Pneg-914 Installation and Operation of Flex-Flo
Contents
1. FLEX FLO MOTOR PNEG 914 Flex Flo 7 Wiring Diagrams Flex Flo Control with Proximity Switch AP 1002 VI NMONg 001 dv NA die HOLIMS ALIINIXOSd NOD N33H9 ON G3Y O N JONVYO NOILO3103d 304 AdVL 0350 LON YOLOW 013 313 ON el V1 AlddflS YAMOd OVA OES e o E 5 o z 7 x 3 x SOLON AZMOd OY Sjee 0 1010 O 0019 O 1019 0 1601 g e E e E lo XN el 2 Di Z9 MIN et c a elle 5 s 59 PNEG 914 Flex Flo 7 Wiring Diagrams Flex Flo Control with Proximity Switch AP 2983 YOLOW 013 313 ONS z 1 AlddNS YAMOd OWA OEZ TET awn NMOMg m HOLIMS ALINIXOWg ON Q3M O N 39NVHO NOILO31OMd 203 3dY1 0350 LON fes N O O 200206002262 l Oe 2 ejoolojoljojo o o O eleleeoeoooooo Oy2. PNEG 914 Flex Flo 62 8 Warranty GSI Group LLC 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 and GSI s only obligation is to repair or replace at GSI s option and expense products that in GSI s judgment contain a material defect in materials or workmanship Expenses incurred by or on behalf of the end user without prior written authorization from the GSI Warranty Group shall be the sole responsibility of the end user Warranty Extensions The Limited Warranty period is extended for the following products Product Warranty Period Performer Series Direct Drive Fan Motor 3 Years Warranty prorated from list price AP Fans and Flooring All Fiberglass Housings Lifetime 0 to 3 years no cost to end user All Fiberglass Propellers Lifetime 3 to 5 years end user pays 25 5 to 7 years end user pays 50 Feeder System Pan Assemblies 5 Years 7 P i Cumberland 7 to 10 years end user pays 75 Feed Tubes 1 3 4 and 2 00 10 Years
3. moam A ANOS IS9 ZHL O i J 0 A A YAONV Td 404 LINN TONLNOD 104 LNOO X3 13 LHVIAS PNEG 914 Flex Flo 96 7 Wiring Diagrams Wiring Diagram for Extension Flex Flo Using Two 2 FLX 4496 Controls NOISN3 LX3 03 HOLON 013 313 ON 61 V1 AlddflS YAMOd OVA OE 38IM Y3dNNF O E gt C O GGG OJle e ejofololololo o o CO OOOOOOOOOOO C 5 3 9 EEE ol S X A 8H39nV NOISNALXA 203 LINN TOU LNOO J39nv TIH UOJ YOLOW 013 313 ONG c1 AlddflS YAMOd OWA OE i N 0 0 w O 000026000660600 OL e elofololololo o o AAAA 4 Oy Eege sch f TONY 1113 8043 LINN TOHLNOO 57 PNEG 914 Flex Flo 58 7 Wiring Diagrams Flex Flo Control with 220 Volt 24 Hour Time Clock 24 HOUR TIME CLOCK FLX 3413 220V m E e kel E e f 230 VAC POWER SUPPLY
4. RE 25 Ee CEET 28 gell en EE 28 Extension Hopper Installation 2 30 Operation Guidelines 1 eee ret eterna 32 Pans LIST pM 35 Flex Flo Feed Line Components 1 000000 36 Direct Drive Power Unit Assemblies AA 37 Model 220 Unloader and Anchor Assembly AAA 40 Model 300 350 and HR Unloader and Anchor Assembly sss 41 Model 500 Unloader and Anchor Assembly AAA 42 Direct Drive and Tube Anchor 43 Belt Drive and Tube Anchor 2 ertt det tote eee dede dtr anten Cut ru e LE uv 44 Model 220 300 and 350 Control Unit FLX 4496 nennen nens 46 Flex Flo Control Unit FEX 5015 E 48 Belt Drive Power Dn E 50 Direct Drive Power nil 00101010 51 Drop Kit Kwik Attach Drop Kit Aiea aaa a a rnnt nen rrr en nnns 52 I oeil 1 0 0000 S 53 Micro Drop Tube Switch Proximity Switch 54 PNEG 914 Flex Flo Table of Contents Chapter 7 Wiring Diagrams sisson C 1 1 1 1 1 2 212 2 2 2 12 1 1 12 1 1 1 55 FLX 4496 or FLX 5015 Factory Wiring 01361813 sese nennen 55 Wiring Diagram for Extension Flex Flo Using Smart Flex Control sse 56 Wiring Diagram for Extension Flex Flo Using Two 2 FLX 4496 Controls 57
5. Feed out of hopper it Tr IU 1 U Feed out of hopper 4m TI gt Feed out of hopper t t t Feed into hopper Figure 5Z Extension Mounting Directions Control unit Extension hopper Figure 5AA Extension System 6 Install the auger for the system that is connected from the tank s to the extension hopper Install as a standard system The auger for the second part of the system should connect to the power control unit at the other end 7 Clamp the auger ends to their applicable anchors and mount the bearing assemblies in place PNEG 914 Flex Flo 31 32 5 8 The extension unit switch should actuate prior to bottoming out when pressed in and return back to its original position after it is released A Ep Figure 5AB Operation Guidelines 1 2 Open the unloader slide completely for the delivery system operation except on tandem system Do not operate the Flex Flo System empty Utilize a time clock with the system whenever possible because A It lessens short cycling by operating on a set schedule versus on demand B It prohibits the system from running excessively when empty if the tank should go dry When the optional unloader switch is used it should be wired so that if the feed tank goes empty the power unit will stop The time clock should be programm
6. Installation and Operation Gi Model 220 300 350 500 and HR Installation and Owner s Manual BY THE GSI GROUP PNEG 914 Date 02 04 11 PNEG 914 PNEG 914 Flex Flo Chapter 1 Chapter 2 Chapter 3 Chapter 4 Chapter 5 Chapter 6 Table of Contents Contents EE 5 IAE le 5 General Safety Statement sss sss 6 DO CANS Sei oso accents aa a 8 Juste HL e RE 10 ele ene 10 le stell EE 10 Elle Tee EEN 10 Installation 00 1 1 aa 10 Flex Flo Specifications English Metric 11 The Feed Tank Connections lu rn idu ar aaa ea 11 119513113116110 15 Boot and Transfer Plate Installation 15 Slide Gate Installation E 16 Inspection Clean Out Plate Installation 17 Restrictor Adjustment erected aaa ee 18 Straight Through Tandem ns 19 Auger TUDING EE 20 Cementing Procedure ERR TI 22 Outlet ee TEE 22 Drop deg UE en WEE 23 Kwik Attach Drop Kit Installation weasels 24 Power Unit and Control Unit
7. ina Feeding Watering Warranty prorated from list price Systems Centerless Augers 10 Years 0 to 3 years no cost to end user Watering Nipples 10 Years 3 to 5 years end user pays 50 Grain Systems Grain Bin Structural Design 5 Years T Motors burner components Grain Systems Portable and Tower Dryers 2 Years and moving parts not included Farm Fans Portable and Tower Dryer Frames and 7 Portable dryer screens included Zimmerman Internal Infrastructure t 9 Years Tower dryer screens not included GSI further warrants that the portable and tower dryer frame and basket excluding all auger and auger drive components shall be free from defects in materials for a period of time beginning on the twelfth 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 OR USE IN CONNECTION WITH I PRODUCT MANU
8. 2 Insert the driver shaft through the bearing assembly The bearing mounting plate should be mounted in between Tighten the set screw on the bearing down to the shaft 3 Bolt the two 2 mounting brackets together with the four 4 bolts and washers provided 4 Attach the motor support assembly to the control unit with the four 4 bolts already in the mounting bracket and belt guard Secure with the four 4 lock washers and hex nuts provided If necessary motor orientation can be reversed by rotating the motor mount 180 5 Slide and clamp a tube coupler on the anchor Figure 5T Belt Drive Power Unit o Mount the motor onto the motor mount base with four 4 bolts and washers N Mount the belt pulleys The two 2 pulleys must be positioned in line with each other to prevent from binding the belt 00 Install the belt 9 Adjust the belt tension by extending and retracing the two 2 mounting brackets Resecure the bolts after adjustment 10 Install belt guard cover 11 Attach the power control unit to the Flex Flo tubing 12 Suspend the power control unit firmly from the ceiling using the chains provided 13 The control unit and the power unit must be wired as shown in the Wiring Diagrams on Pages 55 62 14 Install the auger PNEG 914 Flex Flo 27 5 Auger The auger should be handled with great care Do not install the auger until the kinks have been removed The kink may be re
9. 60 Hz 115 230V CU 7100693 7100693R DDPU 735 RPM 3 4 HP 3 PH 60 Hz 208 230 460V CU 7099968 7099968R DDPU 84 RPM 1 3 HP 3 PH 50 Hz 190 380V 7099342 7099342R DDPU 358 RPM 3 4 HP 3 PH 60 Hz 208 230 460V CU 7099341 7099341R DDPU 358 RPM 1 2 HP 3 PH 60 Hz 208 230 460V CU 7099340 7099340R DDPU 358 RPM 1 3 HP 3 PH 60 Hz 230 460V CU 7099298 7099298R DDPU 368 RPM 3 4 HP 3 PH 50 Hz 190 380V CU 7099263 7099263R DDPU 368 RPM 1 2 HP 3 PH 50 Hz 190 380V CU 7099247 7099247R DDPU 735 RPM 3 4 HP 3 PH 50 Hz 230 380 440V CU 7098894 7098894R DDPU 716 RPM 3 4 HP 1 PH 60 Hz 115 230V CU 7098423 7098423R DDPU 441 RPM 1 3 HP 1 PH 50 Hz 115 230V CU 7098422 7098422R DDPU 368 RPM 1 3 HP 3 PH 50 Hz 190 380V CU FLX 3582 50 FLX 3582 50R DDPU 129 RPM 1 2 HP 1 PH 50 Hz 115 230V FLX 3582 60 FLX 3582 60R DDPU 156 RPM 1 2 HP 1 PH 60 Hz 115 230V FLX 3593 FLX 3593R DDPU 156 RPM 1 2 HP 3 PH 60 Hz 230 460V FLX 3928 50 FLX 3928 50R DDPU 129 RPM 3 4 HP 1 PH 50 Hz 110 220V FLX 3928 60 FLX 3928 60R DDPU 156 RPM 3 4 HP 1 PH 60 Hz 115 230V FLX 3634 50 FLX 3634 50R DDPU 129 RPM 1 HP 1 PH 50 Hz 110 220V FLX 3634 60 FLX 3634 60R DDPU 156 RPM 1 HP 1 PH 60 Hz 115 230V FLX 3635 FLX 3635R DDPU 156 RPM 1 1 2 HP 1 PH 60 Hz 115 230V FLX 2672 60 FLX 2672 60R DDPU 250 RPM 1 3 HP 1 PH 60 Hz 115 230V FLX 2673 60 FLX 2673 60R DDPU 250 RPM 1 2 HP 1 PH 60 Hz 115 230V FLX 2674 50 FLX 2674 5
10. PNEG 914 Flex Flo 60 7 Wiring Diagrams Flex Flo Control with Drop Tube Switch or Hopper Level Switch ul l l I I I I I O I I I I I I I ezsp X14 Av 13a INIL AV 143G AWIL 198101140 HILIM YOLOW 0122313 ONG c1 LI AlddNS YAMOd DVA DE On YOLOW 0 213 vi AlddNS 43M Od DVA DE He Be 9 Ola 61 PNEG 914 Flex Flo 7 Wiring Diagrams Flex Flo Control with Smart IR Sensor FLX 4951 SMART IR SENSOR FLX 4951 Smart IR Sensor O Alarm O Auger GREEN O Product Gran Detected Push and Hold to Set H A MAX ER RUN DELAY v TIME TIME Holts Seconds Hua secans i eram 1o ByPass Day Hours Minutes SMART IR SENSOR O WITH LID REMOVED RELAY FLEX FLO OUTPUT MOTOR ALARM CONTACTS 230 VAC COM Po AN POWER 22 SUPPLY N O
11. x 3 4 bolts See Figure 5Q for more details 2 Slide the driver assembly onto the power unit drive shaft Place the 5 16 hex socket bolt supplied with the driver assembly into the untapped hole of the driver through the drive shaft and tighten the bolt into threaded portion of the driver 3 Mount the control unit to the gearbox unit with four 4 5 16 x 3 4 bolts and four 4 flat washers which are supplied with the power unit See Figure 5H Figure 50 Assembly of Tube Anchor to the Control Unit 4 The control unit and power unit require hard wiring The supply line wires into L1 and L2 N of the relay in the control unit The motor leads wire into the M1 and M2 of the relay in the control unit Auxiliary switch is wired into the male and female spade terminal of the control unit See Wiring Diagrams on Pages 55 62 5 Slide and clamp a tube coupler on the tube anchor 6 Attach the power control unit to the Flex Flo tubing 7 Suspend power control unit firmly from the ceiling as shown in Figure 5S Support holes are provided on the power unit and the control unit Figure 5R Assembly of the Control Unit Figure 5S Direct Drive Power Unit to the Dive Unit 26 PNEG 914 Flex Flo 5 Installation Belt Drive Power Control Unit 1 Bolt the tube anchor to the control unit body with a flat washer on each of the four 4 5 16 x 3 4 bolts See Figure 5Q on Page 26 for more details
12. 0 27 5 19 0 15 0 15 0 26 0 17 0 12 5 29 0 20 0 ys 16 0 27 5 18 0 12 5 31 0 21 0 16 0 17 0 29 5 19 0 13 5 32 5 22 0 16 5 18 0 31 0 20 0 14 0 34 5 23 0 17 0 19 0 33 0 21 0 15 0 36 0 24 0 17 5 20 0 34 5 22 0 15 5 38 0 25 0 18 5 12 PNEG 914 Flex Flo 4 Flex Flo Specifications English Metric pe Figure 4D Equipment Orientation Charts Tank Centerline to Building Entrance Distance X from Given Height H Metric Model 220 with 10 Radius Elbows X for 30 Boot m X for Straight Boot m H m 30 45 60 30 45 60 1 52 3 20 4 57 2 1 83 3 81 3 35 5 18 2 13 4 27 3 66 5 64 5 18 2 2 44 4 88 3 96 6 10 5 49 x 2 74 5 33 4 27 6 71 9 79 3 05 5 94 4 57 7 16 6 10 x 3 35 6 40 4 88 4 42 7 77 6 40 5 94 3 66 7 01 5 18 4 57 8 23 6 71 6 10 3 96 7 47 5 49 4 88 8 84 7 01 6 40 4 27 8 08 5 79 5 03 9 30 7 32 6 55 4 57 8 53 6 10 5 18 9 91 7 62 6 71 4 88 9 14 6 40 5 33 10 36 7 92 6 86 5 18 9 60 6 71 5 49 10 97 8 23 7 01 5 49 10 21 7 01 5 64 11 43 8 53 7 16 5 79 10 67 7 32 5 94 12 04 8 84 7 32 6 10 11 28 7 62 6 10 12 50 9 14 7 62 Model 500 with 6 Radius Elbow X for 30 Boot m X for Straight Boot m H m 30 45 60 30 45 60 152 2 74 3 66 3 05 1 83 3 20 2 44 2 29 4 11 3 35 3 05 2 13 3 66 2 74 2 44 4 72
13. 14 5 2019 21 0 19 5 12 0 23 0 17 0 15 0 27 0 22 0 20 0 13 0 24 5 18 0 16 0 29 0 23 0 21 0 14 0 26 5 19 0 16 5 30 5 24 0 21 5 15 0 28 0 20 0 17 0 32 5 25 0 22 0 16 0 30 0 21 0 17 5 34 0 26 0 22 5 17 0 31 5 22 0 18 0 36 0 27 0 23 0 18 0 33 5 23 0 18 5 37 5 28 0 23 5 19 0 35 0 24 0 19 5 39 5 29 0 24 0 20 0 37 0 25 0 20 0 41 0 30 0 25 0 Model 500 with 6 Radius Elbow X for 30 Boot ft X for Straight Boot ft H ft 30 45 60 30 45 60 5 0 9 0 E 12 0 10 0 6 0 10 5 8 0 7 5 13 5 11 0 10 0 7 0 12 0 9 0 8 0 S0 12 0 11 0 8 0 14 0 10 0 8 5 17 0 13 0 11 5 9 0 15 5 11 0 9 0 19 0 14 0 12 0 10 0 17 0 12 0 9 5 20 0 15 0 12 5 11 0 19 0 13 0 10 0 22 5 16 0 13 0 12 0 20 5 14 0 11 0 23 5 17 0 13 5 13 0 22 5 15 0 1S 26 0 18 0 14 0 14 0 24 0 16 0 12 0 27 0 19 0 15 0 15 0 26 0 17 0 12 5 29 5 20 0 19 9 16 0 27 5 18 0 12 5 30 5 21 0 16 0 17 0 29 5 19 0 13 5 33 0 22 0 16 5 18 0 31 0 20 0 14 0 34 5 23 0 17 0 19 0 33 0 21 0 15 0 36 0 24 0 17 5 20 0 34 5 22 0 15 5 37 5 25 0 18 5 Model 220 300 350 and HR with 5 Radius Elbow X for 30 Boot ft X for Straight Boot ft H ft 30 45 60 30 45 60 5 0 9 0 12 0 10 0 6 0 10 5 8 0 7 5 13 5 11 0 10 0 7 0 12 0 9 0 8 0 5 5 12 0 11 0 8 0 14 0 10 0 8 5 17 0 13 0 11 5 9 0 15 5 11 0 9 0 18 5 14 0 12 0 10 0 17 0 12 0 9 5 20 5 15 0 12 5 11 0 19 0 13 0 10 0 22 0 16 0 13 0 12 0 20 5 14 0 11 0 24 0 17 0 18 5 13 0 22 5 15 0 E 25 5 18 0 14 0 14 0 24 0 16 0 12
14. 5 Drop Kit Installation 1 Wrap the rotary slide over the outlet hole and around the auger tube Position the slides with cut out facing in the same direction for all drops so that the slides will operate the same when the ropes are pulled 2 Thread the rope through the ends of the rotary slide as shown in Figure 5M and tie the slide ends together so that the ends of the rope are the same length Slide knot down tight against hole in rotary slide Figure 5M Drop Kit Installation 3 Slide rope through molded guide holes in drop halves 4 Position the drop halves around the rotary slide and attach both halves together with the hardware provided as shown in Figure 5N Drop installed on PVC tube Figure 5N 5 Test the rotary slide Pull on one rope at a time Check the rotary slide to be sure it is centered over the outlet hole 6 Slide the rotary slide to its open position by pulling the appropriate rope Mark the short rope end at the point where it enters the guide hole Tie a knot on the rope at the mark The location of the knot will show at a glance if the slide is open or closed PNEG 914 Flex Flo 23 5 Drop Kit Installation Continued 7 Thread the short rope end through the red ball and tie a knot in the rope to hold the ball in place Install the green ball the same way on the other rope end 8 Apply a small amount of PVC cement around the drop to prevent it from moving around on t
15. Control Box 1 4 FLX 5017 Bracket Terminal Block Mounting 1 5 FLX 5040 Terminal Block Assembly for Flex Flo Control Unit 1 6 FLX 4517 Electrical Box Lid w Decal 1 7 S 995 Screw MS 10 24 x 1 SS 4 8 S 7931 Hex Nut 10 24 SS 4 9 5 2 Switch DPST ON OFF Toggle 1 10 70 0129 Boot Switch Weather Proof 1 11 S 6622 ON OFF Back Plate 1 12 FLX 4620 Relay Bracket f FLX 4619 1 13 FLX 4619 Relay 4 Pole ST N O 240V 1 14 DC 1515 Decal 208V 230V 3 PH Wire Label 1 15 S 7604 Light 250V Sealed Red Pilot 1 16 S 7707 Safety Limit Switch 1 17 5 3 Screw TCS23 8 32 x 3 8 HWHS ZN Green 1 18 S 8183 Screw MS 6 32 x 3 8 PHP ZN 6 19 S 8686 Screw TCSF 6 32 x 3 8 PHP ZN 2 20 FLX 4522 Control Unit Base Assembly 1 21 S 3674 Flat Washer 10 x 7 32 I D x 1 2 O D x 18 Gauge SAE ZN Grade 2 4 22 5 0 Nylock Nut 10 24 ZN Grade 2 4 23 DC 2124 Decal ETL Intertek Mark 1 PNEG 914 Flex Flo 49 6 Parts List Belt Drive Power Unit Ref Part Description FLX 4179 14 Belt Drive Power Unit Less Motor 1 FLX 2986 Belt Guard Cover 2 S 4307 5 8 I D Locking Collar 3 S 7149 Bolt HHTB 5 16 18 x 1 3 4 ZN Grade 5 4 S 6242 2 7 A Belt Single Groove Pulley 5 8 Bore 5 BLK 11086 AX51 Gripnotch Belt 6 5 0 14 A Belt Single Groove Pulley 7 FLX 2987 Belt Guard Back 8 S 280 Screw SDS 10 16 x 5 8 HWH ZN 9 FLX 2734S Flex Flo Anchor Bearing Assembly with Se
16. Flex Flo Control with 220 Volt 24 Hour Time Clock 0 0000 nn 58 Flex Flo Control with Proximity Switch AP 1002 sse nnne nenne 59 Flex Flo Control with Proximity Switch AP 2983 nnne 60 Flex Flo Control with Drop Tube Switch or Hopper Level Switch 61 Flex Flo Control with Smart IR Sensor FLX 4951 seen nennen 62 Chapter rici 2 0 63 PNEG 914 Flex Flo 1 Safety Safety Guidelines This manual contains information that is important for you the owner operator to know and understand This information relates to protecting personal safety and preventing equipment problems lt is the responsibility of the owner operator to inform anyone operating or working in the area of this equipment of these safety guidelines To help you recognize this information we use the symbols that are defined below Please read the manual and pay attention to these sections Failure to read this manual and its safety instructions is a misuse of the equipment and may lead to serious injury or death 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 A DANGER DANGER indicates a hazardous situation which if not avoided will result in death o
17. HP 1 PH 60 Hz 115 230V FLX 2462 FLX 2462R DDPU 358 RPM 1 1 2 HP 1 PH 60 Hz 115 230V FLX 2461 60 FLX 2461 60R DDPU 358 RPM 1 HP 1 PH 60 Hz 115 230V FLX 2460 60 FLX 2460 60R DDPU 358 RPM 3 4 HP 1 PH 60 Hz 115 230V FLX 2460 50 FLX 2460 50R DDPU 296 RPM 3 4 HP 1 PH 50 Hz 110 220V FLX 2459 60 FLX 2459 60R DDPU 358 RPM 1 2 HP 1 PH 60 Hz 115 230V FLX 2459 50 FLX 2459 50R DDPU 296 RPM 1 2 HP 1 PH 50 Hz 115 230V FLX 2458 60 FLX 2458 60R DDPU 358 RPM 1 3 HP 1 PH 60 Hz 110 220V C2000203 C2000203R DDPU 84 RPM 1 2 HP 1 PH 50 Hz 115 230V 07101557 60 07101557 60R DDPU 250 RPM 1 2 HP 1 PH 60 Hz 115 230V CU 07101481 60 07101481 60R DDPU 250 RPM 1 3 HP 1 PH 60 Hz 115 230V CU PNEG 914 Flex Flo 6 Parts List Direct Drive Power Unit Assemblies Parts List Continued Direct Drive Power Unit Gearbox Orientation Part Description Type A Type B 07100643 60 07100643 60R DDPU 64 RPM 1 2 HP 1 PH 60 Hz 115 230V 07099366 60 07099366 60R DDPU 358 RPM 1 2 HP 1 PH 60 Hz 115 230V CU 07098924 50 07098924 50R DDPU 368 RPM 1 2 HP 1 PH 50 Hz 115 230V CU 07097965 60 07097965 60R DDPU 358 RPM 3 4 HP 1 PH 60 Hz 115 230V CU 07097744 60 07097744 60R DDPU 358 RPM 1 2 HP 1 PH 60 Hz 115 230V CU 07097374 60 07097374 60R DDPU 358 RPM 1 3 HP 1 PH
18. PH 60 Hz 600V FLX 4043 FLX 4043R DDPU 358 RPM 1 HP 3 PH 60 Hz 208 230 460V E P FLX 4041 1PH FLX 4041 1PHR DDPU 358 RPM 1 2 HP 1 PH 60 Hz 208 230 240V ER FLX 3911 FLX 3911R DDPU 358 RPM 1 HP 3 PH 60 Hz 600V FLX 3671 FLX 3671R DDPU 368 RPM 1 1 2 HP 3 PH 50 Hz 190 380 440V FLX 3670 FLX 3670R DDPU 368 RPM 1 HP 3 PH 50 Hz 190 380V FLX 3661 FLX 3661R DDPU 368 RPM 1 1 2 HP 1 PH 50 Hz 110 220V FLX 3652 FLX 3652R DDPU 539 RPM 1 HP 3 PH 60 Hz 208 230 460V FLX 3644 FLX 3644R DDPU 156 RPM 1 HP 3 PH 60 Hz 208 230 460V FLX 3641 FLX 3641R DDPU 441 RPM 1 1 2 HP 1 PH 60 Hz 115 230V FLX 3640 60 FLX 3640 60R DDPU 441 RPM 1 HP 1 PH 60 Hz 115 230V FLX 3640 50 FLX 3640 50R DDPU 368 RPM 1 HP 1 PH 50 Hz 110 220V FLX 3632 FLX 3632R DDPU 368 RPM 1 2 HP 3 PH 50 Hz 190 380V FLX 3555 FLX 3555R DDPU 358 RPM 1 1 2 HP 3 PH 60 Hz 208 230 460V FLX 3552 FLX 3552R DDPU 358 RPM 1 HP 3 PH 60 Hz 208 230 460V FLX 3549BA FLX 3549BAR DDPU 358 RPM 1 2 HP 3 PH 60 Hz 208 230 460V FLX 3549 FLX 3549R DDPU 358 RPM 1 2 HP 3 PH 60 Hz 208 230 460V FLX 3546 FLX 3546R DDPU 358 RPM 1 3 HP 3 PH 60 Hz 230 460V FLX 3543BA FLX 3543BAR DDPU 358 RPM 3 4 HP 3 PH 60 Hz 208 230 460V FLX 3543 FLX 3543R DDPU 358 RPM 3 4 HP 3 PH 60 Hz 208 230 460V FLX 3535 FLX 3535R DDPU 296 RPM 1 1 2 HP 3 PH 50 Hz 190 380 440V FLX 3534 FLX 3534R DDPU 296 RPM 1 HP 3 PH 50 Hz 190 380V FLX 2933 60 FLX 2933 60R DDPU 64 RPM 1 3
19. of products manufactured or sold by GSI 9101239 1 CR rev7 DOC revised July 2009 PNEG 914 Flex Flo 63 This eguipment 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 em 1004 E Illinois St Assumption IL 62510 0020 Phone 1 217 226 4421 Fax 1 217 226 4420 www gsiag com Copyright 2011 by D Group Printed in the USA
20. safety This should be installed as indicated in the enclosed installation instructions and in accordance with the relevant codes and directives User s Manual This manual contains information and instructions essential to the safe installation and use of the Flex Flo System Read this manual thoroughly before attempting any installation or use of the Flex Flo System Keep this manual with the Flex Flo System or in a location where it can be readily accessed Failure to read this manual and its safety instructions is a misuse of the equipment Correct Uses of the Flex Flo System The Flex Flo System is designed for the sole purpose of conveying granular or powdered agricultural animal feed Use of the system in any other way is a misuse of the system and may endanger the health and safety Only genuine AP Cumberland parts are to be used in the installation and use of the Flex Flo System Use of other non genuine parts is a misuse of the system and may lead to dangerous situations imperilling the safety and health of you and others This system is not designed for use in atmospheres where there is a risk of explosion Use in such an environment is prohibited If in doubt contact your dealer or the GSI group Safety Guards The Flex Flo System contains many moving and electrical parts which will cause serious injury or death if touched Guards are placed on the machine to protect you Operating the machine at any time with guards removed or inco
21. trouble free operation possible Avoid unnecessary elbows and curves to ease system installation A feed tank with a 30 unloader is generally required to be at least 10 1 2 3 2 m away from the building With a straight unloader the tank will be approximately 4 1 22 m farther away from the building in order to make auger tube connections The reference points are based upon the height where the system enters the building Different unloaders with various elbows and curves used provide different entrance opportunities The distances are achieved by modifying and adjusting the elbows and tubing as needed See tables on Page 12 English or see tables on Page 13 Metric for tank placement recommendations ny 30 Unloader Figure 4B Figure 4C PNEG 914 Flex Flo 11 4 Flex Flo Specifications English Metric Tank Centerline to Building Entrance Distance X from Given Height H English Model 220 with 10 Radius Elbows X for 30 Boot ft X for Straight Boot ft H ft 30 45 60 30 45 60 5 0 10 5 15 0 6 0 12 5 11 0 S 17 0 s 7 7 0 14 0 12 0 E 18 5 17 0 E 8 0 16 0 13 0 20 0 18 0 9 0 17 5 14 0 E 22 0 19 0 10 0 19 5 15 0 23 5 20 0 11 0 21 0 16 0
22. 0R DDPU 209 RPM 3 4 HP 1 PH 50 Hz 110 220V FLX 2674 60 FLX 2674 60R DDPU 250 RPM 3 4 HP 1 PH 60 Hz 115 230V FLX 3589 50 FLX 3589 50R DDPU 368 RPM 1 3 HP 1 PH 50 Hz 115 230V FLX 3589 60 FLX 3589 60R DDPU 441 RPM 1 3 HP 1 PH 60 Hz 115 230V FLX 3590 50 FLX 3590 50R DDPU 368 RPM 1 2 HP 1 PH 50 Hz 115 230V FLX 3590 60 FLX 3590 60R DDPU 441 RPM 1 2 HP 1 PH 60 Hz 115 230V FLX 3591 50 FLX 3591 50R DDPU 368 RPM 3 4 HP 1 PH 50 Hz 110 220V FLX 3591 60 FLX 3591 60R DDPU 441 RPM 3 4 HP 1 PH 60 Hz 115 230V FLX 3603 FLX 3603R DDPU 441 364 RPM 3 4 HP 3 PH 50 60 Hz 190 380V FLX 3631 FLX 3631R DDPU 368 RPM 1 3 HP 3 PH 50 Hz 190 380V FLX 3633 FLX 3633R DDPU 368 RPM 3 4 HP 3 PH 50 Hz 190 380V FLX 3653 FLX 3653R DDPU 539 RPM 1 1 2 HP 3 PH 60 Hz 208 230 460V PNEG 914 Flex Flo 39 40 6 Parts List Model 220 Unloader and Anchor Assembly Ref Part Description Gty 1 FLX 4331 Model 220 Flex Flo Single through Unloader Body Assembly 1 2 BLK 11137A Transfer and Slide Gate Kit 1 3 FLX 2217 Model 220 300 350 Flex Seal Ring 1 4 FLX 3422 Neoprene Seal 1 5 FLX 4239 Clean Out Plate Assembly 1 6 S 4490 2 1 4 Tube Clamp Model 220 2 7 FLX 4646 Model 220 EP Anchor and Bearing Assembly 1 8 00404238 Iron Ball 3 Hollow 1 1 2 1 9 FLX 3938 Model 220 Flex Flo Twin Unloader Body Assembly 1 10 FLX 2195 16 Straight Black Plastic Boot 1 10 F
23. 1 2 HP 12 12 12 12 le 12 12 12 12 10 10 8 8 8 8 3 4 HP 12 12 12 12 12 12 12 10 10 8 8 8 6 6 6 1 HP 12 12 12 12 12 10 10 8 8 8 6 6 6 6 6 1 1 2HP 12 12 12 10 10 8 8 8 6 6 6 6 4 4 4 NEC Sec 225 6 Conductors in overhead spans must be at least 10 for spans up to 50 and 8 for longer PNEG 914 Flex Flo 33 NOTES PNEG 914 Flex Flo 10 11 12 13 14 Flex Flo Feed Line Components Direct Drive Power Unit Assemblies Model 220 Unloader and Anchor Assembly Model 300 350 and HR Unloader and Anchor Assembly Model 500 Unloader and Anchor Assembly Direct Drive and Tube Anchor Belt Drive and Tube Anchor Model 220 300 and 350 Control Unit FLX 4496 Flex Flo Control Unit FLX 5015 Belt Drive Power Unit Direct Drive Power Unit Drop Kit Kwik Attach Drop Kit Unloader Switch Micro Drop Tube Switch Proximity Switch PNEG 914 Flex Flo 6 Parts List 35 36 6 Parts List Flex Flo Feed Line Components 11 6 7 8 9 5 Ref 8 Model 220 Model 300 Model 350 Model 500 Model HR Description 1 BLK 10847 BLK 10847 BLK 10847 BLK 10847 BLK 10847 16 45 Hopper Extension Kit w Collar 1 BLK 10587 BLK 10587 BLK 10587 BLK 10587 BLK 10
24. 3 66 3 35 2 44 4 27 3 05 2 59 5 18 3 96 3 51 2 74 4 72 3 35 2 74 5 79 4 27 3 66 3 05 5 18 3 66 2 90 6 10 4 57 3 81 35355 5 79 3 96 3 05 6 86 4 88 3 96 3 66 6 25 4 27 3 35 7 16 5 18 4 11 3 96 6 86 4 57 3 51 7 92 5 49 4 27 4 27 7 32 4 88 3 66 8 23 5 79 4 57 4 57 7 92 5 18 3 81 8 99 6 10 4 72 4 88 8 38 5 49 3 81 9 30 6 40 4 88 516 8 99 5 79 4 11 10 06 6 71 5 03 5 49 9 45 6 10 4 27 10 52 7 01 5 18 5 79 10 06 6 40 4 57 10 97 7 32 5 33 6 10 10 52 6 71 4 72 11 43 7 62 5 64 PNEG 914 Flex Flo 13 14 4 Flex Flo Specifications English Metric Model 220 300 350 and HR with 5 Radius Elbow X for 30 Boot m X for Straight Boot m H m 30 45 60 30 45 60 1 52 2 74 3 66 3 05 1 83 3 20 2 44 2 29 4 11 3 35 3 05 2 13 3 66 2 74 2 44 4 72 3 66 3 35 2 44 4 27 3 05 2 59 5 18 3 96 3 51 2 74 4 72 3 35 2 74 5 64 4 27 3 66 3 05 5 18 3 66 2 90 6 25 4 57 3 81 3 35 5 79 3 96 3 05 6 71 4 88 3 96 3 66 6 25 4 27 3 35 7 32 5 18 4 11 3 96 6 86 4 57 3 51 7 77 5 49 4 27 4 27 7 32 4 88 3 66 8 38 5 79 4 57 4 57 7 92 5 18 3 81 8 84 6 10 4 72 4 88 8 38 5 49 3 81 9 45 6 40 4 88 5 18 8 99 5 79 4 11 9 91 6 71 5 03 5 49 9 45 6 10 4 27 10 52 7 01 5 18 5 79 10 06 6 40 4 57 10 97 7 32 5 33 6 10 10 52 6 71 4 72 11 58 7 62 5 64 x Figure 4E Equipment Orientation Charts PNEG 914 Flex Flo 5 Installation
25. 34 1 034 1 034 1 E EE Muda N S 100 1 100 1 100 1 100 1 es a 110 220V 1 PH 60 Hz 1750 15 FLX 4496 FLX 4496 FLX 4496 FLX 4497 FLX 4496 Direct Drive Control Unit 220V N S FLX 4179 FLX 4179 FLX 4179 FLX 4179 Belt Drive Control Unit No Motor 16 FLX 2427 FLX 2427 FLX 2427 FLX 2429 FLX 2427 12 Drop Tube 17 FLX 2428 FLX 2428 FLX 2428 FLX 2430 FLX 2428 6 Telescoping Drop Tube PNEG 914 Flex Flo Direct Drive Power Unit Assemblies 6 Parts List Gearbox orientation type A Gearbox orientation type B PNEG 914 Flex Flo 37 38 6 Parts List Direct Drive Power Unit Assemblies Parts List Direct Drive Power Unit Gearbox Orientation Part d GER GE Description FLX 4873 FLX 4873R DDPU 250 RPM 1 2 HP 3 PH 60 Hz 208 230 460V FLX 4867 FLX 4867R DDPU 441 RPM 1 HP 3 PH 60 Hz 208 230 460V FLX 4754 FLX 4754R DDPU 298 RPM 1 HP 3 PH 50 Hz 190 380V FLX 4645 FLX 4645R DDPU 250 RPM 1 HP 3 PH 50 Hz 190 380V FLX 4632 FLX 4632R DDPU 250 RPM 1 HP 3 PH 60 Hz 208 230 460V FLX 4355 FLX 4355R DDPU 358 RPM 1 1 2 HP 3
26. 587 22 16 60 Hopper Extension Kit w Hopper Collar BLK 10591 BLK 10591 BLK 10591 BLK 10591 BLK 10591 22 16 67 Hopper Extension Kit w Hopper Collar FLX 2194 FLX 2194 FLX 2194 FLX 2194 FLX 2194 16 30 Black Plastic Boot FLX 2194C FLX 2194C FLX 2194C FLX 2194C FLX 2194C 16 30 Clear Plastic Boot N S FLX 2195 FLX 2195 FLX 2195 FLX 2195 FLX 2195 16 Straight Black Plastic Boot N S FLX 2195C FLX 2195C FLX 2195C FLX 2195C FLX 2195C 16 Straight Clear Plastic Boot 4 FLX 4408 FLX 2243 FLX 2178 FLX 2943 FLX 4773 Single Out Unloader No Anchor N S FLX 3937 FLX 2586 FLX 2181 FLX 4743 FLX 4772 Twin Out Unloader No Anchor 5 PVC 1004 PVC 1005 PVC 1006 PVC 1007 PVC 1006 10 PVC Straight Tube 6 PVC 1101 PVC 1001 PVC 1002 PVC 1003 PVC 1002 45 Elbow 5 Radius PVC 1003 is 6 Radius 6 PVC 1000 45 Elbow 10 Radius 7 S 4694 S 4694 S 4694 S 4694 S 4694 2 Weldless Chain 7 S 7313 S 7313 S 7313 S 7313 S 7313 Eye Screw 1 4 20 x 3 1 2 ZN Open Eye Screw 8 FLX 2432 FLX 2433 FLX 2434 FLX 2435 FLX 2434 Drop Kit 9 FLX 2425 FLX 2425 FLX 2427 FLX 2429 FLX 2427 12 Drop Tube 10 FLX 2426 FLX 2426 FLX 2428 FLX 2430 FLX 2428 6 Telescoping Drop Tube 11 FLXA 1520 FLXA 2390 FLXA 2710 FLXA 3800 FLXA 2390 Flex Flo Auger 12 FLX 4682bE FLX 4684E FLX 4686E FLX 2542 FLX 4687E Extension Unit 13 FLX 2537 FLX 2538 FLX 2539 FLX 2540 FLX 2539 PVC Tube Coupler 14 See Direct Drive Power Unit Assembly Part Numbers on Pages 37 39 N S 012 1 012 1 012 1 012 1 Dee Wee N S 034 1 0
27. 7931 Hex Nut 10 24 SS 4 18 FLX 4620 Relay Bracket f FLX 4619 1 19 FLX 4619 Relay 4 Pole ST N O 240V 1 20 DC 1515 Decal 208V 230V 3 PH Wire Label 1 21 5 4 Light 250V Sealed Red Pilot 1 22 S 7707 Safety Limit Switch 1 23 S 6142 Switch DPST ON OFF Toggle 1 24 70 0129 Boot Switch Weather Proof 1 25 S 8823 Screw TCS23 8 32 x 3 8 HWHS ZN Green 1 26 5 3 Screw MS 6 32 x 3 8 PHP ZN 6 27 S 8686 Screw TCSF 6 32 x 3 8 PHP ZN 2 28 FLX 4522 Control Unit Base Assembly 1 29 FLX 2380 Small Diaphram Retainer 1 30 FLX 4410 Diaphram Assembly 1 31 FLX 4510 Control Unit Base Sealed 1 32 5 9 Hex Nut 10 24 ZN Grade 2 4 33 S 3674 Flat Washer 10 x 7 32 I D x 1 2 O D x 18 Gauge SAE ZN Grade 2 4 34 S 2010 Nylock Nut 10 24 ZN Grade 2 4 35 DC 2124 Decal ETL Intertek Mark 1 36 5 2 ON OFF Back Plate 1 37 5 0 Screw SDS 210 16 x 5 8 HWH ZN 5 38 5 1 Screw TCSF 10 32 HWH ZN 3 4 4 39 FLX 4261 Control Box Access Door 1 40 DC 850 Decal European Certification 1 PNEG 914 Flex Flo 47 6 Parts List Flex Flo Control Unit FLX 5015 D S g o BI 9 7 o 7 V A gI 0 VAS 0 7 3 LS g A o PNEG 914 Flex Flo 48 Flex Flo Control Unit FLX 5015 Parts List 6 Parts List Ref Part Description Gty 1 FLX 4516 Electrical Box Bottom Drilled 1 2 FLX 4561 4 x 6 Electrical Box Gasket 1 3 FLX 4569 Back Plate 4 x 6
28. Boot Switch 1 14 S 7319 Screw MS 6 32 x 7 8 R H Side ZN Grade 2 1 15 5 4 Hex Nut 6 32 Grade 2 1 16 E160 1074 Ring Terminal 10 Insulated 1 17 WR 16GRN YLW Wire 16 Gauge Green Yellow Stranded 1 1 18 FLX 2690 Electrical Box Gasket 4 x 4 1 19 FLX 2689 Electrical Box Lid 1 20 DC 1088 Decal Flex Flo Control Unit 1 21 S 995 Screw MS 10 24 x 1 PHP SS 1 22 S 7931 Hex Nut 10 24 SS 1 23 BX 302 Box 13 3 4 x 5 1 2 x 5 1 2 200C FPF Not Shown 1 PNEG 914 Flex Flo 93 54 6 Parts List Micro Drop Tube Switch Proximity Switch uo E Micro drop tube switch Proximity switch Micro Drop Tube Switch Parts List Ref Part Description Qty AP 0990 Plastic Drop Tube Switch 110 220V 1 FLX 3489 Micro Switch Box Assembly Wired N C 1 2 S 7621 Screw SDS 10 16 x 1 HWH ZN Grade 2 6 3 FLX 3448 Drop Tube Switch Baffle Plate 1 4 FLX 3451 Drilled Drop Tube Housing 1 Proximity Switch Parts List Ref Part Description Qty 1 FLX 2425 Drop Tube 3 I D x 12 3 65 Meters 1 2 FLXDF 1172 Capacitive Proximity Switch N C 20 250 VAC 1 3 S 7906 1 2 Cord Connector 1 PNEG 914 Flex Flo 7 Wiring Diagrams FLX 4496 or FLX 5015 Factory Wiring Diagram HOLOIN 0 113 313 HIM YZANN QNO c1 Vi O x owed o o en bw o s ownowo Houms xnv olon samoa 0000000002 Ole e elo o o o o o
29. Description 1 BLK 10488 16 67 16 Hopper Collar 24 Holes BLK 10489 16 60 Hopper Collar 24 Holes BLK 11463 16 60 Hopper Collar 27 Holes BLK 12342 16 60 Hopper Collar 18 Holes FLX 2194 16 30 Black Plastic Boot FLX 2194C 16 30 Clear Plastic Boot FLX 2195 16 Straight Black Plastic Boot FLX 2195C 16 Straight Clear Plastic Boot FLX 4869 16 Double Straight Black Boot BLK 10496 Transfer Plate FLX 4819 FLX 4782 Unloader Brace Slide Gate BLK 10497 5 6 Slide Gate Shield 5 16 x 1 Truss Head Machine Screw S 4337 5 16 18 Nylon Insert Nut ojoon a PI ONINI MH MH S 4338 5 16 Nylon Washer S 8328 Screw MS 5 16 18 x 1 RHS ZN Grade 2 sch o S 396 Hex Nut 5 16 18 YDP Grade 2 16 PNEG 914 Flex Flo 5 Installation Inspection Clean Out Plate Installation Once the installation of the auger tubes and auger is complete insert the inspection clean out plate or the optional unloader switch The inspection clean out plate is to be installed per the following instructions See Figure 5F 1 Back off both wing nuts to the stud ends 2 Slide the plate onto the lower side of the unloader opening 3 Move the plate first against the side of the unloader then upward toward the top of the unloader 4 Tighten the wing nuts while hol
30. FACTURED OR SOLD BY GSI OR Il ANY ADVICE INSTRUCTION RECOMMENDATION OR SUGGESTION PROVIDED BY AN AGENT REPRESENTATIVE OR EMPLOYEE OF GSI REGARDING OR RELATED TO THE CONFIGURATION INSTALLATION LAYOUT SUITABILITY FOR A PARTICULAR PURPOSE OR DESIGN OF SUCH PRODUCTS GSI shall not be liable for any direct indirect incidental or consequential damages including without limitation loss of anticipated profits or benefits The sole and exclusive remedy is set forth in the Limited Warranty which shall not exceed the amount paid for the product purchased This warranty is not transferable and applies only to the original end user GSI shall have no obligation or responsibility for any representations or warranties made by or on behalf of any dealer agent or distributor GSI assumes no responsibility for claims resulting from construction defects or unauthorized modifications to products which it manufactured Modifications to products not specifically delineated in the manual accompanying the equipment at initial sale will void the Limited Warranty This Limited Warranty shall not extend to products or parts which have been damaged by negligent use misuse alteration accident or 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 which apply to the location and installation
31. Improper installation methods of the hardware may cause permanent damage and possible breakage of the boot Boot and Transfer Plate Installation NOTE nstallation of the boot is the same whether the tank has the standard collar or the Sure Flo Feed Flow Control Slide the boot as far as possible into the tank collar or the Sure Flo Feed Flow Control opening See Figure 5A Align the boot with the Flex Flo System that will be installed Using the holes in the collars for guides drill eight 8 11 32 holes into the boot rim See Figure 5B Mount the boot to the collar with the hardware provided Bolt the transfer plate and unloader braces to the boot as shown See Figure 5C for proper usage and assembly direction of hardware for mounting the boot and the transfer plate All connections should be tightened until they are snug Drill these holes 8X into boot 11 32 drill bit Figure 5C PNEG 914 Flex Flo 15 5 Slide Gate Installation Insert the slide into the transfer plate The slide must be in its operating position prior to attaching the slide shield to the transfer plate Use two 2 5 16 18 x 1 truss head tap bolts to mount the slide shield See Figure 5D Bolt unloader to transfer plate unloader brace assembly as shown in Figure 5E Note orientation of these bolts See Figure 5E Figure 5D Figure 5E Ref Part
32. LX 2195C 16 Straight Clear Plastic Boot 1 11 FLX 2194 16 30 Black Plastic Boot 1 11 FLX 2194C 16 30 Clear Plastic Boot 1 PNEG 914 Flex Flo 6 Parts List Model 300 350 and HR Unloader and Anchor Assembly Model 300 Model 350 pia Part Description Part Description 1 FLX 2195 16 Straight Black Plastic Boot FLX 2195 16 Straight Black Plastic Boot 1 FLX 2195C 16 Straight Clear Plastic Boot FLX 2195C 16 Straight Clear Plastic Boot 2 FLX 2194 16 30 Black Plastic Boot FLX 2194 16 30 Black Plastic Boot 2 FLX 2194C 16 30 Clear Plastic Boot FLX 2194C 16 30 Clear Plastic Boot N S FLX 4869 16 Double Straight Black Boot FLX 4869 16 Double Straight Black Boot 3 BLK 11137A j Transfer and Slide Gate Kit BLK 11137A Transfer and Slide Gate Kit 4 00404238 Iron Ball 3 Hollow 1 1 2 00404238 Iron Ball 3 Hollow 1 1 2 5 FLX 4239 Clean Out Plate Assembly FLX 4239 Clean Out Plate Assembly 6 S 4320 3 Tube Clamp 5 9 3 1 2 Tube Clamp 7 FLX 4648 Model 300 Anchor and Bearing Assembly FLX 4650 Model 350 Anchor and Bearing Assembly mew E LEE 9 S 9186 3 1 4 Tube Clamp Model 300 5 3 4 Tube Clamp Model 0 10 FLX 2217 Model 220 300 350 Flex Seal Ring FLX 2217 Model 220 300 350 Flex Seal Ring 11 FLX 3422 Neoprene Seal FLX 3422 Neoprene Seal mde cm SEINE 13 FLX 4819 Unloader Brace FLX 4819 Unloader Brace PNEG 914 Flex Flo 41 6 Parts List Mo
33. LY CONTACT RATING 1 1 2 HP 240 VAC MAX 25 FLA 1 PHASE COIL RATING 208 240 VAC 50 60 Hz A DANGER High Voltage Will cause injury or death Lockout power before servicing THE GSI GROUP FLX 4512 3 ELECTRICAL BOX ASSEMBLY CONTACT RATING 1 1 2 HP 240 VAC MAX 25 FLA 3 PHASE COIL RATING 280 240 VAC 50 60 Hz Ak DANGER High Voltage Will cause injury or death Lockout power before servicing DC 1238 2 3 THE GSI GROUP FLX 4511 ELECTRICAL BOX ASSEMBLY CONTACT RATING 1 HP 120 VAC MAX 25 FLA 1 PHASE COIL RATING 120 VAC 50 60 Hz N DANGER High Voltage Will cause injury or death Lockout power before servicing ROTATING AUGER can crush and dismember e Keep hands out of feed opening e Lockout power and secure auger before servicing DC 8 84 PNEG 914 Flex Flo 2 Decals A WARNING ROTATING AUGER can crush and dismember e Keep hands out of feed opening e Lockout power and secure auger before servicing D 84 PNEG 914 Flex Flo 10 3 Introduction Applications In poultry application Flex Flo Fill System conveys feed from bulk feed tank to hoppers inside the poultry building as shown in Figure 3A Other feed systems i e cycle plus chain feeder etc take the feed from the hopper to the desired locations in the building On this layout hopper level switches may be placed in more than one hopper
34. Model 350 Tube Anchor Plate 4 FLX 2319 Model 500 Tube Anchor Plate 5 5 5 Flat Washer 5 16 55 SAE YDP Grade 2 6 S 396 1 4 20 Hex Nut 7 5 0 2 1 4 Tube Clamp Model 220 7 5 6 3 1 4 Tube Clamp Model 0 7 S 4443 4 Tube Clamp Model 350 7 S 4494 5 1 2 Tube Clamp Model 500 8 FLX 2634 Model 300 Tube Spacer 9 FLXDF 1183 Drop Feed Control Anchor Package 10 FLX 4543 Auger Lock 220 Direct Drive 11 FLX 2685 Model 220 Direct Drive Anchor Washer 12 S 8039 Bolt 1 4 20 x 1 1 4 Socket Head PNEG 914 Flex Flo 43 44 6 Parts List Belt Drive and Tube Anchor PNEG 914 Flex Flo Belt Drive and Tube Anchor Parts List 6 Parts List PNEG 914 Flex Flo Ref Part Description FLX 2695 220 B D Driver and Tube Anchor FLX 2692 300 B D Driver and Tube Anchor FLX 2693 350 B D Driver and Tube Anchor FLX 2694 500 B D Driver and Tube Anchor 1 FLX 4578 Model 300 Belt Driver 1 FLX 4579 Model 350 Belt Driver 2 FLX 4571 Model 300 350 Auger Lock Clamp Pin 3 5 1 Bolt SHCS 5 16 18 x 1 1 2 Model 0 3 5 2 Bolt SHCS 5 16 18 x 1 3 4 Type 8 Cup Point Model 350 4 FLX 2979 Model 220 and 500 Belt Driver 5 FLX 4543 Auger Lock 220 Belt Drive 6 S 845 Flat Washer 5 16 USS SAE YDP Grade 2 y S 8039 Bolt 1 4 20 x 1 1 4 Socket Head 8 FLX 2316 Model 220 Tube Anchor Plate 8 FLX 2317 Model 300 Tube Anchor Plate 8 FLX 2318 Model 350 Tube An
35. aximum restriction is reached When increased feed flow is desired the length of the restrictor tube should be decreased PNEG 914 Flex Flo 5 Installation 8 When a multi story building is supplied by one auger solely obtain total drop out at each outlet A time clock MUST be utilized to ensure that all of the feeders are filled at the same time In the last hopper on every level install a hopper level control 9 With the straight through tandem system open only one tank slide at a time when feeding Operating the system with both unloader slides open is not recommended since horsepower consumption increases considerably Wire Size by Type Minimum Allowable Wire Size Motor Full Load In Cable Conduit or Earth Overhead in Air HP Amps 1 Type RH Bare and Covered Type R T W RHW THW Conductors 1 2 4 9 12 12 10 3 4 6 9 12 12 10 1 8 0 12 12 10 1 1 2 10 0 12 12 10 Copper conductors 1 phase 230V 3 voltage drop In case of conductors supplying several motors on one circuit the wire size is determined by taking 125 of the full load current of the largest motor and 100 for all others Wire Size by Length of Run Length of Run Ft m Motor 50 75 100 150 200 250 300 350 400 500 600 700 800 900 1000 Size 15 22 5 30 45 60 75 90 105 120 150 180 210 240 270 300
36. chor Plate 8 FLX 2319 Model 500 Tube Anchor Plate 9 S 845 Flat Washer 5 16 USS SAE YDP Grade 2 10 S 396 Hex Nut 5 16 18 YDP Grade 2 11 S 4490 2 1 4 Tube Clamp Model 220 11 S 9186 3 1 4 Tube Clamp Model 300 11 S 4443 4 Tube Clamp Model 350 11 S 4494 5 1 2 Tube Clamp Model 500 12 FLX 2634 Model 300 Tube Spacer 13 FLX 2975 Model 500 Belt and Direct Drive Spindle 14 FLX 2974 Model 500 Auger Lock Clamp Pin 15 S 4312 Set Screw 5 16 18 x 1 2 Square Head BK Cup Point 45 46 6 Parts List Model 220 300 and 350 Control Unit FLX 4496 PNEG 914 Flex Flo Model 220 300 and 350 Control Unit FLX 4496 Parts List 6 Parts List Ref Part Description Gty 1 FLX 2017 Powerhead Drop 1 2 DC 884 Decal Rotating Auger Hazard 2 3 FLX 4260 Model 220 300 350 Control Unit Body 1 4 AP 2213 Retaining Clip 4 5 S 4694 Chain 2 Weldless 1 6 5 3 Hook 41 S Hook 1 1 2 Long 3 7 FLX 5015 LB Flex Flo Control Unit 1 8 FLX 4516 Electrical Box Bottom Drilled 1 9 FLX 4561 4 x 6 Electrical Box Gasket 1 10 FLX 4569 Back Plate 4 x 6 Control Box 1 11 FLX 5017 Bracket Terminal Block Mounting 1 12 FLX 5040 Terminal Block Assembly for Flex Flo Control Unit 1 13 FLX 4517 Electrical Box Lid w Decal 1 14 FLX 4560 Electrical Box Lid 4 x 6 1 15 DC 2117 Decal Flex Flo Control 220V 1 16 S 995 Screw MS 10 24 x 1 SS 4 17 S
37. del 500 Unloader and Anchor Assembly Ref Part Description Gty 1 FLX 2065 Model 500 Flex Flo Single through Unloader Body Assembly 1 2 S 4494 5 1 2 Tube Clamp Model 500 1 3 FLX 2218 Model 500 Flex Seal Ring 1 4 FLX 3422 Neoprene Seal 1 5 FLX 4239 Clean Out Plate Assembly 1 6 FLX 2192 Model 500 Anchor and Bearing Assembly 1 7 BLK 11137A Transfer and Slide Gate Kit 1 8 FLX 2095 4 5 Control Unit Seal 1 9 FLX 2194 16 30 Black Plastic Boot 1 9 FLX 2194C 16 30 Clear Plastic Boot 1 10 FLX 2195 16 Straight Black Plastic Boot 1 10 FLX 2195C 16 Straight Clear Plastic Boot 1 42 PNEG 914 Flex Flo 6 Parts List Direct Drive and Tube Anchor Optional Ref Part Description FLX 2699 220 D D Driver and Tube Anchor FLX 2696 300 D D Driver and Tube Anchor FLX 2697 350 D D Driver and Tube Anchor FLX 2698 500 D D Driver and Tube Anchor 1 FLX 4572 Model 300 Direct Drive Spindle 1 FLX 4575 Model 350 Direct Drive Spindle 1 FLX 2975 Model 500 Belt and Direct Drive Spindle 2 FLX 4571 Model 300 350 Auger Lock Clamp Pin 2 FLX 2974 Model 500 Auger Lock Clamp Pin 3 S 6481 5 16 18 x 1 1 2 Hex Socket Cap Screw Model 300 and 350 3 S 6483 5 16 18 x 2 1 2 Hex Socket Cap Screw Model 500 4 FLX 2316 Model 220 Tube Anchor Plate 4 FLX 2317 Model 300 Tube Anchor Plate 4 FLX 2318
38. ding the plate steady f Tem z Figure 5F Clean Out Plate Installation PNEG 914 Flex Flo 17 18 5 Installation Feed Tank Collar The standard bulk feed tank is supplied with a 16 40 64 cm hopper opening If needed 22 55 88 cm hopper openings are also available Consult the dealer for specific ordering instructions Restrictor Adjustment The restrictor may be adjusted to allow more feed flow Do not modify the restrictor until the system is completely operational and the auger has been polished by running feed through the system Instructions 1 Remove the restrictor tube from the unloader 2 Cut 1 2 5 cm from the restrictor See Figure 5G 3 Install the restrictor and the bearing assembly into the unloader 4 Test the feed flow 5 If the desired feed flow rate is not attained repeat the above procedure until the desired rate is reached 9 Q Restrictor as manufactured installed in unloader Q U A i 0 d Q O 1 Le Cut off restrictor for increased
39. e the elbow tubing through the hole in the building Establish and cut if necessary the elbow at the desire length to ensure that the auger tubing will be horizontal See Figure 5K on Page 21 for proper cutting dimensions of the elbows at specific degree angles 3 Fit and clamp a second elbow around the unloader outlet 4 Slide the non belled end of the straight tubing into the belled end of the building elbow Hold the straight tubing in the desired mounting position Mark and cut the unloader elbow at the point where it and the straight tubing intersect 20 PNEG 914 Flex Flo 5 Auger Tubing Installation Continued 5 Remove the non belled end of the straight tubing from the building elbow Slide the belled end of the straight tubing over the freshly cut end of the unloader elbow Mark and cut the straight tubing as needed so that it will fit inside the belled end of the building elbow Dry fit all of the outside tubing to ensure correct installation Once satisfied glue or clamp the tubing together as per the instructions in the section titled cementing procedure on Page 22 When the auger tubing between the unloader and the building is 15 4 57 m or longer the tubes should be supported Locate and cut the outlet holes needed in the remaining straight tubes For the exact size of outlet holes see section titled outlet holes on Page 22 Once ALL of the outlet holes are made and the tubing is dry fitt
40. ed glue or clamp the tubes together per the instructions in the section entitled cementing procedure on Page 22 Suspend the auger tubes and elbows from the ceiling at least once every four feet 4 If horizontal elbows are used support them in at least two 2 places Chain and lag screws are provided in each suspension kit The tubes should be kept as straight and level as possible Do not include belled end when measuring along this surface 5 1 524 m Radius 15 Elbow 15 3 4 40 005 cm 30 Elbow 31 1 2 80 01 cm 45 Elbow 47 1 4 120 015 cm 6 1 829 m Radius 15 Elbow 20 3 16 51 276 cm 30 Elbow 40 5 16 102 394 cm 45 Elbow 60 1 2 153 67 cm 10 3 048 m Radius 15 Elbow 32 81 28 cm 30 Elbow 64 162 56 cm 45 Elbow 96 243 84 cm Figure 5K Cutting Chart for 45 Elbow NOTE Align all outlet holes in proper functional positions prior to gluing the tube joints together PNEG 914 Flex Flo 21 22 5 Cementing Procedure Flex Flo Systems have specially formulated PVC tubing For strong tube connections apply the PVC solvent cement per the instructions as follows 1 Square tube ends and remove all burrs and dirt 2 Check dry fit of tubes The smaller end of the first tube should easily slide one third of the way into the belled end of the second tube The first tube end should be snug in the second tube once it is all the way in 3 When the te
41. ed to start the Flex Flo System often By running the system often long running periods are eliminated and the feeders are kept full When the Flex Flo System is used for filling poultry feeders a time clock should be utilized to ensure that all feeders are filled at the same time The Flex Flo System will have a better opportunity to keep up Position the hopper level control low in the last hopper A safety switch is provided on the control unit to trip out the motor in the event that feed is packed inside If feed does get packed dislodge the feed from the drop tube and clean out the inside of the control unit which will allow the switch to close The hopper level control needs to maintain vertical positioning to keep the paddle swinging freely Check the adjustment regularly The control unit safety switch does not replace the hopper level control When the Flex Flo System is used to convey high moisture feed the auger line should be completely emptied after each running to prevent feed from jamming in the tubes Operate the manual outlets several times each week to free them of feed debris The restrictor on the unloader anchor controls the feed that is flowing into the auger When starting a new system the restrictor should be installed at full length and flush with the front of the unloader Permit the system to polish out the inside of the tubing before modifying the feed flow When the restrictor tube is in the unloader m
42. el 220 3 FLX 350 Model 350 Drop Half 1 AP 1764 Kwik Attach M300 Drop Kit Slide 3 FLX 500 Model 500 Drop Half z 2 PVC 1004 Model 220 PVC Flex Flo Tube 4 5 4 Screw MS 10 24 x 5 8 HWHS SS 10 3 Meters w Belled End 5 Model 220 300 350 500 10 TFR Model 300 PVC Flex Flo Tube Straight Tube 10 3 Meters w Belled End 6 CW 2008 4 Solid Braided Utility Cord MEE Hose Clamp Stainless Steel 7 FLX 2437 Model 220 Nylon Slide 1 3 4 2 3 4 7 FLX 2438 Model 300 Nylon Slide 3 AP 0584 SC M Stainless 7 FLX 2439 Model 350 Nylon Slide z Main Housing for Kwik Attach 7 FLX 2440 Model 500 Nylon Slide 4 APCD 059 Model 220 Drop Kit 7931 Hex Nut 10 24 SS S elus 4 AP 1763 Main Housing for Kwik Attach 9 FLX 2442 Red Indicator Ball 1 Model 300 Drop Kit PNEG 914 Flex Flo 6 Parts List Unloader Switch Ref 8 Part Description Qty 1 FLX 4157A Back Plate Unloader Switch Assembly 1 2 FLX 4410 Diaphragm Assembly 1 3 FLX 2380 Small Diaphragm Retainer 1 4 S 849 Hex Nut 10 24 Grade 2 1 5 FLX 4158A Cover Plate Assembly for Switch 1 6 S 3558 3 8 Washer EPDM Steel Backed 1 7 5 1 Wing Nut 5 16 18 ZN Grade 2 1 8 FLX 4159 Unloader Switch Housing 1 9 S 3674 Flat Washer 10 x 7 32 I D x 1 2 O D x 18 Gauge TSAE ZN Grade 2 1 10 S 2010 Nylock Nut 10 24 ZN Grade 2 2 11 07097327 Micro Switch Spring Bracket 1 12 FLX 3493 Control Unit Switch Bracket 1 13 FLX 2128
43. feed flow Figure 5G Restrictor Adjustment PNEG 914 Flex Flo 5 Installation Straight Through Tandem Installation The straight through tandem system should be installed the same as a single tank system with the following exceptions 1 Mount the boots on both tanks and the single or twin out unloader as instructed 2 Install baffle plate FLX 4310 in the single through unloader as shown in Figure 5H The twin unloader baffle is factory installed as shown in Figure 5H Single restrictor baffle assembly Twin restrictor baffle assembly A Opening for 5 og o agitator ball T o S 8 S Direction of Cover plate in 5 material flow storage position Th 5 1 LE Y SE d Overhead view Overhead view Clean out Auger bh Auger door rotation rotation End view 1 Straight through unloader End view Twin through unloader Figure 5H 3 Slide the belled end of a straight tube onto the unloader outlet on the first tank Hold the straight tubing in the desired mounting position Mark and cut the straight tube at the point where the tube and the inlet of the straight through unloader inlet intersect 4 Slip the appropriate tube coupler over the cut end of the straight tube Position the straight tube in its operating loca
44. he auger tube 9 Two 2 screws are supplied for attaching an optional drop tube See Figure 5N on Page 23 Use both screws to attach the drop tube securely to the drop kit Kwik Attach Drop Kit Installation PVC Tubing Hose clamp 2 Figure 50 Drop Kit Installation 1 Snap the slide around the tube over the outlet hole See Figure 5O 2 Fasten the housing to the tube using two 2 hose clamps Make sure the outlet hole is in the middle of the housing 3 Slide can be rotated from side to side to open and close the drop kit 24 PNEG 914 Flex Flo 5 Power Unit and Control Unit The safety switch on the control unit is provided as a backup switch in case the hopper level or the drop tube switch does not operate properly This switch is not intended to be used for controlling the Flex Flo System but as a safety backup switch only Flex Flo offers two 2 different types of power units direct drive unit and belt drive power unit along with the control unit Installation instructions are provided with each power unit Horsepower requirements are based on length type of Flex Flo System installed number of turns tandem systems etc Table below shows maximum line lengths for Flex Flo Systems plus maximum lengths for extensions hopper installing using various power units Reduction of the maximum line lengths in the chart should be allowed for if the system s incline is greater than 45 and or the
45. his is performed by drawing the auger out of the tubing An important factor is the total system length The auger should be drawn out of the tubing 2 5 cm for every 50 15 m of length for single feed tanks For tandem systems stretch the auger 4 10 cm for every 50 15 m of length 6 While the auger is in the relaxed state mark the auger at the unloader inlet m Stretch flex auger gt Stretch flex auger Single feed tank 2 50 mm per 50 15 m of length Tandem feed tank 4 100 mm per 50 15 m of length Mark here Figure 5V Stretching the Auger 28 PNEG 914 Flex Flo 5 Auger Installation Continued 7 Draw the auger out of the tubing as far as required Measure the length between the mark and the unloader inlet Mark the auger again at the unloader inlet when properly stretched See Figure 5V on Page 28 Stretching the auger too far will cause premature wear at the inside bends of the PVC tubing Stretching the auger not far enough will cause premature wear at the outside bends of the PVC tubing For ease of trimming the auger pull the auger out an additional 8 20 cm past the mark and clamp it at the unloader This clamping releases tension at the mark and thus eases cutting See Figure 5W Twist the unloader anchor into the auger and clasp the auger end in the clamp pin 10 11 12 13 Mount the anchor in the unloader Place the cannonball inside the unloader Moun
46. inion Gear for Gear Reducer 1 3 HP 2 FLX 2973 Gear Reducer Pinion Gear 1 HP 3 FLX 4277 R Gearbox 358 RPM w o Pinion Gear 3 FLX 4400 R Gearbox 156 RPM w o Pinion Gear 3 FLX 4403 R Gearbox 250 RPM w o Pinion Gear 3 FLX 4405 R Gearbox 441 RPM w o Pinion Gear 3 FLX 4406 R Gearbox 539 RPM w o Pinion Gear N S FLX 4358 Adapter Plate Aluminum C Face N S FLX 4407 1 Phase P U Oil and Hardware NOTE To order a gearbox with the opposite orientation rotated 1809 add an R to the end of these part numbers PNEG 914 Flex Flo 51 52 6 Parts List Drop Kit Kwik Attach Drop Kit Drop kit Kwik attach drop kit Drop Kit Parts List Kwik Attach Drop Kit Parts List Ref Part Description Ref Part Description FLX 2432 Model 220 Drop Kit Nylon Kwik Attach Drop Kit for AFODIGE Model 220 236 Single FLX 2433 Model 300 Drop Kit Nylon 9 Kwik Attach Drop Kit for FLX 2434 Model Drop Kit Nyl i 3 EE E Model 300 Single FLX 2435 Model 500 Drop Kit Nylon 3 APCD 110 Kwik Attach Drop Kit for 1 5 0 Screw SDS 10 16 x 5 8 HWH ZN 4 Model 220 236 Box of 10 2 FLX 2441 Green Indicator Ball Kwik Attach Drop Kit for APERIT Model 300 Box of 10 3 FLX 220 Model 220 Drop Half odel 300 Box of 10 3 FLX 300 Model 300 Drop Half 1 APCD 058 Shut Off Slide for Kwik Attach Mod
47. moved by straightening the auger A kink may cause extensive wear on the system and premature part replacement In the event that the kink cannot be removed by straightening the kink must be cut out and the auger welded See brazing recommendations in Figure 5X on Page 29 F Figure 5U Auger Installation Two 2 persons are required to install the auger One person feeds the auger into the tubing while the other makes sure the auger is not damaged Make sure no metal wires or loose ends enter the system 1 The auger must be fed into the Flex Flo System through the unloader Remove the anchor from the unloader Remove the control unit cover plate as well 2 Feed the auger carefully into the Flex Flo System through the unloader Remove the anchor from the unloader and remove the control unit cover plate 3 Push the auger in until it reaches the control unit at the other end Fasten the end of the auger to the clamp pin in the control unit driver assembly Tighten the 5 16 hex head cap screw holding the auger lock clamp pin to 23 ft Ibs If the auger end is not in the appropriate orientation for connection the driver assembly may be rotated by turning the motor drive shaft 4 Pull and release the free end of the auger gently a few times This action should relax the auger into its natural position 5 A certain mechanical stress must be applied when installing the auger therefore stretching the auger is very important T
48. mperature is below 40 F 4 C or above 85 F 29 C consult PVC solvent cement container Apply a liberal coat of cement in the belled end Avoid puddling inside Apply a liberal coat of cement on the smaller end leaving no voids Assemble parts quickly CEMENT MUST BE FLUID If not fluid re coat both parts Push the smaller end into the belled end using a quarter turning motion until the small end bottoms oN U A Hold tubes together for 30 seconds wipe off excess cement with cloth Completed joints should not be disturbed until they have cured enough to withstand handling Keep container closed when not in use Outlet Holes Establish where the outlet drops are to be Once this is done cut holes for the outlet drops See Figure 5L for hole size recommendations If total drop out is necessary it is recommended that the holes are cut using a saber saw or hacksaw When carry over is desired it is recommended that the outlet holes are cut with a holesaw Outlet hole for total dropout EC B Outlet hole when carry over is acceptable Figure 5L Outlet Hole Cutting Chart Full Drop Carry over Model Variable A Variable 8 220 1 1 2 38 mm 1 1 2 38 mm 300 2 1 2 63 mm 2 1 2 63 mm 350 3 76 mm 3 76 mm 500 4 102 mm 4 102 mm HR 3 76 mm 2 1 2 63 mm PNEG 914 Flex Flo
49. n Sequence This manual outlines the recommended order for the installation of the Flex Flo System Following this guideline will provide the safest and easiest method of installation Above all connection of the system to the electrical mains should be the final stage of installation Failure to observe this could lead to a fatal accident PNEG 914 Flex Flo 4 Flex Flo Specifications English Metric Flex Flo Systems Specifications Content 18 Ground Corn 1 25 4 mm Long Model 220 Model 300 Model 350 Model 500 Model HR A 2 2 3 3 1 2 5 3 1 2 Auger Tube Diameter 55 mm 75 mm 90 mm 125 mm 90 mm 15 Ibs min 50 Ibs min 100 Ibs min 220 Ibs min 50 Ibs min Carrying Capacity based 7 kg min 22 kg min 45 kg min 100 kg min 22 kg min on 40 Ibs cubic ft 900 Ibs hr 3000 Ibs hr 6000 Ibs hr 13200 Ibs hr 3000 Ibs hr 420 kg hr 1400 kg hr 2700 kg hr 6000 kg hr 1400 kg hr 1 8 3 175 mm x Shelled Corn or Pellets Larger Feed Fragments jos Maximum Particle Size 1 2 12 7 mm Long Crumble Type 3 16 4 76 mm x Like Shelled Corn or ai and Feed Type Maximum Moisture Feed Mash 1 2 12 7 mm Pellets 3 8 9 52 mm x j 9 52 mm Diameter x 3 4 19 05 mm Long Model 220 Model 300 Model 350 Model 500 Model HR Figure 4A The Feed Tank Connections Feed Tank Orientation Positioning the feed tank in line with the Flex Flo System will provide the most
50. o o O 0 0 0 OY Q 6 Q GI 9 10 XN EN ZNO T zo XN zi HOLIMS AL44VS Ad 03110811093 0 13 1313 GUVGNVLS AlddNS YAMOd OWA OE 0v0S x14 32018 TYNIN Y3L 310d LL I ERG vg wouws amv solon sw HE 262266060 Ole e 626060600 91019 Olol ztL9 S HOLIMS 319501 0 pO9Z S dNV1 LOTId Gay 0331935 OVA 0GZ 4044 S HOLIMS LIA AL44VS 619b X1 Av 138 1109 OVA DEZ ON 1Sd 95 PNEG 914 Flex Flo Wiring Diagram for Extension Flex Flo Using Smart Flex Control 7 Wiring Diagrams ONE d NOISNALXA 21 HO YOLOW 014 X314 AlddflS YAMOd OWA OE aa9NY TINA OJ YOLOW 014 X314 ONG 61 DS 1 E AlddflS 3M Od DVA DE 0 0 pejosjeg jonpoud O 670y X14 X314 LAVWS
51. olator so that only you can turn the power back ON Follow all guidelines given in the maintenance section of this manual Before restarting the Flex Flo System make sure that all electrical enclosures are locked closed and all guards and other safety measures are correctly fitted If in any doubt contact your dealer or the GSI group for assistance Dust Under normal working conditions little or no dust should be created by the Flex Flo System However some dust may be created which may be harmful to your health if inhaled To prevent this wear a suitable type dust mask Noise Noise is not generally a hazard associated with the Flex Flo System Excessive noise may indicate a problem with the machines Tests on this machine indicate noise levels at a position one meter from the drive unit and 1 6 meters above the ground do not exceed 70 dBa continuous A weighted sound pressure or 63 Pa instantaneous C weighted sound pressure Sound Signs and Warnings The following pages show you exactly where the safety and warning decals should be placed on the Flex Flo System If a decal is missing or unreadable please contact your dealer or the GSI group for a free replacement For guidance or assistance on any issues relating to the safe use of the Flex Flo System Contact GSI Group 1004 E Illinois St Assumption IL 62510 Phone 1 217 226 4421 PNEG 914 Flex Flo 2 Decals THE GSI GROUP FLX 4512 ELECTRICAL BOX ASSEMB
52. r serious injury WARNING indicates a hazardous situation which if not avoided could result in death or serious injury CAUTION used with the safety alert symbol indicates a hazardous situation which if not avoided could result in minor or moderate injury NOTICE is used to address practices not related to NOTIC 5 personal injury PNEG 914 Flex Flo 1 Safety General Safety Statement Our foremost concern is your safety and the safety of others associated with grain handling eguipment This manual is to help understand safe operating procedures and some problems which may be encountered by the operator and other personnel As owner and or operator you are responsible to know what requirements hazards and precautions exist and inform all personnel associated with the equipment or in the area Safety precautions may be required from the personnel Avoid any alterations to the equipment which may produce a very dangerous situation where SERIOUS INJURY or DEATH may occur Electrical Safety An adequate and safe power supply to the Flex Flo System unit is essential for safety A competent and qualified electrician must undertake all electrical wiring All wiring is to be installed in accordance with all local and National Standards and Regulations relevant to your country and region Electrical safety devices emergency stops and main isolators are recommended with the Flex Flo System and are essential for
53. rise of the system is higher than 8 2 44 m For each additional 90 2 elbows used beyond chart reduce the maximum line length for each drive unit by 30 9 14 m For each straight out to straight through tandem system decrease the maximum line length for each drive unit size by 50 15 24 m Figure 5P Maximum Line Length Model 220 Model 300 Model 350 Model 500 Model HR Motor Extension Size Maximum Maximum Pitch j Maximum Maximum Maximum Maximum Maximum Maximum Maximum Maximum Maximum Maximum Length Extension Length Extension Length Extension Length Extension Length Extension Length Extension 1 3 HP 150 180 a A d E fi Dry Feed Stuffs High Moisture 0 246 kW 46m 91 m Moisture Levels Systems Moisture below 18 Level from 18 27 1 2 HP 250 2300 300 80 Eu 30 65 30 50 0 373 kW 24m 38 m 38 m 24 m 38 m 9m 20m 7 6m 12 7m 3 4 HP gt 5 400 150 150 90 90 50 50 25 25 90 90 0 559 kW 46m 56m 27m 38m 20 3m 25 4m 1 HP gt s 200 245 150 185 100 100 50 65 150 180 0 746 kW 61m 75m 46m 56m 38 1 m 457 m 1 1 2 HP gt 150 180 715 90 The maximum length is for a system with three 3 elbows PNEG 914 Flex Flo 5 Installation Direct Drive Power Unit Control Unit 1 Bolt the tube anchor to the control unit body with a flat washer on each of the four 4 5 16
54. rrectly fitted is a serious misuse of the machine and endangers safety Safety in Handling the Flex Flo System The Flex Flo drive unit weighs 48 Ibs 22 kgs All precautions should be taken when lifting and or moving the unit Ideally mechanical lift equipment should be used If manual handling is necessary assistance should be sought from other people PNEG 914 Flex Flo 1 Safety CE Compliance In accordance with European Union Directives GSI has made every effort to ensure that this product complies with the essential requirements of the machinery directive the low voltage directive and the electromagnetic compatibility directive As such we have declared conformity and affixed the CE mark Our declaration relates only to genuine GSI Flex Flo Systems installed as intended by GSI We cannot and do not declare conformity for any modifications additions or any systems whatsoever operating on or with GSI products that are not supplied by GSI or are in any way outside the control of GSI Safety in Maintenance The Flex Flo System is designed to keep maintenance to a minimum however some repairs will be necessary in the course of the life of the system Do not attempt any repairs on the system unless you are competent to do so Remember that the Flex Flo operates under automatic control and will start without warning Never attempt any work on the Flex Flo System without first isolating the drive unit from the main power and locking the is
55. t Screw 10 FLX 5043 Inner Belt Drive Motor Bracket 11 S 4309 1 4 20 x 5 8 Allen Head Bolt 12 S 8426 Square Key 3 16 x 1 Long 13 S 845 Flat Washer 5 16 USS SAE YDP Grade 2 14 S 396 Hex Nut 5 16 18 YDP Grade 2 15 S 7299 Bolt HHTB 5 16 18 x 2 1 2 ZN Grade 2 16 FLX 5042 Outer Belt Drive Motor Bracket 17 S 1147 Split Lock Washer 5 16 ZN 18 S 4275 Bolt HHTB 5 16 18 x 3 4 ZN Grade 5 19 S 6236 Eye Bolt 5 16 18 x 2 1 8 w Nut 22 013 1 Motor 1 3 HP 1 PH 110 220V 60 Hz Farm Duty 5 8 Shaft 22 012 1 Motor 1 2 HP 1 PH 110 220V 60 Hz Farm Duty 5 8 Shaft 22 034 1 Motor 3 4 HP 1 PH 110 220V 60 Hz Farm Duty 5 8 Shaft 22 100 1 Motor 1 HP 1 PH 60 Hz 110 220V 1750 RPM 5 8 Shaft 22 112 1 Motor 1 1 2 HP 1 PH 60 Hz 110 220V 1750 RPM 5 8 Shaft 23 S 6381 Black Strain Relief 50 PNEG 914 Flex Flo Direct Drive Power Unit 6 Parts List Ref Part Description 1 FLX 4763 Motor 1 3 HP 1 PH 60 Hz 115 230V 1725 RPM 1 FLX 4764 Motor 1 2 HP 1 PH 60 Hz 115 230V 1725 RPM 1 FLX 4765 Motor 3 4 HP 1 PH 60 Hz 115 230V 1725 RPM 1 FLX 4766 Motor 1 HP 1 PH 60 Hz 115 230V 1725 RPM 1 FLX 2473 Motor 1 1 2 HP 1 PH 60 Hz 115 230V 1725 RPM 2 FLX 4275 Pinion Gear for Gear Reducer 1 8 1 2 and 3 4 HP 2 FLX 4276 Pinion Gear for Gear Reducer 1 and 1 1 2 HP 2 FLX 4542 Pinion Gear for Gear Reducer 1 or 1 1 2 HP 2 FLX 2983 P
56. t the cover on the control unit Place the inspection clean out plate in the unloader Figure 5W Cutting the Auger Brazing the Auger 1 2 3 4 5 Make sure both ends are cleaned Position the auger in an angle iron and clasp it securely to align it for brazing See Figure 5X Braze both ends together Use a bronze flux coated rod Make sure the auger does not get too hot which might cause the auger to warp After the brazing is performed the joint should be allowed to air cool Once the auger has cooled install the auger with the brazed joint closer to the power unit Grind flush and smooth Brazing Figure 5X Brazing the Auger PNEG 914 Flex Flo 29 30 5 Installation Extension Hopper Installation 1 To ease the installation mount the extension hopper top section to the Flex Flo tubing NOTE A Slide the tube clamp on the hopper tube anchor prior to attaching it to the tubing B Make certain when mounting the power unit and the tubing that they are attached to the access slide side When mounted in this orientation the incoming auger is positioned as far away as possible to allow the upper control switch to operate properly 2 Suspend the top section from the ceiling as shown in Figure 5Y Support holes are provided on the top section for mounting When mounting make allowance for future adjustments of the top section after the bottom section has been connected NOTE An
57. tion Slide and clamp the tube coupler over the straight through unloader inlet See Figure 5l NOTE The coupler should be equally distributed between the tubing and the unloader inlet Single out unloader Single through unloader Tube coupler A 1 Clamp PUN Figure 5l Tandem System Installation 5 Feed the auger through the single twin out unloader to the rest of the system and anchor as instructed PNEG 914 Flex Flo 19 5 Installation Auger Tubing Auger Tubing Installation The auger tubing is one of the most important parts of the Flex Flo Fill System Proper installation is very important Dry fit ALL parts before cementing or clamping Once the complete system is fitting properly cement or clamp the entire system The following steps are to be performed in the exact order shown 1 Establish the entry point where the auger tube will enter the building Once the entry point is determined cut a hole large enough to accommodate the tubing A seal ring and a neoprene seal are provided to seal the excess area between the tube and the hole in the building The seal ring and the neoprene seal shall be installed as shown in Figure 5J Es Outside of building wall Neoprene seal FLX 3422 Model 500 flex seal ring FLX 2218 Figure 5J Seal Ring and Neoprene Seal Installation 2 Slid
58. to assure that no hopper empties before the control unit hopper reguires feed All switches must be wired in parallel so that any one switch can start the system ka Figure 3A Poultry Application Layout In swine applications Flex Flo Fill System conveys feed from bulk feed tanks to each individual feeder i e S S hog feeder drop feeder etc directly as shown in Figure 3B It is at this location that feed is being consumed A feed level control is installed at the end to shut off the system after all feeders are filled Ji ek Figure 3B Swine Application Layout Background The Flex Flo Fill System consists of a combination of PVC tubes and preformed PVC elbows A special PVC cement is used to connect the tubes and elbows The PVC tubes are available in four 4 different sizes The PVC tube contains a rotating auger which conveys the feed to the different outlet holes The auger is driven by a direct drive power unit or a belt drive power unit Building Safety If you are intending to install the Flex Flo System at high levels and or suspended from a building structure it is important that you check the structural integrity of the building to carry the additional load For information on the imposed loads on the building by the Flex Flo System please contact the dealer or the GSI group Installatio
59. y aaditional support given to the extension hopper makes for a more solid system and is desirable Take special care if or when the support is modified that the operation of the system and the ability to do a general maintenance are not hindered 3 Mount the unloader under the control unit The control unit should be assembled together prior to mounting This assembly includes the driver assembly Suspend the control unit firmly from the ceiling Support holes are provided on the tube anchor Figure 5Y Extension Hopper 4 Fasten the end of the auger to the anchor in the control unit driver assembly Tighten the 5 16 hex head cap screw holding the auger lock clamp pin to 23 ft Ibs If the auger end is not in the appropriate orientation for connection the driver assembly may be rotated by either turning the motor shaft with a wrench or by turning the large pulley to rotate the driver assembly 5 Remove the anchor assembly and the rear access panel from the bottom section of the extension hopper Mount the bottom section to the top section with 1 4 20 machine screws provided with the hopper The bottom section may be mounted in three 3 various directions See Figure 5Z on Page 31 PNEG 914 Flex Flo 5 Extension Hopper Installation Continued
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