PNEG-2076 - Smart IR II Sensor

PNEG-2076

Smart IR II Sensor

Installation and Operation Manual

PNEG-2076Version: 3.0

Date: 03-30-21

2 PNEG-2076 Smart IR II Sensor

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-2076 Smart IR II Sensor 3

ContentsChapter 1 Safety .....................................................................................................................................................4

Safety Guidelines ...................................................................................................................................4Cautionary Symbols Definitions .............................................................................................................5Safety Cautions ......................................................................................................................................6

Chapter 2 Application ............................................................................................................................................7

Chapter 3 Installation ............................................................................................................................................8

Chapter 4 Basic Operation ....................................................................................................................................9

Chapter 5 Delay Time ..........................................................................................................................................10Check Delay Time Setting ....................................................................................................................10Setting/Adjusting the Delay Time .........................................................................................................11Delay Time Operation ..........................................................................................................................11Delay Time By-Pass .............................................................................................................................11

Chapter 6 Run Time .............................................................................................................................................12Maximum Run Time .............................................................................................................................12Check Maximum Run Time Setting ......................................................................................................13Setting/Adjusting the Maximum Run Time ...........................................................................................13Maximum Run Time Operation ............................................................................................................14Resetting the Maximum Run Timer ......................................................................................................14

Chapter 7 Idle Time ..............................................................................................................................................15Check Maximum Idle Time ...................................................................................................................15Setting/Adjusting the Maximum Idle Time ............................................................................................16Maximum Idle Time Operation .............................................................................................................16

Chapter 8 Unit I.D. Number .................................................................................................................................17Setting the Unit I.D. Number ................................................................................................................17

Chapter 9 Alarm Codes .......................................................................................................................................18

Chapter 10 Sensitivity .........................................................................................................................................19

Chapter 11 Replacement Parts ...........................................................................................................................20Smart IR II Sensor Assembly (FLX-5335) ..........................................................................................20

Chapter 12 Wiring Diagrams ...............................................................................................................................22RS485 Communication in Lid (If Used) ..............................................................................................22Alarm Wiring Diagram ........................................................................................................................23Flex-Flo Control Unit Used with Smart IR II Sensor ...........................................................................24Flex-Flo Control Unit Extension Used with Smart IR II Sensor ..........................................................25AP Wiring Diagram .............................................................................................................................26Choretime Wiring Diagram .................................................................................................................27Universal Wiring Diagram ...................................................................................................................28

Chapter 13 Troubleshooting ...............................................................................................................................29Smart IR II Sensor Test ......................................................................................................................29

Chapter 14 Warranty ............................................................................................................................................31


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, which must be carefully followed in all cases. Authorities having jurisdiction must be 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


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


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

Install and Operate Electrical Equipment Properly

• Electrical controls must be installed by a qualified electrician and must meet the standards set by applicable local codes (National Electrical Code for the US, Canadian Electric Code, or EN60204 along with applicable European Directives for Europe).

• Lock-out power source before making adjustments, cleaning, or maintaining equipment.

• Make sure all equipment is properly grounded.ST-0027-4


2. Application

The Smart IR II Sensor is used 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 a proximity switch or drop tube switch and will operate with or without the aid of a power relay. The sensor is installed underneath a control unit between the powerhead drop (funnel) and the drop tube at the end of a Flex-Flo feed system.

Figure 2A


3. Installation

The sensor (C) is installed underneath a control unit (A) between the powerhead drop (funnel) (E) and the drop tube (D) at the end of a Flex-Flo feed system. The control unit power head drop funnel must be an FLX-2017 or equivalent with an outlet measuring approximately 3-1/4" O.D. Use two (2) #10 x 3/4" self-drilling screws (S-8045) (supplied) (F) to fasten the Smart IR II Sensor to the powerhead dropfunnel (E) and drop tube (D) as shown in Figure 3A.

Figure 3A

Ref # Description

A Flex-Flo Control

B Flex-Flo Motor

C Smart IR II Sensor

D Drop Tube

E Powerhead Drop Funnel (FLX-2017)

F Two (2) #10 x 3/4" Self-Drilling Screws (S-8045) (Supplied)


4. Basic Operation

The Smart IR II Sensor will detect when the last feeder is full and immediately shut the Flex-Flo system off, the yellow “Product Detected” LED will be lit and the display will read “Full”. When the feed falls away from the sensor, it will count down a pre-determined delay time and then turn the Flex-Flo system back on. It also includes a maximum run timer that will shut the system down if the auger runs too long in case of an empty or bridged feed tank or a feed spill. Alarm contacts are available to provide remote notification of a maximum run situation. In addition, it includes a “Maximum Idle Timer” that will register an alarm if extended inactivity of the feed system is detected.

Figure 4A Full


5. Delay Time

Delay time is the length of time after the Smart IR II Sensor no longer detects feed, before it turns the Flex-Flo system back on again. It is used to prevent short-cycling of the Flex-Flo system. Excessive short-cycling will reduce the life of the motor and/or Flex-Flo system. It can also result in the motor running hot and continually activating the thermal reset.

The required delay time setting depends on how quickly the animals can empty the feeders once the feed system is full. Large capacity feeders or younger, smaller animals will allow for longer delay time settings. For best results, use a slightly less delay time setting than the time it takes the animals to completely empty the feeder. Always check a pen where there are the most and largest animals and at the time of day when consumption is highest. As the animals get older and larger and consume more feed, decrease the delay time setting to prevent feeders from going empty.

The range of delay time setting for the Smart IR II Sensor is from 0 hours and 0 minutes to 23 hours and 59 minutes.

Check Delay Time SettingTo check the delay time setting, at any time, push and hold the “On Delay Time” button.

Figure 5A Checking Delay Time

5. Delay Time


Setting/Adjusting the Delay TimeTo adjust the delay time setting, at any time, while pushing and holding the “On Delay Time” button, push either the “arrow up” or “arrow down” button. Each time an “arrow” button is pushed, the time will change by 1 minute. To make the time scroll faster, continue to hold the “arrow” button down for several seconds.

Figure 5B Adjusting the Delay Time

Delay Time OperationOnce the yellow “Product Detected” indicator light goes off, the delay time will begin to count down from its maximum setting. During this time, the green “Auger” indicator light will flash. After the delay time reaches 0.00, the “Auger” indicator light will turn on solid and the Flex-Flo system will start.

Delay Time By-PassWhen the Smart IR II Sensor is in delay time, the green “Auger” indicator light will be flashing. It is not necessary to wait for the delay time to expire before the auger will start-up. To make the auger start immediately, by-pass the delay time for one cycle only, by pressing and holding the “On Delay Time” button down for 5 second.


6. Run Time

Once the Flex-Flo system starts, the display will count up showing the hours/minutes while keeping track of auger run time for the current cycle.

Figure 6A Auger Running

Maximum Run TimeMaximum run time is the maximum time the Flex-Flo system will run each cycle. If this time expires, the Flex-Flo system will shut off and will not start again until the control is reset. The maximum run time is used to shut the Flex-Flo system off in case of an empty or bridged feed tank or a feed spill. In the case of an empty or bridged feed tank, it will prevent the Flex-Flo system from running empty for extended periods of time. In the case of a feed spill, it will prevent the Flex-Flo system from emptying the remaining contents of the feed tank on the floor.

To determine the optimum maximum run time, find the longest possible fill time by measuring the time required to completely fill all feeders when they are empty. Then add approximately 10 minutes to this time to account for variability.

The range of adjustment for the maximum run time is from 1 minute to 23 hours and 59 minutes.

6. Run Time


Check Maximum Run Time Setting

To check the maximum run time setting, at any time, push and hold the “Maximum Run Time” button.

Figure 6B Checking Maximum Run Time Setting

Setting/Adjusting the Maximum Run Time

To adjust the maximum run time setting, at any time, while pushing and holding the “Maximum Run Time” button, push either the “arrow up” or “arrow down” button. Each time an “arrow” button is pushed, the time will change by 1 minute. To make the time scroll faster, continue to hold the “arrow” button down for several seconds.

Figure 6C Adjusting the Maximum Run Time

6. Run Time


If no maximum run time is desired, this feature can be disabled. To shut off the maximum run time, follow the adjustment procedure on Page 13. Using the “arrow down” button, decrease the time to 1 minute. Press the “arrow down” button once more and the display will show “OFF”.

IMPORTANT: Turning the maximum run timer OFF is not recommended.

Figure 6D Disabling the Maximum Run Time Feature (Not Recommended)

Maximum Run Time OperationDuring normal operation, when the Flex-Flo system is running, the display will count up at 1 minute increments. If the displayed time reaches the maximum run time setting before the feed line is full, the Flex-Flo system will shut off. At that time, the display showing the maximum run time setting will begin to flash alternately with the red “Alarm” indicator light. The alarm contacts inside the Smart IR II Sensor will now change state. If these contacts are being utilized, it will send a signal to a remotely connected alarm device (not provided). IMPORTANT: The first cycle, after power loss or resetting of alarm, will have a maximum run time of twice the programmed value.

Resetting the Maximum Run Timer

The Flex-Flo system will not restart automatically once the maximum run time alarm has been activated. To reset the Smart IR II Sensor to automatic mode and disable the alarm, re-cycle the power, in one of three (3) ways:

1. At the Smart IR II Sensor, push and hold the “Maximum Run Time” button for 5 seconds.

2. At the Flex-Flo control unit, switch the toggle “off” then back “on” again.

3. At the main circuit board, switch the controlling circuit breaker “off” then back “on” again.


7. Idle Time

Idle time is defined as: The time after feed is first detected by the feed sensor until feed is no longer detected. 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. If the maximum idle time is exceeded, an alarm will register with the Smart IR II Sensor, indicating excessive feed system inactivity. The best maximum idle time setting is achieved by adding 1 hour to the maximum acceptable feed system inactivity time. This feed system inactivity usually occurs at night or in periods of extreme heat during the day. A typical maximum idle time might be 8 to 10 hours.

Check Maximum Idle TimeTo check the maximum idle time setting, at any time, push and hold the “Max Idle Time” button.

Figure 7A Checking Maximum Idle Time Setting

7. Idle Time


Setting/Adjusting the Maximum Idle Time

To adjust the maximum idle time setting, at any time, while pushing and holding the “Max Idle Time” button, push either the “arrow up” or “arrow down” button. Each time an “arrow” button is pushed, the time will change by 1 minute. To make the time scroll faster, continue to hold the “arrow” button down for several seconds.

Figure 7B Adjusting Maximum Idle Time Setting

Maximum Idle Time OperationDuring normal operation of the idle time, once the auger turns off, the yellow “Product Detected” LED will turn on and the display will show the elapsed idle time since it began. If the displayed idle time reaches the maximum idle time setting, the red “Alarm” LED will begin to flash. The control will go into alarm mode, while flashing “IdL” in the display. To clear the alarm, push and hold the “Max Idle Time” button down for 5 seconds.


8. Unit I.D. Number

Only used with Integra Feed Link Network Master

When configuring the Smart IR II Sensor to be used with a Network Master, each Smart IR II Sensor must have a unique unit I.D. number in order to communicate properly. There is a maximum of twenty five (25) Smart IR II Sensor controls that can be used with each Network Master. The unit I.D. number of each Smart IR II Sensor must fall between a range of “51” and “75”. The default setting is “0” 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 IR II Sensor, for use when programming the Network Master.

Setting the Unit I.D. Number1. Push both “arrow up” and “arrow down” buttons at the same time, then release. Initially the default

setting of “0” 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 “51” through “75”.

3. Once the desired unit I.D. number is selected, pause until display reverts back to normal operation. The unit I.D. number is now saved.

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 IR II Sensor un-intentionally, after 15 minutes, an alarm code of “AC14” will be displayed, indicating a communication error. Press and hold for 5 seconds any button to clear this alarm code. To disable the unit I.D. number, set to “0”.

Figure 8A Setting Node I.D Figure 8B Default Node I.D


9. Alarm Codes

Figure 9A Maximum Run Time Alarm Figure 9B Maximum Idle Time Alarm

Figure 9C Communication Error Alarm


10. Sensitivity

No sensitivity setting is required. The infrared technology that is used in this sensor is not affected by temperature, humidity or type of feed. If the sensor fails to operate properly, disconnect the sensor from the powerhead drop above and use a soft cloth to clean the dust from inside. If it still does not operate properly, contact the nearest AP/Cumberland dealer to aid in troubleshooting.


11. Replacement Parts

Smart IR II Sensor Assembly (FLX-5335)

11. Replacement Parts


Smart IR II Sensor Assembly (FLX-5335) Parts List

Ref # Part # Description Qty

1 FLX-5000 Infrared Sensor Housing Assembly 1

2 FLX-5002 Infrared Sensor Insert Assembly 1

3 FLX-5003 Smart IR II Sensor Power Board Assembly 1

4 FLX-5001 Infrared Sensor Connector Cable 1

5 FLX-5333 Smart IR II Sensor Lid with PC Board 1

6 S-8045 Screw, SDS #10 x 3/4" HWH SS 410 4

7 FLX-5332 Smart IR II Sensor Lid with Decal 1


12. Wiring Diagrams

RS485 Communication in Lid (If Used)

12. Wiring Diagrams


Alarm Wiring Diagram

12. Wiring Diagrams


Flex-Flo Control Unit Used with Smart IR II Sensor

FLEX-FLO CONTROL UNIT (FLX-5350)

L1 L2 L3

M1

M2

M3

Incoming Power Flex-Flo MotorAuxiliary Switch

GR

EE

N

WH

ITE

BL

AC

K

L1

L2 IN

OU

T

CO

M.

N.O

.

Relay OutputS

ign

al

Sig

na

l

Po

we

r

Po

we

r

GR

EE

N

WH

ITE

BL

AC

K

GREEN

BLACK

RED

FLEX-FLOMOTOR

GND

L2

L1

208-230VACPOWER SUPPLY

YELLOW

YELLOW

SMART IR II SENSOR (FLX-5335)

COM.

RELAYOUTPUT

ALARMCONTACTS 230VAC

POWER SUPPLY

N.O.

N.C.YELLOW

YELLOW

CO

M.

N.O

.

N.C

.

GND L1 L2

GR

EE

N

REDBLACK

SMART IR II SENSOR WITH LID REMOVED

12. Wiring Diagrams


Flex-Flo Control Unit Extension Used with Smart IR II Sensor

12. Wiring Diagrams


AP Wiring Diagram

12. Wiring Diagrams


Choretime Wiring Diagram

12. Wiring Diagrams


Universal Wiring Diagram


13. Troubleshooting

Smart IR II Sensor Test

To test sensors, press and hold up and down arrows (old versions) and the maximum run time and the delay buttons (V-1.46) at the same time and wait till 4 digits appear on the display.

Numbers Read in Hexidecimal

The first 2 digits is the hexadecimal reading for one set of IR sensors and the second 2 digits is the hexadecimal reading for the second set of IR sensors.

1. Low Numbers = Full Readings

Example: 01 through 09, 0A, 0B, 0E, 0F, 10, 13, 18, ECT

2. High Numbers = Empty Readings

Example: E5, F5, FC, ECT

NOTE: Hex numbers 40 and higher consider bad for full.

Conversion Chart

Examples of Good High Numbers:

1. FC = 250

2. BA = 186

3. D1 = 209

4. CD = 205

5. D3 = 211

Decimal Hex Decimal Hex

1 1 16 10

2 2 17 11

3 3 18 12

4 4 19 13

5 5 20 14

6 6 30 1E

7 7 40 28

8 8 50 32

9 9 60 3C

10 A 70 46

11 B 80 50

12 C 90 5A

13 D 100 64

14 E 500 1F4

15 F 1000 3E8


NOTES


14. Warranty

Limited Warranty - Protein Products

The GSI Group, LLC. (“GSI”) warrants products which it manufactures, to be free of defects in materials and workmanship under normal usage and conditions for a period of 12 months from the date of purchase (or, if shipped by vessel, 14 months from the date of arrival at the port of discharge). If, in GSI’s sole judgment, a product is found to have a defect in materials and/or workmanship, GSI will, at its own option and expense, repair or replace the product or refund the purchase price. This Limited Warranty is subject to extension and other terms as set forth below.

Warranty Enhancements:

The warranty period for the following products is enhanced as shown below and is in lieu of (and not in addition to) the above stated warranty period.

Conditions and Limitations:THERE ARE NO WARRANTIES THAT EXTEND BEYOND THE LIMITED WARRANTY DESCRIPTION SET FORTH HEREIN; SPECIFICALLY, GSI DISCLAIMS ANY AND ALL OTHER WARRANTIES OF ANY KIND, EXPRESS OR IMPLIED, INCLUDING, WITHOUT LIMITATION, WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OR USE IN CONNECTION WITH: (I) ANY PRODUCT MANUFACTURED OR SOLD BY GSI, OR (II) ANY ADVICE, INSTRUCTION, RECOMMENDATION OR SUGGESTION PROVIDED BY AN AGENT, REPRESENTATIVE OR EMPLOYEE OF GSI REGARDING OR RELATED TO THE CONFIGURATION, INSTALLATION, LAYOUT, SUITABILITY FOR A PARTICULAR PURPOSE, OR DESIGN OF SUCH PRODUCTS.

The sole and exclusive remedy for any claimant is set forth in this Limited Warranty and shall not exceed the amount paid for the product purchased. This Warranty only covers the value of the warranted parts and equipment, and does not cover labor charges for removing or installing defective parts, shipping charges with respect to such parts, any applicable sales or other taxes, or any other charges or expenses not specified in this Warranty. GSI shall not be liable for any other direct, indirect, incidental or consequential damages, including, without limitation, loss of anticipated profits or benefits. Expenses incurred by or on behalf of a claimant without prior written authorization from the GSI warranty department shall not be reimbursed. This warranty is not transferable and applies only to the original end user. GSI shall have no obligation or responsibility for any representations or warranties made by or on behalf of any dealer, agent or distributor. Prior to installation, the end user bears all responsibility to comply with federal, state and local codes which apply to the location and installation of the products.

This Limited Warranty extends solely to products sold by GSI and does not cover any parts, components or materials used in conjunction with the product, that are not sold by GSI. GSI assumes no responsibility for claims resulting from construction defects, unauthorized modifications, corrosion or other cosmetic issues caused by storage, application or environmental conditions. Modifications to products not specifically delineated in the manual accompanying the product at initial sale will void all warranties. This Limited Warranty shall not extend to products or parts which have been damaged by negligent use, misuse, alteration, accident or which have been improperly/inadequately maintained.

Service Parts:

GSI warrants, subject to all other conditions described in this Warranty, Service Parts which it manufactures for a period of 12 months from the date of purchase, unless specified in Enhancements above. Parts not manufactured by GSI will carry the Manufacturer’s Warranty.

Product Warranty Period

AP® Fans Performer Series Direct Drive Fan Motor 3 Years * Warranty prorated from material list price:0 to 3 years - no material cost to end user3 to 5 years - end user pays 25%

5 to 7 years - end user pays 50%

7 to 10 years - end user pays 75%

** Warranty prorated from material list price:0 to 3 years - no material cost to end user3 to 5 years - end user pays 75%

AP® and Cumberland® Flex-Flo/Pan Feeding System Motors 2 Years

Electronic Controls All Protein controls manufactured by GSI24 Months from datecode on part

Cumberland®

Feeding and WateringSystems

Feeder System Pan Assemblies 5 Years, Prorated **

Feed Tubes (1.75" and 2.00") 10 Years, Prorated *

Centerless Augers 10 Years, Prorated *

Watering Nipples 10 Years, Prorated *

(Protein Limited Warranty_REV01_06 November 2018)

Copyright © 2021 by The GSI Group, LLCPrinted in the USA

This equipment shall be installed in accordance with the current installation codes and applicable

regulations, which should be carefully followed in all cases. Authorities having jurisdiction should be

consulted before installations are made.

1004 E. Illinois St. Assumption, IL 62510-0020

Phone: 1-217-226-4421 Fax: 1-217-226-4420

www.automatedproduction.com / www.cumberlandpoultry.com

CN-363229

This product covered by U.S. Patent # 8,056,506.

Documents

PNEG-2076 - Smart IR II Sensor