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1. Simaltaneous x 2955 4 j Det APCD 295 L gt Master Figure 12C Feed Distribution Modes Timed Feed Distribution When feed is distributed according to a 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 be programmed Refer to Installation Setup Section to enable the timed feed distribution method PNEG 602 Chain Disk 59 Chain Disk Controller APCD 295 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 Proximity Sensor Location Proximity sensors are used to detect the presence and absence of feed at the end of the feed lines In Timer Mode When feed is 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 Figure 12D If proximity sensors are used one sensor must be located at the end of each feeder Drive Unit lt Proximity Sensor Last D rop Figure 12D In Continuous Mode When using the continuo
2. Simaltaneous APCD 295 L Master Figure 121 ndependent Feeders with Individual Augers Option A 4 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 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 respective 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 without interruption When a feeder is full its drive unit and associated bin auger stop 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 proximity sensor of the master Chain Disk feeder will stop detecting feed Back to Step 1 66 PNEG 602 Chain Disk Chain Disk Controller APCD 295 Timed Feed Distribution 1 Beginning the Filling P
3. 107 Mounting Proximity 109 Adjusting S nsilivily u u RARR EAEn KATERE ES EARE R n aE 109 GOE WE os ESTEE 111 Chain and Disk Tension 111 Gearbox Fluid Level 9 111 Bushing Replacement Idler 111 Limit Switch 112 Pans 113 Proximity Feed Sensor for Tube 114 Corner Assembly 90 Degree W Hardware Package 116 Chain Disk Drive Unit E 118 Pneumatic Drop Kit Accessories 122 Fill Hopper Assembly a a 124 Drop Kit amp Pneumatic Drop Kit Chain Disk 126 PO UATE OWO E muu a 128 Chain Disk Control m 130 Chapter 19 Troubleshooting U Caccia ar suu Q 132 I l as Me 133 4 PNEG 602 Chain Disk Safety 1 SAFETY Safety Guidelines This manual
4. 236 Installation amp Operation Manual PNEG 602 Date 01 22 08 PNEG 602 PNEG 602 Chain Disk Table of Contents Contents CAPOT uuu E 5 GUIS 5 General Safety 6 dicc E NIC I 5 u 8 Chapier 3 Introduction UU ni amante ai murem ac ur 10 PSI sss 10 Phe Manual e 10 LOUIE unn un au 10 Chaplor 4 SDSCHICOUONRIS 11 Chapter 5 Optional Equipment J U aucun nuc euadere du J J 12 Chapter 6 Tubing amp Drop Kit J J U Q U J Q T J J 13 13 Ay WAC UU MS Tm UT 13 Assembly amp Gluing Sections of PVC 0 13 STi yi alo a 6 uuu ll 14 USMC OL TUDING uu 15 Brom RINS aaO RTT 15 Drop Feeder 16 Chapter 7 Drive Unit Installation J J U
5. Lu I L TOGGLE SWITCH FLEX AUGER PROX SWITCH FLEX AUGER _CHAIN DISK MD Co L COMM E re L 8 Ig bie siena LLL E J L F 24 PNEG 602 Chain Disk Wiring Diagrams Illustration Showing Communication Wires Between Master and Up to 7 Slave Controls APCD 293 8 spr 295 SLAVE CHAIN DISK CONTROL UNIT 1 SWITCH 1 MUST BE DNS MASTER CHAIN DISK CONTROL UNIT SE gt r r w E L Mn te Le CH H EX AUGER CHAIN DISK TROUBLE LIGHT AUGER MOTOR CHAIN DISK MO POWER IN s L BE TEE IMPORTANT NOTE POLARITY MUST BE MAINTAINED AS SHOWN Examples Connect MUD 1 of Master ta CUM 1 of Slave 1 Connect MUD 2 of Master io CUM 2 of Slave 1 Connect COM 1 of Slave to 1 of Slave Connect CUM 2 of Slave 1 ta CUM 2 of Slave 2 APCD 293 3 295 5 SLAVE CHAIN DISK CONTRUL UNIT 6 SLAVE CHAIN DISK CONTROL UNIT 7 SWITCH 6 MUST BE UN SWITCH 7 MUST BE DW BOE IN DISK SAFETY SWITCH TER CHAIN DISK INPUT FLEX AUGER MASTER CHAIN DISK INPUT CHAIN DISK SAFETY SWITCH GLE SWITCH TOGGLE SWITCH PROX SWITCH FLEX AUGER CHAIN DISK WO CHAIN DISK MOT r COMM L E AW ELE LE c TE eisisieisie
6. SUPPLY 421 FLEX FLO CONTROL UNIT MOTOR CHAIN DISK DRIVE UNIT ELECTRICAL JUNCTION BOX 294 PROX SWITCH PNEG 602 Chain Disk 37 Wiring Diagrams Two Chain Disk Loops Filled by One Common Flex Flo Auger with Timed Filling and Feeding by Air Actuation CS CHAIN DISK 295 5 SLAVE CHAIN DISK CONTROL TUBE MOUNTED PROXIMITY SWITCH CHAIN DISK DRIVE UNIT DIRECTIUN OF CHAIN DISK TRAVEL SS TH FLEX FLO POWER UNIT AND FILL HOPPER we FIRST FEEDER TO BE FILLED LAST FEEDER TO BE FILLED AIR COMPRESSOR AIR CYLINDERS SATELLITE TANK SOLENOID VALVE FINGER SHUT OFF VALVE ONE FOR EACH ROOM EXTEND PORT PNEG 602 Chain Disk RETRACT PORT Wiring Diagrams Two Chain Disk Loops Filled by One Common Flex Flo Auger with Timed Filling and Feeding by Air Actuation APCD 295 CHAIN DISK MASTER CHAIN DISK CONTROL THIS CONTROL MUST BE CONNECTED CHAIN DISK LOOP CLOSEST TO FEED TANKS AS SHOWN TUBE MOUNTED PROXIMITY SWITCH CHAIN DISK DRIVE UNIT DIRECTION OF CHAIN DISK TRAVEL ee MODEL 300 FLEX FLO AUGER FIRST FEEDER TO BE FILLED FILL HOPPER LAST FEEDER TO BE FILLED CORD FROM SOLENOID TO CHAIN DISK CONTROL TYPICAL AIR LINES PNEG 602 Chain Disk 39 Wiring Diagrams Two Chain Disk Loops Filled by One Common Flex Flo Auger with Timed Filling and Feeding by Air Actuation
7. BL l une DL LAE PNEG 602 Chain Disk 51 Operation Controls 11 OPERATION CONTROLS 11 1 Current Sensor The Chain Disk System can over fill if the fill system s capacity is greater than the capacity of the Chain Disk System or if longer systems are allowed to recirculate Overfilling will overload the Chain Disk motor causing the thermal reset switch on the motor to kick out and or premature motor failure To prevent this from occurring a current sensor has been installed on the circuit board of the Chain Disk Control Unit This Current sensor monitors the Amp draw of the Chain Disk motor and controls a relay which has the fill system Ex Flex Flo wired to it While the Chain Disk system is filling the amp draw of the motor will increase steadily If the amperage reaches the maximum point of a specified range the current sensor will automatically turn off the fill system temporarily As the Chain Disk system continues to empty itself the amp draw of the motor will decrease steadily If the amperage reaches the minimum point of a specific range the current sensor will automatically turn the fill system back on This ON OFF cycling of the Flex Flo will occur every few minutes untill the Chain Disk feed system is full at which time both the Chain Disk and flex flo will shut OFF See Figure 11B on page 53 Figure 11A PC Board 52 PNEG 602 Chain Disk Operation Controls Window 5 1 5 Amps Max Current Fi
8. Flex Flow Fill System Figure 9A Typical Fill System Installation 20 PNEG 602 Chain Disk Fill System 9 2 Fill Hopper Installation 1 Attach fill hopper to the Flex Flo control unit using 10 x 1 self drilling screws provided with Flex Flo control Figure 9B 2 Adjust the suspension height of the control unit until fill hopper is in line with tubing Cut the tubing so that it butts up to the steel tubing on both the inlet and outlet side of the fill hopper 4 If Ribbed tubing is used clamp ribbed tube adapter on the end of the Ribbed tube 5 Glue the coupler to the PVC tube as detailed on Page 13 6 Clamp the coupler to the drive unit using saddle clamps A proximity switch with time delay can be used in the Fill Hopper to prevent the flex flo auger from short cycling and keep the Fill Hopper from bridging Use the KNOCK OUT hole in one end of the fill hopper to insert the rubber grommet in to hold the proximity switch in place Flex Flo Control Unit Chain Disk Fill Hopper PVC Coupler Saddle Clamp Assembly PVC or Ribbed Tubing Figure 9B Fill Hopper Installation PNEG 602 Chain Disk 21 5 PNEG 602 Chain Disk Wiring Diagrams 10 WIRING DIAGRAMS 10 1 Wiring Instructions o Awe 1 4 SAFETY REGULATIONS A Disconnect all electrical power before inspecting or servicing equipment unless maintenance instructions specifically state otherwise
9. When the Auger Delay has elapsed all drive units keep running while the bin auger brings feed into the feeders Feed is first directed towards the farthest feeder Chain Disk with the highest ID number 62 PNEG 602 Chain Disk Chain Disk Controller APCD 295 4 The Farthest Feeder is Full The controller knows the farthest feeder is full when the proximity sensor located at its end detects feed for 5 seconds without interruption When feed is detected the drive unit of the loaded feeder stops and all other feeders continue running until they are all full 5 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 7 Option B C 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 Feeders To ensure all feeders are empty before bringing new feed the controller activates all drive units during the Auger Delay 4 Filling the Farthest
10. The room temperature where the controller is located MUST ALWAYS REMAIN BETWEEN 32 AND 104 F 0 AND 40 C For indoor use 14 6 Memory Card The memory card is 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 WARNING A Turn off power each time you open the controller s enclosure This prevents accidental exposure to areas of high voltage PNEG 602 Chain Disk 101 Chain Disk Controler APCD 300 To Transfer a Configuration 1 Turn OFF power to the controller 2 Open the latch and lift the controller 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 4 Insert the card in the 49 connector located on the electronic board inside the controller Components of the memory card must face down as illustrated 5 Close the cover then reapply power to the controller The transfer menu should be shown on screen if this is not the case simultaneously press the MENU SELECT up and down arrow keys for 3 seconds to display this menu Memory Card Card Switch Connector Electronic Board Figure 14E 6 Use the ADJUSTMENT up and down arrow keys to select the proper type of transfer
11. g TUBE MOUNTED PROXIMITY SWITCH CHAIN DISK DRIVE UNIT DIRECTION OF CHAIN DISK TRAVEL FLEX FLO POWER UNIT Lp MODEL 300 m m gy FLEX FLO AUGER 5 ap E ey Ez FIRST FEEDER T BE FILLED li i lh LAST FEEDER TO BE FILLED ji ji TT 13 li db I Tm 3 3 alt iji iji Tm m yli yli ili li I 11 Tp m Ji lh iji 11 11 Iji L L J L L PNEG 602 Chain Disk 31 Wiring Diagrams Two Chain Disk Loops Filled by Two Independent Flex Flo Augers with Timed Filling 292 5 SLAVE CHAIN DISK CONTROL UNIT SWITCH 1 MUST BE INS HA CHAIN DISK SAFETY SWITCH CHAIN DISK MOTOR E MASTER CHAIN DISK INPUT PROX SWITCH TOGGLE SWITCH LI caNVAC i SUPPLY Le eS0VAC POWER SUPPLY FLK 4512 LI FLEX FLO CONTROL UNIT CHAIN DISK DRIVE UNIT ELECTRICAL JUNCTION BUX D Evia am 35 LIG I U H T i APCD 294 TUBE MOUNTED PROX SWITCH BEGUN mar SWITCH aH DISK L imm O 32 PNEG 602 Chain Disk Wiring Diagrams Two Chain Disk Loops Filled by Two Independent Flex Flo Augers with Timed Filling MUD 1 OF MASTER MUST BE CONNECTED TO COM 1 UF SLAVE AS SHOWN MOD 2 OF MASTER MUST BE CONNECTED TU CUM 2 Dr SLAVE AS SHOWN
12. li OL u 87 Controllers Operation a a 88 Technical X 89 PNEG 602 Chain Disk 3 Table of Contents Chapter 14 Chain Disk Controler APCD 300 2 2 2 722 2 1 90 Toi 90 R 91 ON ciiin mM 92 Parameter Settings 95 CCMA NOMS 2 101 Misines26 M 101 Chaple TI I sung ol uuu uu uuu l cus Eu 104 W I 104 Chapter 16 Chain Installati n cree 105 Check Drive Sprocket Rotation 2 105 IG er E 105 Pulling Chain Through TUDING uuu rather vnlt ori cua 105 Final Assembly of Corners 106 Wrapping Chain Around Drive Unit Wheels a a 106 Wiel UD
13. 2 Bolt the bottom of the corner to the tubes using the add on clamps these parts need to be snapped off of the top 5 16 x 1 1 4 bolts 5 16 nuts 3 Replace the 1 2 Neoprene backed flat washer and 1 2 locknut on the pivot shaft to retain the idler wheel from being pulled off during chain and disk installation The top of the corner can remain off until after the chain and disks are installed Corner must be suspended using the two angles provided to avoid tubing wear Use one angle on each side of the corner See Figure 8A Place angles over the add on clamps so that corners will be supported before tops are installed Important Two corner suspension angles must be used to support each corner Failure to properly suspend corners will void warranty Corner Suspension Angle Corner Assembly 1 2 Lock Nut 1 2 Neoprene Backed Flat Washer 516 18 Hex nut Comer Top i Add on Clamp l Bearing Idler Wheel Decal Shaft Chain Disk Corner Wheel Asembly 1 2 Flat Washer a Comer Bottom 7 T Ribbed Tube s X apter i b U7 T K Clear PVC Tubing A M 4 a 6 A Bot Neoprene Backed IN S Flat Washer 0 Figure 8A Corner Installation PNEG 602 Chain Disk 19 Fill System 9 FILL SYSTEM 9 1 Installation Figure 9A shows a typical Chain Disk installation including a Flex Flo System A F
14. Disconnect power and remove drive unit cover 2 Activate the limit switch in one direction 3 Replace cover and turn ON power 4 Turn the chain disk control to the manual start position If the chain disk safety switch and alarm indicator light do not come on disconnect power inspect wiring and limit switch and replace if necessary If the alarm indicator light comes on then the switch is working properly 5 Turn the chain disk control to the manual stop 6 chain disk is now ready for normal operation 112 PNEG 602 Chain Disk Parts List 18 PARTS LIST Proximity Feed Sensor for Tube 2 Corner Assembly 90 Degree W Hardware Package 3 Chain Disk Drive Unit 4 Pneumatic Drop Kit Accessories 5 Fill Hopper Assembly 6 Drop Kit amp Pneumatic Drop Kit Chain Disk 7 Proximity Switch 8 Chain Disk Control Unit PNEG 602 Chain Disk 113 Parts List 1 Proximity Feed Sensor for Tube PNEG 602 Chain Disk 114 Parts List Proximity Feed Sensor for Tube ly o APCD 294 NE Prox Feed Sensor for Tube 220 V AP 0583 Clamp 1 3 4 2 3 4 S S Hose Prox Switch Mounting Bracket Proximity Switch N C 20 250 VAC 5 Proximity Switch Mounting Nut APCD 104 Clear PVC tubing 2 00 51mm I D x 2 36 60 mm x 10 ft 3 m PNEG 602 Chain Disk 115 Parts List 2 Corner Assembly 90 Degree W Hardware Package FOR RIBBED TUBE 116 PN
15. Keep area clean and dry Never lubricate service or adjust machine while it is in operation Keep hands feet and clothing from all rotating parts Keep all parts in good condition and properly installed Fix damage immediately Replace worn or broken parts Remove any build up grease oil or um debris i s Maintain Equipment and Work Area PNEG 602 Chain Disk Safety Prepare for Emergencies Be prepared if fire starts Keep a first aid kit and fire extinguisher handy Keep emergency numbers for doctors ambulance service hospital and fire Keep Emergency Equipment Quickly department near your telephone Accessable Wear Protective Clothing Wear close fitting clothing and safety equipment appropriate to the job Eye Protection Safety glasses should be worn at all times to protect eyes from debris Wear gloves to protect your hands from sharp edges on plastic or steel parts Gloves Wear steel toe boots to help protect your toes from falling debris Steel Toe Boots A respirator may be needed if a hog house has poor ventilation Waste fumes be Respirator toxic Remove all jewelry Tuck in any loose or dangling shoe strings Long hair should be tied up and back Wear hard hat to help protect your head Hard Hat OoOO PNEQG 602 Chain Disk 7 Decals 2 DECALS DC 491 is located on the front cover of the drive unit DC 996 is located on the front c
16. Memory Card Controller To transfer the memory card s content into the controller select the to Control Once it is selected simultaneously press the ADJUSTMENT up and down arrow keys to start the transfer Mem Card Ctrl A Press 102 PNEG 602 Chain Disk Chain Disk Controler APCD 300 Controller Memory Card To save the controller s configuration into the memory card select the Control to Mem Card menu Once it is selected simultaneously press the ADJUSTMENT up and down arrow keys to start the transfer Ctrl Mem Card A Press 7 Once the transfer is over simultaneously press and hold the MENU SELECT up and down arrow keys for 5 seconds to exit the transfer menu then remove the memory card from the connector as follows Turn off power to the controller Open the controller s cover Remove the card from the connector Close the cover then reapply power to the controller 8 Lock the card s switch if required Transfer Error WARNING A The controller will not warn you if the transfer is incorrect Respect the following rules to make sure the transfer works properly 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 PNEG 602 Chain Disk 103 Testing of Controls 15 TESTING OF CONTROLS WARNING A If
17. The augers screw brings feed into the feed line 2 he feed line gets loaded and the chain disk reaches its Max Current Consumption The auger s motor is then stopped 3 chain disk keeps running regularly Feed evacuates from the feed line 4 chain disk motor s current consumption decreases as the feed load decreases When the current consumption is below Max Current Consumption Window Size the auger s operation is resumed and feed starts being delivered again into the feed line 35 Refer to nstallation Setup Sectiion to set auger s parameters Chain Disk Operation The controller has two different ways of operating the chain disk system depending on the location of the Proxy Switch The proximity sensor can either be located in the last drop or directly mounted on the feed line tube Second Drop Figure 14B PNEG 602 Chain Disk 93 Chain Disk Controler APCD 300 Operating Mode 2 If the Proxy Switch is Mounted in the Last Drop No Feed is Detected lt The Continuous by the Proxy Sensor x Feed Delay The Chain Disk is Runing Feed is Feed Stops is Launched Detected Being Detected The Chain Disk Stops Figure 14C Step 1 The chain disk motor runs continuously when as no feed is being detected by the Proxy Switch Step 2 The chain disk motor stops when the Proxy Switch detects feed for 5 seconds without Interruption The feed line is now loaded The controller waits for the feed line
18. 62 S S APCD 007 Bushing Main Drive Idler APCD 010 Wheel Main Drive Idler APCD 154 Shaft Drive Unit Idler Wheel APCD 167 Actuator Left D D Chain Disk S 8184 Knob Bar 2 1 4 Dia 5 16 S 7008 Nut 5 16 x 18 S S S 8724 Washer 5 16 x 1 1 2 S S Flat S 8191 Eyebolt 5 16 18 x 2 1 4 S S APCD 043 Spring 18 5 1 1 Dia 5 5 APCD 293 Door Direct Drive Chain Disk S 8006 Knob 1 4 20 x 1 2 S S Stud DC 1709 Decal Logo Chain Disk DC 490 DECAL 3 Automated Production DC 996 DECAL Warning Chain Sprocket 44 DC 997 DECAL Danger Chain Sprocket 45 PR 331 Peak Cap Handle ss 3 WiPameSWibibYDRGRO seme i 3 10 x 3 4 Self Drilling Screw 47 Decal Mfg Label 1 Ph 60 Hz CD Decal Mfg Lable 3 Ph 60 Hz CD Decal Mfg Lable 3 Ph 50 Hz CD 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 PNEG 602 Chain Disk 121 Parts List 4 Pneumatic Drop Kit Accessories 122 PNEG 602 Chain Disk Parts List Pneumatic Drop Kit and Accessories De Pate pen 1 12 V DC Solenoid Valve 24 DC Solenoid Valve 110 V AC Solenoid Valve Adapter fitting 1 8 NPT Male x 1 4 Tube Stem APCD 128 Flow control Valve 1 8 NPT Female Brass APCD 134 Straight fitting 1 8 NPT Male x 1 4 Tube APCD 124T 1 4 O D Polyenthylene Tubing 500 Ft roll Twin AP 2712 T fitting 1 8 NPT Male x 1 4 Tube x 1 4 Tube APCD 119 Pneumatic Drop Kit Chain
19. 8 second delay WARNING A Do not forget to exit from the test mode when the tests are completed 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 The limit switch of an actuator has not been reached after the Closing Time Actuator is not Closed this type of alarm can only occur if the safety sensor is enabled The limit switch of an actuator is still detected after the Opening Time this Actuator is not Opened type of alarm can only occur if the safety sensor is enabled in the Installation Communication is disrupted between the main controller and an b s APCD 295 S slave module ID X Chain Disk is not Running The amperage draw of the master Chain Disk is lower than 2 0 Amps 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 295 S X Current Consumption limit for the Over Current Delay running time of the master Chain Disk drive unit exceeded the Max Run Time Max Run Time parameter value Max Run Time The running time of slave feeder ID X exceeded the Max Run Time APCD 295 S X parameter value Chain Disk Safety Switch The safety switch of the master Chain Disk feeder has been reached Chain
20. APCD 239 5 SLAVE CHAIN DISK CONTROL UNIT SWITCH 1 MUST BE CHAIN DISK MOTOR COMM FLEX AUGER nua rM mu peli HR MASTER CHAIN DISK INPUT J CHAIN DISK SAFETY SWITCH L c H4 PROX SWITCH Le eX VAC metes SUPPLY CHAIN DISK DRIVE UNIT ELECTRICAL JUNCTIUN BUX TUBE MOUNTED PRDX SWITCH 40 PNEG 602 Chain Disk Wiring Diagrams Two Chain Disk Loops Filled by One Common Flex Flo Auger with Timed Filling and Feeding by Air Actuation MID 1 OF MASTER MUST BE CONNECTED TO COM 1 OF SLAVE AS SHUWN APCD 295 MOD 2 OF MASTER MUST BE CONNECTED COM 2 DF SLAVE AS SHOWN MASTER CHAIN DISK CONTROL UNIT THIS CONTROL MUST BE CONNECTED TO CHAIN DISK LOOP CLOSEST TO FEED TANKS CHAIN DISK MOTOR TROUBLE LIGHT ACTUATOR LI CSOVAC SUPPLY Le PS0VAC POWER SUPPLY FLA 4312 11 11 LI FLEX FLO CONTROL UNIT MOTOR LIOVAC c30VAC Le CHAIN DISK DRIVE UNIT ELECTRICAL JUNCTION os SE EM SWITCH ties TE zm m il d EM Eg APCD 294 TUBE MOUNTED PROX SWITCH Ered MIS 27 MOTOR i 2452 DETAILED CONNECTION ILLUSTRATION AIR SOLENOID VALVE MARKED P D l VAL CONNECT EXTEND PORT OF TO ME AIR CYLINDER TO PORT OR 4 OF SOLENOID CONNECT RETRACT PORT OF AIR CYLINDER TO PORT B R 2 SOLENOID PNEG 602 Chain Disk 41 Wiring Diagrams N
21. APCD 295 MASTER CHAIN DISK CONTROL UNIT ET P al e Lal re La C E gt a a o 07 F St ty amp 5 J oF CH H z LUE IP 7 CSR GH WT PR il pes 1 SUPPLY FLX 4ale FLEX FLO FLEX FLO CONTROL UNIT MOTOR CHAIN DISK DRIVE UNIT ELECTRICAL JUNCTION BOX 7 APCD 204 TUBE MOUNTED PROX SWITCH T 7 oie mi J E 3 4 15 6 7 El GE zm Ee a LI L PESE CHAIN DISK 11 l e auo a RET Er PNEG 602 Chain Disk 33 Wiring Diagrams Two Chain Disk Loops Filled by One Common Flex Flo Auger with Timed Filling qp mass CHAIN DISK APCD 295 S SLAVE CHAIN DISK CONTROL TUBE MOUNTED PROXIMITY SWITCH CHAIN DISK DRIVE UNIT DIRECTION CHAIN DISK TRAVEL s FLEX FLO POWER UNIT H 2 s _ AND FILL HOPPER D fs el UT FIRST FEEDER n If TU BE FILLED lh lh ln An LAST FEEDER TO BE FILLED af alt 1 IP M iji l ali ln TE mM ji ji li li i TTE M M Ii ali 1 An TE M 11 H H H H 34 PNEG 602 Chain Disk Wiring Diagrams Two Chain Disk Loops Filled by One Common Flex Flo Auger with Timed Filli
22. DFe vd MID OF MASTER MUST BE CONNECTED COM 8 OF SLAVE AS SHOWN WASTER CHAIN DISE CONTROL UNIT THIS CONTROL MUST CONNECTED TO CHAIN DISK LOOP CLOSEST FEED TANKS Lg gal vAC di SUPPLY E dri SUPPLY N CHAIN DISK MOTOR ACTUATOR LI PIVAC ie SUPPLY He fe FLX 4312 FLEX FLO CONTROL UNIT zr com os Lr CHAIN DISK DRIVE UNU ELECTRICAL JUNCTION AOX C 234 TUBE MOUNTED PROM SWITCH C2430 CURTAIN CONTROLLER 1151 FOR MASTER CHAIN DEK LOOP POWER 100 1195 15V ISOLATION RELAY FOR CURTAIN MACHINES T1 L WHISKER SWITCH 2 K 1 0 em 11 1 Ed Ge I og Ld CURTAIN CONTROLLER MOTOR PNEG 602 Chain Disk 49 Wiring Diagrams One Chain Disk Loop Filling Four Flex Flo Auger Flag Lines Started by any of Four Proximity Switches at End of Flag Lines CHAIN DISK APCD 300 J CHAIN DISK CONTROL CHAIN DISK DRIVE UNIT DIRECTIUN UF CHAIN DISK TRAVEL WIK ATTACH DROP KIT FLEX FLO POWER UNIT FLEX FLO UNLDADER AND AND FILL HOPPER DROP KIT UNLDADER LID QTY 4 FACH al MODEL 300 SS FLEX FLO AUGER FLEX FLO FLAG LINES QTY 4 AP 2983G QTY 4 FEED SENSOR FLEX FLO POWER UNIT QTY 4 AP 2870 LP QTY 4 230VAC COIL o RELAY BOX 50 PNEG 602
23. Keep hands and tools away from exposed chain disks Do not operate equipment without covers and guards properly positioned Failure to do so may cause personal injury or damage to the equipment Fig 10 B Master Chain Disk Control Unit APCD 295 All wiring should be done by a qualified electrician accordance with local and national electrical codes Ground all electrical equipment for safety Use proper size wire according to the national electrical codes to wire all systems Fig 10 C Slave Chain Disk Control Unit APCD 295 S Fig 10 A Chain Disk Junction Box Fig 10 0 Chain Disk Control Unit APCD 300 PNEG 602 Chain Disk 23 Wiring Diagrams Illustration Showing Communication Wires Between Master and Up to 7 Slave Controls 0 295 5 295 5 SLAVE CHAIN DISK CONTROL UNIT 3 SLAVE CHAIN DISK CONTROL UNIT 8e CDIP SWITCH 3 MUST BE IM DIP SWITCH 2 MUST BE UN FLEX AUGER CHAIN DISK ROX SWITCH _CHAIN DISK HAIN DISK SAFETY SWITCH HAIN DISK SAFETY SWITCH m ROX SWITCH FLEX AUGER M a 0 295 5 295 5 SLAVE CHAIN DISK CONTROL UNIT 4 SLAVE CHAIN DISK CONTROL UNIT 3 SWITCH 34 MUST BE UNO SWITCH 5 MUST BE IN 1 pi CHAIN DISK MU CHAIN DISK SAFETY SWITCH POWER IN PROX SWITCH MASTER CHAIN DISK INPUT CHAIN DISK SAFETY SWITCH MASTER CHAIN DISK INPUT LL
24. OR USE IN CONNECTION WITH i PRODUCT MANUFACTURED OR SOLD BY GSI OR ii 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 which 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
25. 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 295 feeder has exceeded the Max Current limit for the Overload Delay or flashes when this occurs to a slave feeder APCD 295 S Current Overload Fix the problem then press and hold the RESET button to restart the system Turns ON when the drive unit of the APCD 295 has reached its Chain Disk Safety Switch safety switch flashes when this occurs to a slave feeder APCD 295 5 Turns ON when the run time of the APCD 295 feeder exceeds the Max Run Time Max Run Time parameter value only if a proximity sensor is used flashes when this occurs to a slave feeder APCD 295 S Feed Switch Turns ON when the proximity sensor detects feed Flashes during the Feed Bypass Delay Chain Disk Output Turns ON when the master Chain Disk feeder is running Auqer Output Turns ON when the bin auger is running Flashes during the Auger Delay Actuator Open Turns ON when the dumps are opened Actuator Close Turns ON when the dumps are closing Manual Mode Turns ON when an output is manually controlled Automatic Mode Turns ON when the automatic control mode is active Symbols Double Insulation 12 2 Installation Mounting Instructions Remove the four screws in the front cover and lift the cover Remove the black caps located on the three mounting holes Mount the enclosure to the wall
26. a Flex Flo System is used turn the toggle switch to the OFF position 15 1 Limit Switch With the motor turned on activate the limit switch in one direction Figure 15A If the motor does not stop refer to the troubleshooting guide To restart refer to Section 11 2 on page 53 pee Figure 15A Test Limit Switch 104 PNEG 602 Chain Disk Chain Installation 16 CHAIN INSTALLATION 16 1 Check Drive Sprocket Rotation Check to make sure the drive sprocket is turning counter clockwise as viewed from inside the drive unit Figure 15 If not rewire the wire connections to the motor according to the wiring connection diagram on the motor 16 2 Direction of Travel WARNING The chain and disks must be installed in the right direction The flat side of the disk must be the leading side See Figure 16A If the chain and disks are installed correctly the disks will smoothly release from the drive sprocket after they travel around it and the system will be more efficient in transporting feed If the chain and disks are installed incorrectly the disks will catch on the drive sprocket during operation causing the system to be jumpy and resulting in excessive wear on the disks Connector Link Drilled out hole to 5 16 8mm Ne Flat side of Disks d Direction of Travel for Ghain and Disks Figure 16A Chain and Disks with Connector Link 16 3 Pulling Chain Through Tubing Note Fish tape required length mu
27. actuators and electric valves and how feed is delivered when no actuator electric valve is used Note that actuators and electric 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 1 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 Oncethe 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 PNEG 602 Chain Disk 67 Chain Disk Controller APCD 295 2 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 3 Feed Delivery 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 gradually as the animals eat Feed Cycles When the feed distribution is performed in timer mode the user must program feed cycles to signal the time at which the feeders are being filled and the time at which feed is delivered to the animals Up to 20 feed c
28. 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 evacuate feed leftovers from the system Clean Drops Yes PNEQG 602 Chain Disk 75 Chain Disk Controller APCD 295 Actuator Open Time Delay that is required for the actuator to open the dumps It can be adjusted from 0 to 120 minutes Only shown if the actuator is enabled below Actuator Open Time 3 00 Actuator Delay This is the time the dumps remain opened right after having been opened It can be adjusted from 0 to 60 minutes Only shown if the actuator is enabled below Actuator Delay 3 00m s Security Sensor Select Yes if the actuator has a security sensor limit switch Only shown if the actuator is enabled below Use Security Sensor No 4 Electric Valve Delay This is the time electric valves remain opened to dump the feed can be adjusted from 0 to 60 minutes Only shown if electric valves are enabled below Elec Valve Delay Time 3 00 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 Max Current 8 5Amp PNEG 602 Chain Disk Chain Disk Controller APCD 295 Window Size This parameter is used to restart a drive unit that was stopped due to an over
29. contains information that is important for you the owner operator to know and understand This information relates to protecting personal safety and preventing equipment problems It is the responsibility of the owner operator to inform anyone operating or working in the area of this equipment of these safety guidelines To help you recognize this information we use the symbols that are defined below Please read the manual and pay attention to these sections Failure to read this manual and it s safety instructions is a misuse of the equipment and may lead to serious injury or death This is the safety alert symbol It is used to alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death DANGER indicates an imminently hazardous situation which if not avoided will result in death or serious injury WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury CAUTION indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury CAUTION used without the safety alert symbol indicates a potentially hazardous situation which if not avoided may result in property damage NOTE indicates information about the equipment that you should pay special attention to PNEG 602 Chain Disk Safety General Safety Statement Our principle concern is your safe
30. current condition The drive unit restarts when its amperage draw becomes lower than its respective Max Current Consumption Window Size The window size is common to all drive units and can be adjusted from 0 5 to 3 0 Amp Window Size 1 5Amp Maximum Current of Slave Feeders Select the maximum allowable current that can be consumed by the drive unit of each slave feeder S1 Slave 1 S2 Slave 2 etc The Maximum Current Consumption can be adjusted from 1 to 14 Amp Available if slave feeders are enabled below Window Size 1 5Amp Over Current Delay An alarm is set off when the amperage draw of a drive unit exceeds its respective maximum current limit for this time delay The Over Current Delay is common to all drive units and can be adjusted from 30 seconds to 15 minutes Over Current Delay 0 30m s Auger Delay When a feed cycle starts the activation of the bin auger is postponed until the end of this delay This allows emptying the feeders before bringing new feed into the system If all feeder have their own bin augers set this delay separately for each slave feeders The Auger Delay can be adjusted from 0 to 60 minutes Auger Delay 0 15m s 4 Auger Delay 51 0 15m s PNEG 602 Chain Disk 77 Chain Disk Controller APCD 295 Max Run Time This is the maximum allowable running time of a feeder The controller sounds an alarm when the continuous run time of a feeder exceeds the Max R
31. enters the drive unit itis able to carry it back out again Because of this the drive unit can be placed anywhere in the system given consideration to accessibility and potential traffic around it The drive unit can also be bolted to the floor bolts not provided or suspended keeping in mind that the position of it in relationship to the rest of the system will affect the number of corners needed However the best position to locate the drive unit is between the last feeder and the fill hopper This ensures that only a minimum amount of feed flows through the drive unit 7 2 Structural Integrity of Support The entire drive unit weighs approximately 170 lbs If the drive unit is suspended the structural member s from which it is suspended must be able to support it Extreme caution should be used to avoid structural damage and bodily injury To evaluate structural integrity of the support consult a qualified structural engineer PNEG 602 Chain Disk 17 Drive Unit Installation 7 3 Suspension of the Drive Unit Although the drive unit can be bolted to the floor the most common installation is to suspend the drive unit See Figure 7A Angle Iron bolts chain and eyebolts are included in the suspension package which must be ordered separately 1 2 d cog go Bolt angle iron to each bottom support of drive unit using four 5 16 x 1 bolts and 5 16 nuts Screw eyebolts into structural members approximately 48 1
32. sprocket as shown in See Figure 16B The fan end of the motor has a shaft extension with flat sides which can be turned with a 1 2 wrench to thread the chain and disks around the drive sprocket Remove the plastic protector cap to expose the motor shaft extension 106 PNEG 602 Chain Disk Chain Installation 4 Cutthe two ends of the chain and disks so that the connection can be made in a conventient location Drill out plastic to 5 16 Diameter 5 Connect the ends using a connector link See Figure 16 6 Rehook the spring 7 Putthe drive unit cover on E m Connector ins Drive Sprocket Chain and Disks f Spring Figure 16B Drive Unit Chain and Disk Connection 16 6 Chain Take Up 1 Run the Chain Disk System for 10 15 seconds 2 Disconnect all electrical power 3 Remove drive unit cover 4 Check to see that the limit switch is in the middle of the switch actuator bracket See Figure 15A In process of breaking in the chain and disks the chain will lengthen causing the switch actuator bracket to move to the left eventually hitting the limit switch and shutting down the system If the switch actuator bracket has moved to the left or has already hit the limit switch links of chain need to be taken out of the system Note Always remove twice as much chain as the idler wheel needs to move As an example if the idler wheel should move 4 inches to the right remove 8 inches of
33. switches equipment dia imei Vesti Refer to limit switch Section 11 2 Motor thermal overload switch Refer to motor overload problem later in activated this guide Low voltage motor runs slow and Check line voltage at motor use adequate overheats wire size in circuits Foreign object caught in chain Check system for any foreign objects and remove them Check Flex Flo Fill System rate check Motor overloads after running briefly Chain Disk System to full with feed feed sensing switch check current sensor setting Wet feed being conveyed or allowed to Clean your system avoid conveying wet stand in system feed or empty line after each feeding Defective motor Replace motor 2 Take out a section of chain referring to 9 9n Section 16 6 push reset button Find where chain has broken and fix using special connector link reset limit switch and then push control unit reset button Chain has broken somewhere in system Limit switch activated Check system for any foreign objects and Foreign object in system remove them reset limit switch and then push the control unit reset button Check Flex Flo Fill System rate check Chain Disk System to full with feed feed sensing switch reset limit switch and then push control unit reset button Polypropylene disks catch on main drive Chain installed in the wrong direction Refer to Section 16 2 on chain install
34. to empty Step 3 The Proxy Switch stops detecting feed The Continuous Feed Delay is launched The controller waits for the end of this delay before restarting the chain disk system Step 4 The chain disk motor restarts back to Step 1 Operating Mode 2 If the Proxy Switch is Mounted in the Feed Line Tube Step 2 Step 3 m pa WW REST No Feed is Detected I Continuous lt Feed by the Proxy Sensor Feed Delay Bypass Delay The Chain Disk is Runing Feed is The Chain Disk Detected is Runing The Chain Disk Stops Figure 14D Step 1 The Proxy Switch does not detect feed The chain disk motor runs continuously Step 2 The Proxy Switch detects feed for 5 seconds without interruption the chain disk motor stops the feed line is now loaded Step 3 The Continuous Feed Delay is launched This delay is required to empty the feed line Step 4 Once the Continuous Feed Delay has elapsed the chain disk motor restarts during the Feed Bypass Delay Step 5 If feed is detected by the Proxy Switch the Continuous Feed Delay is relaunched back to Step 3 If no feed is detected by the Proxy Switch the chain disk motor restarts back to Step 1 94 PNEG 602 Chain Disk Chain Disk Controler APCD 300 WARNING A Note that the whole feed distribution process is stopped when an alarm is active 14 4 Parameter Settings Controller Status This menu indicates the controller s status The following pi
35. 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 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 56 PNEG 602 Chain Disk Chain Disk Controller APCD 295 1 Do not install rigid conduit into electrical Knockouts Only nylon cable glands are permitted for cable or wire fastening 2 switch or circuit breaker shall be included in the building installation 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 3 The main supply circuit breaker for feeder motor L1 L2 POWER IN shall be 20 A 4 Wire gage used for mains supply L1 L2 POWER IN and feeder motor shall be at least 12 AWG 5 Separate circuit breaker shall be used for auger motor 6 The mains supply breaker for auger motor shall be 15 A 7 Wire gage used for auger motor shall be at least 14 AWG WARNING A All wiring must be done by an authorized electrician and must comply with applicable codes laws and regulatio
36. 1 foot 1 5 m left hanging out the tube 8 Connectthe two sections of chain and disk together using a connector link See Figure 16 The plastic in the last link will need to be drilled out using a 5 16 bit so the connector link will fit 9 Pullon the chain and disks until the slack is out of the section 10 Connect the sections of tubing together 11 Connections of chain and disk can be made at the corners as well 12 Repeat steps 4 through 10 until all the chain and disks are pulled through the tubing 16 4 Final Assembly of Corners Important Before the final connection of the chain and disks is made in the drive unit the top on each corner must be replaced Otherwise the tension in the chain will warp the corner housings and make it difficult to replace the tops 1 Remove the 1 2 locknut and 1 2 neoprene backed flat washer which were placed on the pivot shaft previously See Figure 8A 2 Connect the top to the corner using 5 16 x 1 1 4 bolts and 5 16 nuts Torque Hex nuts to 5 ft los DO OVERTIGHTEN 3 Replace the 1 2 Neoprene backed flat washer and 1 2 locknut on the pivot shaft Torque locknut to 10 ft lbs DO OVERTIGHTEN 16 5 Wrapping Chain Around Drive Unit Wheels 1 Unhook the spring inside the drive unit See Figure 16B 2 Slide the idler wheel until it is as close to the drive sprocket as possible 3 Wrapone end of the chain and disks around the idler and the other around the drive
37. 2 m apart from one another to provide a stable suspension Measure and cut chain into four sections leaving each plenty long for adjustment later Fasten chain to angle iron using four 5 16 x 1 bolts 5 16 nuts and 5 16 flat washers Suspend drive unit by hooking other end of the chain on the eyebolts Level drive unit by rehooking chain or by screwing eyebolts in or out Cut the PVC or Ribbed tubing so that it butts up to the stainless steel tubing on both the inlet and outlet side of the drive unit Clamp a Ribbed tube adapter to Ribbed tube If Ribbed tube is used Glue a coupler to the PVC tube as detailed on Page 13 Clamp a coupler to the ribbed tube adapter when using ribbed tube 10 Clamp the coupler to the drive unit using saddle clamps Both Ends Ribbed Tube Adapter d Ribbed Tube Only PVC or Ribbed Tubing Only Coupler Both Ends Both Ends Eyebolt Angle Iron Figure 7A Drive Unit Installation Drive Unit 18 PNEG 602 Chain Disk Corner Installation 8 CORNER INSTALLATION 8 1 Measuring amp Cutting Tube 8 1 1 Ends for Corners 1 Remove the top from the corner and hold the rest of it in place to mark the tubes for cutting See Figure 8A 2 Cut the tubes so they extend into the corner up to the shoulder provided the molding 8 1 2 Initial Assembly of Corners 1 If Ribbed tubing is used clamp ribbed tube adapter on the end of the Ribbed tube
38. 3 14 20 21 22 46 2 NS NS 3 4 NS NS 5 5 5 5 5 7 5 5 5 5 10 11 12 13 14 15 5 9 lt IT ru NO gt D 5 A 119 Parts List 3 Chain Disk Drive Unit Fig 18 C Chain Disk Drive Unit 120 PNEG 602 Chain Disk Parts List Chain Drive Unit Description Key 21 APCD 351 Cord 1 Ph Chain Disk Motor APCD 246 3 Ph Cord 3 Ph Chain Disk Motor 22 07100051 Motor 2 HP 1 Ph 230 VAC 1725 RPM 60 Hz 07100051 150 Motor 2 HP 1 Ph 230 VAG 1425 RPM 50 Hz 07100051 350 Motor 2 HP 3 Ph 230 380 VAC 1425 1725 RPM 50 60 Hz APCD 055 Eyebolt 5 16 LAG x 4 FLX 2377 Key 3 16 x 3 16 x 1 Sq GR2 For Motor S 7104 Bolt 3 8 16 x 1 S S Motor to Gearbox S 8403 Bolt Metric M10 x 1 5 x 20 5 5 Mounting Plate to Gearbox 1414 Chain 3 16 Grade 30 10 ft APCD 025 Angle Drive Unit Suspension 26 APCD 114 i j Suspension Kit for Drive Unit Includes Key Numbers 23 25 APCD 102 20 Bag of Chain with Disks Includes 20 Ft of Key 26 APCD 102 50 Bag of Chain with Disks Includes 50 Ft of Key 26 APCD 102 100 Bag of Chain with Disks Includes 100 Ft of Key 26 APCD 102 150 Bag of Chain with Disks Includes 150 Ft of Key 26 APCD 103 Bag of Connector Links Includes 12 of Key 27 S 7977 EE Chain Connector Link S 7998 Nut 5 8 11 S S Hex Jam S 7999 Washer Flat 641 x 1 187 x 0
39. AP 0583 Stainless Steel Hose Clamp 1 3 4 44 mm 2 3 4 70 mm e Housing Chain DiskDrop Kt e aeeoo 9 APCD 121 Cylinder 1 1 4 x 3 Double Acting 3a Loo NN APCD 250 Lucr MEN 298 APCD250 og APCD 356 APCD 307 APCD297 APCD236 APCD200 Loc NN APCD 262 APCD 380 3a 5 5 4 APCD05 5 APo58 0 PNEG 602 Chain Disk 127 Parts List 7 Proximity Switch 128 PNEG 602 Chain Disk Parts List Proximity Switch Pas y Description 1 1 FLX 2425 Drop Tube 3 00 I D x 3 188 O D x 12 Ft FLXDF 1172 Proximity Switch normally Closed 20 V DC 250 V AC 5 7906 1 2 FLDX 1172N Proximity Switch Mounting Nut PNEG 602 Chain Disk 129 Parts List 8 Chain Disk Control Unit 130 PNEG 602 Chain Disk Parts List Chain Disk control Unit key Pate sition 1 Chain Disk Auto Drop Feed Master Control Bottom Board for APCD 295 Relay for APCD 295 Top Board for APCD 295 Chain Disk Slave Control Bottom Board for APCD 295 S 7 Relay for APCD 295 S Top Board Slave for APCD 295 S Chain Disk Continuous Feed Control 10 Bottom Board for APCD 300 11 Relay for APCD 300 12 Top Board for APCD 300 PNEG 602 Chain Disk 131 Troubleshooting 19 TROUBLESHOOTING Possible Cause Corrective Action Check circuits fuses and ON OFF No power to system
40. CD 175 350 Chain Disk Direct Drive Unit Model 236 3 Ph 50 Hz amp 60 Hz APCD 234 Plate Gearbox Mounting S 7413 Bolt 1 2 13 x 1 S S 5 7417 Nut Nylock 1 2 13 5 5 APCD 174A Trough Assembly D D Chain Disk APCD 181 Electrical Box Drilled S 6732 Screw 10 24 x 1 2 Truss 5 5 S 7931 Nut 10 24 S S APCD 138 Bracket Terminal Block Mounting DC 1374 Decal Terminal Block Label S 8823 Screw TCS23 8 32 x 3 8 HWHS GRN E240 1107 Terminal Block 12 Connector Cut Off 3 Terminals to Make 9 S 7663 Screw MS 6 32 x 3 4 PHP S S APCD 089 Wire 18 GA BLK x 8 with Terminal FLX 4561 Electrical Box Gasket 4 x 6 FLX 4560 Electrical Box Lid 4 x 6 S 8766 Screw 10 24 x 1 1 4 PHP S S S 7931 Nut 10 24 S S 20 5060 Switch SPST 15 A On Off Toggle S 6622 Plate On Off Back DC 889 DECAL Danger High Voltage 70 0129 Boot Switch Weatherproof S 7604 Light 250 V Sealed Red Pilot APCD 014 Sprocket Drive Chain Disk S 7991 Washer 11 32 1 0 S S Fender S 7821 Bolt 5 6 18 x 3 4 S S APCD 169 Bracket Limit Switch Chain Disk S 7821 Bolt 5 6 18 x 3 4 S S NS S 7356 Nut Nylock 5 16 18 S S 16 APCD 352 Cord Limit Switch Chain Disk APGD2 amp amp 158 1 GearMotor Chain Disk T Ph 50 Hz rudes Key Numbers 2 V2 13 14 20 21 22 46 _ APOD24 amp 180 1 GearMotor Chain Disk Ph 80 Hz rudes Key Numbers 2 12 13 14 20 21 22 46 APGbzseasb 1 Ghain Disk 3 Ph 8060 Hz clades Key Numbers 2 12 1
41. Chain Disk Wiring Diagrams One Chain Disk Loop Filling Four Flex Flo Auger Flag Lines Started by any of Four Proximity Switches at End of Flag Lines Ls iod c 9 fL AA l c 1 SEN a Fa tab Lune i e cu 9 xx T 2 iad E Cannan A 4 fe 5 SEs ja NI 33502 ES DJ fe Tao I _ peso Z CL I rrt E HOLIAS ALI4 S XSMI Eine HJLIAS E TEE HALAS 10001 E 7 a Q 900 CONTROL UNIT N APCD Li E FLEX FLO CONTROL UNIT FLY 4512 CHAIN DISK DRIVE UNI ELECTRICAL JUNCTION 253 Le P3DVAC SUPPLY P30VAC POWER SUPPLY E R amp P Pog3n FEED SENSOR FOR FLAG LINE 2 Fj aod a eo toe xc o ep E Ed 5 t VL POE E 5067 1
42. 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 5 The Farthest Feeder is Full a 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 controller 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 b Ifno 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 parameter 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 5 are repeated up until all feeders full PNEG 602 Chain Disk 63 Chain Disk Controller APCD 295 7 Feed Dumping When the Chain Disk system is fully loaded feed is ready to be delivered to the animals Step to Proximity Sensor Location Section Filling Independent Feeders with a Common Bin Auger _ Feeders Filling Order Controller amp ID number APCD 295S S
43. Diagrams One Chain Disk Loop Filled by One Flex Flo Auger with Continuous Feeding After Time Delay APCD 300 CHAIN DISK CONTROL UNIT amp CHAIN DISK SAFETY SWITCH Li 230VAC POWER SUPPLY L2 45 FLEX FLO FLEX FLO CONTROL UNIT MOTOR CHAIN DISK DRIVE UNIT ELECTRICAL JUNCTION m PIU TUBE MOUNTED PROX SWITCH CHAIN DISK MOTOR AUGER MOTOR CHAIN DISK MOTOR TROUBLE LIGHT Le 230VAC POWER SUPPLY LI PNEG 602 Chain Disk 29 Wiring Diagrams Two Chain Disk Loops Filled by Two Independent Flex Flo Augers with Timed Filling 05255 CHAIN DISK 0 295 5 SLAVE CHAIN DISK CONTROL TUBE MOUNTED PROXIMITY SWITCH CHAIN DISK DRIVE UNIT DIRECTION OF CHAIN DISK TRAVEL FLEX FLD power wir AND FILL HOPPER MODEL 300 x tar ey tom FLEX FLO AUGER 3 7 E FIRST FEEDER HL qm di TO BE FILLED li li yli LAST FEEDER BE FILLED M TT t il sli i TT M TT tt ili 1 yli T TT I sli sli ln 1 M M TT I li TH TE MI Jl Jil 99 UI S i J m v 30 PNEG 602 Chain Disk Wiring Diagrams Two Chain Disk Loops Filled by Two Independent Flex Flo Augers with Timed Filling I e ma CHAIN DISK i APCD 295 MASTER CHAIN DISK CONTROL
44. Disk Safety Switch APCD 295 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 PNEG 602 Chain Disk 81 Chain Disk Controller APCD 295 Acknowledging an Alarm 1 Use the menu select buttons to select the STATUS menu The current alarm acknowledgment menu is displayed 2 Press MODIFY The acknowledgment status flashes on the display 3 Press the up arrow key to acknowledge the alarm then press MODIFY to validate The alarm is now acknowledged 12 5 Technical Specifications 230V 10 20 12A 50 60Hz Operating Temperature 55 Storage Temperature 15 to 50 C Ambient Relative Humidity MAX 95 non condensing Alarm 10 mA to 2A 24 VAC or DC MAX Chain Disk Motor 230 VAC 2 HP MAX Auger Motor 115 VAC 1 2 HP MAX Actuator Electric Valve 230 VAC MAX 5A MAX Trouble light 500W MAX 115 VAC Installation Category Categorie Il Overvoltage Category Pollution Degree 2 Altitude Up to 2000m 230 VAC 1 HP MAX The room temperature where the controller is located MUST ALWAYS REMAIN BETWEEN 32 AND 104 F 0 AND 40 C For indoor use 82 PNEG 602 Chain Disk Chain Disk Controller APCD 295 12 6 Memory Card The memory card is used to create a backup copy of your contr
45. EG 602 Chain Disk Parts List Key ay APCD 100 4 APCD 100 4 1 10 11 12 13 14 15 16 17 5 7417 5 8139 APCD 000 APCD 009 APCD 330 APCD 006 APCD 327 APCD 001 APCD 228 APCD 104 APCD 112 5 8452 5 7683 5 9379 APCD 013 DC 1244 Corner Assembly 90 Degree w Hardware Package 4 2 2 1 1 1 1 2 16 16 2 1 1 Description Corner Assembly 90 Degree w Hardware Box of 4 Corner Assembly 90 Degree w Hardware Package Lock Nut 1 2 13 Stainless Steel Flat Washer 1 2 Stainless Steel Corner Top 90 Degree Corner Add on Clamp 90 Degree Corner Bearing 15 mm 1 0 x 32 mm O D x 9 mm width Idler Wheel 90 Degree Corner Shaft 90 Degree Corner Corner Bottom 90 Degree Ribbed Tube Adapter for Ribbed Tube Only Refer Page 127 Clear PVC Tubing 2 00 51 mm I D x 2 36 60 mm O D x 10 ft 3 m White PVC Tubing 2 00 51 mm 1 0 x 2 36 60 mm O D x 10 ft 3 m Hex Nut 5 16 18 Stainless Steel Bolt 5 16 18 x 1 1 4 Stainless Steel Washer 1 2 SS NEOP Bonded Flat Chain Disk Corner Wheel Assembly Including Key Numbers 6 7 8 Decal Warning Chain Disk Corner Suspension Angle Idler PNEG 602 Chain Disk 117 Parts List 3 Chain Disk Drive Unit 118 PNEG 602 Chain Disk Parts List Chain Drive Unit Key Description 1 APCD 175 150 Chain Disk Drive Unit Model 236 1 Ph 50 Hz APCD 175 160 Chain Disk Drive Unit Model 236 1 Ph 60 Hz AP
46. 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 Feed Cycle Temperature Feeders Max Run Time Feed Start Master Slave Slave Slave Slave Slave Slave Slave Dump Cycles Time M mes sm wa 1 The Maximum Run Time parameter value is common to all feed cycles 2 he time at which all feeders are full corresponds to the Start Time Max Run Time of all feeders 3 Make sure the dump is performed after all feeders are full The Dump Time must only be defined if actuators or electric valves are enabled PNEG 602 Chain Disk Chain Disk Controller APCD 295 Run Time Settings The run time parameter represents the time that is required to fill up each feeder It can be adjusted from 00 00 hh mm to 04 00 hh mm Refer to Filling Chain Disk Feeders Section to get information about this parameter 1 Use the menu select buttons to select the FEED CYCLES menu This menu ts only accessible if feed is distributed according to a timer the continuous feeding mode is disabled in the installation and if no proximity sensor is used A password may also be required to access this menu See Installation Setup Section 2 Press the down arrow key in order to select the first run time screen display This is the Run Time of the master Chain Disk Run Time 1 30h
47. ID 3 APCD 295S ID 2 Second x APCD 295S ID 21 APCD 295 J Master Figure 12H ndependent Feeders with a Common Auger Continuous Feed Distribution Option 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 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 bringing 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 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 is Full The controller knows the feeder is loaded when the proximity sensor located its end detects feed for 5 seconds without interruption When feed is detected the drive unit of this feeder stops 5 Filling the Next Feeder When a feeder is ful
48. LO CI Oo x T ck C Lcx x ME CHAIN DISK MOTOR FLEX AUGER Le ee SUPPLY CHAIN DISK DRIVE UNIT ELECTRICAL JUNCTION BUX 44 PNEG 602 Chain Disk Wiring Diagrams Two Chain Disk Loops Filled by One Common Flex Flo Auger with Timed Filling and Feeding by Electric Actuation MOD i OF MASTER MUST BE CONNECTED TO COM 1 OF SLAVE AS SHOWN APCD 293 MOD 2 OF MASTER MUST BE CONNECTED TO COM 2 OF SLAVE AS SHOWN WASTER CHAIN DISK CONTROL UNIT CTHIS CONTROL MUST BE CONNECTED CHAIN DISK LOOP CLOSEST TO FEED TANKS AUGER MOTOR J Lu CHAIN DISK SAFETY SWITCH q ACTUATOR SWITCH TOGGLE SWITCH Bez ACTUATOR M p LIGHT FLA 4 le FLEX FLO CONTROL UNIT CHAIN DISK DRIVE UNIT ELECTRICAL JUNCTION BUX 294 TUBE MOUNTED PROX SWITCH 02430 CURTAIN CONTROLLER FOR AOTH CHAIN DISK LODPS o VAC WHISKER SWITCH CURTAIN CONTROLLER MOTOR PNEG 602 Chain Disk Wiring Diagrams NOTES 46 PNEG 602 Chain Disk Wiring Diagrams Two Chain Disk Loops Filled by One Common Flex Flo Auger with Timed Filling and Feeding by Electric Actuation with Isolation Relay CHAIN DISK Bo Dome CHAIN DISK 2 295 5 SLAVE CHAIN DISK CONTROL APCD 295 MASTER CHAIN DISK CONTROL THIS CONTROL MUST BE CONNECTED TO CHAIN DISK LOOP CLOSEST TO FEED TANKS AS SHOWN UUUUUUUUUU J CORD FROM CUR
49. OTES 42 PNEG 602 Chain Disk Wiring Diagrams Two Chain Disk Loops Filled by One Common Flex Flo Auger with Timed Filling and Feeding by Electric Actuation BD omes CHAIN DISK 225 CHAIN DISK APCD 295 S SLAVE CHAIN DISK CONTROL APCD 295 MASTER CHAIN DISK CONTROL THIS CONTROL MUST BE CONNECTED TO CHAIN DISK LOOP CLOSEST TO FEED TANKS AS SHOWN UUUUUUUUUU J m Ml D V CORD FROM CURTAIN MACHINE WHISKER SWITCH TO ACTUATOR SWITCH TERMINALS IN CHAIN DISK CONTROL 002430 CURTAIN MACHINE CHAIN DISK DRIVE UNIT FLEX FLO POWER UNIT AND FILL HOPPER TUBE MOUNTED CHAIN DISK MODEL 300 PROXIMITY SWITCH DRIVE UNIT CRT FIRST FEEDER FILL HOPPER FIRST FEEDER TO BE FILLED TO BE FILLED TUBE MOUNTED PROXIMITY SWITCH LAST FEEDER TO BE FILLED LAST FEEDER TO BE FILLED C C mei mei 20 A Jm C2 C2 mei mi CI CI Ld 1 Uh 711 C3 C2 zI I IT ri C mi mi Uh 2 D AX 20 20 T T lt lt mi r RETURN SPRING OR COUNTER WEIGHT FOR ACTUATOR ROD OR CABLE PNEG 602 Chain Disk 43 Wiring Diagrams Two Chain Disk Loops Filled by One Common Flex Flo Auger with Timed Filling and Feeding by Electric Actuation APCD 295 8 SLAVE CHAIN DISK CONTROL UNIT SWITCH 31 MUST BE INS ER CHAIN DISK INPUT N DISK SAFETY SWITCH LE SWITCH
50. PNEG 602 Chain Disk 25 Wiring Diagrams One Chain Disk Loop Filled by One Flex Flo Auger with Timed Filling D mman CHAIN DISK APCD 295 MASTER CHAIN DISK CONTROL TUBE MOUNTED PROXIMITY SWITCH CHAIN DISK DRIVE UNIT DIRECTION UF CHAIN DISK TRAVEL p J O a O LI FLEX FLO POWER UNIT H MODEL 300 AND FILL HOPPER FLEX FLU AUGER FIRST FEEDER If FILED al LAST FEEDER BE FILLED D p T MID an D B alj cn Up dh aly 26 PNEG 602 Chain Disk Wiring Diagrams One Chain Disk Loop Filled by One Flex Flo Auger with Timed Filling APCD 299 MASTER CHAIN DISK CONTROL UNIT lt M H2 Le s 8 AUGER MOTOR CHAIN DISK MOTOR LI PIVAC POWER SUPPLY Le FLX 4512 FLEX FLO FLEX FLO CONTROL UNIT MOTOR CHAIN DISK DRIVE UNIT ELECTRICAL JUNCTION BOX TUBE MOUNTED PROX SWITCH CHAIN DISK MOTOR PNEG 602 Chain Disk 27 Wiring Diagrams One Chain Disk Loop Filled by one Flex Flo Auger with Continuous Feeding After Time Delay APCD 300 CHAIN DISK CONTROL TUBE MOUNTED PROXIMITY SWITCH CHAIN DISK DRIVE UNIT DIRECTION CHAIN DISK TRAVEL FLEX FLO POWER UNIT AND FILL HOPPER MODEL 300 FLEX FLO AUGER LAST FEEDER TO BE FILLED FIRST FEEDER TO FILLED 28 PNEG 602 Chain Disk Wiring
51. TAIN MACHINE WHISKER SWITCHES TO ACTUATOR SWITCH TERMINALS IN CHAIN DISK CONTROL 100 1095 2430 CURTAIN MACHINE CURTAIN ISOLATION RELAY CHAIN DISK DRIVE UNIT FLEX FLO POWER UNIT AND FILL HOPPER TUBE MOUNTED CHAIN DISK PROXIMITY SWITCH DRIVE UNIT MODEL 300 FLEX FLO AUGER FIRST FEEDER FILL HOPPER FIRST FEEDER BE FILLED BE FILLED TUBE MOUNTED PROXIMITY SWITCH LAST FEEDER LAST FEEDER TO BE FILLED TO BE FILLED Ti D x T gt n T1 C2 0 q E L tes Es T cC D gt lt gt gt lt lt 71 71 RETURN SPRING OR COUNTER WEIGHT FOR ACTUATOR ROD OR CABLE PNEG 602 Chain Disk 47 Wiring Diagrams Two Chain Disk Loops Filled by One Common Flex Flo Auger with Timed Filling and Feeding Electric by Actuation with Isolation Relay 0 295 5 SLAVE CHAIN DISK CONTROL UNIT DIP SWITCH 1 MUST BE INS Le cd0VAC SUPPLY CHAIN DISK DRIVE UNIT ELECTRICAL JUNCTION BUX 22430 CURTAIN CONTROLLER H5V FOR SLAVE CHAIN DISK LOOP HS VAC POWER WHISKER SWITCH CURTAIN CONTROLLER KOTOR 48 PNEG 602 Chain Disk Wiring Diagrams Two Chain Disk Loops Filled by One Common Flex Flo Auger with Timed Filling and Feeding Electric by Actuation with Isolation Relay MOD DF MASTER MUST BE CONNECTED TO CUM OF SLAVE AS SHOWN APL
52. U meu UU de abunde Odo 17 LO Oj WT s 17 Structural Integrity of 17 Suspension of the Drive Unit 18 Chapter o CorneriInstallaliohau UU ii sa a E 19 Measuring amp Cutting 19 Marec IE EC ua 20 2116 a RE E 20 Pl TNT T Te 21 Chapter 10 Wiring Diagrams J cu amu puc cu J Q J J 23 Wining 23 Chapter 11 Operation Controls 4 4 2 52 ede MEE 52 Full WI 25 m T 53 Chapter 12 Chain Disk Controller 295 2 22 2 2 2 2222 2 422 1 22 55 Terms and Symbols 55 T 56 Controllers Operation 57 mcg cg E E 68 Technical 5 nnns n nnns 82 VEMO eT se sas 83 Chapter 13 Chain Disk Controler 295 5 2 2222 2 222 2 2 2 2 0 85 Terms and Sympo08 uuu u E Pm 85
53. a tube mounted proximity switch is used it should be installed just beyond the last feeder 3 2 Using the Manual Head the entire manual prior to any work being done This installation owner manual is to be used as a guideline for the installation of the Chain Disk Feed System Model 236 All instructions should be construed as recommendations only as the actual installation may vary according to local conditions Wiring diagrams can be found later in this manual Instructions presented in this manual should only be carried out by a trained technician It is essential that the technician has a sound understanding of technical matters and drawings in both mechanical and electrical areas 3 3 Background The Chain Disk Feed System consists of a drive unit which pulls a chain with polypropylene disks attached to it through tubing thus conveying feed from a storage bin to animals inside a building The disks have approximately the same diameter as the inside of the tube therefore being a highly efficient conveying system with total clean out of the tube This system can be adapted to complex configurations because of its ability to go through tight corners and at any angle including vertical The delivery of feed can be controlled manually or automatically with the use of a control unit sensors and drop kits 2 4 4 4 10 PNEG 602 Chain Disk Specifications 4 SPECIFICATIONS Overall system length Types
54. ansfer Mem Ctrl 4 A Press Controller _ y Memory Card To save the controller s configuration into the memory card select the Control to Mem Card menu Once it is selected simultaneously press the ADJUSTMENT up and down arrow keys to start the transfer Ctrl Mem Card 5 Press 7 Once the transfer is over simultaneously press and hold the MENU SELECT up and down arrow keys for 5 seconds to exit the transfer menu then remove the memory card from the connector as follows Turn OFF power to the controller Open the controllers cover Remove the card from the connector Close the cover then reapply power to the controller 8 Lock the card s switch if required Transfer Error WARNING A The controller will not warn you if the transfer is incorrect Respect the following rules to make sure the transfer works properly 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 84 PNEG 602 Chain Disk Chain Disk Controler APCD 295 S 13 CHAIN DISK CONTROLER APCD 295 S 13 1 Terms and Symbols Figure 13A 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 Figure 13B PNEG 602 Chain Disk 85 Chain Disk Controler APCD 295 S Fla
55. arameter 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 90 PNEG 602 Chain Disk Chain Disk Controler APCD 300 Output Status LEDs The LEDs at the right of the control panel give the status of each output When the LED is turned on the output is activated when the LED is turned OFF the output is deactivated The following table gives the LEDS meanings Turns ON when an alarm is detected The chain disk control stops operating until the alarm is acknowledged Turns ON when the chain disk s current exceeds the max current limit for a time period exceeding the Current Overload OVOP The chain disk control stops operating until the alarm is acknowledged Turns ON when the safety switch is reached Chain Disk Safety Switch The chain disk control stops operating until the alarm is acknowledged Turns on when the chain disk s running time exceeds the max run time Max Run Time The chain disk control stops operating until the alarm is acknowledged Turns ON when feed is detected by the proxy switch Feed Switch Flashes during the feed sensor bypass delay Chain Disk Output Turns Turns ON when the Chain Disk is operating si when the Chain Disk is Turns ON when the Chain Disk
56. ation sprocket Gearbox overheating Low fluid level Add fluid refer to Section 17 2 Chain disk motor does Proximity switch sensitivity impropely Refer to Section 16 7 for proper proximity not shut OFF when full adjusted switch adjustment Chain disk motor Proximity switch sensitivity improperly Refer to Section 16 7 for proper proximity always shut OFF adjusted switch adjustment immediately after prox by pass time 132 PNEG 602 Chain Disk GSIGROUP GSD Limited Warranty 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 GSI s only obligation is to repair or replace at GSI s option and expense products that in GSl 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 Product Warranty Period Warranty prorated from list price Performer Series Direct Drive 0 to 3 years no cost to end user AP Fans and Fan Motor oa 3 to 5 years end
57. chain PNEG 602 Chain Disk 107 Chain Installation 5 Unhook the spring inside the drive unit 6 Slide the idler until it is as close to the drive sprocket as possible 7 Cut out a section of chain making sure that the connection can be made in a convenient location Drill out plastic to 5 16 diameter 8 Connect the two ends of chain using a connector link See Figure 16A Note You may want to mark or paint the linked sections so they can easily be identified through a clear tube 9 Rehook the spring Reset limit switch Reset the appropriate chain disk control Refer to Section 11 2 on page 53 10 Replace drive unit cover 11 Connect all electrical power 12 Repeat steps 1 11 until the limit switch stays approximately 2 from the left limit switch tab as shown in Figure 16C actuator bracket Increase the time that the system runs each time these steps are repeated until the system has run for at least 10 minutes ss Left Limit ED Switch Tab i i TR a I mmm mos m E17 LD ri IL ILU RI IARE 22b zl d iila SrH Li aia Figure 16C Limit Switch Adjustment 108 PNEG 602 Chain Disk Chain Installation 16 7 Mounting Proximity Switch 1 Mount Proximity Switch to CLEAR section of tubing located after the last drop tube and before the drive unit See Figure 16D 2 Attach the Proximity Switch Mountin
58. d NC Proxy Switch Normally Open 5 4 Continuous Feeding Delay The Continuous Delay has a different utility depending on the location of the Proxy Switch In both cases the delay can be adjusted from 1 minute to 23 h 59 m Cont Feeding Delay 0 30 1 If the Proxy Switch is located in the last drop Feed Sensor Bypass 0 second The Continuous Feed Delay is the time period that is required before restarting the chain disk once feed stops being detected 2 If the Proxy Switch is located in the last drop Feed Sensor Bypass 0 second The Continuous Feed Delay is the time period that is required before restarting the chain disk once feed stops being detected 5 Feed Sensor Bypass Delay over which the chain disk runs right after the Continuous Delay Set the bypass delay to 0 second if the Proxy Switch is located in the last drop The bypass delay can be adjusted from 0 to 30 minutes Feed Sensor Bypass 0 30m s 4 PNEG 602 Chain Disk 97 Chain Disk Controler APCD 300 6 10 Maximum Current Select the maximum allowable current that can be consumed by the feeder motor Adjustable from 1 to 14 Amp Max Current 8 5Amp Window Size This is the current difference below the Max Current at which the auger motor restarts The auger motor restarts at Max Current Window Size It can be adjusted from 0 5 to 3 0 Amp Window Size 1 5Amp Over Current Delay An alarm is set OFF w
59. d Assy Outer Access Door CTR Hopper 3 8 434 STL Back NEO Washer 2 1 4 Tube Clamp For Ribbed Tube Only 2 1 2 AP Logo for Basket Fans S 4301 5 16 18 Wing Nut GRD 2 Zinc PNEG 602 Chain Disk 125 Parts List 6 Drop Kit amp Pneumatic Drop Kit Chain Disk XO N P Sy PNEG 602 Chain Disk 126 Parts List Drop Kit amp Pneumatic Drop Kit Chain Disk key Pa oy DBesrpin APCD 109 Drop Kit Chain Disk Single APCD 110 Drop Kit Chain Disk Box of 10 APCD 119 Pneumatic Drop Kit Chain Disk APCD 104 _ Clear PVC Tubing 2 00 51 mm I D x 2 36 60 mm O D x 10 ft 3 m APCD 112 White PVC Tubing 2 00 51 mm 1 0 x 2 36 60 x 10 ft 3 m APCD 248H Ribbed Tube Coupler 15 Long with Drop Hole APCD 251 2 x 48 No Holes APCD 285 2 x 62 No Holes APCD 238 2 x 111 No Holes APCD 250 2 x 144 No Holes APCD 314 2 x 120 60 Spacing 2 Holes APCD 356 2 x 120 120 Spacing 1 Hole APCD 307 2 x 132 66 Spacing 2 Holes i Wasi APCD 237 2 x 132 22 Spacing 6 Holes NE NH NE MS APCD 236 2 x 138 23 Spacing 6 Holes APCD 296 2 x 140 20 Spacing 7 Holes APCD 235 2 x 144 24 Spacing 6 Holes APCD 252 2 x 144 48 Spacing 3 Holes APCD 380 2 x 130 26 Spacing 5 Holes APCD 3202 Feeder Adapter For Ribbed Tube 4 APCD 058 1 Slide Chain Disk Drop Kit 5
60. disk AP 2588 Shut off Valve 1 8 NPT Female x 1 8 NPT Female Brass APCD 135 90 Degree Elbow Fitting 1 8 NPT Male x 1 8 NPT Male Brass PNEG 602 Chain Disk 123 124 Parts List 5 Fill Hopper Assembly PNEG 602 Chain Disk Parts List Fill Hopper Assembly Pas y Description 1 1 10 11 12 12 13 14 5 5 15 5 APCD 279 FLX 3486 S 7621 AP 1003 AP 2983 AP 1001 S 7906 FLX 4496 FLX 4520 AP 1770 APCD 275 S 8004 APCD 105 APCD 113 APCD 228 APCD 104 APCD 112 Ref Only APCD 281 APCD 276 S 3558 S 4490 DC 1107 Fill Hopper Assembly Chain Disk Washer Power Head Drop Screw 10 x 1 Self Drilling Grommet 36 5 x 2 mm Groove Use with Proximity Switch Universal Proximity Switch Feed Sensor 110 V Proximity Switch N O or N C 1 second 5 minutes time delay optional 1 2 Cord Connector 220 300 350 Control Unit 220 V Coil 220 300 350 Control Unit 110 V Coil 220 300 350 Control Unit 220 V Coil w proximity Switch Chain Disk Fill Hopper U bolt 5 16 18 x 2 1 2 with Saddle Coupler 2 63 67 mm O D x 2 38 60 5 mm I D Clear PVC Coupler 2 63 67 mm O D x 2 38 60 5 mm I D White PVC Ribbed Tube Adapter for Ribbed Tube Refer Page 126 Only Clear PVC tubing 2 00 51 mm I D x 2 36 60 mm O D x 10 ft 3 m White PVC tubing 2 00 51 mm 1 0 x 2 36 60 mm O D x 10 ft 3 m a Ribbed Tube Refer Page 126 Hopper Screen Wel
61. eces of information can be displayed The chain disk is in manual mode A countdown before the chain disk stops Shut down delay The current that is consumed by the chain disk s motor The alarm acknowledgment must also be performed from this menu Refer to Alarms Sectiion for further information about the alarms The controller automatically returns to this menu after 4 minutes of inactivity 1 Use the menu select buttons to select the STATUS main menu 2 Use the arrow keys to scroll the display Run Time History The APCD 300 keeps a daily history master Chain Disk run times These values are kept in memory for the past 6 days 1 Usethe menu select buttons to select the RUN TIME HISTORY menu The total run time of the last cycle is displayed Run Time History LastCyc 0 35 Y 2 Usethe down arrow key to scroll the display The chain disk run times of the past 6 days are displayed Run Time History Today 1 20 4 PNEG 602 Chain Disk 95 Chain Disk Controler APCD 300 Setting the Time amp Date 1 Use the menu select buttons to select the TIME DATE menu The current time and date are displayed 12 00 00PM 01 01 200X 2 Press MODIFY The hours flash on the display Use the arrow keys to set the hours to the proper value 3 Press MODIFY once again The minutes flash on the display Use the arrow keys to set the minutes to the proper value 4 Press MODIFY once again The seconds flash on the d
62. er Chain Disk feeder All feeders or slave 1 7 feeders Press MODIFY once again to validate Once the desired feeder is selected activate the manual mode as shown in Manual Start Stop Section PNEG 602 Chain Disk 79 Chain Disk Controller APCD 295 Manual Start Stop It is possible to start filling some feeders manually as explained in previous section or to stop the whole Chain Disk system manually 1 Use the menu select buttons to select the MANUAL MODE menu A password may be required to access this menu See Installation Setup Sectiion 2 The manual mode status is displayed on screen Feed Cycles Mode Auto 3 Press MODIFY then use the arrow keys to select the desired status Select Start to enable the manual mode Select Stop to stop the Chain Disk system Select Auto to return to the automatic control mode Manual Dump The actuator electric valve can only be activated manually when no drive unit is running The Manual Mode pilot light flashes while an actuator or electric valve is controlled manually 1 Use the menu select buttons to select the MANUAL MODE menu 2 Press the down arrow key to select the manual mode status of the actuator Only shown if the actuator is enabled See Installation Setup Section Actuator Mode 3 Press MODIFY then use the arrow keys to select the desired status Auto Open Stop Close Press MODIFY again to validate The answer is validated after an 8 second dela
63. etup a Cascade setup b Independent feeders with a common bin auger c Independent feeders with individual bin augers 2 Feed Distribution Mode a Continuous feed distribution b Timed feed distribution PNEG 602 Chain Disk 61 Chain Disk Controller APCD 295 The following sections explain all possible ways Chain Disk feeders can be filled Refer to the Filling Chain Disk Feeders Section that suit your particular feeder setup and feed distribution method WARNING A Please note that the whole feeding system stops when an alarm is active Filling Cascaded Feeders Feeders 1 APCD 295S First ID 3 a s 2 2 f Second APCD 2958 2955 ID 1 APCD 295 Master Figure 12G Cascade Setup Option A 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 feed 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
64. feeders in use Up to 7 slave feeders APCD 295S can be controlled of Slaves 3 4 Feeder setup If slave feeders are used select the proper feeder setup Select Cascade if the feeders connected together select Independent if they are separated from one another This menu is shown if slave feeders are enabled below Feeder Setup Cascade Independent Feeders Feeders PNEG 602 Chain Disk 73 Chain Disk Controller APCD 295 Common Auger If independent slave feeders are enabled above select if all feeders have their own bin auger or if they share a common auger This menu ts shown if independent slave feeders are enabled below Use Common Auger Yes 4 Independent Common Bin Augers Bin Auger Proxy Switch Select Yes if proximity sensors are used to detect the presence of feed at the end of the feeders Use Proxy Switch Yes Proxy Switch Status Choose the normal contact status of all proximity sensors in use Normally Opened NO or Normally Closed NC Only shown proximity sensors are enabled Proxy Switch Normally Open A Feed Sensor Bypass If a proximity sensor is used the Chain Disk stops when feed is 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 cyc
65. g Bracket to the clear tubing using the hose clamps provided Adjust the bracket so the proximity switch is mounted at a 45 angle See Figure 16D Figure 16D 3 The Proximity Switch must touch the clear tube Adjust the top plastic nut until the top of the switch is touching the tube Adjust the bottom plastic nut to secure into place See Figure 16E Indicator Plastic P Sensitivity 1 Adjustment a A Figure 16E 16 8 Adjusting Sensitivity 1 Turn OFF the flex auger so no feed is being added to the line 2 Turn chain disk on in Manual Mode and clear all feed from inside of line You may want to adjust the Feed Sensor Bypass time to allow the line to run longer during setup PNEG 602 Chain Disk 109 Chain Installation Ifthe light is ON when the tube is empty the switch is to sensitive You must reduce the sensing distance by turning the sensitivity screw counter clockwise To increase the sensing distance adjust the screw clockwise See Figure 16E 4 set the correct sensitivity place your index finger on the tubing so it is 1 4 from the top of the proximity switch Then turn the sensitivity screw until the indicator light turns on The light may be solid or may just blink on when a disk passes by Either setup is fine Note Make sure that you have your fist closed with only your index finger open Also do not touch the tube with your other
66. hand or leave anything laying over the tube to interfere with the sensitivity See Figure 16F amp Figure 16G Keep Hand Closed Figure 16G 5 Reset the Feed Sensor Bypass time if it was changed for setup 110 PNEG 602 Chain Disk Maintenance 17 MAINTENANCE WARNING A Always disconnect power before removing any covers from equipment 17 1 Chain and Disk Tension Check the tension in the chain and disk weekly If the switch actuator bracket 15 close to the limit switch Refer to Section 16 6 on Chain Steps 2 11 on how to remove a section of chain Remember to always remove twice as much chain as the distance the idler wheel needs to move to the right 17 2 Gearbox Fluid Level Check Check the gearbox fluid level monthly Maintain a level 1 from top always add a gear lubricant Mobile SHC 634 Part No APCD 286 The Fill plug is at the top of the gearbox The chain disk drive unit may have to be lowered a few inches to provide access 17 3 Bushing Replacement in Idler Wheel Check nylon bushings Part No APCD 007 in main drive idler wheel annually If bushings show excessive wear contact manufacturer for replacements Refer to Parts List later in this manual for a drawing of this bushing Figure 17A Back of Control Unit PNEG 602 Chain Disk 111 Maintenance 17 4 Limit Switch Inspection Check the operation of the limit switch in drive unit monthly 1
67. hen the chain disk motor s current consumption exceeds the Maximum Current limit for this delay The Over Current Delay can be adjusted from 30 seconds to 15 minutes Over Current Delay 0 30m s Auger s Delay The auger starts running when this delay has elapsed right after the chain disk s start up once the Continuous Delay has elapsed Adjustable from 0 to 60 minutes Auger Delay 0 15m s 4 Max Run Time The Max Run Time is the maximum allowable running time of the chain disk Whenever the chain disk reaches this running time an alarm is set off and the system stops operating until the alarm is acknowledged The Max Run Time can be adjusted from 0 to 4 hours Max Run Time m 2 15h m4 98 PNEG 602 Chain Disk Chain Disk Controler APCD 300 11 Time Mode Select the desired time display format 12 h or 24 h mode Time Mode 12h A 12 Shut Down Delay Once feed is detected by the proximity switch at the end of the line a delay is launched before stopping the chain disk motor The bin auger also stops bringing feed into the line over this delay The shut down delay can be adjusted from 0 to 10 minutes shut Down Delay 1 00m s 13 Change password Select Yes if you wish to modify the controller s password then press the downarrow key Change Password Yes 5 1 Press MODIFY The first two digits of the password flash on the display 2 new password must be entered o
68. igure 6B Outlet Holes with Total Dropout 14 PNEG 602 Chain Disk Tubing amp Drop Kit 6 5 Suspension of Tubing Important Suspend the sections of PVC tubing and Ribbed tubing from the ceiling at least once every 4 feet 1 2 m To minimize drag and wear keep the sections of tubing as straight as possible Failure to do this will void the warranty 6 6 Drop Kit Installation 1 Snap the slide around the tube over the outlet hole Figure 6C and Figure 6D 2 When using ribbed tube the adapter must be used Figure 6E 3 Fasten the housing to the tube using two hose clamps Make sure the outlet hole is in the middle of the housing 4 Slide can be rotated from side to side to open and close the drop kit PVC Tubing House Clamp 2 Figure 6C Drop kit Installation PVC Tubing House Clamp 2 Figure 6D Pneumatic Drop kit Installation PNEG 602 Chain Disk 15 Tubing amp Drop Kit Ribbed Tube Adapter Ribbed Tube 6 7 Drop Feeder Installation Refer to the Drop Feeder Installation and Operational Manual to install the drop feeders When Installing ACCU DROP feeders and ECONO DROP feeders to ribbed tube the ribbed tube adapter must be used When installing ultra drop feeders to ribbed tubing do not use the ribbed tube adapter 16 PNEG 602 Chain Disk Drive Unit Installation 7 DRIVE UNIT INSTALLATION 7 1 Location The Chain Disk Model 236 drive unit is designed in such a way that if feed
69. in easy reach of the operator It shall be marked as the disconnecting device for the equipment 3 The main supply circuit breaker for feeder motor L1 L2 POWER IN shall be 20 A 4 Wire gage used for mains supply L1 L2 POWER IN and feeder motor shall be at least 12 AWG 5 Separate circuit breaker shall be used for auger motor 6 mains supply breaker for auger motor shall be 15 A 7 Wire gage used for auger motor shall be at least 14 AWG WARNING A All wiring must be done by authorized electrician 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 specified by the manufacturer 14 3 Controller s Operation Controller s Description The APCD 300 is an electronic device used to control a chain disk system in livestock buildings The APCD 300 takes in charge the feed intake from the bin into the feed line and controls the feed distribution process using a proximity sensor Proxy Switch 92 PNEG 602 Chain Disk Chain Disk Controler APCD 300 Auger s Operation At the start up of each feeding cycle the auger starts bringing feed into the feed distribution line right after the Auger s Delay The auger s motor is stopped when the feed line is loaded The following steps describe the whole process Feed Line Figure 14A 1
70. is operating si Turns ON when the bin auger is operating Output Flashes during the Auger Delay Manual Mode Turns Turns ON when the chain disk is on manual mode si when the chain disk Turns ON when the chain disk is on manual mode si on manual mode Automatic Mode Turns ON when the chain disk is on the automatic mode Symbols Double Insulation 14 2 Installation Mounting Instructions Remove the four screws in 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 PNEG 602 Chain Disk 91 Chain Disk Controler APCD 300 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 1 Do not install rigid conduit into electrical knockouts Only nylon cable glands are permitted for cable or wire fastening 2 switch or circuit breaker shall be included in the building installation It shall be in close proximity to the equipment and with
71. isplay Use the arrow keys to set the seconds to the proper value 5 Press MODIFY The day flashes on the display Use the arrow keys to set the day to the proper value 6 Press MODIFY once again The month flashes on the display Use the arrow keys to set the month to the proper value 7 Press MODIFY once again The year flashes on the display Use the arrow keys to set the year to the proper value Installation Setup The following section describes how to customize the controller for your particular application Normally this setup needs to be done only once 1 Use the menu select buttons to select the INSTALLATION main menu A password may be required to access this menu By default the password is set to 6 1 0 Enter Password 06 01 00 96 PNEG 602 Chain Disk Chain Disk Controler APCD 300 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 adjusting 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 2 Use Password Select Yes to enable a password This password is used to restrain the access to the Installation and Feed Cycle menus Use Password Yes Y 3 Proxy Switch Status Choose the normal status of the proximity switch relay Normally Open NO or Normally Close
72. l the drive unit of the next empty feeder starts following numerical order and the bin auger keeps running 64 PNEG 602 Chain Disk Chain Disk Controller APCD 295 Option B 1 The Last Feeder ts 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 Timed Feed Distribution Beginning the Filling Process The filling process starts at the start up of each feed cycle 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 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 295 rev 07 19 the bin auger starts bringing 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 Filling the First Chain Disk Feeder When the Purge Time is over all drive units stop except for the first feeder to be fil
73. le Set this delay separately for each feeder in use 51 Slave 1 S2 Slave 2 etc It can be adjusted from 0 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 5 PNEG 602 Chain Disk Chain Disk Controller APCD 295 Continuous Feeding Timed Feeding Select YES to use the continuous feeding mode select No to use timed feed distribution See Feed Distribution Modes Section Only shown proximity sensors are enabled below Continuous Feeding 4 Continuous Feeding Delay When using the continuous feed distribution method the Continuous Delay tells when to start a feed cycle from the moment where no feed is detected at the end of the master Chain Disk feeder See Timed Feed Distribution Sectiion It can be adjusted from 1 min to 23 h 59 min Only shown if the continuous feeding mode is enabled below Cont Feeding Delay 0 30 4 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 None to disable feed dumps Only shown if feed distribution is based on a timer if the continuous feeding mode is disabled below Feed dump use Actua 4 Clean Drops This function allows cleaning the drops
74. led the master Chain Disk feeder When the Auger Delay is over the bin auger starts bringing feed toward this feeder The Feeder is Full a 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 controller 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 b 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 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 Feed Dumping When the Chain Disk system is fully loaded feed is ready to be delivered to the animals Step to Proximity Sensor Location Section PNEG 602 Chain Disk 65 Chain Disk Controller APCD 295 Filling Independent Feeders with Individual Bin Augers Feeders Filling Order Controller amp ID number T 1 APCD 295S Simaltaneous D 3 Simaltaneous x APCD 2958 2 Simaltaneous APCD 295S ID4H
75. lex Flo System must be used to transport feed from the bulk feed tank to the Chain Disk System inside the building In colder climates the Chain Disk System can lock up when used outside due to freezing whereas the auger in the Flex Flo System can break loose frozen feed due to its outside rotational motion and winding up tendency Important The correct gearbox must be used on the Model 300 Flex Flo System to prevent overfilling of the Chain Disk System Table 1 shows the maximum fill system rate for different effective lengths of a Chain Disk System and the corresponding flex flo gearbox R P M to deliver that rate The effective length is determined by adding the length of chain plus 25 ft 7 m per corner Refer to the Model 300 Flex Flo Installation amp Operation Manual for proper installation of the Flex Flo System The Flex Flo System can run parallel or perpendicular to the Chain Disk System Maximum Fill System Rates Flex Flo Feed Tank Effective Length of Maximum Fill ip Model 300 Flex Configuration Chain Disk System System Rate Flo Gearbox RPM ena or Tandem ft Ft m Ibs min 1 kg min Upto 700 213 to 700 213 5023 23 358 358 Standard 700 1000 213 305 3509 2 MM ses m MET Effective Length Total ft of Chain 25 ft of Corners Direction of Travel for Chain and Disk 2 4 2 D gt Chain Disk System Chain Disk Drive Unit Flex Flow Control Unit
76. ll System shuts Off Fill System turns back On im O lt o S lt O o lt Feed System Turned On Fill System Runing wo O O N CO 9 10 11 12 13 14 15 16 17 18 19 20 Time minutes Figure 11B Graphical Illustration of Current Sensor Operation for Typical Feed System 11 2 Limit Switch The limit switch See Figure 1 1C which is located in the chain disk drive unit is used as a safety switch The limit switch can be activated in either direction by a bracket which is connected to the idler wheel It will shut the system down if the chain is too long or too short if the chain or spring breaks or if something gets caught in the system To reactivate the system push the blue reset button on the limit switch reset the appropriate control unit by acknowledging the alarm on the APCD 295 control unit or push the reset button on the APCD 295 S control unit Figure 11C Limit Switch in Normal Operating State PNEG 602 Chain Disk 53 Operation Controls Figure 11D Limit Switch in Activated Shut Down State WARNING A Disconnect power and fix the problem before pushing the reset button or acknowledge the alarm on the APCD 295 control 54 PNEG 602 Chain Disk Chain Disk Controller APCD 295 12 CHAIN DISK CONTROLLER APCD 295 12 1 Terms and Symbols LCD Display The LCD display on the left gives the current reading
77. low 40 Fahrenheit or above 85 Fahrenheit consult PVC solvent cement container 4 Apply a coat of cement to both parts being connected 5 Assemble parts quickly CEMENT MUST BE FLUID if not fluid re coat both parts 6 Hold parts 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 PNEG 602 Chain Disk 13 Tubing amp Drop Kit 6 4 Cutting Outlet Holes With the sections of tubing still layed out and the placement of the drop kits already established the next step is to mark on the top of the tube where each drop kit is to be The reason for marking the tube in advance is to make sure the holes stay aligned even if the tubes rotate as the holes are being cut Once the tubes are marked cut the holes for the outlet drops as shown in Figure 6A and Figure 6B When carry over is acceptable drill two 1 5 88 mm dia holes in the tube Figure 6A approximately 3 0 76 mm apart using a holesaw If total dropout is necessary cut a 6 5 165 mm long by 625 16 mm deep hole Figure 6B using a saber saw or hacksaw Be sure to remove any burrs after cutting so the drop kit can perform properly Note Ribbed Tubing Comes with Pre punched Outlet Holes 1 5 38 mm dia Two Holes lt 3 0 76 mm Figure 6A Outlet Holes with Carry over lt 6 5 165 gt 625 16 mm F
78. m 3 Press MODIFY then use the arrow keys to set this parameter to the desired value Press MODIFY once again to validate 4 fslave feeders are used press the down arrow key to select the Run Time of the first slave feeder Run Time 51 1 00h m 5 Press MODIFY then use the arrow keys to set this parameter to the desired value Press MODIFY once again to validate 6 Proceed in similar fashion to set the Run Time of all feeders in use 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 A password may be required to access this menu By default the password is set to 6 1 0 Enter Password 06 01 00 72 PNEG 602 Chain Disk Chain Disk Controller APCD 295 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 adjusting 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 Use Password Yes Y of Slaves Enter the number of additional Chain Disk
79. ne 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 second number etc Enter New kk v 14 Version Show the current version of your controller APCD 300 Version X X A PNEG 602 Chain Disk 99 Chain Disk Controler APCD 300 Manual Mode This mode allows to manually perform a feed cycle The chain disk runs up until feed is detected by the proximity sensor The Manual Mode led is lit when this mode is in use Do not forget to select the automatic mode again once the manual feed cycle is completed 1 Use the menu select buttons to select the MANUAL MODE menu Feed Cycles Mode Auto 2 Press MODIFY to change the feed cycle mode use the arrow keys to choose the proper mode Auto Start Stop Press MODIFY once again to validate The new mode is validated after an 8 second delay if the user does not press on the Modify button Toggle Switch It is possible to connect a toggle switch to the main board This switch allows to manually stop the chain disk and auger motors without setting off the Chain Disk is Not Running alarm until the next feeding cycle Refer to the Wiring Diagram 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 Alarms The following table show
80. ng iroa CHAIN DISK APCD 295 MASTER CHAIN DISK CONTROL C U THIS CONTROL MUST BE CONNECTED g CHAIN DISK LOOP CLOSEST TO FEED TANKS AS SHOWN TUBE MOUNTED PROXIMITY SWITCH CHAIN DISK DRIVE UNIT DIRECTION OF CHAIN DISK TRAVEL FILL HOPPER MODEL 300 FLEX FLO AUGER FIRST FEEDER TO BE FILLED tjr LAST FEEDER BE FILLED T PNEG 602 Chain Disk 35 Wiring Diagrams Two Chain Disk Loops Filled by One Common Flex Flo Auger with Timed Filling 2 295 5 SLAVE CHAIN DISK CONTROL UNIT SWITCH H MUST BE DN CHAIN DISK SAFETY SWITCH PROX SWITCH CHAIN DISK MOTOR FLEX AUGER TOGGLE SWITCH 18 CHAIN DISK DRIVE UNIT ELECTRICAL JUNCTIUN BUA APCD 294 TUBE MOUNTED PRIX SWITCH 1 1 ee E LO oo TOGGLE mtm 4 SWITCH d CHAIN CHAIN DISK 05 MER 36 PNEG 602 Chain Disk Wiring Diagrams Two Chain Disk Loops Filled by One Common Flex Flo Auger with Timed Filling MOD 1 OF MASTER MUST BE CONNECTED CDM 1 OF SLAVE AS SHOWN 2 DF MASTER MUST BE CONNECTED COM 2 DF SLAVE AS SHOWN aaa tae THIS CONTROL MUST BE CONNECTED IU CHAIN DISK LOOF CLOSEST TO FEED TANKS TOGGLE SWITCH PROX SWITCH AUGER MOTOR ACTUATOR rm SWITCH LB a LI C30 v AC
81. ngs Refer to Filling Chain Disk Feeders Section to get information on feed cycles To ease programming the feed cycles write down each of your settings in the feed cycle template in the Feed Cycle Settings section 1 Use the menu select buttons to select the FEED CYCLES menu 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 Installation Setup Sectiion Feeding Cycle 1 StopAt 6 12 2 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 3 Press the down arrow key once The dump time of the first feed cycle is displayed Accessible if actuators or electric valves are enabled See nstallation Setup Sectiion 4 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 5 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 70 PNEG 602 Chain Disk Chain Disk Controller APCD 295 Check Feed Cycles WARNING A The controller automatically rearranges the feed cycles in the case of a programming error The warning message Check
82. ns 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 specified by the manufacturer 12 3 Controller s Operation Controller s Description The APCD 295 controls the feed entry into Chain Disk feeders and the distribution of feed to the animals When used in combination with APCD 295 S auxiliary units this controller can control up to 8 Chain Disk feeders Due to its great number of options the APCD 295 controller can suit most Chain Disk setups 1 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 2 3 4 With one or multiple bin augers 5 With one or multiple Chain Disk feeders 6 With cascade or independent Chain Disk setups PNEG 602 Chain Disk 57 Chain Disk Controller APCD 295 Feeder Setup Up to 7 slave units APCD 295S can be used to drive additional Chain Disk feeders These supplementary feeders can share common bin augers they can be linked together or they can operate independently one from another The following section explains the three possible feeder setups that can be managed by the controller Refer to the nstallation Setup Section to select your specific feeder setup Cascade Setup In this setup all feeders are connected together and share a common bin auger When this auger
83. of feed Electric motor Control unit The rated capacity is up to 50 Ibs min 23 kg min Capacity is based on a feed density of 40 Ibs ft 641 kg m Refer to Page 20 The maximum effective length for this system is 1000 ft 305 m Subtract 25 ft 7 6 m per corner or Effective Length Total ft of Chain 25 ft of Corners The Model 236 Chain Disk is specifically designed to convey normal types of swine and poultry feeds When conveying any other type of material contact the manufacturer as the warranty may be invalidated There are three options Clear and white PVC tubing having dimensions of 2 00 51 mm 1 0 and 2 36 60 mm O D coming in 10 ft 3 m lengths Clear and white PVC couplers having dimensions of 2 38 60 5 mm 1 0 and 2 63 67 mm O D are used to join sections of tubing together Ribbed Tube 2 00 O D 1 9 1 0 w belled end refer to Page 127 for Length and Configuration Each corner has a 9 3 236 mm diameter steel cast wheel with nongreasable ball bearings encased in a nylon housing with a removable cover The chain is heat treated and case hardened with a 3000 Ib 13 3 kN breaking strength Polypropylene disks having 1 8 46 mm O D are molded on every other chain link The chain is connected together using a special open link connector The drive unit having dimensions of 46 1 2 m length 16 5 4 m height and 16 25 4 m width is an enclosed stainless steel housing
84. of your controller APCD 295 Version X X A Manual amp Test Modes The manual mode allows activating manually the actuators electric valves and drive units 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 outputs in order to fill up the required feeder s see the different filling methods in Filling Process Section The manual filling process ends when the feeder is full WARNING If the user starts a manual fill up of a feeder while feed cycle is ongoing the ongoing cycle is bypassed and replaced 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 Manual Start Stop Sectiion Do not forget to exit from the manual mode once the manual filling process 15 completed 1 Use the menu select buttons to select the MANUAL MODE menu A password be required to access this menu See Installation Setup Sectiion 2 Before enabling the manual filling select which feeder must be filled Press the down arrow key to select the Manual Start menu Manual Start Mastr 3 Press MODIFY then use the arrow keys to select the feeder that needs to be filled manually Mast
85. oller 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 WARNING A Turn off power each time you open the controller s enclosure This prevents accidental exposure to areas of high voltage To Transfer a Configuration 1 Turn OFF power to the controller 2 Open the latch and lift the controller 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 4 Insert the card in the J9 connector located on the electronic board inside the controller Components of the memory card must face down as illustrated 5 Close the cover then reapply power to the controller The transfer menu should be shown on screen if this is not the case simultaneously press the MENU SELECT up and down arrow keys for 3 seconds to display this menu Memory Card Card Switch Connector Electronic Figure 12J 6 Use the ADJUSTMENT up and down arrow keys to select the proper type of transfer PNEG 602 Chain Disk 83 Chain Disk Controller APCD 295 Memory Card Controller To transfer the memory card s content into the controller select the Mem Card to Control Once it is selected simultaneously press the ADJUSTMENT up and down arrow keys to start the tr
86. over of the drive unit Moving parts can crush and cut Keep hands clear Do not operate with guard removed Disconnect and lockout power before servicing 99 PNEG 602 Chain Disk Decals DC 490 is located on the electrical box of the drive unit da DANGER High voltage m DC 889 is located on the or death electrical box of the drive unit Lockout power before servicing W i r F L eee ELLE j DC 997 is located inside the A DANGER drive unit Moving parts can crush and cut Keep hands clear Do not operate with guard removed Disconnect and lockout power before servicing PNEG 602 Chain Disk Introduction 3 INTRODUCTION 3 1 Applications Typical Chain Disk System applications are shown as follows In poultry applications switches may be placed in more than one hopper to assure that no hopper empties before the control unit hopper requires feed If this is done all switches must be wired in parallel so that any one switch can start the system If only one hopper level control is used it must be located at the end of the delivery system Direction of Travel for Chain and Disk _ Flex Flow Control Unit Flex Flow Fill System Figure 3A Typical Application In most swine applications the feed control is installed in the last hooper at the end of the delivery system If
87. peration Controller s Description APCD 295 S units allows adding up to 7 feeders to a Chain Disk system that is controlled by an APCD 295 controller The following illustration sums up the situation APCD 295 S ID 3 APCD 295 S ID 2 APCD 295 S ID 1 APCD 295 Master Figure 13D Slave Unit s Operation The feeders connected to all APCD 295 S units are controlled by the master APCD 295 controller This is true except when a current overload occurs or when the drive unit s safety switch is reached When one of these situations occurs the APCD 295 S stops its respective drive unit and stops the feed entry bin auger Reset Button This button is only used if your APCD 295 S unit operates according to the previous communication method if internal switch 8 is set to ON With the new communication mode internal switch 48 to OFF this reset must be performed from the master Chain Disk controller APCD 295 controller Toggle Switch A toggle switch can be connected to the main board This switch allows stopping the drive unit of the APCD 295 S unit and stopping bin augers manually whithout sounding the Chain Disk is Not Running alarm until the next feed cycle WARNING A toggle switch does not cut the power lines to the chain disk motor Disconnect the breaker for servicing and maintenance PNEG 602 Chain Disk Chain Disk Controler APCD 295 S 13 4 Technical Specifica
88. rocess 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 INSTALLATION 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 running and its respective bin auger starts filling it 5 The Feeder is Full a Ifa proximity sensor is used The controller knows a feeder is 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 b 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 Proximity Sensor Location Section 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
89. roughout the system for easy viewing of the feed especially before and after the fill hopper and where the proximity switch is located Things to consider the system must be closed looped sections of tubing can go in any direction and the change in direction of the tubing must be 90 degrees For now overlap the tubes where there is to be a corner and leave the cutting of the tubes to fit various components until these components are installed which will be later on Establish where the outlet drops are to be Make sure that the ends of these tubes don t meet where there Is to be a drop kit or drop feeder f they do one end of the tube must be cut off enough so the coupler or belled end will miss the drop kit 6 3 Assembly amp Gluing Sections of PVC Tubing Once the tubing has been properly layed out the 10 foot 3 m tubes need to be connected together in long sections Note Maximum length of each glued section should not exceed the length of fish tape which will be used later on to install chain Note For extremely long systems we recommend gluing only one side of the coupler leaving an 1 8 3 mm gap between ends of tubing to allow for tubing expansion Chain Disk Systems have specially formulated PVC tubing For strong tube connections apply the PVC solvent cement as the instructions below suggest 1 Square tube ends and remove all burrs and dirt 2 Check to make sure all connections are smooth 3 When the temperature is be
90. s 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 arrow keys A w 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 parameter 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 PNEG 602 Chain Disk 55 Chain Disk Controller APCD 295 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
91. s switch ON unless your dealer tells you to do it Note that turning internal switch 8 ON completely changes the way the APCD 295 S works If you turn it ON refer to revision 01 of the APCD 295 S manual and to revision 02 of the wiring diagram contact your dealer 13 2 Installation Mounting Instructions Open the latch and lift the cover Remove the black caps located on each of the four mounting holes Mount the enclosure on the wall using four 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 in the mounting holes and tighten Fasten the four black caps provided with the controller onto the four mounting holes The enclosure must be mounted in a location that will allow the cover to be completely opened right up against the wall 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 WARNING A 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 PNEG 602 Chain Disk 87 Chain Disk Controler APCD 295 S 13 3 Controller s O
92. s the possible alarms conditions When an alarm occurs the system stops operating until the alarm is acknowledged Condition Meaning 00020220 Chain Disk is not Runing The Chain Disk Motor uses less than 0 2 Amps The Chain Disk Motor s current consumption exceeded the Max Current Overload Occured Current limit for a time period exceeding the over current delay The Chain Disk s run time exceeded the Max run time Max Run Time Occured This Alarm can only occur if a proxy switch sensor has been enabled in the installation setup Chain Disk Safety Switch The chain Disk s safety switch 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 the trouble light 100 PNEG 602 Chain Disk Chain Disk Controler APCD 300 Acknowledging an Alarm 1 Use the menu select buttons to select the STATUS menu The current alarm acknowledgment menu is displayed 2 Press MODIFY The acknowledgment status flashes on the display 3 Press the up arrow key to acknowledge the alarm then press MODIFY to validate The alarm is now acknowledged 14 5 Technical Specifications 230 V 10 20 12A 50 60Hz 556 00000 Storage Temperature 15 to 50xC Ambient Relative Humidity Max95 non condensing 115 VAC 1 2 HP Max a Pollution Degree Altitude Up to 2000 m
93. shes when the amperage draw of the drive unit has exceeded the Max Current limit for the Overload Delay Fix the problem then press and hold the RESET button to restart the Current Overload system Turns ON when the drive unit has reached its safety switch Chain Disk Safety Switch Fix the problem then press and hold the RESET button to restart the system Feed Switch Turns ON when the proximity sensor detects feed Flashes during the Feed Bypass Delay Chain Disk Output Turns ON when the drive unit is running Internal Switches The internal switches are located inside the box on the bottom board When the controller is shipped from the factory all the switches are set to OFF 13 Internal switches 1 7 are used to set the ID number of each APCD 295 S unit Internal switch 8 is used to return to the previous communiation method as explained below Only lift the switch that corresponds to the ID of the APCD 295 S unit Communication terminals are disabled Do not turn this switch on unless your dealer tells you to do it 86 PNEG 602 Chain Disk Chain Disk Controler APCD 295 S Communication Mode WARNING A Internal switch 8 allows stepping back to the communication mode that was previously used by the APCD 295 controller without using COMM terminals This option is used to ensure the compatibility between APCD 295 S units and older versions of the APCD 295 Do not turn thi
94. st be equal to or longer than the longest section of glued PVC tubing Note You may want to mark or paint the linked sections so they can easily be identified through a clear tube 1 Start installing chain at one end of the drive unit so after all the chain is installed the final connection can be made inside the drive unit 2 Atthe other end of the first section of tubing start pushing the fish tape through the tube until it comes out into the drive unit 3 Connect one end of a section of chain and disks to the fish tape make sure the chain and disks are going in the right direction See Figure 16A PNEG 602 Chain Disk 105 Chain Installation 4 Pull the section of chain and disks through the tubing until there is only about 5 feet 1 5 m left in the drive unit If the section of tubing is longer than the chain and disks use more than one section of chain and disks and connect them together using a connector link The plastic in the end links will need to be drilled out using a 5 16 drill bit so the connector link will fit See Figure 16A 5 Go to the other end of the next section of tubing and start pushing the fish tape through the tube until it comes out this end of the tubing 6 Connect one end of a new section of chain and disks to the fish tape make sure the chain and disks are going in the right direction See Figure 16A 7 Pullthe section of chain and disks through the tubing until there is only about
95. starts bringing feed into the feeders all drive units start running to send feed towards the farthest Chain Disk feeder APCD 295 S unit with the highest ID number When this feeder is filled up feed then goes toward the preceding feeder etc APCD 2958 First w 3 f Second APCD 295S APCD 2958 1 APCD 295 Master Figure 12A 58 PNEG 602 Chain Disk Chain Disk Controller APCD 295 Independent Feeders with a Common Auger Independent feeders that share a common bin auger are filled following the numerical order The master Chain Disk feeder is filled first followed by slave feeder 1 slave feeder 2 etc 2955 ID 3 2958 ID 2 Second APCD 295S 12 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 according to its respective parameter settings Filling Order l e 1 APCD 295S _ Simaltaneous D 23 Simaltaneous HEMOS I i ID 2
96. t buttons to select the STATUS main menu 2 Use the arrow keys to scroll the display Run Time History The APCD 295 keeps a daily history master Chain Disk run times These values are kept in memory for the past 6 days 1 Use the menu select buttons to select the RUN TIME HISTORY menu The total run time of the last cycle is displayed Run Time History LastCyc 0 35 Y 1 Usethe down arrow key to scroll the display The chain disk run times of the past 6 days are displayed Run Time History Today 1 20 Time amp Date 1 Use the menu select buttons to select the TIME DATE menu The current time and date are displayed 12 00 00PM 01 01 200X 2 Press MODIFY The hours flash on the display Use the arrow keys to set the hours to the PNEG 602 Chain Disk 69 Chain Disk Controller APCD 295 proper value 3 Press MODIFY once again The minutes flash on the display Use the arrow keys to set the minutes to the proper value 4 Press MODIFY once again The seconds flash on the display Use the arrow keys to set the seconds to the proper value 5 Press MODIFY The day flashes on the display Use the arrow keys to set the day to the proper value 6 Press MODIFY once again The month flashes on the display Use the arrow keys to set the month to the proper value 7 Press MODIFY once again The year flashes on the display Use the arrow keys to set the year to the proper value Feed Cycle Setti
97. tch 220 V 1 sec to 60 min time delay ACCU DROP feeders fitting tube with 2 36 60 mm outside diameter Farrowing drop Feeder Model 236 8 5 Ib capacity Farrowing Drop Feeder Model 236 12 Ib capacity Suspension kit for drive unit Tube mounted prox switch ECONO DROP feeder fitting tube w 2 36 O D Uses FLX 4256 Proximity Switch Ultra Drop feeders for Gestation w 2 36 O D Ultra Drop feeders for Farrowing w 2 36 O D Feeder Adapter for Ribbed tube when attaching ACCU DROP ECONO DROP or Kwik attach drop kits to Ribbed tube PNEG 602 Chain Disk Tubing amp Drop Kit 6 TUBING amp DROP KIT 6 1 Tubing Options There are three options for tubing Ribbed tubing w belled end 2 00 and 1 9 I D coming in various lengths and hole spacings See Page 127 Both clear and white PVC tubing having dimensions of 2 00 51 mm 1 0 and 2 36 60 coming in 10 ft 3 m lengths available Clear and white PVC couplers having dimensions of 2 38 60 5 mm 1 0 and 2 63 67 mm O D are used to join these sections of tubing together 6 2 Laying Out the Tubing Laying out the tubing is one of the most important steps in the installation of the Chain Disk System Place the tubes in approximately the position where they will be installed either on the ground or on top of the penning for the time being If white PVC or Ribbed tubing is used it would be helpful to place sections of clear PVC tubing at various places th
98. tions 230 V 10 20 2 HP 50 60 Hz Ambient Relative Humidity Max 95 Chain Disk Motor 230 VAC Max2 HP Auger Motor Max230 VAC Max1 2 HP Storage Temperature 15 to 50 C The room temperature where the controller is located MUST ALWAYS REMAIN BETWEEN 32 AND 104 F 0 AND 40 C PNEG 602 Chain Disk 89 Chain Disk Controler APCD 300 14 CHAIN DISK CONTROLER APCD 300 14 1 Terms and Symbols 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 step 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 arrow keys a w 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 parameters 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 p
99. ty and the safety of others associated with this equipment We want to keep you as a customer This manual is to help you understand safe operating procedures and some problems which may be encountered by the operator and other personnel As owner and or operator it is your responsibility to know what requirements hazards and precautions exist and to 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 Such alterations may produce a very dangerous situation where SERIOUS INJURY or DEATH may Occur This equipment shall be installed in accordance with 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 Keep Hands Clear of Chain Disk Moving Chain Disk can cut and crush Keep hands clear ig Disconnect and lockout power before servicing Do not operate with guards removed Moving Parts Install amp Operate Electrical Equipment Properly Electrical controls should be installed by a qualified electrician and must meet the standards set by the national electrical code and all local and state codes Disconnect and lock out all power sources before installing wires cables or servicing equipment Electric Shock Hazard Practice Safe Maintenance Understand service procedures before doing work
100. un Time limit of this feeder Set this parameter separately for each feeder in use It can be adjusted from 00 00 hh mm to 04 00 hh mm Max Run Time py 2 15h m4 of Feeding Cycles Activate the proper number of daily feed cycles Up to 20 cycles can be activated The controller automatically restrain the number of feed cycles so that no cycle overlaps another Refer to See Feed Cycle Settings Sectiion to set the feed cycles of Feeding Cycles Time Mode Select the desired time display format 12 h or 24 h mode Time Mode 12h A Shut Down Delay When a 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 0 to 10 minutes Only shown if proximity sensors are enabled above shut Down Delay 1 00m s Change password Select Yes if you wish to modify the controller s password then press the down arrow key Change Password Yes 5 1 Press MODIFY The first two digits of the password flash on the display PNEG 602 Chain Disk Chain Disk Controller APCD 295 2 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 second number etc Enter New FER Vv Version This is the current version
101. us feed distribution mode a proximity sensor must be located in the tube of the last drop of each feeder Drive Unit Proximity Sensor Last Drop Figure 12E 60 PNEG 602 Chain Disk Chain Disk Controller APCD 295 Filling Chain Disk Feeders 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 is full Feed Line Figure 12F 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 Max 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 Max Current Consumption the controller will temporarily shut 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 Consumption Window Size lt gt Refer to Installation Setup Section to set bin auger parameters Filling Process The filling process of Chain Disk feeders is based on two factors 1 Feeder s
102. user pays 25 5 to 7 years end user pays 50 7 to 10 years end user pays 75 Flooring Feedi i eeding Watering Systems Grain Systems Portable amp Tower Dryers 2Yearis Farm Fans Portable amp Tower Dryer Frames Zimmerman and Internal Infrastructure T Warranty prorated from list price 0 to 3 years no cost to end user 3 to 5 years end user pays 50 T Motors burner components and moving parts not included Portable 5 Years Dryer screens included Tower Dryer V 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 12 month from the date of purchase and continuing until the sixtieth 60 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 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
103. which apply to the location and installation of products manufactured or sold by GSI 9101239 1 rev7 DOC revised July 2009 This Equipment Shall Be Installed In Accordance With The Current Installation Codes And Applicable Regulations Which Should Be Carefully Followed In All Cases Authorities Having J urisdiction Should Be Consulted Before Installations Are Made umberland GSI GROUP GSD The GSI Group Inc 1004 E Illinois St Assumption IL 62510 0020 Phone 1 217 226 4421 Fax 1 217 226 4420 Internet http www grainsystems com Copyright 2008 by The GSI Group Printed in the USA
104. with a spring loaded aluminum idler tensioning wheel and drive sprocket inside The drive sprocket is directly coupled to the output shaft of an aluminum housed speed reducer which in turn is driven by an electric motor There are 3 special built 2 HP motors to choose from 230 V 1 Ph 60 Hz 230 V 1 Ph 50 Hz 208 230 460 V 3 Ph 50 60 Hz A 230 V 1 Ph unit is available With an additional 3 PH contactor it can be used to control a 3 Ph drive unit The APCD 295 control unit has a built in 24 hr time clock max run timer and drop feed control The APCD 300 has a built in max run timer and is used for continuous feeding The APCD 295 S is used in conjunction with the APCD 295 when configuring feed systems with multiple chain disk drive units A single APCD 295 can control up to seven APCD 295 5 control units PNEG 602 Chain Disk 11 Optional Equipment 5 OPTIONAL EQUIPMENT APCD 279 APCD 109 APCD 110 APCD 119 FLXDF 1172 FLX 4256 AP 1002 AP 1260 AP 2259 AP 2263 APCD 114 APCD 294 AP 2385 AP 3800 AP 3800A AP 3202 Model 300 Flex Flo Fill System or comparable equivalent having a maximum of 50 Ibs min 23 kg min rated capacity Chain Disk fill hopper which connects to Flex Flo Control Unit Manual Kwik Attach Drop Kit single Manual Kwik Attach Drop Kit Box of 10 Pneumatic Kwik Attach Drop Kit Assembly Proximity Switch 20 V DC to 240 V AC N C Proximity Switch 20 V DC to 240 V AC N O Proximity Swi
105. y 4 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 Installation Setup Sectiion 5 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 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 without sounding the Chain Disk is Not Running alarm until the next feed cycle Refer to the wiring diagram enclosed with this manual to connect the toggle switch WARNING toggle switch does not cut the power lines to the chain disk motor Shut off the circuit breaker for servicing and maintenance PNEG 602 Chain Disk Chain Disk Controller APCD 295 Test Mode The test mode allows simulating the amperage draw of all drive units in order to verify the controller s performances 1 Use the menu select buttons to select the MANUAL MODE menu 2 Press the down arrow key to select the amperage draw display of the drive unit of the master Chain Disk feeder or of a slave feeder 3 Press the down arrow key to select the amperage draw of the selected drive unit 4 Press MODIFY then use the arrow keys to set the simulated current consumption Press MODIFY to validate The answer is validated after
106. ycles 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 which each feed cycle starts WARNING A The controller restrains the time at which feed cycles can start so that no cycle overlaps another 2 Dump Time If 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 12 4 Parameter Settings Controller Status The STATUS menu shows the ongoing operations of the controller All alarms situations must also be acknowledged from this menu Refer to Manual amp Test Modes Section for further information about alarms The controller automatically returns to this STATUS menu after 4 minutes of inactivity 68 PNEG 602 Chain Disk Chain Disk Controller APCD 295 The STATUS menu tells you e lf the test mode is active e lf the manual mode is active e When the next feeding cycle will start When the drive units will stop Shut Down Delay e When the actuator will stop moving e When the Actuator Delay will end e When the Purge Time will end e When the next dump will be performed e What is the amperage draw of each drive unit 1 Use the menu selec

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