GSi Flex-Flo 220 Guide

1
Flex-Flo
Model 220, 300 & 350,
500, and HR
Owner's Manual
Manual# PNEG-914
REVISED: 7/6/06
Installation & Operation

2
Flex-Flo

3
Flex-Flo
Table of Contents
Table of Contents 3
Safety 4-5
Introduction 9
Flex-Flo Specifications(English / Metric) 10-12
Installation
Boot Installation 13
Slide Gate Installation 13
Unloader Installation 13
Restrictor Adjustment 14
Straight-Through Tandem Installation 14
Auger Tubing Installation 15
Cementing Procedure 16
Outlet Hole Cutting Chart 16
Drop Kit Installation 17
Kwik-Attach Drop Kit Installation 18
Power Unit / Control Unit 19-21
Auger Installation 21-22
Extension Hopper Installation 23-24
Operation Guidelines 24-25
Components
Feed Line Components 26
Model 220 Unloader & Anchor Assembly 27
Model 300, 350, & HR Unloader & Anchor Ass. 28
Model 500 Unloader & Anchor Assembly 29
Direct Drive & Tube Anchor 30
Belt Drive & Anchor Tube 31
Control Unit 32
Belt Drive Power Unit 33
Direct Drive Power Unit 34
Drop Kit / Kwik-Attach Drop Kit 35
Unloader Switch 36
Micro Drop Tube Switch, Proximity Switch 37
Wiring Diagram - 220V Control Unit 38
Wiring Diagram - 110V Control Unit 39
Wiring Diagram - 208-230V, 3 Phase Control Unit 40
Warranty 41

Flex-Flo
4
SAFETY FIRST
General Safety Statements
TheGSIGroupInc’sPrincipalconcernisyoursafety
and the safety of others associated with grain han-
dling equipment. We want to keep you as a cus-
tomer. This manual is to help you understand safe
operatingproceduresandsomeproblemswhichmay
beencounteredby the operatorandother personnel.
Asownerand/oroperator, it isyourresponsibilityto
know what requirements, hazards and precautions
existand inform allpersonnel associatedwith,or in
theareaofthe Fill/Feed System. Safetyprecautions
maybe required fromthe personnel. Avoidany al-
terationtotheequipment. Suchalterationsmaypro-
duceaverydangeroussituation,whereseriousinjury
ordeath mayoccur.
DANGERindicates an imminently hazardoussituation
which, if not avoided, will result in death or serious
injury
WARNING indicates a potentially hazardous situation
which , if not avoided, could result in death or serious
injury.
CAUTION indicates a potentially hazardous situation
which, ifnot avoided, may result in minor or moderate
injury.
DANGER
This is the safety alert sym-
bol. It is used to alert you to
potential personal injury
hazards. Obey all safety
messagesthat follow this symbol to avoid
possible injury or death.
WARNING
CAUTION
CAUTION used without the safety alert symbol indi-
cates a potentially hazardous situation which, if not
avoided, may result in property damage.
CAUTION
User’s Manaul
Thismanual contains informationand instructions
essential to the safe installation and use of this
Flex-FloSystem. The manual should be readthor-
oughly before attempting any installation or use
ofthe Flex-Flo System. This manualshouldbekept
with the Flex-Flo System, or in a location where it
canbereadily accessed. Failuretoread thismanual
andits safety instructions is a misuse onthe equip-
ment.
Correct Uses of Your Flex-Flo System
The Flex-Flo System is designed for the sole pur-
pose of conveying powered or granular, agricul-
tural, animal feed. Use of the system in any other
wayisa misuse ofthesystem and mayendangerthe
healthandsafetyof anyandallperson’s.
Danger!
Electrical Safety
Provisionofanadequateandsafe
powersupplytotheFlex-Flounit
is essential to your safety. The GSI Group, Inc.
recommendsthatacompetentandqualifiedelec-
tricianundertakeallelectricalwiring. Allwiringis
to be installed in accordance with all Local and
National Standards and Regulations relevant to
yourCountryandRegion.
Electricalsafety devices, EmergencyStopsand
MainIsolators are recommended with theFlex-
Flo System and are essential for you safety.
These should be installed as indicated in the
enclosed installation instructions and in accor-
dance with the relevant Directives in force.

Flex-Flo
5
In the installation and use of the Flex-Flo System,
only genuine AP/GSI parts are to be used. Use of
other non-genuine parts is a misuse of the system,
andmayleadtodangeroussituationsriskingthesafety
andhealthof youandothers.
Thissystem is notdesigned for usein atmospheres
wheretherisk ofexplosion is foreseen. Usein such
anenvironmentisprohibited. Ifindoubtconactyour
dealeror The GSIGroup, Inc.
SafetyGuards
TheFlex-FloSystemcontainsmanymovingandelec-
tricalparts, whichwould causeserious injury, even
deathiftouched. Guards areplaced on themachine
to protect you. Operating the machine at any time
withguardsremovedorincorrectlyfittedisaserious
misuse of the machine and endangers you and the
safetyofother’s.
Safetyin Handling the Flex-FloSystem
TheFlex-FloDrive Unitweighs 48lbs. (22kgs.)All
precautionsshouldbetakenwhenliftingandormov-
ingtheunit. Ideallymechanicalliftequipmentshould
beused. If manual handlingis necessaryassistance
shouldbesought from otherpeople.
CECompliance
InaccordancewithEuropeanUnionDirectives,
GSIhasmade everyeffortto ensurethat this
productcomplieswith the essential requirements of
theMachineryDirective,theLowVoltageDirec-
tive,andtheElectromagneticCompatibilityDirec-
tive. Assuch,we havedeclaredconformity and
affixerdtheCE Mark. Ourdeclarationrelates only
togenuineGSIFlexFloSystems installed as
intended by GSI. We cannot and do not declare
conformityforanymodifications,additionsorany
systemswhatsoeveroperatingon orwithGSI
productsthat arenot supplied by GSI orare inany
wayoutsidethe controlofGSI.
SafetyinMaintenance
TheFlex-FloSystemisdesignedtokeepmaintenance
toaminimum,however, somerepairswillbeneces-
sary in the course of the life of the system. Do not
attemptanyrepairsonthesystemunlessyouarecom-
petent to do so. Remember that the Flex-Flo oper-
ates under automatic control and will start without
warning. Never attempt any work on the Flex-
Flo system without first isolating the drive unit
from the main power, and locking the isolator
so that only you can turn the power back on.
For your safety, follow the guidelines given in the
maintenancesectionofthismanual.
Before re-starting the Flex-Flo System, make sure
thatall electrical enclosuresare locked closed, and
allguards and other safetymeasuresarecorrectlyfit-
ted. Ifin any doubtcontact your dealeror The GSI
Group,Inc.for assistance.
Dust
Under normalworking conditions little or no dust
should be created by the Flex-Flo System. How-
ever,somedust maybecreated,whichmaybeharm-
fulto yourhealth if inhaled. To prevent this,wear a
suitabletypedustmask.
Noise
Noiseisnot generally ahazardassociatedwith the
Flex-FloSystem. Excessivenoisemayindicate a
problemwiththemachines. Testsonthismachine
haveindicatednoiselevels at aposition1meter
fromthedrive unitand1.6 meters abovethe ground
donotexceed 70dBa,continuous “A”weighted
soundpressure or63 Pa, instantaneous“C”
weightedsoundpressure.
SoundSignsandWarnings
Thefollowingpagesshowyouextactlywherethe
safetyandwarning decals shouldbeplaced onyour
Flex-FloSystem. Ifa decalismissing orunread-
able,please contactyour dealer or The GSIGroup,
Inc.fora freereplacement.
Forguidanceorassistance onanyissuerelating to
thesafeuse ofyour Flex-Flo Systemcontact The
GSI Group, Inc. at 1-217-226-4421 or fax us at
1-217-226-4420.
TheGSI Group,Inc.
1004EastIllinoisStreet
Assumption,Il.62510

Flex-Flo
6

Flex-Flo
7

Flex-Flo
8

Flex-Flo
9
Background
The Flex-Flo fill system consists of a
combination of PVC tubes and pre-
formed PVC elbows. A special PVC
cementis usedto connectthe tubes and
elbows. The PVC tubes are available
in 4 different sizes. The PVC tube
contains a rotating auger which con-
veys the feed to the different outlet
holes. The auger is driven by a direct
drive power unit or a belt drive power
unit.
Applications
InPoultryApplication, Flex-Flo FillSystemconveys feedfrom
BulkFeedTank tohoppersinside thePoultrybuildingas shown
in Figure 1. Other feed systems (i.e. Cycle Plus, Chain Feeder
etc.)takethe feed fromthehopper tothedesired locations inthe
building. Onthislayout,hopperlevelswitchesmay be placed in
more than one hopper to assure that no hopper empties before
thecontrolunithopperrequiresfeed. (Allswitchesmustbewired
inparallelso that anyoneswitch can startthesystem.)
InSwineapplications,Flex-FloFill System conveysfeedfrom
BulkFeedTankstoeachindividualfeeder(i.e.S.S.HogFeeder,
Drop Feeder etc.) Directly as shown in Figure 2. It is at this
location that feed is being consumed. A feed level control is
installed at the end to shut off the system after all feeders are
filled.
Introduction
Figure1:PoultryApplicationlayout
Figure2: SwineApplicationlayout
BuildingSafety
IfyouareintendingtoinstalltheFlex-Flo
Systemat highlevels and/or suspended
fromabuilding structure,itis important
thatyoucheck thestructural integrity of
yourbuildingtocarrytheadditionalload.
Forinformationontheimposedloadson
yourbuilding by your Flex-Flo system,
please contact your dealer or the GSI
GroupInc.
Installation Sequence
Thismanual outlines the recommended
order for the installation of the Flex-
Flo System. Following this guideline
will provide the safest and easiest
methodof installation. Above all,con-
nection of the system to the electrical
mains should be the final stage of in-
stallation. Failureto observe this could
lead to a fatal accident.

Flex-Flo
10
Flex-FloSystems Specifications
The Feed Tank Connections
FeedTankOrientation
Positioningthefeedtankinlinewith the
Flex-Flo System will provide the most
trouble-free operation possible. Avoid
unneccessaryelbowsandcurves to ease
system installation. A feed tank with a
30°unloader isgenerally required tobe
at least 10 1/2’ (3.2m) away from the
building. Withastraightunloader,thetank
willbeapproximately 4’ (1.22m) farther
awayfromthebuildinginorderto make
auger tube connections. The reference
pointsare based upon the height where
thesystem enters thebuilding. Different
unloaderswithvariouselbowsandcurves
usedprovidedifferent entrance opportu-
nities. The distances are achieved by
modifyingandadjustingtheelbowsand
tubing as needed. See Table 1 on page
11(English)orpage12(Metric)fortank
placementrecommendations.
Model 220 Model 300 Model 350 Model 500 Model HR
Auger Tube Diameter 2.2" 3" 3.5" 5" 3.5"
55mm 75mm 90mm 125mm 90mm
Carring Capacity 15 lbs/min 50 lbs/min 100 lbs/min 220 lbs/min 50 lbs/min
based on 40 lbs./cubic ft. 7 kg/min 22 kg/min 45 kg/min 100 kg/min 22 kg/min
900 lbs/hr 3,000 lbs/hr 6,000 lbs/hr 13,200 lbs/hr 3,000 lbs/hr
420 kg/hr 1,400 kg/hr 2,700 kg/hr 6,000 kg/hr 1,400 kg/hr
Maximum Partical Size 1/8" (3.175mm) x crumble type feed shelled corn or pellets larger feed fragments High moisture shelled
and Feed Type 1/2" (12.7mm) L max mash 3/16" (4.76mm) x like shelled corn or corn (up to 27%) or
moisture content 18% 1/2" (12.7mm) ground pellets 3/8" (9.52mm) x ground feed.3/8" (9.52mm)
corn 1" (25.4mm) L dia x3/4" (19.05mm) long
Ø 3.0"
(75mm)
Ø 2.2"
(55mm) Ø 3.5"
(90mm) Ø 5.0"
(125mm) Ø 3.5"
(90mm)
Model220 Model300 Model350 Model500 ModelHR
straight unloader
30° unloader

Flex-Flo
11
"H" (ft) 30o45o60o30o45o60o
5 10.5 -- -- 15.0 -- --
6 12.5 11.0 -- 17.0 -- --
7 14.0 12.0 -- 18.5 17.0 --
8 16.0 13.0 -- 20.0 18.0 --
9 17.5 14.0 -- 22.0 19.0 --
10 19.5 15.0 -- 23.5 20.0 --
11 21.0 16.0 14.5 25.5 21.0 19.5
12 23.0 17.0 15.0 27.0 22.0 20.0
13 24.5 18.0 16.0 29.0 23.0 21.0
14 26.5 19.0 16.5 30.5 24.0 21.5
15 28.0 20.0 17.0 32.5 25.0 22.0
16 30.0 21.0 17.5 34.0 26.0 22.5
17 31.5 22.0 18.0 36.0 27.0 23.0
18 33.5 23.0 18.5 37.5 28.0 23.5
19 35.0 24.0 19.5 39.5 29.0 24.0
20 37.0 25.0 20.0 41.0 30.0 25.0
Model 220 with 10' Radius Elbows
"X" for strai
g
ht boot
(
ft
)
"X" for 30o boot
(
ft
)
"H" (ft) 30o45o60o30o45o60o
5 9.0 -- -- 12.0 10.0 --
6 10.5 8.0 7.5 13.5 11.0 10.0
7 12.0 9.0 8.0 15.5 12.0 11.0
8 14.0 10.0 8.5 17.0 13.0 11.5
9 15.5 11.0 9.0 19.0 14.0 12.0
10 17.0 12.0 9.5 20.0 15.0 12.5
11 19.0 13.0 10.0 22.5 16.0 13.0
12 20.5 14.0 11.0 23.5 17.0 13.5
13 22.5 15.0 11.5 26.0 18.0 14.0
14 24.0 16.0 12.0 27.0 19.0 15.0
15 26.0 17.0 12.5 29.5 20.0 15.5
16 27.5 18.0 12.5 30.5 21.0 16.0
17 29.5 19.0 13.5 33.0 22.0 16.5
18 31.0 20.0 14.0 34.5 23.0 17.0
19 33.0 21.0 15.0 36.0 24.0 17.5
20 34.5 22.0 15.5 37.5 25.0 18.5
Model 500 with 6' Radius Elbow
"X" for 30o boot
(
ft
)
"X" for strai
g
ht boot
(
ft
)
Table 1: (English) Tank centerline to building entrance distance “X” from given heigth “H”
Equipment Orientation Charts.
"X" FOR 30 BOOT(FT) "X" FOR STRAIGHTBOOT(FT)
"H" (FT) 30 45 60 30 45 60
5 9 -- -- 12 10 --
6 10.5 8 7.5 13.5 11 10
7 12 9 8 15.5 12 11
8 14 10 8.5 17 13 11.5
9 15.5 11 9 18.5 14 12
10 17 12 9.5 20.5 15 12.5
11 19 13 10 22 16 13
12 20.5 14 11 24 17 13.5
13 22.5 15 11.5 25.5 18 14
14 24 16 12 27.5 19 15
15 26 17 12.5 29 20 15.5
16 27.5 18 12.5 31 21 16
17 29.5 19 13.5 32.5 22 16.5
18 31 20 14 34.5 23 17
19 33 21 15 36 24 17.5
20 34.5 22 15.5 38 25 18.5
MODEL 220,300,350,HR,WITH 5' RADIUS ELBOW

12
Flex-Flo
Table 1: (Metric) Tank centerline to building entrance distance “X” from given heigth “H”
Equipment Orientation Charts.
"X" for 30° boot (m) "X" for straight boot (m)
"H" (m) 30° 45° 60° 30° 45° 60°
1.52 2.74 -- -- 3.66 3.05 --
1.83 3.20 2.44 2.29 4.11 3.35 3.05
2.13 3.66 2.74 2.44 4.72 3.66 3.35
2.44 4.27 3.05 2.59 5.18 3.96 3.51
2.74 4.72 3.35 2.74 5.64 4.27 3.66
3.05 5.18 3.66 2.90 6.25 4.57 3.81
3.35 5.79 3.96 3.05 6.71 4.88 3.96
3.66 6.25 4.27 3.35 7.32 5.18 4.11
3.96 6.86 4.57 3.51 7.77 5.49 4.27
4.27 7.32 4.88 3.66 8.38 5.79 4.57
4.57 7.92 5.18 3.81 8.84 6.10 4.72
4.88 8.38 5.49 3.81 9.45 6.40 4.88
5.18 8.99 5.79 4.11 9.91 6.71 5.03
5.49 9.45 6.10 4.27 10.52 7.01 5.18
5.79 10.06 6.40 4.57 10.97 7.32 5.33
6.10 10.52 6.71 4.72 11.58 7.62 5.64
Model 220,300,350, and HR, with 5' Radius Elbow
"H" (m) 30o45o60o30o45o60o
1.52 3.20 -- -- 4.57 -- --
1.83 3.81 3.35 -- 5.18 -- --
2.13 4.27 3.66 -- 5.64 5.18 --
2.44 4.88 3.96 -- 6.10 5.49 --
2.74 5.33 4.27 -- 6.71 5.79 --
3.05 5.94 4.57 -- 7.16 6.10 --
3.35 6.40 4.88 4.42 7.77 6.40 5.94
3.66 7.01 5.18 4.57 8.23 6.71 6.10
3.96 7.47 5.49 4.88 8.84 7.01 6.40
4.27 8.08 5.79 5.03 9.30 7.32 6.55
4.57 8.53 6.10 5.18 9.91 7.62 6.71
4.88 9.14 6.40 5.33 10.36 7.92 6.86
5.18 9.60 6.71 5.49 10.97 8.23 7.01
5.49 10.21 7.01 5.64 11.43 8.53 7.16
5.79 10.67 7.32 5.94 12.04 8.84 7.32
6.10 11.28 7.62 6.10 12.50 9.14 7.62
Model 220 with 10' Radius Elbows
"X" for 30o boot
(
m
)
"
X" for strai
g
ht boot
(
m
)
"H" (m) 30o45o60o30o45o60o
1.52 2.74 -- -- 3.66 3.05 --
1.83 3.20 2.44 2.29 4.11 3.35 3.05
2.13 3.66 2.74 2.44 4.72 3.66 3.35
2.44 4.27 3.05 2.59 5.18 3.96 3.51
2.74 4.72 3.35 2.74 5.79 4.27 3.66
3.05 5.18 3.66 2.90 6.10 4.57 3.81
3.35 5.79 3.96 3.05 6.86 4.88 3.96
3.66 6.25 4.27 3.35 7.16 5.18 4.11
3.96 6.86 4.57 3.51 7.92 5.49 4.27
4.27 7.32 4.88 3.66 8.23 5.79 4.57
4.57 7.92 5.18 3.81 8.99 6.10 4.72
4.88 8.38 5.49 3.81 9.30 6.40 4.88
5.18 8.99 5.79 4.11 10.06 6.71 5.03
5.49 9.45 6.10 4.27 10.52 7.01 5.18
5.79 10.06 6.40 4.57 10.97 7.32 5.33
6.10 10.52 6.71 4.72 11.43 7.62 5.64
Model 500 with 6' Radius Elbow
"X" for 30o boot
(
m
)
"
X" for strai
g
ht boot
(
m
)

13
Flex-Flo
Boot Installation
Slide the boot as far as possible into the tank collar
opening. Align the boot with the Flex-Flo System
thatwill be installed. Usingtheholesinthecollarfor
guides,drill11/32inchholesintothebootrim. Mount
the boot to the collar with the hardware provided.
SeeFigure5forproperusageofhardwareformount-
ingtheboot andslidegate. All connectionsshallbe
tighteneduntiltheyare“Snug”.
Slide Gate Installation
Bolt the transfer plate to the boot. See Figure 3 for
properinstallationmethods. Once theplateis prop-
erly installed insert the slide into the transfer plate.
The slide must be in its operating position prior to
attaching the slide shield to the transfer plate. Use
two (2) 5/16 inch - 18 UNC by 3/4 inch truss head
tapboltstomount the slideshield.
Note: Slide gate & shield must be installed in
the same direction that the Flex System is
traveling.
Tank Collar
Slide Boot
Transfer
Plate
UnloaderBody
Key Description Part #
1 5/16" X 1" Truss Head Machine Screw S-4336
2 5/16" Nylon Washer S-4338
3 5/16" - 18 Nylon Hex Nut S4337
Fi
g
ure 3: Boot and Slide Gate Installation
Unloader Installation
The Unloader
Attach the unloader to the transfer plate. Use four
(4) 5/16 inch 18UNC by 3/4 inch round head tap
bolts. Once the installation of the auger tubes and
augeriscomplete,inserttheinspection/clean-outplate
ortheoptionalunloaderswitchin place.
Inspection/Clean-Out Plate Installation
The inspection/clean-out plate is to be installed
per the following instructions:
1. Back off both wing nuts to the stud ends.
2. Slide the plate onto the lower side of the
unloader opening.
3. Move the plate first against the side of the
unloader then upward toward the top of the
unloader. (See Figure4.)
4. Tighten the wing nuts while holding the plate
steady.
Step 2
Step 3
Figure 4: Clean-Out Plate Installation
FeedTank Collar
ThestandardBulkFeedTank is supplied witha16”
(40.64cm) hopper opening. If needed, 22”
(55.88cm)hopperopeningsarealsoavailable. Con-
sultyour dealerforspecificorderinginstructions.

14
Flex-Flo
Restrictor Adjustment
The restrictor may be adjusted to allow more feed
flow. Do not modify the restrictor until the sys-
tem is completely operational and the auger has
been polished by running feed through the sys-
tem.
Instructions:
1. Removetherestrictor tubefrom the unloader.
2. Cut1"(2.5cm)fromthe restrictor (SeeFigure5).
3. Installtherestrictorandthebearingassemblyinto
theunloader.
4. Test the feed flow.
5. If the desired feed flow rate is not attained,
repeat the above procedure until the desired
rate is reached.
Straight-through Tandem Installation
The straight-through tandem system should be
installed the same as a single tank system with
the following exceptions:
1. Mount theboots on bothtanks andthesingle or
twinoutunloaderasinstructed.
2. Install baffle plate (FLX-4310) in the single-
throughunloaderasshowninFigure6. The twin
unloader baffle is factory installed as shown
in Figure 7.
3. Slide the belled end of a straight tube onto the
unloaderoutletonthefirsttank. Holdthestraight
tubing in the desired mounting position. Mark
and cut the straight tube at the point where the
tubeandtheinletofthestraight-throughunloader
inletintersect.
4. Slip the appropriate tube coupler over the cut
end of the straight tube. Position the straight
tube in its operating location. Slide and clamp
the tube coupler over the straight-through
unloaderinlet. (SeeFigure 8).
Note: Thecouplershould be equally distrib-
uted between the tubing and the unloader
inlet.
5. Feed the auger through the single/twin-out
unloaderto therest ofthe system and anchor as
instructed.
Restrictor as Manufactured, Installed in Unloader
Cut-off Restrictor for Increased Feed Flow
Figure 5: Restrictor Adjustment.
Figure 6: Straight
Through Unloader.
Clean-Out
Door
Single-Thru
Unloader
TubeCoupler
Clamp
Single-Out
Unloader
Figure 8: Tandem System Installation.
FLX-4310
Material Flow
Plan View
Figure 7: Twin
Through Unloader.
Uni-directional
Bi-directional
1”(2.5cm)

15
Flex-Flo
Auger Tubing
Auger Tubing Installation
The auger tubing is one of the most important parts of the Flex-
Flo Fill System. Proper installation is very important. Dry fit
ALL parts before cementing or clamping. Once the complete
systemisfittingproperly,cementorclamptheentiresystem.
The following steps are to be performed in the exact order
shown:
1. Establishtheentrypointwheretheaugertubewillenterthebuild-
ing. Oncetheentrypointisdetermined,cutaholelargeenough
toaccommodatethetubing. Asealringandaneoprenesealare
providedtosealtheexcessareabetweenthetubeandtheholein
thebuilding. Thesealringandtheneoprenesealshallbeinstalled
asshowninFigure9.
2. Slidetheelbowtubingthroughtheholeinthebuilding. Establish
andcut(if necessary) the elbow at the desirelengthtoensure
thattheaugertubingwillbehorizontal. SeeFigure10forproper
cuttingdimensionsoftheelbowsatspecificdegreeangles.
3. Fitandclampasecondelbowaroundtheunloaderoutlet.
4. Slide the non belled end of the straight tubing into the belled
end of the “building” elbow. Hold the straight tubing in the
desired mounting position. Mark and cut the “unloader”
elbow at the point where it and the straight tubing intersect.
5. Remove the non-belled end of the straight tubing from the
“building”elbow. Slidethebelledendofthestraighttubingover
thefreshlycutendofthe“unloader”elbow. Markandcutthe
straighttubing(asneeded)sothatitwillfitinsidethebelledendof
the“building”elbow.
6. Dry fit all of the outside tubing to ensure correct installation.
Once satisfied, glue or clamp the tubing together per the
instructionsinthesectiontitled“CementingProcedure”pg16
7. When the auger tubing between the unloader and the build-
ingis15’(4.57m)orlonger,thetubesshouldbesupported.
8. Locateandcuttheoutletholesneededintheremainingstraight
tubes. Fortheexactsizeofoutletholes,seesectiontitled“Outlet
Holes”pg16. OnceALLoftheoutletholesaremadeandthe
tubingisdryfitted,glueorclampthetubestogetherperthein-
structionsinthesectionentitled“CementingProcedure”pg16.
9. Suspendtheaugertubesandelbowsfromtheceilingatleastonce
everyfour(4)feet. Ifhorizontalelbowsareused,supportthem
inatleasttwo(2)places. Chainandlagscrewsareprovidedin
eachsuspensionkit. Thetubesshouldbekeptasstraightand
levelaspossible.
FLX-2218
FLX-3422
Outside of Building Wall
15o
30o
45o
5’ (1.524m) Radius
15oElbow - 15 3/4” (40.005cm)
30oElbow - 31 1/2” (80.01cm)
45oElbow - 47 1/4” (120.015cm)
Do not include Belled End
when measuring along this surface.
Note: Align all outlet holes in proper
functional posistions prior to gluing
the tube joints together.
Figure 9: Seal Ring and Neoprene Seal
Installtion
Figure 10: Cutting Chart for 45oelbow
6’ (1.829m) Radius
15oElbow - 20 3/16” (51.276cm)
30oElbow - 40 5/16” (102.394cm)
45oElbow - 60 1/2” (153.67cm)
10’ (3.048m) Radius
15oElbow - 32” (81.28cm)
30oElbow - 64” (162.56cm)
45oElbow - 96” (243.84cm)

16
Flex-Flo
Cementing Procedure
Flex-Flo Systems have specially for-
mulated PVC tubing. For strong tube
connections, apply the PVC solvent
cement per the instructions as follows:
1. Square tube ends and remove all
burrs and dirt.
2. Check dry-fit of tubes. The smaller
end of the first tube should easily slide
one-thirdof theway into the belled end
of the second tube. The first tube end
should be snug in the second tube once
it is all the way in.
3. Whenthe temperatureis below
40°F (4°C) or above 85°F (29°C), con-
sultPVCsolventcementcontainer.
4. Applya liberal coat of cementin the
belledend. Avoidpuddling inside.
5. Apply a liberal coat of cement on
the smaller end, leaving no voids.
6. Assemble parts quickly! CEMENT
MUSTBE FLUID! If notfluid, re-coat
both parts.
7. Push the smaller end into the belled
end using a quarter turning motion
until the small end bottoms.
8. Hold tubes together for 30 seconds,
wipe off excess cement with cloth.
Completed joints should not be dis-
turbed until they have cured enough
to withstand handling.
Keep container closed when not in
use.
Outlet Holes
Establish where the outlet drops are to be. Once this is done,
cutholes for theoutlet drops. SeeFigure 11 belowfor hole size
recommendations. Iftotaldropoutisnecessary,itisrecommended
thattheholesarecut using asabersaworhacksaw. Whencarry-
over is desired, it is recommended that the outlet holes are cut
withaholesaw.
OutletHolefortotalDrop-out
“A”
“B”
OutletHolewhenCarry-over is
acceptable
1.0”(25mm)
Model Full Drop Carry Over
Variable "A" Variable "B"
220 1.5" (38mm) 1.5" (38mm)
300 2.5" (63mm) 2.5" (63mm)
350 3" (76mm) 3" (76mm)
500 4" (102mm) 4" (102mm)
HR 3" (76mm) 2.5" (63mm)
Figure 11: Outlet Hole Cutting Chart

17
Flex-Flo
Drop Kit Installation
1. Wrap the rotary slide over the outlet
hole and around the auger tube. Position
the slides with cutout facing in the same
directionfor all drops so thatthe slides will
operate the same when the ropes are
pulled.
2. Thread the rope through the ends of
therotaryslideasshowninFigure12andtie
theslideendstogethersothat the ends ofthe
ropearethe samelength.
3. Slide rope through molded guide holes
in drop halves.
4. Position the drop halves around the ro-
tary slide and attach both halves together
withthehardware provided asshownin
Figure13
5. Testtherotaryslide. Pull ononeropeata
time. Check the rotary slide to be sure it is
centeredoverthe outlethole.
6. Slide the rotary slide to its open posi-
tion by pulling the appropriate rope. Mark
the short rope end at the point where it
enters the guide hole. Tie a knot on the
rope at the mark. The location of the knot
will show at a glance if the slide is open or
closed.
7. Threadtheshortropeend through thered
ballandtie a knotinthe rope toholdthe ball
inplace. Installthe green ballthe same way
onthe other rope end.
8. Apply a small amount of PVC cement
around the drop to prevent it from moving
around on the auger tube.
9. Two screws are supplied for attaching
an optional drop tube (See Fig. 14). Use
bothscrews to attachthe droptubesecurely
to the drop kit.
Figure 12: Drop Kit Installation
Figure13:Drop Kit InstallationonFlex Flo Tube
Figure14:DropKitinstallationw/DropTube
Tie Knot
Square Knot Drop Half
Rope
Rotary Slide

18
Flex-Flo
Figure 15: Drop Kit Installation
PVCTubing
Slide
HoseClamp(2) Housing
1. Snaptheslidearoundthetubeoverthe outlet hole.
(Fig.15)
2. Fasten the housing to the tube using two hose
clamps. Makesuretheoutlet hole isinthemiddle
ofthehousing.
3. Slidecan berotated from side to sideto openand
closethe dropkit.
Kwik-Attach Drop Kit Installation

19
Flex-Flo
Power Unit and Control Unit
Flex-Flo offers two different types of power units,
direct drive unit and belt drive power unit, along with
thecontrolunit. Installationinstructionsareprovidedwith
each powerunit.
Horsepower requirements are based on length, type of
Flex-FloSysteminstalled,numberof turns, tandemsys-
temsetc. Table2showsmaximumlinelengthsfor Flex-
FloSystemsplusmaximumlengthsforentensionshopper
installion,usingvariouspowerunits.
Reductionofthemaximumlinelengthsinthechartshould
beallowed forif thesystem’sincline isgreater than450
and/or the rise of the system is higher than 8’ (2.44m).
For each additional 90o(2 elbows) used beyond chart,
reducethemaximumlinelengthforeachdriveunitby30’
(9.14m). For each straight-out to straight-thru tandem
system,decrease the maximumlinelengthforeachdrive
unitsizeby 50’(15.24m).
Direct Drive Power Unit/Control Unit
1. Bolt the tube anchor to the control unit body with a flat washer
oneach of thefour (4) 5/16 inch by3/4 inch bolts.(See Figure 16 for
moredetails.)
2. Slide the driver assembly onto the power unit drive shaft. Place
the 5/16 inch hex socket bolt (supplied with the driver assembly)
into the untapped hole of the driver through the drive shaft and
tighten the bolt into threaded portion of the driver.
3. Mount the control unit to the gearbox unit with four (4) 5/16” x
3/4” bolts and four (4) flat washers, which are supplied with the
powerunit. (See Figure17)
Table 2: The maximum length is for a system with three elbows.
CAUTION
Figure 16: Assembly of tube
anchor to the control unit
Caution: The safety switch on the con-
trol unit is provided as a backup swich in
case the hopper level or the drop tube
switch does not operate properly. This
switch is not intended to be used for con-
trolling the Flex-Flo System, but as a
safety backup switch only.
Ext. Pitch
Max. Max. Max. Max. Max. Max. Max. Max. Max. Max. Max. Max.
Motor Size Length Extension Length Extension Length Extension Length Extension Length Extension Length Extension
1/3 hp 150' 180' -- -- -- -- -- --
.246 kW 46m 91m -- -- -- -- -- --
1/2 hp 250' 300' 300' 80' 80' 30' 65' 30' 50'
.373 kW 24m 38m 38m 24m 38m 9m 20m 7.6m 12.7m
3/4 hp -- -- 400' 150' 150' 90' 90' 50' 50' 25' 25' 90' 90'
.559 kW -- -- 46m 56m 27m 38m 20.3m 25.4m
1 hp -- -- 200' 245' 150' 185' 100' 100' 50' 65' 150' 180'
.746 kW -- -- 61m 75m 46m 56m 38.1m 457m
1 1/2 hp -- -- -- -- -- -- 150' 180' 75' 90 -- --
-- -- -- -- -- -- -- --
Model 220 Maximum Line Len
g
th
Model 300 Model 350
from 18% - 27%
Model HR
Dry feed stuffs moisture
levels below 18%
Model 500
High-moisture
Systems moisture level

20
Flex-Flo
Figure 17: Assebly of the control
unit to the drive unit
4. Thecontrol unit and power unitrequire hardwiring. The supply
linewiresintoL1 &L2/Nofthe relayinthecontrol unit. The motor
leadswireintotheM1&M2oftherelayinthecontrolunit. Auxiliary
switchiswired intothemale & femalespade terminal ofthecontrol
unit(Seeback of manual for wiring diagram).
5. Slideand clamp a tube coupleron thetube anchor.
6. Attach the power/control unit to the Flex-Flo tubing.
7. Suspend power/control unit firmly from the ceiling as shown
inFigure 18. Support holes are providedon thepower unit and the
controlunit.
Figure 18: Direct Drive/Power Unit
Belt Drive Power/Control Unit
1. Bolt the tube anchor to the control unit body with a flat washer
on each of the four (4) 5/16” x 3/4” bolts. (See Figure 16 for more
detail.)
2. Insert the driver shaft through the bearing assembly. The
bearing mounting plate should be mounted in between. Tighten
the set screw on the bearing down to the shaft.
3. Bolt the two mounting brackets together with the four (4)
bolts and washers provided.
4. Attach the motor support assembly to the control unit with the
four (4) bolts already in the mounting bracket and belt guard.
Secure with the four (4) lockwashers and hex nuts provided. If
necessary, motor orientation can be reversed by rotating the mo-
tormount 180°.
5. Slideand clampa tube coupler on theanchor.