SmartIR Feed Sensor Unit Owner's Manual

SmartIR Feed Sensor Unit Owner's Manual
Smart IR Sensor
Installation and Operation Manual
PNEG-1640
Date: 12-21-11
PNEG-1640
2
PNEG-1640 Smart IR Sensor
Table of Contents
Contents
Chapter 1 Safety .....................................................................................................................................................4
Safety Guidelines ...................................................................................................................................4
Chapter 2 Application ............................................................................................................................................6
Chapter 3 Installation ............................................................................................................................................7
Chapter 4 Basic Operation ....................................................................................................................................8
Chapter 5 Delay Time ............................................................................................................................................9
Check Delay Time Setting ......................................................................................................................9
Setting/Adjusting the Delay Time .........................................................................................................10
Delay Time Operation ..........................................................................................................................10
Delay Time By-Pass .............................................................................................................................10
Chapter 6 Run Time .............................................................................................................................................11
Maximum Run Time .............................................................................................................................11
Check Maximum Run Time Setting ......................................................................................................12
Setting/Adjusting the Maximum Run Time ...........................................................................................12
Maximum Run Time Operation ............................................................................................................13
Resetting the Maximum Run Timer ......................................................................................................13
Chapter 7 Sensitivity ...........................................................................................................................................14
Chapter 8 Replacement Parts .............................................................................................................................16
Smart IR Sensor Assembly (FLX-4951) ...............................................................................................16
Chapter 9 Wiring Diagrams .................................................................................................................................18
Alarm Wiring Diagram ..........................................................................................................................18
AP Wiring Diagram ...............................................................................................................................19
Choretime Wiring Diagram ...................................................................................................................21
Universal Wiring Diagram ....................................................................................................................22
Chapter 10 Warranty ............................................................................................................................................23
PNEG-1640 Smart IR Sensor
3
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. It is the
responsibility of the owner/operator to inform anyone operating or working in the area of this equipment
of these safety guidelines. To help you recognize this information, we use the symbols that are defined
below. Please read the manual and pay attention to these sections. Failure to read this manual and 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.
DANGER
WARNING
4
DANGER indicates a hazardous situation which, if not
avoided, will result in death or serious injury.
WARNING indicates a hazardous situation which, if not
avoided, could result in death or serious injury.
CAUTION
CAUTION, used with the safety alert symbol, indicates a
hazardous situation which, if not avoided, could result in
minor or moderate injury.
NOTICE
NOTICE is used to address practices not related to
personal injury.
PNEG-1640 Smart IR Sensor
1. Safety
Install and Operate Electrical Equipment Properly
Electrical controls should be installed by a qualified electrician
and must meet the standards set by the National Electrical Code
and all local and state codes.
Disconnect and lock out all power sources before installing
wires/cables or servicing equipment.
Electric Shock Hazard
Prepare for Emergencies
Be prepared if fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors, ambulance service,
hospital, and fire department near your telephone.
Keep Emergency Equipment
Quickly Accessible
Wear Protective Clothing
Wear close-fitting clothing and safety equipment appropriate
to the job.
Eye Protection
Remove all jewelry.
Tie long hair up and back.
Gloves
Wear safety glasses at all times to protect eyes from debris.
Wear gloves to protect your hands from sharp edges on plastic
or steel parts.
Wear steel-toed boots to help protect your feet from falling
debris. Tuck in any loose or dangling shoestrings.
Steel-Toed Boots
Respirator
A respirator may be needed to prevent breathing potentially
toxic fumes and dust.
Wear a hard hat to help protect your head.
Hard Hat
Wear appropriate fall protection equipment when working at
elevations greater than six feet (6').
Fall Protection
PNEG-1640 Smart IR Sensor
5
2. Application
The Smart IR Sensor is used as the primary control for a Flex-Flo feed line. It uses “infrared” technology
to detect the presence of all types of mash and pellet feeds. It is designed to be used in place of a proximity
switch or drop tube switch and will operate with or without the aid of a power relay. The sensor is installed
underneath a control unit between the powerhead drop (funnel) and the drop tube at the end of a Flex-Flo
feed system.
Figure 2A
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PNEG-1640 Smart IR Sensor
3. Installation
The sensor is installed underneath a control unit between the powerhead drop (funnel) and the drop tube
at the end of a Flex-Flo feed system. The control unit power head drop funnel must be an FLX-2017
or equivalent with an outlet measuring approximately 3-1/4" O.D. Use two (2) #10 x 3/4" self-drilling
screws (S-8045) (supplied) to fasten the Smart IR Sensor to the powerhead drop funnel and drop tube as
shown in Figure 3A.
Figure 3A
PNEG-1640 Smart IR Sensor
7
4. Basic Operation
The Smart IR Sensor will detect when the last feeder is full and immediately shut the Flex-Flo system off,
the yellow “Product Detected” LED will be lit and the display will read “Full”. When the feed falls away from
the sensor, it will count down a pre-determined delay time and then turn the Flex-Flo system back on.
It also includes a maximum run timer that will shut the system down if the auger runs too long in case of
an empty or bridged feed tank or a feed spill. Alarm contacts are available to provide remote notification
of a maximum run situation.
Figure 4A Full
Figure 4B Maximum Run Time Alarm
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PNEG-1640 Smart IR Sensor
5. Delay Time
Delay time is the length of time after the IR sensor no longer detects feed, before it turns the Flex-Flo
system back on again. It is used to prevent short-cycling of the Flex-Flo system. Excessive short-cycling
will reduce the life of the motor and/or Flex-Flo system. It can also result in the motor running hot and
continually activating the thermal reset.
The required delay time setting depends on how quickly the animals can empty the feeders once the feed
system is full. Large capacity feeders or younger, smaller animals will allow for longer delay time settings.
For best results, use a slightly less delay time setting than the time it takes the animals to completely empty
the feeder. Always check a pen where there are the most and largest animals and at the time of day when
consumption is highest. As the animals get older and larger and consume more feed, decrease the delay
time setting to prevent feeders from going empty.
The range of delay time setting for the Smart IR Sensor is from 0 hours and 0 minutes to 23 hours and
59 minutes.
Check Delay Time Setting
To check the delay time setting, at any time, push and hold the “On Delay Time” button.
Figure 5A Checking Delay Time
PNEG-1640 Smart IR Sensor
9
5. Delay Time
Setting/Adjusting the Delay Time
To adjust the delay time setting, at any time, while pushing and holding the “On Delay Time” button, push
either the “arrow up” or “arrow down” button. Each time an “arrow” button is pushed, the time will change
by 1 minute. To make the time scroll faster, continue to hold the “arrow” button down for several seconds.
Figure 5B Adjusting the Delay Time
Delay Time Operation
Once the yellow “Product Detected” indicator light goes off, the delay time will begin to count down from
its maximum setting. During this time, the green “Auger” indicator light will flash. After the delay time
reaches 0.00, the “Auger” indicator light will turn on solid and the Flex-Flo system will start.
Delay Time By-Pass
When the Smart IR Sensor is in delay time, the green “Auger” indicator light will be flashing. It is not
necessary to wait for the delay time to expire before the auger will start-up. To make the auger start
immediately, by-pass the delay time for one cycle only, by pressing and holding the “On Delay Time”
button down for 5 second.
10
PNEG-1640 Smart IR Sensor
6. Run Time
Once the Flex-Flo system starts, the display will count up showing the hours/minutes while keeping track
of auger run time for the current cycle.
Figure 6A Auger Running
Maximum Run Time
Maximum run time is the maximum time the Flex-Flo system will run each cycle. If this time expires, the
Flex-Flo system will shut off and will not start again until the control is reset. The maximum run time is used
to shut the Flex-Flo system off in case of an empty or bridged feed tank or a feed spill. In the case of an
empty or bridged feed tank, it will prevent the Flex-Flo system from running empty for extended periods of
time. In the case of a feed spill, it will prevent the Flex-Flo system from emptying the remaining contents
of the feed tank on the floor.
To determine the optimum maximum run time, find the longest possible fill time by measuring the time
required to completely fill all feeders when they are empty. Then add approximately 10 minutes to this time
to account for variability.
The range of adjustment for the maximum run time is from 1 minute to 23 hours and 59 minutes.
PNEG-1640 Smart IR Sensor
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6. Run Time
Check Maximum Run Time Setting
To check the maximum run time setting, at any time, push and hold the “Maximum Run Time” button.
Figure 6B Checking Maximum Run Time Setting
Setting/Adjusting the Maximum Run Time
To adjust the maximum run time setting, at any time, while pushing and holding the “Maximum Run Time”
button, push either the “arrow up” or “arrow down” button. Each time an “arrow” button is pushed, the time
will change by 1 minute. To make the time scroll faster, continue to hold the “arrow” button down for
several seconds.
Figure 6C Adjusting the Maximum Run Time
12
PNEG-1640 Smart IR Sensor
6. Run Time
If no maximum run time is desired, this feature can be disabled. To shut off the maximum run time, follow
the adjustment procedure on Page 12. Using the “arrow down” button, decrease the time to 1 minute.
Press the “arrow down” button once more and the display will show “OFF”.
IMPORTANT: Turning the maximum run timer OFF is not recommended.
Figure 6D Disabling the Maximum Run Time Feature (Not Recommended)
Maximum Run Time Operation
During normal operation, when the Flex-Flo system is running, the display will count up at 1 minute
increments. If the displayed time reaches the maximum run time setting before the feed line is full, the
Flex-Flo system will shut off. At that time, the display showing the maximum run time setting will begin to
flash alternately with the red “Alarm” indicator light. The alarm contacts inside the Smart IR Sensor will
now change state. If these contacts are being utilized, it will send a signal to a remotely connected alarm
device (not provided). IMPORTANT: The first cycle, after power loss or resetting of alarm, will have a
maximum run time of twice the programmed value.
Resetting the Maximum Run Timer
The Flex-Flo system will not restart automatically once the maximum run time alarm has been activated.
To reset the Smart IR Sensor to automatic mode and disable the alarm, re-cycle the power, in one of
three (3) ways:
1. At the Smart IR Sensor, push and hold the “Maximum Run Time” button for 5 seconds.
2. At the Flex-Flo control unit, switch the toggle “off” then back “on” again.
3. At the main circuit board, switch the controlling circuit breaker “off” then back “on” again.
PNEG-1640 Smart IR Sensor
13
7. Sensitivity
No sensitivity setting is required. The infrared technology that is used in this sensor is not affected by
temperature, humidity or type of feed. If the sensor fails to operate properly, disconnect the sensor from
the powerhead drop above and use a soft cloth to clean the dust from inside. If it still does not operate
properly, contact the nearest AP/Cumberland dealer to aid in troubleshooting.
14
PNEG-1640 Smart IR Sensor
NOTES
PNEG-1640 Smart IR Sensor
15
8. Replacement Parts
Smart IR Sensor Assembly (FLX-4951)
16
PNEG-1640 Smart IR Sensor
8. Replacement Parts
Smart IR Sensor Assembly (FLX-4951) Parts List
Ref #
Part #
Description
Qty
1
FLX-5000
Infrared Sensor Housing Assembly
1
2
FLX-5002
Infrared Sensor Insert Assembly
1
3
FLX-5003
Infrared Sensor Power Board Assembly
1
4
FLX-5001
Infrared Sensor Connector Cable
1
5
FLX-5004
Infrared Sensor Face Plate Assembly
1
6
S-8045
Screw, SDS #10 x 3/4" HWH SS 410
4
PNEG-1640 Smart IR Sensor
17
9. Wiring Diagrams
Alarm Wiring Diagram
18
PNEG-1640 Smart IR Sensor
9. Wiring Diagrams
AP Wiring Diagram
PNEG-1640 Smart IR Sensor
19
9. Wiring Diagrams
AP Wiring Diagram (Continued)
20
PNEG-1640 Smart IR Sensor
9. Wiring Diagrams
Choretime Wiring Diagram
PNEG-1640 Smart IR Sensor
21
9. Wiring Diagrams
Universal Wiring Diagram
22
PNEG-1640 Smart IR Sensor
10. 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:
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%
Feeder System Pan Assemblies
5 Years **
Feed Tubes (1-3/4" and 2.00")
10 Years *
** Warranty prorated from list price:
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
Grain Systems
Farm Fans
Zimmerman
Portable and Tower Dryers
2 Years
Portable and Tower Dryer Frames and
Internal Infrastructure †
5 Years
AP Fans and Flooring
Cumberland
Feeding/Watering
Systems
5 to 7 years - end-user pays 50%
7 to 10 years - end-user pays 75%
† Motors, burner components
and moving parts not included.
Portable dryer screens included.
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 (12th) month from the date of purchase
and continuing until the sixtieth (60th) 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 MANUFACTURED OR SOLD BY GSI OR (II) ANY ADVICE,
INSTRUCTION, RECOMMENDATION OR SUGGESTION PROVIDED BY AN AGENT, REPRESENTATIVE OR
EMPLOYEE OF GSI REGARDING OR RELATED TO THE CONFIGURATION, INSTALLATION, LAYOUT, SUITABILITY
FOR A PARTICULAR PURPOSE, OR DESIGN OF SUCH PRODUCTS.
GSI shall not be liable for any direct, indirect, incidental or consequential damages, including, without limitation, loss of
anticipated profits or benefits. The sole and exclusive remedy is set forth in the Limited Warranty, which shall not exceed
the amount paid for the product purchased. This warranty is not transferable and applies only to the original end-user. GSI
shall have no obligation or responsibility for any representations or warranties made by or on behalf of any dealer, agent
or distributor.
GSI assumes no responsibility for claims resulting from construction defects or unauthorized modifications to products
which it manufactured. Modifications to products not specifically delineated in the manual accompanying the equipment at
initial sale will void the Limited Warranty.
This Limited Warranty shall not extend to products or parts which have been damaged by negligent use, misuse, alteration,
accident or which have been improperly/inadequately maintained. This Limited Warranty extends solely to products
manufactured by GSI.
Prior to installation, the end-user has the responsibility to comply with federal, state and local codes which apply to the
location and installation of products manufactured or sold by GSI.
9101239_1_CR_rev7.DOC
PNEG-1640 Smart IR Sensor
(revised July 2009)
23
This equipment shall be installed in accordance with
the current installation codes and applicable
regulations which should be carefully followed in all
cases. Authorities having jurisdiction should be
consulted before installations are made.
This product covered by U.S. Patent # 8,056,506.
1004 E. Illinois St.
Assumption, IL 62510-0020
Phone: 1-217-226-4421
Fax: 1-217-226-4420
www.gsiag.com
Copyright © 2011 by
Printed in the USA
Group
CN-206383
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