APCD-500 - Farmer Boy Ag Systems
Contents
1. e The new password must be entered one number at a time Use the arrow keys to enter the first number Press MODIFY to step to the next number Use the arrow keys to enter the sec ond number etc Version This is the current version of your con troller Shut down delay 1 00m s Feed Purge Time A Y Delay 1 00 5 Change password Yes Y EnterNewPassword APCD 500 Version APCD 500 rev 01 A Y 37 APCD 500 5 7 Manual Test Modes The manual mode allows activating manually the actuators electric valves and drive units 5 7 1 Manual Filling of the Feeders It is possible to fill some Chain Disk feeders without waiting for a feed cycle to start When this manual start up is performed the Manual Mode pilot light turns on and the controllers activates the proper out puts in order to fill up the required feeder s see the different filling methods in section 4 5 2 The manual filling process ends when the feeder is full If the user starts a manual fill up of a feeder while a feed cycle is ongoing the ongoing cycle is bypassed and re placed by the manual filling process When the controller returns to the automatic mode it will not resume the previous cycle but will perform the dump at the next Dump Time if applicable A manual dump can also be performed see next section Do not forget to exit from the manual mode once the manual filling process2. First APCD 500 MASTER lt gt Referto section 4 5 2 2 to getinformation about the filling process in this feeder setup 10 APCD 500 rev 01 APCD 500 4 2 3 Independent Feeders with Individual Augers Independent feeders that all have their own bin auger are being filled simultaneously when a feed cycle starts Each feeder filled accord ing to its respective parameter settings Feeders Filling Order Controller amp ID number Simultaneous APCD 500 S J 10 3 Simultaneous APCD 500 S J ID 2 Simultaneous APCD 500 S 1 ID 44 Simultaneous APCD 500 J MASTER lt gt Refer to section 4 5 2 3 to get information about the filling process in this feeder setup APCD 500 rev 01 11 APCD 500 4 3 Feed Distribution Modes 4 3 1 Timed Feed Distribution When feed is distributed according to timer the user chooses at what time the feeders start being filled and at what time feed starts being delivered to the animals Up to daily 20 feed cycles can be programmed Refer to section 5 6 to enable the timed feed distribution method 4 3 2 Continuous Feed Distribution Method The continuous feeding method allows filling the feeders from the moment they are empty when the proximity sensor located at the end of the master Chain Disk feeder stops detecting feed a delay is launched to restart filling all feeders 4 4 Pro
3. None to disable feed dumps Only shown if feed distribution is based on a timer if the continuous feeding mode is disabled above Clean Drops This function allows cleaning the drops at the very beginning of each feed cycles the controller uses the Actuator Open Time parameter to open and close the drops 3 times in a row in order to evacu ate feed leftovers from the system Actuator Open Time Delay that is required for the actuator to open the dumps It can be adjusted from Oto 120 minutes Only shown if the actuator is enabled above 34 APCD 500 01 Continuous Feeding Cont Feeding Delay 0 30 7 Feed dump use Actua Clean Drops Yes Actuator Open Time 3 00m s APCD 500 Actuator Delay This is the time the dumps remain opened right after having been opened It can adjusted from O to 60 minutes Only shown if the actuator Is enabled above Security Sensor Select Yes if the actuator has a secu rity sensor limit switch Only shown if the actuator Is enabled above Electric Valve Delay This 15 the time electric valves remain opened to dump the feed It can be ad justed from O to 60 minutes Only shown if electric valves are enabled above Maximum Current of the Master Feeder Select the maximum allowable current that can be consumed by the drive unit of the master feeder This parameter can be adjusted from 1 to 14 Amp Window Size This parameter is used to
4. e The main supply circuit breaker for feeder motor L1 L2 POWER IN shall be 20 A e Wire gage used for mains supply L1 L2 POWER IN and feeder motor shall be at least 12 AWG e Separate circuit breaker shall be used for auger motor e The mains supply breaker for auger motor shall be 15 e Wire gage used for auger motor shall be at least 14 AWG ALL WIRING MUST BE DONE BY AN AUTHORIZED ELECTRICIAN AND MUST COMPLY WITH APPLICABLE CODES LAWS AND REGULATIONS BE SURE POWER IS OFF BEFORE DOING ANY WIRING TO AVOID ELECTRICAL SHOCKS AND EQUIPMENT DAMAGE Safety may be jeopardized if the equipment is used in a manner not speci fied by the manufacturer APCD 500 rev 01 4 CONTROLLER S OPERATION 4 1 Controller s Description The APCD 500 controls the feed entry into Chain Disk feeders and the distribution of feed to the animals When used in combination with APCD 500 S auxiliary units this controller can control up to 8 Chain Disk feeders Due to its great number of options the APCD 500 controller can suit most Chain Disk setups Timed or continuous feed cycles With or without proximity sensors at the end of the feeders With or without actuators electric valves to open the drops With one or multiple bin augers With one or multiple Chain Disk feeders With cascade or independent Chain Disk setups 8 APCD 500 rev 01 APCD 500 4 2 Feeder Setup Up to 7 slave units APCD 500S can be used to driv
5. Mode ssssrssssssssssss 12 DEENEN NENEN 12 4 5 Filling Chain Disk Feeders 13 4 5 1 Operation of the Bin Auger 13 4 5 2 RIMMING PIG666S2u 2 a as uu u aasashaspunasskuyakaayasauskuapupakisapukupukaxnsasanapashus 14 4 5 2 1 Filling Cascaded Feeders 15 4 5 2 2 Filling Independent Feeders with a Common Bin Auger 18 4 5 2 3 Filling Independent Feeders with Individual Augers 21 4 6 Feed Delivery Process 24 4 7 Feed 25 2 APCD 500 rev 01 APCD 500 5 PARAMETER SETTINGS 26 5 1 Controller Status 2 2 2 26 52 uu u uu u 27 539 ul 28 5 4 Feed Cycle Settings 29 5 5 Run Time Settings 31 b 6 Installation Setup r r 32 5 7 Manual amp Test Modes 38 5 7 1 Manual Filling
6. evacuate feed leftovers from the system 3 Emptying the Feeders To ensure all feeders are empty before bringing new feed the con troller activates all drive units during the Auger Delay 4 Filling the Farthest Chain Disk Feeder When the Auger Delay has elapsed all drive units keep running while the bin auger brings feed into the feeders Feed is directed towards the farthest feeder at first Chain Disk with the highest ID number 16 APCD 500 rev 01 APCD 500 b The Farthest Feeder is Full Ifa proximity sensor is used the controller knows the feeder is full when the proximity sensor located its end detects feed for 5 seconds without interruption When feed is detected the con troller stops the feed entry bin auger and stops all other drive units the drive unit of the loaded feeder keeps running for the Shutdown Delay then stops e If no proximity sensor is used when no proximity sensor is used the controller knows the farthest feeder is full when the drive unit of this feeder has been running for its respective Run Time param eter value The controller stops the drive unit of this feeder once it is full 6 Filling the Next Feeder When the loaded feeder stops the drive units of all empty feeders restart and feed enters once again into the feed line Steps 4 and 5 are repeated up until all feeders are full 7 Feed Dumping When the Chain Disk system is fully loaded feed is ready to be deliv ered to th
7. is completed Use the menu select buttons to select the MANUAL MODE menu A password be required to access this menu see sec 5 6 e Before enabling the manual fill ing select which feeder must Manual Start be filled press the down arrow Mastr key to select the Manual Start menu Press MODIFY then use the arrow keys to select the feeder that needs to be filled manually Master Chain Disk feeder All feed slave 1 7 feeders Press MODIFY once again to validate Once the desired feeder is selected activate the manual mode as shown in section 5 7 2 38 APCD 500 rev 01 APCD 500 5 7 2 Start Stop You can choose to start filling a feeder or to stop it manually as explained in previous section Use the menu select buttons to select the MANUAL MODE menu A password be required to access this menu see sec 5 6 The manual mode status Is dis played on screen Feed cycles Mode Auto Press MODIFY then use the arrow keys to select the de sired status select Start to enable the manual mode select Stop to stop the Chain Disk sys tem select Auto to return to the automatic control mode 5 7 3 Bypassing a Feeder If required the controller can bypass a feeder slave or master feeder Use the menu select buttons to select the MIANUAL menu A password be required to access this menu see sec 5 6 Press the down arrow key to select the s
8. is running Turns on when the bin auger is running Flashes during the Auger Delay Turns on when the dumps are opened Turns on when the dumps are closed Turns on when an output is manually controlled Turns on when the automatic control mode is active Double insulation Caution risk of danger 6 APCD 500 01 WARNING 3 INSTALLATION 3 1 Mounting Instructions Remove the four screws the front cover and lift the cover Remove the black caps located on the three mounting holes Mount the enclosure to the wall using three screws Be sure the electrical knockouts are at the bottom of the enclosure in order to prevent water from entering the controller Insert the screws Into the mounting holes and tighten Fasten the black caps onto the mounting holes 3 2 Connections To connect the controller refer to the wiring diagram enclosed with this user s manual Use the electrical knockouts provided at the bottom of the enclosure Do not make additional holes in the enclosure particularly on the side of the enclosure when using a computer communications module Do not install rigid conduit into electrical knockouts Only nylon cable glands are permitted for cable or wire fastening e switch or circuit breaker shall be included in the building in stallation It shall be in close proximity to the equipment and within easy reach of the operator It shall be marked as the disconnecting device for the equipment
9. restart a drive unit that was stopped due to an over cur rent condition The drive unit restarts when its amperage draw becomes lower than its respective Max Current Con sumption Window Size The window size Is common to all drive units and can be adjusted from O 5 to 3 0 Amp Maximum Current of Slave Feeders Select the maximum allowable current that can be consumed by the drive unit of each slave feeder 51 Slave 1 52 Slave 2 etc The Maximum Current Con sumption can be adjusted from 1 to 14 Amp Available if slave feeders are enabled above Actuator Delay 3 00m s Use security Sensor No A Y Elec Valve Delay Time 3 00m s Max Current 8 5 Window Size 1 5Amp Max Current 54 8 5Amp APCD 500 rev 01 A Y Y Y Y 35 APCD 500 Over Current Delay An alarm 15 set off when the amperage draw of a drive unit exceeds its respec Over Current tive maximum current limit for this time Delay 0 30 5 delay The Over Current Delay is com mon to all drive units and can be adjusted from 30 seconds to 15 minutes Auger Delay When a feed cycle starts the activation of the bin auger is postponed until the Auger Delay end of this delay This allows emptying 0 15m s the feeders before bringing new feed into the system If all feeder have their own bin augers set this delay separately for Auger Delay 51 each slave feeders The Auger Delay can 0 1
10. the side of the controller below for future reference Model number APCD 500 Serial number 4 500 rev 01 2 TERMS AND SYMBOLS A CHAIN DISK STATUS ALARM SN1YLS RUN TIME HISTORY CURRENT OVERLOAD CHAIN DISK TIME DATE SAFETY SWITCH FEED CYCLES MAX RUN TIME INSTALLATION FEED SWITCH MANUAL MODE CHAIN DISK AUGER ACTUATOR OPEN ACTUATOR CLOSE MANUAL AUTO LCD Display The LCD display on the left gives the current readings and parameters to be adjusted when you select a function The three keys at the right of the display are used to edit parameters and to navigate through the screen display When the parameters for a given function cannot all be presented at once on the display arrows are displayed on the right hand side to indicate that additional parameters can be displayed using the ar row keys a v After 4 minutes of inactivity the display returns to the STATUS display Arrow keys The arrow keys that are located next to the LCD display have 2 purposes They are first used to step through the parameters that are displayed on the display They are also used to modify a parameter s value when a parameter flashes on the display Menu Select Buttons These keys are used to select the functions that are located in the main menu Adjusting a parameter Use the arrow keys to select the parameter that needs to be adjusted Once the parameter is selected press MODIFY The param
11. 5m s adjusted from O to 60 minutes Run Time This is the maximum allowable running time of a feeder The controller sounds Max Run Time an alarm when the continuous run time 2 15h m of a feeder exceeds the Max Run Time limit of this feeder Set this parameter separately for each feeder in use It adjusted from 00 00 hh mm to 04 00 hh mm of Feeding Cycles Activate the proper number of daily feed cycles Up to 20 cycles can be activated of Feeding The controller automatically restrain the num Cycles ber of feed cycles so that no cycle overlaps another Refer to sec 5 4 to set the feed cycles Time Mode Select the desired time display format Time Mode 12h 12h or 24h mode 36 APCD 500 rev 01 APCD 500 Shut Down Delay When proximity sensor detects feed at the end of a feeder the controller stops the feed entry bin auger and launches the Shutdown Delay before stopping the drive unit This delay can be adjusted from O to 10 minutes Only shown if proximity sensors are enabled above Feed Purge Time Delay The Purge Delay is the amount of time required for feedlines to become empty Set this delay to the desired value Accessible if many feeders are sharing a com mon bin auger Change password Select Yes if you wish to modify the controller s password then press the down arrow key e Press MODIFY The first two digits of the password flash on the display
12. 99 JO Ji luo 15 u saye si y ns Jo UNY Xew LEIS y spuods uio2o in USIUA OWI SUL 72 01 SI OWI uny L oz 2 2 61 2 2 81 2 2 91 SL vl I5 S L IS OS ZL IS S LL I5 S OL a19A9 6 aj9A9 8 912 43 2 9 91242 S 243 r 2 2 2 2 2 lt 11 L 2 2 06 11 N N N N N N N N N N 08 00 08 00 06 10 00 60 Z 9 S t 1 p 4 5 5 2 5 1 p 3 5 5 5 N s 5 O9 9 L UNY XEN 30 APCD 500 rev 01 LAAHSMYOM 41949 G33d APCD 500 5 5 Time Settings The run time parameter represents the time that is required to fill up each feeder It can be adjusted from O0 00 hh mm to 04 00 hh mm Refer to section 4 5 to get information about this parameter Use the menu select buttons to select the FEE
13. Chain Disk Controller APCD 500 User s Manual BOS CHAIN DISK STATUS ALARM SNLVLS RUN TIME HISTORY CURRENT OVERLOAD CHAIN DISK TIME DATE SAFETY SWITCH FEED CYCLES MAX RUN TIME INSTALLATION 8 FEED SWITCH MANUAL MODE CHAIN DISK AUGER MENU SELECT ACTUATOR OPEN ACTUATOR CLOSE g MANUAL AUTO TABLE OF CONTENTS 1 PRECAUTIONS 4 2 TERMS AND 5 3 INSTALLATION 7 3 1 Mounting Instructions 7 COMMC CIOS 7 4 CONTROLLER S OPERATION 8 4 1 Controller s Description 8 4 2 Feeder Setup 9 4 2 1 Cascade 9 4 2 2 Independent Feeders with Common Auger 10 4 2 3 Independent Feeders with Individual Augers 11 4 3 Feed Distribution Modes 12 4 3 1 Timed Feed Distribution 12 4 3 2 Continuous Feed Distribution Method 1 2 4 4 Proximity Sensor Location 12 4 4 1 In Timer
14. D CYCLES menu This menu is only accessible if feed is distributed according to a timer the continuous feeding mode 15 disabled in the installation and if no proximity sensor Is used A password may also be required to access this menu see sec 5 6 e Press the down arrow key In order to select the first run time Run Time screen display This is the Run 1 30h m Time of the master Chain Disk e Press MODIFY then use the arrow keys to set this parameter to the desired value Press MODIFY once again to validate If slave feeders are used press the down arrow key to select the Run Time of the first slave feeder Run Time 51 1 00h m e Press MODIFY then use the arrow keys to set this parameter to the desired value Press MODIFY once again to validate Proceed in similar fashion to set the Run Time of all feeders in use APCD 500 rev 01 31 APCD 500 5 6 Installation Setup The following section describes how to customize the controller for your particular application Normally this setup needs to be done only once Enter Password Use the menu select buttons to select the INSTALLATION main menu password may be required to access this menu By default the password 15 set to 6 1 0 Enter password 06 01 00 The following parameters are presented below in the order they appear on the display To modify a parameter press MODIFY then use the arrow keys to change it When you are finished adjust
15. TION menu the controller opens and closes the drops tree times in a row to evacuate feed leftovers from the system 3 Emptying Feeders To ensure all Chain Disk feeders are empty before bringing new feed the controller activates all drive units during their respective Auger Delay 4 Filling Chain Disk Feeders When the Auger Delay of a feeder has elapsed the feeder keeps run ning and its respective bin auger starts filling it 5 The Feeder is Full Ifa proximity sensor is used The controller knows a feeder 15 full when the proximity sensor located at its end detects feed for 5 seconds without interruption When feed is detected the controller stops the feed entry bin auger and the drive unit keeps running for the Shutdown Delay then stops 22 APCD 500 rev 01 APCD 500 If no proximity sensor is used The controller knows the feeder is full when the drive unit has been running for the Run Time parameter value The controller stops the drive unit of this feeder once it is full 6 Feed Dumping When the Chain Disk system is fully loaded feed is ready to be delivered to the animals Step to section 4 4 APCD 500 rev 01 23 APCD 500 4 6 Feed Delivery Process After the feeders have been filled up feed is ready to be delivered to the animals This section explains how feed is dumped by actuators and elec tric valves and how feed 15 delivered when no actuator electric valve is used Note that actuators and elec
16. ch each feed cycle starts The controller restrains the time at which feed cycles can start so that no cycle overlaps another 2 Dump Time actuators or electric valves are used set the time at which the dumps must open Make sure this dump is performed when all feeders are full Start time Max Run Time of all feeders see below 3 Run Time This is the time that is required to fill up each feeder This function is only available if no proximity sensor is used APCD 500 rev 01 25 5 PARAMETER SETTINGS 5 1 Controller Status The STATUS menu shows the ongoing operations of the controller All alarms situations must also be acknowledged from this menu refer to sec tion 5 7 for further information about alarms The controller automatically returns to this STATUS menu after 4 minutes of inactivity The STATUS menu tells you if the test mode 15 active if the manual mode 15 active when the next feeding cycle will start when the drive units will stop Shut Down Delay when the actuator will stop moving when the Actuator Delay ends when the Time ends when the next dump will be performed what Is the draw of each drive unit e Use the menu select buttons to select the STATUS main menu e Usethe arrow keys to scroll the display 26 APCD 500 rev 01 APCD 500 5 2 Run Time History The controller has an history menu in which the daily run time of t
17. e additional Chain Disk feeders These supplementary feeders can share common bin augers they can be linked together or they can operate independently one from an other The following section explains the three possible feeder setups that can be managed by the controller Refer to the Installation Setup chapter to select your specific feeder setup 4 2 1 Cascade Setup In this setup all feeders are connected together and share a common bin auger When this auger starts bringing feed into the feeders all drive units start running to send feed towards the farthest Chain Disk feeder APCD 500 S unit with the highest ID number When this feeder Is filled up feed then goes toward the preceding feeder etc lt gt Referto section 4 5 2 1 to get information about the filling processin this feeder setup Feeders Filling Order Controller amp ID number APCD 500 S First ID 3 Second APCD 500 S ID 2 Third APCD 500 S J ID 1 rant APCD 500 MASTER APCD 500 rev 01 0 APCD 500 4 2 2 Independent Feeders with a Common Auger Independent feeders that share a common bin auger filled follow ing the numerical order the master Chain Disk feeder is filled first followed by slave feeder 1 slave feeder 2 etc Feeders Filling Order Controller amp ID number APCD 500 S 10 3 Last Third APCD 500 S J 10 2 Second APCD 500 S ID 1
18. e animals Step to section 4 4 APCD 500 rev 01 17 APCD 500 4 5 2 2 Filing Independent Feeders with a j Feeders Filling Order Controller amp ID number Last APCD 500 S ID 3 APCD 500 S ID 2 Second APCD 500 S J J MASTER Independent Feeders with a Common Auger Common Bin Auger Option lt Continuous Feed Distribution 1 Beginning the Filling Process The filling process starts once the Continuous Delay has elapsed this delay is launched when the proximity sensor located in the last drop of the master Chain Disk feeder stops detecting feed 2 Emptying the Bin Auger and Feeders Once the Continuous Delay has elapsed the controller activates all drive units during the Purge Time and launches the Auger Delay Once the Auger Delay has elapsed the bin auger starts brigning feed into the feeders Normally the Purge Time should be longer than the Auger Delay to prevent feed accumulation at the end of the bin auger 18 APCD 500 rev 01 3 Filling the First Chain Disk Feeder When the Purge Time is over all drive units stop except for the first feeder to be filled the master Chain Disk feeder When the Auger Delay Is over the bin auger starts bringing feed toward this feeder 4 The Feeder 15 Full The controller knows the feeder is loaded when the proximity sensor located its end detects feed for b seconds without interruption When feed Is detected the drive unit of thi
19. ed 2 Emptying the Feeders Once the Continuous Delay has elapsed the controller activates all drive units during the Auger Delay to make sure all feeders are empty before bringing new feed 3 Filling the Farthest Chain Disk Feeder When the Auger Delay has elapsed all drive units keep running while the bin auger brings feed Into the feeders Feed is first directed to wards the farthest feeder Chain Disk with the highest ID number APCD 500 rev 01 15 APCD 500 4 The Farthest Feeder is Full The controller knows the farthest feeder 15 full when the proximity sensor located at its end detects feed for 5 seconds without interrup tion When feed 15 detected the drive unit of the loaded feeder stops and all other feeders continue running until they are all full 6 The Last Feeder is Full When the last feeder is loaded last feeder master Chain Disk feeder the bin auger stops and all drive units are off As the animals eat the feed load will decrease gradually the Continuous Delay will be launched once again when the proximity sensor of the master Chain Disk feeder will stop detecting feed back to step 1 Option Timed Feed Distribution 1 Beginning the Filling Process The filling process starts at the start up of each feed cycle 2 Cleaning the Drops If actuators are used and the Clean Drop option is enabled in the INSTALLATION menu the controller opens and closes the drops tree times in a row to
20. ed cycle worksheet see next page e Use the menu select buttons to select the FEED CYCLES menu Feeding Cycle 1 Start 6 12A4 This menu is only accessible if feed is distributed according to a timer the continuous feeding mode is disabled in the installation A password may also be required to access this menu see sec 5 6 e Press MODIFY The start time of the first feed cycle flashes on the display Use the arrow keys to adjust It to the proper value Press MODIFY once again to validate e Press the down arrow key once The dump time of the first feed cycle 15 displayed Accessible if actuators or electric valves are enabled see sec 5 6 e Press MODIFY The dump time of the first feed cycle flashes on the display Use the arrow keys to adjust It to the proper value Press MODIFY once again to validate the new value e Press the down arrow key once The start time of the second feed cycle is displayed Proceed in similar fashion to set the start and dump times of all feed cycles in use CHECK FEED CYCLES The controller automatically rearranges the feed cycles C WARNING in the case of a programming error The warning mes sage Check Feed Cycles is displayed afterwards The user has to validate the new arrangement of the feed cycles by scrolling down the whole Feed Cycle menu The warning message will then disappear APCD 500 rev 01 29 Q lt p q8u 2l11
21. eter then flashes on the display It can now be adjusted with the arrow keys Once it is properly set Press MODIFY once again to validate the new value If the value does not flash after having pressed the MODIFY it means that the value is a reading A reading cannot be modified APCD 500 rev 01 5 APCD 500 Status LEDs The LEDs at the right of the control panel give the status of each output The following table gives the meaning of each pilot light CURRENT OVERLOAD CHAIN DISK SAFETY SWITCH MAX RUN TIME FEED SWITCH CHAIN DISK OUTPUT AUGER OUTPUT ACTUATOR OPEN ACTUATOR CLOSE MANUAL MODE AUTOMATIC MODE SYMBOLS Turns on when an alarm is detected The feeding system stops operating until the alarm is acknowledged Flashes when the amperage draw of the APCD 500 feeder has exceeded the Max Current limit for the Overload Delay or flashes when this occurs to a slave feeder APCD 500 S Fix the problem then press and hold the RESET button to restart the system Turns on when the drive unit of the APCD 500 has reached its safety switch flashes when this occurs to a slave feeder APCD 500 S Turns on when the run time of the APCD 500 feeder exceeds the Max Run Time parameter value only if a proximity sensor is used flashes when this occurs to a slave feeder APCD 500 S Turns on when the proximity sensor detects feed Flashes during the Feed Bypass Delay Turns on when the master Chain Disk feeder
22. gers Option A O Continuous Feed Distribution 1 Beginning the Filling Process The filling process starts once the Continuous Delay has elapsed this delay is launched when the prox imity sensor located in the last drop of the master Chain Disk feeder stops detecting feed 2 Emptying the Feeders Once the Continuous Delay has elapsed the controller activates all drive units during their respective Auger Delay to make sure all feeders are empty before bringing new feed 3 Filling Chain Disk Feeders When the Auger Delay of a feeder has elapsed all feeders keep running and start being filled by their respec tive bin auger 4 A Feeder is Full The controller knows a feeder is full when the proximity sensor located at its end detects feed for 5 seconds with out interruption When a feeder is full its drive unit and associated bin auger stop APCD 500 rev 01 21 APCD 500 5 All Feeders are Full When the last feeder is full all bin augers and drive units are off As the animals eat the feed load in the feeders will decrease gradually The Continuous Delay will be launched once again when the proxim ity sensor of the master Chain Disk feeder will stop detecting feed back to step 1 Option B Q Timed Feed Distribution 1 Beginning the Filling Process The filling process starts at the start up of each feeding cycle 2 Cleaning the Drops If actuators are used and the Clean Drop option is enabled in the INSTALLA
23. he feed ers master and slave feeders are logged in for the past 5 days Use the menu select buttons to select the RUN HISTORY menu Press MODIFY then use the arrow keys to select the desired feeder master S x slave x APCD 500S x e Press MODIFY once again to access to the run time history of the selected feeder The run time of the last cycle performed by this feeder is displayed e Use the down arrow key to scroll the display The daily run times of the se lected feeder are displayed for the past 5 days Run Time Index Mastr Y Run Time Run Time Hist 54 LastCyc 0 35 Run Time Hist S1 Today 1 20 APCD 500 rev 01 27 APCD 500 5 3 Time amp Date Use the menu select buttons to select the TIME DATE menu The current time and date are displayed 12 00 00PM 01 01 200X e Press MODIFY The hours flash on the display Use the arrow keys to set them to the proper value e Press MODIFY once again The minutes flash on the display Use the arrow keys to set them to the proper value e Press MODIFY again The seconds flash on the display Use the arrow keys to set the seconds to the proper value e Press MODIFY then proceed in similar fashion to set the date dd mm yyyy 28 APCD 500 01 APCD 500 5 4 Feed Cycle Settings Refer to section 4 5 to get Information on feed cycles lt To facilitate feed cycle programming fill out the fe
24. he up arrow key to acknowledge the alarm then press MODIFY to validate The alarm is now acknowledged APCD 500 rev 01 43 6 TECHNICAL SPECIFICATIONS Type Main supply fuse F1 Main supply frequency Housing Operating temperature Storage temperature Ambient relative humidity Alarm Chain disk motor Auger motor Actuator Electric valve Trouble light Installation category Pollution degree Altitude APCD 500 F 1A 250V fast blow 230V 10 20 12 50 60Hz Plastic casing O to 40 C 15 to 50 C MAX 95 non condensing 1 to 2A 24 VAC DC MAX 230 VAC 2HP MAX 230VAC 1HP MAX 115 VAC 1 2 HP MAX 230VAC MAX 5A MAX 500W MAX 115VAC Categorie Il Overvoltage category 2 Up to 2000m The room temperature where the controller is located MUST ALWAYS REMAIN BETWEEN 32 AND 104 F O AND 40 C For indoor use 44 APCD 500 rev 01 7 MEMORY CARD The memory card 15 used to create a backup copy of your controller s configuration The card is also useful to transfer the configuration of one controller to another controller of the same type The switch at the bottom of the card is used to lock or to unlock the card locked unlocked Turn off power each time you open the controller s enclosure TO TRANSFER A CONFIGURATION Turn off power to the controller This prevents accidental exposure to areas of high voltage Open the latch and lift the contr
25. hen remove the memory card REMOVE THE from the connector as follows CARD FROMI THE Turn off power to the controller CONNECTOR WHEN Open the controller s cover THE TRANSFER Remove the card from the connector IS OVER Close the cover then reapply power to the controller 8 Lock the card s switch if required TRANSFER ERROR The controller will not warn you if the transfer is incorrect Respect the following rules to make sure the transfer works properly e Make sure the card switch is at the unlocked position before transferring a configuration on the card Do not move or hold the card while a transfer is ongoing 46 APCD 500 rev 01 8 INDEX A Actuator Electric valve Activation amp settings 34 35 Actuator status LED 6 Current actuator status 26 Dump Manual feed dump 40 Principle of operation 25 Settings 29 Principle of operation 24 Security sensor limit switch 35 Adjusting a parameter 5 Alarms Alarm conditions 42 Status LED 6 Amperage draw see Chain Disk Auger see Bin auger B Backup see Memory card Bin auger Auger status LED 6 Principle of operation 13 Settings 33 36 Buttons 5 C Card Memory card 45 Chain Disk Amperage draw Current status 26 Overload protection 13 Overload protection settings 35 Testmode 41 Chain disk status LED 6 Filing Process see Feeder setup Manual filling 38 Run time History 27 runtime 36 Runtime setting
26. ing a parameter press MODIFY once again to validate the new value and return to the display mode Press the down arrow key to move to the next parameter Use Password Select Yes to enable a password this password Is used to restrain the access to the Installation and Feed Cycle menus of Slaves Enter the number of additional Chain Disk feeders in use Up to 7 slave feeders 5005 can be controlled Feeder setup If slave feeders are used select the proper feeder setup select Cascade if the feeders are connected together select Independent if they are separated from one another This menu is shown If slave feeders are en abled above Cascade Independent feeders feeders 32 APCD 500 rev 01 Use password Yes Y of Slaves Feeder Setup Casca APCD 500 Common Auger Ifindependent slave feeders are enabled above select If all feeders have their own bin auger or if they share a com mon auger This menu is shown if independent slave feed ers are enabled above Use Common Auger Yes Independent Common bin augers bin auger Proxy Switch Select Yes if proximity sensors are Use Proxy used to detect the presence of feed at Switch Yes the end of the feeders Proxy Switch Status Choose the normal contact status of all proximity sensors use Normally Proxy Switch Opened NO or Normally Closed NC Normally Open Only shown proximity senso
27. ning alarm until the next feed cycle Refer to the wiring dia gram enclosed with this manual to connect the toggle switch THE TOGGLE SWITCH DOES NOT CUT THE POWER LINES TO THE CHAIN DISK MOTOR SHUT OFF THE CIRCUIT BREAKER FOR SERVICING AND MAINTENANCE 40 APCD 500 rev 01 APCD 500 5 7 6 Test test mode allows simulating the amperage draw of all drive units in order to verify the controller s performances e Use the menu select buttons to select the MANUAL MODE menu e Pressthe down arrow key to select the amperage draw display of the drive unit of the master Chain Disk feeder or of a slave feeder e Pressthe down arrow key to select the amperage draw of the selected drive unit Press MODIFY then use the arrow keys to set the simulated current consumption Press MODIFY to validate The answer is validated after an 8 second delay Do not forget to exit from the test mode when tests are completed APCD 500 rev 01 41 APCD 500 5 8 Alarms The following table shows the possible alarms conditions When an alarm occurs the whole Chain Disk system stops operating until the alarm is acknowledged Alarm Messages Meaning The limit switch of an actuator has not been reached after the Closing Time this type of alarm can only occur if the safety sensor is enabled ACTUATOR IS NOT CLOSED The limit switch of an actuator is still detected after the Opening Time this type of alarm can only
28. occur if the safety sensor is enabled in the installation APCD 500 S X COMM Communication is disrupted between the main controller and an ALARM APCD 500 S slave module ID x CHAIN DISK IS NOT The amperage draw of the master Chain Disk is lower than 2 0 RUNNING Amps ACTUATOR IS NOT OPENED CURRENT OVERLOAD The amperage draw of the master Chain Disk exceeded its Maximum Current Consumption limit for the Over Current Delay CURRENT OVERLOAD The amperage draw of slave feeder ID X exceeded the Maximum APCD 500 S X Current Consumption limit for the Over Current Delay MAX RUN TIME The running time of the master Chain Disk drive unit exceeded the Max Run Time parameter value MAX RUN TIME APCD The running time of slave feeder ID X exceeded the Max Run Time 500 S X parameter value CRAIN DISKE The safety switch of the master Chain Disk feeder has been reached SWITCH CHAIN DISK SAFETY I SWITCH APCD 500 S X The safety switch of slave feeder ID X has been reached TROUBLE LIGHT It is possible to connect a trouble light to the main controller This light turns on whenever an alarm occurs Refer to the wiring diagram enclosed with this manual to connect this light 42 APCD 500 rev 01 APCD 500 5 8 1 Acknowledging an alarm Use the menu select buttons to select the STATUS menu The current alarm acknowledgment menu 15 displayed Press MODIFY The acknowledgment status flashes on the display Press t
29. of the Feeders 38 5 7 2 Manual Start lt us ua ssmaqwququaasaauaawewawaqahasmaqguqsqisramassis 39 5 7 3 Bypassing a Feeder 39 5 7 4 Manual Dump r r rr r 40 Toggle a wantuspa wasipa 40 5 756 T estM liMog aa yaa alus hayaq 41 42 5 8 1 Acknowledging an alarm 43 6 TECHNICAL SPECIFICATIONS 4 4 7 MEMORY CARD 45 S INDEX E EER 47 Thevco Thevco Electronics 5200 Armand Frappier St Hubert Ouebec Canada J3Z 1G5 APCD 500 rev 0i1 3 1 PRECAUTIONS Although fuses at the input and outputs of the controller protect its circuits in case of an overload or overvoltage we recommend installing an additional protection device on the controller s supply circuit The room temperature where the controller is located 5 ALWAYS REMAIN BETWEEN 32 F AND 104 F 0 C TO 40 C For indoor use To avoid exposing the controller to harmful gases or excessive humidity it is preferable to install it in a corridor DO NOT SPRAY WATER ON THE CONTROLLER FOR CUSTOMER USE Enter the serial number located on
30. oller s cover If you are about to copy the controller s configuration on the memory card make sure the card s switch is at the unlocked position Insert the card in the J9 connec tor located on the electronic board inside the controller Components of the memory card must face down as illustrated Close the cover then reapply power to the controller The transfer menu should be shown on screen if this 15 not the case simultaneously press the MENU SELECT up and down arrow keys for 3 seconds to display this menu Memory Card Switch Connector Electronic Board APCD 500 rev 01 45 APCD 500 6 Usethe ADJUSTMENT up and down arrow keys to select the proper type of transfer MEMORY CARD CONTROLLER To transfer the memory card s content into the controller select the Mem Card Mem Card gt Ctrl to Control Once it is selected simulta Press neously press the ADJUSTMENT up and down arrow keys to start the transfer CONTROLLER MEMORY CARD To save the controller s configuration into the memory card select the Control to Ctrl gt Mem Card Mem Card menu Once it is selected Press simultaneously press the ADJUSTMENT up and down arrow keys to start the transfer 7 Once the transfer is over simultaneously press and hold the MENU SELECT up and lt down arrow keys for 5 seconds to exit the transfer menu t
31. rs are enabled Feed Sensor Bypass If a proximity sensor is used the Chain Disk stops when feed 15 detected at the end of the feeder However when a feed cycle starts some feed leftovers from the previous cycle are likely to remain at the end of the feed line The Feed Sensor Bypass delay allows ignoring the presence of these leftovers at the beginning of a feed cycle Set this delay separately for each feeder in use S1 Slave 1 S2 Slave 2 etc It be adjusted from O to 30 minutes Only shown If proximity sensors are enabled above and if feed distribution is based on a timer if the continuous feeding mode is disabled below Feed Sensor Bypass 0 30m s APCD 500 rev 01 33 APCD 500 Continuous Feeding Timed Feeding Select Yes to use the continuous feed ing mode select No to use timed feed distribution see sec 4 3 Only shown proximity sensors are enabled above Continuous Feeding Delay When using the continuous feed distribu tion method the Continuous Delay tells when to start a feed cycle from the mo ment where no feed is detected at the end of the master Chain Disk feeder see sec 4 3 1 It can be adjusted from 1 min to 23959 min Only shown the continuous feeding mode 15 enabled above Feed Dump Actuators Electric Valves Select Actua to enable feed dumps that are controlled by an actuator select Valve to enable feed dumps that are controlled by an electric valve select
32. s 31 Setup see Feeder setup Configuration module see Memory Card Connections 7 Precautions 4 Controller Controller s description 8 Current status 26 Model number 4 Mounting instructions 7 Safety backup see Memory card Serial number 4 Status LEDs 6 Version 37 Current consumption see Chain Disk D Date 28 Display 5 Drive units see Chain Disk Dumps see Actuator Electric valve E Electric valve see Actu Electric V Electrical specifications 44 Error transfer 46 Feed cycles Activation 36 Feed cycle status 26 Principle of operation 25 Programming feed cycles 29 Template 31 Warning 29 APCD 500 rev 01 47 APCD 500 Feed distribution Continuous mode Activation amp settings 34 Feed delivery process 24 Feeders filling process see Feeder setup Principle of operation 12 Settings 34 Timer mode Activation 34 Feed delivery process 24 Feeders filling process see Feeder setup Principle of operation 12 Programming feed cycles 25 29 Feeder motor see Chain Disk Feeder setup 9 Cascade setup Activation 32 Feeders fllingprocess 14 15 17 38 Setup view 9 Independent feeders w ind augers Activation 32 Feeders fllingprocess 14 21 23 38 Setup view 11 Independent feeders w 1 auger Activation 32 Feeders fllingprocess 14 18 20 38 Setup view 10 Flex auger see Bin auger H History 27 Installation setup 32 37 Keys 5 48 APCD 500 rev 01 L LCD display 5 LEDs stat
33. s feeder stops 5 Filling the Next Feeder When a feeder is full the drive unit of the next empty feeder starts following numerical order and the bin auger keeps running 6 The Last Feeder is Full When the last feeder is full slave feeder with the highest ID the bin auger stops and all drive units are off As the animals eat the feed load in the feeders will decrease gradually the Continuous Delay will be launched once again when the proximity sensor of the master Chain Disk feeder will stop detecting feed back to step 1 Option B Timed Feed Distribution 1 Beginning the Filling Process The filling process starts at the start up of each feed cycle 2 Cleaning the Drops If actuators are used and the Clean Drop option is enabled in the INSTALLATION menu the controller opens and closes the drops tree times in a row to evacuate feed leftovers from the system 3 Emptying the Bin Auger and Feeders To ensure the bin auger and feeders are empty before bringing new feed the controller first activates all drive units during the Purge Time and launches the Auger Delay Once the Auger Delay has elapsed APCD 500 rev 01 19 the bin auger starts brigning feed into the feeders Normally the Purge Time should be longer than the Auger Delay to prevent feed accumu lation at the end of the bin auger 4 Filling the First Chain Disk Feeder When the Purge Time is over all drive units stop except for the first feeder
34. tatus menu of the desired feeder Accessible If slave feeders are used APCD 500 Master Status Auto Bypas Press MODIFY then use the APCD 500S 1 arrow keys to select the de Status Auto Bypas sired status Auto Bypass Press MODIFY again to vali date APCD 500 rev 01 39 APCD 500 5 7 4 Dump The actuator electric valve can only be activated manually when drive unit is running The Manual Mode pilot light flashes while an actuator or electric valve is controlled manually Use the menu select buttons to select the MANUAL menu Press the down arrow key to se lect the manual mode status of the actuator Only shown if the actuator is enabled see sec 5 6 Press MODIFY then use the arrow keys to select the desired status Actuator Auto Open Stop Close Press Mode Auto MODIFY again to validate The answer is validated after 8 seconds Press the down arrow key once The manual mode status of the electric valve is displayed Only shown if the electric valve is enabled see sec 5 6 Press MODIFY then use the arrow keys to select the proper status Auto Open Close Press MODIFY again to validate The answer is validated after an 8 second delay 5 7 5 Toggle Switch A toggle switch can be connected to the main board This switch allows stopping the drive unit of the master Chain Disk feeder and stopping bin augers manually whithout sounding the Chain Disk is Not Run
35. to be filled the master Chain Disk feeder When the Auger Delay Is over the bin auger starts bringing feed toward this feeder b The Feeder is Full If a proximity sensor is used The controller knows the feeder is full when the proximity sen sor located its end detects feed for 5 seconds without interrup tion When feed is detected the controller stops the feed entry bin auger and the drive unit of the loaded feeder keeps running for the Shutdown Delay then stops If no proximity sensor is used The controller knows the feeder is full when the drive unit has been running for its Run Time parameter value The controller stops the drive unit of this feeder once it is full 6 Loading Next Feeder When the loaded feeder stops the next empty feeder starts and the bin auger starts sending feed towards this feeder Steps 4 and 5 are repeated up until all feeders are full 7 Feed Dumping When the Chain Disk system is fully loaded feed is ready to be deliv ered to the animals Step to section 4 4 20 APCD 500 rev 01 APCD 500 4 5 2 3 Filing Independent Feeders with Individual Bin Augers Feeders Filling Order Controller amp ID number APCD 500 S J ID 3 Simultaneous Simultaneous APCD 500 S ID 2 Simultaneous APCD 500 S l ID 1 Simultaneous APCD 500 MASTER Independent Feeders with Individual Au
36. tric valves can only be used when using the timer based feed distribution method and note that their parameters are common to all feeders in use Feed Delivery using Actuators a The actuator opens the drops during the opening time b Once the opening time has elapsed the actuator stops moving during the Actuator Delay c Once the Actuator Delay has elapsed the actuator fully closes the drops during twice the opening time or until the security sensor limit switch is reached d End of the feed cycle Feed Delivery using Electric Valves a Electric valves open the dumps at the DumpTime b The dumps remain opened during the Electric Valve Delay c Electric valve close after the Electric valve Delay has elapsed d End of the feed cycle e Feed Delivey without Actuators Electric Valves If no actuator or electric valve is used the feed that enters into Chain Disk feeders directly falls in the drops while the feeders are being filled Once all feeders are full feed will unload gradu ally as the animals eat 24 APCD 500 rev 01 APCD 500 4 7 Feed Cycles When the feed distribution is performed in timer mode the user must pro gram feed cycles to signal the time at which the feeders are being filled and the time at which feed 15 delivered to the animals Up to 20 feed cycles can be performed every day Refer to section 5 6 to enable the required number of cycles 1 Feed Cycle Start Time This is the time at whi
37. us 6 Limit switch see Security sensor Manual mode Activation 39 Dumping feed manually 40 Filing the feeders manually 38 Status 26 Status LED 6 Memory card 45 Menu selection 5 Model number 4 Motor see Chain Disk P Parameter adjustment 5 Password Activation 32 Change the password 37 Enter a password 32 Pilot lights see also LEDs Trouble light 42 Precautions 4 Proximity sensor Activation amp settings 33 Feed switch status LED 6 Location 12 APCD 500 R Run time History 27 Max run time Settings 36 Status LED 6 Run time settings 25 31 S Safety backup see Memory card Safety switch status LED 6 Serial number 4 Slave feeders 9 Activation 32 Status Current controller status 26 Status LEDs 6 T Technical specifications 44 Test mode 41 Status 26 Time Time and date 28 Time format 36 Toggle switch 40 Transfer configuration 45 Transfer error 46 Trouble light 42 V Valve see Actuator Electric V Version 37 W Warnings Check feed cycles 29 Wiring see Connections APCD 500 rev 01 49 890 00472 01 PN895 00523 REV 01
38. ut down the bin auger while the Chain Disk keeps running in order to discharge the feed As the feed load decreases the amperage draw also decreases the bin auger restarts when the current consumption gets lower than the Max Current Consump tion Window Size lt gt Refer to section 5 6 to set bin auger parameters APCD 500 rev 01 13 APCD 500 4 5 2 Filling Process The filling process of Chain Disk feeders is based on two factors 1 Feeder setup Cascade setup Independent feeders with a common bin auger Independent feeders with individual bin augers 2 Feed Distribution Mode Continuous feed distribution Timed feed distribution The following sections explain all possible ways Chain Disk feeders can be filled Refer to the section that suit your particular feeder setup and feed distribution method PLEASE NOTE THAT THE WHOLE FEEDING SYSTEM STOPS WHEN AN ALARM IS ACTIVE 14 APCD 500 rev 01 APCD 500 4 5 2 1 Filing Cascaded Feeders Feeders Filling Order Controller amp ID number APCD 500 S First m ID 3 Second 1 APCD 500 S ID 2 APCD 500 S J ID 1 APCD 500 MASTER Cascade Setup Option A lt Continuous Feed Distribution 1 Beginning the Filling Process The filling process starts when the Continuous Delay has elapsed this delay is launched when the proximity sensor located in the last drop of the master Chain Disk feeder stops detecting fe
39. ximity Sensor Location Proximity sensors are used to detect the presence and absence of feed at the end of the feed lines 4 4 1 In Timer Mode drive unit When feed 15 distributed according to a timer optional proximity sensors can be used to stop the entry of feed when feed is detected at the end of the feed line see illustration If proximity sensors used one sensor must be located at the end of each feeder drive unit 4 4 2 In Continuous Mode When using the continuous feed distribu tion mode a proximity sensor must be lo cated in the tube of the last drop of each feeder proximity sensor last drop 12 APCD 500 01 APCD 500 4 5 Filling Chain Disk Feeders 4 5 1 Operation of the Bin Auger At the start up of each feeding cycle right after the Auger s Delay has elapsed the bin auger starts bringing feed into the feeders and stops when the feeder is loaded There are two ways the controller can detect that a feeder 15 full FEED LINE 1 The proximity sensor located at the end of the line detects feed for 5 seconds without interruption 2 The drive unit has been running for the Run Time parameter value only if no proximity sensor is used Chain Disk Overload Protection The controller monitors the amperage draw of Chain Disk drive units to prevent overloading the system If the amperage exceeds the limit Wax Current Consumption the controller will tempo rarily sh
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