Cumberland Flex-Flo FLX-5350 User manual

PNEG-2223
Flex-Flo Control Unit with Auto
Calibration
For 208-230 Volt, 1 PH and 3 PH Applications
Operation Manual
PNEG-2223
Version: 3.0
Date: 02-25-20

2 PNEG-2223 Flex-Flo Control Unit with Auto Calibration
All information, illustrations, photos, and specifications in this manual are based on the latest
information available at the time of publication. The right is reserved to make changes at any
time without notice.

Table of Contents
PNEG-2223 Flex-Flo Control Unit with Auto Calibration 3
Contents
Chapter 1 Safety .....................................................................................................................................................4
Safety Guidelines ...................................................................................................................................4
Cautionary Symbols Definitions .............................................................................................................5
Safety Cautions ......................................................................................................................................6
Safety Sign-Off Sheet ............................................................................................................................7
Chapter 2 Operation and Maintenance ................................................................................................................8
Standard Systems ..................................................................................................................................8
Extension Systems .................................................................................................................................8
Indicator Lights Under Toggle Switch ....................................................................................................8
Manual ON Button ..................................................................................................................................9
Safety Backup Switch Time Delay .........................................................................................................9
Safety Backup Switch Sensitivity .........................................................................................................10
Calibration Mode ..................................................................................................................................10
Auto Calibration at First Time Start-Up ................................................................................................10
Manual Calibration ...............................................................................................................................10
Alternate Manual Calibration ................................................................................................................10
Auto Calibration ....................................................................................................................................10
Bypass Mode .......................................................................................................................................11
Error Signals ........................................................................................................................................11
Replacing Top Circuit Board ................................................................................................................11
Chapter 3 Parts List .............................................................................................................................................12
Flex-Flo Control Unit (FLX-5350) .........................................................................................................12
Chapter 4 Wiring Diagrams .................................................................................................................................14
Flex-Flo Control Unit Used with 5 Wire Sensor ....................................................................................14
Flex-Flo Control Unit Extension System - Dependent ..........................................................................15
Flex-Flo Control Unit Extension System - Independent .......................................................................18
Flex-Flo Control Unit Used with Hopper Level Controls .......................................................................19
Flex-Flo Control Unit Used with IR Plus Feed Sensor .........................................................................20
Flex-Flo Control Unit Used with IR Plus Feed Sensor as Hopper Level Controls ................................21
Flex-Flo Control Unit Used with Smart IR Sensor ................................................................................22
Flex-Flo Control Unit Used with 3 Phase Power ..................................................................................23
Flex-Flo Control Unit Used with Universal Sensor ...............................................................................24
Chapter 5 Warranty ..............................................................................................................................................25

4 PNEG-2223 Flex-Flo Control Unit with Auto Calibration
1. Safety
Safety Guidelines
Safety guidelines are general-to-specific safety rules that must be followed at all times. This manual is
written to help you understand safe operating procedures and problems that can be encountered
by the operator and other personnel when using this equipment. Read and save these instructions.
As owner or operator, you are responsible for understanding the requirements, hazards, and precautions
that exist and to inform others as required. Unqualified persons must stay out of the work area at all times.
Alterations must not be made to the equipment. Alterations can produce dangerous situations resulting in
SERIOUS INJURY or DEATH.
This equipment must be installed in accordance with the current installation codes and applicable
regulations,whichmustbecarefully followed inallcases. Authoritieshaving jurisdictionmustbe consulted
before installations are made.
When necessary, you must consider the installation location relative to electrical, fuel and water utilities.
Personnel operating or working around equipment must read this manual. This manual must be
delivered with equipment to its owner. Failure to read this manual and its safety instructions is a misuse
of the equipment.
ST-0001-4

1. Safety
PNEG-2223 Flex-Flo Control Unit with Auto Calibration 5
Cautionary Symbols Definitions
Cautionary symbols appear in this manual and on product decals. The symbols alert the user of potential
safety hazards, prohibited activities and mandatory actions. To help you recognize this information, we
use the symbols that are defined below.
DANGER
WARNING
CAUTION
NOTICE
This symbol indicates an imminently hazardous situation
which, if not avoided, will result in serious injury or death.
This symbol indicates a potentially hazardous situation
which, if not avoided, can result in serious injury or death.
This symbol indicates a potentially hazardous situation which,
if not avoided, can result in minor or moderate injury.
This symbol is used to address practices not related to
personal injury.
This symbol indicates a general hazard.
This symbol indicates a prohibited activity.
This symbol indicates a mandatory action.
ST-0005-2

1. Safety
6 PNEG-2223 Flex-Flo Control Unit with Auto Calibration
Safety Cautions
Use Personal Protective Equipment
Eye
Protection
Hearing
Protection
Hand
Protection
Head
Protection
Respiratory
Protection Foot
Protection
Fall
Protection
• Use appropriate personal protective equipment:
• Wear clothing appropriate to the job.
• Remove all jewelry.
• Tie long hair up and back.
ST-0004-1
Follow Safety Instructions
• Carefully read all safety messages in this manual and
safety signs on your machine. Keep signs in good condition.
Replace missing or damaged safety signs. Be sure new
equipment components and repair parts include the current
safety signs. Replacement safety signs are available from
the manufacturer.
• Learn how to operate the machine and how to use controls
properly. Do not let anyone operate without instruction.
• If you do not understand any part of this manual or need
assistance, contact your dealer.
ST-0002-1
Operate Motor Properly
• All electrical connections must be made in accordance with
applicable local codes (National Electrical Code for the US,
Canadian Electric Code, or EN60204 along with applicable
European Directives for Europe). Make sure equipment and
bins are properly grounded.
• Lock-out power before resetting motor overloads.
• Do not repetitively stop and start the drive in order to free a
plugged condition. Jogging the drive in this manner can damage
the equipment and drive components.
ST-0009-3

1. Safety
PNEG-2223 Flex-Flo Control Unit with Auto Calibration 7
Safety Sign-Off Sheet
Below is a sign-off sheet that canbe used to verify that all personnel have read and understood the safety
instructions. This sign-off sheet is provided for your convenience and personal record keeping.
Date Employee Name Supervisor Name
Maintain Equipment and Work Area
• Understand service procedures before doing work. Keep area
clean and dry.
• Never service equipment while it is operating. Keep hands, feet,
and clothing away from moving parts.
• Keep your equipment in proper working condition. Replace
worn or broken parts immediately.
ST-0003-1
ST-0007

8 PNEG-2223 Flex-Flo Control Unit with Auto Calibration
2. Operation and Maintenance
Standard Systems
The Flex-Flo Control Unit is primarily controlled by an auxiliary switch, such as a proximity switch or
infraredsensoror hopperlevelcontrol. Referto wiringdiagramson Pages14-24thatmatches theauxiliary
switch used. The auxiliary switch is installed underneaththe Flex-Flo Control Unit. The Flex-Flo auger can
only run when the auxiliary switch is calling for feed. If the auxiliary switch fails to shut the Flex-Flo auger
OFFwhen thefeed isfull, thefeedwillbuild-up insidethebox behindthe controlunit andthe safetybackup
switch will be activated. As a result, the Flex-Flo auger will shut off until the feed drops away.
Extension Systems
The Flex-Flo Control Unit may also be used to control a fill system auger that feeds into an extension
systemauger. Inthe caseofanextensionsystem,there isno auxiliaryswitchusedtocontrol thefillsystem
auger. If the fill system auger is to be controlled independent of the extension system auger, there must
be a jumper wire across the “Auxiliary” switch terminals marked “Signal IN” and “Signal Out” of the fill
system control unit. Refer to wiring diagram for “Flex-Flo Control Unit Extension System - Independent”
on Page 18. When wired this way, the fill system auger is controlled by the safety backup switch.
If the fill system auger is to be controlled by the extension system auger, there needs to be a two (2)
conductor cord from the fill system control unit “Auxiliary” terminals marked “Signal IN” and “Signal Out”,
to the extension system control unit terminals marked “Relay Output”. Refer to wiring diagram for
“Flex-Flo Control Unit Extension System - Dependent” on Pages 15-17. When wired this way, the fill
system auger is controlled by the extension system control unit.
Indicator Lights Under Toggle Switch
Located on the side of the Flex-Flo Control Unit, underneath the toggle switch are multi-color indicator
lights and a grey Manual ON button.
When the bottom light is green, it indicates that the toggle switch is ON and the safety backup switch has
not been activated. In this state, the Flex-Flo auger will run if the auxiliary switch is calling for feed.
(See Figure 2A.)
Figure 2A Control on Box - Green

2. Operation and Maintenance
PNEG-2223 Flex-Flo Control Unit with Auto Calibration 9
When the bottom light is red, it indicates that the toggle switch is ON and the safety backup switch has
been activated. In this state, the Flex-Flo auger will not run. (See Figure 2B.)
When the top light is yellow, it indicates that a manual calibration must be performed. (See Figure 2C.)
Figure 2B Control on Box - Red Figure 2C Control on Box - Yellow
Manual ON Button
The grey button located under the toggle switchis the Manual ON Button. When the buttonis pressed, the
auger will turn ON manually and disable the sensor that has turned OFF the auger.
If the Manual ON button is pressed, the yellow light will begin to flash. Release the button and press again
and the auger will turn ON. (This is to prevent the case of a button failure and keeping the auger running.)
If the button is held down for 5 seconds, the flashing will stop (the yellow LED will go OFF) and a manual
calibration will automatically be performed.
Safety Backup Switch Time Delay
The Flex-Flo Control Unit safety backup switch has a fixed 30 second time delay. Once feed falls away
from the safety backup switch, the Flex-Flo Control Unit will begin to count down until the 30 second has
expired. At that time, the Flex-Flo auger will be allowed to run as long as the auxiliary switch is calling for
feed. The green LED under the toggle switch on the right hand side of the enclosure will flash during the
30secondtime delayperiod.Oncethe30secondtime delayperiodhasexpired,thegreenLEDwillremain
on solid and the Flex-Flo auger will be allowed to run.

2. Operation and Maintenance
10 PNEG-2223 Flex-Flo Control Unit with Auto Calibration
Safety Backup Switch Sensitivity
The safety backup switch inside the Flex-Flo Control Unit does not rely on feed pressure to activate. It
usesa specialelectronicsensor insidetheenclosure thatcansense thepresenceof feedthroughthe back
plastic wall of the enclosure. When feed builds up to a level that is even with the center of the enclosure,
it activates the safety backup switch. This prevents feed pressure from causing a bridging event once the
feed falls away.
NOTE: The safety backup switch is factory adjusted to the proper sensitivity level for feed.
Calibration Mode
Calibration Mode is used to correct the unit when the Safety Backup Switch does not properly sense the
presence of feed through the enclosure and housing wall. It may fail by sensing feed that is not present
and prevent the auger motor from starting. Or it may fail by not sensing feed that is present and prevent
the auger from shutting off when full, resulting in a motor overload.
When starting Calibration Mode, the sensitivity will be displayed by flashing the external red LED.
During Calibration Mode, the external red LED will flash 4 times, followed by a pause. It will continue this
sequence of flashes for 15 seconds, before completing a red/green LED flashing sequence for 5 seconds
at the end of the Calibration Mode cycle.
NOTE: In Calibration Mode feed MUST NOT be in front of the Flex-Flo Control Unit.
Auto Calibration at First Time Start-Up
When the customer receives a new Flex-Flo unit, it will not be calibrated. Upon start-up the first time the
unit receives power, the Flex-Flo will automatically enter Calibration Mode. See Calibration Mode above.
Manual Calibration
When the light is not solid green and the Manual ON button is pressed, the yellow light will begin to flash.
Release the button then press and hold the button again and the auger will turn ON. (This is to prevent
the case of a button failure and keeping the auger running.) If the button is held down for 5 seconds, the
flashing will stop (the yellow LED will go OFF) and a manual calibration will automatically be performed.
There will be no other light indicators for the calibration.
Alternate Manual Calibration
At start-up (turn the power switch on the side from the OFF to the ON position) the red external LED light
will flash one time. Right after the one flash and the LED turns OFF, turn the power switch OFF and back
ON again. The red external LED will now flash two (2) times. When the LED goes OFF after the second
flash, turn the power OFF and back ON again. The red external LED will now flash three (3) times.
After the third flash, turn power OFF and back ON. The unit will now enter Calibration Mode.
Auto Calibration
The control unit will sense changing environmental conditions and automatically perform calibrations
as needed.

2. Operation and Maintenance
PNEG-2223 Flex-Flo Control Unit with Auto Calibration 11
Bypass Mode
If auto or manual calibration still does not allow the auger to run, the unit may be set to “Bypass Mode”.
This mode is only available for units manufactured in November of 2018 and after. In bypass mode, the
auger will run for a maximum of 2 hours or until the primary feed sensor shuts it OFF. To set the control
unit (FLX-5350) into bypass mode, power up and push the grey button once within the first 5 seconds after
the red light has flashed once. The auger will turn ON and the green indicator light will be on solid while
the yellow indicator light will flash quickly. To disable bypass mode, re-cycle power.
Error Signals
Broken Sensor
The red external LED will continuously flash in normal runtime mode.
Calibration Failed or Lost
If the red external LED continuously flashes very quickly and the auger does not run, the calibration has
failed or been lost. A Manual Calibration must be performed to correct this problem. See “Manual
Calibration” on Page 10.
Replacing Top Circuit Board
Before determining if top circuit board is bad, contact your nearest AP or Cumberland Service
Representative to aid in diagnosis.
To replace the top circuit board, begin by removing the “Incoming Power” and “Flex-Flo Motor” wires from
the left terminal block. Un-plug the “Auxiliary Switch” terminal block plugs on the right side of the top circuit
board. Unplug the “Toggle Switch” spade terminal wires from the right side of the top board. These wires
must not be reversed. Remove the Flex-Flo relay terminal connection from the left side of the top board.
Remove the four (4) screws (S-7393) that secure the top board to the bottom enclosure.
To attach a new top circuit board, reverse the procedure above. (See Figure 2D.)
Figure 2D Remove Connections from Board

12 PNEG-2223 Flex-Flo Control Unit with Auto Calibration
3. Parts List
Flex-Flo Control Unit (FLX-5350)

3. Parts List
PNEG-2223 Flex-Flo Control Unit with Auto Calibration 13
Flex-Flo Control Unit (FLX-5350) Parts List
Ref # Part # Description Qty
1FLX-5350-B Bottom Circuit Board with Enclosure for FLX-5350 1
2 FLX-5350-T Top Circuit Board Assembly for FLX-5350 1
3FLX-4561 4 x 6 Electrical Box Gasket 1
4 FLX-5350-DL Lid with Decal for FLX-5350 1
5S-995 Screw, MS #10-24 x 1" SS 4
6 S-7931 Hex Nut #10-24 SS 4
7S-8183 Screw, SMSA #6-32 x 3/8" PHP ZN 8
8 S-10292 Cable Gland, PG7 Thread Size (BECS Technology) 2
9FH-1310 Connector Cord Heyco #3231 3
10 FH-7400 Washer 1/2" PVC Connector YLW 3
11 FH-1309 Nut, Lock 1/2" with Pipe Threads 3
12 FLX-5308-5 Plug, 5 Wire for FLX-5350 1
13 E105-1024 Wire Kit for FLX-5350 Switch 2
14 20-5060 Switch, Toggle SPST 15A with ON/OFF 1
15 70-0129 Boot Switch Weather-Proof 1
16 FLX-5270-5 Terminal Block Plug, Five Connector for FLX-5350 1
17 FLX-5270-2 Terminal Block Plug, Two Connector for FLX-5350 1
18 FLX-5413 Plug for 7/8" Diameter Hole with Lock Nut and O-Ring 3

14 PNEG-2223 Flex-Flo Control Unit with Auto Calibration
4. Wiring Diagrams
Flex-Flo Control Unit Used with 5 Wire Sensor
FLEX-FLO CONTROL UNIT (FLX-5350)
PROXIMITY SWITCH (AP-1002)
L1 L2 L3
M1
M2 M3
Incoming Power Flex-Flo Motor Auxiliary Switch BLACK 3
BLACK 1
BLUE
BROWN
GREEN
WHITE BLACK
GREEN
WHITE BLACK
L1 L2 IN
OUT COM. N.O.
Relay
Output
Signal
Signal
Power Power
N.O. - BLACK 4 (NOT USED) N.C. - BLACK 3 COM. - BLACK 1 LINE - BLUE LINE - BROWN
TAPE FOR PROTECTION
FLEX-FLO
MOTOR
GND
L2
L1
208-230VAC
POWER SUPPLY

4. Wiring Diagrams
PNEG-2223 Flex-Flo Control Unit with Auto Calibration 15
Flex-Flo Control Unit Extension System - Dependent
FLEX-FLO CONTROL UNIT
FILL SYSTEM (FLX-5350) FLEX-FLO CONTROL UNIT EXTENSION SYSTEM (FLX-5350)
L1
L2
L3
M1
M2 M3
Incoming Power Flex-Flo Motor Auxiliary Switch
GREEN
WHITE BLACK
L1 L2
IN
OUT
COM. N.O.
Relay
Output
Signal
Signal
Power Power
GREEN
WHITE BLACK BLACK WHITE
GREEN
WHITE BLACK
GREEN
WHITE BLACK BLACK WHITE
RED BROWN
L1
L2
L3
M1
M2 M3
Incoming Power Flex-Flo Motor Auxiliary Switch
L1 L2
IN
OUT
COM.
N.O.
Relay
Output
Signal
Signal
Power Power
FLEX-FLO
MOTOR
GND
L2
L1
208-230VAC
POWER SUPPLY
FLEX-FLO
MOTOR
GND
L2
L1
208-230VAC
POWER SUPPLY
UNIVERSAL SENSOR (AP-2983)
TAPE FOR
PROTECTION
N.O. - ORANGE (NOT USED)
LINE - BROWN
N.C. - RED
GROMMET INSERTION LINE

4. Wiring Diagrams
16 PNEG-2223 Flex-Flo Control Unit with Auto Calibration
Flex-Flo Control Unit Extension System - Dependent (Continued)
FLEX-FLO CONTROL UNIT
FILL SYSTEM (FLX-4512) FLEX-FLO CONTROL UNIT
EXTENSION SYSTEM (FLX-5350)
M2
WHITE
GREEN
WHITE
BLACK
BLACK WHITE
RED
BROWN
L1
L2
L3
M1
M2
M3
Incoming Power Flex-Flo Motor Auxiliary Switch
L1
L2
IN
OUT
COM.
N.O.
Relay
Output
Signal
Signal
Power
Power
BLACK
M1
L1 L2
GREEN
WHITE
BLACK
BLACK
GREEN
WHITE
FLEX-FLO
MOTOR
FLEX-FLO
MOTOR
L2
L1
208-230VAC
POWER
SUPPLY
UNIVERSAL SENSOR (AP-2983)
TAPE FOR
PROTECTION
N.O. - ORANGE (NOT USED)
LINE - BROWN
N.C. - RED
GROMMET INSERTION LINE
GREEN
WHITE
BLACK
GND GND
L2
L1
208-230VAC
POWER
SUPPLY

4. Wiring Diagrams
PNEG-2223 Flex-Flo Control Unit with Auto Calibration 17
Flex-Flo Control Unit Extension System - Dependent (Continued)
FLEX-FLO CONTROL UNIT
FILL SYSTEM (FLX-5350) FLEX-FLO CONTROL UNIT
EXTENSION SYSTEM (FLX-4512)
BLACK
WHITE
GREEN
BLACK
WHITE
L1
L2
L3
M1
M2
M3
Incoming Power Flex-Flo Motor Auxiliary Switch
L1
OUT
COM.
N.O.
Relay
Output
Signal
Power
FLEX-FLO
MOTOR FLEX-FLO
MOTOR
GND
L1
208-230VAC
POWER SUPPLY
UNIVERSAL SENSOR (AP-2983)
TAPE FOR
PROTECTION
N.O. - ORANGE (NOT USED)
LINE - BROWN
N.C. - RED
GROMMET INSERTION LINE
L1
M1
GREEN
WHITE
BLACK
L2 GND
L2
208-230VAC
POWER SUPPLY
WHITE
GREEN
GREEN
BLACK
L2Power
IN
Signal
WHITE
BLACK
WHITE
BLACK
WHITE
BLACK
L1
GREEN
BLACK
WHITE
L2
M2 L3
M3 AUX
AUX C2 C1
REPLACE 2-POLE RELAY
WITH 4-POLE RELAY PLUS
BRACKET (FLX-4619 PLUS
FLX-4620) AND RE-WIRE AS
SHOWN.

4. Wiring Diagrams
18 PNEG-2223 Flex-Flo Control Unit with Auto Calibration
Flex-Flo Control Unit Extension System - Independent
FLEX-FLO CONTROL UNIT
FILL SYSTEM (FLX-5350) FLEX-FLO CONTROL UNIT
EXTENSION SYSTEM (FLX-5350)
L1
L2
L3
M1
M2 M3
Incoming Power Flex-Flo Motor Auxiliary Switch
GREEN
WHITE BLACK
L1 L2
IN
OUT
COM. N.O.
Relay
Output
Signal
Signal
Power Power
GREEN
WHITE BLACK
GREEN
WHITE BLACK
GREEN
WHITE BLACK
RED BROWN
L1
L2
L3
M1
M2 M3
Incoming Power Flex-Flo Motor Auxiliary Switch
L1 L2
IN
OUT
COM. N.O.
Relay
Output
Signal
Signal
Power Power
FLEX-FLO
MOTOR
GND
L2
L1
208-230VAC
POWER SUPPLY
FLEX-FLO
MOTOR
GND
L2
L1
208-230VAC
POWER SUPPLY
AP-2983 UNIVERSAL SENSOR
TAPE FOR PROTECTION
N.O. - ORANGE (NOT USED)
LINE - BROWN
N.C. - RED
GROMMET INSERTION LINE
JUMPER WIRE

4. Wiring Diagrams
PNEG-2223 Flex-Flo Control Unit with Auto Calibration 19
Flex-Flo Control Unit Used with Hopper Level Controls
FLEX-FLO CONTROL UNIT (FLX-5350)
L1
L2
L3
M1
M2 M3
Incoming Power Flex-Flo Motor Auxiliary Switch
GREEN
WHITE BLACK
L1 L2
IN
OUT
COM. N.O.
Relay
Output
Signal
Signal
Power Power
GREEN
WHITE BLACK
7051400
HOPPER LEVEL CONTROL #1
GREEN
BLACK
WHITE
FLEX-FLO
MOTOR
GND
L2
L1
208-230VAC
POWER SUPPLY
7051400
HOPPER LEVEL CONTROL #2
COM. N.C. GND.
WHITE
BLACK
GREEN
COM. N.C. GND.
WHITE
BLACK
GREEN

4. Wiring Diagrams
20 PNEG-2223 Flex-Flo Control Unit with Auto Calibration
Flex-Flo Control Unit Used with IR Plus Feed Sensor
FLEX-FLO CONTROL UNIT (FLX-5350)
L1
L2
L3
M1
M2 M3
Incoming Power Flex-Flo Motor Auxiliary Switch
GREEN
WHITE BLACK
L1 L2
IN
OUT
COM. N.O.
Relay
Output
Signal
Signal
Power Power
GREEN
WHITE BLACK
GREEN
BLACK
RED
FLEX-FLO
MOTOR
GND
L2
L1
208-230VAC
POWER SUPPLY
YELLOW
YELLOW
IR PLUS FEED SENSOR (FLX-5262)
IR PLUS FEED SENSOR
WITH LID REMOVED
Time Delay
0 Sec.
30 Sec.
60 Sec.
90 Sec.
Power
LED
Auger
LED
Detect
LED
COM
N.O. N.C.
EARTH GND LINE 2 LINE 1
GREEN
YELLOW
YELLOW
RED
BLACK