Cumberland Smart-Flex FLX-4629 User manual

PNEG-1186
Smart-Flex (FLX-4629)
Operation Instructions
Owner’s Manual
PNEG-1186
Date: 01-01-15

2PNEG-1186Smart-Flex (FLX-4629) Operation Instructions
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-1186 Smart-Flex (FLX-4629) Operation Instructions 3
Contents
Chapter 1 Safety .....................................................................................................................................................4
Safety Guidelines ...................................................................................................................................4
Chapter 2 Smart-Flex (FLX-4629) Operation Instructions ..................................................................................6
The Smart-Flex Controller ......................................................................................................................6
Setting the Delay Time ...........................................................................................................................6
Setting the Maximum Run Time .............................................................................................................7
Setting the Maximum Idle Time ..............................................................................................................8
Setting the Sensitivity Level ...................................................................................................................9
Setting the Unit I.D. Number (Only Used with Network Master) ..........................................................10
Sensor Setting Guidelines ....................................................................................................................11
Alarms ..................................................................................................................................................12
Chapter 3 Wiring Diagrams .................................................................................................................................14
Standard Configuration ........................................................................................................................14
Relay Box .............................................................................................................................................15
Standard Mode .....................................................................................................................................16
Extension Mode ...................................................................................................................................17
Chain Disk Mode ..................................................................................................................................18
IR Plus Feed Sensor or N.O. Micro Switch ..........................................................................................19
Chapter 4 Smart-Flex Optional Equipment ........................................................................................................20
Smart-Flex Extension Unit (FLX-4820) ................................................................................................20
Lid Clear Protector Cover Kit (FLX-4738) ............................................................................................21
Chapter 5 Parts List .............................................................................................................................................22
Smart-Flex Parts ..................................................................................................................................22
Smart-Flex Relay Box Assembly (FLX-4778) ......................................................................................24
AP 4 x 6 Electrical Box Clear Cover Kit (AP-4738) ..............................................................................26
Chapter 6 Warranty ..............................................................................................................................................29

4PNEG-1186Smart-Flex (FLX-4629) Operation Instructions
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.
DANGER
WARNING
CAUTION
CAUTION
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.
This symbol indicates a potentially hazardous situation which,
if not avoided, may result in serious injury or death.
This symbol indicates a potentially hazardous situation which,
if not avoided, may result in minor or moderate injury.
This symbol indicates a potentially hazardous situation
which, if not avoided, may result in property damage.
This symbol indicates an imminently hazardous situation
which, if not avoided, will result in serious injury or death.

1. Safety
PNEG-1186 Smart-Flex (FLX-4629) Operation Instructions 5
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.
Remove all jewelry.
Tie long hair up and back.
Wear safety glasses at all times to protect eyes from debris.
Wear gloves to protect your hands from sharpedges on plastic
or steel parts.
Wear steel-toed boots to help protect your feet from falling
debris. Tuck in any loose or dangling shoestrings.
A respirator may be needed to prevent breathing potentially
toxic fumes and dust.
Wear a hard hat to help protect your head.
Wear appropriate fall protection equipment when working at
elevations greater than six feet (6').
Eye Protection
Gloves
Steel-Toed Boots
Respirator
Hard Hat
Fall Protection

6PNEG-1186Smart-Flex (FLX-4629) Operation Instructions
2. Smart-Flex (FLX-4629) Operation Instructions
The Smart-Flex Controller
The Smart-Flex controller has combined several feed system functions into one unit and is now able to
communicate with the Network Master which enables remote monitoring and adjustment. The following
instructions will help you to understand how to set and manage these functions correctly. All four (4)
functions below can be programmed with the toggle switch in the OFF position or in the normal operating
mode. The display must be flashing in order to make changes to any settings. The “Set/Clr” button must
be pushed to save the desired settings.
Setting the Delay Time
The Delay Time is defined as: The time after feed is no longer detected before the auger begins. It is used
to prevent the auger from short cycling. The best Delay Time setting is the longest time that can be set
that will not quite allow a feeder to go empty. The Delay Time can be decreased as the animals in a barn
get older and eat more or it can be permanently kept at the minimum time that will work for all situations,
including when the animals are older.
To Set the Delay Time
1. Push the PROG button until the green LED next to the Delay Time begins to flash.
The display will also flash with the 4 digit current setting.
2. Push the arrow button up or down to increase or decrease the Delay Time.
The Delay Time can be adjusted in one minute increments, within a range between zero and
99 hours and 59 minutes. By pushing the arrow button once, the time will increment by one minute.
By holding the arrow button down, it will increment at a faster rate.
3. Once the Delay Time is set, push the Set/Clr button to save the new setting.
During normal operation of the Delay Time, when feed is no longer detected, the green Delay Time
LED will turn on and the display will show the time left before the auger starts. When the displayed time
reaches zero, the green Delay Time LED will turn off and the green Run Time LED will turn on and the
auger will begin to run. (See Figure 2A.)
Figure 2A Delay Time

2. Smart-Flex (FLX-4629) Operation Instructions
PNEG-1186 Smart-Flex (FLX-4629) Operation Instructions 7
Setting the Maximum Run Time
The Maximum Run Time is defined as: The maximum time an auger is allowed to run during one feed
cycle before shutting off and going into alarm mode. If this time is reached before the feed system is full,
the auger will shut off and remain off until the Maximum Run Time is reset. The Maximum Run Time is
used to prevent a major feed spill and also prevent the auger from running empty for long periods of time
during a feed outage. The best Maximum Run Time setting is achieved by adding 15 minutes to the time
it takes to fill all feeders when they are completely empty.
To Set the Maximum Run Time
1. Push the PROG button until the green LED next to the Run Time begins to flash.
The display will also flash with the 4 digit current setting.
2. Push the arrow button up or down to increase or decrease the Run Time.
The Run Time can be adjusted in one minute increments, within a range between zero and 99 hours
and 59 minutes. By pushing the arrow button once, the time will increment by one minute. Holding
the arrow button down, it will increment at a faster rate.
3. Once the Run Time is set, push the Set/Clr button to save the new setting.
NOTE: To disable the Maximum Run Time, set the time to zero.
During normal operation of the Run Time, once the auger turns on, the green Auger LED will turn on.
The display will show the auger run time since it began. If the displayed Run Time reaches the Maximum
Run Time setting, the green Auger LED will shut off and the red Alarm LED will begin to flash and the
auger will shut off. The control will go into alarm mode, while flashing Run in the display. To reset the
control, push the Set/Clr button. (See Figure 2B.)
Figure 2B Maximum Run Time

2. Smart-Flex (FLX-4629) Operation Instructions
8PNEG-1186Smart-Flex (FLX-4629) Operation Instructions
Setting the Maximum Idle Time
TheMaximum Idle Time is definedas: The time after feedisfirstdetecteduntilfeedisnolongerdetected.
Excessive Idle Time can be caused by animals not eating for long periods of time or by feed bridging in
the drop tube in front of the sensor. It can also be caused by improper sensitivity adjustment of the feed
sensor(toosensitive).ThebestMaximum Idle Time setting is achieved byadding 1 hour to the maximum
expected time between animals eating during full times such as at night or during excessively hot periods
during the day. A typical Maximum Idle Time might be 8 to 10 hours.
To Set the Maximum Idle Time
1. Push the PROG button until the green LED next to the Idle Time begins to flash.
The display will also flash with the 4 digit current setting.
2. Push the arrow button up or down to increase or decrease the Idle Time.
The Idle Time can be adjusted in one minuteincrements, within a range between zero and 99hours
and 59 minutes. By pushing the arrow button once, the time will increment by one minute. Holding
the arrow button down, it will increment at a faster rate.
3. Once the Idle Time is set, push the Set/Clr button to save the new setting.
NOTE: To disable the Maximum Idle Time, set the time to zero.
During normal operation of the Idle Time, once the auger turns off, the green Product Detected LED will
turn on and the display will show the elapsed Idle Time since it began. If the displayed Idle Time reaches
theMaximum Idle Time setting,theredAlarm LEDwillbegintoflash.Thecontrolwillgointoalarmmode,
while flashing IdL in the display. To reset the control, push the Set/Clr button. (See Figure 2C.)
Figure 2C Maximum Idle Time

2. Smart-Flex (FLX-4629) Operation Instructions
PNEG-1186 Smart-Flex (FLX-4629) Operation Instructions 9
Setting the Sensitivity Level
The Smart-Flex has six (6) incremental levels of sensitivity adjustment settings to match the different
situations and feed types you may encounter. Level 1 is the least sensitive and should only be used with
very wet feed. Level 6 is the most sensitive and should only be used with very dry feed or when the sensor
is oriented in a vertical position. The factory setting is level 4 and will cover most situations and feed types.
If at a given sensitivity level, the system senses falling feed and shuts off prematurely, reduce the setting
by one level and try it again. If at a given sensitivity level, the system does not sense the feed and does
not shut off when full, increase the setting by one level and try it again. (See Figure 2D.)
IMPORTANT: When attempting to set sensor at levels 1 through 6, prior to adjustment, the sensor must
be placed in the grommet with no feed near the end of the sensor.
To Set the Sensitivity Level
1. Push the PROG button until the green LED next to the Set Sensitivity begins to flash.
The display will also flash with the current level setting.
2. Push the arrow button up or down to increase or decrease the sensitivity level.
3. Once the sensitivity level is set, push the Set/Clr button to save the new setting.
Figure 2D Sensitivity level

2. Smart-Flex (FLX-4629) Operation Instructions
10 PNEG-1186 Smart-Flex (FLX-4629) Operation Instructions
Setting the Unit I.D. Number (Only Used with Network Master)
When configuring the Smart-Flex to be used with a Network Master, each Smart-Flex must have a unique
unit I.D. number in order to communicate properly. There is a maximum of twenty five (25) Smart-Flex
controls that can be used with each Network Master. The unit I.D. number of each Smart-Flex must fall
between a range of “0051” and “0075”. “0000” is the default setting and indicates no unit I.D. number.
Be sure to record this I.D. number along with a brief description of its location, for each Smart-Flex, for use
when programming the Network Master.
To Set the Unit I.D. Number
1. Push both arrow up and arrow down buttons at the same time, then release. Initially the default
setting of “0000” indicating no unit I.D. number, will be displayed.
2. Use the arrow button up or down to scroll through to the desired unit I.D. number from “0051”
through “0075”.
3. Once the unit I.D. number is selected, push the Set/Clr button to save this setting.
4. Record this unit I.D. number along with a brief description of its location for future use when
programming the Network Master.
5. If a unit I.D. number is set on the Smart-Flex un-intentionally, after 15 minutes, an alarm code of
“AC14” will be displayed, indicating a communication error. Press the Set/Clr button to clear this
alarm code. To disable the unit I.D. number, set to “0000”.

2. Smart-Flex (FLX-4629) Operation Instructions
PNEG-1186 Smart-Flex (FLX-4629) Operation Instructions 11
Sensor Setting Guidelines
In addition to the six (6) sensitivity levels, there are two (2) situational levels:
Level “Cd” refers to Chain Disk. Use this level when filling a ChainDisk feed system with a Flex-Flo auger
that includes the Smart-Flex control. In place of the Smart-Flex sensor, run a two (2) conductor cord
between the Smart-Flex control (FLX-4629LS) and the Chain Disk control (APCD-500 or APCD-600).
See wiring diagram on Page 18. (See Figure 2E.)
Level “Ir” refers to Infra-Red (IR Plus Feed Sensor). Use this level when connecting to a IR Plus Feed
Sensor with no display or when connecting to a hopperlevel control switch that includes a Normally Open
(N.O.) Micro Switch. See wiring diagram on Page 19. (See Figure 2F.)
Sensor Level Settings
Figure 2E Chain Disk Situation Level Figure 2F IR Plus Feed Sensor Situation Level
Sensor Level Setting Description
Level Cd Chain Disk
Level 1 Very High Moisture Feeds
Level 2 High Fat or High Moisture Feeds
Level 3 Most Feed Types
Level 4 Factory Setting, Most Feed Types
Level 5 Dry Feed or Accu-Drop Feeder
Level 6 Very Dry Feed or Accu-Drop Feeder
Level Ir IR Plus Feed Sensor

2. Smart-Flex (FLX-4629) Operation Instructions
12 PNEG-1186 Smart-Flex (FLX-4629) Operation Instructions
Alarms
There are five (5) alarms modes for the Smart-Flex:
To reset alarms 2 through 5 above, you must push the Set/Clr button.
* When the pressure switch is activated, it will not sound an alarm when in extension mode.
Figure 2G Figure 2H
1Toggle switch turned off Display will flash “OFF” (See Figure 2G.)
* 2 Pressure switch activated Display will flash “PrS” and sound an alarm (See Figure 2H.)
3Maximum Run Time exceeded Display will flash “run” and sound an alarm (See Figure 2I on Page 13.)
4Maximum Idle Time exceeded Display will flash “IdL” and sound an alarm (See Figure 2J on Page 13.)
5Lost communication with Network Master Display will flash “AC14” (See Figure 2K on Page 13.)

2. Smart-Flex (FLX-4629) Operation Instructions
PNEG-1186 Smart-Flex (FLX-4629) Operation Instructions 13
Figure 2I Figure 2J
Figure 2K

14 PNEG-1186 Smart-Flex (FLX-4629) Operation Instructions
3. Wiring Diagrams
Standard Configuration
Figure 3A Standard Configuration

3. Wiring Diagrams
PNEG-1186 Smart-Flex (FLX-4629) Operation Instructions 15
Relay Box
Figure 3B Wiring Diagram for Relay Box

3. Wiring Diagrams
16 PNEG-1186 Smart-Flex (FLX-4629) Operation Instructions
Standard Mode
The standard configuration of the Smart-Flex uses the proximity sensor (AP-2984). The two (2) wires
from the proximity sensor connect to the terminals in the lid marked “Sensor +V” and “Sensor -V”.
(See Figure 3C.) This configuration with the proximity sensor (AP-2984) is the only one that the
set sensitivity levels 1 through 6 correspond to.
Figure 3C Wiring Diagram for Standard Mode

3. Wiring Diagrams
PNEG-1186 Smart-Flex (FLX-4629) Operation Instructions 17
Extension Mode
The Smart-Flex can be configured without the proximity sensor to control the Flex-Flo fill auger of an
extension system. To use in extension mode without the proximity sensor, add a jumper wire connected
to the terminals in the lid marked “Sensor +V” and “Ext. Mode”. (See Figure 3D.) In this configuration, the
pressure switch will operate without setting off or sounding the alarm.
Figure 3D Wiring Diagram for Extension Mode

3. Wiring Diagrams
18 PNEG-1186 Smart-Flex (FLX-4629) Operation Instructions
Chain Disk Mode
The Smart-Flex can be used as the Flex-Flo fill auger control to fill a chain disk feed system. For this
configuration, the proximity sensor is not used. In place of the proximity sensor, connect a two (2)
conductor cord from the terminals in the Smart-Flex lid marked “Sensor +V” and “Sensor -V” to the
terminals of the chain disk control marked “Auger Motor”. (See Figure 3E.) The set sensitivity must be set
to level “Cd”. In this configuration, the chain disk feed system will control the Flex-Flo auger.
Figure 3E Wiring Diagram for Chain Disk Mode

3. Wiring Diagrams
PNEG-1186 Smart-Flex (FLX-4629) Operation Instructions 19
IR Plus Feed Sensor or N.O. Micro Switch
The Smart-Flex can be connected to any N.O. Micro Switch or IR Plus Feed Sensor. For this configuration,
the proximity sensor is not used. In place of the proximity sensor, connect a two (2) conductor cord from
the terminals in the Smart-Flex lid marked “Sensor +V” and “Sensor -V” to the corresponding terminals of
the IR Plus Feed Sensor or N.O. Micro Switch.
(See Figure 3F.) The set sensitivity must be set to level “Ir”.
Figure 3F Wiring Diagram for IR Plus Feed Sensor or N.O. Micro Switch Mode

20 PNEG-1186 Smart-Flex (FLX-4629) Operation Instructions
4. Smart-Flex Optional Equipment
Smart-Flex Extension Unit (FLX-4820)
A Smart-Flex extension unit is available to extend the user interface to a more favorable location for easier
access. The maximum distance the extension unit can be mounted away from the main Smart-Flex
control is 200'. In addition to the extension unit, an Alpha 6344, eight (8) conductor extension wire is
needed to connect the two (2) components together. The extension wire is available in either 50' length
(FLX-4821-50) or 200' length (FLX-4821-200). Install the Smart-Flex extension unit according to the
instructions that are supplied with it. (See Figure 4A.)
Figure 4A Smart-Flex Extension Unit