 9 52 mm dia x 3 4 19 05 mm long 1 8 3 175 mm x 1 2 12 7 mm L max Crumble typ
14. anchor from the unloader Remove the control unit cover plate as well 2 Feed the auger carefully into the Flex Flo System through the unloader Remove the anchor from the unloader and remove the control unit cover plate 3 Push the auger in until it reaches the control unit at the other end Fasten the end of the auger to the clamp pin in the control unit driver assembly Tighten the 5 16 hex head cap screw holding the auger lock clamp pin to 23 ft Ibs If the auger end is not in the appropriate orientation for connection the driver assembly may be rotated by turning the motor drive shaft 4 Pull and release the free end of the auger gently a few times This action should relax the auger into its natural position 5 A certain mechanical stress must be applied when installing the auger therefore stretching the auger is very important This is performed by drawing the auger out of the tubing An important factor is the total system length The auger should be drawn out of the tubing 2 5 cm for every 50 15 m of length for single feed tanks For tandem systems stretch the auger 4 10 cm for every 50 15 m of length See Figure 5Z 6 While the auger is in the relaxed state mark the auger at the unloader inlet o Stretch flex auger Stretch flex auger Single feed tank 2 50 mm per 50 15 m of length Tandem feed tank 4 100 mm per 50 15 m of length Mark here Figure 5Z Stretching the Auger PNEG 914 Instal
15. rope end through the red ball and tie a knot in the rope to hold the ball in place Install the green ball the same way on the other rope end 8 Apply a small amount of PVC cement around the drop to prevent it from moving around on the auger tube 9 Two 2 screws are supplied for attaching an optional drop tube See Figure 5N on Page 22 Use both screws to attach the drop tube securely to the drop kit Kwik Attach Drop Kit Installation PVC Tubing Hose clamp 2 Figure 5O Kwik Attach Drop Kit Installation 1 Snap the slide around the tube over the outlet hole See Figure 5O 2 Fasten the housing to the tube using two 2 hose clamps Make sure the outlet hole is in the middle of the housing 3 Slide can be rotated from side to side to open and close the drop kit PNEG 914 Installation and Operation of Flex Flo 23 24 5 Installation Power Unit and Control Unit The safety switch on the control unit is provided as a backup switch in case the hopper level or the drop tube switch does not operate properly This switch is not intended to be used for controlling the Flex Flo System but as a safety backup switch only Flex Flo offers two 2 different types of power units direct drive unit and belt drive power unit along with the control unit Installation instructions are provided with each power unit Horsepower requirements are based on length type of Flex Flo System installed number of turns tandem syst
16. 2f When the auger tubing between the unloader and the building is 15 4 57 m or longer the tubes should be supported Locate and cut the outlet holes needed in the remaining straight tubes For the exact size of outlet holes see section titled outlet holes on Page 21 Once ALL of the outlet holes are made and the tubing is dry fitted glue or clamp the tubes together per the instructions in the section entitled cementing procedure on Page 2f Suspend the auger tubes and elbows from the ceiling at least once every four feet 4 If horizontal elbows are used support them in at least two 2 places Chain and lag screws are provided in each suspension kit The tubes should be kept as straight and level as possible Do not include belled end when measuring along this surface 5 1 524 m Radius 15 Elbow 15 3 4 40 005 cm 30 Elbow 31 1 2 80 01 cm 45 Elbow 47 1 4 120 015 cm 6 1 829 m Radius 15 Elbow 20 3 16 51 276 cm 30 Elbow 40 5 16 102 394 cm 45 Elbow 60 1 2 153 67 cm 10 3 048 m Radius 15 Elbow 32 81 28 cm 30 Elbow 64 162 56 cm 45 Elbow 96 243 84 cm Figure 5K Cutting Chart for 45 Elbow NOTE Align all outlet holes in proper functional positions prior to gluing the tube joints together PNEG 914 Installation and Operation of Flex Flo 5 Installation Cementing Procedure Flex Flo Systems have specially formulated PVC tubing For strong tube co
17. 60 Control Unit Electrical Box 220V 22 FLX 5270 3 Terminal Block Plug Three 3 for Poly CU Connector PNEG 914 Installation and Operation of Flex Flo 45 6 Parts List Belt Drive Povver Unit I I I I I I I I 77 D Ref Fang Description 14 Belt Drive Power Unit Less Motor Belt Guard Cover 5 8 LD Locking Collar Bolt HHTB 5 16 18 x 1 3 4 ZN Grade 5 2 7 A Belt Single Groove Pulley 5 8 Bore AX51 Gripnotch Belt 14 A Belt Single Groove Pulley FLX 2987 Belt Guard Back S 280 Screw SDS 10 16 x 5 8 HWH ZN Flex Flo Anchor Bearing Assembly with Set Screw 10 Inner Belt Drive Motor Bracket 11 1 4 20 x 5 8 Allen Head Bolt 12 Key SQ 3 16 x 1 Long 13 Flat Washer 5 16 USS SAE YDP Grade 2 14 Hex Nut 5 16 18 YDP Grade 2 15 Bolt HHTB 5 16 18 x 2 1 2 ZN Grade 2 Bolt HHTB 5 16 18 x 3 4 ZN Grade 5 Eye Bolt 5 16 18 x 2 1 8 w Nut Motor 173 HP 1 PH 110 220V 60 Hz Farm Duty 5 8 Shaft Motor 1 2 HP 1 PH 110 220V 60 Hz Farm Duty 5 8 Shaft Motor 3 4 HP 1 PH 110 220V 60 Hz Farm Duty 5 8 Shaft Motor 1 HP 1 PH 60 Hz 110 220V 1750 RPM 5 8 Shaft Motor 1 1 2 HP 1 PH 60 Hz 110 220V 1750 RPM 5 8 Shaft PNEG 914 Installation and Operation of Flex Flo 6 Parts List Drop Kit Kwik Attach Drop Kit Kwik attach drop kit Drop Kit Description FLX2432 Model220 Drop
18. B amm Pi p in I i A ja du AN d d 7 u lilii SZ i f d d DA d se n d F 1 Zei T E THE j F T id PT ES FLEJ R S FFF ie j 8 i 22 ET i WK D H D LEY ieee Installati of Flex Flo Te SA S cs gen on and Operation Model 220 300 300P 350 500 and HR Installation and Ovvner s Manual PNEG 914 Date 06 15 15 PNEG 914 All information illustrations photos and specifications in this manual are based on the latest information available at the time of publication The right is reserved to make changes at any time vvithout notice PNEG 914 Installation and Operation of Flex Flo Table of Contents Contents Sol Lc 4 Cautionary Symbols Definitions eessssssessssssseeeeen nennen nennen nennen eee eee te tee eee eee meet 4 General Safety Statement ecelesie ee cesscsasas sas a EEN aa 4 4 44 es SEN eset zoti ses sene se sis ret 5 KE DCC m M 7 Scr ae NIT e e Te re Ne M 9 hYelele uopqd T 9 zie do Te RR RC e agi E 9 PCAC Ale EE 9 Installation SEQUENCE M EEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEMM 9 Chapter 4 Flex Flo Specifications English Metric 11111 e none ss rere rene e eee rere ne eee rere ee meme eee annnm 10 The Fe
19. DECHE The maximum length is for a system vvith three 3 elbovvs PNEG 914 Installation and Operation of Flex Flo 5 Installation Direct Drive Power Unit Control Unit 1 Bolt the tube anchor to the control unit body with a flat washer on each of the four 4 5 16 x 3 4 bolts See Figure 5Q for more details 2 Slide the driver assembly onto the power unit drive shaft Place the 5 16 hex socket bolt supplied with the driver assembly into the untapped hole of the driver through the drive shaft and tighten the bolt into threaded portion of the driver 3 Mount the control unit to the gearbox unit with four 4 5 16 x 3 4 bolts and four 4 flat washers which are supplied with the power unit See Figure 5H NOTE Gearbox is shipped without oil Fill with 15 oz of 80W 90 gear lube part FLX 4471 Figure 5Q Assembly of Tube Anchor to the Control Unit 4 The control unit and power unit require hard wiring The supply line wires into L1 and L2 N of the relay in the control unit The motor leads wire into the M1 and M2 of the relay in the control unit Auxiliary switch is wired into the male and female spade terminal of the control unit See Wiring Diagram on Pages 50 58 5 Slide and clamp a tube coupler on the tube anchor 6 Attach the power control unit to the Flex Flo tubing 7 Suspend power control unit firmly from the ceiling as shown in Figure 5S Support holes are provided on the power unit and the control u
20. Hose Stainess Steel 1 197167 297 Model 220 JA Clamp Hose Stainless Steel 3 4 Model 300 300P and 350 NE UNI Clamp 5 7 Geared Hose Model 500 BEES e S8s09 Bo SHCS 14 20 x 1 14 THD Lock Grade 8 Aloy gel Jr 9 Lg Ve 220 Drop Feed Control Anchor Package 3 i0 FiX45t9 Auger Lock Model 220 freie T FLX2685 Model 220 Direct Drive Anchor Washer Bolt SHCS 5 16 18 x 1 1 4 Cup Point eme Bolt HHCS 5 16 18 x 1 ZN Grade 5 04 HT u HATH PNEG 914 Installation and Operation of Flex Flo 43 6 Parts List Belt Drive Driver and Plastic Anchor Package 2 lt ij FLX 5274 Model 220 Belt Drive Driver and Plastic Tube Anchor FLX 5278 Model 300 Belt Drive Driver and Plastic Tube Anchor FLX 5285 Model 350 Belt Drive Driver and Plastic Tube Anchor KH FLX 5292 Model 500 Belt Drive Driver and Plastic Tube Anchor FLX 2979 Model 220 and 500 Positive Lock Belt Driver Model 300 Positive Lock Belt Driver Model 350 Positive Lock Belt Driver Model 300 and 350 Auger Lock Clamp Pin Bolt SHCS 5 16 18 x 1 1 2 Type B Cup Point Grade 8 Alloy Steel Model 300 Bolt SHCS 5 16 18 x 1 3 4 Type B Cup Point Grade 8 Alloy Steel Model 350 Bolt SHCS 5 16 18 x 2 1 2 Type B Cup Point Grade 8 Alloy Steel Model 500 aS 4 Leen Model 220 and s00BetDrver 2 S FUX496 Awerlok2DBetDier SC 6 S845 FlatWasher S USSZN Oooo a Bolt SHCS 1 4 20 x 1 1 4 THD Lock Grade 8 Alloy Steel BEEN 8 Fs Mz Tube Anc
21. Kit Nylon L r xaus Model 300 and 300P Drop Kit lon L rucmu moder 50 Drop Ki Nyon E E ruxams Modet 500 Drop Kit Nyo Screw SDS 10 16 x 5 8 HWH ZN s Jo Mode 20 800 300P 850 500 10 Sri Tue e fewa Ja Soia raced uitiy God e fera lem L s rxzuz Reimkww d Kwik Attach Drop Kit mus a Fee L 8545 ee Drop Ki for Node reese mz rare Drop Kit for Model 300 and 300P Single apco 110 Kwitcatach Drop Kit for Model 220236 Box or 10 Lesen parc Drop Kit tor Model 300 and 300P Box or 10 Model 220 PVC Flex Flo Tube 10 3 Meters w Belled End Model 300 and 300P PVC Flex Flo Tube 10 3 Meters w Belled End Hose Clamp Stainless Steel 1 3 4 2 3 4 Hose Clamp Stainless Steel 3 4 PNEG 914 Installation and Operation of Flex Flo 47 6 Parts List Unloader Switch Description Back Plate Unloader Switch Assembly Diaphragm Assembly Small Diaphragm Retainer Hex Nut 10 24 Grade 2 Cover Plate Assembly for Switch 6 3558 S 8 WasherEPDM Steel Backed Wing Nut 5 16 18 ZN Grade 2 8 FLX 4159 Unloader Switch Housing 9 sea Flat Washer 10 x 7 92 1 0 x1 2 O D x18 Gauge TSAE ZNGrade2 1 10 S200 N ckNuMIO24ZNGnde2 07097827 Micro Switch Spring Braket TJ 12 Fux3493 ControlUnit Switch Braoket O O fo mae ET
22. Radius Elbows X for 30 Boot ft X for Straight Boot ft H ft Model 500 with 6 Radius Elbow eee o qm ON pow 4a e s e eo ws so 75 15 mo 100 70 10 se 8e 15 10 mg so mo wo es vo 190 ns so 1s mo 9o 1o 1 19 Model 220 300 300P 350 and HR with 5 Radius Elbow X for 30 Boot ft X for Straight Boot ft H ft PNEG 914 Installation and Operation of Flex Flo 11 4 Flex Flo Specifications English Metric 1T ZA HH Figure 4D Equipment Orientation Charts Tank Centerline to Building Entrance Distance X from Given Height H Metric Model 220 with 10 Radius Elbows X for 30 Boot m X for Straight Boot m OT os 4e e se 4 9 185 91 395 W 258 x i e EE EE eS EE 244 488 396 610 549 E kee 805 594 as 716 6340 SE EE 6 10 Model 500 with 6 Radius Elbow X for 30 Boot m X for Straight Boot m mmm o a se 4 EE 12 PNEG 914 Installation and Operation of Flex Flo 4 Flex Flo Specifications English Metric Model 220 300 300P 350 and HR with 5 Radius Elbow X for 30 Boot m X for Straight Boot m WW E RAECACIEA 7 01 5 18 1 32 9 33 7 62 9 64 NITTI ZA HH Figure 4E Equipment Orientation Charts PNEG 914 Installation and Ope
23. THE LIMITED WARRANTY DESCRIPTION SET FORTH ABOVE SPECIFICALLY GSI MAKES NO FURTHER WARRANTY OF ANY KIND EXPRESS OR IMPLIED INCLUDING WITHOUT LIMITATION WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OR USE IN CONNECTION WITH I PRODUCT MANUFACTURED OR SOLD BY GSI OR Il ANY ADVICE INSTRUCTION RECOMMENDATION OR SUGGESTION PROVIDED BY AN AGENT REPRESENTATIVE OR EMPLOYEE OF GSI REGARDING OR RELATED TO THE CONFIGURATION INSTALLATION LAYOUT SUITABILITY FOR A PARTICULAR PURPOSE OR DESIGN OF SUCH PRODUCTS GSI shall not be liable for any direct indirect incidental or consequential damages including without limitation loss of anticipated profits or benefits The sole and exclusive remedy is set forth in the Limited Warranty which shall not exceed the amount paid for the product purchased This warranty is not transferable and applies only to the original end user GSI shall have no obligation or responsibility for any representations or warranties made by or on behalf of any dealer agent or distributor GSI assumes no responsibility for claims resulting from construction defects or unauthorized modifications to products which it manufactured Modifications to products not specifically delineated in the manual accompanying the equipment at initial sale will void the Limited Warranty This Limited Warranty shall not extend to products or parts which have been damaged by negligent use misuse alteration accident or whi
24. art IR Sensor aaa aaa aaa nenen eke ene see e eee e eee pene ee ee pene eee nnn 56 Flex Flo Control Unit Used with 3 Phase Power 57 Flex Flo Control Unit Used with Universal Sensor aaa nana aaa aaa nana ae aa ee nane eee eee eee rene nnne 58 See o Ec 59 PNEG 914 Installation and Operation of Flex Flo 1 Safety Cautionary Symbols Definitions Cautionary symbols appear in this manual and on product decals The symbols alert the user of potential safety hazards prohibited activities and mandatory actions To help you recognize this information we use the symbols that are defined below This symbol indicates an imminently hazardous situation which if not avoided will result in serious 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 is used to address practices not related to personal injury This symbol indicates a general hazard This symbol indicates a prohibited activity This symbol indicates a mandatory action vl PNEG 914 Installation and Operation of Flex Flo 1 Safety General Safety Statement Our foremost concern is your safety and the safety of others associated vvith grain handling equipment This manual is to help you understand safe operating procedures and some problems that may be encount
25. cess area between the tube and the hole in the building The seal ring and the neoprene seal shall be installed as shown in Figure 5J Outside of building wall Neoprene seal FLX 3422 Model 500 Flex seal ring FLX 2218 Figure 5J Seal Ring and Neoprene Seal Installation 2 Slide the elbow tubing through the hole in the building Establish and cut if necessary the elbow at the desire length to ensure that the auger tubing will be horizontal See Figure 5K on Page 20 for proper cutting dimensions of the elbows at specific degree angles 3 Fit and clamp a second elbow around the unloader outlet 4 Slide the non belled end of the straight tubing into the belled end of the building elbow Hold the straight tubing in the desired mounting position Mark and cut the unloader elbow at the point where it and the straight tubing intersect PNEG 914 Installation and Operation of Flex Flo 19 5 Installation Auger Tubing Installation Continued 5 Remove the non belled end of the straight tubing from the building elbovv Slide the belled end of the straight tubing over the freshly cut end of the unloader elbow Mark and cut the straight tubing as needed so that it will fit inside the belled end of the building elbow Dry fit all of the outside tubing to ensure correct installation Once satisfied glue or clamp the tubing together as per the instructions in the section titled cementing procedure on Page
26. ch have been improperly inadequately maintained This Limited Warranty extends solely to products manufactured by GSI Prior to installation the end user has the responsibility to comply with federal state and local codes which apply to the location and installation of products manufactured or sold by GSI 9101239 1 GR rev8 DOC revised January 2014 PNEG 914 Installation and Operation of Flex Flo 59 This equipment shall be installed in accordance vvith the current installation codes and applicable regulations which should be carefully followed in all cases Authorities having jurisdiction should be consulted before installations are made This product covered by U S Patent 8 056 506 umberland 1004 E Illinois St Assumption IL 62510 0020 Phone 1 217 226 4421 Fax 1 217 226 4420 WWW gsiag com Za Your Agriculture Company AP and Cumberland are a part of GSI a worldwide brand of AGCO Corporation Copyright O 2015 by The GSI Group LLC Printed in the USA CN 317990
27. der Figure 5H 3 Slide the belled end of a straight tube onto the unloader outlet on the first tank Hold the straight tubing in the desired mounting position Mark and cut the straight tube at the point where the tube and the inlet of the straight through unloader inlet intersect 4 Slip the appropriate tube coupler over the cut end of the straight tube Position the straight tube in its operating location Slide and clamp the tube coupler over the straight through unloader inlet See Figure 5l NOTE The coupler should be equally distributed between the tubing and the unloader inlet Single out unloader Single through unloader Tube coupler do bo cj Clamp Figure 5l Tandem System Installation 5 Feed the auger through the single twin out unloader to the rest of the system and anchor as instructed 18 PNEG 914 Installation and Operation of Flex Flo 5 Installation Auger Tubing Installation The auger tubing is one of the most important parts of the Flex Flo Fill System Proper installation is very important Dry fit ALL parts before cementing or clamping Once the complete system is fitting properly cement or clamp the entire system The following steps are to be performed in the exact order shown 1 Establish the entry point where the auger tube will enter the building Once the entry point is determined cut a hole large enough to accommodate the tubing A seal ring and a neoprene seal are provided to seal the ex
28. e Shelled corn or pellets Larger feed fragments like Maximum Particle feed mash 3 16 4 76 mm x 1 2 shelled corn or pellets 3 8 Size and Feed Type Crumble type feed mash moisture content 1896 and pellets 12 7 mm ground corn 9 52 mm x 1 25 4 mm L Model 220 Model 300 and 300P Model 350 Model 500 Model HR Figure 4A The Feed Tank Connections Feed Tank Orientation Positioning the feed tank in line with the Flex Flo System will provide the most trouble free operation possible Avoid unnecessary elbows and curves to ease system installation A feed tank with a 30 unloader is generally required to be at least 10 1 2 3 2 m away from the building With a straight unloader the tank will be approximately 4 1 22 m farther away from the building in order to make auger tube connections The reference points are based upon the height where the system enters the building Different unloaders with various elbows and curves used provide different entrance opportunities The distances are achieved by modifying and adjusting the elbows and tubing as needed See Table on Page 1 1 English or See Table on Page 12 Metric for tank placement recommendations Figure 4B 30 Unioader Figure 4C Straight Unloader 10 PNEG 914 Installation and Operation of Flex Flo 4 Flex Flo Specifications English Metric Tank Centerline to Building Entrance Distance X from Given Height H English Model 220 with 10
29. ed Tank Connections aa aaa aaa aaaa nenen ane e eee nen tipe eee teke e nene e eee eee tipe nete eee ee eee ede eee tee ee eee e eee ee ee eee nnns 10 Chapter 5 Installation ga ad ve nda cT 14 Boot ana Transfer Plate Installation EE 14 ee EECH TT e E 15 Inspection Clean Out Plate Installation aaa nnaaaaaaaanana ane e kene eee ede ae pere e ee eee eee nete eee ene ee epe eee e eee eee teke ete 16 Restrictor Acdustmment EM 17 otraight Through Tandem INStallauOn EE 18 Auger Tubing Installation gazeve PR EON REST 19 eG ING Geet Ga e omm 21 ET OI o5 V 21 TOPIN AMANOT nene e Umm 22 Kwik Attach Drop Kit Installation aaa aaa aaaana eee nane eee ne eee eee eee eee teen eter eee teke eee eee eee eee nnnm nnns 23 Fover uge Ke de UNG ne O 24 o mS 29 were dini zie cm 29 Extension Hopper Installation au naaaaaaaaaaaaaaaaae eee eee r enen eren ese kene teze e ete petet epet ere et epe ne neper n nnn eee nn nnns 31 EEN ne 33 GJ AKS LIST og ee n aa ada Gj etcetera m Rem 35 Flex Flo Feed Line Components aaa aa aaa nan ann eee e eee eee eee enet ee penne e eee nennen eee pene nnn nnn nnns nna nnns a nnn nnns 36 Direct Drive Power Unit Assemblies 37 Model 220 Unloader and Anchor Assembly aaa aaa e ena nene eee ne eee eee nete eee enet ee eee eee 40 Model 300
30. ems etc Table below shows maximum line lengths for Flex Flo Systems plus maximum lengths for extensions hopper installing using various power units Reduction of the maximum line lengths in the chart should be allowed for if the system s incline is greater than 45 and or the rise of the system is higher than 8 2 44 m For each additional 90 2 elbows used beyond chart reduce the maximum line length for each drive unit by 30 9 14 m For each straight out to straight through tandem system decrease the maximum line length for each drive unit size by 50 15 24 m Figure 5P Maximum Line BE S Model 220 Model 300 and 300P Model350 350 Model 500 Mode HR Mode HR Max Max pi E Max Max Max Max Max Max Max Max Max Length Extension pibe peni Extension Length Extension IER Extension Length Extension Length Extension wee iso 10 ae ee TEES Dry feed stuffs High moisture systems High moisture systerne Mill RR Bees pee ae to ee eee ane jes so so sv so so es oi eee Ls s jo s7akw 24m 38m 38m 24m 38m 9m 2m m t27m mau veo sw 9 e Larl 9 9 e ossaw d4em 56m 27m sem Pom sun be c 20 249 10 185 too 10 so e 10 180 Q746KW etm 75m 46m sm 881m an reuemp o qoos quo J qo j o ues s Jose qom qu pos REH NEEN WEE ECHTEN ee ee E
31. en carry over is acceptable Figure 5L Outlet Hole Cutting Chart mune se Variable A Variable B 1 1 2 38 mm 1 1 2 38 mm PNEG 914 Installation and Operation of Flex Flo 21 5 Installation Drop Kit Installation 1 Wrap the rotary slide over the outlet hole and around the auger tube Position the slides with cut out facing in the same direction for all drops so that the slides will operate the same when the ropes are pulled 2 Thread the rope through the ends of the rotary slide as shown in Figure 5M and tie the slide ends together so that the ends of the rope are the same length Slide knot down tight against hole in rotary slide Figure 5M Drop Kit Installation 3 Slide rope through molded guide holes in drop halves 4 Position the drop halves around the rotary slide and attach both halves together with the hardware provided as shown in Figure 5N Drop installed on PVC tube Figure 5N 5 Test the rotary slide Pull on one rope at a time Check the rotary slide to be sure it is centered over the outlet hole 6 Slide the rotary slide to its open position by pulling the appropriate rope Mark the short rope end at the point where it enters the guide hole Tie a knot on the rope at the mark The location of the knot will show at a glance if the slide is open or closed 22 PNEG 914 Installation and Operation of Flex Flo 5 Installation Drop Kit Installation Continued 7 Thread the short
32. er e Keep hands out of feed opening e Lockout power and secure auger The GSI Group 217 226 4421 before servicing DC 884 PNEG 914 Installation and Operation of Flex Flo 3 Introduction Applications In poultry application Flex Flo Fill System conveys feed from bulk feed tank to hoppers inside the poultry building as shown in Figure 3A Other feed systems i e cycle plus chain feeder etc take the feed from the hopper to the desired locations in the building On this layout hopper level switches may be placed in more than one hopper to assure that no hopper empties before the control unit hopper requires feed All switches must be wired in parallel so that any one switch can start the system Figure 3A Poultry Application Layout In swine applications Flex Flo Fill System conveys feed from bulk feed tanks to each individual feeder i e S S hog feeder drop feeder etc directly as shown in Figure 3B It is at this location that feed is being consumed A feed level control is installed at the end to shut off the system after all feeders are filled Figure 3B Swine Application Layout Background The Flex Flo Fill System consists of a combination of PVC tubes and preformed PVC elbows A special PVC cement is used to connect the tubes and elbows The PVC tubes are available in four 4 different sizes The PVC tube contains a rotating auger which conveys the feed to the different outlet holes The auger is driven by
33. ered by the operator and other personnel As owner and or operator you are responsible to know what requirements hazards and precautions exist and inform all personnel associated with the equipment or in the area Safety precautions may be required from the personnel Avoid any alterations to the equipment which may produce a very dangerous situation where SERIOUS INJURY or DEATH may occur Electrical Safety An adequate and safe power supply to the Flex Flo System unit is essential for safety A competent and qualified electrician must undertake all electrical wiring All wiring is to be installed in accordance with all local and National Standards and Regulations relevant to your country and region Electrical safety devices emergency stops and main isolators are recommended with the Flex Flo System and are essential for safety This should be installed as indicated in the enclosed installation instructions and in accordance with the relevant codes and directives User s Manual This manual contains information and instructions essential to the safe installation and use of the Flex Flo System Read this manual thoroughly before attempting any installation or use of the Flex Flo System Keep this manual with the Flex Flo System or in a location where it can be readily accessed Failure to read this manual and its safety instructions is a misuse of the equipment Correct Uses of the Flex Flo System The Flex Flo System is designed for the
34. estrictor until the system is completely operational and the auger has been polished by running feed through the system Instructions 1 Remove the restrictor tube from the unloader 2 Cut 1 2 5 cm from the restrictor See Figure 5G 3 Install the restrictor and the bearing assembly into the unloader 4 Test the feed flow 5 If the desired feed flow rate is not attained repeat the above procedure until the desired rate is reached Cut off restrictor for increased feed flow Figure 5G Hestrictor Adjustment PNEG 914 Installation and Operation of Flex Flo 17 5 Installation Straight Through Tandem Installation The straight through tandem system should be installed the same as a single tank system with the following exceptions 1 Mount the boots on both tanks and the single or twin out unloader as instructed 2 Install baffle plate FLX 4750 in the Model 350 single through unloader as shown in Figure 5H The twin unloader baffle is factory installed as shown in Figure 5H Single restrictor baffle assembly Single restrictor baffle assembly Twin restrictor baffle assembly for Model 300 for Model 350 for Model 300 and 350 Restrictor baffle FLX 4786 2 Direction of material flow Uni directional Bi directional Opening for agitator ball Cover plate in Overhead view storage position Clean out doors End view End view Straight through unloader Straight through unloader End view Twin through unloa
35. f the largest motor and 100 for all others Wire Size by Length of Run Length of run Ft m E HP 3 4 HP fae sla NEC Sec 225 6 Conductors in overhead spans must be at least 10 for spans up to 50 and 8 for longer 34 PNEG 914 Installation and Operation of Flex Flo 10 11 12 6 Parts List Flex Flo Feed Line Components See Page 36 Direct Drive Povver Unit Assemblies See Pages 37 39 Model 220 Unloader and Anchor Assembly See Page 40 Model 300 300P 350 and HR Unloader and Anchor Assembly See Page 41 Model 500 Unloader and Anchor Assembly See Page 42 Direct Drive Driver and Plastic Tube Anchor Package See Page 43 Belt Drive Driver and Plastic Anchor Package See Page 44 Control Unit See Page 45 Belt Drive Power Unit See Page 46 Drop Kit Kwik Attach Drop Kit See Page 47 Unloader Switch See Page 48 Micro Drop Tube Switch Proximity Switch See Page 49 PNEG 914 Installation and Operation of Flex Flo 35 6 Parts List 36 Flex Flo Feed Line Components mm D LI Hil SI Bis Model 220 Model 300 Model 300P Model 350 Model 500 Model HR Ea 22 16 67 Hopper Extension Kit w Hopper Collar 6 PVC 1101 PVC 1001 PVC 1001 PVC 1002 PVC 1003 PVC 1002 45 Elbow 5 Radius PVC 1003 is 6 Radius ON Screw Eye 1 4 20 x 3 1 2 ZN Open Eye Screw 5 pee ries oes oe o Ree Bmp
36. feed from jamming in the tubes OD Operate the manual outlets several times each week to free them of feed debris N The restrictor on the unloader anchor controls the feed that is flowing into the auger When starting a new system the restrictor should be installed at full length and flush with the front of the unloader Permit the system to polish out the inside of the tubing before modifying the feed flow When the restrictor tube is in the unloader maximum restriction is reached When increased feed flow is desired the length of the restrictor tube should be decreased PNEG 914 Installation and Operation of Flex Flo 33 5 Installation 8 When a multi story building is supplied by one auger solely obtain total drop out at each outlet A time clock MUST be utilized to ensure that all of the feeders are filled at the same time In the last hopper on every level install a hopper level control 9 With the straight through tandem system open only one tank slide at a time when feeding Operating the system with both unloader slides open is not recommended since horsepower consumption increases considerably Wire Size by Type Minimum Allowable Wire Size Full Load Amps In Cable Conduit or Earth Overhead in Air Weg RH Bare and Covered Copper conductors 1 Phase 230V 396 voltage drop In case of conductors supplying several motors on one 1 circuit the wire size is determined by taking 125 of the full load current o
37. hor Molded VV 8 FUE M800 Tube Anchor Molded SSCS 8 pen Mss Tube Anchor Molded SiC 8 riesen MS00Tube Anchor Molded TJ 9 S4312 Set Screw 5 16 18 x 1 2 SQ HD BK Cup Point WE 0 S74M J Hex Nut S16 T8 JSE00 Grade 5 JA AP 0586 Clamp Hose Stainless Stee DIE 234 Model 220 IT Ti aper Clamp Hose Stainless Stee 34 Model 800 and 350 f S 4282 Clamp 5 7 Geared Hose Model 500 FLX 2975 Model 500 Belt and Direct Drive Spindle S 1196 Bolt HHCS 5 16 18 x 1 ZN Grade 5 FLX 2974 Model 500 Clamp Pin EI 44 PNEG 914 Installation and Operation of Flex Flo 6 Parts List Control Unit eee Sees Jen mer eme 1 mes eere eur Eee EL ism vill 11 S 10292 Cable Gland PG7 Size Compression Limiters SEN NENI 12 FLX 5260 T Top Circuit Board Assembly Compression Limiters FLX 5230 Inspection Door Molded Door Molded FLX 4561 Gasket Electrical Box 4x6 Electrical Box 4 x 6 3 FLX 2017 eee Model 220 300 350 i4 FLX 4560 Cover Electrical Box Lid 4 x 6 Power Head w o a FLX 2309 Drop Model 500 Power Head 15 S 995 Screw MS 10 24 x 1 PHP SS No Hardware Included Screw SDS 10 16 x 1 1 4 HWH SS410 Screw SDS 10 x 3 4 HWH SS410 KEE MNA S 8045 Screw SDS 10 x 3 4 HWH SS410 E105 1024 SLI GAB dor Pomana lem 5 Long 1 4 Ins Fem Disc Term B Bottom Circuit Board with Enclosure for Terminal Block Plug Two 2 m poer EE FLX 5270 2 Connector 10 FLX 52
38. lation and Operation of Flex Flo 29 5 Installation Auger Installation Continued 7 Draw the auger out of the tubing as far as required Measure the length between the mark and the unloader inlet Mark the auger again at the unloader inlet when properly stretched See Figure 5Z on Page 29 Stretching the auger too far will cause premature wear at the inside bends of the PVC tubing Stretching the auger not far enough will cause premature wear at the outside bends of the PVC tubing 8 For ease of trimming the auger pull the auger out an additional 8 20 cm past the mark and clamp it at the unloader This clamping releases tension at the mark and thus eases cutting See Figure 5AA 9 Twist the unloader anchor into the auger and clasp the auger end in the clamp pin 10 Mount the anchor in the unloader 11 Place the cannonball inside the unloader 12 Mount the cover on the control unit 13 Place the inspection clean out plate in the unloader Figure 5AA Cutting the Auger Brazing the Auger 1 Make sure both ends are cleaned 2 Position the auger in an angle iron and clasp it securely to align it for brazing See Figure 5AB 3 Braze both ends together Use a bronze flux coated rod Make sure the auger does not get too hot which might cause the auger to warp 4 After the brazing is performed the joint should be allowed to air cool 5 Once the auger has cooled install the auger with the brazed joint closer to the
39. lo Control Unit Extension System Dependent FLEX FLO CONTROL UNIT FLEX FLO CONTROL UNIT FILL SYSTEM FLX 5260 EXTENSION SYSTEM FLX 5260 FLEX FLO FLEX FLO MOTOR MOTOR GND GND 208 230VAC 208 230VAC L2 POWER SUPPLY L2 POWER SUPPLY L1 L1 PROTECTION UNIVERSAL SENSOR AP 2983 E N O ORANGE NOT USED LINE BROWN N C RED PNEG 914 Installation and Operation of Flex Flo 51 7 VViring Diagrams Flex Flo Control Unit Extension System Independent FLEX FLO GONTROL UNIT FLEX FLO GONTROL UNIT FILL SYSTEM FLX 5260 EXTENSION SYSTEM FLX 5260
40. nit Figure 5R Assembly of the Control Unit to the Drive Unit Figure 5S Direct Drive Power Unit PNEG 914 Installation and Operation of Flex Flo 25 5 Installation Installing and Un Installing the Pinion 1 Un install the gearbox C from the motor by removing the bolts A and washers B See Figure 5T Figure 5T mus Paus Dein 8 mg omtower e je 2 Un install the bolt D from the pinion shaft Remove the washers E and F and the set screw H from the pinion shaft G See Figure 5U Figure 5U Prev ran moin D S402983 Bolt HHCS 3 8 16 x 1 2 Grade 5 Zinc DR o mm 26 PNEG 914 Installation and Operation of Flex Flo 5 Installation 3 Hold the pinion with a wrench and install a 3 8 16 x 2 1 2 or longer bolt I into the end of the pinion and turn until the pinion is released from the shaft See Figure 5V rere rang Description See Chart below Gear Pinion Shaft 3 6762 Bolt HHCS 3 8 16 x 2 1 2 ZN Grade 5 Gear Pinion Shaft G Gear Pinion 14T 1 2 Shaft Diameter 1 3 HP and 1 2 HP Gear Pinion 14T 5 8 Shaft Diameter Fees 3 4 HP 1 HP and 1 1 2 HP Motors Gear Pinion 14T 5 8 Shaft Diameter FLX 4542 4 HP or 1 1 2 HP 3 000 Long 4 Replace the pinion onto the shaft and install the set screw Torque to 50 in lbs FLX 4275 Figure 5V 5 Re install the washers E and F and bolt D to the end of the pinion shaft G Torque to 50 in lbs
41. nnections apply the PVC solvent cement per the instructions as follows 1 Square tube ends and remove all burrs and dirt 2 Check dry fit of tubes The smaller end of the first tube should easily slide one third of the way into the belled end of the second tube The first tube end should be snug in the second tube once it is all the way in 3 When the temperature is below 40 F 4 C or above 85 F 29 C consult PVC solvent cement container Apply a liberal coat of cement in the belled end Avoid puddling inside Apply a liberal coat of cement on the smaller end leaving no voids Assemble parts quickly CEMENT MUST BE FLUID If not fluid re coat both parts Push the smaller end into the belled end using a quarter turning motion until the small end bottoms O N O OC KA Hold tubes together for 30 seconds wipe off excess cement with cloth Completed joints should not be disturbed until they have cured enough to withstand handling Keep container closed when not in use Outlet Holes Establish where the outlet drops are to be Once this is done cut holes for the outlet drops See Figure 5L for hole size recommendations If total drop out is necessary it is recommended that the holes are cut using a saber saw or hacksaw When carry over is desired it is recommended that the outlet holes are cut with a holesaw Outlet hole for total dropout 1 25 mm A La Hi 33 Outlet hole wh
42. ol unit driver assembly Tighten the 5 16 hex head cap screw holding the auger lock clamp pin to 23 ft lbs If the auger end is not in the appropriate orientation for connection the driver assembly may be rotated by either turning the motor shaft with a wrench or by turning the large pulley to rotate the driver assembly 5 Remove the anchor assembly and the rear access panel from the bottom section of the extension hopper Mount the bottom section to the top section with 1 4 20 machine screws provided with the hopper The bottom section may be mounted in three 3 various directions See Figure 5AD on Page 32 PNEG 914 Installation and Operation of Flex Flo 31 32 5 Installation Extension Hopper Installation Continued Feed out of hopper Feed out of hopper Qe Feed out of hopper t Feed into hopper Figure 5AD Extension Mounting Directions Control unit Extension hopper Figure 5AE Extension System 6 Install the auger for the system that is connected from the tank s to the extension hopper Install as a standard system The auger for the second part of the system should connect to the power control unit at the other end 7 Clamp the auger ends to their applicable anchors and mount the bearing assemblies in place PNEG 914 Installation and Operation of Flex Flo 5 Installation Figure SAF Operation Guidelines 1 Open the unloader slide completely for the delivery system operation exce
43. power unit Grind flush and smooth Brazing Figure 5AB Brazing the Auger 30 PNEG 914 Installation and Operation of Flex Flo 5 Installation Extension Hopper Installation 1 To ease the installation mount the extension hopper top section to the Flex Flo tubing NOTE A Slide the tube clamp on the hopper tube anchor prior to attaching it to the tubing B Make certain when mounting the power unit and the tubing that they are attached to the access slide side When mounted in this orientation the incoming auger is positioned as far away as possible to allow the upper control switch to operate properly 2 Suspend the top section from the ceiling as shown in Figure 5AC Support holes are provided on the top section for mounting When mounting make allowance for future adjustments of the top section after the bottom section has been connected NOTE Any additional support given to the extension hopper makes for a more solid system and is desirable Take special care if or when the support is modified that the operation of the system and the ability to do a general maintenance are not hindered 3 Mount the unloader under the control unit The control unit should be assembled together prior to mounting This assembly includes the driver assembly Suspend the control unit firmly from the ceiling Support holes are provided on the tube anchor Figure 5AC Extension Hopper 4 Fasten the end of the auger to the anchor in the contr
44. pt on tandem system 2 Do not operate the Flex Flo System empty Utilize a time clock vvith the system vvhenever possible because A It lessens short cycling by operating on a set schedule versus on demand B It prohibits the system from running excessively when empty if the tank should go dry When the optional unloader switch is used it should be wired so that if the feed tank goes empty the power unit will stop 3 The time clock should be programmed to start the Flex Flo System often By running the system often long running periods are eliminated and the feeders are kept full When the Flex Flo System is used for filling poultry feeders a time clock should be utilized to ensure that all feeders are filled at the same time The Flex Flo System will have a better opportunity to keep up Position the hopper level control low in the last hopper 4 A safety switch is provided on the control unit to trip out the motor in the event that feed is packed inside If feed does get packed dislodge the feed from the drop tube and clean out the inside of the control unit which will allow the switch to close The hopper level control needs to maintain vertical positioning to keep the paddle swinging freely Check the adjustment regularly The control unit safety switch does not replace the hopper level control 5 When the Flex Flo System is used to convey high moisture feed the auger line should be completely emptied after each running to prevent
45. r All Fiberglass Propellers 3 to 5 years end user pays 25 5 to 7 years end user pays 50 AP and Cumberland Flex Flo Pan Feeding System Motors Ad 7 to 10 years end user pays 75 Feeder System Pan Assemblies iu adi d Feed Tubes 1 3 4 and 2 00 Warranty prorated from list price Feeding Watering Systems Centerless Augers 0 to 3 years no cost to end user Watering Nipples 3 to 5 years end user pays 50 Grain Systems Grain Bin Structural Design T Motors burner components Grain Systems Portable and Tower Dryers and Tower Portable and Tower Dryers 2 Years and moving parts not included Farm Fans Portable and Tower Dryer Frames and PYES Portable dryer screens included Zimmerman Internal Infrastructure T Tower dryer screens not included GSI further warrants that the portable and tower dryer frame and basket excluding all auger and auger drive components shall be free from defects in materials for a period of time beginning on the twelfth 1 ath month from the date of purchase and continuing until the sixtieth 601 month from the date of purchase extended warranty period During the extended warranty period GSI will replace the frame or basket components that prove to be defective under normal conditions of use without charge excluding the labor transportation and or shipping costs incurred in the performance of this extended warranty Conditions and Limitations THERE ARE NO WARRANTIES THAT EXTEND BEYOND
46. ration of Flex Flo 13 14 5 Installation VY Improper installation methods of the hardware may cause permanent damage and possible breakage of the boot Boot and Transfer Plate Installation NOTE nstallation of the boot is the same whether the tank has the standard collar or the Sure Flo Feed Flow Control olide the boot as far as possible into the tank collar or the Sure Flo Feed Flow Control opening See Figure 5A Align the boot with the Flex Flo System that will be installed Using the holes in the collars for guides drill eight 8 11 32 holes into the boot rim See Figure 5B Mount the boot to the collar with the hardware provided Bolt the transfer plate and unloader braces to the boot as shown See Figure 5C for proper usage and assembly direction of hardware for mounting the boot and the transfer plate All connections should be tightened until they are snug Drill these holes 8X into boot 11 32 drill bit Figure 5C PNEG 914 Installation and Operation of Flex Flo 5 Installation Slide Gate Installation Insert the slide into the transfer plate The slide must be in its operating position prior to attaching the slide shield to the transfer plate Use two 2 5 16 18 x 1 truss head tap bolts to mount the slide shield See Figure 5D Bolt unloader to transfer plate unloader brace assembly as shown in Figure 5E Note orientation of these bolts See Figure 5E
47. se is not generally a hazard associated with the Flex Flo System Excessive noise may indicate a problem with the machines Tests on this machine indicate noise levels at a position one meter from the drive unit and 1 6 meters above the ground do not exceed 70 dBa continuous A weighted sound pressure or 63 Pa instantaneous C weighted sound pressure Sound Signs and Warnings The following pages show you exactly where the safety and warning decals should be placed on the Flex Flo System If a decal is missing or unreadable please contact your dealer or the GSI group for a free replacement For guidance or assistance on any issues relating to the safe use of the Flex Flo System Contact GSI Group 1004 E Illinois St Assumption IL 62510 Phone 1 217 226 4421 Fax 1 217 226 4420 PNEG 914 Installation and Operation of Flex Flo umberland FLX 5260 ELECTRICAL BOX ASSEMBLY CONTACT RATING 1 1 2 HP 240 VAC MAX 25 FLA 1 PHASE COIL RATING 208 240 VAC 50160 HZ DANGER High Voltage Will cause injury or death Lockout power before servicing DC 1238 Power before servicing i a 2 Decals ROTATING AUGER can crush and dismember e Keep hands out of feed opening e Lockout power and secure auger The GSI Group 217 226 4421 before servicing PNEG 914 Installation and Operation of Flex Flo DC 884 2 Decals ROTATING AUGER can crush and dismemb
48. sole purpose of conveying granular or powdered agricultural animal feed Use of the system in any other way is a misuse of the system and may endanger the health and safety Only genuine AP Cumberland parts are to be used in the installation and use of the Flex Flo System Use of other non genuine parts is a misuse of the system and may lead to dangerous situations imperilling the safety and health of you and others This system is not designed for use in atmospheres where there is a risk of explosion Use in such an environment is prohibited If in doubt contact your dealer or the GSI Group Safety Guards The Flex Flo System contains many moving and electrical parts which will cause serious injury or death if touched Guards are placed on the machine to protect you Operating the machine at any time with guards removed or incorrectly fitted is a serious misuse of the machine and endangers safety Safety in Handling the Flex Flo System The Flex Flo drive unit weighs 48 Ibs 22 kgs All precautions should be taken when lifting and or moving the unit Ideally mechanical lift equipment should be used If manual handling is necessary assistance should be sought from other people PNEG 914 Installation and Operation of Flex Flo 1 Safety CE Compliance In accordance with European Union Directives GSI has made every effort to ensure that this product complies with the essential requirements of the machinery directive the low voltage directi
49. ve Power Unit 6 Mount the motor onto the motor mount base with four 4 bolts and washers 7 Mount the belt pulleys The two 2 pulleys must be positioned in line with each other to prevent from binding the belt 8 Install the belt 9 Agjust the belt tension by extending and retracing the two 2 mounting brackets Resecure the bolts after adjustment 10 Install belt guard cover 11 Attach the power control unit to the Flex Flo tubing 12 Suspend the power control unit firmly from the ceiling using the chains provided 13 The control unit and the power unit must be wired as shown in the Wiring Diagram on Pages 50 58 14 Install the auger PNEG 914 Installation and Operation of Flex Flo 5 Installation Auger The auger should be handled with great care Do not install the auger until the kinks have been removed The kink may be removed by straightening the auger A kink may cause extensive wear on the system and premature part replacement In the event that the kink cannot be removed by straightening the kink must be cut out and the auger welded See brazing recommendations in Figure 5AB on Page 30 Figure 5Y Auger Installation Two 2 persons are required to install the auger One person feeds the auger into the tubing while the other makes sure the auger is not damaged Make sure no metal wires or loose ends enter the system 1 The auger must be fed into the Flex Flo System through the unloader Remove the
50. ve and the electromagnetic compatibility directive As such we have declared conformity and affixed the CE mark Our declaration relates only to genuine GSI Flex Flo Systems installed as intended by GSI We cannot and do not declare conformity for any modifications additions or any systems whatsoever operating on or with GSI products that are not supplied by GSI or are in any way outside the control of GSI Safety in Maintenance The Flex Flo System is designed to keep maintenance to a minimum however some repairs will be necessary in the course of the life of the system Do not attempt any repairs on the system unless you are competent to do so Remember that the Flex Flo operates under automatic control and will start without warning Never attempt any work on the Flex Flo System without first isolating the drive unit from the main power and locking the isolator so that only you can turn the power back ON Follow all guidelines given in the maintenance section of this manual Before restarting the Flex Flo System make sure that all electrical enclosures are locked closed and all guards and other safety measures are correctly fitted If in any doubt contact your dealer or the GSI group for assistance Dust Under normal working conditions little or no dust should be created by the Flex Flo System However some dust may be created which may be harmful to your health if inhaled To prevent this wear a suitable type dust mask Noise Noi
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