GSi AP Cumberland IR-Plus Feed Sensor User manual

PNEG-1945
IR Plus Feed Sensor
Installation and Operation Manual
PNEG-1945
Date: 06-12-14

2PNEG-1945 IR Plus Feed Sensor

Table of Contents
PNEG-1945 IR Plus Feed Sensor 3
Contents
Chapter 1 Safety .....................................................................................................................................................4
Safety Guidelines ...................................................................................................................................4
Chapter 2 Application ............................................................................................................................................6
Chapter 3 Basic Operation ....................................................................................................................................7
Basic Operation for Swine ......................................................................................................................7
Basic Operation for Poultry ....................................................................................................................7
Chapter 4 Delay Time ............................................................................................................................................8
Chapter 5 Indicator LED Lights ............................................................................................................................9
Chapter 6 Sensitivity ...........................................................................................................................................10
Chapter 7 Replacement Parts .............................................................................................................................12
IR Plus Feed Sensor Assembly (FLX-5262) ........................................................................................12
Chapter 8 Wiring Diagrams for Swine Application ...........................................................................................14
IR Plus Feed Sensor Used with Smart-Flex in Swine Application .......................................................14
Wiring Diagram for Smart-Flex to IR Plus Feed Sensor ......................................................................16
Wiring Diagram for IR Plus Feed Sensor to Smart-Flex ......................................................................17
Wiring Diagram for Relay Box ..............................................................................................................19
Chapter 9 Wiring Diagrams for Poultry Application .........................................................................................20
IR Plus Feed Sensor Hopper Level Control Model 350 .......................................................................20
IR Plus Feed Sensor Hopper Level Control Model 300 .......................................................................22
IR Plus Feed Sensor Wiring Diagram for Poultry Application ..............................................................24
Chapter 10 Warranty ............................................................................................................................................25

4PNEG-1945 IR Plus Feed Sensor
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
NOTICE
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.
WARNING indicates a hazardous situation which, if not
avoided, could result in death or serious injury.
CAUTION, used with the safety alert symbol, indicates a
hazardous situation which, if not avoided, could result in
minor or moderate injury.
NOTICE is used to address practices not related to
personal injury.
DANGER indicates a hazardous situation which, if not
avoided, will result in death or serious injury.

1. Safety
PNEG-1945 IR Plus Feed Sensor 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 fromsharp 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.
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-1945 IR Plus Feed Sensor
2. Application
In a swine application, the IR Plus Feed Sensor is used in conjunction with a Smart-Flex 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 the proximity switch in a Smart-Flex control.
The sensor is installed underneath a Smart-Flex control unit between the powerhead drop (funnel) and
the drop tube at the end of a Flex-Flo feed system as shown in Figure 2A.
Figure 2A Swine
In a poultry application, the IR Plus Feed Sensor is used as a hopper level control to maintain the feed
level in one or more hoppers. It uses “INFRARED” technology to detect the presence of all types of mash
and pellet feeds. The sensor is installed under a drop kit and above each hopper of an incoming Flex-Flo
feed system as shown in Figure 2B.
Figure 2B Poultry
Ref # Description
AIR Plus Feed Sensors

PNEG-1945 IR Plus Feed Sensor 7
3. Basic Operation
Basic Operation for Swine
The IR Plus Feed Sensor is connected to a Smart-Flex control unit and will immediately shut the
Flex-Flo auger system OFF when feed is full. When the feed falls away from the IR Plus Feed Sensor, it
will count down a pre-determined “Delay Time” and then turn the Flex-Flo auger system back ON when
the “Delay Time” has expired.
Basic Operation for Poultry
The IR Plus Feed Sensor is used as a hopper level control. It can be used alone or with multiple IR Plus
Feed Sensors connected together in parallel, to operate an incoming Flex-Flo auger. When all hoppers
are full of feed, the incoming Flex-Flo auger will shut OFF immediately. When the feed falls away from
at least one IR Plus Feed Sensor, it will count down a pre-determined “Delay Time” and then turn the
incoming Flex-Flo auger back ON when the “Delay Time” has expired.

8PNEG-1945 IR Plus Feed Sensor
4. Delay Time
The “Delay Time” is adjustable inside the IR Plus Feed Sensor enclosure using a small pin jumper.
The “Delay Time” can be adjusted to 0 seconds or 30 seconds or 60 seconds or 90 seconds, depending
on the choice of the user. The factory default setting is 60 seconds. Place the pin jumper over the pins
next to the desired “Delay Time”. (See Figure 4A.)
Figure 4A Delay Time Jumper

PNEG-1945 IR Plus Feed Sensor 9
5. Indicator LED Lights
The IR Plus Feed Sensor is equipped with three (3) LED indicator lights on the PC board inside the
enclosure. These LED lights help to diagnose the condition of the IR Plus Feed Sensor.
The top green LED indicates the state of electrical power to the sensor. When power to the sensor is ON,
this green LED will be illuminated. When power is OFF, the green LED will be OFF. (See Figure 5A.)
The middle green LEDindicates the state of the Flex-Flo auger. Whentheauger isrunning, the green LED
will be illuminated. When the auger is about to run, during the “Delay Time” period, the green LED will be
flashing. When the feed level is full and the auger is OFF, the green LED will be OFF. (See Figure 5B.)
The bottom amber LED indicates when feed is detected by the sensor. When feed is detected, the feed
level is full and the amber LED will be illuminated. Once the feed level falls below the sensor, the amber
LED will be OFF. (See Figure 5C.)
Figure 5A Power LED
Figure 5B Auger LED Figure 5C Detect LED

10 PNEG-1945 IR Plus Feed Sensor
6. Sensitivity
No sensitivity setting is required. The infrared technology that is used in the IR Plus Feed Sensor is not
affected by temperature, humidity or feed type. If the sensor fails to operate properly, disconnect the
sensor and use a soft cloth to clean the dust from inside. If it still does not operate properly, contact the
nearest AP or Cumberland dealer to aid in troubleshooting.

PNEG-1945 IR Plus Feed Sensor 11
NOTES

12 PNEG-1945 IR Plus Feed Sensor
7. Replacement Parts
IR Plus Feed Sensor Assembly (FLX-5262)
Repeat for four (4)
screws and nuts
Repeat for four (4) screws
Repeat for two (2) screws

7. Replacement Parts
PNEG-1945 IR Plus Feed Sensor 13
IR Plus Feed Sensor Assembly (FLX-5262) Parts List
Ref # Part # Description Qty
1FLX-5000 Sensor Housing Assembly 1
2FLX-5002 Sensor Insert Assembly 1
3FLX-5263 Replacement Power Board for IR Plus Feed Sensor 1
4FLX-5001 Sensor Connector Cable 1
5FLX-5267 Sensor Replacement Lid with Cover 1
6S-8045 Screw, SDS #10 x 3/4" HWH SS 410 4
7S-995 Screw, MS #10-24 x 1" PHP SS 4
8S-7931 Hex Nut #10-24 SS 4

14 PNEG-1945 IR Plus Feed Sensor
8. Wiring Diagrams for Swine Application
IR Plus Feed Sensor Used with Smart-Flex in Swine Application
THE GSI GROUP
FLX-4778
SMART-FLEX RELAY BOX
COIL RATING:
CONTACT RATING:1 1/2 HP, 240 VACMAX.,
25 FLA, 1 PHASE
208-240 VAC, 50/60 Hz.
DANGER
High voltage.
Will cause injury
or death.
Lock out power
before servicing.
THE GSI GROUP
FLX-4629
SMART-FLEX
Auger
Product
Detected
Alarm
Hr Min
Prog Set/
Clr
Delay Time
Run Time
Idle Time
Set Sensitivity

8. Wiring Diagrams for Swine Application
PNEG-1945 IR Plus Feed Sensor 15
IR Plus Feed Sensor Used with Smart-Flex in Swine Application
(Continued)
Ref # Part # Description
AFLX-4778 Smart-Flex Relay Box Assembly
B FLX-4629LS Smart-Flex Control Without Sensor
CFLX-2017 Power Head Drop
D S-8045 Screw, SDS #10 x 3/4" HWH SS410
EFLX-5262 IR Plus Feed Sensor
F FLX-2427 Drop Tube
GFLX-5265 Cord
H Flex-Flo Power Unit
I208-230 VAC Power Supply
J To Alarm (if Used)
KRS485 IN (if Used)
L RS485 OUT (if Used)

8. Wiring Diagrams for Swine Application
16 PNEG-1945 IR Plus Feed Sensor
Wiring Diagram for Smart-Flex to IR Plus Feed Sensor
RELAY BOX (FLX-4778)
GND
L1
L2
208-230VAC
POWER SUPPLY
FLEX-FLO
MOTOR
GND
M2
M1
IR PLUS FEED SENSOR (FLX-5262)
SMART-FLEX (FLX-4629LS)
TOP
TO ALARM SYSTEM
(IF USED)
IN - RS485 CABLE (IF USED)
TO NETWORK MASTER
COMMUNICATION
BOTTOM
OUT - RS485 CABLE (IF USED) TO NETWORK MASTER
COMMUNICATION
CORD (FLX-5265)

8. Wiring Diagrams for Swine Application
PNEG-1945 IR Plus Feed Sensor 17
Wiring Diagram for IR Plus Feed Sensor to Smart-Flex
IR PLUS FEED SENSOR (FLX-5262)
SHOWN WITH LID REMOVED
Time Delay
0 Sec.
60 Sec.
90 Sec.
Power
LED
Auger
LED
Detect
LED
GREEN
RED
BLACK
YELLOW
YELLOW
EARTH GND LINE 2 LINE 1
RED
BLACK
YELLOW
YELLOW
COM
N.O. N.C.
ADD MALE SPADE TERMINALS
REMOVE YELLOW WIRES
FROM RELAY AND CONNECT
TO MALE SPADE TERMINALS
TO SMART-FLEX TOP
TO RELAY BOX
TO SMART-FLEX BOTTOM
30 Sec.
SET JUMPER PIN ON “0 SEC.”

8. Wiring Diagrams for Swine Application
18 PNEG-1945 IR Plus Feed Sensor
Wiring Diagram for Smart-Flex to IR Plus Feed Sensor (Continued)
SMART-FLEX (FLX-4629LS)
(Set Sensitivity Level to “Ir”)
TOP Sensor -V
Sensor +V
Ext. Mode
N.C.
COM
N.O.
SHIELD
OUT (B) SHIELD
IN (B)
SHIELD B A
RS485
Line 1
Relay 1
Relay 2
Line 2
TO ALARM SYSTEM
(IF USED)
TO IR PLUS FEED SENSOR
IN - RS485 CABLE (IF USED)
TO NETWORK MASTER
COMMUNICATION
TO IR PLUS FEED SENSOR
TO NETWORK MASTER
COMMUNICATION
BOTTOM
OUT - RS485 CABLE (IF USED)
BLACK
YELLOW
RED
YELLOW
IN (A)
OUT (A)

8. Wiring Diagrams for Swine Application
PNEG-1945 IR Plus Feed Sensor 19
Wiring Diagram for Relay Box
RELAY BOX (FLX-4778)
L1
M1 L2
M2 L3 M3 AUX
AUX C2
C1
RED
BLACK
YELLOW
YELLOW
GREEN GND
GND
L1
L2
208-230VAC
POWER
SUPPLY
GND
M2
M1
FLEX-FLO
MOTOR
TO IR PLUS FEED SENSOR

20 PNEG-1945 IR Plus Feed Sensor
9. Wiring Diagrams for Poultry Application
IR Plus Feed Sensor Hopper Level Control Model 350
IR PLUS FEED SENSOR USED AS HOPPER LEVEL CONTROL IN
MODEL 350 FLEX-FLO POULTRY APPLICATION