GSi FLX-5260 User manual

PNEG-1955
Flex-Flo Control Unit
Operation Manual
PNEG-1955
Date: 07-23-14

2PNEG-1955 Flex-Flo Control Unit

Table of Contents
PNEG-1955 Flex-Flo Control Unit 3
Contents
Chapter 1 Safety .....................................................................................................................................................4
Safety Guidelines ...................................................................................................................................4
Chapter 2 Operation and Maintenance of Flex-Flo Control Unit .......................................................................6
Standard Systems ..................................................................................................................................6
Extension Systems .................................................................................................................................6
Indicator Lights Under Toggle Switch ....................................................................................................6
LED Indicator Lights Inside Enclosure ...................................................................................................7
Safety Backup Switch Time Delay .........................................................................................................7
Safety Backup Switch Sensitivity Level Adjustment ...............................................................................7
Replacing Top Circuit Board ..................................................................................................................9
Chapter 3 Parts List .............................................................................................................................................10
Flex-Flo Control Unit (FLX-5260) .........................................................................................................10
Chapter 4 Wiring Diagrams .................................................................................................................................12
Flex-Flo Control Unit Used with 5 Wire Sensor ....................................................................................12
Flex-Flo Control Unit Extension System - Dependent ..........................................................................13
Flex-Flo Control Unit Extension System - Independent .......................................................................14
Flex-Flo Control Unit Used with Hopper Level Controls .......................................................................15
Flex-Flo Control Unit Used with IR Plus Feed Sensor .........................................................................16
Flex-Flo Control Unit Used with IR Plus Feed Sensor as Hopper Level Controls ................................17
Flex-Flo Control Unit Used with Smart IR Sensor ................................................................................18
Flex-Flo Control Unit Used with 3 Phase Power ..................................................................................19
Flex-Flo Control Unit Used with Universal Sensor ...............................................................................20
Chapter 5 Warranty ..............................................................................................................................................21

4PNEG-1955 Flex-Flo Control Unit
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-1955 Flex-Flo Control Unit 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 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.
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-1955 Flex-Flo Control Unit
2. Operation and Maintenance of Flex-Flo Control Unit
Standard Systems
The Flex-Flo Control Unit is primarily controlled by an auxiliary switch, such as a proximity switch or
infraredsensororhopperlevelcontrol. Refertowiringdiagramson Pages 12-20that matches 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 the feedisfull, thefeedwill build-upinsidethebox behind thecontrol unitandthesafety backup
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.In thecaseof an extensionsystem, there is no auxiliaryswitchused to controlthefillsystem
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 14. 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 Page 13. When wired this way, the fill system
auger is controlled by the extension system control unit.
Indicator Lights Under Toggle Switch
There are two (2) indicator lights on the end of the Flex-Flo Control Unit underneath the toggle switch.The
lower light is green and indicates that the toggle switch is ON and the safety backup switch has not been
activated.TheFlex-Floaugerwill be allowedtorunif theauxiliaryswitchis callingforfeed,whenthis green
light is ON. (See Figure 2A.)
The upper light is red and indicates that the toggle switch is ON and the safety backup switch has been
activated. The Flex-Flo auger will not run when this red light is ON. (See Figure 2B.)
Figure 2A Control on Box - Green Figure 2B Control on Box - Red

2. Operation and Maintenance of Flex-Flo Control Unit
PNEG-1955 Flex-Flo Control Unit 7
LED Indicator Lights Inside Enclosure
There are three (3) LED indicator lights inside the enclosure on the lower left portion of the bottom PC
board. The left LED is red and indicates when the Flex-Flo Control Unit is in “sensitivity level programming
mode” used to adjust the sensitivity level of the safety backup switch.
The center LED is yellow and indicates whenthe safety backup switch has been activated and is detecting
feed. When this light is ON, the Flex-Flo auger will not run.
The right LED is green. When it is on solid, the safety backup switch has not been activated and the
Flex-Flo auger will be allowed to run as long as the auxiliary switch is calling for feed. When the green LED
is flashing, the Flex-Flo auger is in the 30 seconds time delay period prior to being allowed to run.
(See Figure 2C.)
Figure 2C LED Indicator Lights Inside Enclosure
Safety Backup Switch Time Delay
The Flex-Flo Control Unit safety backup switch has a fixed 30 seconds time delay. Once feed falls away
from the safety backup switch, the Flex-Flo Control Unit will begin to count down until the 30 seconds 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 inside the enclosure on the lower left portion of the bottom PC board will flash during
the 30 seconds timedelay period. Once the 30 seconds time delay period has expired, the green LED will
remain on solid and the Flex-Flo auger will be allowed to run.
Safety Backup Switch Sensitivity Level Adjustment
The safety backup switch inside the Flex-Flo Control Unit does not rely on feed pressure to activate. It
uses a special sensor inside the enclosure that can sense the presence of feed through the 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 most feeds. It should
only require adjusting if it fails to activate when feed builds up inside the box behind the control unit
enclosure and causes the auger motor’s thermal overload protector to kick out.
WARNING
While adjusting the sensitivity level of the Flex-Flo Control Unit’s safety backup
switch, there is live high voltage power inside the enclosure. Use a screwdriver with
an insulated handle to adjust the sensitivity level. While adjusting the sensitivity
level, make sure to never touch any terminals or exposed bare wire ends.

2. Operation and Maintenance of Flex-Flo Control Unit
8PNEG-1955 Flex-Flo Control Unit
IMPORTANT: Before adjusting the sensitivity level, make sure there is no feed inside the box behind the
control unit. Attempting to adjust the sensitivity level with feed inside the box behind the
control unit will result in failure of the safety switch.
Inside the enclosure, located on the lower right portion of the bottom PC board, is a square shaped push
button switch. It is used for programming the sensitivity level of the safety backup switch. To program the
sensitivity level, carefully insert a small screwdriver with an insulated handle and push the switch once,
and then hold down for approximately 5 seconds until the red LED comes ON. Then release the button.
The flashing red LED indicates that the control is in “sensitivity level programming mode”. The red LED
will continue to flash the same number of times equal to the setting, 1 through 6 for several cycles.
Setting 1 is the least sensitive. Setting 6 is the most sensitive. A setting of 3 or 4 works the best for most
types of feed. To advance to the next setting, push and release the switch once. The number of flashes
will then be advanced to the next higher setting. The settings will roll over from 6 back to 1. Once the
desired setting is achieved, wait until the red light stops flashing. All three (3) LED’s will then begin to flash
alternately for 30 seconds. Once the 30 seconds has expired, the control will jump out of “sensitivity level
programming mode” back to normal operation. (See Figures 2D and 2E.)
Figure 2D Delay Adjustment
Figure 2E Delay Red Flash

2. Operation and Maintenance of Flex-Flo Control Unit
PNEG-1955 Flex-Flo Control Unit 9
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 top board. Remove the four (4) screws
(S-7393) that secure the top board to the bottom board.
IMPORTANT: The left end of the top circuit board is plugged into a socket on the bottom circuit board, so
you must wiggle the top circuit board back and forth, while applying upward pressure until
the board becomes free.
To attach a new top circuit board, reverse the procedure above. Be sure the plug on the left side of the
circuit board is aligned with the socket on the bottom board before pressing into place. (See Figures 2F
and 2G.)
Figure 2F Remove Connections from Board
Figure 2G Removing Board

10 PNEG-1955 Flex-Flo Control Unit
3. Parts List
Flex-Flo Control Unit (FLX-5260)

3. Parts List
PNEG-1955 Flex-Flo Control Unit 11
Flex-Flo Control Unit (FLX-5260) Parts List
Ref # Part # Description Qty
1FLX-4560 Cover, Electrical Box Lid 4" x 6" 1
2 S-995 Screw, MS #10-24 x 1" PHP SS 4
3FLX-4561 Gasket, Electrical Box 4" x 6" 1
4 S-7393 Screw, MS #6-32 x 1/4" PHP ZN Grade 2 4
5FLX-5270-3 Terminal Block Plug, Three (3) Connector 1
6 FLX-5270-2 Terminal Block Plug, Two (2) Connector 2
7FLX-5260-T Top Circuit Board Assembly 1
8 S-8183 Screw, SMSA #6 x 3/8" PHP ZN 4
9FLX-5260-B Bottom Circuit Board with Enclosure 1
10 E105-1024 Wire Kit 1/4" Fem x 1/4" Fem x 5" Long 2
11 20-5060 Switch, Toggle SPST 15A with ON/OFF 1
12 S-7931 Hex Nut #10-24 SS 4
13 S-6622 Plate, ON-OFF Back 1
14 70-0129 Switch, Boot Weatherproof 1
15 S-10292 Cable Gland, PG7 Thread Size 2
16 FH-1310 Connector, Cord Heyco #3231 3
17 FH-7400 Washer, 1/2" PVC Connector Yellow 3
18 FH-1309 Lock Nut 1/2" with Pipe Threads 3

12 PNEG-1955 Flex-Flo Control Unit
4. Wiring Diagrams
Flex-Flo Control Unit Used with 5 Wire Sensor
FLEX-FLO CONTROL UNIT (FLX-5260)
PROXIMITY SWITCH (AP-1002)
L1 L2 L3
M1
M2 M3
Incoming Power Flex-Flo Motor Auxiliary Switch RED
GREEN
BLACK
BROWN
GREEN
WHITE BLACK
GREEN
WHITE BLACK
L1 L2 IN
OUT COM. N.O.
Relay
Output
Signal
Signal
Power Power
N.O. - ORANGE (NOT USED) N.C. - RED COM. - GREEN LINE - BLACK LINE - BROWN
TAPE FOR PROTECTION
FLEX-FLO
MOTOR
GND
L2
L1
208-230VAC
POWER SUPPLY

4. Wiring Diagrams
PNEG-1955 Flex-Flo Control Unit 13
Flex-Flo Control Unit Extension System - Dependent
FLEX-FLO CONTROL UNIT
FILL SYSTEM (FLX-5260) FLEX-FLO CONTROL UNIT EXTENSION SYSTEM (FLX-5260)
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
14 PNEG-1955 Flex-Flo Control Unit
Flex-Flo Control Unit Extension System - Independent
FLEX-FLO CONTROL UNIT
FILL SYSTEM (FLX-5260) FLEX-FLO CONTROL UNIT EXTENSION SYSTEM (FLX-5260)
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-1955 Flex-Flo Control Unit 15
Flex-Flo Control Unit Used with Hopper Level Controls
FLEX-FLO CONTROL UNIT (FLX-5260)
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
16 PNEG-1955 Flex-Flo Control Unit
Flex-Flo Control Unit Used with IR Plus Feed Sensor
FLEX-FLO CONTROL UNIT (FLX-5260)
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

4. Wiring Diagrams
PNEG-1955 Flex-Flo Control Unit 17
Flex-Flo Control Unit Used with IR Plus Feed Sensor as Hopper
Level Controls
FLEX-FLO CONTROL UNIT (FLX-5260)
FLEX-FLO
MOTOR
GND
L1
208-230VAC
POWER SUPPLY
IR PLUS FEED SENSOR
WITH LID REMOVED
Time Delay
0 Sec.
30 Sec.
60 Sec.
90 Sec.
Power LED
Auger LED
Detect LED
N.O. N.C.
YELLOW
BLACK
L2
YELLOW
BLACK
GREEN
GREEN
YELLOW YELLOW
RED
EARTHGND
RED
LINE 2 LINE 1
COM
IR PLUS FEED SENSOR
WITH LID REMOVED
Time Delay
0 Sec.
30 Sec.
60 Sec.
90 Sec.
Power LED
Auger LED
Detect LED
N.O. N.C.
BLACK
YELLOW
EARTH GND
GREEN
LINE 2 LINE 1
COM
YELLOW RED
IR PLUS FEED SENSOR
FOR HOPPER 1 (FLX-5262)
IR PLUS FEED SENSOR
FOR HOPPER 2 (FLX-5262)
BLACK
WHITE
GREEN
BLACK
WHITE
GREEN
L1
L2
L3
M1
M2
M3
Incoming Power Flex-Flo Motor Auxiliary Switch
GREEN
RED
BLACK
YELLOW
YELLOW
Power L1
L2
Power
Signal
Signal
IN
CUT
COM.
N.O.
Relay
Output

4. Wiring Diagrams
18 PNEG-1955 Flex-Flo Control Unit
Flex-Flo Control Unit Used with Smart IR Sensor
FLEX-FLO CONTROL UNIT (FLX-5260 )
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
SMART IR SENSOR (FLX-4951 )
COM.
RELAY
OUTPUT
ALARM
CONTACTS 230VAC
POWER
SUPPLY
N.O.
N.C. YELLOW
YELLOW
COM. N.O. N.C.
GND L1 L2
GREEN
RED
BLACK
SMART IR SENSOR
WITH LID REMOVED

4. Wiring Diagrams
PNEG-1955 Flex-Flo Control Unit 19
Flex-Flo Control Unit Used with 3 Phase Power
FLEX-FLO CONTROL UNIT (FLX-5260)
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
BROWN
RED
FLEX-FLO
3 PHASE
MOTOR
GND
L3
L2
208-230VAC
3 PHASE
POWER SUPPLY
UNIVERSAL SENSOR (AP-2983)
RED
GREEN
WHITE BLACK RED
L1
GROMMET INSERTION LINE
N.O. - ORANGE (NOT USED) LINE - BROWN N.C. - RED
TAPE FOR PROTECTION

4. Wiring Diagrams
20 PNEG-1955 Flex-Flo Control Unit
Flex-Flo Control Unit Used with Universal Sensor
FLEX-FLO CONTROL UNIT (FLX-5260)
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
BROWN
RED
FLEX-FLO
MOTOR
GND
L2 208-230VAC
POWER SUPPLY
UNIVERSAL SENSOR (AP-2983)
GREEN
WHITE BLACK
L1
GROMMET INSERTION LINE
N.O. - ORANGE (NOT USED) LINE - BROWN N.C. - RED
TAPE FOR PROTECTION