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Installation and Operation of Flex-Flo

1. SQV31010W 3SH3A3MH NOLLV LOM YOLOW 40 OL amp OL SQV313010W HOV LLV div SZ OWA 02 00 SOVLIOA 1109 09 109 LO XAY LA zo CXDM 6 01 CASEL 0909 96t X 14 NO aasn LINN TONLNOD SSWHd LIOA 27 1 JHL OL ANY Z HOVLLV 51 PNEG 914 Flex Flo PNEG 914 Flex Flo uaonv NOISNALXA 1115 HOLON YOLON LINN O14 X314 A M M EE 5 OWA 082 Li 96vv X 14 H39nv i NOISNALX4 40 3 LINN TOMLNOO O14 X314 4 YSONV 1114 40 LINN 1 1 014 e LN A HOLIMS 13431 33ddOH ASN HOLIMS Sani asn 92862 HOLIMS asn 9 1 S3IM 2 lt 1 9014 1 SAYIM 353 Extension Flex Flo Feed System Using Two 2 FLX 4496 Controls 7 Wiring Diagrams 52 8 Warranty GSI Group LLC Limited Warran
2. 50 205 230 3 Phase Control Ee TEE 51 Extension Flex Flo Feed System Using Two 2 FLX 4496 Controls 52 oru 53 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 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 1 DANGER indicates an imminently hazardous situation which if avoided will result in death or serious injury AWARN N G WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury C AU T CAUTION indicates a potentially hazardous situation which if not avoid
3. 1 Cut off restrictor for increased feed flow Figure 5G Hestrictor Adjustment PNEG 914 Flex Flo 17 5 Installation Straight through Tandem Installation The straight through tandem system should be installed the same as a single tank system with the following exceptions 1 Mount the boots on both tanks and the single or twin out unloader as instructed 2 Install baffle plate FLX 4310 in the single through unloader as shown in Figure 5H The twin unloader is factory installed as shown in Figure 5H Single restrictor baffle assembly Twin restrictor baffle assembly Opening for 8 itator ball i 5 5 o Direction of Cover plate _ 5 material flow 2 storage position il F 9 5 O eje oi Overhead view Overhead view Clean out door End view 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
4. SINIL M AENl 3 418 MOTIAA M E 5 LINN 1041400 OL WNIANSL OL 3 onid ze m mes y 5 ER 0 Dr i OU 3 o TS 25 1 IN WE cSv X 14 4 l 1 1 4 1 1 1 1 1 1 l Lisa ero eae AM Tad ANIL TWNOILdO HLIM AOL L AOZZ HOLIMS 1OHINOO 13431 33ddOH Z08 X 13 AOL L AOZZ dINY OZ HOLIMS 13431 7660 4 AOLL AOZZ HOLIMS M 1 0660 4 HOLIMS 13 31 HOLIMS 38fl L OHOIN sejou Bunsixe y 5 SJoj2euuoo 1965 sunsse 32079 TIVNOLLdO YAMOd LIOA 022 EH Kl 2 n Dnm DEI E MEER LINN TOW LNOO 009 TSCOW L ck LINN TOM LNOO OSE ANY 00 022 TSCOW LINN ITOHLNOO O 137X3134 LIOA OLL PNEG 914 Flex Flo 50 7 Wiring Diagrams 208 230V 3 Phase Control Uni 43 1 3901 S IVNIIASH3 L LOANNOD 035 LON SI HOLIMS 5 V 4 LINN 1OS LNOO NI 38001 31VIN34 3 VIN OL HOLIMS T3A 31 HOLIMS AHL S38IM LOANNOO
5. Focos gemeng Body 16 30 Black Plastic Boot 16 30 Clear Plastic Boot PNEG 914 Flex Flo 6 Parts List Model 300 350 and HR Unloader and Anchor Assembly SE 16 Siaight Black Plasto 00404238 Iron Ball 3 Hollow 1 1 2 Iron Ball 3 Hollow 1 1 2 S 9186 3 1 4 Tube Clamp Model 300 FLX 4671B Model 300 Flex Flo Twin through Unloader FLX 2116B Model 350 Flex Flo Twin through Unloader Body Assembly Body Assembly FLX 4819 Unloader Brace FLX 4819 Unloader Brace PNEG 914 Flex Flo 39 40 6 Parts List Model 500 Unloader and Anchor Assembly Ret Pate Description ___ Oy ES 2 S 4494 5 1 2 Tube Clamp Model 500 FLX 2218 Model 500 Flex Seal Ring Neoprene Seal Clean out Plate Assembly 6 FLX 2192 M 500 Anchor and Bearing Assembly Transfer and Slide Gate Kit 4 5 Control Unit Seal 9 FLX 2194 16 30 Black Plastic Boot 9 FLX 2194C 16 30 Clear Plastic Boot 16 Straight Clear Plastic Boot PNEG 914 Flex Flo 6 Parts List Direct Drive and Tube Anchor Optional Description 90 2699 ____ 220 D D Driver Tube Anchor 300 D D Driver and Tube Anchor RX2697 350 D D Driver and Tube Anchor FLX 2698 500 D D Driver and Tube Anchor Model 300 Direct Drive Spindle Model 350 Direct Drive Spindle Model 500 Belt and Direct Drive Spindle 5 16 18 x 1 1 2 Hex Socket Cap Screw Model 300 and 350 5 16 18 x 2 1 2 H
6. N IW A d Mi d CH s D I Installation and Operation of Flex Flo Model 220 300 and 350 500 and HR Installation and Owner s Manual umberland 914 Date 03 29 10 PNEG 914 Flex Flo Table of Contents Contents Chapter 1 Safety aa 4 4 Statement om m 5 Mirco ddp c 7 CPET M 9 T 9 Background a a a 9 B lding Slety ener E 9 Installation Sequence 9 Chapter 4 Flex Flo Specifications English Metric 10 The Feed Tank Connections m 10 Chapter 5 Installation FM 14 Boot Transfer ENEE NEE 14 Slide Gate Installation E 15 Inspection Clean out Plate Installation BET 16 d C n 17 Straight through Tandem Inst
7. 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 50 2 Fasten the housing to the tube using two 2 hose clamps Make sure the outlet hole is in the middle of the housing 3 Slide can be rotated from side to side to open and close the drop kit PNEG 914 Flex Flo 23 5 Installation Power Unit and Control Unit The safety switch on the control unit is provided as a backup switch in case the hopper level or the drop tube switch does not operate properly This switch 15 CAUTION 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 rise of the system is higher than 8 2 44 m For each additional 90 2 elbows used beyond chart
8. EC ee 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 H ft X for Straight Boot ft 60 10 0 11 0 11 5 12 0 12 5 13 0 13 5 12 0 275 15 0 125 29 0 155 14 0 16 0 16 5 17 0 155 38 0 185 17 5 11 4 Flex Flo Specifications English Metric 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 e ew Ea s CER ese gt ay 1 83 381 335 5 18 2 13 427 56 5 18 2 44 4 88 6 10 5 49 2 74 5 33 4 27 6 71 5 79 3 05 594 457 7 16 6 10 3 35 6 40 7 77 6 40 5 94 3 66 7 01 8 23 6 71 6 10 3 96 7 47 8 84 7 01 6 40 4 27 8 08 9 30 7 32 6 55 4 57 8 53 7 62 6 71 4 88 9 14 6 40 5 33 10 36 7 92 6 86 5 18 9 60 8 23 7 01 5 49 10 21 7 16 5 79 10 67 7 32 7 62 Model 500 with 6 Radius Elbow X for 30 Boot m X for Straight Boot m EE on a 1 83 3 20 4 11 3 35 3 05 2 13 3 66 472 3 66 3 35 2 44 4 27 5 18 3 96 3 51 2 74 4 72 5 79 4 27 3 66 3 05 5 18 6 10 4 57 3 81 3 35 5 79 6 86 4 88 3 96 3 66 6 25 7 16 5 18 4 11
9. 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 Hold tubes together for 30 seconds wipe off excess cement with cloth Completed joints should not be disturbed until they have cured enough to withstand handling Keep container closed when not in use Outlet Holes Establish where the outlet drops are to be Once this is done cut holes for the outlet drops See Figure 5L for hole size recommendations If total drop out is necessary it is recommended that the holes are cut using a saber saw or hacksaw When carry over is desired it is recommended that the outlet holes are cut with a holesaw Outlet hole for total dropout 1 25 mm lt Outlet hole when carry over is acceptable Figure 5L Outlet Hole Cutting Chart Full Drop Carry over Variable A Variable B 300 2 1 2 63 mm 2 1 2 63 mm 3 76 mm 3 76 mm 4 102 mm 4 102 mm 3 76 mm 2 1 2 63 mm PNEG 914 Flex Flo 21 5 Installation Drop Kit Installation 1 Wrap the rotary slide over the outlet hole and around the auger tube Position th
10. 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 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 Type A Type B 07100643 60 Direct Drive Power Unit Assemblies Parts List Continued Direct Drive Power Unit Gearbox Orientation 07100643 60R Description 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 07097965 60 07097965 60R 07097744
11. 60 07097744 60R 07097374 60 07098924 50R 07097374 60R CU DDPU 368 RPM 1 2 HP 1 PH 50 Hz 115 230V CU DDPU 358 RPM 3 4 HP 1 PH 60 Hz 115 230V CU DDPU 358 RPM 1 2 HP 1 PH 60 Hz 115 230V CU DDPU 358 RPM 1 3 HP 1 PH 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 7099341 7099341R 7099340 7099340R 7099298 7099342R 7099298R DDPU 358 RPM 3 4 HP 3 PH 60 Hz 208 230 460V CU DDPU 358 RPM 1 2 HP 3 PH 60 Hz 208 230 460V CU DDPU 358 RPM 1 3 HP 3 PH 60 Hz 230 460V CU 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 7098894 7098894R 7098423 7098423R 7098422 7099247R 7098422R DDPU 735 RPM 3 4 HP 3 PH 50 Hz 230 380 440V CU DDPU 716 RPM 3 4 HP 1 PH 60 Hz 115 230V CU DDPU 441 RPM 1 3 HP 1 PH 50 Hz 115 230V CU 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 3928 50 FLX 3928 50R FLX 3928 60 FLX 3928 60R FLX 3634 50 FLX 3593R FLX 3634 50R DDPU 156 RPM 1 2 HP 3 PH 60 Hz 230 460V DDPU 129 RPM 3 4 HP 1 PH 50 Hz 110 220V DDPU 156
12. Belt Drive Power Unit Mount the motor onto the motor mount base with four 4 bolts and washers Mount the belt pulleys The two 2 pulleys must be positioned in line with each other to prevent from binding the belt Install the belt Adjust the belt tension by extending and retracing the two 2 mounting brackets Resecure the bolts after adjustment Install belt guard cover Attach the power control unit to the Flex Flo tubing Suspend the power control unit firmly from the ceiling using the chains provided The control unit and the power unit must be wired as shown in the Wiring Diagram on Pages 49 52 Install the auger PNEG 914 Flex Flo 5 Installation Auger The auger should be handled with great care Do not install the auger until the kinks have been removed The kink may be removed by straightening the auger A kink may cause extensive wear on the system and premature part replacement In the event that the kink cannot be removed by straightening the kink must be cut out and the auger welded See brazing recommendations in Figure 5X on Page 28 Figure 5U Auger Installation Two 2 persons are required to install the auger One 1 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 c
13. Flo Tube 10 3 Meters w Belled End Hose Clamp Stainless Steel 1 3 4 2 3 4 0584 Hose Clamp Stainless Steel 3 4 APCD 059 Main Housing for Kwik Attach M220 Drop Kit AP 1763 Main Housing for Kwik Attach M300 Drop Kit 46 PNEG 914 Flex Flo 6 Parts List Unloader Switch Ref Part Description Qty 1 FLX 4157A Back Plate Unloader Switch Assembly 2 FLX 4410 Diaphragm Assembly 3 FLX 2380 Small Diaphragm Retainer 4 S 849 Hex Nut 10 24 Grade 2 5 FLX 4158A Cover Plate Assembly for Switch 6 8 3558 3 8 Washer EPDM Steel Backed 7 4301 Wing Nut 5 16 18 ZN Grade 2 8 FLX 4159 Unloader Switch Housing 9 S 3674 Flat Washer 10 x 7 32 I D x 1 2 O D x 18 Gauge TSAE ZN Grade 2 10 S 2010 Nylock Nut 10 24 ZN Grade 2 11 07097327 Micro Switch Spring Bracket 12 FLX 3493 Control Unit Switch Bracket 13 FLX 2128 Boot Switch 14 S 7319 Screw MS 6 32 x 7 8 R H Side ZN Grade 2 15 S 6144 Hex Nut 6 32 Grade 2 16 160 1074 Ring Terminal 10 Insulated 17 WR 16GRN YLW Wire 16 Gauge Green Yellow Stranded 1 18 FLX 2690 Electrical Box Gasket 4 x 4 19 FLX 2689 Electrical Box Lid 20 _ DC 1088 Decal Flex Flo Control Unit 21 S 995 Screw MS 10 24 x 1 PHP SS 22 S 7931 Hex Nut 10 24 SS 23 302 Box 13 3 4 x 5 1 2 x 5 1 2 200C FPF Not Shown PNEG 914 Flex Flo 47 48 6 Parts List Micro Drop Tube Switch Proximity Switch Micro drop tube switch Ref Part AP 09
14. Gasket FLX 4517 Lid for Control Box with DC 1238 Decal 1 2 FLX 4261A Access Door w DC 884 Decal 3 FLX 2017 220 300 350 Power Head Drop No Hardware FLX 2309 500 Power Head Drop No Hardware 1 1 5 995 Screw 10 32 x 1 2 4 5 7931 Hex Nut 10 32 4 5 6622 ON OFF Plate for Toggle Switch 4 AP 2213 Power Head Drop Retaining Clip 5 Screw SDS 10 16 x 1 HWH ZN Grade 2 FLX 2380 Small Diaphragm Retainer FLX 4410 Diaphragm Assembly 5 4694 2 Weldless Chain S 280 Screw SDS 10 16 x 5 8 HWH ZN 5 849 Hex Nut 10 24 Grade 2 FLX 4510 Base Plate 7 8 9 0 2 3 4 5 5 2010 Nylock Nut 10 24 ZN Grade 2 S 3674 Flat Washer 10 x 7 32 I D x 1 2 O D x 18 Gauge TSAE ZN Grade 2 Nut Ring for S 7707 12 mm x 0 75 Thread PNEG 914 Flex Flo S S 5 3383 S Hook 5 8 1 1 2 41 5 5 8183 Screw SMSA 6 x 3 8 PHP ZN 1 1 1 2 N 2 2 2 2 N N 43 6 Parts List Belt Drive Power Unit Description Ref Pati M 14 Belt Drive Power Unit Less Motor Belt Guard Cover 5 8 1 0 Locking Collar Bolt HHTB 5 16 18 x 1 3 4 ZN Grade 5 2 7 A Belt Single Groove Pulley 5 8 Bore AX51 Gripnotch Belt s6240 14 A Belt Single Groove Pulley Belt Guard Back S 280 Screw SDS 10 16 x 5 8 HWH ZN Se Flex Flo Anchor Bearing Assembly with Set Screw 10 FLX 5043 Inner Belt Drive Motor Bracket 1 4 20 x 5 8 Allen Head Bolt 12 5 8426 Key SQ 3 16 x 1 Lon
15. be completely emptied after each running to prevent feed from jamming in the tubes 6 Operate the manual outlets several times each week to free them of feed debris 7 The restrictor on the unloader anchor controls the feed that is flowing into the auger When starting a new system the restrictor should be installed at full length and flush with the front of the unloader Permit the system to polish out the inside of the tubing before modifying the feed flow When the restrictor tube is in the unloader maximum restriction is reached When increased feed flow is desired the length of the restrictor tube should be decreased PNEG 914 Flex Flo 31 32 5 Installation 8 When a multi story building is supplied by one 1 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 1 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 Bare and Covered BEER RHW THW Conductors Copper conductors 1 Phase 230V 3 voltage drop In case of conductors supplying several motors on
16. 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 5 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 isolator so that only you can turn the power ba
17. location Slide and clamp the tube coupler over the straight through unloader inlet See Figure 51 NOTE The coupler should be equally distributed between the tubing and the unloader inlet Single out unloader Single through unloader Tube coupler Figure 51 Tandem System Installation 5 Feed the auger through the single twin out unloader to the rest of the system and anchor as instructed 18 PNEG 914 Flex Flo 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 5u Outside of building wall Neoprene seal FLX 3422 Model 500 Flex seal ring FLX 2218 Figure 5J Seal Ring and Neoprene Seal Installation 2 Slide the elbow tubing through the hole in the building Establish and cut if neces
18. 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 Model220 220 XEM Model 300 Model 350 Model 500 Model HR xtension Max Max Pitch Max Max Max Max Max Max Max Max Max Max ength Extension Length Extension Length Extension Length Extension Length Extension Length Extension Dry feed stuffs High moisture systems Ea aaa moisture levels moisture level from below 18 18 27 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 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 5Q Assembly of Tube Anchor to the Control Unit 4 The control unit and power unit require hard wiring The supply line wires into L1 and L2 N of t
19. slide completely for the delivery system operation except on tandem system 2 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 3 The time clock should be programmed to start the Flex Flo System often By running the system often long running periods are eliminated and the feeders are kept full When the Flex Flo System is used for filling poultry feeders a time clock should be utilized to ensure that all feeders are filled at the same time The Flex Flo System will have a better opportunity to keep up Position the hopper level control low in the last hopper 4 A safety switch is provided on the control unit to trip out the motor in the event that feed is packed inside If feed does get packed dislodge the feed from the drop tube and clean out the inside of the control unit which will allow the switch to close The hopper level control needs to maintain vertical positioning to keep the paddle swinging freely Check the adjustment regularly The control unit safety switch does not replace the hopper level control 5 When the Flex Flo System is used to convey high moisture feed the auger line should
20. 13 X3 13 LIOA 022 49 PNEG 914 Flex Flo iagrams 110V Control Uni D iring T ejqeoiade JO e2ujooejo pazis o soiioedeo pue sezis 10 21215 220 JO pesn Ou ul SI 5 5 O 4 xa 10 uomnejjejsul eu 20 se pasn si 5141 310 1 4 S i 1 o 2 x n 8 1 lt 1 B E OL 2 i 1 OL 5 1 o LA IVNIIAHH3LE OL 1 1 1 1 1 2019 3INLL LIOA 011 1 1 1 2010 LIOA OLL YOLOIN O13 X3 14 ei Li a ly ei a ea Ae Ne a a a 9 Si i a ig 2 LINN 1051409 OL 1041109 OL E 5 gg 9 5 in 2 gt SE 5 qm S e 6 S n ee m KE 5 Zb 855 D Lo 9 58 255 2 8 58 day icem ceoz dv L001 dv xg Go ALIAIXOdd ALIAIXONd ALINIXOMd HOLIMS ALIINIXOSd AV T30 M 3904 LIOA OLL L660 d V HOLIMS ALINWIXO Id
21. 2 HP 240 MAX 25 FLA 1 PHASE COIL RATING 208 240 VAC 50 60 Hz 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 MAX 25 FLA 3 PHASE COIL RATING 280 240 VAC 50 60 Hz DANGER High Voltage Will cause injury or death Lockout power before servicing 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 7 DANGER High Voltage Will cause injury or death Lockout power before servicing PNEG 914 Flex Flo 2 Decals ROTATING AUGER can crush and dismember Keep hands out of feed opening e Lockout power and secure auger before servicing _ 8 84 2 Decals ROTATING AUGER can crush and dismember Keep hands out of feed opening e Lockout power and secure auger before servicing PNEG 914 Flex Flo 3 Introduction Applications In poultry application Flex Flo Fill System conveys feed from bulk feed tank to hoppers inside the poultry building as shown in Figure 3A Other feed systems i e cycle plus chain feeder etc take the feed from the hopper to the desired locations in the building On this layout hopper level switches may be placed in more than one 1 hopper to assure that no hopper empties before the control unit
22. 3 96 6 86 7 92 5 49 4 27 4 27 7 32 8 23 5 79 4 57 4 57 7 92 8 99 6 10 472 4 88 8 38 9 30 6 40 4 88 5 18 8 99 10 06 6 71 5 03 5 49 9 45 10 52 7 01 5 18 5 79 10 06 10 97 7 32 5 33 5 64 12 PNEG 914 Flex Flo 4 Flex Flo Specifications English Metric Model 220 300 350 and HR with 5 Radius Elbow for 30 Boot X for Straight Boot m 30 45 60 30 45 60 3 05 3 35 3 51 3 96 4 11 4 27 5 49 4 57 9 45 6 10 5 18 5 79 10 06 6 40 5 33 6 10 10 52 6 71 5 64 Figure 4E Equipment Orientation Charts PNEG 914 Flex Flo 13 14 5 Installation A Improper installation methods of the hardware may cause permanent damage and CAUTION 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 Bo
23. 90 1 FLX 3489 5 7621 2 3 FLX 3448 4 FLX 3451 Proximity switch Micro Drop Tube Switch Description Plastic Drop Tube Switch 110 220V Micro Switch Box Assembly Wired NC Screw SDS 10 16 x 1 HWH ZN Grade 2 Drop Tube Switch Baffle Plate Drilled Drop Tube Housing Proximity Switch Ref Part 1 FLX 2425 Description Drop Tube 3 1 0 x 12 3 65 Meters 2 FLXDF 1172 Capacitive Proximity Switch NC 20 250 VAC 3 S 7906 1 2 Cord Connector PNEG 914 Flex Flo iagrams D iring T 220V Control Uni ejqeoidde JO suomeoyioeds opoo pazis 0 esnj pue sazis sepoo euorjeu 10 91215 220 opasJedns JO ajejOIA ABM Ou SI J 5 8 4 4 Jo uonejjejsui 104 e se oj si SIU 310 WNIWYAL ONS OL LINN TOHLNOO OL 022 ZW TWNIWYAL OL TO CONTROL UNIT OL 32072 LIOA 022 175 ee a tS Zitt E ee ee St ce 420719 AWIL LIOA 022 YOLOIN O 13 X314 TOMLNOO OL LINN 1054 09 OL LINN 103109 OL fo A xal d E dd d lad 8 a 22 gt gt m z 4 gt in a zz
24. RPM 3 4 HP 1 PH 60 Hz 115 230V 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 2673 60 FLX 2673 60R FLX 2674 50 FLX 2674 50R FLX 2674 60 FLX 2672 60R FLX 2674 60R DDPU 250 RPM 1 3 HP 1 PH 60 Hz 115 230V DDPU 250 RPM 1 2 HP 1 PH 60 Hz 115 230V DDPU 209 RPM 3 4 HP 1 PH 50 Hz 110 220V 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 60 FLX 3590 60R FLX 3591 50 FLX 3591 50R FLX 3591 60 FLX 3590 50R FLX 3591 60R DDPU 368 RPM 1 2 HP 1 PH 50 Hz 115 230V DDPU 441 RPM 1 2 HP 1 PH 60 Hz 115 230V DDPU 368 RPM 3 4 HP 1 PH 50 Hz 110 220V 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 37 6 Parts List Model 220 Unloader and Anchor Assembly e sso emmcee B e ronsar
25. X 4358 Adapter Plate Aluminum C Face N S FLX 4407 1 Phase P U Oil and Hardware NOTE order a gearbox with the opposite orientation rotated 1809 add to the end of these part numbers PNEG 914 Flex Flo 6 Parts List Drop Kit Kwik Attach Drop Kit Drop kit Kwik attach drop kit Drop Kit Parte Description FLX 2432 Model 220 Drop Kit Nylon Model 300 Drop Kit Nylon Model 350 Drop Kit Nylon Model 500 Drop Kit Nylon 5 280 Screw SDS 10 16 x 5 8 HWH ZN FLX 2441 Green Indicator Ball FLX 220 Model 220 Drop Half FLX 300 Model 300 Drop Half FLX 350 Model 350 Drop Half FLX 500 Model 500 Drop Half 5 8174 Screw MS 10 24 x 5 8 HWHS SS Model 220 300 350 500 10 Straight Tube CW 2008 4 Solid Braided Utility Cord FLX 2437 Model 220 Nylon Slide FLX 2438 Model 300 Nylon Slide FLX 2439 Model 350 Nylon Slide FLX 2440 Model 500 Nylon Slide 5 7931 Hex Nut 10 24 SS FLX 2442 Red Indicator Ball Kwik Attach Drop Kit Ref Part Description APCD 109 Kwik Attach Drop Kit for Model 220 236 Single 2276 Kwik Attach Drop Kit for Model 300 Single APCD 110 Kwik Attach Drop Kit for Model 220 236 Box of 10 2277 Kwik Attach Drop Kit for Model 300 Box of 10 Shut Off Slide for Kwik Attach Model 220 Kwik Attach M300 Drop Kit Slide Model 220 PVC Flex Flo Tube 10 3 Meters w Belled End Model 300 PVC Flex
26. allation EE 18 Ager TUDING ee ee 19 MET mo mm 21 Outlet Holes E 21 Drop Kit Installation 22 Kwik Attach Drop Kit Installation MEM 23 Pow r Unit and Control EE 24 Die ve ete _______ ____ _______ ____ 27 Auger Installation c 27 Extension Hopper xe Ete EEN 29 Te E ln GE EN Chapter Parts LiSt E 33 Flex Flo Feed Line Components 34 Direct Drive Power Unit Assemblies 35 Model 220 Unloader and Anchor Assembly eene rene iens 38 Model 300 350 and HR Unloader and Anchor Assembly 39 Model 500 Unloader and Anchor Assembly enn 40 Direct Drive and Tube 41 Belt Drive and T be en E 42 eu e _________________ _____ 43 BeltDrive POwWer UNIT TE 44 Direct Drive Power Unit 45 Drop 46 _ __ 47 Micro Drop Tube Switch Proximity Switch eege 48 Chapter 7 Wiring rec 49 220V _____ 49 DOV ECT c
27. cidental 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 of products manufactured or sold by GSI 9101239 1 CR rev7 DOC revised July 2009 PNEG 914 Flex Flo 53 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 consult
28. ck 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 1 meter from the drive unit and 1 6 meters above the ground do not exceed 70 dBa continuous A weighted sound pressure or 63 Pa instantaneous C weighted sound pressure Sound Signs and Warnings The following pages show you exactly where the safety and warning decals should be placed on the Flex Flo System If a decal is missing or unreadable please contact your dealer or the GSI group for a free replacement For guidance or assistance on any issues relating to the safe use of the Flex Flo System Contact GSI Group 1004 E Illinois St Assumption IL 62510 Phone 1 217 226 4421 Fax 1 217 226 4420 PNEG 914 Flex Flo THE GSI GROUP FLX 4512 ELECTRICAL BOX ASSEMBLY CONTACT RATING 1 1
29. closed 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 incorrectly fitted is a serious misuse of the machine and
30. d 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 10 4 Flex Flo Specifications English Metric Auger Tube Diameter Carrying Capacity based on 40 Ibs cubic ft Maximum Particle Size and Feed Type Model 220 Flex Flo Systems Specifications Model 220 212 55 mm 15 Ibs min 50 Ibs min 7 kg min 22 kg min 900 Ibs hr 3000 Ibs hr 420 kg hr 1400 kg hr 1 8 3 175 mm x 1 2 12 7 mm L max moisture P content 18 Model 300 The Feed Tank Connections Feed Tank Orientation Positioning the feed tank in line with the Flex Flo System will provide the most trouble free operation possible Avoid unnecessary elbows and curves to ease system installation A feed tank with a 30 unloader is generally required to be at least 10 1 2 3 2 m away from the building With a straight unloader the tank will be approximately 4 1 22 m farther away from the building in order to make auger tube connections The reference points are based upon the height where the system enters the building Different unloaders with various elbows and curves used provide different entrance opportunities The distances are achieved by modifying and adjusting the elbows and tubing as needed See Table on Page 1 1 English or see Table on Page 12 Metric for tank placement recommendations 30 Un
31. e B 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 3 PH 50 Hz 190 380V Description 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 8 PH 60 Hz 600V DDPU 358 RPM 1 HP 3 PH 60 Hz 208 230 460V E P FLX 4043 FLX 4043R FLX 4041 1PH FLX 4041 1PHR DDPU 358 RPM 1 2 HP 1 PH 60 Hz 208 230 240V E P 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 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
32. e 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 1 rope at a time Check the rotary slide to be sure it is centered over the outlet hole 6 Slide the rotary slide to its open position by pulling the appropriate rope Mark the short rope end at the point where it enters the guide hole Tie a knot on the rope at the mark The location of the knot will show at a glance if the slide is open or closed 22 PNEG 914 Flex Flo 5 Installation 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 the auger tube 9 Two 2 screws are supplied for attaching an optional drop tube See Figure 5N on Page 22
33. ed may result in minor or moderate injury CAUTION used without the safety alert symbol indicates a CAU N potentially hazardous situation which if not avoided may result in property damage ill N OTE NOTE indicates information about the equipment that you should pay special attention PNEG 914 Flex Flo 1 Safety General Safety Statement Our foremost concern is your safety and the safety of others associated with grain handling equipment 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 you are responsible to know what requirements hazards and precautions exist and inform all personnel associated with the equipment or in the area Safety precautions may be required from the personnel Avoid any alterations to the equipment which may produce a very dangerous situation where SERIOUS INJURY or DEATH may occur Electrical Safety An adequate and safe power supply to the Flex Flo System unit is essential for safety A competent and qualified electrician must undertake all electrical wiring All wiring is to be installed in accordance with all local and National Standards and Regulations relevant to your country and region Electrical safety devices emergency stops and main isolators are recommended with the Flex Flo System and are essential for safety This should be installed as indicated in the en
34. ed before installations are made 1004 E Illinois St Assumption IL 62510 0020 Phone 1 217 226 4421 Fax 1 217 226 4420 www gsiag com Copyright 2010 byG D Group Printed in the USA
35. er Collar FLX 3937 FLX 2586 FLX 2181 FLX 4743 FLX 4772 Twin out Unloader No Anchor PVC 1006 PVC 1007 10 PVC Straight Tube PVC 1101 PVC 1001 PVC 1002 PVC 1003 PVC 1002 45 Elbow 5 Radius PVC 1003 is 6 Radius S 7313 Screw Eye 1 4 20 x 3 1 2 ZN Open Eye Screw FLX 4687E Extension Unit See Direct Drive Power Unit Assembly Part Numbers on Pages 35 37 1 2 HP Belt Drive Motor 110 220V 1 PH 60 Hz Farm Duty 012 1 012 1 012 1 012 1 5 8 Shaft 3 4 HP Belt Drive Motor 110 220V 1 PH 60 Hz Farm Duty N N N 1 1 1 3 3 S S 4 S 5 7 7 10 11 12 13 1 HP Belt Drive Motor 110 220V 1 PH 60 Hz 1750 RPM 100 1 100 1 100 1 100 1 5 8 Shaft FLX 4496 FLX 4496 FLX 4496 FLX 4497 FLX 4496 Direct Drive Control Unit 220V FLX 4179 FLX 4179 FLX 4179 FLX 4179 Belt Drive Control Unit No Motor FLX 2427 FLX 2427 FLX 2427 FLX 2429 FLX 2427 12 Drop Tube FLX 2428 FLX 2428 FLX 2428 FLX 2430 FLX 2428 6 Telescoping Drop Tube N N N N wech AR S S S 15 S 16 17 PNEG 914 Flex Flo 6 Parts List Direct Drive Power Unit Assemblies Gearbox orientation type A UU JL Gearbox orientation type PNEG 914 Flex Flo 35 6 Parts List Direct Drive Power Unit Assemblies Parts List Direct Drive Power Unit Gearbox Orientation Part Type A Typ
36. ex Socket Cap Screw Model 500 Flat Washer 5 16 USS SAE YDP Grade 2 sme 3 1 4 300 5 FC 00 FLx0F 1183 Feed Anchor Bolt 1 4 20 x 1 1 4 Socket Head PNEG 914 Flex Flo 41 6 Parts List Belt Drive and Tube Anchor 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 Model 300 Belt Driver Model 350 Belt Driver Model 300 350 Auger Lock Clamp Pin Bolt SHCS 5 16 18 x 1 1 2 Model 300 FLX 2316 Model 220 Tube Anchor Plate FLX 2318 Model 350 Tube Anchor Plate 5 845 Washer 5 16 USS SAE YDP Grade 2 Hex Nut 5 16 18 YDP Grade 2 2 1 4 Tube Clamp Model 220 FLX 2974 Model 500 Auger Lock Clamp Pin 5 4312 Set Screw 5 16 18 x 1 2 SQ HD Refs _____ 8 8 EE E RE Se SC 9 10 11 11 11 11 12 13 14 5 1 42 PNEG 914 Flex Flo 6 Parts List Control Unit ___ m 1 21 FLX 4496 220 300 350 Control Unit 220V FLX 4497 500 Control Unit 220V FLX 4512 Control Unit Electrical Box 220V S 7604 Red Light 250V 1 20 5060 Toggle Switch SPST 15A w ON OFF Boot for Toggle Switch FLX 4260 220 300 350 Control Unit Body Assembly FLX 3819 500 Control Unit Body Assembly 15 70 0129 16 FLX 4561
37. ft lbs If the auger end is not in the appropriate orientation for connection the driver assembly may be rotated by either turning the motor shaft with a wrench or by turning the large pulley to rotate the driver assembly 5 Remove the anchor assembly and the rear access panel from the bottom section of the extension hopper Mount the bottom section to the top section with 1 4 20 machine screws provided with the hopper The bottom section may be mounted in three 3 various directions See Figure 5Z on Page 30 PNEG 914 Flex Flo 29 5 Installation Extension Hopper Installation Continued Feed out of hopper Feed out ofhopper _____ Feed out of hopper gt 1 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 30 PNEG 914 Flex Flo 5 Installation 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 Figure 5AB Operation Guidelines 1 Open the unloader
38. g Flat Washer 5 16 USS SAE YDP Grade 2 Bolt HHTB 5 16 18 x 2 1 2 ZN Grade 2 S 4275 Bolt HHTB 5 16 18 x 3 4 ZN Grade 5 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 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 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 Black Strain Relief 44 PNEG 914 Flex Flo 6 Parts List Direct Drive Power Unit 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 3 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 Pinion 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 FL
39. ger 28 PNEG 914 Flex Flo 5 Installation Extension Hopper Installation 1 To ease the installation mount the extension hopper top section to the Flex Flo tubing NOTE A Slide the tube clamp on the hopper tube anchor prior to attaching it to the tubing B Make certain when mounting the power unit and the tubing that they are attached to the access Slide side When mounted in this orientation the incoming auger 15 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 Any additional support given to the extension hopper makes for a more solid system and is desirable Take special care if or when the support is modified that the operation of the system and the ability to do a general maintenance are not hindered 3 Mount the unloader under the control unit The control unit should be assembled together prior to mounting This assembly includes the driver assembly Suspend the control unit firmly from the ceiling Support holes are provided on the tube anchor Figure 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
40. he relay in the control unit The motor leads wire into the M1 and M2 of the relay in the control unit Auxiliary switch is wired into the male and female spade terminal of the control unit See Wiring Diagram on Pages 49 52 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 to the Figure 5S Direct Drive Power Unit Drive Unit PNEG 914 Flex Flo 25 26 5 Installation Belt Drive Power Control Unit 1 10 11 12 13 14 the tube anchor to the control unit body with flat washer on each of the four 4 5 16 x 3 4 bolts See Figure 5Q on Page 25 for more details 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 Bolt the two 2 mounting brackets together with the four 4 bolts and washers provided 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 Slide and clamp a tube coupler on the anchor Figure 5T
41. hopper requires feed All switches must be wired in parallel so that any one 1 switch can start the system Figure 3A Poultry Application Layout In swine applications Flex Flo Fill System conveys feed from bulk feed tanks to each individual feeder i e S S hog feeder drop feeder etc directly as shown in Figure SB It is at this location that feed is being consumed A feed level control is installed at the end to shut off the system after all feeders are filled Figure 3B Swine Application Layout Background The Flex Flo Fill System consists of a combination of PVC tubes and preformed PVC elbows A special PVC cement is used to connect the tubes and elbows The PVC tubes are available in four 4 different sizes The PVC tube contains a rotating auger which conveys the feed to the different outlet holes The auger is driven by a direct drive power unit or a belt drive power unit Building Safety If you are intending to install the Flex Flo System at high levels and or suspended from a building structure it is important that you check the structural integrity of the building to carry the additional load For information on the imposed loads on the building by the Flex Flo System please contact the dealer or the GSI Group Installation Sequence This manual outlines the recommended order for the installation of the Flex Flo System Following this guideline will provide the safest and easiest metho
42. loader Figure 4B 100 Ibs min 45 kg min 6000 Ibs hr 2700 kg hr Shelled corn or pellets 3 16 4 76 mm x 1 2 12 7 mm ground corn Model 350 Figure 4A 220 Ibs min 100 kg min 13200 Ibs hr 6000 kg hr Larger feed fragments like shelled corn or pellets 3 8 9 52 mm x 1 25 4 mm L Model 500 Figure 4C Model 300 p 350 Model 500 HR 35 5 85 s ae mm 90 mm mm 90 mm 50 Ibs min 22 kg min 3000 Ibs hr 1400 kg hr High moisture shelled corn up to 27 or ground feed 3 8 9 52 mm dia x 3 4 19 05 mm long PNEG 914 Flex Flo 4 Flex Flo Specifications English Metric Tank Centerline to Building Entrance Distance X from Given Height English PNEG 914 Flex Flo Model 220 with 10 Radius Elbows X for 30 Boot ft H _ ee ea e X for Straight Boot ft 7 0 14 0 12 0 18 5 17 0 11 0 21 0 16 0 14 5 12 0 23 0 17 0 15 0 16 0 29 0 21 0 165 30 5 21 5 25 5 21 0 19 5 27 0 22 0 20 0 15 0 28 0 20 0 17 0 16 0 30 0 21 0 17 5 18 0 36 0 23 0 18 5 37 5 235 32 5 25 0 22 0 34 0 26 0 22 5 19 0 35 0 24 0 19 5 20 0 37 0 25 0 20 0 Model 500 with 6 Radius Elbow X for 30 Boot ft ft x x s 39 5 29 0 24 0 41 0 30 0 25 0 X for Straight Boot ft
43. m z zz in z E 3 E b 5 5 W a E 8 8 8 i a a 7 8 5 5 Pr 8 ER 8 Sh m m um sg 500 se 200 D D P 3979 2 8 3 B 525 920 zB AgS 7 5 A7 8 8 Dep ama cgec dv 200 200 7 HOLIMS ALIWIXOSd HOLMS ALIWIXOSd HOLIMS ALIWIXOMd HOLIMS Av DO M 3801 bettie ee oot ee ee ee eater ee ee ee oe EE toe be Boe eee eh ee oe eR ee eee eee eh or SS SSS SS See LINN TOHLNOO OL OL OMd OL JWW OL TO CONTROL UNIT TIVNINH3I OL onda avia OL ATW OL AY130 ANIL AW140 AWIL IVNOLLdO AOL HOLIMS 1OHINOO T3A31 H3ddOH Z08 X 14 AO0LL AOZZ HOLIMS T3A31 H3ddOH 660 dV AOLL AOZZ HOLIMS OWOIIN M AENL dOHG 0660 HOLIMS 13 31 H3ddOH HO HOLIMS 38fl L OHOIN sejou Bunsixe eui esn sJojoeuuoo zy 2 ejenbepe eJnsse SO AWIL TWNOILdO LIOA 022 1 27 81 LINN 009 6 1 LINN TOM LNOO 096 ANY 00 022 96 1 LINN TOYLNOD O
44. ns in the section entitled Cementing Procedure on Page 21 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 5 Installation 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 temperature is below 40 F 4 C or above 85 F 29 C
45. on of the auger tubes and auger is complete insert the inspection clean out plate or the optional unloader switch The inspection clean out plate is to be installed per the following instructions See Figure 5F 1 Back off both wing nuts to the stud ends 2 Slide the plate onto the lower side of the unloader opening 3 Move the plate first against the side of the unloader then upward toward the top of the unloader 4 Tighten the wing nuts while holding the plate steady Figure 5F Clean out Plate Installation 16 PNEG 914 Flex Flo 5 Installation Feed Tank Collar The standard bulk feed tank is supplied with a 16 40 64 cm hopper opening If needed 22 55 88 cm hopper openings are also available Consult the dealer for specific ordering instructions Restrictor Adjustment The restrictor may be adjusted to allow more feed flow Do not modify the 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
46. one 1 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 ae 100 150 200 250 300 350 400 500 600 700 Sue 15 22 5 30 60 75 90 105 120 150 180 210 12 12 12 12 12 12 12 12 10 10 8 12 12 12 12 10 10 8 euis 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 10 11 12 13 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 Control Unit 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 33 6 Parts List 34 Flex Flo Feed Line Components BLK 10847 BLK 10847 BLK 10847 BLK 10847 BLK 10847 16 45 Hopper Extension Kit w Collar BLK 10587 BLK 10587 BLK 10587 BLK 10587 BLK 10587 22 16 60 Hopper Extension Kit w Hopper Collar 22 16 67 Hopper Extension Kit w Hopp
47. ontinued 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 27 Stretching the auger too far will cause premature wear at the inside bends of the PVC tubing Stretching the auger not far enough will cause premature wear at the outside bends of the PVC tubing 8 For ease of trimming the auger pull the auger out an additional 8 20 cm past the mark and clamp it at the unloader This clamping releases tension at the mark and thus eases cutting See Figure 5W 9 Twist the unloader anchor into the auger and clasp the auger end in the clamp pin 10 Mount the anchor in the unloader 11 Place the cannonball inside the unloader 12 Mount the cover on the control unit 13 Place the inspection clean out plate in the unloader Figure 5W Cutting the Auger Brazing the Auger 1 Make sure both ends are cleaned 2 Position the auger in an angle iron and clasp it securely to align it for brazing See Figure 5X 3 Braze both ends together Use a bronze flux coated rod Make sure the auger does not get too hot which might cause the auger to warp 4 After the brazing is performed the joint should be allowed to air cool 5 Once the auger has cooled install the auger with the brazed joint closer to the power unit Grind flush and smooth Brazing Figure 5X Brazing the Au
48. ontrol 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 lbs If the auger end is not in the appropriate orientation for connection the driver assembly may be rotated by turning the motor drive shaft 4 Pull and release the free end of the auger gently a few times This action should relax the auger into its natural position 5 A certain mechanical stress must be applied when installing the auger therefore stretching the auger is very important This is performed by drawing the auger out of the tubing An important factor is the total system length The auger should be drawn out of the tubing 2 5 cm for every 50 15 m of length for single feed tanks For tandem systems stretch the auger 4 10 cm for every 50 15 m of length 6 While the auger is in the relaxed state mark the auger at the unloader inlet Wm Stretch flex auger Stretch flex auger Single feed tank 2 50 mm per 50 15 m of length Tandem feed tank 4 100 mm per 50 15 m of length Mark here Figure 5V Stretching the Auger PNEG 914 Flex Flo 27 5 Installation Auger Installation C
49. ot 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 5 Installation Slide Gate Installation Insert the slide into the transfer plate The slide must be in its operating position prior to attaching the slide shield to the transfer plate Use two 2 5 16 18 x 1 truss head tap bolts to mount the slide shield See Figure 5D Bolt unloader to transfer plate unloader brace assembly as shown in Figure 5E Note orientation of these bolts See Figure 5E Figure 5E Description EE 16 67 16 Hopper Collar 24 Holes 16 60 Hopper Collar 24 Holes 16 60 Hopper Collar 27 Holes 16 60 Hopper Collar 18 Holes 16 30 Black Plastic Boot FLX 2194C 16 30 Clear Plastic Boot ae 16 Straight Black Plastic Boot FLX 2195C 16 Straight Clear Plastic Boot FLX 4869 16 Double Straight Black Boot BLK 10496 Transfer Plate 2 2 2 2 3 Unloader Brace om mE 2 Slide Gate Slide Gate Shield 5 16 x 1 Truss Head Machine Screw 5 16 18 Nylon Insert Nut 5 16 Nylon Washer Screw MS 5 16 18 x 1 RHS ZN Grade 2 11 S 396 Hex Nut 5 16 18 YDP Grade 2 PNEG 914 Flex Flo 15 5 Installation Inspection Clean out Plate Installation Once the installati
50. rs and moving parts not included Farm Fans Portable and Tower Dryer Frames and 5Y Portable dryer screens included Zimmerman Internal Infrastructure ears 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 12t 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 1 PRODUCT MANUFACTURED OR SOLD BY GSI OR 1 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 in
51. sary the elbow at the desire length to ensure that the auger tubing will be horizontal See Figure 5K on Page 20 for proper cutting dimensions of the elbows at specific degree angles 3 Fit and clamp a second elbow around the unloader outlet 4 Slide the non belled end of the straight tubing into the belled end of the building elbow Hold the straight tubing in the desired mounting position Mark and cut the unloader elbow at the point where it and the straight tubing intersect PNEG 914 Flex Flo 19 5 Installation Auger Tubing Installation Continued 5 Remove the non belled 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 21 When the auger tubing between the unloader and the building is 15 4 57 m or longer the tubes should be supported Locate and cut the outlet holes needed in the remaining straight tubes For the exact size of outlet holes see section titled Outlet Holes on Page 21 Once ALL of the outlet holes are made and the tubing is dry fitted glue or clamp the tubes together per the instructio
52. ty 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 Warranty Period Performer Series Direct Drive Fan Motor Warranty prorated from list price AP Fans and Flooring All Fiberglass Housings Lifetime 0 to 3 years no cost to end user 3 to 5 years end user pays 25 All Fiberglass Propellers Lifetime 5 to 7 years end user pays 50 Feeder System Pan Assemblies Cumberland 7 to 10 years end user pays 75 Feed Tubes 1 3 4 and 2 00 P Feeding Watering Warranty prorated from list price Systems Centerless Augers 0 to 3 years no cost to end user Watering Nipples 3 to 5 years end user pays 50 Grain Systems Grain Bin Structural Design T Motors burner components Grain Systems Portable and Tower Dryers 2 Yea

Installation and Operation of Flex-Flo

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